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Engine Data
Description | | 1.25l Zetec SE | 1.4l Zetec SE | 1.6l Zetec SE |
Engine management |
|
EEC V |
EEC V |
EEC |
Emission standard |
|
96 EEC |
96 EEC |
96 EEC |
Fuel |
|
95 RON |
95 RON |
95 RON |
Engine code from '96 MY (emission level D3/Germany) |
|
DHA |
|
|
Engine code '96,5 MY to '99,5 MY (emission level D3/Germany) |
|
|
FHA |
|
Engine code from '99 MY (emission level D4/Germany) |
|
DHB |
|
|
Engine code from '99,5 MY (emission level Stage II /Europe) |
|
DHC/DHD* |
|
|
Engine code from '99,5 MY (emission level D4/Germany) |
|
|
FHA |
|
Engine code from '99,5 MY (emission level Stage II /Europe) |
|
|
FHE |
|
Engine code 2001 MY (emission level Stage IV) |
|
DHF |
|
|
Engine code 2000.5 MY (emission level D4/E4) |
|
|
|
L1T |
Engine code 2001 MY (emission level Stage IV) |
|
|
|
L1V |
Firing order |
|
1 - 3 - 4 - 2 |
1 - 3 - 4 - 2 |
1 - 3 - 4 - 2 |
Bore diameter |
mm |
71.9 |
76.0 |
79.0 |
Stroke |
mm |
76.5 |
76.5 |
81.4 |
Displacement |
cm 3 |
1242 |
1388 |
1595 |
Compression ratio |
|
10:1 |
10.3:1 |
11:1 |
Power output (EC) |
kW |
55 |
66 |
76 |
Power output (EC) |
PS |
75 |
90 |
103 |
Power output (EC), at |
rpm |
5200 |
5600 |
6000 |
Torque |
Nm |
110 |
125 |
145 |
Torque at |
rpm |
4000 |
4500 |
4000 |
Max. engine speed, continuous |
rpm |
5950 |
6350 |
6450 |
Max. engine speed, intermittent |
rpm |
6175 |
6575 |
6800 |
* DHA and DHD engines - MAF-calibration, CTX automatic transmission from '99 MY.
* DHB and DHC engines - speed density calibration, iB5 manual transmission
Camshaft
Description | | 1.25l Zetec SE | 1.4l Zetec SE | 1.6l Zetec SE |
Drive |
|
Timing belt |
Timing belt |
Timing belt |
Inlet opens before TDC |
Degrees |
2 |
4 |
6 |
Inlet closes after BDC |
Degrees |
42 |
44 |
46 |
Exhaust opens before BDC |
Degrees |
34 |
34 |
38 |
Exhaust closes after TDC |
Degrees |
10 |
10 |
6 |
Valves
Description | | 1.25l Zetec SE | 1.4l Zetec SE | 1.6l Zetec SE |
Valve control |
|
Bucket tappets |
Bucket tappets |
Bucket tappets |
Valve clearance (engine cold), inlet |
mm |
0.17 - 0.23 |
0.17 - 0.23 |
0.17 - 0.23 |
Valve clearance (engine cold), exhaust |
mm |
0.27 - 0.33 |
0.27 - 0.33 |
0.31 - 0.37 |
Free valve spring length |
mm |
53.2 |
53.2 |
53.2 |
Valve spring inside diameter |
mm |
16.85 - 17.15 |
16.85 - 17.15 |
16.85 - 17.15 |
Valve spring wire diameter |
mm |
2.77 - 2.83 |
2.77 - 2.83 |
2.77 - 2.83 |
Number of turns (active) |
|
7.2 |
7.2 |
7.2 |
Valve length, inlet |
mm |
97.65 |
97.35 |
96.95 |
Valve length, exhaust |
mm |
99.70 |
99.40 |
99.40 |
Valve head diameter, inlet |
mm |
25.95 - 26.25 |
27.95 - 28.25 |
29.95 - 30.25 |
Valve head diameter, exhaust |
mm |
21.95 - 22.25 |
23.95 - 24.25 |
23.95 - 24.25 |
Cylinder Block Dimensions
Description | | 1.25l Zetec SE | 1.4l Zetec SE | 1.6l Zetec SE |
