torque FORD GRANADA 1985 Service Owner's Manual

together, guide the torque converter studs
through the holes in the driveplate. When the
engine is positioned flush with the engine
adapter plate and the transmission housing,
check that the torque converter is free to move
axially a small amount before refitting and
tightening the engine-to-transmission bolts.
6Do not tighten the torque converter-to-
driveplate nuts until the lower engine-to-
transmission bolts have been fitted and
tightened.
7Ensure that the roadwheels and the steering
wheel are in the straight-ahead position then
align the marks made on removal and
reconnect the intermediate shaft to the
steering gearing. Tighten the clamp bolt to the
specified torque.
8Reconnect the selector rod and adjust as
described in Chapter 7, PartB.
9Refit the propeller shaft.
10Refit the exhaust system.
11Fill the engine with the correct grade and
quantity of oil.
12Check the throttle cable adjustment. Where
necessary, also adjust the speed control cable
in the same way so that there is only a small
amount of slack present in the cable.
13Reconnect the coolant hoses to the water
pump housing.
14Fill the cooling system.
15Check and if necessary top-up the
transmission fluid level.
16Tighten all fixings to the specified torque,
where applicable.
Proceed as described in Part A, Section 23
of this Chapter but note that on certain
models, it may be necessary to unbolt the
engine mounting brackets from the cylinder
block to allow sufficient clearance to remove
the mountings.
1Refer to Part A, Section 8 of this Chapter,
paragraphs 1 to 8 inclusive.
2A selection of splined and Torx sockets will
be required to remove many of the bolts when
dismantling the engine.
3Before dismantling the main engine
components, the following externally mounted
ancillary components can be removed.
a)Inlet manifold (and carburettor, where
applicable).
b)Exhaust manifold.
c)Alternator.
d)Water pump, and thermostat.
e)Water pump/alternator drivebelt tensioner.
f)Distributor cap, HT leads and spark plugs.
g)Oil pressure warning lamp switch.
h)Crankshaft speed/position sensor.
i)Oil filter.
j)Dipstick.
k)Engine mounting brackets (if not already
done).
l)Crankcase ventilation pipe and hoses.m)Clutch.
n)Alternator mounting bracket.
o)Air conditioning compressor mounting
bracket (where applicable).
p)Engine lifting brackets.
Note: A puller will be required to remove the
crankshaft pulley. A new crankshaft pulley bolt,
a new timing chain tensioner plunger
assembly, new upper and lower timing chain
cover gaskets and a new camshaft cover
gasket and reinforcing sleeve sealing rings
must be used on refitting.
1If the engine is in the car, carry out thefollowing operations.
a)Disconnect the battery negative lead.
b)To improve access, remove the radiator. It
will be difficult to remove the crankshaft
pulley with the radiator in place.
c)On carburettor models, remove the air
cleaner.
d)On fuel-injection models, remove the air
inlet hose, plenum chamber and air
cleaner lid as an assembly.
e)Disconnect the breather hose from the
camshaft cover.
f)Remove the distributor cap and HT leads,
and the rotor arm and housing.
2Proceed as described in paragraphs 2 to 11
inclusive of Section 18 (see illustration).
3Remove the water pump/alternator
drivebelt.
15Timing chain and sprockets -
removal and refitting
14Engine dismantling - general
information
13Engine mountings - renewal
2B•8DOHCengine
1 Upper timing chain guide
2 Exhaust camshaft sprocket
3 Timing chain
4 Lower timing chain guide
5 Crankshaft sprocket (double)
6 Crankshaft
7 Oil pump chain tensioner
8 Oil pump drive chain
9 Oil pump10 Oil pressure relief valve
11 Oil passage to timing chain tensioner
plunger
12 Plug
13 Timing chain tensioner plunger
14 Timing chain tensioner sprocket
15 Timing chain tensioner arm
16 Inlet camshaft sprocket
17 Copper chain links
15.2 Timing chain, oil pump drive chain and associated components
procarmanuals.com

prevent the chain from dropping into the
timing case, as during removal.
18Locate the double chain sprocket loosely
over the end of the crankshaft (larger sprocket
nearest the crankcase), with the timing mark
pointing vertically down.
19Fit the chain over the inner, larger
sprocket, aligning the coppered link in the
chain with the timing mark on the sprocket
(see illustration).
20Coat the threads of the lower timing chain
guide lower securing bolt with a suitable
thread-locking compound.
21Introduce the lower timing chain guide
through the top of the timing case,
manipulating the chain around the guide as
necessary, then fit the chain guide lower
securing bolt and tighten it finger-tight.
22Push the double chain sprocket onto the
crankshaft, engaging the notch in the sprocket
with the groove in the end of the crankshaft.
