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Specifications
Engine Data
Engine management |
|
EDC |
EDC |
Emission standard |
|
96 EC |
96 EC |
Fuel |
|
Diesel |
Diesel |
Engine code |
|
1Z (to 15.09.96) or AHU (from 16.09.96) |
AFN (from 11/97) |
Injection Sequence |
|
1‐3‐4‐2 |
1‐3‐4‐2 |
Bore |
mm |
79,5 |
79,5 |
Stroke |
mm |
95,5 |
95,5 |
Cubic capacity (effective) |
cm3 |
1896 |
1896 |
Compression ratio |
|
19,5:1 |
19,5:1 |
Compression pressure at starter motor speed, new |
bar |
25‐31 |
25‐31 |
Compression pressure at starter motor speed, wear limit |
bar |
19 |
19 |
Compression pressure at starter motor speed, max. permitted pressure difference between cylinders |
bar |
5 |
5 |
Power output (EC) |
kW(PS) |
66 (90) |
81 (110) |
|
rev/min |
4000 |
4150 |
Torque (EC) |
Nm |
202 |
235 |
Torque according to EC (from 08/97) |
Nm |
210 |
235 |
|
rev/min |
1900 |
1900 |
Idle speed |
rev/min |
900 |
900 |
Max. engine speed (intermittent) |
rev/min |
5100 |
5100 |
Location of engine code on cylinder block
1. Engine code (two or three characters).
Diesel engine 90 PS:1Z (built to 15.09.96) or AHU (built from 16.09.96)
Diesel engine 110 PS: AFN (from 11/97)
2. Engine serial number.
Engine code location on the timing belt cover
1 Timing belt cover.
2 Label showing engine code and serial number.
Number of main bearings |
|
5 |
Cylinder bore Ø, class 1. |
mm |
79,51 |
Cylinder bore Ø, class 2. |
mm |
79,76 |
Cylinder bore Ø, class 3. |
mm |
80,01 |
Main bearing clearance (radial), new |
mm |
0,03 ‐ 0,08 |
Main bearing clearance (radial), wear limit |
mm |
0,17 |
Main bearing journal diameter, standard |
mm |
53,958 ‐ 53,978 |
Main bearing journal Ø, stage 1 |
mm |
53,708 ‐ 53,728 |
Main bearing journal Ø, stage 2 |
mm |
53,458 ‐ 53,478 |
Main bearing journal Ø, stage 3 |
mm |
53,208 ‐ 53,228 |
Crankshaft end‐float, new |
mm |
0,07 ‐ 0,17 |
Crankshaft end‐float, wear limit |
mm |
0,37 |
Big‐end bearing/rod bearing journal diameter, standard |
mm |
47,538 ‐ 47,778 |
Big‐end bearing journal Ø, stage 1 |
mm |
47,508 ‐ 47,528 |
Big‐end bearing journal Ø, stage 2 |
mm |
47,258 ‐ 47,278 |
Big‐end bearing journal Ø, stage 3 |
mm |
47,008 ‐ 47,028 |
Axial play, connecting rod to crank web, wear limit |
mm |
0,37 |
Locating dowel projection, speed sensor on crankshaft |
mm |
2,5 ‐ 3,0 |
Big‐end bearing clearance (radial), wear limit |
mm |
0,08 |
Piston Ø (measured at a right angle to the piston pin bore), class 1 |
mm |
79,47 |
Piston Ø, class 2 |
mm |
79,72 |
Piston Ø, class 3. |
mm |
79,97 |
Piston ring clearance in piston groove, upper compression ring |
mm |
0,06 ‐ 0,09 |
Wear limit |
mm |
0,25 |
Piston ring clearance in piston groove, lower compression ring |
mm |
0,05 ‐ 0,08 |
Wear limit |
mm |
0,25 |
Piston ring clearance in piston groove, oil control ring |
mm |
0,03 ‐ 0,06 |
Wear limit |
mm |
0,15 |
Piston ring gap, upper compression ring |
mm |
0,20 ‐ 0,40 |
Wear limit |
mm |
1,00 |
Piston ring gap, lower compression ring |
mm |
0,20 ‐ 0,40 |
Wear limit |
mm |
1,00 |
Piston ring gap, oil scraper ring |
mm |
0,25 ‐ 0,50 |
Wear limit |
mm |
1,00 |
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. The ring gaps are offset to one‐another.) |
Degrees |
120 |
Piston pin retention |
|
Snap ring |
Valve seat angle |
Degrees |
45 |
Classification of the cylinder head gasket depending on the piston protrusion |
|
Number of notches/holes |
Piston protrusion 0,91 ‐ 1,00 mm |
|
1 |
Piston protrusion 1,01 ‐ 1,10 mm |
|
2 |
Piston protrusion 1,11 ‐ 1,20 mm |
|
3 |
Max. permissible unevenness/distortion across the whole surface of the cylinder head |
mm |
0,1 |
Do NOT rework the cylinder head mating face |
|
|
Crack width between valve seats |
mm |
max. 0,5 |
Number of camshafts |
|
1 |
Drive |
|
Timing Belt |