Cylinder bore dia., class 1 |
mm |
71.900 - 71.910 |
76.000 - 76.010 |
79.000 - 79.010 |
Cylinder bore dia., class 2 |
mm |
71.910 - 71.920 |
76.010 - 76.020 |
79.010 - 79.020 |
Cylinder bore dia., class 3 |
mm |
71.920 - 71.930 |
76.020 - 76.030 |
79.020 - 79.030 |
Crankshaft Dimensions
Description | | 1.25l Zetec SE | 1.4l Zetec SE | 1.6l Zetec SE |
Crankshaft end float |
mm |
0.220 - 0.430 |
0.220 - 0.430 |
0.220 - 0.430 |
Piston Dimensions
Description | | 1.25l Zetec SE | 1.4l Zetec SE | 1.6l Zetec SE |
Piston diameter, class 1 (1.25l up to 13.10.96 and 1.4l) |
mm |
71.875 - 71.885 |
75.975 - 75.985 |
78.955 - 78.965 |
Piston diameter, class 2 (1.25l up to 13.10.96 and 1.4l) |
mm |
71.885 - 71.895 |
75.985 - 75.995 |
78.965 - 78.975 |
Piston diameter, class 3 (1.25l up to 13.10.96 and 1.4l) |
mm |
71.895 - 71.905 |
75.995 - 80.005 |
78.975 - 78.985 |
Piston diameter, class 1 (from 14.10.96) |
mm |
71.885 - 71.915 |
- |
- |
Piston diameter, class 2 (from 14.10.96) |
mm |
71.895 - 71.925 |
- |
- |
Piston diameter, class 3 (from 14.10.96) |
mm |
71.905 - 71.935 |
- |
- |
Piston diameter, class 1 (from 05.03.97) |
mm |
71.875 - 71.905 |
- |
- |
Piston diameter, class 2 (from 05.03.97) |
mm |
71.885 - 71.915 |
- |
- |
Piston diameter, class 3 (from 05.03.97) |
mm |
71.895 - 71.925 |
- |
- |
Piston ring gap, upper |
mm |
0.2 - 0.3 |
0.2 - 0.3 |
0.18 - 0.28 |
Piston ring gap, middle |
mm |
0.3 - 0.5 |
0.3 - 0.5 |
0.7 - 0.9 |
Piston ring gap, lower |
mm |
0.3 - 0.7 |
0.15 - 0.65 |
0.15 - 0.65 |
Piston ring end float, upper |
mm |
0.04 - 0.08 |
0.04 - 0.08 |
0.04 - 0.08 |
Piston ring end float, middle |
mm |
0.03 - 0.06 |
0.03 - 0.06 |
0.025 - 0.07 |
The piston ring gaps must be distributed evenly around the circumference of the piston. This also applies to the elements of the oil scraper ring. Offset the ring gaps by 120° to one another.
Cylinder Head
Description | | 1.25l Zetec SE | 1.4l Zetec SE | 1.6l Zetec SE |
Maximum distortion (mating face) |
mm |
0.05 |
0.05 |
0.05 |
Engine Oil
Viscosity/ambient temperature | Type | Specification |
Recommended engine oils: |
SAE 5W30 / below -20 to over 40 degrees Celsius |
Ford Formula E Economy Motor Oil |
ACEA A1/B1 and WSS-M2C912-A1 or WSS-M2C913-A |
Engine oils for topping up: |
SAE 10W30 / -20 to over 40 degrees Celsius |
Ford Super Multigrade Engine Oil |
ACEA A1/B1 or A2/B2 and/or API/SH/CD EC |
SAE 10W40 / -20 to over 40 degrees Celsius |
Ford XR+ High Performance High Lubricity Engine Oil |
ACEA A3/B3 and/or API/SH/CD EC |
SAE 5W40 / below -20 to over 40 degrees Celsius |
Ford Formula S Synthetic Motor Oil |
ACEA A3/B3 and/or API/SH/CD EC |
If these specified engine oils are not available, other engine oils may be used, provided they at least fulfil the API/SH/EC specification.
