General Specifications Location of engine code/serial ... - Ford Scorpio

2,5l TCI Diesel EngineGeneral SpecificationsEngine Data2,5 TCI Diesel EngineEngine managementEDCEmission standard94 EEC/12FuelDieselEngine codeSCDInjection sequence 1–3–4–2Bore mm 92Stroke mm 94Cubic capacity effective cc 2498Compression ratio 20,2 – 21,7 : 1Compression pressure at starter motor speed bar 24 – 26Power output (EEC) kW 92at rev/min 4200Power output (DIN) kW 85PS PS 115at rev/min 4200Torque (EEC/DIN) 293at rev/min 2000Idle speed rev/min 875 25Location of engine code/serial number11. Serial number2. Engine code2D2103095DimensionsmmCylinder block and main bearing housingsNumber of main bearings 5Main bearing inside ∅, frontStandard 63,043 – 63,0881st undersize 0,25 62,793 – 62,8382nd undersize 0,50 62,543 – 62,588Main bearing shell width, front 31,750 – 32,250Main bearing clearance (radial), front 0,043 – 0,10310/96 Scorpio ’95 00-01-1

2,5l TCI Diesel EngineDimensionsmmFront main bearing, depth from front face 6Main bearing inside ∅ - main bearing housingStandard 63,050 – 63,0931st undersize 0,25 62,800 – 62,8432nd undersize 0,50 62,550 – 62,593Main bearing shell width - main bearing housing 29,750 – 30,000Main bearing clearance (radial) - main bearing housing 0,030 – 0,073Main bearing inside ∅, rearStandard 70,050 – 70,0651st undersize 0,25 69,800 – 69,8152nd undersize 0,50 69,550 – 69,565Main bearing shell width, rear 31,750 – 32,250Main bearing clearance (radial), rear 0,050 – 0,085Camshaft bearing inside ∅,Windscreen 53,540 – 53,590Middle 53,540 – 53,590Rear 53,540 – 53,590Camshaft bearing clearance (radial) 0,030 – 0,095Cylinder linersCylinder liner ∅Class A 92,000 – 92,010Class B 92,010 – 92,020Cylinder liner protrusion 0,00 – 0,05Thickness of shims 0,15 / 0,17 / 0,20 / 0,23 / 0,25CrankshaftMain bearing journal ∅, frontStandard 62,985 – 63,0001st undersize 0,25 62,735 – 62,7502nd undersize 0,50 62,485 – 62,500Main bearing journal ∅ – main bearing housingStandard 63,005 – 63,0201st undersize 0,25 62,755 – 62,7702nd undersize 0,50 62,505 – 62,520Main bearing journal ∅, rearStandard 79,980 – 80,0001st undersize 0,25 79,730 – 79,7502nd undersize 0,50 79,480 – 79,500Big-end bearing journal ∅Standard 53,940 – 53,9551st undersize 0,25 53,690 – 53,7052nd undersize 0,50 53,440 – 53,440Crankshaft end float 0,153 – 0,304Thickness of thrust washers10/96 Scorpio ’95 00-01-2

2,5l TCI Diesel EngineDimensionsmmStandard 2,311 – 2,3621st oversize 2,411 – 2,4622nd oversize 2,511 – 2,562Connecting RodsBearing inner ∅, big-endStandard 53,977 – 54,0161st undersize 0,25 53,727 – 53,7662nd undersize 0,25 53,477 – 53,516Bearing shell width 22,750 – 23,250Connecting rod bearing clearance (radial), big-end 0,022 – 0,076Bearing inner ∅, small end 30,035 – 30,050PistonsPiston ∅ (measured at right-angles to the piston pinbore)Class A 91,935 – 91,945Class B 91,945 – 91,955Piston clearance (when first fitted) class A – B 0,055 – 0,075Piston protrusion at TDC 0,530 – 0,820Piston ring gaps (fitted)Upper compression ring 0,25 – 0,50Lower compression ring 0,20 – 0,35Oil control ring 0,25 – 0,58Piston ring clearance in piston grooveupper compression ring 0,080 – 0,130lower compression ring 0,070 – 0,102Oil control ring 0,040 – 0,072Ring gap positionsThe piston ring gaps must be spreadevenly around the circumference of thepiston. This also applies to the elements ofthe oil control ring. Stagger the ring gaps atintervals of 120.Piston pinsPiston pin typePiston pin retentionPiston pin ∅“Floating” in piston and connecting rodCirclipsClass A 29,990 – 29,993Class B 29,993 – 29,996Piston pin clearance (radial)Class A 0,039 – 0,042Class B 0,057 – 0,060Cylinder headsNumber of cylinder heads 4Height of cylinder heads 89,950 – 90,050Height of end spacers 89,295 – 90,05010/96 Scorpio ’95 00-01-3

