General Specifications Scorpio 1995 (10/1994-06/1998)

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Specifications
Engine Data
Description Litres
Engine management EEC V/SFI
Emission standard 96 EEC
Engine code NSD
Firing order 1‐3‐4‐2
Bore mm 86,0
Stroke mm 86,0
Cubic capacity cc 1998
Compression ratio 9,8 : 1
Power output (EEC) kW 85
Power output (EEC) PS 115
Power output (EEC), at rev/min 5500
Torque (EEC) Nm 167
Torque (EEC), at rev/min 2500
Idle speed rev/min 875
Maximum permissible engine speed, continuous rev/min 5950
Maximum permissible engine speed, intermittent rev/min 6175
Dimensions
Cylinder block
Cast mark 20
Cylinder bore ∅, standard class 1 mm 86,000 ‐ 86,010
Cylinder bore ∅, standard class 2 mm 86,010 ‐ 86,020
Cylinder bore ∅, oversize 0,15 mm 86,160 ‐ 86,170
Cylinder bore ∅, oversize 0,5 mm 86,500 ‐ 86,510
Number of main bearings 5
Centre main bearing width (excl. thrust half rings) mm 21,17 ‐ 21,23
Fitted main bearing shells
Vertical inside ∅, service standard (yellow) mm 54,983 ‐ 55,020
Vertical inside ∅, standard mm 55,003 ‐ 55,030
Vertical inside ∅, 1st undersize 0,05 mm 54,953 ‐ 54,980
Vertical inside ∅, 2nd undersize 0,25 mm 54,753 ‐ 54,780
Vertical inside ∅, 3rd undersize 0,50 mm 55,503 ‐ 54,530
Main bearing parent bore ∅, standard mm 59,287 ‐ 59,300
Main bearing parent bore ∅, oversize 0,40 (black) mm 59,687 ‐ 59,700
Crankshaft
End float mm 0,093 ‐ 0,303
Main bearing journal ∅, standard (yellow) mm 54,98 ‐ 54,99
Main bearing journal ∅, (red) mm 54,99 ‐ 55,00
Main bearing journal ∅, undersize 0,25 (green) mm 54,73 ‐ 54,75
Main bearing journal to shell clearance mm 0,011 ‐ 0,048
Big‐end bearing journal j, standard mm 50,89 ‐ 50,91
Big‐end bearing journal j, undersize 0,25 (green) mm 50,64 ‐ 50,66
Thrust half washer thickness, standard mm 2,301 ‐ 2,351
Thrust half washer thickness, oversize 0,38 (yellow) mm 2,491 ‐ 2,541
Width of centre main bearing journal, standard mm 26,025 ‐ 26,075
Width of centre main bearing journal, oversize 0,38
mm 26,405 ‐ 26,455
(yellow)
Connecting rod
Bore ∅, big‐end mm 53,890 ‐ 53,910
Bore ∅, small end mm 20,589 ‐ 20,609
Fitted big‐end bearing shells
Vertical inside ∅, standard mm mm 50,916 ‐ 50,950
Vertical inside ∅, 1st undersize (0,25 mm) mm 50,666 ‐ 50,700
Vertical inside ∅, 2nd undersize (0,50 mm) mm 50,416 ‐ 50,150
Big‐end bearing journal to shell clearance mm 0,006 ‐ 0,060
Big‐end bearing end float mm 0,09 ‐ 0,31
Camshafts
Number of camshaft bearings 2x5
Single roller chain,
Drive
hydraulic chain tensioner
Camshaft end float mm 0,02 ‐ 0,26
Cam lift, inlet mm 10,83
Cam lift, exhaust mm 10,83
Cam length (between heel and toe), inlet mm 52,71 ‐ 52,94
Cam length (between heel and toe), exhaust mm 52,71 ‐ 52,94
Inlet valve opens before TDC ° 9
Inlet valve closes after BDC ° 51
Exhaust valve opens before BDC ° 51
Exhaust valve closes after TDC ° 9
Camshaft bearing journal ∅ mm 25,96 ‐ 25,98
Bearing inside diameter mm 26,00 ‐ 26,03
Pistons
Uncoated piston ‐ ∅ (unused), service standard mm 85,970 ‐ 85,990
Uncoated piston ‐ ∅ (unused), oversize 0.15 mm 86,120 ‐ 86,140
Uncoated piston ‐ ∅ (unused), oversize 0.50 mm 86,460 ‐ 86,480
Piston clearance in bore (unused, piston uncoated), prod. mm 0,03 ‐ 0,05
Piston clearance in bore (unused, piston uncoated), service mm 0,02 ‐ 0,05
Coated piston ‐ ∅ (unused), service standard mm 85,990 ‐ 86,030
Coated piston ‐ ∅ (unused), oversize 0.15 mm 86,140 ‐ 86,180
Coated piston ‐ ∅ (unused), oversize 0.50 mm 86,480 ‐ 86,520
Piston clearance in bore (unused, piston coated), prod. mm 0,01 ‐ 0,03
Piston clearance in bore (unused, piston coated), service mm 0,02 ‐ 0,03
Piston pin length mm 63,4
Piston pin ∅, white mm 20,622 ‐ 20,625
Piston pin ∅, red mm 20,625 ‐ 20,628
Piston pin ∅, blue mm 20,628 ‐ 20,631
Clearance in piston (colour match) mm 0,008 ‐ 0,014
Interference fit in small end bore mm 0,016 ‐ 0,042
Piston ring gaps (fitted), top mm 0,30 ‐ 0,60
Piston ring gaps (fitted), middle mm 0,50 ‐ 0,80
Piston ring gaps (fitted), oil control ring (three part) mm 0,40 ‐ 1,50
Ring gap positions Piston ring gaps should
be distributed evenly
 around the piston
circumference; this also
applies to the gaps of the
intermediate oil control
rings in relation to the
expander gap.
Valves
Valve timing DOHC
Valve clearances Hydraulic tappets
Hydraulic tappet ∅ mm 42
Hydraulic tappet clearance in housing mm 0,025 ‐ 0,080
Valve length, inlet mm 108,24 ‐ 108,70
Valve length, exhaust mm 108,68 ‐ 109,20
Valve head ∅, inlet mm 42,5 ‐ 42,7
Valve head ∅, exhaust mm 37,9 ‐ 38,1
Valve stem ∅, standard (inlet) mm 7,025 ‐ 7,043
Valve stem ∅, standard (exhaust) mm 6,999 ‐ 7,017
Valve stem∅, oversize 0,2 (inlet) mm 7,255 ‐ 7,243
Valve stem∅, oversize 0,2 (exhaust) mm 7,199 ‐ 7,217
Valve stem∅, oversize 0,4 (inlet) mm 7,425 ‐ 7,443
Valve stem∅, oversize 0,4 (exhaust) mm 7,399 ‐ 7,417
Valve stem∅, oversize 0,6 (inlet) mm 7,625 ‐ 7,643
Valve stem∅, oversize 0,6 (exhaust) mm 7,599 ‐ 7,617
Valve stem∅, oversize 0,8 (inlet) mm 7,825 ‐ 7,843
Valve stem∅, oversize 0,8 (exhaust) mm 7,799 ‐ 7,817
Valve stem clearance in guide, inlet mm 0,020 ‐ 0,069
Valve stem clearance in guide, exhaust mm 0,046 ‐ 0,095
Colour code, outer spring Green/Blue
Colour code, inner spring Green/Blue
Free valve spring height, outer spring mm 48,2
Free valve spring height, inner spring mm 49,2
Valve spring inner ∅, outer spring mm 24
Valve spring inner ∅, inner spring mm 17,5
Valve spring wire (oval profile), outer spring mm 4,1 x 4,95
Valve spring wire ∅, inner spring mm 2,6
Number of turns, outer spring 6,83
Number of turns, inner spring 8,82
Lubrication
Oil pressure at 875 rev/min (with SAE 10W/30 oil at a
bar 1,60
temperature of 80°)
Oil pressure at 2000 rev/min (with SAE 10W/30 oil at a
bar 3,10
temperature of 80°)
Pressure relief valve opens at bar 3,70 ‐ 4,60
Oil pressure warning light comes on at bar 0,30 ‐ 0,50
Oil pump rotor/housing clearance mm 0,154 ‐ 0,304
Inner/outer rotor clearance mm 0,05 ‐ 0,20
Rotor end float at mating face mm 0,014 ‐ 0,079
Cylinder head with valve seat inserts
Cast mark 20
Upper correction angle (production), inlet/exhaust ° 25
Lower correction angle (production), inlet/exhaust ° 60
Valve seat angle ° 44,5 ‐ 45
Valve seat width, inlet mm 1,33 ‐ 2,19
Valve seat width, exhaust mm 1,68 ‐ 2,54
Stem bore (inlet/exhaust valve), standard mm 7,063 ‐ 7,094
Camshaft bearing parent bore ∅ (all) mm 26,00 ‐ 26,03
Shims for the sump
Range of adjustment Available shims Colour coding
0 to 0,25 mm No adjustment
0,26 to 0,29 mm 0,15 mm Silver
0,30 to 0,44 mm 0,30 mm Pale blue
0,45 to 0,59 mm 0,45 mm Red
0,60 to 0,75 mm 0,60 mm Black
Lubricants, Adhesives and Sealers
Description Ford
Specification
Transmission fluid ESD‐M2C186‐A
Coolant ESD‐M97B49‐A
Sealer for front oil seal carrier (Loctite 518) WSK‐M2G348‐A5
Sealer for sump (Hylosil 502) WSK‐M4G320‐A
Sealer for coolant pump angle connector, coolant temperature sender
WSK‐M2G349‐A7
unit, oil pressure switch (Loctite 243)
Lubricant for O‐ring of crankshaft position sensor (CKP) SM1C‐115‐A
Lubricant for clutch release bearing guide sleeve ESD‐M1C‐220‐A
Lubricant for transmission input shaft splines ESD‐M1C‐220‐A
Power steering fluid SQM 2C‐9010‐A
Thread‐locking compound (Loctite 270) SDM‐M4G9107‐A
Spark plug thread ('Never Seeze') ESE‐M1244‐A
Thread‐locking compound, power steering pump to bracket (Loctite 270) SDM‐M4G9107‐A
Silicone grease A960‐M1C171‐AA
Capacity
Description Litres
Engine oil, initial fill including filter 5,1
Engine oil, oil change with filter change 4,25
Engine oil, oil change without filter change 4,00
Coolant 7,9
Engine oil
Ambient temperature Designation Specification
Ford Multigrade Super Engine
‐10 to over 40° C SAE 20W50 API/SG/CD
Oil
Ford Multigrade Super Engine
‐15 to over 40° C SAE 15W40 API/SH/CD
Oil
Ford Multigrade Super Engine
‐20 to over 40° C SAE 10W30 API/SH/CD EC
Oil
XR+ High‐performance High‐
‐20 to over 40° C SAE 10W40 API/SH/CD EC
lubricity Engine Oil
Ford Formula S Synthetic
‐30 to over 40° C SAE 5W50 API/SG/CD
Engine Oil
Synthetic/Semi‐synthetic
‐30 to over 40° C SAE 5W40 API/SH/CD EC
Engine Oil
 Ford Multigrade Super Engine
40 to below ‐30° C SAE 5W30 API/SG/CD
Oil
The engine oil to specification SAE 5W30 API/SG/CD has only been approved for use in
northern European territories
If engine oils of other brands are used, it is imperative to ensure that these conform to API
SG/CD or better in the particular viscosity class.
Torques
Nm lbf.ft
General
Hose clips 4 3
Engine undershields to front crossmember 19 14
Rear axle reinforcing bar 49 36
Front axle reinforcing bar 80 59
Front axle to side members 80 59
Exhaust
Exhaust system heat shield to cylinder head 7 5
Exhaust mounting to transmission 44 32
Exhaust mounting to transmission crossmember 47 35
Exhaust bracket to engine 47 35
Catalyst to exhaust manifold 47 35
Inlet manifold
Studs (coated with microcapsules) 14 10
Inlet manifold nuts 23 17
Throttle housing 10 7
Idle air control (IAC) valve 10 7
Exhaust manifold
Studs (coated with microcapsules) 17 13
Exhaust manifold nuts 23 17
Exhaust gas recirculation (EGR) valve 10 7
Transmission
Earth lead to transmission 44 32
Starter motor 44 32
Engine/transmission flange bolts 44 32
Bolt ‐ adaptor plate to transmission 11 8
Driveshaft to rear axle 66 49
Driveshaft centre bearing to floor assembly 21 15
Driveshaft to vibration damper 78 58
Oil dipstick tube 10 7
Transmission crossmember to floor assembly 36 27
Transmission crossmember to transmission 62 46
Air conditioning system
Compressor to cylinder block 25 18
Coolant circuit
Coolant pump 23 17
Coolant temperature gauge sender unit 6 4
Thermostat housing 10 7
Engine coolant temperature (ECT) sensor 12 9
Angle connector to water pump 14 10
Water pump blanking plug 16 12
Blanking cover for rear coolant outlet 20 15
Steering
Intermediate shaft to steering shaft 18 13
Power steering pump to bracket 23 17
Power steering pump pulley 25 18
Engine mounting
Engine mounting nuts 50 37
Oil circuit
Oil drain plug 25 18
Oil pressure switch 27 20
Oil filter mounting 21 15
Oil filter 14 10
Oil cooler 60 44
Oil baffle to cylinder block 21 15
Oil pump 12 9
Oil intake pipe to cylinder block 13 10
Sump to cylinder block (studs and nuts) 12 9
Power steering
Power steering pump to bracket 25 18
Cylinder block
Lower timing chain cover 10 7
Rear oil seal housing 13 10
Front oil seal housing 26 19
Crankshaft position/speed sensor 4 3
Timing chain guide rail, M6 12 9
Timing chain guide rail, M8 26 19
Crankcase breather 9 7
Main bearing caps 97 72
Big‐end bearing caps, stage 1 7 5
Big‐end bearing caps, stage 2 16 12
Big‐end bearing caps, stage 3 90° 90°
Crankshaft vibration damper, stage 1 52 38
Crankshaft vibration damper, stage 2 85° 85°
Flywheel 87 64
Clutch pressure plate 24 18
Oil pump chain tensioner arm 12 9
Oil pump sprocket 18 13
Cylinder Head
Cylinder head, stage 1 10 7
Cylinder head, stage 2 35 26
Cylinder head, stage 3 90° 90°
Cylinder head, stage 4 90° 90°
Cylinder head cover, stage 1 3 2
Cylinder head cover, stage 2 9 7
Auxiliary cylinder head bolts (x3) 38 28
Upper timing case cover 11 8
Fuel rail 24 18
Fuel pressure regulator 10 7
Camshaft bearing caps 24 18
Camshaft sprockets 59 44
Engine lifting eyes 25 18
Studs to cylinder head (x20) 20 15
Blanking plugs 52 38
Blanking cover for rear coolant outlet 20 15
Spark plugs 18 13
Ignition coils 10 7