Lubricants, Sealers and Adhesives
Item | Specification |
Sealer, oil pan contact surface to oil seal carrier, oil pan to cylinder block, oil pan to oil pump |
WSK-M4G323-A4 |
Oil pressure switch sealer (Loctite 243) |
WSK-M2G349-A7 |
Sealer, camshaft bearing cap to cylinder head |
WSK-M2G348-A2 |
Lubricant, spark plug threads (Never Seez) |
ESE-M1244-A |
Lubricant for Special Tool 21-215 |
WSD-M1C227-A |
Coolant (Motorcraft Super Plus 4 AntiFreeze) |
ESDM-97B49-A |
Power steering fluid |
ESPM-2C-166-A |
Transmission fluid (AFT) |
ESP-M2C166-H |
Transmission fluid (Tutela) |
A92CT-7000-EM/FC |
Silicone grease |
ESE-M1C171-AA |
Engine Lubrication
Description | | |
Oil pressure (minimum, oil temperature 80 degrees C) at 800 rpm |
bar |
1.0 |
Oil pressure (minimum, oil temperature 80 degrees C) at 2000 rpm |
bar |
2.5 |
Pressure relief valve opening pressure |
bar |
5 |
If other engine oil brands are used, it must be ensured that they conform to the relevant API SH/EC or higher viscosity class.
Capacities - 1.25l/1.4L
Description | Litres |
Engine oil, for initial fill |
4.25 |
Engine oil, for oil change incl. filter (EFL500) |
3.75 |
Engine oil, for oil change incl. filter (EFL10) |
3.80 |
Engine oil, for oil change excl. filter |
3.50 |
Capacities - 1.6l
Description | Litres |
Engine oil, for initial fill incl. filter (EFL600) |
4.50 |
Engine oil, for initial fill incl. filter (EFL10) |
4.30 |
Engine oil, for oil change incl. filter (EFL600) |
4.25 |
Engine oil, for oil change incl. filter (EFL10) |
4.10 |
Engine oil, for oil change excl. filter |
3.75 |
Tightening Torques
Description | Nm | lb-ft | lb-in |
Exhaust pipe to flexible exhaust pipe |
47 |
35 |
— |
Exhaust manifold to catalytic converter |
47 |
35 |
— |
Stabilizer link rod |
47 |
35 |
— |
Lower suspension arm to wheel knuckle |
52 |
38 |
— |
Track rod to wheel knuckle |
36 |
27 |
— |
Nut - halfshaft hub |
270 |
199 |
— |
Center bearing to bracket |
24 |
18 |
— |
Battery cable to starter motor |
6 |
— |
53 |
Solenoid switch cable to starter |
11 |
8 |
— |
Radiator crossmember |
25 |
18 |
— |
Fluid pipes to transmission |
21 |
15 |
— |
Ground lead to transmission |
30 |
22 |
— |
Ground lead to generator |
11 |
8 |
— |
Suspension strut nut |
45 |
33 |
— |
Wheel nuts |
85 |
63 |
— |
Battery box |
25 |
18 |
— |
Tightening Torques
Description | Nm | lb-ft | lb-in |
Front engine mounting bracket bolts |
55 |
41 |
— |
Rear engine mounting bracket nuts |
69 |
51 |
— |
Rear engine mounting bracket bolts |
49 |
36 |
— |
Engine roll restrictor to engine |
50 |
37 |
— |
Engine roll restrictor to front crossmember |
70 |
52 |
— |
Tightening Torques
Description | Nm | lb-ft | lb-in |
EGR pipe to intake manifold |
20 |
15 |
— |
EGR pipe bracket to cylinder head |
9 |
— |
80 |
EGR pipe to EGR valve |
55 |
41 |
— |
EGR valve to cylinder head |
31 |
23 |
— |
EGR pipe to exhaust manifold |
72 |
53 |
— |
Tightening Torques
Description | Nm | lb-ft | lb-in |
Drive belt idler pulley |
24 |
18 |
— |
