Technical specifications (Escort 5)

Main parameters

Engine designation - 1.8 ONS

Engine type:

• naturally aspirated - RTE, RTF.
• turbocharged - RFD.

Cylinder diameter - 82.5 mm.

Piston stroke - 82 mm.

Working volume - 1753 cm³

Compression ratio: 2.8 - 3.4 MPa.

Nominal power

• rTE, RTF engines - 44 kW (60 hp) at 4800 rpm
• rFD engines - 66 kW (90 hp) at 4500 rpm

Maximum torque

• rTE engines. RTF - 110 Nm at 2500 rpm
• rFD engines - 178 Nm at 2000 rpm

Cylinder head

Caution: Regrinding of the cylinder head is not permitted.

Permissible non-flatness of the lower surface of the cylinder head - 0.061 mm

Diameters of the holes of the camshaft bearing seats:

• nominal - 30.500 - 30.525 mm
• repair - 30.575 - 30.600 mm

Tappet seat hole diameters:

• nominal - 35.000 - 35.030 mm
• repair - 35.500 - 35.530 mm

Clearance of pushers in guide bushings - 0.015-0.030 mm
Valve guide hole diameters:

• nominal - 8.000 - 8.035 mm
• repair - 8.263 - 8.288 mm

Diameters of the swirl combustion chamber nests (Fig. 2E.19):

• nominal
  • size A - 31.250 - 31.280 mm
  • size B - 27.530 - 27.660 mm

• repair
  • size A - 31.550 - 31.580 mm
  • size B - 27.830 - 27.960 mm

Height of the nests of the swirl combustion chambers (C, Fig. 2E.19):

• nominal - 4.983 - 5.034 mm
• repair - 5.233 - 5.284 mm

Cylinder head gasket

The thickness of the cylinder head gasket is selected depending on the protrusion of the pistons above the upper plane of the cylinder block, taking into account the value of the most protruding piston. The thickness of the gasket is identified by the corresponding designation.

• for cylinder blocks with nominal cylinder diameters - the gasket has cutouts
• for cylinder blocks with repair cylinder diameters (+0.5 or +1.0) - the gasket has a hole

Piston protrusion (mm)	nominal	repair
0.500 — 0.680	2 cutouts	2 holes
0.681 — 0 740	3 cutouts	3 holes
0.741 — 0.840	4 cutouts	4 holes

Installation method - the cylinder head gasket is installed with the inscription "OBEN-TOP" in the direction of the head (up).

Combustion chambers

Chamber type - vortex Ricardo Comet Mark V

The protrusion of the combustion chambers from the lower plane of the cylinder head is 0-0.061 mm

Valve seat dimensions (Fig. 2E.20)

Inlet valve:

• Nominal
  • size A - 38.00-38.03 mm
  • size B - 8.3-8.5 mm

• Repair 1
  • size A - 38.20-38.23 mm
  • size B - 8.6-8.8 mm

• Repair 2
  • size A - 38.40-38.43 mm
  • size B - 8.9-9.1mm

Exhaust valve:

• Nominal:
  • size A - 33.00-33.03 mm
  • size B - 8.8-9.0 mm

• Repair 1:
  • size A - 33.20-33.23 mm
  • size B - 9.1-9.3 mm

• Repair 2:
  • size A - 33.40-33.43 mm
  • size B - 9.4-9.6 mm

Valve springs

The springs are the same for both intake and exhaust valves.

Free length - 43 mm

Valves

Inlet valve:

• Valve length - 107.05 - 107.15 mm
• Valve plate diameter - 36.40 - 36.60 mm

Valve stem diameter:

• nominal - 7.82 - 7.97 mm
• 1. Repair - 8.02 - 8.17 mm
• 2. Repair - 8.22 - 8.37 mm

Exhaust valve:

• Valve length 109.15 - 109.25 mm
• Valve plate diameter - 31.90 - 32.10 mm

Valve stem diameter:

• nominal - 7.81 - 7.96 mm
• 1 Repair - 8.01 - 8.16 mm
• 2 Repair - 8.21 - 8.36 mm

Valve clearance (cold)

Intake valve clearance - 0.35 ±0.05 mm

Exhaust valve clearance - 0.50 ±0.05 mm

Adjusting the valve clearance by selecting the thickness of the adjusting plates located in the recess of the tappets.



