Main settings
Engine | 1.8 ONS | 2.0 ONS | 2.0 ONS | 2.0 ONS | 2.0 ONS |
| engine's type | REC | NEL | NER | NRC | NRA |
| Cylinder diameter (mm) | 86,20 | 90,82 | 90,82 | 90,82 | 90,82 |
| piston stroke (mm) | 76,95 | 76,95 | 76,95 | 76,95 | 76,95 |
| Volume (see3) | 1798 | 1993 | 1993 | 1993 | 1993 |
| Compression ratio | 9,5 | 9,2 | 9,2 | 9,2 | 9,2 |
| Compression pressure (MPa) | 1,1 – 1,3 | 1,1 – 1,3 | 1,1 – 1,3 | 1,1 – 1,3 | 1,1 – 1,3 |
| Rated power: | |||||
| – kW at rpm | 66 at 5400 | 77 at 5200 | 74 at 5400 | 74 at 5100 | 85 at 5500 |
| – HP at rpm | 90 at 5400 | 105 at 5200 | 100 at 5400 | 100 at 5100 | 115 at 5500 |
| Max Torque (Nm at rpm) | 140 at 3500 | 157 at 4000 | 153 at 4000 | 148 at 4000 | 160 at 4000 |
Cylinder head
The head is made of a special aluminum alloy and has inlet valve seats made directly in the material of the cylinder head, while the exhaust valve seats are press-fitted.
| Designation: | |
| – 1.8 dm engine3 | 85 |
| – 2.0 dm engine3 | 0 |
Valve seats
| Valve face angle | 90° |
| Upper Cone Angle: | |
| - inlet | 70° |
| - graduation | 40° |
| Valve seat face width | 1.5 - 2.0 mm |
Regrinding of the lower plane of the cylinder head is not provided.
Camshaft bearing bore diameters
| front bearing | 45.072 - 45.102 mm |
| Middle bearing | 47.692 - 47.772 mm |
| Rear bearing | 48.072 - 48.102 mm |
Cylinder head gasket
Brand: Reinz.
Valve guides
The guide holes are made directly in the cylinder head at an angle of 7°30'.
| Nominal diameter | 8.063 - 8.088 mm |
| Repair size: | |
| – exceeding 0.2 | 8.263 - 8.288 mm |
| – exceeding 0.4 | 8.463 - 8.488 mm |
| – exceeding 0.6 | 8.663 - 8.688 mm |
| – exceeding 0.8 | 8.863 - 8.888 mm |
Valves
The valves are installed in the cylinder head and inclined at an angle of 7°30' to the cylinder axis.
intake valve | Exhaust valve | |
| Valve length: | ||
| – REC engine | 111,75 – 112,75 | 111,15 – 112,15 |
| – engine NEL, NER | 110,65 – 111,65 | 110,05 – 111,05 |
| – engine NRA, NRC | 110,65 – 111,65 | 110,75 – 111,75 |
| Plate diameter: | ||
| – REC engine | 41,80 – 42,20 | 34,00 – 34,40 |
| – engine NEL, NER, NRA, NRC | 41,80 – 42,20 | 35,80 – 36,20 |
| Valve travel | 10,10 | 10,10 |
| Inlet valve sizes common to all engines: | ||
| – rod diameter: | ||
| nominal | 8.025 - 8.043 mm | |
| repair size +0.2 | 8.225 - 8.243 mm | |
| repair size +0.4 | 8.425 - 8.443 mm | |
| repair size +0.6 | 8.625 - 8.643 mm | |
| repair size +0.8 | 8.825 - 8.843 mm | |
| – rod clearance in the guide | 0.020 - 0.063 mm | |
| Exhaust valve sizes common to all engines: | ||
| – rod diameter: | ||
| nominal | 7.999 - 8.017 mm | |
| repair size +0.2 | 8.199 - 8.217 mm | |
| repair size +0.4 | 8.399 - 8.417 mm | |
| repair size +0.6 | 8.599 - 8.617 mm | |
| repair size +0.8 | 8.799 - 8.817 mm | |
| – rod clearance in the guide | 0.046 - 0.089 mm | |
| Valve clearance (with a cold engine): | ||
| - inlet valve | 0.20 mm | |
| - Exhaust valve | 0.25 mm | |
Valve springs
The same springs are used for intake and exhaust valves.
