Technical specifications (Mondeo 2)

Technical characteristics of the 16V Zetec-E engine

	1.6 l		1.8 l	2.0 l
Type	Four-cylinder, with two camshafts and 16 valves. Camshaft drive by toothed belt
Engine designations:
until May 1998.	L1J		RKB	NGA
since May 1998.	L1L		RKF/RKJ	NGB
Cylinder firing order	1-3-4-2		1-3-4-2	1-3-4-2
Cylinder diameter, mm	76,0		80,6	84,8
Piston stroke, mm	88,0		88,0	88,0
Engine displacement, cm³	1598		1796	1989
Compression ratio	10,3		10,0	10,0
Engine power, kW (hp)/at frequency rotation, min⁻¹:
until May 1998.	66 (90)/5250		82 (111)/5750	100 (136)/6000
since May 1998.	66 (90)/5250		82 (111)/5750	100 (136)/6000
Maximum torque, Nm/at rotation speed, min⁻¹	138		158	180
Idle speed, min⁻¹	830		800	800
Speed limit, min⁻¹	7100		7100	7100

Technical data of the 16V engine

Cylinder block If not specified, the first value is valid for all engines
				1.6 l	1.8 l	2.0 l
Number of main bearings				5	5	5
Cylinder diameter, mm
class 1				76,000-76,010	80,600-80,610	84,800-84,810
class 2				76,010-76,020	80,610-80,620	84,810-84,820
class 3				76,020-76,030	80,620-80,630	84,820-84,830
Inner diameter of built-in bearing shells, mm				58,011-58,038	58,011-58,038	58,011-58,038
Main bearing working clearance, mm				0,011-0,058	0,011-0,058	0,011-0,058
Main bearing bore, mm				62,287-62,300	62,287-62,300	62,287-62,300
Crankshaft
Main bearing journal diameter, mm				57,980-58,000
Crankshaft axial clearance, mm				0,09-0,26	0,09-0,26	0,09-0,26
Crankshaft journal diameter, mm				46,890-46,910	46,890-46,910	46,890-46,910
Connecting rods
Connecting rod lower head bore diameter, mm				49,890-49,910	49,890-49,910	49,890-49,910
Connecting rod upper head bore diameter, mm:
until May 1998.				20,589-20,609	20,589-20,609	20,589-20,609
since May 1998.				18,958-18,982	18,958-18,982	18,958-18,982
Inner diameter of bearing shells (built-in), mm				46,926-46,960	46,926-46,960	46,926-46,960
				1.6 l	1.8 l	2.0 l
Working clearance of connecting rod bearings, mm:
until May 1998				0,016-0,046	0,016-0,046	0,016-0,046
since May 1998				0,016-0,070	0,016-0,070	0,016-0,070
Axial clearance of connecting rod bearing, mm				0,090-0,32	0,090-0,32	0,090-0,32
Pistons
Piston diameter, mm:
class 1 (before May 1998)				75,975-75,985	80,570-80,580	84,770-84,780
class 1 (since May 1998)					80,580-80,610	84,780-84,810
class 2 (before May 1998)				75,985-75,995	80,580-80,590	84,780-84,790
class 2 (since May 1998)					80,590-80,620	84,790-84,820
class 3 (before May 1998)				75,995-76,005	80,590-80,600	84,790-84,800
class 3 (since May 1998)					80,600-80,630	84, 800-84,830
Piston working clearance, mm:
until May 1998.				0,040-0,060	0,040-0,060	0,010-0,030
since May 1998.				0,040-0,060	0,010-0,030	0,010-0,030
Clearances in piston ring lock, mm
upper compression ring (before May 1998)				0,30-0,50	0,30-0,50	0,30-0,50
upper compression ring (since May 1998)				0,30-0,50	0,25-0,36	0,22-0,37
second compression ring (before May 1998)				0,30-0,50	0,30-0,50	0,30-0,50
second compression ring (since May 1998)				0,30-0,50	0,70-0,90	0,70-0,90
oil scraper ring (before May 1998)				0,25-1,00	0,38-1,14	0,40-1,40
oil scraper ring (since May 1998)				0,25-1,00	0,38-1,14	0,20-0,70
Installing piston rings				The piston ring locks are spaced at equal distances around the piston circumference. This also applies to the three elements of the oil scraper ring, the locks of which are located at an angle of 120°
Piston pins
Piston pin length, mm:
in engines installed before May 1998.				63,00 - 63,80
in engines installed since May 1998:
1.6/1.8 liter engines				49,85-50,15	49,85-50,15	49,85-50,15
2-liter engines				54,70-55,00	54,70-55,00	54,70-55,00
Piston pin diameter, mm (marked with color marks) - before May 1998:
white mark				20,622-20,625	20,622-20,625	20,622-20,625
red mark				20,625-20,628	20,625-20,628	20,625-20,628
blue mark				20,628-20,631	20,628-20,631	20,628-20,631
Piston pin diameter (since May 1998):
1.6/1.8 liter engines				18,997-19,000	18,997-19,000	18,997-19,000
2-liter engines				18,997-19,000	18,997-19,000	18,997-19,000
Working clearance of piston pins in pistons, mm:
until May 1998.				0,010-0,016	0,010-0,016	0,010-0,016
since May 1998.				0,010-0,017 (1,6/1,8)	0,010-0,017 (1,6/1,8)	0,010-0,017 (1,6/1,8)
				0,010-0,016 (2,0)	0,010-0,016 (2,0)	0,010-0,016 (2,0)
Press fit of pins in connecting rod, mm				0,013-0,042	0,013-0,042	0,013-0,042
				1.6 l	1.8 l	2.0 l
Camshaft
Number of bearings				5	5	5
Drive				Toothed belt
Main journal diameter, mm				25,960-25,980	25,960-25,980	25,960-25,980
Working clearance of camshaft bearings, mm				0,020-0,070	0,020-0,070	0,020-0,070
Axial clearance of camshafts, mm				0,080-0,220	0,080-0,220	0,080-0,220
Maximum camshaft delay, mm				0,10	0,10	0,10
Cylinder head
Valve seating angle, deg				90	90	90
Inner diameter of valve guide bushings, mm				6,060-6,091	6,060-6,091	6,060-6,091
Valve tappet bore diameter, mm				28,395-28,425	28,395-28,425	28,395-28,425
Valves
Valve length, mm:
intake				96,87-97,33
graduation				96,87-97,93
Valve head diameter, mm:
intake				26.0 (1.6), 32.0 (other)
graduation				24.5 (1.6), 28.0 (other)
Valve stem diameter, mm:
intake				6,028-6,043
graduation				6,010-6,025
Operating clearance of valve stem in guides, mm:
intake				0,017-0,064
graduation				0,035-0,081