23Proceed as described in paragraphs 34 to 42
of Section 18, but when fitting the chain over the
camshaft sprockets, align the timing mark on
each sprocket between the two corresponding
coppered links in the chain.
24Coat the threads of the lower timing chain
guide upper securing bolt with a suitable
thread-locking compound, then fit the bolt and
tighten it finger-tight.
25Proceed as described in paragraphs 43 to 46
of Section 18.
26Tighten the two chain guide securing bolts
to the specified torque.
27Proceed as described in paragraphs 47 to 55
of Section 18.
28Fit the oil pump drive chain around the
outer crankshaft sprocket and the oil pump
sprocket, then refit the oil pump sprocket, and
tighten the securing bolt to the specified
torque. If necessary, a screwdriver can be
inserted through one of the holes in the
sprocket to prevent it from turning as the
securing bolt is tightened.
29Refit the oil pump drive chain tensioner,
and tighten the securing bolt to the specified
torque.
30Refit the Woodruff key to the end of the
crankshaft.
31Inspect the oil seal in the lower timing
chain cover. If the oil seal is in good condition,the cover can be refitted as follows, but if the
seal is damaged, or has been leaking, a new
seal should be fitted to the cover. If necessary,
carefully prise the old oil seal from the cover
using a screwdriver, and drive in the new seal
using a suitable metal tube. Make sure that the
seal lip faces into the engine. Note that the oil
seal should be fitted dry. Take care not to
damage the timing chain cover (see
illustration).
32Fit the lower timing chain cover using a
new rubber gasket (see illustration).
33Loosely refit the timing chain cover
securing bolts.
34Refit the crankshaft pulley to the end of the
crankshaft, and draw the pulley onto the
crankshaft using the original securing bolt, at the
same time centering the lower timing chain cover.
35With the lower timing chain cover
centralised, and the pulley fully home on the
crankshaft, remove the old securing bolt, then
fit a new bolt.
36Tighten the new crankshaft pulley bolt to
the specified torque, in the two stages given in
the Specifications at the beginning of this
Chapter. Prevent the crankshaft from turning
as during removal.
37Tighten the lower timing chain cover
securing bolts to the specified torque.
38Refit the drivebelt tensioner assembly,
ensuring that the lug on the rear of the
tensioner bracket engages with the
corresponding hole in the cylinder block, and
tighten the securing bolt.39Swing the alternator into position to align
the upper mounting bolt hole with the
corresponding hole in the drivebelt tensioner
assembly, then refit the upper mounting bolt,
and tighten the upper bolt and the lower
through-bolt.
40Refit the water pump/alternator drivebelt.
41If the engine is in the vehicle, reverse the
operations described in paragraph 1 of
Section 15.
42Where applicable, refill the cooling
system.
1Examine all the teeth on the camshaft and
crankshaft sprockets. If the teeth are “hooked”
in appearance, renew the sprockets.
2Examine the chain tensioner plastic
sprocket for wear. If excessive wear is evident,
the complete tensioner assembly must be
renewed as the sprocket cannot be renewed
independently.Note that the tensioner plunger
assembly must be renewed whenever the
timing chain is removed.
3Examine the timing chain for wear. If the
chain has been in operation for a considerable
time, or if when held horizontally (rollers
vertical) it takes on a deeply bowed
appearance, renew it.
Note: The cylinder head must not be removed
when the engine is warm. Refer to the note at
the beginning of the following Section before
proceeding.
1Disconnect the battery negative lead.
2On carburettor models, remove the air
cleaner.
3On fuel-injection models, remove the air
inlet hose, plenum chamber, and air cleaner lid
as an assembly.
4Drain the cooling system.
5Disconnect the heater coolant hose from
the inlet manifold (see illustration).
17Cylinder head - removal and
refitting (engine in vehicle)
16Timing chain, sprockets and
tensioner - examination and
renovation
2B•10DOHCengine
15.19 Coppered link in timing chain aligned
with crankshaft sprocket timing mark
(arrowed)
17.5 Disconnecting the heater coolant hose
from the inlet manifold
15.31 Fitting a new lower timing chain
cover oil seal15.32 Lower timing chain cover gasket in
position. Ensure that lug on gasket
engages with notch in cover (arrowed)
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dowels. Note that the gasket can only fit in one
position (see illustration). Do not use jointing
compound.
23Lower the cylinder head onto the gasket,
making sure that the locating dowels engage.
24Oil the threads of the new main cylinder
head bolts, and insert them into their locations
in the cylinder head.
25Tighten the bolts in the order shown (see
illustration)and in the four stages given in the
Specifications.
26Insert the three smaller M8 cylinder head
bolts through the top of the timing case (see
illustration)and tighten them to the specified
torque. Note that new bolts must be used, and
that they should be of the latest type with
hexagonal heads.
