Last update:

08/03/2005

 

 

 

      Engine Data DOHC2300 16V

                                                    General
 

Engine management

                                                                                  

EEC V

Emission standard     

                                                                                

96 EC

Engine code                 

                                                                              

Y5

Firing order                    

                                                                            

 1-3-4-2 

Bore                                 

                                                                 mm 

89.6

Stroke                               

                                                                mm  

 91

Cubic capacity                  

                                                              cc 

 2295 

Compression ratio             

                                                                       

 10.0:1

Engine power (EC rating)  

                                                            kW 

  108 

Engine power (EC rating)   

                                                           PS 

  147 

Engine power (EC rating) at

                                                         rpm 

 5600 

Torque (EC rating)              

                                                            Nm 

 202 

Torque (EC rating) at

                                                                     rpm 

4500 

Idle speed                    

                                                                    rpm 

  875 

Engine speed max. continuous  

                                                  rpm 

6150 

Engine speed max. intermittent

                                                    rpm 

 6375 

Spark plugs                                  

                                                            

  AGPR22P1 

Spark plug gap                              

                                                   mm  

   1.0

      

                                                   Dimensions

Cylinder block                                                                                                           

Cast mark                                                                                                        2,3   

Cylinder bore diameter, standard class 1                                  mm            89,60 - 89,61         

Cylinder bore diameter, standard class 2                                  mm            89,61 - 89,62         

Number of main bearings                                                                              5      

Thrust bearing width (without thrust half washers) standard     mm            21,17 - 21,23         

Fitted main bearing shells                                                                              

Vertical inner diameter, standard                                                 mm            55,003 - 55,030    

Vertical inner diameter, 1st undersize 0,02                               mm            54,993 - 55,020    

Vertical inner diameter, 2nd undersize 0,25                              mm            54,753 - 54,780    

Vertical inner diameter, 3rd undersize 0,50                               mm            54,503 - 54,530    

Vertical inner diameter, 4th undersize 0,75                               mm            54,253 - 54,280    

Main bearing parent bore diameter, standard                           mm            59,287 - 59,300    

Main bearing parent bore diameter, oversize 0,40                   mm            59,687 - 59,700    

Crankshaft 

End float                                                                                          mm                     0,093 - 0,303

Main bearing journal diameter, standard                                   mm                     54,98 - 55,00

Main bearing journal diameter, undersize (green)                    mm                     54,73 - 54,75

Bearing shell to main bearing journal clearance                       mm                     0,011 - 0,048

Big end journal diameter, standard                                             mm                     50,89 - 50,91

Big end journal diameter, undersize 0,25 (green)                     mm                     50,64 - 50,66

Thrust half washer thickness, standard                                       mm                     2,301 - 2,351

Thrust half washer thickness, oversize 0,38 mm (yellow)         mm                     2,491 - 2,541

Thrust bearing journal width, standard                                        mm                     26,025 - 26,075       

Thrust bearing journal width, oversize 0,38 (yellow)                  mm                     26,405 - 26,455       

Connecting rod

Bore diameter, big end                                                                 mm                     53,89 - 53,91

Bore diameter, small end                                                             mm                     20,589 - 20,609       

Fitted big-end bearing shells                                                                         

Vertical inner diameter, standard                                                mm                     50,916 - 50,950       

Vertical inner diameter, 1st undersize 0,025                             mm                     50,892 - 50,926       

Vertical inner diameter, 2nd undersize 0,25                              mm                     50,666 - 50,700       

Vertical inner diameter, 3rd undersize 0,50                               mm                     50,416 - 50,450       

Vertical inner diameter, 4th undersize 0,75                               mm                     50,166 - 50,200       

Vertical inner diameter, 5th undersize 1,00                               mm                     49,916 - 49,950       

Big-end bearing journal to shell clearance                                 mm                     0,006 - 0,060

Big-end bearing end float                                                            mm                     0,090 - 0,3610          

Uncoated pistons (unused)    

Piston diameter, class 1                                                               mm                     89,560 - 89,570       

Piston diameter, class 2                                                              mm                     89,570 - 89,580       

Coated pistons (unused)        

Piston diameter, class 1                                                              mm                     89,580 - 89,610       