Description and Operation Scorpio 1995 (10/1994-06/1998)

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Description and Operation

Engine wiring harness

Item Description
1 DIS ignition coils
2 Coolant temperature sender unit
Engine coolant temperature (ECT)
3
sensor
4 Throttle position sensor (TPS)
5 Idle air control (IAC) valve
6 Oil pressure switch
7 Crankshaft position sensor (CPS)
8 Central connector
9 Injectors
10 Camshaft position sensor (CID)
Item Description
1 Crankshaft belt pulley
2 Automatic belt tensioner
3 Alternator
4 Water pump
5 Power steering pump
6 Air conditioning compressor
Locations of the angles on the valve seat.
1. Locations of the angles on the valve seat.
1. Upper correction angle
2. Valve seat angle
3. Lower correction angle
4. Valve seat width

Revised parts from '95 MY onwards

2. Connecting rods
• In place of the existing oil splash bore, there is now
a recess on each side of the connecting rod.
• This recess conveys the oil from the bearing shells
to the cylinder bore.
• This provides additional lubrication on the
pressurised side of the cylinder bore.
• New connecting rod bolts marked ”KX120" on the
head.
 NOTE:
Coated pistons have no valve recesses in
the piston crown (from build month 05/97).
3. Pistons
• The distance from piston crown to first piston ring
was reduced to 5 mm.
• The piston rings are phosphated.
• The tolerances have been reduced.

4. Cylinder head gasket.

   With effect from the '95 model year, a multi‐
layered steel gasket is used.

5. Inlet manifold gasket.

• Four Viton gaskets arranged in the inlet manifold.
• The four gaskets are not symmetrical.

6. Exhaust manifold gasket.

• With effect from the '95 model year, a two‐layered
steel gasket is used.
• Two gaskets per engine.
Item Description
Yellow line for standard size (∅ 54,99
1
‐ 54,98) main bearing journals.
Red line for standard size (∅ 55,00 ‐
1
54,99) main bearing journals.
Green line for production undersize
2
(0,25) main bearing journals.
Green line for production undersize
3
(0,25) main bearing journals.
Yellow line for undersize (0,38) centre
4
main bearing journal width.
5 Centre main bearing journal width.

Engine ‐ Dismantle and Assemble

Scorpio 1995 (10/1994-06/1998)
(engine removed) (21 134 8)
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Removal and Installation

Special Tools

15‐030A Universal flange‐

holding wrench

16‐067 Locator for clutch disc

17‐055‐02 Depth gauge,

cylinder head work
 21‐023 Universal mounting
spindle for assembly stand

21‐031 B Mounting bracket

21‐036A Remover for pilot

bearing

21‐044A Installer/locator for

pilot bearing/clutch disc

21‐141 Installer for radial oil

seal

21‐146C Mounting plate

21‐147 Remover for vibration

damper

21‐168 Crankshaft
immobilising tool

21‐540 Angle gauge

Materials
Description
Obtainable
through: Replacement
Services Limited, 30
Euston
Plastigage
Street, Freemans
Industrial
Estate, Leicester, LE2
7ST.
Sealer for crankshaft
front oil seal carrier WSK‐M2G348‐A5
(Loctite 518)
Sealer for sump
WSK‐M4G320‐A
(Hylosil 502)
Sealer for oil pressure
switch, coolant pump
angle connector, WSK‐M2G349‐A7
coolant temperature
sensor (Loctite 243)
Lubricant for O‐ring of
crankshaft
SM1C‐115‐A
position/speed sensor
(CPS)
Workshop Equipment
Description
Mounting stand with
21‐187
geared drive
Proprietary Tools
Description
Dial indicator
Magnetic fixture
Piston ring compressor
Oil filter strap wrench
Internal gauge
Steel straight edge
Dismantle
1. Attach the engine to the assembly stand using
Special Tools 21‐031B, 21‐023 and 21‐146C.
2. Preparatory measures.
   Drain off the engine oil.
3. Detach the clutch assembly.

4. Detach the crankshaft belt pulley/vibration

damper.
• Immobilise the flywheel using Special Tool 21‐168
• Unscrew the retaining bolt.
• Pull off the crankshaft pulley/vibration damper
using the special tool.

5. Detach the flywheel.

• Undo the bolts.
• Remove the flywheel.
6. Disconnect the exhaust gas recirculation (EGR)
pipe.
1. Remove the exhaust gas recirculation (EGR) valve
from the inlet manifold.
2. Detach the bracket from the cylinder head.
3. Detach the bracket from the heat shield.
4. Detach the pipe from the exhaust manifold.

7. Detach the engine lifting eyes.

8. Detach the cylinder head cover (11 bolts and 4
nuts).

9. Remove the upper timing chain cover.

10. Remove the lower timing chain cover.

11. Detach the oil pump sprocket and chain.
1. Remove the oil pump chain tensioner.
2. Remove the oil pump chain sprocket and chain.

12. Line up the camshaft sprockets on the marks.

NOTE:
The chain guide must be renewed on
reassembly.
13. Detach the upper chain guide rail.

14. Detach the camshaft sprockets.

15. Remove the chain tensioner arm.

1. Pull off the circlip with pliers.
2. Withdraw the chain tensioner pivot pin with a bolt
(M6).
3. Remove the chain tensioner arm from the housing.
 16. Release the chain guide.

17. Remove the timing chain.

• Remove the Woodruff key from the crankshaft.
• Remove the crankshaft sprocket with the timing
chain.

CAUTION:
Do not reuse the oil‐filled plunger.

18. Remove the oil‐filled plunger of the chain

tensioner and the timing chain.

Remove the camshafts.

 19. Remove the camshafts.
• Detach the chain guide bracket with the front
bearing caps.
• Remove the hydraulic tappets and keep them in
order.

Remove the cylinder head.

CAUTION:
Before undoing the bolts, allow the cylinder
head to cool to below 30 °C.
NOTE:
Only re‐use those cylinder head bolts which
have integrated washers (see next step).
NOTE:
Release the three auxiliary bolts first.

20. Slacken and remove the cylinder head bolts in

accordance with the loosening sequence.

21. Identification of cylinder

head bolts.
1. New cylinder head bolt
with integrated washer.
2. Old cylinder head bolt
with washer.
22. Detach the water pump.

23. Detach the oil pump.

24. Detach the parts mounted on the left‐hand side of

the engine.
1. Crankshaft position/speed sensor (CPS)
2. Oil pressure switch
3. Oil filter

CAUTION:
Oil sludge and abraded particles must not
get into the engine.
25. Remove the sump downwards.
 CAUTION:
Do not damage the cylinder bores.

26. Remove the carbon from the upper edge of the

cylinder bores.

27. Detach the oil intake pipe and oil baffle.

28. Detach the front oil seal carrier.

29. Detach the crankshaft rear oil seal housing.

30. Remove the crankshaft pilot bearing.

 31. Remove the pistons.
• Detach the big‐end bearing caps.
• Remove the big‐end bearing shells from the big‐end
bearing caps and connecting rods and mark them.
• Press out the pistons with the connecting rods.

32. Remove the crankshaft.

• Detach the main bearing caps.
• Remove the crankshaft.
• Remove the bearing shells and thrust half rings and
keep them in order or mark them for further use.

Assemble engine
33. Preparatory measures.
• Clean all the mating faces and reusable parts
thoroughly and check them for damage.
• When applicable, the upper and lower timing chain
covers are renewed complete with the radial oil seal in
place.
NOTE:
The crankshaft must be re‐worked or
renewed if the values determined do not
match the values prescribed in the Technical
Data.
34. Measure the diameters of the main and big‐end
bearing journals using a proprietary micrometer
screw.
   Repeat each measurement at 90°.

Measure the crankshaft main bearing clearance.

CAUTION:
Do not damage the crankshaft bearings
during fitment.
35. Fit the crankshaft.
• Place the grooved bearing shells in the cylinder
block.
• Place the crankshaft dry in the cylinder block.
 CAUTION:
The crankshaft must not be turned during the
measuring operation.
36. Measure the crankshaft main bearing clearance.
NOTE:
The point at which the measurement is made
must be dry.
• Lay a length of Plastigage thread on the bearing
journal across the bearing.
• Fit the bearing cap (see sub‐operation ).
NOTE:
Measure the clearance of the bearings in
turn in numerical order (1 ‐ 5).
37. Measure the crankshaft main bearing clearance
(continued).
NOTE:
The bearing cap numbering starts at the
timing chain end.
• Fit the bearing cap with the associated bearing
shell, with the arrow pointing towards the timing
chain end, and secure it.
• Remove the bearing cap.
NOTE:
If the specified bearing clearance is still not
obtained, with standard cylinder blocks and
crankshafts to a maximum of 0,02 mm
undersize the bearing shells of the next size
up can be fitted. However, the bearing
clearance must not have been greater than
0,098 mm.
38. Measure the crankshaft main bearing clearance
(continued).
• Compare the Plastigage thread with the Plastigage
scale.
• The reading corresponds to the bearing clearance.
NOTE:
If the specified bearing clearance of 0,011 ‐
0,048 mm is not obtained, the bearing shells
should be renewed and the measuring
operation repeated from sub‐operation
onwards.
NOTE:
Fit the bolts with the stud extensions in
bearings 3 and 5.
39. Install the crankshaft.
• Lubricate the main bearing journals and bearing
shells and the threads of all the bolts and bolt contact
faces with engine oil.
• Fit the crankshaft.
• Fit the thrust half rings with the copper‐coloured
side facing the crankshaft.
• Coat the contact faces and the sides of the rear
main bearing cap with sealer.
NOTE:
The bearing cap numbering starts at the
timing chain end, to which the arrows also
point.
• Fit the crankshaft main bearing caps with the
associated bearing shells.
• Tighten the bolts.
40. Check the crankshaft end float.
• Set up a dial indicator.
• Measure the end float by lifting the crankshaft with
the aid of a screwdriver.
• Correct the end float as necessary by fitting thrust
half rings to main bearing no. 3.

41. Check the piston ring gaps.

   The figures indicated in the Technical Data are for a
gauge ring used in production. The figures measured
in the cylinder can exceed these by 0,15 mm.

CAUTION:
The maximum width of the piston rings
corresponds to the diameter of the cylinder
bore + 1,7 mm.
CAUTION:
The upper piston rings are coated with
molybdenum. This coating must not be
damaged.
42. Arrangement of the piston rings.