27Lubricate the cam follower bores in the
cylinder head, and the cam followers
themselves, then insert the cam followers into
their original locations in the cylinder head.
28Lubricate the camshaft bearing surfaces in
the cylinder head and the bearing caps.
29Lubricate the surfaces of the camshafts,
then carefully lay the camshafts in their original
positions in the cylinder head. Position the
camshafts with the slots in their front ends
pointing away from each other.
30Fit the bearing caps L1, L3, L5, R1, R3,
and R5 (see illustration), then lay the
camshaft oil spray bars and the timing chain
guide plate in position over the studs (see
illustrations).31Carefully tighten the bearing cap securing
nuts by hand in the following stages to lower
the camshafts into position.
Tighten the nuts for bearing caps L1 and R1
by half-a-turn (180°)
Tighten the nuts for bearing caps L5 and R5
by half-a-turn (180°)
Tighten the nuts for bearing caps L3 and R3
by half-a-turn (180°)
Continue to tighten the nuts in the small
stages given until the bearing caps contact the
cylinder head.
32Fit bearing caps L2, L4, R2 and R4, and
tap them into position on the cylinder head
using light taps from a soft-faced mallet.
Tighten the securing nuts evenly by hand.
33Tighten all the bearing cap nuts to the
specified torque in half turn stages, using the
following sequence.
L1 and R1
L5 and R5
L3 and R3
L2 and L4
R2 and R4
34Fit a newchain tensioner plunger
assembly to the housing in the cylinder head
with the piston uppermost. Before fitting the
new plunger assembly, take note of the
position of the piston (see illustration). The
assembly is normally supplied with the piston
protruding slightly from the cylinder, or slightlybelow the top surface of the cylinder (A). If the
new assembly is supplied with the piston
partially unlatched (B), or fully unlatched with
the latching ring visible (C), it must not be used.
35Locate the chain tensioner arm in position,
then insert the pivot pin, and secure it with the
circlip. Take care not to drop the circlip into
the timing case.
36Release the cable-tie securing the timing
chain, and lay the chain over the exhaust
camshaft sprocket, aligning the marks made
previously on the chain and sprocket, so that
the timing chain is taught on the exhaust side
of the engine.
37Fit the sprocket to the exhaust camshaft,
with the camshaft in the TDC position (ie with
the exhaust camshaft sprocket timing mark in
line with the top edge of the cylinder head,
pointing to the exhaust side of the engine, see
paragraph 4). If necessary, use a pair of pliers
on one of the unmachined sections of the
camshaft to turn the camshaft to the TDC
position. Take care not to damage the
machined surfaces of the camshaft.
38With the sprocket fitted, fit the spacer to
the end of the camshaft, and tighten the
securing bolt finger-tight (see illustration).
39Lay the timing chain over the inlet
DOHCengine 2B•13
2B
18.22 Fitting a new cylinder head gasket18.30a Camshaft bearing cap tightening
sequence18.30b Camshaft oil spray bars correctly
fitted
18.30c Fitting the timing chain guide plate
18.34 Timing chain tensioner plunger
assembly
A Piston retracted - plunger assembly useable
B Piston partially unlatched - discard plunger
assembly
C Latching ring (1) visible - discard plunger
assembly
18.38 Spacer and sprocket securing bolt
fitted to end of camshaft, with camshaft in
TDC position (timing marks arrowed)
Warning: Take care when
installing the plunger assembly,
as there is a risk of injury if the
piston flies out.
procarmanuals.com

camshaft sprocket, aligning the marks made
previously on the chain and the sprocket.
40Fit the sprocket to the inlet camshaft, with
the camshaft in the TDC position (ie with the
inlet camshaft sprocket timing mark in line
with the top edge of the cylinder head,
pointing to the inlet side of the engine see
paragraph 4). Again, turn the camshaft if
necessary to enable the sprocket to be fitted.
41With the sprocket fitted, fit the distributor
rotor shaft to the end of the camshaft, and
tighten the securing bolt finger-tight. Note that
it is acceptable for the timing chain to sag
slightly between the two pulleys.
42Fit a new upper timing chain guide to the
plate at the front of the cylinder head.
43Turn the crankshaft clockwise until the
inlet camshaft begins to turn.
44If the chain tensioner plunger piston
protrudes from the cylinder, unlatch the piston by
pressing the chain tensioner arm down by hand.
45If the plunger piston is below the top
surface of the cylinder, a tool must be
fabricated to unlatch the piston (see
illustration). It is suggested that 2.5 mm
diameter welding rod is used to manufacture
the tool. Use the tool to release the piston as
follows.
46Carefully lift the chain tensioner arm with a
screwdriver, and insert the tool between the
tensioner arm and the piston. Remove the
screwdriver, and release the piston by
pressing the tensioner arm down by hand.
Carefully withdraw the tool once the piston
has been released.