Range of adjustment plates by thickness 3.00 - 4.75 mm

The difference in thickness of the adjustment plates is 0.05 mm

Pushers

Outer diameter:

• nominal - 34.950 - 34.975 mm
• repair - 35.450 - 35.475 mm

Engine cylinder block

Cylinder block designation - LR 27108

Cylinder diameters:

• nominal:
  • group A - 82.500-82.515 mm
  • group B - 82.515-82.530 mm
  • group C - 82.660-82.675 mm
  • group D 82.675-82.690 mm

• repair:
  • + 0.5 - 83.000-83.015 mm
  • + 1.0 - 83.500-83.515 mm

The diameter of the holes of the main bearing shells is 53.683-53.696 mm

Crank mechanism

Crankshaft

Main journal diameter:

• nominal - 53.970-53.990 mm
• repair -0.25 - 53.720-53.740 mm
• repair -0.50 - 53.470-53.490 mm

Connecting rod journal diameter:

• nominal - 48.970-48.990 mm
• repair -0.25 - 48.720-48.740 mm
• repair -0.50 - 48.470-48.490 mm

Width of the middle main bearing:

• nominal - 31.69-31.75 mm
• repair - 32.07-32.13 mm

Radial clearance of crankshaft main bearings - 0.015-0.062 mm

Crankshaft axial clearance - 0.093-0.306 mm

Maximum friction moment in the crankshaft main bearings (without piston-connecting rod units installed) - 10 Nm

Main bearing shells

Nominal and repair liners, reduced by 0.25 mm and 0.50 mm, are supplied as spare parts.

Connecting rods

Connecting rods are manufactured with four distances between the axes of the head and base holes to ensure the same compression ratio in all engine cylinders. Designations "A". "B". "C" and "D". applied to the side surface of the connecting rod caps determine the selective group of the distance between the axes of the head and base holes. The method of installing the connecting rod relative to the cylinder block, the letter "F. applied to the side surface of the connecting rod, must be on the side of the gas distribution system drive.



Connecting rod bearing seat bore diameter - 52.000-52.020 mm

The diameter of the hole in the connecting rod head bushing is 26.012-26.020 mm

Distance between the axes of the holes in the head and base of the connecting rod:

• group A - 129.880-129.940 mm
• group B - 129.941-130.000 mm
• group C - 130.011-130.060 mm
• group D - 130.061-130.120 mm

Connecting rod bearing shells

Nominal and repair liners are supplied as spare parts: reduced by 0.25 mm and 0.50 mm.

Pistons

RTE, RTF engines

Piston diameters (measured at right angles to the piston pin axis):

• nominal:
  • group A - 82.460-82.475 mm
  • group B - 82.475-82.490 mm
  • group C - 82.620-82.635 mm
  • group D - 82.635-82.650 mm

• repair
  • group E (+0.5 mm) - 82.961-82.979 mm
  • group F (+1.0 mm) - 83.461-83.479 mm

• Piston clearance in cylinder
  • groups from A to D - 0.025-0.055 mm
  • groups E and F - 0.021-0.054 mm

The protrusion of the piston bottom at TDC above the upper plane of the cylinder block is 0.50-0.84 mm.

RFD Engines

Piston diameters (measured at right angles to the piston pin axis):

• nominal, group A - 82,461-82,479 mm
• nominal, group B - 82.476-82.494 mm
• nominal, group C - 82.621-82.639 mm
• nominal, group D - 82.636-82.654 mm

Piston pins:

Installing the retaining rings in the piston groove, with the cut facing upwards.

