ENGINE OIL SPECIFICATIONS
| Viscosity/ambient temperature | Description | Specification |
|---|---|---|
| Recommended engine oil | ||
| SAE 5W-30 / below -20°C to over +40°C | Engine oil GF3 | WSS-M2C915-A |
ENGINE OIL SPECIFICATIONS
If engine oils of this specification are not available, engine oils of specification API SH/EC, ACEA A2/B2 or ACEA A3/B3 may also be used.
CAPACITIES SPECIFICATIONS
| Litres | |
|---|---|
| Engine oil, initial fill including filter | 4.35 |
| Engine oil, oil change including filter | 4.25 |
| Engine oil, oil change excluding filter | 3.75 |
CAPACITIES SPECIFICATIONS
LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES SPECIFICATIONS
| Item | Specification |
|---|---|
| Sealant, camshaft bearing caps | WSK-M2G348-A5 |
| Sealant, cylinder block mating faces (Hylosil 502) | WSK-M4G320-A |
| Sealant, cylinder block mating faces (Loctite Ultrablack) (alternative) | WSE-M4G320-A2 |
| Sealant, crankshaft position sensor | ESW-1C155-A |
| Sealant, crankshaft position sensor (alternative) | WSD-M1C-226-A |
| Sealant, oil pan | WSE-M4G323-A6 |
| Thread locking compound | SDM-M4G9107-A |
| Spark plug thread lubricant (Never Seeze) | WSD-M13P8-A1 |
| Lubricant, injection nozzle O-rings | WSEM-2C903-A1 |
| Silicone grease for spark plug connector seal | A696-M1C171-AA |
| High-temperature grease for clutch disc engagement splines | ESD-M1C220-A |
LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES SPECIFICATIONS
CYLINDER BLOCK SPECIFICATIONS
| Description | Mm |
|---|---|
| Cylinder bore diameter, class 1. | 84.800 - 84.810 |
| Cylinder bore diameter, class 2. | 84.810 - 84.820 |
| Cylinder bore diameter, class 3. | 84.820 - 84.830 |
| Inner diameter, main bearing shells installed | 58.011 - 58.038 |
| Inner diameter, main bearing shells installed (main bearing shells with stepped sizes) | 58.008 - 58.031 |
| Main bearing radial clearance | 0.011 - 0.058 |
| Main bearing radial clearance (main bearing shells with stepped sizes) | 0.020 - 0.042 |
| Main bearing parent bore | 62.287 - 62.300 |
CYLINDER BLOCK SPECIFICATIONS
PISTONS SPECIFICATIONS
| Description | Mm |
|---|---|
| Piston diameter, class 1. | 84.770 - 84.780 |
| Piston diameter, class 2. | 84.780 - 84.790 |
| Piston diameter, class 3. | 84.790 - 84.800 |
| Piston clearance in cylinder bore | 0.010 - 0.030 |
| Piston ring gaps (installed) | |
| Upper compression ring | 0.300 - 0.500 |
| Lower compression ring | 0.300 - 0.500 |
| Oil scraper ring | 0.400 - 1.400 |
PISTONS SPECIFICATIONS
Ring gap position: The piston ring gaps must be distributed evenly around the circumference of the piston This also applies to the oil scraper ring elements. Align the ring gaps at 120 degrees to each other.
CRANKSHAFT SPECIFICATIONS
| Description | Mm |
|---|---|
| Main bearing journal diameter | 57.980- 58.000 |
| Main bearing journal end float | 0.090 - 0.260 |
| Connecting rod bearing journal diameter | 46.890 - 46.910 |
CRANKSHAFT SPECIFICATIONS
CYLINDER BLOCK AND LOWER CRANKCASE SPACERS SPECIFICATIONS
| Description | Mm |
|---|---|
| Required spacer thickness if there is a gap between the cylinder block and the lower crankcase of | |
| 0.26 mm - 0.50 mm | 0.25 |
| 0.51 mm - 0.75 mm | 0.50 |
CYLINDER BLOCK AND LOWER CRANKCASE SPACERS SPECIFICATIONS
CONNECTING ROD SPECIFICATIONS
| Connecting rod | Mm |
|---|---|
| Big end bore diameter | 49.890 - 49.910 |
| Small end bore diameter | 19.951 - 19.981 |
| Inner diameter, connecting rod bearing shells installed | 46.926 - 46.960 |
| Radial connecting rod bearing clearance | 0.016 - 0.070 |
| Axial connecting rod bearing clearance | 0.090 - 0.320 |
CONNECTING ROD SPECIFICATIONS
PISTON PIN SPECIFICATIONS
| Description | Mm |
|---|---|
| Piston pin length | 55.800 - 56.200 |
| Piston pin diameter, white | 19.997 - 20.000 |
| Piston pin diameter, red | 20.625 - 20.628 |
| Piston pin clearance in piston | 0.010 - 0.019 |