Piston diameter, class 2                                                              mm                     89,590 - 89,620       

Piston clearance in cylinder bore (unused, uncoated piston)  mm                     0,03 - 0,05    

Piston clearance in cylinder bore (unused, coated piston)      mm                     -0,01 - +0,03 

Piston pin length                                                                            mm                     63,0 - 63,8    

Interference fit in small-end bore                                                 mm                     0,016 - 0,042

Piston ring gap (installed), top                                                     mm                     0,3 - 0,46       

Piston ring gap (installed), middle                                              mm                     0,5 - 0,76       

Piston ring gap (installed), bottom                                              mm                     0,15 - 0,71    

Ring gap positions                                                                        Set the ring gaps at 90 to each other
                                                 
                                                      around the piston circumference; this also
                                                 
                                                      applies to each part of the oil scraper ring.

Cylinder head with valve seat inserts* 

Cast mark                                                                                                                  2,3      

Upper correction angle, inlet valve (production)                                                 30       

Upper correction angle, exhaust valve (production)                                           30       

Valve seat angle                                                                                                    44,5 - 45,5    

Valve seat width, inlet                                                                   mm                     1,18 - 2,02    

Valve seat width, exhaust                                                             mm                     1,35 - 2,19    

Lower correction angle, inlet (production)                                                           75       

Lower correction angle, exhaust (production)                                                     75       

Valve stem guide diameter, inlet                                                 mm                     7,063 - 7,094

Valve stem guide diameter, exhaust                                          mm                     7,063 - 7,094

Camshaft bearing parent bore diameter                                    mm                     26,00 - 26,03

Camshafts                               

Number of camshaft bearings, each camshaft                                                      5         

Drive                                                                                                                Single roller chain 

Camshaft end float                                                                        mm                     0,02 - 0,26    

Cam lift, inlet                                                                                  mm                     9,4      

Cam lift, exhaust                                                                            mm                     8,75   

Valve timing, inlet opens BTDC                                                  CS                   9         

Valve timing, inlet closes ABDC                                                 CS                   51       

Valve timing, exhaust opens BBDC                                           CS                   48       

Valve timing, exhaust closes ATDC                                           CS                   12       

Camshaft bearing journal diameter                                            mm                     25,96 - 25,98

Valves                                      

Valve timing                                                                                                      DOHC        

Valve clearance adjustment                                                                           Hydraulic tappets  

Hydraulic tappet diameter                                                            mm            30    

Hydraulic tappet clearance in housing                                        mm            0,025 - 0,071         

Inlet valve length                                                                            mm            111,67 - 112,13    

Exhaust valve length                                                                     mm            111,37 - 111,83    

Valve head diameter, inlet                                                           mm            33,5

Valve head diameter, exhaust                                                     mm            30,0

Valve stem diameter, standard inlet                                           mm            7,025 - 7,043         

Valve stem diameter, standard exhaust                                     mm            6,999 - 7,017         

Valve stem diameter, oversize 0,2 inlet                                     mm            7,225 - 7,243         

Valve stem diameter, oversize 0,2 exhaust                               mm            7,199 - 7,217         

Valve stem diameter, oversize 0,4 inlet                                     mm            7,425 - 7,443         

Valve stem diameter, oversize 0,4 exhaust                               mm            7,399 - 7,417         

Inlet valve stem guide clearance                                                 mm            0,020 - 0,069         

Exhaust valve stem guide clearance                                          mm            0,046 - 0,095         

Free valve spring height                                                               mm            43,6

Spring height (compressed)                                                        mm            max. 26,5   

Valve spring inner diameter                                                         mm            17,2

Valve spring coil diameter                                                           mm            3,7   

Number of turns                                                                                               7,4   


                                                  
Lubrication                                                 

Oil pressure at 800 rpm
(with SAE 10W/30 and 80C oil temperature)                           bar               1,60   

 Oil pressure at 2000 rpm
(with SAE 10W/30 and 80C oil temperature)                           bar               3,10   

Pressure relief valve opens at                                                                       bar               3,70 - 4,60    

Oil control light comes on at                                                                           bar               0,30 - 0,50    

Oil pump rotor/housing clearance                                                                 mm               0,154 - 0,304

