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Old 05-03-2013, 08:12 PM   #4
BlkNite713
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SECTION 303-01A: Engine - 2.0L Zetec-E 2000 Focus Workshop Manual
SPECIFICATIONS
________________________________________

Engine Data
2.0L DOHC 16V
Engine management EEC V/SEFI
Emission standard 96 EEC
Fuel 91 RON unleaded
Identification code CAA
Firing order 1-3-4-2
Bore 84.8 mm
Stroke 88.0 mm
Cubic capacity 1,988 cm 3
Compression ratio 9.6:1
Maximum engine performance at 5,300 rpm 130 hp
Maximum engine torque at 4,000 rpm 130 lb ft
Idle speed rpm 800 rpm
Speed limitation (rev/min) 7,100 rpm


Engine oil
Viscosity/ambient temperature Description Specification
Recommended engine oils – –
SAE 5W-20 / below -30C to over +40C SAE 5W-20 Engine Oil certified for gasoline engines by the american Petroleum Institute ILSAC GF-3 and WSS-M2C153-H
SAE 5W-20 / below -30C to over +40C Ford Formula E Economy Engine Oil ACEA A1/B1 and WSS-M2C914-A
If engine oils of this specification are not available, engine oils of specification API SH/EC, ACEA A2/B2 or ACEA A3/B3 may also be used.


Capacities
Litres
Engine oil, initial fill including filter 4.35
Engine oil, oil change including filter 4.25
Engine oil, oil change excluding filter 3.75


Lubricants, Fluids, Sealers and Adhesives
Item Specification
Sealant, camshaft bearing caps WSK-M2G348-A5
Sealant, cylinder block mating faces (Hylosil 502) WSK-M4G320-A
Sealant, cylinder block mating faces (Loctite Ultrablack) (alternative) WSE-M4G320-A2
Sealant, crankshaft position sensor ESW-1C155-A
Sealant, crankshaft position sensor (alternative) WSD-M1C-226-A
Sealant, oil pan WSE-M4G323-A6
Thread locking compound SDM-M4G9107-A
Spark plug thread lubricant (Never Seeze) WSD-M13P8-A1
Lubricant, injection nozzle O-rings WSEM-2C903-A1
Silicone grease for spark plug connector seal A696-M1C171-AA
High-temperature grease for clutch disc engagement splines ESD-M1C220-A


Cylinder Block
Description mm
Cylinder bore diameter, class 1. 84.800 - 84.810
Cylinder bore diameter, class 2. 84.810 - 84.820
Cylinder bore diameter, class 3. 84.820 - 84.830
Inner diameter, main bearing shells installed 58.011 - 58.038
Inner diameter, main bearing shells installed (main bearing shells with stepped sizes) 58.008 - 58.031
Main bearing radial clearance 0.011 - 0.058
Main bearing radial clearance (main bearing shells with stepped sizes) 0.020 - 0.042
Main bearing parent bore 62.287 - 62.300


Pistons
Description mm
Piston diameter, class 1. 84.770 - 84.780
Piston diameter, class 2. 84.780 - 84.790
Piston diameter, class 3. 84.790 - 84.800
Piston clearance in cylinder 0.010 - 0.030
Piston ring gaps (installed)
- upper compression ring 0.30 - 0.50
- lower compression ring 0.30 - 0.50
- oil scraper ring 0.40 - 1.40
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. Align the ring gaps at 120 degrees to each other.


Crankshaft
Description mm
Main bearing journal diameter 57.980-58.000
Main bearing journal end float 0.09-0.26
Connecting rod bearing journal diameter 46.89-46.91


Lower Crankshaft Spacer
Description mm
Required spacer washer thickness if there is a gap between the cylinder block and the lower crankcase of:
0.26 mm - 0.50 mm 0.25
0.51 mm - 0.75 mm 0.50


Connecting Rod
Description mm
Big end bore diameter 49.89 - 49.91
Small end bore diameter 19.951 - 19.981
Inner diameter, connecting rod bearing shells installed 46.926 - 46.960
Radial connecting rod bearing clearance 0.016 - 0.070
Axial connecting rod bearing clearance 0.090 - 0.320