47Tighten the camshaft sprocket securing
bolts to the specified torque, holding the
sprockets stationary as during removal.
48Turn the crankshaft clockwise through two
complete revolutions, and check that the
timing marks on the camshaft sprockets are
still aligned with the top face of the cylinder
head as described in paragraph 4.
49Turn the crankshaft clockwise through
another complete revolution, and check that
the timing marks on the camshaft sprockets
are facing each other, directly in line with the
top face of the cylinder head.
50If the timing marks do not align as
described, the timing chain has been
incorrectly fitted (probably one chain link awayfrom the correct position on one of the
camshaft sprockets), and the chain should be
removed from the sprockets and fitted in the
correct position.
51Inspect the oil seal in the upper timing
chain cover. If the oil seal is in good condition,
the cover can be refitted as follows, but if the
seal is damaged, or has been leaking, a new
seal should be fitted to the cover. If necessary,
carefully prise the old oil seal from the cover
using a screwdriver, and drive in the new seal
using a suitable metal tube. Make sure that the
seal lip faces into the engine. Take care not to
damage the timing chain cover.
52Fit the upper timing chain cover using a
new rubber gasket. Great care must be taken
to avoid damage to the oil seal when passing
the seal over the end of the inlet camshaft.
Careful manipulation will be required (possibly
using a thin feeler blade) to avoid damage to
the oil seal sealing lip. Note that the oil seal
should be fitted dry.
53Refit the timing chain cover securing bolts
and studs in their original locations and tighten
them to the specified torque (see illustration).
54Remove the reinforcing sleeves from the
camshaft cover, and renew the rubber sealing
rings. Note that the four short reinforcing
sleeves fit at the front of the cover (see
illustration).
55Refit the camshaft cover using a new
gasket, and tighten the securing bolts and
studs to the specified torque.
Note: A valve spring compressor will be
required during this procedure. New valve
stem oil seals should be used on reassembly.
Dismantle the cylinder head as described in
paragraphs 2 to 4, Section 12, PartA of this
Chapterand reassemble the head as
described in paragraphs 4 to 6, Section 42,
Part A of this Chapter, noting the following
points:
a)Ignore the references to the special tool.
b)Double valve springs are used on all the
valves (see illustration).
c)Refer to the following Section if the
cylinder head is to be inspected and
renovated.Refer to Part A, Section 34 of this Chapter,
noting the following points.
a)Valve and valve seat cutting and
regrinding can be carried out using
conventional tools.
b)The cylinder head cannot be resurfaced,
and if the surface distortion exceeds the
specified limits, the cylinder head must be
renewed.
Note: Once the timing chain has been
removed from the camshaft sprockets, do not
turn the crankshaft until the timing chain has
been correctly refitted - this is to prevent
contact between the valves and pistons. A
new timing chain tensioner plunger assembly,
a new upper timing chain cover gasket, and a
new camshaft cover and reinforcing sleeve
sealing rings must be used on refitting.
1If the engine is in the vehicle, carry out the
following operations.
a)Disconnect the battery negative lead.
b)On carburettor models, remove the air
cleaner.
c)On fuel-injection models, remove the air
inlet hose, plenum chamber, and air
cleaner lid as an assembly.
21Camshafts and cam followers
- removal, inspection and
refitting
20Cylinder head - inspection and
renovation
19Cylinder head - dismantling
and reassembly
2B•14DOHCengine
18.45 Fabricated tool used to unlatch
tensioner plunger piston
19.1 Withdrawing the double valve springs
from the cylinder head
18.53 Upper timing chain cover securing
stud locations (arrowed)18.54 Fitting a camshaft cover reinforcing
sleeve and sealing ring
procarmanuals.com

13Apply a sealing compound to the faces of
the cylinder block and sump at the points
indicated(see illustration).
14Apply suitable thread-locking compound
to the sump securing studs and bolts, then
locate the sump on the cylinder block and fit
the securing nuts and bolts, but do not fully
tighten them at this stage.
15Align the sump so that the end faces and
the cylinder block are flush. To do this, use a
straight-edge. If the sump cannot be
positioned so that the faces of the cylinder
block and sump are flush, measure the
difference in height using a feeler blade as
shown (see illustration).
16Tighten the sump securing nuts and bolts
to the specified torque, then repeat the
measurement made in paragraph 15. If the
end faces of the sump and cylinder block are
not flush, suitable shims must be fitted
(available from a Ford dealer) between the
sump and the gearbox/transmission to
eliminate the clearance when mating the
engine to the gearbox/transmission. Note that
shims should be fitted at both sides of the
sump, as required. Select suitable shims from
those listed in the following table.