Inner/outer rotor clearance                                                                             mm               0,05 - 0,20    

Rotor end float at mating face                                                                       mm               0,039 - 0,104


Balancer shaft housing                                                                                            

Balancer shaft end float                                                                                   mm               0,050 - 0,100

Balancer shaft radial clearance                                                                     mm               0,022 - 0,074

Distance plate for balancer shaft housing

Range of adjustment              Available shims                                             Colour coding        

0,26 - 0,29 mm                        0,15 mm                                                        Silver
0,30 - 0,44 mm                        0,30 mm                                                        Pale blue   
0,45 - 0,59 mm                        0,45 mm                                                        Red
0,60 - 0,75 mm                        0,60 mm                                                        Black         
0,76 - 0,90 mm                        0,75 mm                                                        Green        

 

                                                   Lubricants, Adhesives and Sealers

Description                                                                                                       Ford
                                                                                                                           Specification         

Coolant                                                                                                             ESD-M97B49-A   

Sealer, coolant temperature sensor, coolant pump angle connector, oil WSK-M2G349-A7

pressure switch (Loctite 243)                                                                                

Sealer for rear oil seal carrier to balancer shaft housing                            WSE-M4G323-A6

Lubricant for O-ring of crankshaft position/speed sensor (CPS)              WSD-M1C226-A  

Power steering fluid                                                                                        SQM-2C-9010-A  

Lubricant for spark plug threads, HO2S sensor (`Never Seez')                ESE-M1244-A      

High-temperature grease                                                                               ESDM-1C220-A   

Silicone grease                                                                                              A960-M1C171-AA           

                                                   Capacity

Description                                                                                                       Litres          

Engine oil, initial fill, with filter                                                                        5,1   

Engine oil, oil change incl. filter (every 15,000 km)                                     4,25

Engine oil, oil change excl. filter                                                                    3,75

                                                  

                                                   Engine oil

Ambient temperature               Designation                                                            Specification

-10 to above 40C                  Ford Super Multigrade Engine Oil             SAE 20W50 API/SG/CD 

-15 to above 40C                  Ford Super Multigrade Engine Oil             SAE 15W40 API/SH/CD 

-20 to above 40C                  Ford Super Multigrade Engine Oil             SAE 10W30 API/SH/CD EC       

-20 to above 40C                  Ford XR+ High-performance High             SAE 10W40 API/SH/CD EC
                                                  
-lubricity Engine Oil                                                                                   

-30 to above 40C                  Ford Formula S Synthetic Engine Oil        SAE 5W50 API/SG/CD   

-30 to above 40C                  Synthetic/Semi-synthetic Engine Oil          SAE 5W40 API/SH/CD EC         

+40 to below -30C              Ford Super Multigrade Engine Oil             SAE 5W30 API/SG/CD   

The engine oil to specification SAE 5W30 API/SG/CD has only been approved for use in northern European
territories
If engine oils of other brands are used, it is imperative to ensure that these conform to API SG/CD or better in the particular viscosity class.                                                                    

                                                   Torques

                                                   General                                                          Nm               lbf.ft    

Front axle reinforcing bar                                                                               80                 59       

Air conditioning compressor                                                                         47                 35       

Air baffle - fan motors                                                                                     11                 8         

Hood hinges                                                                                                    23                 17       

EGR valve to bracket                                                                                      24                 18       

EGR tube to exhaust manifold                                                                       75                 55       

EGR tube bracket to exhaust manifold                                                         23                 17       

Transmission crossmember to body                                                            36                 27       

Transmission crossmember to automatic transmission                             62                 46       

Driveshaft to rear axle                                                                                    66                 49       

Driveshaft centre bearing                                                                               21                 15       

Starter motor to automatic transmission                                                      44                 32       

Automatic transmission to engine (flange bolts)                                         44                 32       

Starter motor bracket to cylinder block                                                         44                 32       

Torque converter to engine drive plate                                                         44                 32       

Earth lead to automatic transmission                                                           44                 32       

Oil dipstick tube bracket to automatic transmission                                   44                 32       

Oil pipes to automatic transmission                                                             25                 18       

Oil pipe bracket to automatic transmission                                                 44                 32       

Engine mounting bracket to cylinder block                                                  47                 35       