| Spring diameter | 23.445 - 23.95 mm |
| Spring wire diameter | 3.87 - 3.93 mm |
| Number of turns | 4,7 |
| free length | 47.00 mm |
Engine block
The engine block is cast iron. The cylinders are made directly in the cylinder block.
| Support bearing width | 27.17 - 27.22 mm |
| Internal diameters of main bearings (measured vertically): | |
| – nominal: | 57.000 - 57.034 mm |
| - repair size -0.25 | 56.750 - 56.784 mm |
| – repair size -0.50 | 56.500 - 56.534 mm |
| – repair size -0.75 | 56.250 - 56.284 mm |
| – repair size -1.00 | 56.000 - 56.034 mm |
| Bore diameters of the main bearing seats in the cylinder block: | |
| - nominal size | 60.620 – 60.640 mm |
| – repair size +0.4 | 61.020 – 61.040 mm |
Cylinder diameters (mm)
| Engine | 1.8 dm3 | 2.0 dm3 |
| Designation | REC | NEL, NER, NRA, NRC |
| Nominal standard diameters: | ||
| – group 1 | 86,180 – 86,190 | 90,800 – 90,810 |
| – group 2 | 86,190 – 86,200 | 90,810 – 90,820 |
| – group 3 | 86,200 – 86,210 | 90,820 – 90,830 |
| – group 4 | 86,210 – 86,220 | 90,830 – 90,840 |
| Nominal diameters with tolerance: | ||
| – group A | 86,690 – 86,700 | 91,310 – 91,320 |
| - group B | 86,700 – 86,710 | 91,320 – 91,330 |
| - group C | 86,710 – 86,720 | 91,330 – 91,340 |
| Repair dimensions: | ||
| – standard | 86,210 – 86,220 | 90,830 – 90,840 |
| - with a tolerance of 0.5 | 86,710 – 86,720 | 91,330 – 91,340 |
| – with a tolerance of 1.0 | 87,210 – 87,220 | 91,830 – 91,840 |
Crank mechanism
Crankshaft
The steel crankshaft is supported by five bearings.
| Axial play: | 0.08 - 0.28 mm |
| Diameters of main journals: | |
| - nominal size | 56.970 - 56.990 mm |
| - repair size -0.25 | 56.720 - 56.740 mm |
| – repair size -0.50 | 56.470 - 56.490 mm |
| – repair size -0.75 | 56.220 - 56.240 mm |
| – repair size -1.00 | 55.970 - 55.990 mm |
| Clearance in main bearings | 0.010 - 0.064 mm |
Warning! The measurement is carried out using Plastigage measuring rods. | |
| Connecting rod diameters: | |
| - nominal size | 51.980 – 52.000 mm |
| - repair size -0.25 | 51.730 – 51.750 mm |
| – repair size -0.50 | 51.480 – 51.500 mm |
| – repair size -0.75 | 51.230 – 51.250 mm |
| – repair size -1.00 | 50.980 – 50.000 mm |
| Thickness of thrust half rings: | |
| - nominal size | 2.30 - 2.35 mm |
| - repair size | 2.50 - 2.55 mm |
Flywheel
The flywheel is fixed to the crankshaft flange with six bolts.
Intermediate shaft
The intermediate shaft is located in front of the cylinder block, on the left side. Provides a drive for the ignition distributor, as well as oil and fuel pumps.
Axial clearance: 0.050–0.204 mm.
Connecting rods
The connecting rods are forged from steel and have an I-beam profile in their cross section. The piston pin is pressed into the connecting rod head.
| Connecting rod head bore diameter | 23.964 - 23.976 mm |
| Pin tension in the connecting rod head | 0.018 - 0.039 mm |
| Heating temperature of the connecting rod head during pin installation | 250°- 300°С |
| Connecting rod bore diameter | 55.000 – 55.020 mm |
| The inner diameters of the holes of the connecting rod bearings: | |
| - nominal size | 52.006 - 52.044 mm |
| - repair size -0.25 | 51.756 - 51.794 mm |
| – repair size -0.50 | 51.706 - 51.744 mm |
| – repair size -0.75 | 51.256 - 56.294 mm |
| – repair size -1.00 | 51.006 - 51.044 mm |
| Clearance in connecting rod bearings | 0.006 - 0.064 mm |
Warning! The measurement is carried out using Plastigage measuring rods. | |
| Permissible non-perpendicularity of the axis of the holes relative to the axis of the connecting rod: | |
| - head hole | 0.10 mm |
| - base hole | 0.15mm |
Pistons
The pistons are made of light alloy, without grooves on the conductive part, with a cast invar ring to limit thermal dimensional changes. In the upper part there are three grooves for piston rings. The axis of the piston pin hole is offset relative to the piston axis. Pistons are supplied in kits with pins and connecting rods.