Clearance measuredShims required
0 to 0.25 mmNo shims required
0.25 to 0.29 mm0.15 mm (silver)
0.30 to 0.44 mm0.30 mm (light blue)
0.45 to 0.59 mm0.45 mm (red)
0.60 to 0.75 mm0.60 mm (black)
17If the engine is in the vehicle, reverse the
procedure described in paragraphs 3 to 8,
noting the following points.
a)Ensure that the roadwheels and the
steering wheel are in the straight-aheadposition then align the marks made on
removal and reconnect the intermediate
shaft to the steering gear. Tighten the
clamp bolt to the specified torque.
b)Fill the engine with the correct grade and
quantity of oil.
c)Refit the engine adapter plate and the
flywheel/driveplate.
d)Refit the gearbox or automatic
transmission, as applicable, ensuring that
the required shims are fitted between the
sump and the gearbox/transmission.
e)Tighten all fixings to the specified torque
where applicable.
Note: A suitable puller will be required to
remove the crankshaft pulley. A new
crankshaft pulley bolt, a new lower timing
chain cover gasket and a new oil pump gasket
must be used on refitting.
1If the engine is in the car, carry out the
following operations.
a)Disconnect the battery negative lead.
b)To Improve access, remove the radiator. It
will be difficult to remove the crankshaft
pulley with the radiator in place.
c)On fuel-injection models, remove the air
inlet hose, plenum chamber and air
cleaner lid as an assembly.
2Proceed as described in paragraphs 3 to 10
of Section 15.3Unscrew the four securing bolts and
withdraw the oil pump from the cylinder block
(see illustration). Recover the gasket and
discard it.
4If desired, the pump can now be dismantled
and inspected.
5Thoroughly clean the mating faces of the
pump and the cylinder block.
6Prime the pump by injecting clean engine oil
into it and turning it by hand.
7Place a new gasket on the oil pump flange,
ensuring that the gasket is correctly located so
that the holes align with the oil passages in the
pump.
8Fit the oil pump, and tighten the securing
bolts to the specified torque.
9Proceed as described in paragraphs 28 to 40
of Section 15.
10If the engine is in the vehicle, reverse the
operations described in paragraph 1.
1The oil pump can be dismantled for
cleaning, but if any of the components are
worn, the pump must be renewed as an
assembly.
2To dismantle the pump, proceed as follows.
3Unscrew the two securing bolts, and
remove the pump cover (see illustration).
4Lift the inner and outer rotors from the
pump casing.
5Unscrew the pressure relief valve plug from
27Oil pump - dismantling,
inspection and reassembly
26Oil pump - removal and
refitting
2B•16DOHCengine
25.13 Apply sealing compound to the
sump/cylinder block mating faces at the
points indicated (2)
Dimensions are for guidance only
27.3 Removing the oil pump cover27.5a Unscrew the pressure relief valve
plug and washer . . .
25.15 Measuring the clearance between the
cylinder block and sump end faces26.3 Oil pump securing bolts (arrowed)
procarmanuals.com

9Extract the bearing shells, and recover the
thrustwashers, keeping them identified for
location.
10The crankshaft and bearings can be
examined and if necessary renovated.
11Commence refitting as follows(see
illustration).
12Wipe the bearing shell locations in the
crankcase, and the crankshaft journals with a
soft non-fluffy rag.
13If the old main bearing shells are to be
renewed (not to do so is a false economy,
unless they are virtually new) fit the five upper
halves of the main bearing shells to their
locations in the crankcase.
14Fit the thrustwashers to the centre main
bearing location, using a little grease to retain
them if necessary. The oil grooves in the
thrustwashers must face outwards (ie facing
the crankshaft webs). Note that where
standard thrustwashers have been fitted in
production, the centre main bearing is
unmarked, but if oversize (0.38 mm)
thrustwashers have been fitted, the centre
main bearing will carry a yellow paint mark.
15Lubricate the crankshaft journals and the
upper and lower main bearing shells with
clean engine oil, then carefully lower the
crankshaft into the crankcase.
16Lubricate the crankshaft main bearing
journals again, and then fit the main bearing caps
in their correct locations, with the arrows on the
caps pointing towards the front of the engine.
17Fit the main bearing cap bolts, noting that
the studded bolts secure bearing caps Nos 3
and 5.
18Lightly tighten all the securing bolts, then
progressively tighten all bolts to the specified
torque.
19Check that the crankshaft rotates freely.
Some stiffness is to be expected with newcomponents, but there must be no tight spots
or binding.
20Check that the crankshaft endfloat is
within the specified limits by inserting a feeler
blade between the centre crankshaft web and
the thrustwashers.
21Refit the sump mounting plate to the front
of the cylinder block, and tighten the securing
bolts to the specified torque.
22Carefully wind a thin layer of tape around
the rear edge of the crankshaft to protect the
oil seal lips as the rear oil seal is installed.
