Last update:

08/03/2005

  Engine Data 2.9 24v

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Engine Data 2.0 8V
Engine Data 2.0 16V
Engine Data 2.3 16v
Engine Data 2.9 12V
Engine Data 2.9 24v
Engine Data 2.5 TD
Ford-Cosworth 24V
2.3 Engine Overview
A4LDE Auto Box
MT75 Manual Box
Vacuum Pipes
Wiring Loom Diagrams

 

Engine Top End

Inlet Manifold

Air filter

Cylinder Head

Exhaust Manifold

Piston


Timing Gear


Timing Gear

Gasket Set Bottom End


Vacuum Control


Sump


Gasket Set Top End

Fuel Evap System

Fuel Rail

EGR

General

Engine management EEC V module
Emission standard 96 EEC
Super 95 RON unleaded
Engine code BOB
Firing order 1-4-2-5-3-6
Bore mm 93.0
Stroke mm 72.0
Cubic capacity 2935cc
Compression ratio 9.7:1
Compression pressure bar14
Power output (EEC) kW151.4
  at rpm 6000
Power output (DIN) kW 154.5
  (PS)210
  at rpm6000
Torque (EEC) Nm281
Torque (DIN) Nm286.6
  at rpm 4250
Idle speed rpm N=730. D=650
Max. engine speed rpm 6150. 6250

Dimensions

Cylinder block
Number of main bearings 4
Cylinder bore . class 1 mm93.01 - 93.02
Cylinder bore . class 2 mm93.02 - 93.03
Cylinder bore . class 3 mm93.03 - 93.05
Main bearing shells. inside diameter mm60.620 - 60.640

Crankshaft  

Main bearing journal . class 1 mm56.980 - 57.000
Main bearing journal end float mm0.08 - 0.32

Connecting rod 

Bore diameter. big end mm56.820 - 56.840
Bore diameter. small end mm23.958 - 23.976
Connecting rod. distance between bores mm130.515 - 130.585
Big-end bearing clearance (radial)  

Pistons

Piston . class 2 mm 92.985 - 92.995
Piston . class 3 mm92.995 - 93.005
Piston ring groove. upper compression ring mm0.41 - 0.48
Piston ring groove. lower compression ring mm 1.73 - 1.79
Upper compression ring mm 0.4 - 0.65
Lower compression ring m m 0.9 - 1.1
Oil control ring mm0.3 - 0.6
Top ring max. clearance mm0.20
Compression ring max. clearance mm0.10
Piston ring clearance: excessive piston ring
clearance is identifiable by high oil consumption
and sometimes also by blue  exhaust smoke.
Piston Pins
Piston pin diameter mm24.013 - 24.019
Ring gap position: the piston ring gaps
must be spread evenly around the
circumference of the piston. This also
applies tothe elements of the oil control
ring. Stagger the ring gaps at intervals of 120.
Camshafts 
Number of camshafts 4
Number of camshaft bearings 4/4
Drive 2 timing chains
Camshaft bearing. inside diameter mm34.5 - 34.52
Camshaft bearing. inside diameter mm 28.0 - 28.21
Max cam lift. inlet mm 9.5
Max cam lift. exhaust mm 9.5
Bearing journal diameter mm34.439 - 34.460
Bearing journal diameter mm 27.939 - 27.960
Valve timing. inlet opens BTDC 8
Valve timing. inlet closes ABDC 62
Valve timing. exhaust opens BBDC 56
Valve timing. exhaust closes ATDC 14
Valve timings. overlap 22

Valves

Valve tappet diameter mm 34.9659 - 34.975
Valve head . inlet mm 34
Valve head . exhaust mm 30
Valve length. inlet mm 105.59
Valve length. exhaust mm 104.15
Valve stem . inlet mm 6.90 - 6.94
Valve stem . exhaust mm 6.90 - 6.94
Valve spring length. fitted mm 32.0
Valve spring length. not fitted mm 40.4

Cylinder Heads

Valve tappet bore diameter mm35.000 - 35.015
Valve guide bore diameter mm 7.0 - 7.015
Valve seat angle 450" - 4515"
Cylinder head mating face.
maximum distortion diagonally or mm 0.06
along length
Cylinder head mating face.
maximum distortion across width mm0.02
Rework to a maximum depth of mm 0.13
Thickness of cylinder head gasket mm 1.2

Lubricants. Adhesives and Sealers

Ford Specification
Coolant ESD-M97B49-A 
No. 4 rear crankshaft main bearing cover only ESK-M4G269
Lubricant for spark plug threads (Never Seeze) ESE-M1244-A
Timing chain housing on cylinder block and on
cylinder head (M8x60 only) ESK-M4G269
Timing chain tensioner housing on cylinder head WSK-M2G 349-A7
Right-hand timing chain guide on cylinder block WSK-M2G 349-A7
Intermediate shaft bearing plate WSK-M2G 349-A7
Sump on cylinder block. rubber gasket ends ESK-M4G269
Locking compound ESK-M4G247-A
Capacity Litres
Engine oil incl. filter 4.5
Engine oil excl. filter 4.2
Coolant 9.5

 

