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Engine - 2.0L Zetec: Specifications Ford Escape I

Mechanical 12 illustrations ~602 words

General Specifications

ItemSpecification
Lubricants and Sealants
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C153-H
Silicone Gasket and Sealant F7AZ-19554-EAWSE-M4G323-A4
Stud and Bearing Mount E0AZ-19554-BAWSK-M2G349-A1
Gasket Maker F8AZ-19B508-ABWSK-M2G348-A5
Engine
Displacement2.0L (121 cubic inches)
Number of cylinders4
Bore84.8 mm (3.34 in)
Stroke88.0 mm (3.46 in)
Firing order1-3-4-2
Oil pressure (hot 4,000 RPM)370-550 kPa (54-80 psi)
Oil capacity (with filter)4.25 L (4.5 qts)
Compression ratio9.6:1
Cylinder Head and Valve Train
Cylinder head gasket surface flatness0.05/0.520/076 150 x 150
Combustion chamber volume
Valve arrangement (front to rear)
Valve clearance - intake0.11-0.18 mm (0.004331-0.007087 in)
Valve clearance - exhaust0.27-0.34 mm (0.0106299-0.0133858 in)
Valve guide bore diameter (insert counterbore diameter)6.06 mm (0.23858 in)
Valve stem diameter6.03 mm (0.23740 in)
Valve stem-to-guide clearance0.017-0.064 mm (0.000662-0.0025196 in)
Valve head diameter - intake32.0 mm (1.2598 in)
Valve head diameter - exhaust28.0 mm (1.10236 in)
Valve face runout0.035 mm (0.0013779 in)
Valve face angle45 degrees
Valve seat width
Valve seat runout
Valve seat angle
Valve spring free length43.2 mm (1.701 in)
Valve spring squareness
Valve spring compression pressure - intake365 N (82.1 lb) @ 25.1 mm (0.988 in)
Valve spring compression pressure - exhaust422 N (94.94 lb) @ 26.1 mm (1.0275 in)
Valve spring installed height34.2 mm (1.346 in)
Valve spring installed pressure
Roller follower ratio
Camshaft
Theoretical valve lift @ 0 lash - intake9.254 mm (0.3643 in)
Theoretical valve lift @ 0 lash - exhaust8.6 mm (0.33858 in)
Lobe lift - intake8.9 mm (0.3504 in)
Lobe lift - exhaust8.7 mm (0.3425 in)
Allowable lobe lift loss
Journal diameter25.960-25.980 mm (1.0221-1.0227 in)
Camshaft journal bore inside diameter
Camshaft journal-to-bearing clearance
Runout
End play0.080-0.220 mm (0.00315-0.00866 in)
Cylinder Block
Cylinder bore diameter - standard84.807-84.823 mm (3.3389-3.3395 in)
Cylinder bore diameter - oversize85.060-85.070 mm (3.3488-3.3492 in)
Cylinder bore maximum taper+0.025 mm (0.0009842 in)-0.013 mm (0.0005118 in) max.
Cylinder bore maximum out-of-round0.025 mm (0.0009842 in) max.
Main bearing bore inside diameter (bearing caps installed)58.011-58.0380 mm (2.28389-2.284956 in)
Main bearing bore inside diameter (bearing caps installed) - bearing caps graded by size58.008-58.031 mm (2.2837749-2.284680 in)
Head gasket surface flatness
Crankshaft
Main bearing journal diameter57.980-58.000 mm (2.2826726-2.28346 in)
Main bearing journal maximum taper
Main bearing journal maximum out-of-round
Main bearing journal-to-cylinder block clearance
Connecting rod journal diameter46.89-46.91 mm (1.846059-1.850036 in)
Connecting rod journal maximum taper
Connecting rod journal maximum out-of-round
Crankshaft maximum end play0.09-0.26 mm (0.0035433-0.010236 in)
Piston and Connecting Rod
Piston diameter - standard84.758-84.772 mm (3.3369-3.3375 in)
Piston diameter - oversize85.008-85.022 mm (3.3468-3.3473 in)
Piston-to-cylinder bore clearance0.035-0.065 mm (0.0014-0.0025 in)
Piston Ring End Gap
Piston ring groove width - upper compression ring1.484 mm (0.058425 in)
Piston ring groove width - lower compression ring1.734 mm (0.0682675 in)
Piston ring groove width - oil control ring2.905 mm (1.1143698 in)
Piston ring width - upper and lower compression ring0.30-0.50 mm (0.011811-0.019685 in)
Piston ring width - oil control ring0.40-1.40 mm (0.015748-0.055118 in)
Piston ring-to-groove clearance
Piston Pin Bore Diameter
Piston pin diameter - white20.662-20.625 mm (0.8134629-0.8120062 in)
Piston pin diameter - red20.625-20.628 mm (0.8120062-0.8121243 in)
Piston pin diameter - blue20.628-20.631 mm (0.8121243-0.8122424 in)
Piston pin length63.00-63.80 mm (2.48031-2.51181 in)
Piston pin-to-piston fit0.010-0.015 mm (0.0003937-0.0005905 in)
Piston-to-connecting rod clearance0.016-0.049 mm (0.0006299-0.0019291 in)
Connecting rod-to-pin clearance
Connecting rod pin bore diameter20.589-20.609 mm (0.810589-0.811376 in)
Connecting rod length
Connecting rod maximum allowed bend
Connecting rod maximum allowed twist
Connecting rod bearing bore diameter46.89-46.91 mm (1.846059-1.846847 in)
Connecting rod bearing-to-crankshaft clearance0.016-0.070 mm (0.0006299-0.0027559 in)
Connecting rod side clearance