2,5l TCI Diesel EngineDimensionsThickness of cylinder head gasket with piston protrusionofmm(Number of notch marks)0,53 – 0,62 1,42 (1)0.63 – 0.72 mm 1,52 (2)0.73 – 0.82 mm 1,62 (0)CamshaftValve timingsInlet opens BTDC26 C/SExhaust closes ATDCCam lift (camshaft)36 C/SInlet 7,019Exhaust 7,303Thickness of thrust plate, (S) 3,950 – 4,050Camshaft end float 0,050 – 0,200Bearing journal ∅53,495 – 53,5101st undersize 0,25 53,245 – 53,260Fuel injection pumpManufacturerTypeBoschVP36–VE4/10E2100 L688Setting – plunger stroke after BDC 0,53 – 0,57Engine OilAmbient TemperatureSpecification–15 to above +40 C Ford Super Engine Oil SAE 15W40 – API SH/CD–10 to above +40 C Ford Super Engine Oil SAE 20W50 API SG/CD–25 to above +40 C Ford XR+High-performanceHigh-lubricity Engine Oil–25 to above +40 C Ford Formula S SyntheticEngine OilSAE 15W40 – API SH/CDSAE 5W50 API SG/CDEngine LubricationbarOil pressure (minimum) , at idle speed 1,5(Oil temperature approx. 100 C) at 4000 rev/min 4Pressure relief valve opening pressure 6,38Lubricants, Fluids and SealersDescriptionCoolantTransmission fluid (MT 75)Lubricant – cylinder liner (bottom), connecting rod bolts, crankshaft rearoil seal, hydraulic tappetsFord SpecificationESD-M97B-49-AESD–M2C186–ASAE 15W40 API SG/CD(engine oil)10/96 Scorpio ’95 00-01-4

2,5l TCI Diesel EngineLubricants, Fluids and SealersLubricant for main and camshaft bearings, big-end bearings, oil pumppivot pins, vacuum pump pivot pins, timing gearsLubricant for M12 cylinder head boltsLubricant for M14 cylinder head boltsLubricant for O-rings, crankshaft thrust washersCylinder liner adhesive Loctite 222Adhesive for oil dipstick tube, fuel injection pump studs, oilway blankingplugs, piston cooling nozzlesAdhesive for coolant temperature sensors, crankshaft pulley/vibrationdamper nut (Loctite 510)Adhesive for pressure relief valve, cylinder block plugsSealer for sumpSealer for injectorsSealer – timing cover to engine blockSQM–2C–9002–AAHypoid oil SAE90SAE 15W40 – API SG/CD(engine oil)SQM–2C–9002–AAHypoid oil SAE90ESD-M1C220-AWSK-M2G351-A4WSK-M2G349-A1WSK–M2G349–A7WSK–M2G348–A5SLM–4G9111–AESEAM–1C1014SPM–2G9121–ACapacitiesDescriptionLitresEngine oil, first fill with filter 7,3incl. filter change 6,6excl. filter change 6,0Coolant 7,0Transmission fluid (MT 75) 1,2Timing Belt TensionDescriptionBelt tension, new (N) 332 – 375Setting of automatic belt tensioner (X) 85Follow the instructions toadjust the belt tension.TorquesGeneral Nm lbf.ftHood hinge bolts 23 17Front axle transverse brace to side members 80 59Front axle/engine crossmember to side members 80 59Starter motorPositive lead to starter motorStarter motor to transmission intermediate flange 35 26Heat shield bracket to starter motor 12 9Inlet manifoldInlet manifold to cylinder heads 32 24Exhaust manifoldExhaust manifold to cylinder heads 32 2410/96 Scorpio ’95 00-01-5

2,5l TCI Diesel EngineTorquesExhaust manifold to catalytic converter 47 35Exhaust pipe to turbocharger 45 33Exhaust pipe to catalytic converter 45 33Fuel injection pumpGear to fuel injection pump 88 65Blanking plug in fuel injection pump timing openingFuel injection pipes to injectors and fuel injection pump 17 13Fuel return pipe to fuel injection pump 27 20AlternatorAlternator bracket to cylinder block (M10) 47 35Alternator to bracket – lower position 28 21Alternator to bracket – upper position 47 35TransmissionTransmission intermediate flange to engine (M8) 27 20M10 47 35Transmission intermediate flange to sump 37 27Transmission housing to sump 38 28Transmission housing to transmission intermediate flange 44 32Transmission mounting bracket 44 32Starter motor to transmission intermediate flange 35 26Crankshaft position (CKP) sensor to transmission intermediate flange 12 9Coolant circuitRadiator and intercooler to crossmember 23 17Coolant collecting pipe to cylinder heads 12 9Coolant pump to cylinder block 25 18Coolant pipe bracket to cylinder block 27 20Coolant expansion tank to engine 5 4SteeringSteering intermediate shaft to steering shaft 24 18Power steering pump pulley 31 23Power steering pump with bracket to cylinder block 132 97Power steering pump to bracket 21 16Oil circuitOil intake pipe bracket to cylinder block 27 20Oil feed pipe to turbocharger 27 20Sump blanking plug 35 26Oil pipes to oil filter intermediate housing 60 44Sump to cylinder block 12 9Oil pump to cylinder block 27 20Rocker arm oil feed pipe to cylinder heads 13 10Oil feed pipe extension to cylinder block 25 18Rocker arm oil feed pipe to connector 23 17Oil feed pipe to hollow retaining screw in main bearing housing 33 24Oil feed pipes to extension 25 1810/96 Scorpio ’95 00-01-6