Engine oil  
Ambient temperature Designation Specification
-10 to above 40 degrees C Ford Multigrade Super Motor Oil SAE 20W50 API/SG/CD
-15 to above 40 degrees C Ford Multigrade Super Motor Oil SAE 15W40 API/SH/CD
  -20 to above 40 degrees C Ford Multigrade Super Motor Oil SAE 10W30 API/SH/CD EC
-20 to above 40 degrees C XR+ high-performance high-lubricity SAE 10W40 API/SH/CD EC
-30 to above 40 degrees C Ford Formula S synthetic engine SAE 5W50 API/SG/CD
-30 to above 40 degrees C Semi-synthetic/synthetic engine oil SAE 5W40 API/SH/CD EC
40 to below -30 degrees C Ford Multigrade Super Motor Oil SAE 5W30 API/SG/CD
Specification SAE 5W30 API/SG/CD
engine oil is only approved for
northern European countries.
If other makes of engine oil are used
make sure these are of the
required API SG/CD viscosity class or better.
 
Torques  

General

Nm

lbf.ft

Wheel nuts 85 63

Intake system

Inlet manifold cover 4 3
Bracket for speed control cable 9 7
Inlet manifold to cylinder head 16 12

Exhaust

Catalytic converters to bracket (between the    
catalytic converters) 23 17
Catalytic converter bracket to transmission
crossmember 47 35
Catalytic converter bracket to transmission 23 17
Catalyst to exhaust manifold 47 35
EGR valve. pipe to intake air plenum
chamber 9 7
EGR valve. pipe to inlet manifold 9 7
EGR valve. bracket to cylinder head 19 14
Heat shields to exhaust manifold 9 7

Alternator

Bracket for alternator/power steering
pump to cylinder block 44 32
Alternator to bracket 25 18
Tensioning pulley for alternator/power
steering pump 44 32

Driveshaft

Driveshaft to differential 66 49
Driveshaft centre to floor assembly 21 15

Transmission

Ground lead to transmission 44 32
Transmission crossmember to floor  
Assembly 36 27

Air conditioning system

Tensioning pulley for air conditioning compressor 41 30
A/C compressor to bracket 25 18
A/C compressor to cylinder block 44 32

Coolant circuit

Coolant pump to timing chain housing 12 9
Bracket for the coolant pipe to the oil cooler 9 7
Coolant pump pulley 19 14
Thermostat housing bracket 9 7
Thermostat housing connector 9 7
Coolant pipe bracket to cylinder head 19 14
Coolant pipe clamp to cylinder head 9 7

Steering

Power steering pump to bracket 25 18
Power steering pump pulley 25 18
Intermediate shaft to steering shaft 18 13

Engine mounting

Engine mounting nuts 50 37

Front axle

Transverse brace to front axle 80 59
Front axle to side member 80 59
Suspension arm to spindle carrier 83 61
Link rod to stabiliser bar 47 35
Track rod to spindle carrier 63 46

Oil circuit

Sump M6x20 12 9
Sump M6x45 12 9
Sump M6x115 12 9
Oil pump 20 15
Oil drain plug 24 18
Oil baffle plate 21 15
Oil filter to oil cooler (after contact) 270 270
Oil cooler to oil pick-up pipe 33 24
Oil filter connector 35 26

Cylinder block

Main bearing caps 97 72
Big-end bearing cap. (big-end bearings and  
connecting rod bolts 6AA or KX 110) 30 22
Big-end bearing cap. (big-end bearings and  
connecting rod bolts 5AB or KX 900) 20 15
stage 1  
Big-end bearing caps. stage 2 90 90
Camshaft bearing caps 10 7
Right-hand timing chain guide 12 9
Timing chain housing to cylinder block M8 19 14
Crankshaft pulley/vibration damper. stage 1 45 33
Crankshaft pulley/vibration damper. stage 2 90 90
Crankcase breather connector to sump 9 7
Clamping sleeve bolt (crankcase breather) 9 7
Oil pressure switch 20 15
Intermediate shaft bearing plate 12 9
Intermediate shaft sprocket 50 37
Clamping piece for oil pump drive assembly bearing  
bracket 19 14
CKP sensor bracket to cylinder block 9 7
CKP sensor to bracket 9 7
CKP sensor wiring clamp 12 9
Drive plate to crankshaft 68 50

Cylinder Head

CMP sensor to cylinder head 9 7
Camshaft sprockets 72 53
Upper chain guides 19 14
Left-hand timing chain guide 9 7
Timing chain tensioner housing 9 7
Timing chain tensioner threaded plug 13 10
Right-hand chain guide retaining bolt 9 7
Cylinder head bolts. stage 1 50 37
Cylinder head bolts. stage 2 (or 2 x 90) 180 180
Cylinder head bolt in timing chain housing 19 14
Cylinder head covers 7 5
Fuel rails 9 7
Fuel pipe bracket 9 7
Spark plugs 20 15
Cylinder head heat shield 9 7
Engine lifting eyes to cylinder head 19 14
Ignition coil bracket M6 9 7
Ignition coil bracket M8 19 14
Oil dipstick tube to cylinder head 9 7
 

 

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