23Refit the crankshaft rear oil seal housing,
using a new gasket, and tighten the securing
bolts to the specified torque.
24Install the new oil seal with reference to
Section 24.
25With the oil seal installed, carefully pull the
tape from the edge of the crankshaft.
26Refit the pistons and connecting rods as
described previously in this Chapter.
27Refit the flywheel/driveplate, and the
timing chain and crankshaft sprocket.
Proceed as described in Part A, Section 27
of this Chapter, noting that the production
bearing undersizes are indicated as follows.
Yellow or red paint marks on crankshaft —
standard diameter main bearing journals.
Green line on crankshaft front counterweight
— main bearing journals 0.25 mm
undersize.
Green spot on counterweight — big-end
bearing journals 0.25 mm undersize.
Refer to Part A, Section 25 of this Chapter,
but note that the connecting rod bolts should
be renewed on reassembly, and when
renewing the cylinder head bolts, the latest
type bolts with hexagonal heads should
always be used.
Proceed as described in Part A, Section 35
of this Chapter, noting the following points.
a)If the cylinder head has been removed,
pay particular attention to the note at the
beginning of Section 18.
b)If removed during any dismantling
operations, new flywheel driveplate bolts
and connecting rod bolts must be used.
c)After reassembling the main engine
components, refer to paragraph 3 of
Section 14 and refit the ancillary
components listed.Refer to Part A, Section 51 of this Chapter,
but note that when the engine is first started, a
metallic tapping noise may be heard. This is
due to the timing chain tensioner plunger
assembly taking time to pressurize with oil,
resulting in a temporarily slack chain. The
noise should stop after a short time, once oil
pressure has built up.
1When engine performance is down, or if
misfiring occurs which cannot be attributed to
the ignition or fuel system, a compression test
can provide diagnostic clues. If the test is
performed regularly it can give warning of
trouble before any other symptoms become
apparent.
2The engine must be at operating
temperature, the battery must be fully charged
and the spark plugs must be removed. The
services of an assistant will also be required.
3Disable the ignition system by dismantling
the coil LT feed. Fit the compression tester to
No 1 spark plug hole. (The type of tester which
screws into the spark plug hole is to be
preferred.)
4Have the assistant hold the throttle wide
open and crank the engine on the starter.
Record the highest reading obtained on the
compression tester.
5Repeat the test on the remaining cylinders,
recording the pressure developed in each.
6Desired pressures are given in the
Specifications. If the pressure in any cylinder
is low, introduce a teaspoonful of clean engine
oil into the spark plug hole and repeat the test.
7If the addition of oil temporarily improves
the compression pressure, this indicates that
bore or piston wear was responsible for the
pressure loss. No improvement suggests that
leaking or burnt valves, or a blown head
gasket, may be to blame.
8A low reading from two adjacent cylinders is
almost certainly due to the head gasket
between them having blown.
9On completion of the test, refit the spark
plugs and reconnect the coil LT feed.
35Compression test -
description and interpretation
34Initial start-up after overhaul
or major repair
33Engine reassembly - general
information
32Examination and renovation -
general information
31Crankshaft and bearings -
examination and renovation
2B•18DOHCengine
30.11 Crankshaft main bearings and
associated components
1 Bearing cap
2 Thrustwasher
3 Stud for oil baffle
4 Identification markings
5 Bearing shell without oil groove
6 Bearing shell with oil groove
7 Bearing seat in cylinder block
procarmanuals.com

Chapter 2 Part C:
2.4, 2.8 and 2.9 litre V6 engines
Ancillary components - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Ancillary components - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Camshaft and bearings - examination and renovation . . . . . . . . . .22
Camshaft and intermediate plate - refitting . . . . . . . . . . . . . . . . . . .32
Camshaft and intermediate plate - removal . . . . . . . . . . . . . . . . . . .14
Compression test - description and interpretation . . . . . . . . . . . . .43
Crankcase ventilation system - general information . . . . . . . . . . . .29
Crankshaft and bearings - examination . . . . . . . . . . . . . . . . . . . . . .26
Crankshaft and main bearings - refitting . . . . . . . . . . . . . . . . . . . . .31
Crankshaft and main bearings - removal . . . . . . . . . . . . . . . . . . . . .15
Crankshaft front oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . .17
Crankshaft rear oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Cylinder bores - examination and renovation . . . . . . . . . . . . . . . . .24
Cylinder heads - overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Cylinder heads - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Cylinder heads - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Engine - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Engine - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine dismantling - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Engine mountings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Engine reassembly - general information . . . . . . . . . . . . . . . . . . . . .30
Examination and renovation - general infomation . . . . . . . . . . . . . .19Flywheel/driveplate and adapter plate - refitting . . . . . . . . . . . . . . .35
Flywheel/driveplate and adapter plate - removal . . . . . . . . . . . . . . .11
Flywheel ring gear - examination and renovation . . . . . . . . . . . . . . 28
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Initial start-up after overhaul or major repair . . . . . . . . . . . . . . . . . .42
Major operations possible with the engine in the vehicle . . . . . . . . .2
Major operations requiring engine removal . . . . . . . . . . . . . . . . . . . .3
Methods of engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Oil pump - dismantling, examination and reassembly . . . . . . . . . . .27
Oil pump - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Oil pump - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Pistons and connecting rods - examination and renovation . . . . . .25
Pistons and connecting rods - refitting . . . . . . . . . . . . . . . . . . . . . .33
Pistons and connecting rods - removal . . . . . . . . . . . . . . . . . . . . . .13
Rocker shaft - dismantling, examination and reassembly . . . . . . . .20
Sump - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Sump - removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Tappets and pushrods - examination . . . . . . . . . . . . . . . . . . . . . . .21
Timing cover and drive - refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Timing cover and drive - removal . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Valve clearances - checking and adjustment . . . . . . . . . . . . . . . . . .39
2.8 litre engine
General