NOTE:
The numbering on the connecting rods starts
at the timing chain end. The arrow on the
piston crown points towards the timing case.
43. Install the pistons.
• Lubricate the pistons and cylinder bores with engine
oil.
• Distribute the piston ring gaps evenly around the
circumference; this also applies to the elements of the
oil control ring.
• Compress the piston rings using a proprietary piston
ring compressor.
• Press pistons 1 and 4 into the cylinders using the
handle of a hammer. The big‐end bearing journal must
be at BDC.
• Lubricate the bearing shells with engine oil.
• Place the appropriate bearing shells in the
connecting rod and bearing cap.
• Install the bearing caps.
• Turn the crankshaft 180°, fit pistons 2 and 3.
44. Measure the big‐end bearing clearance.
   Measure the big‐end bearing clearance as described
in steps to
 NOTE:
The connecting rods and their bearing caps
have the same numbers.
45. Fit the bearing caps.
• Lubricate the bearing shells and bearing journals
with engine oil.
• Fit the associated bearing caps and bearing shells
and secure them.

46. Install the crankshaft pilot bearing.

47. Remove the oil seal from the rear oil seal
housing.

Install the rear oil seal housing

48. Align the oil seal housing.
   Fit the oil seal housing using a new gasket and
screw in the bolts loosely.
1. The mating face of the oil seal housing must be
below the mating face of the cylinder block. The
difference in height must not exceed 0,46 mm.
2. Tighten the bolts.
 49. General description of the procedure for fitting a
radial oil seal into a special tool with a guide sleeve.
CAUTION:
The radial oil seal must be fitted into the
tool as far as the shoulder.
   For correct fitment, the special tool is placed on a
vice and the radial oil seal is pressed in using the
handle of a hammer.
1. Incorrectly fitted.
2. Correctly fitted.

50. Fit the crankshaft rear oil seal.

   Draw in the radial oil seal using two flywheel
retaining bolts.

NOTE:
Surplus sealer must not be removed before
the sump is fitted.
51. Attach the front oil seal carrier.
• Apply sealer (WSK‐M4G320‐A) to the mating face
intersections.
• Apply four beads of sealer with a diameter of 3 ‐ 5
mm and a length of 10 mm.
NOTE:
The sealer must protrude sufficiently at the
front and sides after fitment of the oil seal
housing.
52. Fit the oil baffle.
NOTE:
Attach the oil baffle plate in such a way that
the oil dipstick and oil strainer can be
attached.
53. Fit the oil strainer.

Install sump
 NOTE:
The bead of sealer must cover the mating
face gaps.
54. Apply sealer to the flywheel end of the cylinder
block.
• Use Hylosil 502 sealer (WSK‐M2G320‐A).
• Apply a bead of sealer with a thickness of 3 ‐ 5 mm
and a width of 10 mm on both sides.

55. Fit the sump using a new gasket.

• Align the sump as described in sub‐operation
• Tighten the three nuts and the twelve bolts.

56. Align the sump.

• Align the sump so that it stands a maximum of 0,25
mm short or 0,1 mm proud.
• Measure the difference in height using a steel
straight edge and a feeler gauge; make a note of the
measurement.
• Eliminate the difference with shims (see Technical
Data) when installing the engine.

NOTE:
It can only be fitted in one position.

CAUTION:
Use new bolts.

57. Fit the flywheel.

 58. Centre the clutch disc on the pressure plate.

59. Fit the clutch assembly.

1. Fit the clutch pressure plate with the centred clutch
disc.
2. Tighten the six bolts uniformly, one turn at a time,
working diagonally.
3. Remove the special tool.

CAUTION:
A new oil pump must be filled with oil and
turned over by hand before it is fitted.
60. Clean the oil pump.
   Dismantle the oil pump.
NOTE:
The oil pump must be renewed as a single
component if it is worn.
61. Reassemble the oil pump.
NOTE:
The dot marks must face outwards.

NOTE:
The passages of the oil pump must not be
covered by the gasket.
62. Fit the oil pump using a new gasket.

63. Fit the parts mounted on the left‐hand side of the

engine.
NOTE:
Apply lubricant (SM1C‐115‐A) to the O‐ring
of the CKP sensor.
• Crankshaft position sensor (CPS)
NOTE:
Apply sealer (WSK‐M2G349‐A7) to the
thread of the oil pressure switch.
• Oil pressure switch
• Oil filter
Check cylinder head evenness.
 64. Check cylinder head mating face for distortion.
• The maximum acceptable distortion at combustion
chamber lands is: transverse 0.05mm, longitudinal
and diagonal 0.10mm.
• Place straightedge transversely across all combustion
chamber lands and check at three locations.
• Place straightedge longitudinally across the cylinder
head at three locations in the combustion chamber
area and check at all combustion chamber lands.
• Place straightedge diagonally across the cylinder
head and check at all combustion chamber lands.
• If necessary re‐machine cylinder head as described
in step
65. Note: machining of cylinder head.
NOTE:
Maintain peak‐to‐valley height Rz of 13,5
micrometres during machining.
   The cylinder head may be machined (milled or
surface ground) by a maximum of 0.20mm. During
machining dimension ”a" must remain at least 16,35
mm (see step ) and "b" at least 147,25 mm.

NOTE:
Remove carbon deposits at the measuring
site.
66. Location of measuring site for dimension ”a" in the
combustion chamber.

Install the cylinder head

67. Bring the piston of cylinder no. 1 to a point 25
mm before TDC.
 68. Fit the cylinder head.
1. Insert the locating bushes.
2. Fit the cylinder head gasket.
3. Fit the cylinder head.

CAUTION:
Do not re‐use an old cylinder head bolt which
needs a separate washer.
69. Only re‐use the new style cylinder head bolts with
integral washer if the length is not more than 174.3
mm and the bolt shows no sign of damage.
1. New cylinder head bolts
2. Old cylinder head bolts

70. Tighten the cylinder head bolts in accordance with

the tightening sequence.
 71. Tighten the cylinder head bolts (continued).
   Turn through 90°twice.

72. Tighten the auxiliary cylinder head bolts.

Install the camshafts

73. Bring the piston of cylinder no. 1 to a point
approximately 25 mm before TDC.
   Position of the crankshaft belt pulley/ vibration
damper.

74. Install the camshafts.

CAUTION:
Before the camshafts are installed, the
piston of cylinder no. 1 must be at a point
approximately 25 mm before TDC.
CAUTION:
After installation of the camshafts, it is
imperative to wait 15 minutes before the
engine is turned.
   Oil the bearings.
1. Fit the hydraulic tappets.
2. Fit the camshafts so that none of the cams is at
full lift.
NOTE:
R is the inlet side, L is the exhaust side.

3. Fit the camshaft bearing caps so that the position

markings can be read from the rear.
   Fit the chain guide bracket with the front bearing
caps.

Install the timing chain

75. Bring the camshafts and crankshaft to TDC.

CAUTION:
Fully and partially released plungers
(whether new or used) must not be fitted.
76. Check the new chain tensioner plunger.
1. Plunger latched.
2. Plunger partly released.
3. Plunger fully released (the detent ring is visible).

77. Install the chain tensioner plunger.

CAUTION:
Only use a new latched plunger.

78. Insert the timing chain with the chain guide.

   Do not secure the chain guide yet.

79. Fit the timing chain at the bottom.

• Slide the sprocket on approximately 10 mm.
• Lay the timing chain around the inner sprocket.
• Fit the Woodruff key in the crankshaft.
80. Tighten the chain guide bolts.

81. Install the chain tensioner.

1. Insert the chain tensioner.
2. Insert the pin.
3. Fit the circlip.

82. Fit the timing chain at the top.

NOTE:
The timing chain must be taut on the long
side.
   If necessary, turn the camshaft slightly.

NOTE:
The timing chain may sag slightly between
the camshaft sprockets.
83. Fit the timing chain at the top (continued).
 84. Clip a new upper chain guide into the bracket.

NOTE:
If the chain tensioner arm does not reach
the oil‐filled plunger, the plunger must be
released using an auxiliary tool.
85. Release the chain tensioner plunger.
   Press the chain tensioner arm down by hand and
unlatch the oil‐filled plunger.

86. Fabricate an auxiliary tool.

   Use a 220 mm length of 2,5 mm welding rod.

CAUTION:
Before securing the sprockets, ensure that
they have engaged in the camshaft groove.
87. Secure the camshaft sprockets.

NOTE:
If it is necessary to correct the valve timing,
i.e. release the timing chain, a new oil‐filled
plunger must also be fitted for the chain
tensioner.
88. Checking the valve timing.
   Turn the engine in the normal direction of rotation
and line up the sprockets on the marks.
 89. Additional check.
1. Turn the engine in the normal direction of rotation
to the next TDC position.
2. The marks on the camshaft sprockets must face
one another exactly level with the upper edge of the
cylinder head.

90. Install the oil pump drive assembly.

1. Lay the chain around the crankshaft driving
sprocket.
2. Fit the oil pump sprocket with the chain to the oil
pump.
3. Fit the chain tensioner.

91. Fit the lower timing chain cover.

NOTE:
Use a new cover with an integral gasket and
radial oil seal.
• Fit the cover with the centring cap.
• Tighten the bolts.
• Remove the centring cap.

CAUTION:
It is essential that the torque is observed.
Use Special Tool 21‐540.
92. Fit the crankshaft pulley/vibration damper.
   Immobilise the engine with Special Tool 21‐168.

93. Fit the water pump with a new gasket.

 NOTE:
The upper edge of the cover must be a
maximum of 0,13 mm below the mating
face of the cylinder head cover.
94. Fit the upper timing chain cover.

95. Attach the positive crankcase ventilation (PCV)

hose.
1. Push it into the exhaust manifold.
2. Attach the bracket to the cylinder head.
3. Connect it to the inlet manifold.

96. Fit the cylinder head cover with a new gasket (11
bolts and four nuts).
 97. Fit the engine lifting eyes.

Cylinder Head ‐ Remove and Install (21

Scorpio 1995 (10/1994-06/1998)
163 0)
 Print

Removal and Installation

Special Tools

15‐030A Universal flange‐

holding wrench

17‐055‐02 Depth gauge,

cylinder head processing

21‐540 Angle gauge

24‐003 Remover and installer,

radiator hose clip

Materials
Engine oil
Coolant ESD‐M97B49‐A
Workshop Equipment
500x5 steel
straightedge
Feeler gauge
Remove
1. General note.
   If necessary, use remover and installer 24‐003 to
remove and install coolant or ventilation hoses.
2. Standard preparatory operations
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
• Detach the battery cover.
CAUTION:
Disconnect the battery earth lead.

WARNING:
If the engine is warm, wrap a thick cloth
around and over the coolant expansion tank
cap before opening it, to prevent the risk of
scalding.
• Open the coolant expansion tank.
3. Raise the vehicle.
4. Detach the engine undershield.
WARNING:
Danger of scalding if the engine is warm.

5. Drain off the coolant.

6. Drain off the engine oil.

7. Detach the oil filter.

8. Disconnect the plugs from the oil pressure switch
and the crankshaft position sensor (CKP sensor).
9. Lower the vehicle.

10. Disconnect the coolant hoses from the thermostat

housing.

11. Detach the throttle cable.

 WARNING:
Escaping fuel. Observe the safety regulations
for working with fuel.
12. Disconnect the fuel lines.

13. Disconnect the vacuum hoses.

1. From the idle air control (IAC) valve
2. To the brake servo.
3. From the EGR valve.
4. From the EGR system vacuum controller (CVT).
5. To the evaporative emission control system valve
(EVAP).

14. Disconnect the plugs.

1. From the DIS ignition coils
2. From the throttle position sensor (TPS)
3. From the engine coolant temperature (ECT) sensor
4. From the IAC valve
5. Injector wiring rail
6. From the temperature gauge sender unit
7. From the noise suppression capacitor

15. Detach the earth lead from the bulkhead.

16. Detach the exhaust manifold heat shield (three

bolts, one nut).
   Disconnect the two vacuum hoses from the
differential pressure feedback EGR (DPFE sensor).
17. Remove the oil dipstick tube.
   Withdraw the oil dipstick.

18. Remove the EGR valve (two bolts).

19. Detach the exhaust pipe from the exhaust

manifold (four nuts).
20. Remove the camshafts as described in Operation
No. 21 284 0.

21. Remove the upper chain guide.

 CAUTION:
Before undoing the bolts, allow the cylinder
head to cool to below 30 °C.
NOTE:
Only re‐use those cylinder head bolts which
have integral washers (see next step).
NOTE:
Release the three auxiliary bolts first.

22. Remove the cylinder head.

23. Identification of cylinder head bolts.

1. New cylinder head bolt with integrated washer.
2. Old cylinder head bolt with washer.

Fit the cylinder head

24. Preparatory measures.
CAUTION:
Do not use abrasive paper. The debris could
cause engine damage.
   All mating faces and reusable parts must be
thoroughly cleaned with brake cleaner and a spatula
and examined for damage.
25. Bring the piston of cylinder no. 1 to a point 25
mm before TDC.

Check cylinder head evenness.

