DOHC Engine Specifications

Engine	2.0NS DOHC 2V	2.0NS DOHC EFI
engine's type	N8A	N9A
Cylinder diameter (mm)	86	86
piston stroke (mm)	86	86
Working volume (see3)	1998	1998
Compression ratio	10,3	10,3
Compression pressure (MPa)	1,1 – 1,3	1,1 – 1,3
Rated power:
– in kW at rpm	80 at 5600	92 at 5600
- pm. at rpm	109 at 5600	125 at 5600
Maximum moment (Nm)	168	174
Number of revolutions at maximum torque (rpm)	3000	2500

Engine cylinder head

The cylinder head is die-cast light alloy and has valve seat inserts.

Designation: 20.

Camshaft bearing bushing bore diameters: 26.00–26.03 mm.

Attention! Grinding the bottom surface of the cylinder head is not allowed.

Cylinder head gasket

The cylinder head gasket is installed without the use of sealant.

Brand: Reinz.

Valves

Valves in V arrangement, inclined at an angle of 20°to the cylinder axis and actuated by two camshafts (intake valves and exhaust valves).

Valve sizes (mm)

valve type	Inlet	High school graduation
Length	108,24 – 108,70	108,71 – 109,17
Plate diameter	42,5 – 42,7	37,9 – 38,1
Rod diameter:
- nominal	7,025 – 7,043	6,999 – 7,017
- repair 0.2	7,225 – 7,243	7,199 – 7,217
- repair 0.4	7,425 – 7,443	7,399 – 7,417
- repair 0.6	7,625 – 7,643	7,599 – 7,617
- repair 0.8	7,825 – 7,843	7,799 – 7,817
Gap of the rod in the guide (mm)	0,020 – 0,069	0,046 – 0,095
Chamfer Angle	90°	90°

Valve clearance

The engine uses hydraulic tappets to automatically adjust the valve clearance.

Valve seats

The valve seats, made from an alloy of steel and copper, are inserted into the cylinder head.

Valve seat dimensions

Saddle type	intake valve seat	Exhaust valve seat
Top chamfer angle	60°	60°
Chamfer Angle	89° – 90°	89° – 90°
Chamfer Width	1,33 – 2,19	1,68 – 2,54
Bottom chamfer angle	140°	140°

Valve guides

The valve guides are made of cast iron, inserted into the cylinder head and inclined to the cylinder axis at an angle of 120°.

Guide hole diameters (standard): 7.063 - 7.094 mm.

Valve springs

Two springs are used for each valve.

Characteristics of valve springs

Spring type	Outdoor	Internal
free length (mm)	46,8	46,2
Inner diameter (mm)	24	17,5
The diameter of the wire (mm)	4,5	2,5
Number of working turns	6,1	8

Engine block

The cylinder block is cast iron, has cylinders made directly in the cylinder block and five crankshaft main bearings.

Designation (made in casting)	20
Nominal cylinder diameters
Standard:
– group 1	86.000 – 86.010 mm
– group 2	86.010 - 86.020 mm
Increased +0.15:
– group A	86.150 – 86.100 mm
- group B	86.160 - 86.170 mm
Increased +0.5	86.500 - 86.510 mm
Width of middle main bearing shell	21.17 - 21.23 mm
Diameters of seats of main bearings:
– nominal	59.287 - 59.300 mm
– increased +0.4	59.687 - 59.700 mm

Crank mechanism

Crankshaft

The crankshaft is forged with counterweights and supported by five main bearings.

The axial clearance is regulated by the thickness of the thrust half rings in the middle main bearing.

Diameters of main journals
Nominal:
- yellow sign	54.980 - 54.990 mm
- red sign	54.990 – 55.000 mm
Decreased (sign green)	54.730 - 54.750 mm
Radial clearance in main bearings	0.011 - 0.048 mm
Axial clearance of the crankshaft	0.090 - 0.300 mm
Thickness of thrust half rings:
- nominal	2.301 - 2.351 mm
- repair (sign yellow)	2.491 - 2.541 mm
Diameter of connecting rod journals:
- nominal	50.890 - 50.910 mm
- decreased (sign green)	50.640 - 50.660 mm

Indigenous liners

Half liners located in the cylinder block have a hole and a groove for oil.