Manufacturer’s code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRE
Bore - mm (in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.0 (3.66)
Stroke - mm (in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.5 (2.70)
Cubic capacity - cc (cu in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2792 (170)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2:1
Compression pressure at cranking speed . . . . . . . . . . . . . . . . . . . . . . . 11.5 to 12.5 bar (167 to 181 lbf/in
2)
Maximum power (DIN, kW @ rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 @ 5800
Maximum torque (DIN, Nm @ rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 @ 3000
Lubrication system
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See “Lubricants and fluids”
Oil capacity (drain and refill, including filter) . . . . . . . . . . . . . . . . . . . . . . 4.25 litres (7.5 pints) approx
Oil pressure (SAE 10W/30 oil at 80°C/176°F):
At 750 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 bar
At 2000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 bar
Oil pressure relief valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . 4.0 to 4.7 bar
Oil pressure warning light switch setting . . . . . . . . . . . . . . . . . . . . . . . . 0.3 to 0.5 bar
2C•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanicDifficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert
DIY or professional
Degrees of difficulty
Specifications Contents
2C
procarmanuals.com

V6 engines 2C•3
2C
Camshaft
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear
Gear backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.17 to 0.27 mm
Valve timing:
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26°30’ BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69°30’ ABDC
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75°30’ BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22°30’ ATDC
Cam lift:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6 mm
Cam length:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35.995 to 36.165 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35.895 to 36.065 mm
Thrust plate thickness:
Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.960 to 3.985 mm
Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.986 to 4.011 mm
Spacer thickness:
Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.075 to 4.100 mm
Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.101 to 4.125 mm
Camshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.02 to 0.10 mm
Bearing journal diameter:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.903 to 43.923 mm
Front centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.522 to 43.542 mm
Rear centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.141 to 43.161 mm
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.760 to 42.780 mm
Bearing bush internal diameter:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.948 to 43.968 mm
Front centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.567 to 43.587 mm
Rear centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43.186 to 43.206 mm
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42.805 to 42.825 mm
Valve clearances (cold)
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.35 mm (0.014 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.40 mm (0.016 in)
Inlet valves
Head diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41.85 to 42.24 mm
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105.25 to 106.95 mm
Stem diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.025 to 8.043 mm
Oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .+0.2, 0.4, 0.6 and 0.8 mm
Stem-to-guide clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.020 to 0.063 mm
Valve stem oil seal type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rubber, one size
Exhaust valves
Head diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35.83 to 36.21 mm
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105.20 to 106.20 mm
Stem diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.999 to 8.017 mm
Oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .+0.2, 0.4, 0.6 and 0.8 mm
Stem-to-guide clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.046 to 0.089 mm
Valve stem oil seal:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Nylon, selective sizes
Identification:
Standard size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .White
+ 0.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Red
+ 0.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue
+ 0.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Green
+ 0.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Black
Torque wrench settingsNmlbf ft
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 to 10466 to 77
Big-end cap nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 to 3319 to 24
Crankshaft pulley/damper central bolt . . . . . . . . . . . . . . . . . . . . . . . . . .115 to 13085 to 96
Camshaft gear bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 to 5031 to 37
Camshaft thrust plate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 2113 to 16
Timing cover to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 2113 to 16
procarmanuals.com

2C•4V6 engines
Torque wrench settings (continued)Nmlbf ft
Timing cover to intermediate plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 to 1710 to 13
Intermediate plate to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 2113 to 16
Oil pump to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 to 1710 to 13
Oil pump cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 137 to 10
Rocker shaft securing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 to 7046 to 52
Sump bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 to 73 to 5
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 to 105 to 7
Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2816 to 21
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 to 159 to 11
Oil cooler threaded sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 to 4015 to 30
Cylinder head hexagon bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 to 4530 to 33
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 to 7041 to 52
Stage 3 (after 10 to 20 minutes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 to 11570 to 85
Stage 4 (after warm-up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 to 11570 to 85
Cylinder head - Torx bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 to 4026 to 30
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 to 7552 to 55
Stage 3 (after 5 minutes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tighten further 90°Tighten further 90°
Rocker cover bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 to 84 to 6
Fuel pump blanking plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 to 1812 to 13
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 to 7047 to 52
Bellhousing-to-engine bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 to 3020 to 22
2.4 litre engine
Note: Unless otherwise stated, the specifications and torque wrench settings for the 2.4 litre engine are as given for the 2.8 litre engine.