26. Check cylinder head mating surface for distortion.
• The maximum acceptable distortion at combustion
chamber lands is: transversely 0,05 mm, longitudinally
and diagonally 0,10 mm.
• Place straightedge transversely across all combustion
chamber lands and check at three locations.
• Place straightedge longitudinally across the cylinder
head at three locations in the combustion chamber
area and check at all combustion chamber lands.
• Place straightedge diagonally across the cylinder
head and check at all combustion chamber lands.
• If necessary, re‐machine cylinder head as described
in step
27. Note ‐ machining of cylinder head.
NOTE:
Maintain a peak‐to‐valley height Rz of 13,5
micrometres during re‐machining.
   The cylinder head may be machined (milled or
surface ground) by a maximum of 0.20mm. During
machining dimension ”a" must remain at least 16,35
mm (see step ) and ”b" at least 147,25 mm.

NOTE:
Remove carbon deposits at the measuring
site.
28. Location of measuring site for dimension ”a" in the
combustion chamber.

29. Fit the cylinder head.

1. Insert the locating bushes.
2. Put a new cylinder head gasket in place.
3. Fit the cylinder head.

CAUTION:
Do not re‐use an old cylinder head bolt which
needs a separate washer.
30. Only re‐use the new style cylinder head bolts with
integral washer if the length is not more than 174.3
mm and the bolt shows no sign of damage.
1. New cylinder head bolts
2. Old cylinder head bolts
31. Tighten the cylinder head bolts.

32. Tighten the cylinder head bolts (continued).

   Turn through 90°twice.

33. Tighten the auxiliary cylinder head bolts.

34. Fit the upper chain guide.

35. Fit the camshafts as described in Operation No.
21 284 0.
36. Attach the exhaust pipe to the exhaust manifold.

37. Attach the EGR valve to the bracket.

38. Install the oil dipstick tube.

   Insert the oil dipstick.

39. Fit the exhaust manifold heat shield (three bolts,

one nut).
   Connect the two vacuum hoses to the DPFE sensor.

40. Attach the earth lead to the bulkhead.

 41. Connect the plugs.
1. To the DIS ignition coils
2. To the TP sensor
3. To the ECT sensor
4. To the IAC valve
5. Injector wiring rail.
6. To the temperature gauge sender unit
7. To the noise suppression capacitor

42. Connect the vacuum hoses.

1. To the IAC valve
2. To the brake servo.
3. To the EGR valve
4. To the EGR pressure transducer
5. To the EVAP valve

43. Connect the fuel pipes.

44. Attach the throttle cable.

• Attach the throttle cable.
• Fit the accelerator cable clip in the bracket.

45. Attach the coolant hoses to the thermostat

housing.
 46. Raise the vehicle.
47. Connect the plugs to the oil pressure switch and
the CKP sensor.
48. Attach the oil filter.

49. Attach the engine undershield.

50. Lower the vehicle.

51. Standard finishing operations.

• Connect the battery earth lead.
• Fit the battery cover.
• Top up the coolant.
• Check the engine and cooling system for leaks.
• Enter the radio keycode.
• Reprogramme the preset radio stations.
• Reset the clock.
• Carry out a road test to enable the PCM to gather
data.
• Check the fluid levels and rectify as necessary.

Valve Seat ‐ Cut (One)(Valve(s)

Scorpio 1995 (10/1994-06/1998)
Removed) (21 231 9)
 Print

Removal and Installation

Proprietary Tools
Valve seat mill (locked in valve guide)
Mill 25°, 45° and 70°
Re‐machine
1. Locations of the angles on the valve seat.
1. Upper correction angle
2. Valve seat angle
3. Lower correction angle
4. Valve seat width
 NOTE:
Use only tools which fit in the valve guide
without side play.
NOTE:
Procedure shown with proprietary tool. Follow
tool manufacturer's operating instructions.
2. Insert guide mandrel in valve guide and tighten.
3. Place handle on the valve seat mill.

NOTE:
Avoid chatter marks.

4. Milling process.
NOTE:
Taking off more than 0.1 mm of material
necessitates the renewal of the cylinder head.
• Place 45° mill with handle on the guide mandrel and
turn clockwise uniformly with light pressure of about 2
kg.
• Repeat the procedure until an even mating surface is
achieved.
5. Check valve seat width and valve seating.
• Make four pencil marks distributed uniformly on the
valve seat insert.
• Insert valves and turn 90°.
• The smudging of the pencil marks can be used to
determine the valve seat width, the location of the
valve seat face on the valve and the uniformity of the
mating face.
• If necessary, repeat the milling procedure.
6. Correct the position and width of the valve seat
face.
NOTE:
The seat face of the valve should lie
centrally on the seat face of the valve seat
insert.
• The seat width and the position of the mating face
can be modified by machining the correction angle
(see step ).
• By machining the lower correction angle (25°) the
valve seat face is made smaller and displaced in the
direction of the valve stem.
• Milling the upper correction angle (70°) makes the
valve seat face smaller and displaces it in the
direction of the valve head.

Camshafts ‐ Remove and Install (both)

Scorpio 1995 (10/1994-06/1998)
(21 284 0)
 Print

Removal and Installation

Special Tools

15‐030A Universal flange‐

holding wrench
 21‐226 Pliers, spark plug
connector

Materials
Silicone grease A960‐M1C171‐AA
Remove
1. Standard preparatory measures:
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
• Detach the battery cover
CAUTION:
Disconnect the battery earth lead.

2. Remove the air filter housing with the intake pipe.

1. Disconnect the plug from the mass air flow (MAF)
sensor.
2. Unclip the rubber mountings.
3. Detach the intake connector.

3. Remove the air filter housing with the intake pipe

(continued).
1. Detach the hose clip.
2. Disconnect the multiplug from the intake air
temperature sensor (IAT sensor).

4. Disconnect the plug from the idle air control (IAC)

valve.
CAUTION:
Do not pull the cable when removing the
spark plug connector. If necessary, remove
the ignition cables from the ignition coil to
avoid kinking the cables. Turn the spark plug
connector slightly before removing to loosen
the seal.
CAUTION:
Pull off the spark plug connectors in line with
the spark plugs (for bent spark plug
connectors use Special Tool 21‐226).
5. Disconnect the spark plug connectors.
6. Remove the injector wiring rail.
7. Disconnect the plug and the hose.
1. Engine breather hose (PCV).
2. Camshaft position (CMP) sensor plug

8. Remove the DIS ignition coils and the noise

suppression capacitor.
   Disconnect the plug from the noise suppression
capacitor.

9. Remove the cylinder head cover (11 bolts, four

nuts).
   Remove the gasket.

10. Remove the upper timing chain cover (seven

bolts).
   Remove the gasket.

NOTE:
Renew the upper chain guide during
reassembly.
11. Remove the upper chain guide.
12. Release the camshaft sprockets.

13. Set the camshaft sprockets to the mark.

14. Mark the position of the timing chain and the left
and right‐hand camshaft sprockets with a scriber.

15. Remove the camshaft sprockets with the timing

chain.

16. Remove the timing chain tensioner.

1. Remove the retaining ring with a pair of pliers.
2. Remove the pivot pin using an M6 bolt.
3. Remove the tensioning arm.
 17. Remove the timing chain tensioner (continued).
CAUTION:
Do not re‐use the plunger.

• Take out the hydraulic plunger.

• Tie the timing chain up to one side.
• Remove the bracket from the upper chain guide
together with the front bearing caps.

18. Remove the camshafts.

Install
19. Install the camshafts.
CAUTION:
Before installing the camshafts, turn the
crankshaft to approximately 605 BTDC.
CAUTION:
After installing the camshafts do not turn
the crankshaft for about 15 minutes.
   Coat the bearings with oil.
1. Fit the camshafts so that none of the cams is at
full lift.
NOTE:
R is the inlet side, L is the exhaust side.

2. Install the camshaft bearing caps and make sure

that the position markings can be read from the
flywheel side.
20. Check the new hydraulic plunger for the timing
chain tensioner.
1. Plunger latched.
2. Plunger partly released.
3. Plunger fully released (the detent ring is visible).

CAUTION:
Only use a new latched plunger.

21. Install the timing chain tensioner.

• Fit the hydraulic plunger.
• Attach the bracket to the upper chain guide together
with the front bearing caps.

22. Install the timing chain tensioner (continued).

1. Insert the tensioning arm.
2. Insert the pin.
3. Fit the locking ring.

NOTE:
The timing chain must be taut on the
tensioned run.
NOTE:
The markings on the timing chain.

23. Fit the camshaft sprocket (exhaust side) with the

timing chain laid in place.
   If necessary rotate the camshaft slightly.
NOTE:
Do not tighten the bolt.

   Insert the bolt on the exhaust side.

NOTE:
It does not matter if the timing chain sags
slightly between the sprockets.
NOTE:
The markings on the timing chain.

24. Fit the camshaft sprocket (inlet side) with the

timing chain laid in place.
NOTE:
Do not tighten the bolt.

   Insert the bolt on the inlet side.

 NOTE:
If the hydraulic plunger does not reach the
tensioning arm, unlatch the plunger with the
aid of an auxiliary tool.
25. Compress the hydraulic plunger.
   Press down the tensioning arm by hand and unlatch
the hydraulic plunger.

26. Fabricate an auxiliary tool.

   Use a 2,5 mm length of 220 mm welding rod.

27. Tighten the camshaft sprockets.

28. Clip a new upper chain guide in place.

 NOTE:
If it is necessary to adjust the valve timing
(and to loosen the chain) fit a new hydraulic
plunger.
29. Set the camshafts and the crankshaft to TDC on
cylinder no. 1.
30. Check the valve timing.
   Rotate the engine twice in the normal direction of
rotation and set it to the timing marks as shown.

31. Additional check.

1. Rotate the engine in normal direction of rotation so
that cylinder is at TDC.
2. The marks on the camshaft sprockets must face one
another exactly level with the upper edge of the
cylinder head.

NOTE:
The upper edge of the cover must be a
maximum of 0,13 mm below the mating
face of the cylinder head cover.
32. Fit the upper timing chain cover with a new
gasket.
 NOTE:
Bolt tightening sequence.

33. Fit the cylinder head cover with a new gasket (11
bolts, four nuts) and tighten it in two stages.

34. Fit the DIS ignition coils and the noise suppression
capacitor.
   Connect the plug to the noise suppression capacitor.

35. Fit the injector wiring rail.

CAUTION:
Use a blunt object (e.g. a plastic cable tie) to
apply the silicone grease, to avoid damaging
the spark plug connector seal.
CAUTION:
Push on the spark plug connectors, keeping
them in line with the spark plugs.
NOTE:
Coat the inside of the spark plug connector
with silicone grease (A960‐M1C171‐AA) to a
depth of 5‐10 mm.
36. Connect the spark plug connectors.
37. Connect the plug to the IAC valve.
38. Connect the plug and the hose.
1. Engine breather hose (PCV).
2. CMP sensor plug
 39. Fit the air cleaner housing with the intake pipe.
1. Tighten the hose clamp.
2. Connect the plug to the IAT sensor.

40. Fit the air cleaner housing with the intake pipe
(continued).
1. Connect the air intake.
2. Hook the rubber retainers in place.
3. Connect the plug to the mass air flow (MAF)
sensor.

41. Standard finishing operations.

• Connect the battery earth lead.
• Fit the battery cover.
• Enter the radio keycode.
• Reprogramme the preset radio stations.
• Reset the clock.
• Carry out a road test to enable the PCM to gather
data.
• Check the fluid levels and correct if necessary.