The inner diameter of the liners after installation in the cylinder block:
- nominal	55.001 - 55.038 mm
- repair -0.05	54.951 - 54.988 mm
- repair -0.25	54.751 - 54.788 mm
- repair -0.50	54.501 - 54.538 mm
- repair -0.75	54.251 - 54.288 mm

Connecting rods

The connecting rods are forged from steel and have an I-section stem and a straight split line on the lower head. The hole in the bottom head of the connecting rod is used to spray oil into the piston for cooling and lubrication, as well as to cool the piston pin and the connecting rod head. Connecting rods, depending on the mass, are divided into four groups (A, B, C, D). The connecting rods in the engine must belong to the same group.

Bottom head hole diameter	53.890 - 53.910 mm
Head hole diameter	20.589 - 20.609 mm
Radial clearance in connecting rod bearings	0.006 - 0.060 mm

Connecting rod bearings

The inner diameter of the liners after installation in the connecting rod:
- nominal	50.916 - 50.950 mm
- repair -0.025	50.891 - 50.925 mm
- repair -0.25	50.666 - 50.700 mm
- repair -0.50	50.416 - 50.450 mm
- repair -0.75	50.166 - 50.200 mm
– repair -1.00	49.916 - 49.950 mm
Axial clearance of connecting rod (on the crankshaft)	0.090 - 0.310 mm

Pistons

Pistons are cast from light alloy, have a full jacket and a shifted axis of the piston pin bore.

Installation method: the arrow on the bottom must be directed towards the drive of the gas distribution system.

Nominal piston diameters:
– group 1	85.970 – 85.980 mm
– group 2	85.980 – 85.990 mm
Piston repair diameters:
– standard	85.980 – 86.000 mm
– repair +0.15	86.130 - 86.150 mm
– repair +0.50	86.470 - 86.490 mm
Piston clearance in cylinder:
- nominal	0.020 - 0.040 mm
- repair	0.010 - 0.040 mm

Piston rings

Each piston has three rings:

• first (top) – sealing barrel-shaped;
• second (average) – sealing conical;
• third (bottom) – oil scraper (three-piece with spring expander).

Ring lock gap (placed in a cylinder):
- the first sealing	0.30 - 0.60 mm
- second sealing	0.50 - 0.80 mm
– oil scraper	0.40 - 1.50 mm

Piston pins

Pins made of steel are pressed into the connecting rod head and rotate in the piston hubs.

Installation method: after heating the connecting rod to a temperature of 260°–300°C.

Length:	63.4 mm
Diameter:
- marking in white	20.622 - 20.625 mm
- marking in red	20.626 - 20.628 mm
- marked in blue	20.628 - 20.631 mm
- marked in yellow	20.631 - 20.634 mm
Clearance in piston hubs	0.008 - 0.014 mm
Tension in the connecting rod head	0.018 - 0.039 mm

Flywheel

The flywheel is bolted to the crankshaft with six asymmetrical bolts.

Gas distribution system

Two camshafts are located in the cylinder head and are driven by a separate roller chain from the crankshaft and actuate the valves via hydraulic tappets.

Camshafts

The two camshafts in the cylinder head are supported by five bearings: one drives the intake valves and the other drives the exhaust valves.

Neck diameter	25.960 - 5.980 mm
Axial clearance	0.02 - 0.26 mm
Cam lift:
- inlet valves in a carburetor engine	10.5mm
- inlet valves in a gasoline injection engine	11.1mm
– exhaust valves	10.9 mm

Valve timing

engine's type	N8A	N9A
OZD	13°before TDC	13°before TDC
ZZD	39°after BDC	51°after BDC
OZW	43°before BDC	43°before BDC
ZZW	13°after TDC	13°after TDC
OZD and ZZD - opening and closing of the intake valve, respectively
OZW and ZZW - opening and closing of the exhaust valve, respectively

Timing chain

Single row roller chain 3/8" with hydraulic tension.