Installation Method: The arrow on the bottom of the piston must point towards the front of the engine (towards the drive of the gas distribution system).
Engine 1.8 dm3 | Engine 2.0 dm3 | |
| Nominal standard diameters: | ||
| – group 1 | 86,145 – 86,155 | 90,765 – 90,775 |
| – group 2 | 86,155 – 86,165 | 90,775 – 90,785 |
| – group 3 | 86,165 – 86,175 | 90,785 – 90,795 |
| – group 4 | 86,175 – 86,185 | 90,795 – 90,805 |
| Repair dimensions: | ||
| – standard | 86,170 – 86,195 | 90,790 – 90,815 |
| - with a tolerance of 0.5 | 86,670 – 86,695 | 91,290 – 91,315 |
| – with tolerance 1.0 | 87,170 – 87,195 | 91,790 – 91,815 |
| Clearance of new pistons in cylinders | 0,015 – 0,050 | 0,015 – 0,050 |
Piston pins
Pins made of steel and heat treated, pressed into the connecting rod heads (hot mounting at head temperature 250°– 300°С) and rotate in the piston hubs.
| Length: | |
| – engine 1.8 dm3 | 68.0 - 68.8 mm |
| – engine 2.0 dm3 | 72.0 - 72.8 mm |
| Diameter (mm): | |
| - marking in red | 23,994 – 23,997 |
| - marked in blue | 23,997 – 24,000 |
| - marked in yellow | 24,000 – 24,003 |
| Clearance in piston hubs | 0.008 - 0.014 mm |
| Tension in the connecting rod head | 0.018 - 0.039 mm |
Piston rings
Each piston has three rings: two sealing and one oil scraper.
| O-ring lock clearance (installed in the cylinder): | |
| – engines 1.8 dm3 | 0.30 - 0.50 mm |
| – engine 2.0 dm3 | 0.38 - 0.48 mm |
| Clearance of the lock of an oil scraper ring | 0.40 - 1.40 mm |
| Location of ring locks: | |
| – sealing | by 150° (in opposite directions) in relation to the oil scraper lock |
| – oil scraper | the expanding spring lock is installed in accordance with the direction of the arrow on the bottom of the piston; the locks of the upper and lower plates are set 25 mm to the right and left of the direction of the arrow |
Gas distribution system
The camshaft is located in the cylinder head, drives the valves through the valve lever and is driven by the toothed belt.
| Valve clearance (cold): | |
| - inlet | 0.20 mm |
| – graduation | 0.25 mm |
Distribution phases
| OZD | 24°before TDC |
| ZZD | 64°after BDC |
| OZW | 70°before BDC |
| ZZW | 18°after TDC |
ZD and ZZD - opening and closing of the intake valve, respectively;
OZW and ZZW - opening and closing of the exhaust valve, respectively;
TDC and BDC are top and bottom dead center respectively.
Toothed belt
| Brand | Ford Powergrip |
| Type: | |
| – engines 1.8 dm3 | 70NM 6288 AA |
| – engine 2.0 dm3 | 70NM 6268 AA |
| Number of teeth: | |
| – engines 1.8 dm3 | 119 |
| – engine 2.0 dm3 | 122 |
Camshaft
The camshaft rotates in three bearings.
| Camshaft bearing diameters: | |
| - front | 41.987 - 42.013 mm |
| – medium | 44.607 - 44.633 mm |
| - rear | 44.987 - 45.013 mm |
| Inner diameters of bearing bushes: | |
| - front | 42.035 - 42.055 mm |
| – medium | 44.655 - 44.675 mm |
| - rear | 45.035 - 45.055 mm |
| Camshaft end play | 0.104 - 0.204 mm |
| Thickness of camshaft thrust pads | 3.96 - 4.01 mm |
| Cam lift: | |
| – engine 1.8 dm3 | 5.9639 mm |
| – engine 2.0 dm3 | 6.3323 mm |
| Jaw height: | |
| – engine 1.8 dm3 | 35.894 - 36.234 mm |
| – engine 2.0 dm3 | 36.260 – 36.600 mm |
Lubrication system
Pressure lubrication is provided by a gear oil pump housing a bypass valve.