General Specifications Scorpio 1995 (10/1994-06/1998)

 Print

Specifications
Engine Data
General
Engine management EEC V / SEFI
Emission standard 96 EEC
Engine code N3A
Firing order 1‐3‐4‐2
Bore mm 86,0
Stroke mm 86,0
Cubic capacity cc 1998
Compression ratio 9,8:1
Power output (EEC) kW 100
(PS) (136)
at rev/min 6300
Torque (EEC) Nm 175
at rev/min 4200
Idle speed (with manual transmission) rev/min 875
(with automatic transmission) rev/min 800
Continuous
Max. permitted engine speed 6450
rev/min
 Intermittent
6675
rev/min
Spark plugs AGPR22C1
Dimensions
Cylinder block
Cast mark 20
Cylinder bore ∅, standard class 1 mm 86,000 ‐ 86,010
Cylinder bore ∅, standard class 2 mm 86,010 ‐ 86,020
Cylinder bore ∅, oversize 0,15 mm 86,160 ‐ 86,170
Cylinder bore ∅, oversize 0,5 mm 86,500 ‐ 86,510
Number of main bearings 5
Track main bearing width (excl. thrust half rings),
mm 21,17 ‐ 21,23
standard,
Fitted main bearing shells
Vertical inner ∅, service engine standard (yellow) mm 54,993 ‐ 55,020
Standard mm 55,003 ‐ 55,030
Vertical inner ∅, 1st undersize 0,05 mm 54,953 ‐ 54,980
Vertical inner ∅, 2nd undersize 0,25 mm 54,753 ‐ 54,780
Vertical inner ∅, 3rd undersize 0,50 mm 55,503 ‐ 54,530
Main bearing parent bore ∅, standard mm 59,287 ‐ 59,300
Main bearing parent bore ∅, oversize 0,40 (black) mm 59,687 ‐ 59,700
Dimensions
Crankshaft
End float mm 0,093 ‐ 0,303
Main bearing journal ∅, standard (yellow) mm 54,98 ‐ 54,99
Main bearing journal ∅, (red) mm 54,99 ‐ 55,00
Main bearing journal ∅, undersize 0,25 (green) mm 54,73 ‐ 54,75
Main bearing journal to shell clearance mm 0,011 ‐ 0,048
Big‐end bearing journal ∅, standard mm 50,89 ‐ 50,91
Big‐end bearing journal ∅, undersize 0,25 (green) mm 50,64 ‐ 50,66
Thrust half ring thickness, standard mm 2,301 ‐ 2,351
Thrust half ring, over‐width 0,38 (yellow) mm 2,491 ‐ 2,541
Track bearing journal width, standard mm 26,025 ‐ 26,075
Track bearing journal width, oversize 0,38 (yellow) mm 26,405 ‐ 26,455
Dimensions
Connecting rods
Bore ∅, large eye mm 53,890 ‐ 53,910
Bore ∅, small eye mm 20,589 ‐ 20,609
Fitted big‐end bearing shells
Vertical inner ∅, standard mm 50,916 ‐ 50,950
Vertical inner ∅, 1st undersize 0,25 mm 50,666 ‐ 50,700
Vertical inner ∅, 2nd undersize 0,50 mm 50,416 ‐ 50,150
Big‐end bearing journal to shell clearance mm 0,006 ‐ 0,060
Big‐end bearing end float mm 0,09 ‐ 0,31
Dimensions
Camshafts
Number of camshaft bearings 2x5
Drive Single roller
chain, hydraulic
 chain tensioner
Camshaft end float 0,02 ‐ 0,26
Lift ‐ cam, inlet mm 9,99
Lift ‐ cam, exhaust mm 9,16
Cam length (between heel and tip), inlet mm 51,87 ‐ 52,10
Cam length (between heel and tip), exhaust mm 51,04 ‐ 51,27
Valve timing, inlet closes before TDC 9°
Valve timing, inlet closes after BDC 59°
Valve timing, exhaust opens before BDC 57°
Valve timing, exhaust closes after TDC 11°
Bearing journal Ø ‐ camshaft mm 25,96 ‐ 25,98
Bearing inside diameter mm 26,00 ‐ 26,03
Dimensions
Pistons
Piston ∅ (not run), service engine standard mm 85,980 ‐ 86,000
Piston ∅ (not run), oversize 0,15 mm 86,130 ‐ 86,150
Piston ∅ (not run), 0,50 mm 86,470 ‐ 86,490
Piston installation clearance (not run), production mm 0,02 ‐ 0,04
Piston installation clearance (not run), service engine mm 0,01 ‐ 0,04
Piston pin length mm 63,4
Piston pin ∅,white mm 20,622 ‐ 20,625
Piston pin ∅, red mm 20,625 ‐ 20,628
Piston pin ∅, blue mm 20,628 ‐ 20,631
Clearance in piston (colour match) mm 0,008 ‐ 0,014
Interference fit in small end bore mm 0,018 ‐ 0,039
Piston ring gap (installed), top mm 0,30 ‐ 0,60
Piston ring gap (installed), middle mm 0,50 ‐ 0,80
Piston ring gap (installed), oil ring (three‐part) mm 0,40 ‐ 1,50
Ring gap position (piston ring gaps distributed equally
around piston circumference; this also applies to gap
of oil intermediate rings in relation to support spring
gap.)
Dimensions
Valves
Valve timing DOHC
Valve clearances Hydraulic tappets
Hydraulic tappet ∅ mm 30
Hydraulic tappet clearance in housing mm 0,025 ‐ 0,071
Valve length, inlet mm 111,67 ‐ 112,13
Valve length, exhaust mm 111,37 ‐ 111,83
Valve head ∅, inlet mm 33,5
Valve head ∅, exhaust mm 30
Valve stem ∅ standard, inlet mm 7,025 ‐ 7,043
Valve stem ∅ standard, exhaust mm 6,999 ‐ 7,017
Valve stem ∅ oversize 0,2, inlet mm 7,225 ‐ 7,243
Valve stem ∅ oversize 0,2, exhaust mm 7,199 ‐ 7,217
Valve stem ∅ oversize 0,4, inlet mm 7,425 ‐ 7,443
Valve stem ∅ oversize 0,4, exhaust mm 7,399 ‐ 7,417
Valve stem guide clearance, inlet mm 0,020 ‐ 0,069
Valve stem guide clearance, exhaust mm 0,046 ‐ 0,095
Colour code ‐ spring Red
Free valve spring height mm 44,8
Inlet and exhaust spring strengths are identical
Spring strength, valve open N 635
Spring strength, valve closed N 210
Spring height (compressed), valve open mm 28,0
Spring height (compressed), valve closed mm 38,0
Valve spring inside ∅ mm 17,2
Valve spring wire ∅ mm 3,7
Number of turns 7,4
Dimensions
Lubrication
Oil pressure (with SAE 10W/30 and 80°C oil
bar 1,60
temperature) at 800/min
Oil pressure (with SAE 10W/30 and 80°C oil
bar 3,10
temperature) at 2000/min
Pressure relief valve opens at bar 3,70 ‐ 4,60
Oil pressure warning light comes on at bar 0,30 ‐ 0,50
Oil pump rotor/housing clearance mm 0,154 ‐ 0,304
Oil pump, inner/outer rotor gap mm 0,05 ‐ 0,20
Oil pump, sealing surface/rotor axial clearance mm 0,039 ‐ 0,104
Dimensions
Cylinder head with valve seat inserts*
Cast mark 20
Upper correction angle (production), inlet/exhaust 15°/20°
Lower correction angle (production), inlet/exhaust 30°/30°
Valve seat angle 45°±30'
Valve seat width, inlet mm 1,17 ‐ 2,02
Valve seat width, exhaust mm 1,34 ‐ 2,19
Valve guide inner Ø (inlet/exhaust valve), standard mm 7,063 ‐ 7,094
Camshaft bearing parent bore ∅, (all) mm 26,00 ‐ 26,03
* The locations of the angles on the valve seat are explained in Description and Operation.

Shims for the sump

Range of adjustment Available shims Colour coding
0 0,25 mm No adjustment
0,26 0,29 mm 0,15 mm Silver
0,30 0,44 mm 0,30 mm Pale blue
0,45 0,59 mm 0,45 mm red
0,60 0,75 mm 0,60 mm black
Lubricants, Adhesives and Sealers
Description Ford
Specification
Transmission fluid ESD‐M2C186‐A
Coolant ESD‐M97B49‐A
Sealing compound, front crankshaft oil seal carrier, Loctite 518 WSK‐M2G348‐A5
Sealing compound, sump, Hylosil 502 WSK‐M4G320‐A
Adhesive sealing compound, coolant pump elbow flange, Loctite 243 WSK‐M2G349‐A7
Adhesive sealing compound, coolant temperature display sender, Loctite WSK‐M2G349‐A7
243
Lubricant for O‐ring of crankshaft position sensor (CKP) sensor SM1C‐115‐A
Lubricant for clutch release bearing guide sleeve ESD‐M1C‐220‐A
Lubricant for transmission input shaft splines ESD‐M1C‐220‐A
Power steering fluid SQM 2C‐9010‐A
Thread locking material, Loctite 270 SDM‐M4G9107‐A
Spark plug thread, Never Seez ESE‐M1244‐A
Thread locking compound, power steering pump to bracket, Loctite 270 SDM‐M4G9107‐A
Filling capacity
Description Litres
Engine oil, first filling with filter 5,1
Engine oil, oil change, with filter change 4,25
Engine oil, oil change, without filter change 4,0
Coolant 7,5
Engine Oil
Ambient Temperature Designation Specification
Ford Multigrade Super Engine
‐10 to above 40 °C SAE 20W50 API/SG/CD
Oil
Ford Multigrade Super Engine
‐15 to above 40 °C SAE 15W40 API/SG/CD
Oil
Ford Multigrade Super Engine
‐20 to above 40 °C SAE 10W30 API/SG/CD
Oil
XR+ High‐performance High‐
‐20 to above 40 °C SAE 10W40 API/SG/CD
lubricity Engine Oil
Ford Formula S Synthetic
‐30 to above 40 °C SAE 5W50 API/SG/CD
Engine Oil
Synthetic/Semi‐synthetic
‐30 to above 40 °C SAE 5W40 API/SG/CD
Engine Oil
Ford Multigrade Super Engine
40 to below ‐30 °C SAE 5W30 API/SG/CD
Oil
The engine oil to specification SAE 5W30 API/SG/CD has only been approved for use in
northern European countries.
If engine oils of other brands are used, it is imperative to ensure that these conform to API
SG/CD or better in the particular viscosity class.
Torques
General Nm lbf.ft
Hose clips 4 3
Engine undershields to front crossmember 19 14
Rear axle reinforcing bar 49 36
Front axle reinforcing bar 80 59
Front axle to side members 80 59
Torques
Exhaust gas recirculation (EGR) Nm lbf.ft
EGR tube to exhaust manifold 75 56
EGR tube bracket to cylinder head 23 17
Flange on connecting pipe to inlet manifold 23 17
Torques
Exhaust Nm lbf.ft
Exhaust system heat shield to cylinder head 7 5
Exhaust mounting to transmission 44 32
Exhaust mounting to transmission crossmember 47 35
Exhaust mounting to engine 47 35
Exhaust flange bolts 47 35
Catalytic converter to exhaust manifold 47 35
Catalytic converter to bracket 47 35
Catalytic converter heat shield 23 17
Torques
Inlet manifold Nm lbf.ft
Inlet manifold bracket 23 17
Studs 14 10
Retaining nuts 22 17
Throttle housing 10 7
Idle speed control (ISC) valve 10 7
Torques
Exhaust manifold Nm lbf.ft
Studs 14 10
Retaining nuts 23 17
Exhaust gas recirculation (EGR) valve 10 7
Torques
Alternator Nm lbf.ft
Alternator bracket to cylinder block 47 35
Torques
Transmission Nm lbf.ft
Earth lead to transmission 44 32
Torque converter to drive plate 47 35
Starter motor 44 32
Engine/transmission flange bolts 44 32
Bolt ‐ adaptor plate to transmission 11 8
Driveshaft to rear axle 66 49
Driveshaft centre bearing to floor assembly 21 15
Driveshaft to vibration damper 78 58
Oil dipstick tube 10 7
Transmission crossmember to floor assembly 36 27
Transmission crossmember to transmission 62 46
Oil line bracket to engine mounting 50 37
Torques
Air Conditioning Nm lbf.ft
Air conditioning compressor to cylinder block 25 18
Air conditioning compressor bracket to cylinder block 47 35
Torques
Coolant circuit Nm lbf.ft
Water pump 23 17
Coolant temperature display sender 6 4
Thermostat housing 10 7
Engine coolant temperature (ECT) sensor 12 9
Angle connector to water pump 14 10
Water pump blanking plug 16 12
Blanking cover for rear coolant outlet 20 15
Torques
Steering Nm lbf.ft
Intermediate shaft to steering shaft 18 13
Power‐assisted steering pump to bracket 23 17
Power‐assisted steering pump pulley 25 18
Torques
Engine mounting Nm lbf.ft
Engine mounting nuts 50 37
Engine mounting bracket to cylinder block 47 35
Torques
Oil circuit Nm lbf.ft
Oil drain plug 25 18
Oil pressure switch. 27 20
Oil filter mounting 21 15
Oil filter 15 11
Oil baffle to cylinder block 21 15
Oil pump 12 9
Oil intake pipe to cylinder block 13 10
Sump to cylinder block (studs) 9 7
Sump to cylinder block (nuts and bolts) 11 8
Torques
Power steering Nm lbf.ft
Power‐assisted steering pump to bracket 23 17
Pulley to power‐assisted steering pump 25 18
Torques
Cylinder block Nm lbf.ft
Lower timing chain cover 10 7
Rear oil seal housing 13 10
Front oil seal housing 26 19
Crankshaft position/speed sensor 4 3
Timing chain guide rail M6 12 9
Timing chain guide rail M8 26 19
Crankcase ventilation tube bracket 9 7
Main bearing caps 97 72
Big‐end bearing cap, 1st stage 7 5
Big‐end bearing cap, 2nd stage 16 12
Big‐end bearing cap, 3rd stage 90° 90°
Crankshaft oscillation damper, 1st stage 52 38
Crankshaft oscillation damper, 2nd stage 85° 85°
Flywheel 87 64
Oil pump chain tensioner arm 12 9
Oil pump sprocket 18 13
Clutch pressure plate 24 18
Torques
Cylinder head Nm lbf.ft
Cylinder head, 1st stage 10 7
Cylinder head, 2nd stage 35 26
Cylinder head, 3rd stage 90° 90°
Cylinder head, 4th stage 90° 90°
Cylinder head cover, 1st stage 3 2
Cylinder head cover, 2nd stage 9 7
Ignition coil covers 5 4
Auxiliary cylinder head bolts (x3) 38 28
Upper timing chain cover 11 8
Fuel rail 24 18
Fuel pressure regulator 10 7
Camshaft bearing caps 24 18
Camshaft sprockets 59 44
Engine lifting eyes 25 18
Studs to cylinder head (x20) 20 15
Blanking plugs 52 38
Rear blanking cover for rear coolant outlet 20 15
Spark plugs 18 13