Outer diameter of the pin - 25.996-26.000 mm

Piston rings

Installation method: the inscription "Tor" (top) is directed towards the bottom of the piston.

Width of the lock (cut) of the ring located in the cylinder:

• top ring (sealing) - 0.35-0.50 mm
• middle ring (sealing) - 0.35-0.50 mm
• lower ring (oil scraper) - 0.25-0.45 mm

Piston Groove Clearance:

• top ring (sealing) - 0.090-0.122 mm
• middle ring (sealing) - 0.050-0.082 mm
• lower ring (oil scraper) - 0.030-0.065 mm

Flywheel

• Radial runout - 0.13 mm
• Number of teeth on the crown - 135

Gas distribution system

Valve timing (measured at operating valve clearance)

• OZD - 6° before TDC
• ZZD - 32° after BDC
• OZW - 57° before BDC
• ZZW - 7° after TDC

OZD and ZZD - opening and closing of the intake valve, respectively; OZW and ZZW - opening and closing of the exhaust valve, respectively.

Camshaft

RTE, RTF engines

Valve lift:

• inlet - 10 mm
• outlet - 9 mm

Axial clearance - 0.1-0.2 mm

Bearing journal diameter - 27.960-27.980 mm

Bearing clearance of the camshaft - 0.020-0.079 mm

RFD Engines

Valve lift:

• inlet 9 mm
• outlet 10 mm

Axial play - 0.1-024mm

Toothed belt:

Brand - Motorcraft 89 FF GK 288-AB

The tension is adjusted automatically by a roller tensioner.

Replacement frequency - every 60,000 km

Lubrication system

Oil pump

Oil pressure (at 100°C)

• at 750 rpm - 0.075 MPa
• at 2000 rpm - not less than 0.15 MPa

Opening pressure of the bypass valve 0.2 - 0.4 MPa

Oil filter

Make and type - Motorcraft EFL 344

Replacement frequency - every 10,000 km

Motor oil

Quantity - 4.5 dm³ (with 0.4 dm³ in the filter)

Type: All-season oil according to API SG/CD, viscosity according to SAE 10W30, 15W40 or 20W50

Replacement frequency (with filter) - every 10,000 km

Cooling system

Expansion tank

Opening pressure of the two-way valve in the expansion tank cap - 120 kPa

Thermostat

Temperature of opening start - 85°-89°C
Full opening temperature 102±3°C

Coolant

Quantity - 9.3 dm³



Type - a mixture of 60% distilled water and 40% special antifreeze mixture Motorcraft with the designation Ford SSM 97 B 9103 A

Replacement frequency: every 4 years.

Fuel system

Fuel Filter - Brand and Type Ford EFG 3

Air Filter - Brand and Type Motorcraft EFA 18

Fuel pump

Brand and type - Bosch VER 285 or CAV Roto diesel F 18 INA 01.

Idle speed 840-870 rpm.

Maximum speed (no load) 5350±50 rpm.

Injection sequence (cylinder No.1 from the valve timing drive side) - 1 - 3 - 4 - 2.

Pump installation - using an installation tool.

RFD engine fuel pump since 1991

Brand and type - Lucas Diesel 8344 V 795 D

Idle speed - 900 ±100 rpm.

Maximum speed (no load) - 4800 rpm.

Injection sequence (cylinder #1 from the valve timing drive side) - 1 - 3 - 4 - 2

Pump installation - using an installation tool.

RFD engine fuel pump since 1994

Brand and type - Lucas DPC F18 ITCI20

Idle speed: 820-850 rpm.

Maximum speed (no load) - 5350±50 rpm.

Injection sequence (cylinder No.1 from the valve timing drive side) - 1 - 3 - 4 - 2.

Pump installation - using an installation tool.