| Minimum oil pressure (at 80°С): | |
| – at 750 rpm | 0.1 MPa |
| – at 2000 rpm | 0.5 MPa |
| bypass valve opening pressure (at 1000 rpm) | 0.40 - 0.47 MPa |
| Pressure of ignition of a control bulb of pressure of oil | 0.03 MPa - 0.06 MPa |
| A low engine oil level is signaled by a warning light on the instrument cluster. | |
| The volume of engine oil in the engine, dm3: | |
| - with filter replacement | 3,75 |
| – without filter replacement | 3,25 |
Oil pump
The gear oil pump, with internal arrangement of teeth, type Hobourn-Eaton, is put in action from an intermediate shaft.
| Gap of a gear with an internal arrangement of teeth relative to the housing | 0.150 - 0.301 mm |
| Gap between gear teeth | 0.05 - 0.20 mm |
| Axial gear clearance | 0.028 - 0.104 mm |
Oil filter
The full bore oil filter is located on the left side of the cylinder block.
Brand and type: Motorcraft EFL 90.
Cooling system
The closed antifreeze cooling circuit contains a radiator, an expansion tank, a coolant pump, a thermostat and a fan.
Radiator and expansion tank
The crossflow radiator has tanks made of artificial material. The expansion tank is made of transparent material and is marked with maximum and minimum coolant levels. In vehicles equipped with an automatic transmission, an automatic transmission oil cooler is located in the right radiator tank (type oil coolant).
Opening pressure of the overpressure valve in the plug of the expansion tank: 85–110 kPa.
Coolant pump
The centrifugal coolant pump, located on the front wall of the cylinder block, is driven by a V-belt together with the generator.
V-belt
| Brand and type | Motorcraft 83 HF 6 C 301 AA |
| Tension (measured with special tool Ford): | |
| - new belt | 400 - 500 N |
| - used belt | 300 - 400 N |
| Deflection | 10mm in the middle of the longer thumb pressure area |
Fan
Manufactured from artificial material, has seven blades, is located on the shaft of the coolant pump and is driven by a V-belt along with the pump and generator.
Thermostat
Wax, located on the pipeline that drains the coolant from the engine cylinder head.
| Opening start temperature | 85°- 89°С |
| Rated opening temperature | 88°C |
Coolant
| Quantity | 8 dm3 |
| Type | mixture of special antifreeze liquid Ford SSM 97 B 9103 A and distilled water (by 50%) form protection up to -30°С |
| Replacement frequency | every 60,000 km or every two years |
Tightening torques
| Main bearing cap bolts | 88 - 102 Nm |
| Connecting rod bolts | 26 - 33 Nm |
| crankshaft pulley bolt | 110 – 130 Nm |
| Camshaft Pulley Bolt | 45 – 50 Nm |
| flywheel bolts | 67 - 70 Nm |
| Oil pump mounting bolts | 14 - 17 Nm |
| Oil pump cover bolts | 9 – 13 Nm |
| Oil pan bolts: | |
| – 1st stage | 1 – 2 Nm |
| – 2nd stage | 6 – 8 Nm |
| – 3rd stage (after 20 minutes of engine operation) | 8 – 10 Nm |
| Oil drain plug in the oil pan | 21 – 28 Nm |
| Oil pressure sensor | 12 – 15 Nm |
| Valve clearance adjustment bolts near the valve levers | 50 – 55 Nm |
| Cylinder head bolts: | |
| – 1st stage | 35 – 40 Nm |
| – 2nd stage | 70 – 75 Nm |
| – 3rd stage (after 10 - 20 minutes) | tighten by 90° |
| – 4th stage (after 15 minutes of engine operation at 1000 rpm, with a hot engine) | 95 – 115 Nm |
| casing of the gas distribution system | 13 - 17 Nm |
| Intake manifold | 17 - 21 Nm |
| An exhaust manifold | 21 – 25 Nm |
| Spark plug | 20 – 28 Nm |
| thermostat housing | 17 - 21 Nm |
| Cylinder head cover bolts: | |
| – bolts 1 – 6 | 5 – 7 Nm |
| – bolts 9 and 10 | 2 - 2.5 Nm |
| – bolts 7 and 8 | 5 – 7 Nm |
| – bolts 9 and 10 | 5 – 7 Nm |
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