General
Manufacturer’s code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ARC
Bore - mm (in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.0 (3.307)
Stroke - mm (in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72.0 (2.865)
Cubic capacity - cc (cu in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2394 (146.1)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.5:1
Maximum power (DIN, kW @ rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 @ 5800
Maximum torque (DIN, Nm @ rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193 @ 3000
Cylinder block
Identification mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D
Bore diameter:
Standard grade 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.000 to 84.010 mm
Standard grade 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.010 to 84.020 mm
Standard grade 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.020 to 84.030 mm
Standard grade 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.030 to 84.040 mm
Oversize grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.510 to 84.520 mm
Oversize grade B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.520 to 84.530 mm
Oversize grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.530 to 84.540 mm
Standard service grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.030 to 84.040 mm
Oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.530 to 84.540 mm
Oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85.030 to 85.040 mm
Pistons
Diameter:
Standard grade 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83.962 to 83.972 mm
Standard grade 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83.972 to 83.982 mm
Standard grade 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83.982 to 83.992 mm
Standard grade 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83.992 to 84.002 mm
Standard service grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83.978 to 84.002 mm
Oversize 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.478 to 84.502 mm
Oversize 1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84.978 to 85.002 mm
Clearance in bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.028 to 0.048 mm
Piston ring end gap:
Top and centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.30 to 0.50 mm
Bottom (oil control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.40 to 1.40 mm
Cylinder head
Identification mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H
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V6 engines 2C•5
2C
Crankshaft
Thrustwasher thickness:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28 to 2.33 mm
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.48 to 2.53 mm
Crankshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.08to 0.32 mm
Permitted undersize for main and big-end bearing journals . . . . . . . . . .0.254 mm
Camshaft
Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chain
Cam lift (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.72 mm
Cam lobe height (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . .36.08 to 36.25 mm
Camshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.065 to 0.165 mm
Thrust plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.02 to 4.05 mm
Valves
Valve timing:
Inlet opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24°BTDC
Inlet closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64°ABDC
Exhaust opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66°BBDC
Exhaust closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22°ATDC
Head diameter:
Inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39.67 to 40.06 mm
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.83 to 34.21 mm
Length:
Inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106.2 to 106.9 mm
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106.1 to 107.1 mm
Valve spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55.12 mm
Torque wrench settingsNmlbf ft
Camshaft sprocket bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 to 6844 to 50
Camshaft thrust plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 137 to 10
Timing chain guide to block bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 to 127 to 9
Timing chain tensioner to block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 117 to 8
Oil inlet pipe to oil pump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 137 to 10
Oil pump to block bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 to 2113 to 15
Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 to 2815to 21
Crankshaft pulley to vibration damper bolts . . . . . . . . . . . . . . . . . . . . . .27 to 3320 to 24
Crankshaft vibration damper bolt:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 to 5030 to 37
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tighten further 80°to 90°Tighten further 80°to 90°
2.9 litre engine
Note: Unless otherwise stated, the specifications and torque wrench settings for the 2.9 litre engine are as given for the 2.8 litre engine.
General
Manufacturer’s code:
Models without catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . .BRC
Models equipped with type N manual gearbox or automatic
transmission and a catalytic converter . . . . . . . . . . . . . . . . . . . . . .BRD
Models equipped with MT75 manual gearbox and catalytic converter . .BRE
Stroke - mm (in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72.0 (2.835)
Cubic capacity - cc (cu in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2936 (179.2)
Compression ratio:
BRC engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.5:1
BRD and BRE engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.0:1
Maximum power (DIN, kW @ rpm):
BRC engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 @ 5700
BRD and BRE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 @ 5500
Maximum torque (DIN, Nm @ rpm):
BRC engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233 @ 3000
BRD engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222 @ 3000
BRE engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226 @ 3000
Cylinder block
Identification mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F
Pistons
Clearance in bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.028 to 0.048 mm
Piston ring end gaps:
Top and centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.30 to 0.50 mm
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