Description and Operation Scorpio 1995 (10/1994-06/1998)

 Print

Description and Operation

Changed components compared to the Escort RS 2000:
 Cylinder block.
 Revised inlet manifold.
 Pistons with compression rings higher up; the compression has been reduced from
10,3 to 9,8 due to modification to the piston crown.
 New compression rings and revised piston pins.
 Connecting rods with lateral lubricating grooves (instead of oil spray bore) on big‐end
bearing. Big‐end bearing shells without bore.
 New cylinder head gaskets; soft gaskets are renewed using multi‐layered steel
gaskets.
 Valve covers are made of aluminium instead of plastic.
 New valve cover gasket.
 Revised upper and lower timing cover.
 Use of platinum spark plugs; electrode gap 1 mm.
 New fuel rail with flanged on, revised pressure control valve.
 New engine management (EEC V) with sequential multipoint fuel injection (SFI).
 New camshaft position sensor (CMP sensor).
 Revised crankshaft position sensor (CKP sensor).
 New oil dipstick tube sealed with an O‐ring at the cylinder block; the O‐ring does not
have to be renewed during removal or installation.
 Revised oil pick‐up pipe.
 Revised sump and revised oil deflecting plate.
 New oil filter.
 New drive belt for ancillary components.
 Revised rear starter motor mounting.
 Modified oil seals.
 New, improved heated oxygen sensor (HO2S)
 Use of exhaust gas recirculation (EGR) which works on the principle of the DPFE.
 New coolant expansion tank and new pipes in the cooling system.
Engine main wiring loom multiplugs
Item Description
1 DIS ignition coils
2 Idle speed control valve (ISC valve)
3 Throttle position sensor (TP sensor)
4 Coolant temperature display sender
Engine coolant temperature (ECT)
5
sensor
6 Oil pressure switch
7 Crankshaft position/speed sensor
8 Central connector
9 Injectors
10 Camshaft position sensor (CID)
Drive belt routing
Item Description
1 Crankshaft belt pulley
2 Automatic belt tensioner
3 Alternator
4 Water pump
5 Power‐assisted steering pump
6 Air conditioning compressor
Locations of the angles on the valve seat.

1.Lower correction angle

2.Upper correction angle

3. Valve seat angle

4. Valve seat width

Cylinder head gasket.

With effect from the '95 model year, a multi‐layered steel gasket is used.
Crankshaft with paint marks.
Item Description
Yellow line for standard size (∅ 54,99
‐ 54,98) main bearing journals, red
1
line for standard size (∅ 55,00 ‐
54,99) main bearing journals
Green line for production undersize
2
(0,25) main bearing journals.
Green line for production undersize
3
(0,25) main bearing journals.
Yellow line for undersize (0,38) centre
4
main bearing journal width.
5 Centre main bearing journal width.

Camshafts ‐ Remove and Install (both)

Scorpio 1995 (10/1994-06/1998)
(21 284 0)
 Print

Removal and Installation

Special Tools

15‐030A Universal flange‐

holding wrench

21‐226 Pliers, spark plug

connector

Materials
Silicone grease A960‐M1C171‐AA
Remove
1. Standard preparatory measures:
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
• Detach the battery cover
CAUTION:
Disconnect the battery earth lead.

2. Remove the air filter housing with the intake pipe.

1. Disconnect the plug from the mass air flow (MAF)
sensor.
2. Unclip the rubber mountings.
3. Detach the intake connector.

3. Remove the air filter housing with the intake pipe

(continued).
1. Detach the hose clip.
2. Disconnect the multiplug from the intake air
temperature sensor (IAT sensor).

4. Disconnect the plug from the idle air control (IAC)

valve.
CAUTION:
Do not pull the cable when removing the
spark plug connector. If necessary, remove
the ignition cables from the ignition coil to
avoid kinking the cables. Turn the spark plug
connector slightly before removing to loosen
the seal.
CAUTION:
Pull off the spark plug connectors in line with
the spark plugs (for bent spark plug
connectors use Special Tool 21‐226).
5. Disconnect the spark plug connectors.
6. Remove the injector wiring rail.
7. Disconnect the plug and the hose.
1. Engine breather hose (PCV).
2. Camshaft position (CMP) sensor plug
8. Remove the DIS ignition coils and the noise
suppression capacitor.
   Disconnect the plug from the noise suppression
capacitor.

9. Remove the cylinder head cover (11 bolts, four

nuts).
   Remove the gasket.

10. Remove the upper timing chain cover (seven

bolts).
   Remove the gasket.

NOTE:
Renew the upper chain guide during
reassembly.
11. Remove the upper chain guide.

12. Release the camshaft sprockets.

13. Set the camshaft sprockets to the mark.
14. Mark the position of the timing chain and the left
and right‐hand camshaft sprockets with a scriber.

15. Remove the camshaft sprockets with the timing

chain.

16. Remove the timing chain tensioner.

1. Remove the retaining ring with a pair of pliers.
2. Remove the pivot pin using an M6 bolt.
3. Remove the tensioning arm.

17. Remove the timing chain tensioner (continued).

CAUTION:
Do not re‐use the plunger.

• Take out the hydraulic plunger.

• Tie the timing chain up to one side.
• Remove the bracket from the upper chain guide
together with the front bearing caps.
 18. Remove the camshafts.

Install
19. Install the camshafts.
CAUTION:
Before installing the camshafts, turn the
crankshaft to approximately 605 BTDC.
CAUTION:
After installing the camshafts do not turn
the crankshaft for about 15 minutes.
   Coat the bearings with oil.
1. Fit the camshafts so that none of the cams is at
full lift.
NOTE:
R is the inlet side, L is the exhaust side.

2. Install the camshaft bearing caps and make sure

that the position markings can be read from the
flywheel side.

20. Check the new hydraulic plunger for the timing

chain tensioner.
1. Plunger latched.
2. Plunger partly released.
3. Plunger fully released (the detent ring is visible).
 CAUTION:
Only use a new latched plunger.

21. Install the timing chain tensioner.

• Fit the hydraulic plunger.
• Attach the bracket to the upper chain guide together
with the front bearing caps.

22. Install the timing chain tensioner (continued).

1. Insert the tensioning arm.
2. Insert the pin.
3. Fit the locking ring.

NOTE:
The timing chain must be taut on the
tensioned run.
NOTE:
The markings on the timing chain.

23. Fit the camshaft sprocket (exhaust side) with the

timing chain laid in place.
   If necessary rotate the camshaft slightly.
NOTE:
Do not tighten the bolt.

   Insert the bolt on the exhaust side.

NOTE:
It does not matter if the timing chain sags
slightly between the sprockets.
NOTE:
The markings on the timing chain.

24. Fit the camshaft sprocket (inlet side) with the

timing chain laid in place.
NOTE:
Do not tighten the bolt.

   Insert the bolt on the inlet side.

NOTE:
If the hydraulic plunger does not reach the
tensioning arm, unlatch the plunger with the
aid of an auxiliary tool.
25. Compress the hydraulic plunger.
   Press down the tensioning arm by hand and unlatch
the hydraulic plunger.
26. Fabricate an auxiliary tool.
   Use a 2,5 mm length of 220 mm welding rod.

27. Tighten the camshaft sprockets.

28. Clip a new upper chain guide in place.

NOTE:
If it is necessary to adjust the valve timing
(and to loosen the chain) fit a new hydraulic
plunger.
29. Set the camshafts and the crankshaft to TDC on
cylinder no. 1.
30. Check the valve timing.
   Rotate the engine twice in the normal direction of
rotation and set it to the timing marks as shown.
31. Additional check.
1. Rotate the engine in normal direction of rotation so
that cylinder is at TDC.
2. The marks on the camshaft sprockets must face one
another exactly level with the upper edge of the
cylinder head.

NOTE:
The upper edge of the cover must be a
maximum of 0,13 mm below the mating
face of the cylinder head cover.
32. Fit the upper timing chain cover with a new
gasket.

NOTE:
Bolt tightening sequence.

33. Fit the cylinder head cover with a new gasket (11
bolts, four nuts) and tighten it in two stages.
34. Fit the DIS ignition coils and the noise suppression
capacitor.
   Connect the plug to the noise suppression capacitor.

35. Fit the injector wiring rail.

CAUTION:
Use a blunt object (e.g. a plastic cable tie) to
apply the silicone grease, to avoid damaging
the spark plug connector seal.
CAUTION:
Push on the spark plug connectors, keeping
them in line with the spark plugs.
NOTE:
Coat the inside of the spark plug connector
with silicone grease (A960‐M1C171‐AA) to a
depth of 5‐10 mm.
36. Connect the spark plug connectors.
37. Connect the plug to the IAC valve.
38. Connect the plug and the hose.
1. Engine breather hose (PCV).
2. CMP sensor plug

39. Fit the air cleaner housing with the intake pipe.
1. Tighten the hose clamp.
2. Connect the plug to the IAT sensor.

40. Fit the air cleaner housing with the intake pipe
(continued).
1. Connect the air intake.
2. Hook the rubber retainers in place.
3. Connect the plug to the mass air flow (MAF)
sensor.

41. Standard finishing operations.

• Connect the battery earth lead.
 • Fit the battery cover.
• Enter the radio keycode.
• Reprogramme the preset radio stations.
• Reset the clock.
• Carry out a road test to enable the PCM to gather
data.
• Check the fluid levels and correct if necessary.

Engine ‐ Remove and Install (21 134 0) Scorpio 1995 (10/1994-06/1998)

 Print

Removal and Installation

Special Tools

21‐068A Engine lifting tackle

24‐003 Removing and fitting

tool, radiator hose clip

Workshop Equipment
Description
Transmission jack
Trolley jack
Materials
Thread locking
SDM‐M4G9107‐A
compound
Coolant ESD‐M97B49‐A
Cable ties
Remove
1. General instructions
   Use special tool 24‐003 when removing the coolant
and ventilation hoses if necessary.
2. Standard preparatory work
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
CAUTION:
Disconnect the battery earth lead.

WARNING:
Wrap a thick cloth around the coolant
expansion tank cover before opening the
cooling system when the engine is at
operating temperature in order to prevent
scalding.
• Open the coolant reservoir.
• Withdraw the transmission fluid dipstick.
• Drain off the coolant.
   Remove the engine undershield (front).
3. Detach the hood.
• Detach the hood sound‐damping matting.
1. Disconnect and unclip the windscreen washing
system hose and plug.
2. Unclip the hood damping strut.
• Unclip the retaining ring.
3. Remove the hood retaining bolts.

4. Remove the air cleaner complete.

1. Detach the crankcase ventilation hose.
2. Release the two hose clips.
3. Disconnect the multiplug from the air charge
temperature sensor.
4. Disconnect the multiplug from the mass air flow
(MAF) sensor.
5. Detach the intake connector.
6. Unhook the two rubber insulators.
5. Detach the components on the right‐hand side of
the engine compartment.
1. Unhook and detach the accelerator cable and the
speed control system cable.
2. Ground lead.
3. Disconnect the coolant hose running to the heater.
WARNING:
Escaping fuel. Observe safety regulations
regarding the handling of fuel.
4. Disconnect the fuel pipes.
   Vacuum lines:
5. To the evaporative emission system valve (EVAP).
6. From the variable intake system (VIS) servo motor.
7. To the solenoid (VIS+EGR).
8. To the brake servo.
6. Detach the components on the right‐hand side of
the engine compartment (continued).
1. Pull the power‐assisted steering reservoir out
upwards.
2. Disconnect the alternator.
3. Coolant hose from the thermostat housing.
4. Separate the transmission main wiring loom central
multiplug.
5. Engine breather vacuum line.
7. Disconnect the multiplug.
• Remove the ignition coil cover.
1. Ignition coils (DIS)
2. Idle speed control valve (ISC)
3. Throttle position sensor
4. Coolant temperature display sender
5. Engine coolant temperature (ECT) sensor
6. Injectors
7. Remove the injector wiring rail.
8. Camshaft position sensor
8. Detach the ancillary components on the left‐hand
side of the engine.
1. Pull off the vacuum hose from the exhaust gas
recirculation valve (ERG valve).
2. Detach the oil dipstick tube.
3. Pull the vacuum hoses off the exhaust gas
recirculation (EGR) pipes.
4. Detach the heat shield.
5. Detach the catalytic converter from the exhaust
manifold.
6. Pull off the heated oxygen sensor (HO2S) multiplug.
9. Detach the air baffle and fan motors from the
radiator.
• Unhook the coolant hose.
• Pull off the two fan motor plugs.
• Remove the two retaining nuts.
 10. Remove the power steering pump pulley.
1. Slacken the bolts of the belt pulley.
2. Slacken and remove the drive belt.
• Detach the belt pulley.