V6 Duratec Engine Specifications

	2.5 l	2.5 l ST 200
Type	V6, with four camshafts (see section 19). Camshaft drive by chains
Engine Designations	SEA	SAG
Cylinder firing order	1-4-2-5-3-6	1-4-2-5-3-6
Cylinder diameter, mm	82,40	82,40
Piston stroke, mm	79,50	79,50
Cylinder displacement, cm ³	2543	2543
Compression ratio	9,7	10,25
Engine power, kW (hp)/ at rotation speed, min ⁻¹ :	125 (170)/ 6250	151 (200)/ 6700
Maximum torque, Nm / at rotation speed, min ⁻¹	220/ 4250	229/
Idle speed, min ⁻¹	725	725
Lubrication system
Engine oil used	Ford Formula E, Ford Super - all-season oil, Ford XP - heavy-duty oil or Ford Formel S - synthetic oil (these engine oils are used depending on the temperature (see section 3)
Volume of oil to be filled for a 16-valve engine (16V), l:
with oil filter, dry engine	4,50
	2.5 l	2.5 l ST 200
oil change including oil filter	4,25
oil change, without oil filter	3,75
Volume of oil to be filled in V6 engine, l:
with oil filter, dry engine	5,85
oil change including oil filter	5,5
oil change, without oil filter	5,0
Cooling system
Volume of liquid to be poured, l	About 7.0
Antifreeze	Motorcraft Super Plus 4
Radiator design	With horizontal coolant flow, with aluminum block and plastic tank
Thermostat:
design	Thermostat with solid filler
opening temperature, °C	from 85 to 89
fully open, °C	102
Expansion tank shut-off plug opening pressure, MPa	0,12
Speed limit, min ⁻¹	6936	6925
Clutch
Design	Single-plate dry clutch with diaphragm spring
Manufacturer	Fichtel & Sachs
Clutch drive	Hydraulic
Adjustment	Not required
External diameter, mm:
1.6 and 1.8 liters	210
2 liter	228
2.5 liter	240
Thickness of driven disk, mm	7,30

Manual transmission
Model	MTX-75
Gear ratios:
	Gear block	Drive transmission
1.6 liter engine	A	4,06: 1
1.6 liter engine	D	3,84: 1**
1.8 liter engine	A	3,84: 1*
1.8 liter engine	A	3,41: 1
2.0 liter engine	A	3,84: 1
2.0 liter engine	B1	3,84: 1***
2.5 liter engine	A	3,82: 1
2.5 liter engine	A	3,41: 1*
***For France only. *** Only for France, serial. ***For France, sports models.