Number of camshaft bearings |
|
5 |
Valve timings, inlet opens after TDC |
Degrees CS |
16 |
Valve timings, inlet closes after BDC |
Degrees CS |
25 |
Valve timings, exhaust opens before BDC |
Degrees CS |
28 |
Valve timings, exhaust closes before TDC |
Degrees CS |
19 |
Camshaft end‐float, wear limit |
mm |
max. 0,15 |
Camshaft bearing radial clearance, wear limit |
mm |
max. 0,11 |
Out of true ‐ camshaft |
mm |
max. 0,01 |
Valve tappet clearance, wear limit |
mm |
0,1 |
Valve head diameter, inlet |
mm |
35,95 |
Valve head diameter, exhaust |
mm |
31,45 |
Valve stem diameter, standard inlet |
mm |
7,97 |
Valve stem diameter, standard exhaust |
mm |
7,95 |
Valve length, inlet |
mm |
96,85 |
Valve length, exhaust |
mm |
96,85 |
Valve stem guide free play, inlet |
mm |
max. 1,3 |
Valve stem guide free play, exhaust |
mm |
max. 1,3 |
Oil pressure (oil temperature approx. 80°C) at 2000 rev/min |
bar |
min. 2,0 |
Oil pressure (oil temperature approx. 80°C) at higher engine speeds |
bar |
max. 7,0 |
Pressure relief valve opening pressure |
bar |
5,7 ‐ 6,7 |
Oil pump backlash, new |
mm |
0,05 |
Oil pump backlash, wear limit |
mm |
0,20 |
Oil pump end float, wear limit |
mm |
0,15 |
Recommended engine oils: |
|
|
SAE 10W40 / ‐20 to over 40 degrees Centigrade |
Ford XR+ High‐performance High‐lubricity Motor Oil |
ACEA A3‐96, B3‐96 or API/SH/CD EC |
Alternative engine oils: |
|
|
SAE 5W40 / below ‐20 to above 40 degrees Centigrade |
Ford Formula S Synthetic Motor Oil |
ACEA A3‐96, B3‐96 or API/SH/CD EC |
SAE 15W40 / ‐15 to over 40 degrees Centigrade |
Ford Super Multigrade Motor Oil |
ACEA A2‐96, B2‐96 or A3‐96, B3‐96 or API/SH/CD EC |
If engine oils to these specifications are not available, then only engine oils which at least meet the API SH/CD EC specification and the CCMC PD2 specification may be used. |
Lubricants, Adhesives and Sealers
Coolant |
ESDM‐97B49‐A |
Brake and clutch fluid (DOT 4) |
SAM 6C9103 A |
Manual transmission fluid (VXT 75) |
ESD‐M2C186‐A |
Power steering hydraulic fluid |
N052146 VX00 |
Sealer ‐ joints in sealing flange face/cylinder block, sump side |
SM‐M8G1013‐AA |
Sealer ‐ contact surfaces to the oil filter bracket outside the sealing ring |
AMV 188 100 02 (VW) |
Sealer ‐ oil spray nozzles, piston crown cooling |
AMV 188 100 02 (VW) |
Engine oil (incl. filter change) |
4,3 |
Engine oil (excl. filter change) |
3,8 |
Coolant (vehicles with booster heater) |
9,2 |
Manual transmission fluid (VXT 75), total capacity |
2,0 |
Manual transmission fluid (VXT 75), total capacity (from '98 MY) |
2,25 |
Turbocharger intake tube to intake manifold |
10 |
7 |
Intake manifold to cylinder head |
25 |
18 |
Exhaust manifold to cylinder head |
25 |
18 |
Turbocharger bracket to cylinder block/turbocharger |
25 |
18 |
Heat shield to exhaust manifold |
25 |
18 |
Exhaust gas recirculation (EGR) pipe |
25 |
18 |
Turbocharger to exhaust manifold |
35 |
26 |
Front exhaust pipe to turbocharger |
25 |
18 |
Front exhaust pipe to catalytic converter |
25 |
18 |
Alternator to auxiliary bracket |
23 |
17 |
Cable (terminal 30) to alternator |
14 |
10 |
Clutch pressure plate |
25 |
18 |
Ground lead to transmission flange |
17 |
13 |
Cable guide to starter motor |
17 |
13 |
Cable (terminal 30) to starter motor |
14 |
10 |
Driveshaft centre bearing to cylinder block bracket |
27 |
20 |
Oil drain plug ‐ manual transmission |
35 |
26 |
Oil filler plug ‐ manual transmission |
35 |
26 |
Air conditioning compressor |
44 |
32 |
Injection pump |
25 |
18 |
Injection pump bracket (install new bolts), 1st stage |
20 |
15 |
Injection pump bracket, 2nd stage |
90° |
90° |
Injection pump timing pulley |
55 |
41 |
Fuel feed banjo bolt to injection pump |
23 |
17 |
Fuel return banjo bolt to injection pump |
23 |
17 |
Injection pipes |
25 |