Nozzles

Injectors - Bosch or CAV RotoDiesel
Sprayer type - Pmteau
Injector opening pressure:

• Bosch 13.5-14 0 MPa
• CAV RotoDiesel 12.0-13.5 MPa

Leakage test - no fuel leakage for 10 seconds under a pressure of 12 MPa

Pressure drop time in the range of nominal injection pressures - 5 - 40 seconds

Glow plugs

Type - rod

Heating temperature - 1150°C

Brand - Bosch 0250 202 018 or Ford EZD 8

Glow plugs on the engine - FORD EDC.

So-called pencil glow plugs (small diameter) are used



Brand and type - Motorcraft EZD 8 or Vega 666 MJ

Operating temperature - 1150"C

Resistance - 0.25 Ohm

Electronic engine control FORD EDC

Acceleration lever position sensor

Brand and type - Lucas 419131-94-300

Resistance between contacts 1 and 2:

• at idle - 5000 Ohm
• at full load - 1000 Ohm

Resistance between contacts 1 and 3 (idle) - 3300-5000 Ohm

Coolant temperature sensor

Make and type - Ford F2AF-12A648-AA

Sensor resistance:

• at 10°C - 58 kOhm
• at 20°C - 37 kOhm
• at 30°C - 24 kOhm
• at 40°C - 16 kOhm
• at 50°C - 11 kOhm
• at 60°C - 7 kOhm

Solenoid vacuum valve:

• Make and type - Ford 92VB-9E882-AB
• Resistance - 4-7 Ohm
• Operating frequency - 140 Hz

Cold engine injection advance corrector:

• Brand and type - Lucas 4410-151294
• Resistance - 65-160 Ohm

Cold Engine Injection Advance Relay:

• Make and type - Ford B74PG-93BG14N089AA
• Control circuit resistance (between contacts 85 and 86) - 75 0m

Injection advance corrector at low engine loads:

• Brand and type - Lucas В12М-08М
• Resistance - 13-18 Ohm

Tightening moments

Cylinder head mounting bolts (new bolts each time)
— Stage 1	20-30 Nm
— Stage 2	76-92 Nm
— Stage 3	wait 2 minutes
— Stage 4	tighten 90°
Cylinder head mounting bolts for engines from 03.92.
— Stage 1	10 Nm
— Stage 2	100 Nm
— Stage 3	wait 3 minutes
— Stage 4	unscrew the bolts sequentially by 180°
— Stage 5	tighten with a torque of 70 Nm
— Stage 6	tighten 120° in sequence
Camshaft Bearing Caps	16-22 Nm
Main bearing caps
— Stage 1	20-30 Nm
— Stage 2	tighten by 45°
Main bearing caps on engines from 03.92.
— Stage 1	27 Nm
— Stage 2	tighten by 75°
Connecting rod caps
— Stage 1	20-30 Nm
— Stage 2	tighten to 60°
— Stage 3	tighten by 20°
Flywheel
— Stage 1	15-20 Nm
— Stage 2	tighten by 45°
— Stage 3	tighten by 45°
Intermediate shaft pulley	40-51 Nm
Fuel pump pulley	20-25 Nm
Fuel pump drive toothed belt tensioner	40-57 Nm
Camshaft pulley
- bolt M6	8-10 Nm
- bolt M8	27-33 Nm
Timing Belt Tensioner for Camshaft Drive	45-55 Nm
Rear cover to the cylinder block	16-21 Nm
Front cover to cylinder block	20-28 Nm
Oil pump to cylinder block	20-25 Nm
Intermediate shaft seal	20-25 Nm
Oil pan	6-9 Nm
Fuel pump	18-22 Nm
Cylinder head cover	3-4 Nm
Glow plugs	25-30 Nm
Injectors to the cylinder head	60-80 Nm
Injector Pipeline Connections	15-25 Nm
Intake and exhaust manifolds to the cylinder head	10-14 Nm
Fastening the turbocharger to the exhaust manifold	38 Nm
Exhaust Gas Recirculation Valve Fastening	20-25 Nm