GENERAL SPECIFICATIONS

Torque Specifications

DescriptionNmLb-ftLb-in
A/C compressor bracket bolts2418
A/C compressor bracket nuts4835
Accessory drive belt idler pulley4535
Battery cable nut (starter)129
Block heater screw327
Camshaft cap bolts1914
Camshaft sprocket bolts6850
Catalytic converter bracket bolts2418
Cylinder head bolts (1)
Clutch pressure plate bolts (2)2418
Clutch slave cylinder bolts2216
Coil bracket bolts2015
Coolant tube bolt/nut2015
Coolant tube bracket bolt (oil cooler)1089
Coolant tube stud2418
Crankcase vent oil separator bolts1089
Crankshaft rear oil seal housing bolts (1)
Crankshaft position sensor bolt871
Crankshaft pulley bolt11585
Cylinder head temperature sensor1089
Exhaust gas recirculation (EGR) tube nuts6246
EGR tube bracket bolt1089
EGR tube bracket bolt2518
EGR tube bracket nut (lifting eye)2518
Engine lifting eye nut (rear)1511
Engine lifting eye bolt (front)3526
Engine mount bolts/nut5541
Engine mount ground wire nut (engine)980
Engine mount ground wire nut (body)1089
Engine mount lower bracket bolts5037
Engine mount bolts/nut3425
Engine/transaxle mounting bolts4533
Exhaust manifold bolts/nuts (2)1612
Flywheel bolts11283
Front transaxle mount through bolt9066
Generator bolts4533
Generator bracket bolt (upper)2418
Generator bracket bolts/nut (lower)4735
Generator wire nut871
Ground cable bolt (transaxle)980
Ground wire bolt (fender)980
Ground wire bolt (transaxle bracket)980
Inner timing belt cover bolts1089
Intake manifold bolts/nuts (2)1813
Knock sensor nut2015
LH transaxle mount bolt (engine)9066
LH transaxle mount bolts (body)5541
Lower cylinder block bolts (2)3022
Lower engine mount bracket bolts5037
Lower engine mount bracket studs3425
Lower timing belt cover bolts762
Lower splash shield bolts980
Oil cooler bolt5843
Oil filter1612
Oil level indicator and tube nut1089
Oil pan bolts (1)
Oil pan drain plug2518
Oil pressure sender2720
Oil pump bolts (1)
Oil pump screen cover and tube bolts1089
Powertrain control module (PCM) connector bolt653
PCM ground wire bolt980
Positive crankcase ventilation tube bolt1089
Power distribution box cable nuts129
Power steering line bracket (pump)2015
Power steering line bracket bolt (head)1089
Power steering line bracket bolts (rack)1089
Power steering line bracket bolts (body)1089
Power steering pump bolts2518
Power steering pump bracket bolts2720
Rear transaxle mount bolts5541
Shifter shaft bolt/nut2015
Shifter strut rod bolt4533
Speed control unit nuts1089
Starter bolts2518
Starter control wire nut544
Thermostat housing bolts2015
Timing belt idler pulley bolt2418
Timing belt tensioner bolt2418
Upper timing belt cover bolts871
Valve cover bolts980
Coolant pump adapter bolts2015
Coolant pump pulley bolts2317
Wire harness connector bolt1089
(1) Refer to the procedure for the tightening specifications. (2) Refer to the procedure for tightening sequences.
(1)Refer to the procedure for the tightening specifications.
(2)Refer to the procedure for tightening sequences.