2,5l TCI Diesel EngineTorquesOil feed pipe to vacuum pump 27 20Oil filter intermediate housing to cylinder block 60 44TurbochargerFront exhaust pipe to turbocharger 45 33Oil feed pipe to turbocharger 27 20Heat shield to turbocharger, nuts 10 7Heat shield to turbocharger, bolts 12 9Vacuum pumpOil feed pipe to vacuum pump 27 20Vacuum pump to cylinder block 21 15Vacuum pump connector to cylinder block 54 40Vacuum pump oil feed pipe to cylinder block 13 10Vacuum pump oil feed pipe bracket to cylinder block 27 20Engine mountingEngine mounting to front axle/engine support bar 50 37Right-hand engine mounting bracket to cylinder block 47 35Left-hand engine mounting bracket to cylinder block 47 35Cylinder blockPipe flange to EGR valve 27 20Fix cylinder liners with clamps 50 37Main bearing housings 42 31Hollow locating screws - main bearing housings to engine block 47 35Big-end bearing caps, 1st stage 29 21Big-end bearing caps, 2nd stage 60° 60°Oil seal housing and main bearing housing to transmission flange 12 9Sump to cylinder block 12 9Oil pump to cylinder block 27 20Oil intake pipe bracket to cylinder block 27 20Camshaft thrust plate to cylinder block 29 21Vacuum pump to cylinder block 21 15Vacuum pump connector to cylinder block 54 40Timing pulley to fuel injection pump 88 65Timing cover to cylinder block 12 9Crankshaft pulley/vibration damper to crankshaft 196 145Flywheel to crankshaft, 1st stage 20 15Flywheel to crankshaft, 2nd stage 75° 75°Clutch to flywheel 27 20Fuel injection pump to cylinder block 30 22Oil feed pipe extension to cylinder block 25 18Oil feed pipe to hollow retaining screw in main bearing housing 33 24Vacuum pump oil feed pipe to cylinder block 13 10Vacuum pump oil feed pipe bracket to cylinder block 27 20Fuel filter retaining plate to cylinder block, M8 27 20Fuel filter retaining plate to cylinder block, M10 47 3510/96 Scorpio ’95 00-01-7

2,5l TCI Diesel EngineTorquesAutomatic belt tensioner clamp bolt 47 35Automatic belt tensioner bracket to cylinder block 69 51Alternator bracket to cylinder block 47 35Air conditioning compressor 25 18Engine lifting eye to cylinder block 47 35Right-hand engine mounting bracket to cylinder block 47 35Oil filter intermediate housing to engine block 60 44Left-hand engine mounting bracket to cylinder block 47 35Alternator upper bracket to cylinder block, M10 47 35Alternator upper bracket to cylinder block, M12 69 51Cylinder headsExhaust manifold to cylinder heads 32 24Glow plugs in cylinder heads 24 18Cylinder head bolts M14, inner, 1st stage 30 22Cylinder head bolts M14, inner, 2nd stage 70° 70°Cylinder head bolts M14, inner, 3rd stage 70° 70°Cylinder head bolts M12, outer, 1st stage 30 22Cylinder head bolts M12, outer, 2nd stage 85° 85°Inlet manifold to cylinder heads 32 24Rocker shaft to cylinder heads 27 20Injectors 69 51Cylinder head cover to cylinder heads 16 12Rocker arm oil feed pipe to cylinder heads 13 10Coolant collecting pipe to cylinder heads 12 9Retorque cylinder head boltsCylinder head bolts M14, inner, 1st stage –180°(undo)–180°(undo)Cylinder head bolts M14, inner, 2nd stage 30 22Cylinder head bolts M14, inner, 3rd stage 130° 130°Cylinder head bolts M12, outer, 1st stage 90 6610/96 Scorpio ’95 00-01-8