Gear ratios of the gearbox:
	Gear Block A	Gear Block B1	Gear Block D
first	3,417	3,417	3,666
second	2,136	2,136	2,047
	Gear Block A	Gear Block B1	Gear Block D
third	1,448	1,483	1,258
fourth	1,028	1,114	0,865
fifth	0,767	0,854	0,674
reverse	3,460	3,460	3,460
Drive transmissions	See above
Transmission oil:
filling volume, l	2,0
brand	ford production

Automatic transmission
Type	CD4E
Car model	2- and 2.5-liter models
Number of gears	Four
Transmissions:
first	2,890
second	1,571
third	1,000
fourth	0,689
reverse	3,920
Oil filling volume, l:
in a 2-liter engine	8,6
in a 2.5-liter engine	9,97
Brand of oil	Ford Automatic Transmission Fluid
Front wheel suspension
Type	MacPherson strut with rear wishbone and anti-roll bar
Front wheel alignment angles
Wheel alignment, mm (angular minutes):
when checking	1.5 to -1.5 mm (0° 15' to -0° 15')
when adjusting	0.0 mm ±1.0 mm (0° ±10')
Longitudinal angle of kingpin:
nominal	2° 19'
acceptable	1° 14'-3° 25'
Longitudinal angle of kingpin (station wagon):
nominal without self-leveling	2° 11'
with self-leveling	2° 8'
permissible without self-leveling	1° 11'-3° 11'
with self-leveling	1° 8'-3° 8'
Camber angle (four- and five-door cars):
nominal	-0° 32'
acceptable	0° 45' to -1° 50'
Camber angle (station wagon):
nominal without self-leveling	-0° 32'
nominal with self-leveling	-0° 32'
permissible without self-leveling	from 0° 45' to -1° 49'
permissible with self-leveling	Same
Rear wheel suspension
Type (limousine)	Four-link, consisting of two horizontal longitudinal suspension arms, steering trapezoid arms, push rods, MacPherson shock absorber strut and anti-roll bar. There are differences in the transverse suspension arm for the 2.5-liter engine
Type (station wagon)	Three-link suspension consisting of transverse arms, longitudinal arms and upper, inner-outer lateral arms. Telescopic shock absorber strut and anti-roll bar
Rear wheel alignment angles
Toe-in, mm (deg, min)	0.0±1.0 (0° to 0° ±10')
Camber angle (four- and five-door cars):
nominal	-0 34'
acceptable	from 0° 45' to -1° 53'
Camber angle (station wagon):
nominal (all models) (see below)	0° 25'
acceptable (all models)	from 0° 50' to -1° 40'
Note: The values given apply to vehicles with self-levelling. If the system is not installed, the values given are increased by 3'
Camber angle (four- and five-door), mm:
when checking	from 3.9 to -0.1
when adjusting	1,9±1,2
Wheel camber angle (station wagon), mm:
when checking	from +2.7 to -1.3
when adjusting	0,7±1,2

Brake system
Type	Dual-circuit braking system with disc brakes on the front wheels and drum or disc brakes on the rear wheels. Parking brake acts on the rear wheels via brake cables. Brake actuator and brake control valve. Optional or standard with ABS. Diagonally split brake system
Front disc brakes	16V engine	2.5 liter engine
Brake disc diameter, mm	260,0	278,0
Thickness of brake disc (new), mm	24,15	24,15
Thickness of brake disc (extremely worn), mm	22,20	22,20
Max. brake disc runout, mm	0,15	0,15
Brake caliper piston diameter, mm	60,0	60,0
Min. brake shoe lining thickness, mm	1,6	1,6
Rear wheel drum brakes
Drum brake diameter, mm:
1.6-liter models	203,0
1.8- and 2-liter models and station wagon	228,6
Min. permissible diameter of drum brakes, mm:
1.6-liter models	204,2
1.8- and 2-liter models and station wagon	229,6
	16V engine	2.5 liter engine
Brake cylinder diameter, mm:
1.6-liter models	22,20
1.8 and 2-liter models	20,60
station wagon	22,20
Brake pad width, mm	31.8 (1.6-liter) or 57.1 (all others)
Rear disc brakes	8.3.10.2
Brake disc diameter, mm	252,0
Thickness of brake disc (new), mm	20,0
Thickness of brake disc (worn to the limit), mm	18,0
Max. brake disc runout, mm	0,15
Brake caliper piston diameter, mm	36,0

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