TORQUE SPECIFICATIONS

The 2.0L Zetec engine is a four cylinder in-line engine with double overhead camshafts and 16 valves. The 16 valve cylinder head improves volumetric efficiency, particularly at high engine speeds.

The cylinder head is made of aluminum alloy and the cylinder block is made of cast iron.

Scheme 517

Scheme 517: Location of Serial Number on Cylinder Block

The spark plug is installed in the center of the roof-shaped combustion chamber to ignite the air/fuel mixture in the combustion chamber. The central location of the spark plug causes the flame front to be evenly spread across the combustion chamber, which also reduces spark knock.

Both camshafts are driven by a shared timing belt, and operate four valves per cylinder by means of mechanical valve tappets. One valve spring on each valve is used to close the valve.

Scheme 518

Scheme 518: Upper Engine Components

Scheme 519

Scheme 519: Cylinder Head Components

Scheme 520

Scheme 520: Lower Engine Components

Scheme 521

Scheme 521

Scheme 522

Scheme 522

Scheme 523

Scheme 523: Cylinder Block Components

Scheme 524

Scheme 524: Automatic Belt Tensioner
CAUTIONOnly tension the timing belt counterclockwise.

An automatic timing belt tensioner makes sure of correct timing belt tension. An additional spring-loaded cam provides proper belt tension during operation. The belt tensioner can operate 30 degrees either side of its central position.

The basic adjustment of the belt tensioner can no longer be controlled after the aligning tools and adjusting pin have been taken out (the spring forces from the valve train exert pressure on the timing belt and alter the position of the belt tensioner).

The 2.0L Zetec engine is equipped with a glass fiber-reinforced plastic intake manifold. The intake manifold ports are designed so the intake paths are the same length for all the cylinders.

  1. This gives the following advantages: reduced heat transfer to the injectors, thereby avoiding vapor locks lighter weight reduction of fuel deposits on the intake walls during cold starts less heating of the intake air when the engine is hot

The crankshaft runs on five bearings and has a counterweight for each cylinder. The central main bearing has two bearing half shells which guide the crankshaft along its axis as well as adjusting the end float.

Scheme 525

Scheme 525: Crankshaft Bearings

The connecting rods are numbered one to four starting at the timing belt end. It is practically impossible to mix up the connecting rod bearing caps and connecting rods since the connecting rod bearing caps are broken away from the connecting rod during production. The fracture profile of a connecting rod bearing cap therefore only fits one of the connecting rods.

Scheme 526

Scheme 526: View of Lower Crankcase

The EEC-V module manages the 2.0L Zetec engine. The module requires a large amount of information about the current operating conditions of the engine and, where appropriate, the automatic transaxle. The EEC-V module obtains this information by means of sensors.

The EEC-V module controls

  1. the fully electronic ignition system (EI)
  2. the sequential electronic fuel injection system (SFI)
  3. the air conditioning system together with the cooling system.

The purpose of the lower crankcase is to reduce engine vibrations. This further reduces the level of noise inside the vehicle. There is a metal gasket between the lower crankcase and the cylinder block.

Scheme 527

Scheme 527: Lower Crankcase Spacer Shims

Lower crankcase spacer shims are used to even out any excessively large gaps between the transaxle and the lower crankcase (see SPECIFICATIONS ).

The engine is closed off at the bottom with a pressed steel oil pan which is directly attached to the lower crankcase. It is sealed with a 3 mm (0.12 in) wide bead of sealer.

For mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION .

For driveability concerns, refer to the SELF-DIAGNOSTICS - EEC-V - GASOLINE & NGV .

Scheme 528

Scheme 528: Special Tool(s)