| Piston pin clearance in connecting rod | 0.016 - 0.049 |
PISTON PIN SPECIFICATIONS
CAMSHAFT SPECIFICATIONS
| Description | Mm |
|---|---|
| Bearing journal diameter | 25.960 - 25.980 |
| Camshaft bearing radial clearance | 0.020 - 0.070 |
| Camshaft end float | 0.080 - 0.220 |
CAMSHAFT SPECIFICATIONS
VALVES SPECIFICATIONS
| Valves | Mm |
|---|---|
| Intake valve clearance in the valve guide | 0.017 - 0.064 |
| Exhaust valve clearance in the valve guide | 0.017 - 0.064 |
| Intake valve clearance (at 20°C $$ 5°C) | 0.110-0.180 |
| Exhaust valve clearance (at 20°C $$ 5°C) | 0.270 - 0.340 |
VALVES SPECIFICATIONS
CYLINDER HEAD SPECIFICATIONS
| Cylinder head | |
|---|---|
| Maximum distortion (mating surface) | 0.1 mm |
| Height of mating surface | 1.76mm - 2.12 mm |
| Peak-to-valley height of mating surface (reference length 2.5 mm vertical to groove direction) | R 3z = 6.0 $$m |
| Oil pressure at 800 rpm - 850 rpm | 1.3 bar - 2.5 bar |
| Oil pressure at 4000 rpm | 3.7 bar - 5.5 bar |
CYLINDER HEAD SPECIFICATIONS
TORQUE SPECIFICATIONS
| Description | Nm | Lb-ft | Lb-in |
|---|---|---|---|
| Hose clamps | 4 | 35 | |
| Intake manifold studs | 5 | 44 | |
| Intake manifold bolts and nuts | 18 | 13 | |
| Heat shield to exhaust manifold | 10 | 89 | |
| Exhaust manifold studs | 5 | 44 | |
| Exhaust manifold nuts | 16 | 12 | |
| Exhaust manifold bolts | 18 | 13 | |
| Catalytic converter to exhaust manifold | 48 | 35 | |
| Catalytic converter to exhaust | 47 | 35 | |
| Generator to bracket | 25 | 18 | |
| Generator bracket to upper cylinder block bolts | 25 | 18 | |
| Generator bracket to lower cylinder block bolts | 65 | 48 | |
| Transmission flange bolts | 47 | 35 | |
| Starter motor to transmission | 35 | 26 | |
| Flywheel bolts | 112 | 83 | |
| Clutch pressure plate | 29 | 21 | |
| Engine roll restrictor to transmission | 48 | 35 | |
| Engine roll restrictor to subframe | 48 | 35 | |
| Engine rear mount to body | 48 | 35 | |
| Engine rear mount (nut on transmission mount bracket) | 133 | 98 | |
| Engine front mount to engine | 80 | 59 | |
| Engine front mount to body | 48 | 35 | |
| Power steering pump bracket | 48 | 35 | |
| Cylinder head | (1) | ||
| Camshaft bearing cap | 15 | 11 | |
| Cylinder head cover | (1) | ||
| Spark plugs | 15 | 11 | |
| Timing belt tensioner | 25 | 18 | |
| Camshaft timing belt pulley | 68 | 50 | |
| Camshaft VCT unit | 120 | 89 | |
| Camshaft VCT unit plug | 38 | 25 | |
| Upper timing belt cover | 8 | 71 | |
| Ignition coil (El) bracket to cylinder head | 21 | 15 | |
| Thermostat housing | 20 | 15 | |
| Fuel rail | 10 | 89 | |
| Engine rear lifting eye | 20 | 15 | |
| Engine rear lifting eye studs | 7 | 62 | |
| Engine front lifting eye | 35 | 26 | |
| Engine oil drain plug | 25 | 18 | |
| Oil pressure switch | 27 | 20 | |
| Cylinder block oil gallery blanking plugs | 23 | 17 | |
| Heater pipe bracket to oil pan | 10 | 89 | |
| Oil pan to lower crankcase | (1) | ||
| Lower crankcase to cylinder block | 30 | 22 | |
| Oil pump | (1) | ||
| Oil intake pipe to oil pump | 10 | 89 | |
| Main bearing cap bolts | (1) | ||
| Connecting rod bearing cap bolts | (1) | ||
| Coolant pump | 20 | 15 | |
| Rear crankshaft oil seal carrier | 20 | 15 | |
| Drive belt idler pulley | 40 | 30 | |
| Crankcase ventilation pipe bracket | 23 | 17 | |
| Crankcase ventilation | 10 | 89 | |
| Coolant pump pulley | 24 | 18 | |
| Crankshaft belt pulley | 115 | 85 | |
| Crankshaft position sensor bracket | 21 | 15 | |
| Crankshaft position sensor to bracket | 8 | 71 | |
| Timing belt idler pulley | 38 | 25 | |
| Knock sensor | 20 | 15 | |
| (1) Refer to the procedure in this article. | |||
| (1) | Refer to the procedure in this article. |
TORQUE SPECIFICATIONS
The 2.0L Duratec ST engine is based on the 2.0L Zetec-E engine. In comparison to the 2.0L Zetec-E engine the modifications are
See also:
• JACKING AND LIFTING