Power steering pump to cylinder block |
23 |
17 |
— |
Tightening Torques
Description | Nm | lb-ft | lb-in |
Coolant pump to cylinder block |
9 |
— |
80 |
Coolant pump belt pulley |
24 |
18 |
— |
Thermostat housing to cylinder block |
9 |
— |
80 |
Coolant outlet housing to cylinder head |
20 |
15 |
|
Engine coolant temperature sensor (ECT sensor) to coolant outlet |
12 |
9 |
|
Blower thermoswitch to coolant outlet housing |
9 |
— |
80 |
Radiator drain plug |
20 |
15 |
— |
Tightening Torques
Description | Nm | lb-ft | lb-in |
Oil pump to cylinder block |
9 |
— |
80 |
Oil baffle to cylinder block |
9 |
— |
80 |
Oil intake pipe to main bearing bridge and to oil pump |
9 |
— |
80 |
Oil pan to cylinder block |
20 |
15 |
— |
Oil pressure switch to cylinder block |
15 |
11 |
— |
Oil dipstick tube to cylinder head |
9 |
— |
80 |
Oil drain plug |
37 |
27 |
— |
Oil filter |
17 |
13 |
— |
Oil filter connector to cylinder block connector |
45 |
33 |
— |
Tightening Torques
Description | Nm | lb-ft | lb-in |
Cylinder head to cylinder block stage 1 |
15 |
11 |
— |
Cylinder head to cylinder block stage 2 |
30 |
22 |
— |
Cylinder head to cylinder block stage 3 (degrees) |
90 |
90 |
— |
Front engine mounting bracket |
55 |
41 |
— |
Cylinder head cover to cylinder head, stage 1 |
3 |
— |
27 |
Cylinder head cover to cylinder head, stage 2 |
10 |
— |
89 |
Cylinder head cover plate |
6 |
— |
53 |
Intake manifold |
18 |
13 |
— |
Fuel rail |
23 |
17 |
— |
Exhaust manifold studs |
10 |
— |
89 |
Exhaust manifold |
54 |
40 |
— |
Camshaft position sensor (CMP sensor) |
8 |
— |
71 |
Spark plugs |
15 |
11 |
— |
Front engine lifting eye (up to 6/98) |
50 |
37 |
— |
Rear engine lifting eye |
20 |
15 |
— |
Coolant outlet studs |
10 |
— |
89 |
DIS ignition coil to coolant outlet housing |
6 |
— |
53 |
Tightening Torques
Description | Nm | lb-ft | lb-in |
Camshaft bearing caps, stage 1 |
6 |
— |
53 |
Camshaft bearing caps, stage 2 |
15 |
11 |
— |
Upper timing belt cover to cylinder block |
9 |
— |
80 |
Lower timing belt cover to crankcase |
9 |
— |
80 |
Anti-skip device to cylinder block |
9 |
— |
80 |
Timing belt tensioning pulley |
20 |
15 |
— |
Camshaft pulley bolt |
60 |
44 |
— |
Tightening Torques
Description | Nm | lb-ft | lb-in |
Crankshaft position (CKP) sensor mounting to cylinder block |
9 |
— |
80 |
Crankshaft position (CKP) sensor to mounting |
9 |
— |
80 |
Rear crankshaft oil seal carrier |
9 |
— |
80 |
Crankcase breather to cylinder block |
9 |
— |
80 |
Bore blanking plug for TDC peg |
20 |
15 |
— |
Tightening Torques
Description | Nm | lb-ft | lb-in |
Vibration damper to crankshaft, stage 1 |
40 |
30 |
— |
Vibration damper to crankshaft, stage 2 (degrees) |
90 |
90 |
— |
Big-end bearing cap to connecting rod, stage 1 |
8 |
— |
71 |
Big-end bearing cap to connecting rod, stage 2 (degrees) |
90 |
90 |
— |
Flywheel to crankshaft, stage 1 |
30 |
22 |
— |
Flywheel to crankshaft, stage 2 (degrees) |
80 |
80 |
— |
Clutch to flywheel |
30 |
22 |
— |
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