Lubrication system

The pressure lubrication system comprises an oil pump driven by a chain from the crankshaft, an oil filter with a replaceable element, and an oil bypass valve.

Oil pump

The gear oil pump is located in front of the engine block.

Oil pressure (at 80°C):
– at 750 rpm	0.16 MPa
– at 2000 rpm	0.31 - 0.46 MPa
bypass valve opening pressure	0.37 - 0.46 MPa
Clearance of the outer gear in the crankcase	0.154 - 0.304 mm
Clearance between outer and inner gears	0.05 - 0.20 mm

Oil filter

The replaceable oil filter contains a side channel that opens automatically in case of excessive contamination of the filter element.

Brand and type: Motorcraft EFL 90.

Replacement frequency: after 10,000 km of vehicle run or after six months of vehicle use, then every 20,000 km or once a year.

Engine oil

Quantity (with filter): 4.75 in.³.

Type: multigrade engine oil according to API SG/CD viscosity SAE 10W 30, 10W 40 or 10W 50.

Replacement frequency: after 10,000 km of vehicle run or after six months of vehicle use, then every 20,000 km or once a year.

Cooling system

Thermostat

The wax thermostat is located in front of the engine near the intake manifold.

Opening start temperature: 85°–89°С.

Full opening temperature: 102°±3°C.

Fan

The fan is driven by an electric motor switched on by a thermal switch located in the radiator drain plug.

The cooling system of vehicles equipped with a manual transmission contains one fan, while vehicles equipped with an automatic transmission contain two fans.

Expansion tank

The expansion tank is made of artificial material.

Opening pressure of the overpressure valve in the plug of the expansion tank: 120 - 140 kPa.

Coolant

Quantity:

• engine 2.0 NS DONS 2V (N8A): 7.9 in³;
• engine 2.0 NS DONS EFI (N9A): 7.3 in.³.

Type: mixture of Ford Super Plus SSM 97 B 9103 A special antifreeze and distilled water (by 50%).

Replacement frequency: every two years.

Fuel system

Fuel System Engine 2.0 NS DOHC 2V (N8A) uses an electric fuel pump and a Weber TLD carburetor, and the 2.0 HC DOHC EFI engine (N9A) the Ford Motorcraft EFI injection system is used, combined with the ignition system and is included in the EEC IV engine management system.

Fuel tank

The fuel tank, made of sheet steel, is secured with two steel clamps in front of the rear axle.

Capacity: 60 dm³.

Fuel type: 98 octane leaded or unleaded 95 octane or higher (engines adapted to run on unleaded petrol).

Air filter

The air filter has a replaceable paper element.

Make and type: Motorcraft EFA 56.

Fuel filter

Make and type: Motorcraft EFG 21.

Fuel pump

Carbureted engine

The fuel pump is electric.

Fuel injected engine

Ford roller fuel pump.

Created pressure (at a voltage of 12 V and a closed fuel outlet): 300 kPa.

Weber carburetor

The Weber TLD dual chamber sequential carburetor has a 2nd chamber throttle controlled by intake manifold vacuum, an accelerator pump, an enrichment device in the 2nd chamber and an automatically actuated starting choke.

Weber TLD Carburetor Adjustment Data

Parameter	1st camera	2nd camera
diffuser diameter (mm)	23	25
Main fuel jet	115	157
emulsion tube	F114	F13
Main air jet	175	145
Float installation	29 ± 0,5	29 ± 0,5
Throttle opening	5 ± 0,5	5 ± 0,5
"Fast" idle speed (rpm)	1800 ± 50	1800 ± 50
idle speed (rpm)	850 ± 25*	850 ± 25*
CO content (%)	1 ± 0,25	1 ± 0,25

* Vehicles with automatic transmission: 800±50 rpm.

