General specs on the SPI

[b16sir1991]

I am going to list about all the specs that you guys may need. This is being done mainly because of all the questions that I get from time to time and Doug (WD-40) was talking to me about doing a sticky for you guys, so here you go:
First is the SPi cars:

General Specifications Item Specification
Displacement 2.0 Liters (121 CD)
Number of cylinders 4
Bore and stroke 84.8 mm x 88 mm
Firing order 1-3-4-2
Oil pressure (hot 2000 rpm) 240 kPa -450 kPa
Drive belt tension 178 N-311 N
Compression ratio 9.35:±0.25
Coolant capacity 5.0-5.8 Liters



Cylinder Head and Valve Train Item Specification (mm)
Valve guide inner diameter (I.D) 8.063-8.094
Intake and exhaust 8.063-8.094
Valve seats width — intake and exhaust 1.75-2.32
Angle 45 degrees
Runout (total indicated runout [T.I.R.]) 0.064 MAX
Bore diameter (insert counterbore diameter) intake 39.940 MIN.
39.965 MAX.
Bore diameter (insert counterbore diameter) exhaust 34.940 MIN.
39.965 MAX.
Gaskets surface flatness 0.04/26 0.08/156
0.15 Total
Head face surface finish 0.2/2.5 0.8
Valve stem to guide clearance intake 0.020-0.069
Valve stem to guide clearance exhaust 0.049-0.095
Valve head diameter intake 41.9-42.1
Valve head diameter exhaust 34.9-35.1
Valve face runout limit intake and exhaust 0.005
Valve face angle 45.5 degrees
Valve stem diameter standard (std.) intake 8.025-8.043
Valve stem diameter standard (std.) exhaust 8.006-8.017
Valve springs 4.3 turns
Compression pressure — loaded 83.0 N @ 29.27
Compression pressure — unloaded 350 N @ 39.53
Free length (approximate) 52.4
Installed spring height 39.53
Valve springs assembled height 39.53
Service limit, pressure lost @ specified height % 5



Rocker Arm Item Specification (mm)
Ratio 1.65
Valve tappet, hydraulic diameter (std.) 22.200-22.212
Clearance to bore 0.023-0.065
Roundness 0.013
Finish micro 0.2
Service limit 0.127
Collapsed tappet gap 0-4.5
Tappet bore diameter 22.25 ± 0.15
Camshaft bore inside diameter no. 1, 2, 3, 4, 5 45.796-45.821



Camshaft Item Specification (mm)
Lobe lift intake 6.23
Lobe lift exhaust 6.23
Allowable lobe lift loss 0.127
Theoretical valve maximum lift intake 10.28
Theoretical valve maximum lift exhaust 10.28
End play 0.02-0.20
Service limit 0.20
Journal to cylinder head bearing surface clearance 0.03335-0.0835
Journal diameter standard 45.7375-45.7625
Runout limit 0.127 (runout of center bearing relative to bearing nos. 1 and 5)
Out-of-round limit 0.08
Camshaft drive assembled gear face runout crankshaft 0.65
Camshaft drive assembled gear face runout camshaft 0.275



Cylinder Block Item Specification (mm)
Head gasket surface finish roughness height (CLA) 3.8-2.0
Head gasket surface finish roughness height cut-off 0.8
Dowel height chamfer 0.8x30°
Dowel height chamfer total 12.5
Cylinder bore diameter 84.8
Piston to cylinder bore clearance 0.020-0.040
Surface finish (RA) each bore min. 15-38
Average of all bores of a cylinder block (Ra) min. 20-30
Out-of-round limit 0.025
Tappet limit 0.013
Main bearing bore diameter @ ± 30° PF Bearing Cap P/L 62.2835-62.3145
Main bearing bore diameter other than above 62.2935 ± .0100



Crankshaft Item Specification (mm)
Main bearing journal diameter 57.98-58.0
Out-of-round limit 0.008
Taper limit 0.008 per 25.4 (l)
Journal runout limit (runout of bearing 2, 3, and 4) 0.05
Crankshaft end play 0.100-0.300
Surface finish (RMS) micro 0.3
Clearance to crankshaft 0.020-0.065
Thrust bearing journal length 28.825-28.854
Connecting rod journal length 28.825-28.854
Out-of-round limit 0.008
Taper limit 0.008 per 25.4 (l)
Surface limit (RMS) micro 0.6 rear
Surface limit (RMS) micro 0.9 front
Main bearing thrust face surface finish (RMS) micro 0.6
Main bearing thrust face surface finish (RMS) rear micro 0.9
Main bearing thrust face surface finish (RMS) front runout limit 0.025
Runout limit (T.I.R.) 0.180
Flywheel ring (gear lateral runout (T.I.R.) manual transmission 1.5
Crankshaft end play 0.100-0.300



Connecting Rod Item Specification (mm)
Connecting rod bearings clearance to crankshaft 0.020-0.065
Bearing wall thickness (std.) 1.476-1.488
Clearance of crankshaft without cylinder head desired — 0.0457-0.0660
Clearance of crankshaft without cylinder head allowable — 0.0461-0.0859
Clearance of crankshaft with cylinder head desired — 0.0279-0.0483
Clearance of crankshaft with cylinder head allowable — 0.0276-0.0674
Bearing wall thickness 2.117-2.129
Connecting rod piston pin bore diameter 20.570-20.610
Crankshaft bearing bore diameter 46.89-46.91
Out-of-round limit — piston pin bore .008
Taper limit piston pin bore 0.0038/25.4
Length (center to center) 131.905-131.975
Out-of-round-limit — bearing bore 0.010
Taper limit — bearing bore 0.010
Alignment bore-to-bore (max. differential) twist 0.05
Alignment bore-to-bore (max. differential) bend 0.038
Side clearance (assembled to crank) standard 0.092-0.268
Side clearance (assembled to crank) service limit 0.356