18 |
Injector mountings |
22 |
16 |
Pulley to coolant pump |
23 |
17 |
Coolant neck to cylinder head (left and rear sides of engine) |
10 |
7 |
Coolant pipe bracket to cylinder block |
10 |
7 |
Thermostat housing |
10 |
7 |
Power steering pump |
25 |
18 |
Power steering pump pressure line bracket to cylinder block. |
20 |
15 |
Power steering pump pulley |
23 |
17 |
Steering gear to front crossmember |
48 |
35 |
Engine roll restrictor (steel) to transmission |
98 |
72 |
Engine roll restrictor (aluminium) to transmission bolt, 88 mm long, Stage 1 |
60 |
44 |
Engine roll restrictor (aluminium) to transmission bolt, 88 mm long, Stage 2 |
90° |
90° |
Front engine mounting bracket to hydraulic engine mounting |
54 |
40 |
Front engine mounting bracket to engine support plate |
61 |
45 |
Engine support plate to engine |
58 |
43 |
Engine support plate (outer part to inner) |
23 |
17 |
Rear hydraulic engine mounting to body |
54 |
40 |
Turbocharger oil return pipe banjo bolt |
30 |
22 |
Turbocharger oil feed pipe, banjo bolt to cylinder head |
25 |
18 |
Turbocharger oil feed pipe, pipe to turbocharger, union nut |
25 |
18 |
Oil pump to cylinder block |
25 |
18 |
Oil intake pipe to oil pump |
10 |
7 |
Oil pump cover |
10 |
7 |
Sump |
20 |
15 |
Engine oil drain plug |
30 |
22 |
Oil filter carrier to cylinder block |
25 |
18 |
Oil cooler to oil filter carrier |
25 |
18 |
Oil pressure switch |
25 |
18 |
Front axle crossmember to bodywork, stage 1 |
150 |
111 |
Front axle crossmember to bodywork, stage 2 |
90° |
90° |
Transverse arm ball joint to spindle carrier |
55 |
41 |
Track rod end to spindle carrier, stage 1 |
30 |
22 |
Track rod end to spindle carrier, stage 2 |
90° |
90° |
Stabiliser bar link rod to suspension strut |
100 |
74 |
Suspension strut nut |
60 |
44 |
Wheel bolts (except with 16 inch aluminium wheels) |
140 |
103 |
Wheel bolts (only with 16 inch aluminium wheels) |
170 |
125 |
Oil spray nozzle, piston crown cooling |
10 |
7 |
Main bearing (install new bolts), 1st stage |
65 |
48 |
Main bearing, 2nd stage |
90° |
90° |
Big‐end bearing (install new bolts), 1st stage |
30 |
22 |
Big‐end bearing, stage 2 |
90° |
90° |
Front crankshaft oil seal carrier |
25 |
18 |
Rear crankshaft oil seal carrier |
10 |
7 |
Engine adapter plate |
10 |
7 |
Flywheel (install new bolts), 1st stage |
60 |
44 |
Flywheel, stage 2 |
90° |
90° |
Vacuum pump to cylinder block |
20 |
15 |
Lower timing belt cover |
10 |
7 |
Rear timing belt cover to cylinder head |
10 |
7 |
Auxiliary shaft oil seal carrier |
25 |
18 |
Auxiliary shaft pulley |
45 |
33 |
Timing belt tensioner |
20 |
15 |
Timing belt idler pulley |
25 |
18 |
Crankshaft timing pulley (install new bolts), 1st stage |
90 |
66 |
Crankshaft timing pulley, 2nd stage |
90° |
90° |
Camshaft timing pulley. |
45 |
33 |
Pulley/vibration damper to crankshaft timing pulley |
25 |
18 |
Accessory bracket to injector pump bracket |
30 |
22 |
Accessory bracket to cylinder block |
30 |
22 |
Crankshaft position (CKP) sensor to cylinder block |
10 |
7 |
Engine speed sensor ring to crankshaft (install new bolts), 1st Stage |
10 |
7 |
Engine speed sensor ring to crankshaft 2nd Stage |
90° |
90° |
Mounting bracket 21‐150A to cylinder block |
43 |
32 |
Crankcase breather connector to cylinder block |
25 |
18 |
Driveshaft centre bearing bracket to cylinder block |
43 |
32 |
Crankcase breather to cylinder block |
25 |
18 |
Cylinder head, stage 1 |
40 |
30 |
Cylinder head, stage 2 |
60 |
44 |
Cylinder head, stage 3 |
90° |
90° |
Cylinder head, stage 4 |
90° |
90° |
Camshaft bearing caps |
20 |
15 |
Glow plugs |
15 |
11 |
Cylinder head cover |
10 |
7 |
Engine wiring harness bracket to cylinder head |
10 |
7 |
Camshaft bearing caps |
20 |
15 |
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