Ford Motorcraft EFI injection system

Electronically controlled multi-point fuel injection, Ford Motorcraft EFI, combined with an ignition system included in the EEC IV engine management system, is used. Fuel is supplied to the injectors at a constant pressure. The EEC IV electronic control unit doses the portion of the atomized fuel and controls the ignition, and also shuts off the fuel supply to the engine during engine braking.

Fuel pressure control

Brand: Bosch.

Adjustable pressure: 230–250 kPa.

Fuel injectors

The fuel injectors are electronically controlled.

Brand: Bosch.

Adjustment data

Number of turns of idling: 875±25 rpm.

CO content: 1.25±0.25%.

Ignition system

Engine 2.0 NS DOHC 2V (N8A) a rechargeable, microprocessor-based ignition system of the ESC II type is used, and in the 2.0 HC DOHC EFI engine (N9A) a rechargeable, microprocessor-based ignition system of the ESC IV type was installed, combined with a Ford Motorcraft EFI injection system.

The principle of operation of both types of ignition system is identical, however, the system integrated with the injection system is more powerful.

The ignition system includes:

• ignition coil;
• an ignition distributor comprising a speed sensor and a high voltage distributor;
• an electronic ignition control module or an electronic device that controls injection and ignition;
• four spark plugs.

Besides, (depending on the type) the ignition system contains:

• coolant temperature sensor (ESC II and EEC IV);
• vacuum gauge (ESC II);
• automatic transmission shift lever neutral position sensor (ESC II and EEC IV);
• throttle position sensor (EEC IV);
• absolute pressure sensor (EEC IV).

Ignition coil

Brand and type: Bosch 0 221 122 450.

Primary winding resistance: 0.72 - 0.88 ohms.

Secondary winding resistance: 4.5 - 7 kOhm.

Distributor

The ignition distributor contains a non-contact Hall sensor, which also acts as a speed sensor, as well as a high voltage distributor. Located at the front end of the intake camshaft.

Brand: Motorcraft.

Ignition order (cylinder N1 on the drive side of the gas distribution system): 1–3–4–2.

Direction of rotation: clockwise.

N8A Engine Electronic Module

Brand: Motorcraft.

Type: Ford ESC II.

Electronic engine control module N9A

Brand: Motorcraft.

Type:

• vehicles with manual transmission: Ford EEC IV 88 BB 12A 650 AB;
• vehicles with automatic transmission: Ford EEC IV 88 GB 12A 650 RB.

Spark plug

Brand and type:

• engine 2.0 NS DONS 2V (N8A): Motorcraft AGPR 32 CD;
• engine 2.0 NS DONS EFI (N9A): Motorcraft Super AGPR 22 CD.

Gap between electrodes: 0.75 mm.

Tightening torques

Cylinder head bolts:
– 1st stage (M11 bolts - sequence 1 - 10)	25 Nm
– 2nd stage (M11 bolts - sequence 1 - 10)	55 Nm
– 3rd stage (M11 bolts - sequence 1 - 10)	tighten by 90°
– 4th stage (M11 bolts - sequence 1 - 10)	tighten by 90°
– 5th stage (M8 bolts - sequence 1 - 13)	24 - 27 Nm
cylinder head cover	6 – 8 Nm
casing of the gas distribution system	65 – 95 Nm
Timing chain guides:
– top	10 – 13 Nm
- lower	24 - 28 Nm
Camshaft sprockets	55 - 63 Nm
Camshaft bearing caps	22 - 26 Nm
Main bearing caps	90 - 104 Nm
Connecting rod caps	26 - 34 Nm
– 1st stage	6 – 8 Nm
– 2nd stage	15 – 17 Nm
– 3rd stage	tighten 85°– 95°
Vibration damper, crankshaft	110 – 130 Nm
– 1st stage	45 - 58 Nm
– 2nd stage	tighten 80°– 90°
Oil pump to cylinder block	8.5 - 11.5 Nm
Oil pump pulley	16 - 19 Nm
Oil pump drive chain tensioner	10 – 13 Nm
coolant pump	21 – 28 Nm
Coolant pump pulley	21 – 28 Nm
thermostat housing	9 – 12 Nm