NOTE:
Hydraulic lines should not be disconnected.

11. Remove the power‐assisted steering pump.

   Remove the three bolts from the front and one bolt
from the rear.

NOTE:
The air conditioning system should not be
opened.
12. Detach the air conditioning compressor and tie it
up to one side.
   Pull off the magnetic clutch plug.

13. Disconnect the oil pressure switch multiplug.

14. Disconnect the starter motor.

   Detach the wiring from the solenoid.
 15. Remove the starter motor.
NOTE:
Only when the engine is being removed
without the transmission.
1. Remove the bracket from the cylinder block.
2. Remove the bolts.

16. Detach the front axle transverse brace (left‐hand

side shown).

17. Remove the rear part of the exhaust system.

1. Detach the exhaust flange.
2. Unhook the rubber insulators.
18. Remove the catalytic converter.
1. Separate the heated oxygen sensor (HO2S)
multiplug.
2. Detach the bracket.
 NOTE:
Necessary in order to prevent damage to the
heated oxygen sensor (HO2S) when the
catalytic converter is removed.
19. Turn the steering intermediate shaft.

20. Remove the catalytic converter (continued).

21. Detach the heat shields.
   Unscrew the nine panel nuts and remove the heat
shields.

CAUTION:
The driveshaft is finely balanced using bolts
of different lengths. Mark the installed
position of the driveshaft and the bolts.
22. Detach the driveshaft from the rear axle.
NOTE:
Vehicles from Jan. '96 are not fitted with the
transverse brace.
1. Detach the rear axle transverse brace.
2. Detach it from the rear differential.

Only vehicles with MT 75 manual transmission

CAUTION:
Do not disconnect the driveshaft from the
rubber coupling.
23. Detach the driveshaft from the vibration damper.

24. Remove the driveshaft.

NOTE:
Only when the engine is being removed with
the transmission.
1. Remove the bolts.
2. Slacken the bolts.
3. Turn the two brackets 90°.
• Withdraw the driveshaft from the transmission.
• Seal the transmission with an assembly plug.
 25. Lower the transmission at the rear.
NOTE:
Only when the engine is being removed with
the transmission.
• Place a transmission jack under the transmission.
1. Detach the crossmember from the body.
2. Detach the crossmember from the transmission.
• Detach the selector rod from the selector lever.
• Lower the transmission.

26. Detach the fluid pipes to the transmission fluid

cooler.
   Detach the bracket from the engine mounting.

27. Detach the fluid pipes to the transmission fluid

cooler.
1. Unscrew the return pipe from the transmission and
place it to one side.
2. Remove the delivery pipe.

28. Release the torque converter.

NOTE:
Only when the engine is being removed
without the transmission.
   Remove the four nuts.

29. Detach the automatic transmission wiring harness

and remove the flange bolts.
NOTE:
Only remove the flange bolts when the
engine is being removed without the
transmission.
1. Unclip it at the engine mounting.
2. Remove the flange bolts.
• Remove the transmission fluid dipstick tube.
 NOTE:
Only when the engine is being removed
without the transmission.
30. Remove the flange bolts.

31. Unscrew the flange bolts.

NOTE:
Only when the engine is being removed
without the transmission.
   Release the engine from the transmission.

32. Detach the right and left‐hand engine mountings

from the axle housing.
• Remove the transmission jack.
• Lower the vehicle.

NOTE:
If the engine is being removed without the
transmission, the transmission must be
supported with a trolley jack.
33. Remove the engine.
   Attach the engine lifting bracket.

Install
34. General instructions
NOTE:
Renew the circlips and self‐locking nuts.

   Use special tool 24‐003 when fitting the coolant and

ventilation hoses if necessary.
35. Bring the torque converter on the transmission and
the drive plate on the engine into the correct position
for installation.
NOTE:
Only when the engine is being installed
without the transmission.
1. Torque converter
2. Drive plate

36. Install the engine (with the transmission).

NOTE:
Correct insertion of the torque converter in
the drive plate.
• Make sure the engine mounting is sitting correctly in
relation to the axle housing.
• Attach the engine and transmission with two flange
bolts.

37. Remove the trolley jack.

NOTE:
Only when the engine is being installed
without the transmission.
38. Detach the engine lifting bracket.
NOTE:
Only when the engine is being installed
without the transmission.
39. Attach the engine to the transmission.

NOTE:
Only when the engine is being installed
without the transmission.
40. Connect the engine and the transmission.
41. Connect the oil pipes to the oil cooler.
1. Connect the feed pipe.
2. Connect the return pipe.

42. Attach the fluid pipes to the transmission fluid

cooler.
   Attach the bracket to the engine mounting.

43. Secure the torque converter.

NOTE:
Only when the engine is being installed
without the transmission.
   Four nuts

44. Install the automatic transmission wiring harness

and tighten the flange bolts.
NOTE:
Only when the engine is being installed
without the transmission.
1. Tighten the flange bolt for the wiring loom bracket.
2. Tighten the flange bolt for the earth lead.
3. Clip the wiring loom on to the engine mounting.
• Tighten the flange bolt at the top of the
transmission fluid dipstick tube bracket.

45. Attach the transmission crossmember.

NOTE:
Only when the engine is being installed with
the transmission.
• Place a transmission jack under the transmission.
• Raise the transmission.
• Attach the crossmember.
• Attach the selector rod to the selector lever.
 46. Tighten the engine mounting.

47. Install the starter motor.

NOTE:
Only when the engine is being installed
without the transmission.
1. Tighten the three bolts.
2. Install the starter bracket on the cylinder block.

48. Connect the starter motor.

   Tighten the two nuts.

49. Fit the driveshaft.

NOTE:
Only when the engine is being installed with
the transmission.
• Remove the assembly plug from the transmission.
• Insert the driveshaft in the transmission.
• Attach the centre bearing loosely.

CAUTION:
The driveshaft is finely balanced using bolts
of different length. Pay attention to the
installed position marks on the driveshaft
and the bolts.
50. Install the driveshaft (continued).
1. Attach the driveshaft to the rear axle flange.
NOTE:
Vehicles from Jan. '96 are not fitted with the
transverse brace.
2. Attach the transverse brace.
Only vehicles with MT 75 manual transmission
 51. Install the driveshaft on the vibration damper.

NOTE:
Only when the engine is being installed with
the transmission.
52. Align the centre bearing free of stress and secure
it.

53. Connect the oil pressure switch multiplug.

54. Fit the air conditioning compressor.

   Connect the magnetic clutch plug.

NOTE:
Insert the bolts using thread locking
compound (SDM‐M4G9107‐A).
55. Install the power‐assisted steering pump.
   Tighten the three bolts from the front and one bolt
from the rear.
56. Turn the steering intermediate shaft to the position
shown.
NOTE:
Necessary so that the heated oxygen sensor
(HO2S) will not be damaged when the
catalytic converter is installed.
57. Fit the heat shields.
   Nine panel nuts.

58. Fit the catalytic converter loosely.

59. Fit the power steering pump pulley.

1. Put on the drive belt.
2. Tighten the belt pulley.

60. Fit the air baffle with the fan motors to the
radiator.
• Connect the two fan motor plugs.
1. Screw on two nuts.
2. Hook the coolant hose in place.
61. Attach the ancillary components on the left‐hand
side of the engine.
1. Connect the HO2S multiplug.
2. Attach the catalytic converter to the exhaust
manifold.
3. Fit the heat shield.
4. Connect the vacuum line to the exhaust gas
recirculation (EGR) valve.
5. Fit the oil dipstick tube.
6. Push on the vacuum hoses.
62. Connect the multiplugs.
1. Ignition coils (DIS)
2. ISC valve
3. TPS
4. Coolant temperature display sender
5. ECT sensor
6. Injectors
7. CMP sensor
8. Injector wiring rail
• Fit the ignition coil cover.
63. Install the components on the right‐hand side of
the engine compartment.
1. Engine breather vacuum line.
2. Connect the central connector of the main
transmission wiring harness.
3. Coolant hose to thermostat housing.
4. Connect the alternator wiring.
5. Power‐assisted steering reservoir.

64. Install the components on the right‐hand side of

the engine compartment (cont.).
   Vacuum lines:
1. To the brake servo.
2. From the variable intake air system (VIS) servo
motor.
3. To the solenoid (VIS+EGR).
4. To evaporative emission system valve (EVAP).
5. Ground lead.
6. Heater coolant hose.
7. Connect the fuel pipes.
8. Install the accelerator and speed control system
cables and connect them.

65. Fit the air filter complete.

1. Fit the two rubber insulators.
2. Fit the intake connector.
3. Push on the MAF multiplug.
4. Push on the IAT sensor multiplug.
5. Tighten the two hose clips.
6. Install the crankcase ventilation hose.
66. Fit the hood.
1. Fit the engine cover bolts.
2. Clip in the hood support strut.
• Clip the retaining ring in place.
3. Join the windscreen washer system hoses, connect
the plug and fix them in place.
• Attach the hood noise‐damping matting.
67. Tighten the catalytic converter bolts.

68. Attach the exhaust system to the transmission

crossmember.
1. Install the bracket on the transmission
crossmember.
2. Connect the HO2S multiplug.

69. Fit the rear part of the exhaust system.

1. Hook the exhaust into the rubber insulators.
2. Attach the exhaust flange.
70. Attach the front axle transverse brace (left‐hand
side shown).
71. Fit the rear engine undershield (if present).

72. Finishing operations.

• Fill up with coolant.
 • Check that the vacuum hoses and wires are routed
correctly and secure them with cable ties.
• Connect the battery earth lead.
• Enter the radio keycode and reprogramme the preset
radio stations.
• Reset the clock.
• Carry out a road test to enable the PCM (EEC IV) to
collect data.
• Check the fluid levels after the road test and correct
them as necessary.

Engine ‐ Dismantle and Assemble (21

Scorpio 1995 (10/1994-06/1998)
134 8)
 Print

Removal and Installation

Special Tools

15‐030A Universal flange‐

holding wrench

16‐067 Aligner for clutch disc

21‐023 Universal mounting

spindle for assembly stand

21‐031B Mounting bracket

21‐036A Remover for pilot

bearing

21‐044A Installer/locator for

pilot bearing/clutch disc

21‐141 Installer for oil seal

21‐146C Mounting plate

21‐147 Remover for vibration

damper
 21‐226 Pliers, spark plug
connectors

21‐540 Angle gauge

Materials
Description
Obtainable
through: Replacement
Services Limited, 16,
Euston
Plastigage
Street, Freemans
Industrial
Estate, Leicester LE2
7ST
Sealer Loctite 518 WSK‐M2G348‐A5
Sealer Hylosil 502 WSK‐M4G320‐A
Silicone grease A960‐M1C171‐AA
Workshop Equipment
Description
Assembly stand
Proprietary Tools
Description
Dial gauge
Magnetic fixture
Piston ring compressor
Oil filter strap wrench
Micrometer screw
Steel rule
Dismantle
1. Preparatory measures.
• Drain off the engine oil.
• Remove the oil dipstick tube.
2. Detach the engine mounting bracket with the engine
mounting.
3. Attach the engine to the assembly stand.

4. Detach the bracket.

5. Detach the EGR system.

6. Detach the inlet manifold bracket from the engine.

7. Detach the alternator and bracket.

 8. Detach the engine mounting bracket with the
engine mounting.
9. Detach the crankshaft position sensor (CKP
sensor).
10. Detach the oil filter.

11. Detach the clutch.

12. Detach the crankshaft belt pulley/vibration

damper.
• Immobilise the flywheel using Special Tool 21‐168
• Remove the bolt.
• Pull it off using the special tool.

13. Detach the flywheel.

• Remove the bolts.
• Remove the flywheel.
 14. Detach the crankcase breather (PCV) tube.
1. Detach the bracket from the cylinder head.
2. Disconnect the tube from the inlet manifold.
3. Lever it off exhaust manifold.

CAUTION:
Do not pull on the cable when removing the
spark plug connectors. Remove the high‐
tension lead from the ignition coil to prevent
kinks in the lead if necessary. Turn the spark
plug connectors slightly before removing
them in order to loosen the seal.
CAUTION:
Remove the spark plug connectors in a
straight line in relation to the spark plugs
(use special tool 21‐226 for offset spark plug
connectors).
15. Remove the spark plugs.
• Detach the ignition coil cover.
• Disconnect the spark plug connectors.
• Remove the ignition coils (two bolts each).
• Remove the spark plugs.