Pistons Item Specification (mm)
Piston-to-bore clearance rebuild 0.020-0.040
Piston-to-bore clearance service 0.020-0.070
Piston diameter 84.77-84.80
Pin bore diameter 20.632-20.641
Ring groove width compression (top) 1.53-1.55
Ring groove width compression (bottom) 1.53-1.55
Ring groove width oil 4.008-4.032
Ring groove width compression ring (top) to ring groove clearance 0.04-0.08
Ring groove width compression ring (bottom) to ring groove clearance 0.06-0.09
Squish height 0.908-1.858
Piston pin length 66.2-67.0
Diameter standard 20.622-20.631
Pin to piston clearance 0.007-0.013
Pin to rod clearance press fit — 8 KN



Pistons rings Item Specification (mm)
Piston ring width compression (top) 1.47-1.49
Ring width compression (bottom) 1.46-1.49
Ring width oil ring service limit (Side clearance) 0.15 MAX.
Ring gap compression (top) 0.25-0.28
Ring gap compression (bottom) 0.25-0.28
Ring gap oil ring (steel rail) 0.04-1.68
Side clearance 1st ring 0.04-0.08
Side clearance 2nd ring 0.04-0.09



Lubrication System Item Specification (mm)
Oil pump relief valve spring tension 41.4-45.8 N @ 28.1
Relief valve-to-bore clearance 0.02-0.08
Oil pump type Gerotor
Rotor clearance outer gear to housing clearance 0.074-0.161
Rotor clearance inner and outer gear to cover clearance (end play) 0.013-0.089
Rotor clearance inner to outer gear tip clearance 0.05-0.18
Oil capacity with filter 3.76 Liters



Lubricants Specification
Super premium 5W20 SAE engine oil XO-5W20-QSP WSS-M2C153-H
Silicone gasket and sealant F7AZ-19554-EA WSK-M2G343-A4
Crankcase conditioner B7A-19579-C ESR-M99C80-A



Torque Specifications Description Nm lb-ft lb-in
Intake manifold nuts 10+90 degrees 10+90 degrees 89+90 degrees
Intake manifold bracket nuts and bolts 10 — 89
Front engine accessory drive bracket bolts 47 35 —
Front engine accessory drive bracket nuts 47 35 —
A/C compressor bolts 25 18 —
Upper generator bolts 48 35 —
Lower generator bolt 48 35 —
EGR valve to intake manifold 25 18 —
EGR valve to EGR manifold tube 24 18 —
EGR manifold tube to exhaust manifold 6 — 53
Flexible exhaust pipe 47 35 —
Exhaust manifold nuts 27 20 —
Catalytic converter to exhaust manifold bolts 40 30 —
Oil control plug, iB5 transmission 35 26 —
Thermostat housing 13 10 —
Starter motor to transaxle 35 26 —
Lower transaxle flange bolts 47 35 —
Upper transaxle flange bolts 47 35 —
Left-hand transaxle flange bolts 47 35 —
Engine roll restrictor to transaxle 48 35 —
Engine roll restrictor to subframe 48 35 —
Rear engine mounting to body 48 35 —
Rear engine mounting (nut on transmission mounting bracket) 133 98 —
Front engine mounting to engine 80 59 —
Front engine mounting to body 48 35 —
Wheel nuts 128 94 —
Suspension strut to body 48 35 —
Lower suspension arm ball joint to spindle carrier 47 35 —
Power steering pump 23 17 —
Power steering pump pulley 47 35 —
Cylinder head boltsa — — —
Timing belt tensioner 25 18 —
Spark plugs 15 11 —
Oil level indicator tube 10 — 89
Valve cover bolts 9 — 80
Ignition coil (EI) bracket to cylinder head 10 — 89
Rocker arms 25 18 —
Camshaft thrust plate bolts 10 — 89
Camshaft pulley bolt 105 77 —
Camshaft position sensor (CMP) 25 18 —
Oil pressure switch 13 10 —
Oil pump 13 10 —
Oil pump tube 10 — 89
Coolant pump 25 18 —
Oil intake pipe to oil pump 10 — 89
Main bearing bolts 99 73 —
Rear crankshaft oil seal retainer 25 18 —
Big end bearing cap nuts (stage 1) 38 28 —
Intermediate shaft bracket 48 35 —
Oil pan to crankcase 25 18 —
Oil pan baffle 25 18 —
Upper timing belt cover 48 35 —
Lower timing belt cover 10 — 89
Upper strut mount nuts 30 22 —
Engine oil drain plug 25 18 —
Knock sensor 20 15 —
Flywheel 82 60 —
Crankshaft position sensor 6 — 53
Crankshaft pulley 120 89 —
Battery tray 25 18 —

a refer to the procedure in this section
Second is the Zetec cars:

Engine Data Description 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 cm3
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 -30°C to over +40°C 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 -30°C to over +40°C 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 Description Liters
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) a
Upper compression ring 0.30-0.50
Lower compression ring 0.30-0.50
Oil scraper ring 0.40-1.40

a 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
Crankshaft end play 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 20°C ± 5°C) 0.11-0.18
Exhaust valve clearance (at 20°C ± 5°C) 0.27-0.34



Cylinder Head Description Specification
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 μm
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 boltsa — — —
Cylinder head covera — — —
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 blocka — — —
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 crankcasea — — —
Lower crankcase to cylinder block 22 16 —
Oil pump 11 8 —
Oil intake pipe to oil pump 10 — 89
Main bearing boltsa — — —
Connecting rod bearing cap boltsa — — —
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 —

I am continuing on another thread for the rest.........

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