Piston Pin
Description mm
Piston pin length 55.800 - 56.200
Piston pin diameter, white 19.997 - 20.000
Piston pin diameter, red 20.625 - 20.628
Piston pin clearance in piston 0.016 - 0.049


Camshaft
Description mm
Bearing journal diameter 25.960 - 25.980
Camshaft bearing radial clearance 0.020 - 0.070
Camshaft end float 0.080 - 0.220
Lobe lift intake 8.90
Lobe lift exhaust 8.70
Theoretical valve maximum lift intake 8.90
Theoretical valve maximum lift exhaust 8.70


Valves
Description mm
Valve clearance in the valve guide
Intake valve 0.017-0.064
Exhaust valve 0.017-0.064
Intake valve clearance (at 20C 5C) 0.11-0.18
Exhaust valve clearance (at 20C 5C) 0.27-0.34


Cylinder Head
Description
Maximum distortion (mating surface) 0.1 mm
Height of mating surface 1.76 mm - 2.12 mm
Peak-to-valley height of mating surface (reference length 2.5 mm vertical to groove direction) R 3z = 6.0 m
Oil pressure at 800 - 850 rpm 1.3 bar - 2.5 bar
Oil pressure at 4000 rpm 3.7 bar - 5.5 bar


Torque Specifications
Description Nm lb-ft lb-in
Hose clamps 4 – 35
Intake manifold studs 5 – 44
Intake manifold bolts and nuts 18 13 –
EGR tube assembly to EGR valve 40 30 –
EGR pipe to ignition coil bracket 6 – 53
EGR tube assembly to catalyst 40 30 –
Heat shield to exhaust manifold 10 – 89
Exhaust manifold studs 5 – 44
Exhaust manifold nuts 16 12 –
Catalytic converter to exhaust manifold 48 35 –
Catalytic converter to exhaust 47 35 –
Right-hand driveshaft center bearing 25 18 –
Generator to bracket 25 18 –
Generator bracket to upper cylinder block bolts 25 18 –
Generator bracket to lower cylinder block bolts 65 48 –
Transmission flange bolts 47 35 –
Starter motor to transmission 35 26 –
Oil drain plug, MTX transmission 45 33 –
Oil control plug, MTX transmission 45 33 –
Flywheel bolts 112 83 –
Clutch pressure plate 29 21 –
Engine roll restrictor to transmission 48 35 –
Engine roll restrictor to subframe 48 35 –
Engine rear mount to body 48 35 –
Engine rear mount (nut on transmission mounting bracket) 133 98 –
Engine front mount to engine 80 59 –
Engine front mount to body 48 35 –
Power steering pump to bracket 24 18 –
Power steering pump bracket 48 35 –
Cylinder head bolts a) – –
Camshaft bearing cap bolts a – -
Cylinder head cover a) – -
Spark plugs 15 11 –
Timing belt tensioner 25 18 –
Camshaft timing belt pulleys 68 50 –
Upper timing belt cover 10 – 89
Ignition coil (EI) bracket to cylinder head 21 15 –
Thermostat housing 20 15 –
Fuel rail 10 – 89
Engine rear lifting eye 16 12 –
Engine rear lifting eye studs 6 – 53
Engine front lifting eye 47 35 –
Cylinder block – – –
Engine oil drain plug 25 18 –
Oil pressure switch 27 20 –
Cylinder block oil gallery blanking plugs 23 17 –
Heater pipe bracket to oil pan 10 – 89
Oil pan to lower crankcase a) – -
Lower crankcase to cylinder block 22 16 –
Oil pump 11 8 –
Oil intake pipe to oil pump 10 – 89
Main bearing bolts a) - –
Connecting rod bearing cap bolts a) - –
Coolant pump 18 13 –
Crankshaft rear oil seal carrier 20 15 –
Drive belt idler pulley 40 30 –
Crankcase ventilation pipe bracket 23 17 –
Crankcase ventilation 10 – 89
Coolant pump pulley 24 18 –
Crankshaft belt pulley 115 85 –
Crankshaft position sensor bracket 21 15 –
Crankshaft position sensor to bracket 8 – 71
Idler pulley 23 17 –
Knock sensor 20 15 –
__________________
Anthony ....The one and only GTS Blue SVT
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