Engine mounting nuts                                                                                     50                 37       

                                                  Steering                                                         Nm               lbf.ft    

Intermediate shaft to steering shaft                                                               18                 13       

Steering gear - 1st stage                                                                               15                 11       

Steering gear - 2nd stage                                                                              90              90    

Power steering pump to bracket                                                                   25                 19       

Power steering pump pulley                                                                          25                 19       

                                                  Exhaust system                                             Nm               lbf.ft    

Front to rear exhaust pipe                                                                              47                 35       

Front exhaust pipe bracket to transmission crossmember                        47                 35       

Catalytic converter to exhaust manifold                                                        47                 35       

Catalytic converter bracket to automatic transmission                               44                 33       

Catalytic converter bracket to body                                                              47                 35       

Front catalytic converter bracket                                                                   24                 18       

                                                   Cylinder block                                                Nm               lbf.ft    

Main bearing                                                                                                   97                 72       

Big end bearing, 1st stage                                                                            7                   5         

Big end bearing, 2nd stage                                                                           16                 12       

Big end bearing, 3rd stage                                                                            90              90    

Balancer shaft housing to cylinder block, 1st stage                                    5                   4         

Balancer shaft housing to cylinder block, 2nd stage                                   17                 13       

Crankshaft rear oil seal carrier                                                                      15                 11       

Crankshaft pulley/vibration damper, 1st stage                                            52                 38       

Crankshaft pulley/vibration damper, 2nd stage                                           85              85    

Clutch Disk and Pressure Plate                                                                    29                 21       

Flywheel                                                                                                           87                 64       

Lower timing chain cover                                                                               11                 9         

Crankshaft position/speed sensor                                                                4                   3         

                                                   Cylinder Head                                               Nm               lbf.ft    

Cylinder head bolts, 1st stage                                                                       10                 7         

Cylinder head bolts, 2nd stage                                                                      35                 26       

Cylinder head bolts, 3rd stage                                                                      90              90    

Cylinder head bolts, 4th stage                                                                       90              90    

Auxiliary cylinder head bolts                                                                          38                 28       

Camshaft bearing caps                                                                                  24                 18       

Timing chain top guide                                                                                   12                 9         

Timing chain bottom guide                                                                            26                 19       

Camshaft sprockets                                                                                       59                 44       

Timing chain upper cover                                                                               11                 8         

Cylinder head cover, 1st stage                                                                      3                   2         

Cylinder head cover, 2nd stage                                                                    9                   7         

Camshaft position sensor (CMP sensor)                                                     5                   4         

Spark plugs                                                                                                     18                 13       

DIS ignition coils                                                                                             10                 7         

Ignition coil cover                                                                                            5                   4         

Studs for exhaust manifold                                                                             14                 10       

Engine oil dipstick tube bracket                                                                    24                 18       

Engine lifting eye, rear right                                                                           25                 18       

Engine lifting eye, front left                                                                             47                 35       

Inlet manifold                                                                                                    22                 16       

Fuel rail                                                                                                            23                 17       

Throttle housing                                                                                               10                 7         

Idle speed control valve                                                                                  10                 7         

Engine coolant temperature sensor (ECT sensor)                                     27                 20       

                                                   Oil circuit                                                        Nm               lbf.ft    

Oil intake tube to balancer shaft housing                                                     12                 9         

Sump to balancer shaft housing                                                                    12                 9         

Oil drain plug                                                                                                   24                 18       

Oil pressure switch                                                                                         27                 20       

Oil filter connector                                                                                           57                 42       

Oil pump                                                                                                           11                 8         

Oil pump sprocket                                                                                           21                 15       

Oil pump cover                                                                                                10                 7         

Oil pump sprocket                                                                                           21                 15       

Oil pump drive chain upper guide                                                                 26                 19       

Oil pump drive chain lower guide                                                                  12                 9         

Oil pump drive chain tensioner                                                                      12                 9         

                                                   Balancer shaft housing                                 Nm               lbf.ft    

Balancer shaft bearing caps to housing                                                       12                 9         

Sprockets to shaft stub                                                                                   19                 14       

                                                   Coolant circuit                                               Nm               lbf.ft    

Coolant pump                                                                                                  23                 17       

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