16. Detach the engine lifting eyes.

17. Detach the cylinder head cover (eleven bolts and
four nuts).
18. Detach the upper timing chain cover.

19. Detach the lower timing chain cover.

20. Detach the oil pump sprocket and chain.

1. Remove the chain tensioner for the oil pump chain.
2. Remove the oil pump sprocket with the chain.

21. Set the camshaft sprockets to the marks.

NOTE:
The chain guide must be renewed during
installation.
22. Remove the upper chain guide rail.
23. Remove the camshaft sprockets.

24. Remove the chain tensioner arm.

1. Remove the retaining ring with a pair of pliers.
2. Withdraw the chain tensioner pivot pin with a bolt
(M6).
3. Remove the chain tensioner arm from the housing.

25. Release the chain guide.

26. Remove the timing chain.

• Remove the Woodruff key from the crankshaft.
• Remove the crankshaft chain sprocket with the
timing chain.
 CAUTION:
Do not reuse the oil‐filled plunger.

27. Remove the chain tensioner plunger and the

timing chain.

28. Remove the camshafts.

• Detach the chain guide bracket with the front
bearing caps.
• Remove the hydraulic tappets and keep them in
order.

CAUTION:
The cylinder head should be left to cool
down to 30 °C or below before the bolts are
slackened.
NOTE:
Only reuse cylinder head bolts which have
an integral washer (see next operation).
NOTE:
Release the three auxiliary bolts first.

29. Unscrew the cylinder head bolts in the sequence

indicated.
30. Cylinder head bolts, distinguishing features
1. New cylinder head bolt with integral washer.
2. Old cylinder head bolt with separate washer.

31. Detach the water pump.

32. Detach the oil pump.

CAUTION:
Oil sludge and abraded particles must not
get into the engine.
33. Remove the sump downwards.
 CAUTION:
Do not damage the cylinder bore.

34. Remove the carbon from the upper edge of the

cylinder bore.

35. Detach the oil intake pipe and oil baffle.

36. Detach the crankshaft front oil seal housing.

37. Detach the crankshaft rear oil seal housing.

38. Remove the crankshaft pilot bearing.

 39. Remove the pistons.
• Detach the big‐end bearing caps.
• Remove the big‐end bearing shells from the big‐end
bearing caps and connecting rods and mark them.
• Press out the pistons with the connecting rods.

40. Remove the crankshaft.

• Detach the main bearing caps.
• Remove the crankshaft.
• Remove the bearing shells and thrust half rings and
keep them in order or mark them for further use.

Assemble engine
41. Preparatory measures.
• Clean all the mating faces and reusable parts
thoroughly and check them for damage.
• When applicable, the upper and lower timing chain
covers are renewed complete with the oil seal in place.
NOTE:
Rework or renew the crankshaft if the
values are not within the tolerances
specified in the technical data.
42. Measure the diameters of the main and big‐end
bearing journals using a proprietary micrometer
screw.
   Repeat each measurement at 90°.

Measure bearing clearance

CAUTION:
Do not damage the crankshaft bearings
during fitment.
43. Fit the crankshaft.
• Place the grooved bearing shells in the cylinder
block.
• Place the crankshaft dry in the cylinder block.
 CAUTION:
The crankshaft must not be turned during the
measuring operation.
44. Measure the crankshaft main bearing clearance.
NOTE:
The point at which the measurement is made
must be dry.
• Lay a length of Plastigage thread on the bearing
journal across the bearing.
• Fit the bearing cap (see operation ).
NOTE:
Measure the clearance of the bearings in
turn in numerical order (1 ‐ 5).
45. Measure the crankshaft main bearing clearance
(continued).
• Fit the bearing cap with the associated bearing
shell, with the arrow pointing towards the timing
chain end, and secure it.
NOTE:
The bearing cap numbering starts at the
timing chain end.
• Fit the bearing cap.
NOTE:
If the specified bearing clearance is not
achieved, on a standard cylinder block and
with a crankshaft which is a maximum of
0,02 mm undersize, the next largest bearing
shells may be fitted. However, the bearing
clearance must not have been more than
0,098 mm.
46. Measure the crankshaft main bearing clearance
(continued).
• Compare the Plastigage thread with the Plastigage
scale.
• The reading corresponds to the bearing clearance.
NOTE:
If the specified bearing clearance of 0.011 ‐
0.048 mm is not obtained, fit new bearing
shells and repeat the measuring sequence,
starting with operation
NOTE:
Fit the bolts with the threaded pins in
bearings 3 and 5.
47. Fit the crankshaft.
• Lubricate the main bearing journals and bearing
shells and the threads and contact faces of all the
bolts with engine oil.
• Fit the crankshaft.
• Fit the thrust half rings with the copper‐coloured
side facing the crankshaft.
• Coat the contact faces and the sides of the rear
main bearing cap with sealer.
• Fit the crankshaft main bearing caps with the
associated bearing shells.
NOTE:
The bearing cap numbering starts at the
timing chain end, to which the arrows also
point.
• Tighten the bolts.
48. Check the crankshaft end float.
• Set up a dial indicator.
• Measure the end float by lifting the crankshaft with
the aid of a screwdriver.
• Correct the end float as necessary by fitting new
thrust half rings to main bearing no. 3.

49. Check the piston ring gaps.

   The figures indicated in the Technical Data are for a
gauge ring used in production. The figures measured
in the cylinder can exceed these by 0,15 mm.

CAUTION:
The maximum width of the piston rings
corresponds to the diameter of the cylinder
bore + 1,7 mm.
50. Arrangement of the piston rings.
CAUTION:
The upper piston rings are coated with
molybdenum. This coating must not be
damaged.

NOTE:
The connecting rod numbering 1 to 4 starts
at the timing chain end. The arrow on the
piston crown points towards the timing case.
51. Install the pistons.
• Lubricate the pistons and cylinder liner bores with
engine oil.
• Distribute the piston ring gaps uniformly around the
circumference; this also applies to the elements of the
oil control ring.
• Compress the piston rings using a proprietary piston
ring compressor.
• Press pistons 1 and 4 into the cylinders using the
handle of a hammer. The big‐end bearing journal must
be at BDC.
• Lubricate the bearing shells with engine oil.
• Fit the appropriate bearing shells in the connecting
rod and bearing cap.
• Use new connecting rod bolts (bolt head marking
”KX120" on connecting rods with side groove).
• Fit the bearing cover.
• Turn the crankshaft 180°, fit pistons 2 and 3.
52. Measure the big‐end bearing clearance.
   Measure the big‐end bearing clearance as described
in sub‐operations to
 NOTE:
The connecting rods and their bearing caps
have the same numbers.
53. Fit the bearing caps.
• Lubricate the bearing shells and bearing journals
with engine oil.
• Fit the associated bearing caps and bearing shells
and secure them.

54. Install the crankshaft pilot bearing.

55. Remove the oil seal from the rear oil seal
housing.

Install the rear oil seal housing

56. Align the oil seal housing.
• Fit the oil seal housing using a new gasket and
screw in the bolts loosely.
1. The mating face of the oil seal housing must be
below the mating face of the cylinder block. The
difference in height must not exceed 0,46 mm.
2. Tighten the bolts.
 57. General description of the procedure for fitting a
oil seal into a special tool with a guide sleeve.
CAUTION:
The oil seal must be fitted into the tool as
far as the shoulder.
• For correct fitment, the special tool is placed on a
vice and the oil seal is pressed in using the handle of
a hammer.
1. Incorrect fitment.
2. Correct fitment.

58. Fit the crankshaft rear oil seal.

   Pull in the oil seal using two flywheel bolts.

NOTE:
Do not remove any excess sealer before
installing the sump.
59. Fit the crankshaft front oil seal housing.
• Use sealer (WSK‐M2G348‐A5).
• Apply four beads of sealer, each of 3‐5 mm
diameter and 10 mm long.
NOTE:
After installing the oil seal carrier the sealer
must stand proud adequately at the front
and sides.
60. Fit the oil baffle.
NOTE:
Fit the oil baffle so that the oil dipstick and oil
strainer can be fitted.
61. Fit the oil strainer.

Install the sump

 NOTE:
The bead of sealer must cover the mating
face gaps.
62. Apply sealing compound to the cylinder block on
the flywheel side.
• Use sealer (WSK‐M4G320‐A).
• Apply a bead of sealer with a thickness of 3 ‐ 5 mm
and a width of 10 mm on both sides.

63. Fit the sump using a new gasket.

• Align the sump as described in sub‐operation
• Tighten the three nuts and the twelve bolts.

64. Align the sump.

• Align the sump so that it stands a maximum of 0,25
mm short or 0,1 mm proud.
• Measure the difference in height using a steel
straightedge and a feeler gauge; make a note of the
measurement.
• Reduce the difference to zero when installing the
engine by using shims (see Technical Data).

NOTE:
It can only be fitted in one position.

CAUTION:
Use new bolts.

65. Fit the flywheel.

 66. Centre the clutch disc on the pressure plate.

67. Fit the clutch assembly.

1. Fit the clutch pressure plate with the centred clutch
disc.
2. Tighten the six bolts uniformly, working diagonally.
3. Remove the special tool.

CAUTION:
A new oil pump must be filled with oil and
turned over by hand before it is fitted.
68. Clean the oil pump.
   Dismantle the oil pump.
NOTE:
In the event of wear, an entire new oil
pump must be fitted.
69. Reassemble the oil pump.
NOTE:
The dot marks must face outwards.

NOTE:
The passages of the oil pump must not be
covered by the gasket.
70. Fit the oil pump using a new gasket.

Install the cylinder head

71. Bring the piston of cylinder no. 1 to a point 25
mm before TDC.
 CAUTION:
Do not reuse old cylinder head bolts which
have separate washers.
72. The new bolts with integral washer may be reused
providing that the distance of 174,3 mm is not
exceeded and the cylinder head bolts show no signs of
damage.
1. New cylinder head bolts.
2. Old cylinder head bolts.

73. Position the cylinder head and tighten in the

sequence indicated.
   Fit the cylinder head gasket.

74. Tighten the cylinder head bolts (continued).

   Tighten twice through 90°.

75. Tighten the auxiliary cylinder head bolts.

Install the camshafts

 76. Bring the piston of cylinder no. 1 to a point
approximately 25 mm before TDC.
   Position of the crankshaft belt pulley/vibration
damper.

77. Install the camshafts.

CAUTION:
The piston in the first cylinder must be
approx. 25 mm in front of TDC before the
camhafts can be fitted.
CAUTION:
After installation of the camshafts, it is
imperative to wait 15 minutes before the
engine is turned.
• Oil the bearings.
1. Fit the hydraulic tappets.
2. Fit the camshafts so that none of the cams is at full
lift.
NOTE:
R is the inlet side, L is the exhaust side.

3. Fit the camshaft bearing caps so that the position

markings can be read from the rear.
• Fit the chain guide bracket with the front bearing
caps.

Install the timing chain

78. Bring the camshafts and crankshaft to TDC.

CAUTION:
Fully and partially released plungers
(whether new or used) must not be fitted.
79. Check the new chain tensioner plunger.
1. Plunger latched.
2. Plunger partially latched.
3. Plunger fully released (the detent ring is visible).
80. Install the chain tensioner plunger.
CAUTION:
Only use a new latched plunger.

81. Insert the timing chain with the chain guide.

   Do not secure the chain guide yet.

82. Fit the timing chain at the bottom.

• Slide the sprocket on approximately 10 mm.
• Lay the timing chain around the inner sprocket.
• Fit the Woodruff key in the crankshaft.

83. Tighten the timing chain guide rail bolts.

84. Install the chain tensioner.

1. Insert the chain tensioner.
2. Insert the pin.
3. Fit the circlip.
 85. Fit the timing chain at the top.
NOTE:
The timing chain must be taut on the long
side.
   If necessary, turn the camshaft slightly.

NOTE:
The timing chain may sag slightly between
the camshaft sprockets.
86. Fit the timing chain at the top (continued).

87. Clip a new upper chain guide into the bracket.

NOTE:
If the chain tensioner arm does not reach
the oil‐filled plunger, the plunger must be
released using and auxiliary tool.
88. Release the chain tensioner plunger.
   Press the chain tensioner arm down by hand and
unlatch the oil‐filled plunger.

89. Fabricate an auxiliary tool.

   Use a 120 mm length of 2,5 mm welding rod.
90. Tighten the camshaft sprockets.

NOTE:
If it is necessary to correct the valve
timings, i.e. release the timing chain, a new
oil‐filled plunger must also be fitted for the
chain tensioner.
91. Check the valve timings.
   Turn the engine in the normal direction of rotation
and line up the sprockets on the mark.

92. Additional check.

1. Turn the engine in the normal direction of rotation
to the next TDC position.
2. The markings on the camshaft sprockets must be
exactly opposite each other at the height of the
cylinder head top edge.

93. Install the oil pump drive assembly.

1. Lay the chain around the crankshaft driving
sprocket.
2. Fit the oil pump sprocket with the chain to the oil
pump.
3. Fit the chain tensioner.

94. Fit the lower timing chain cover.

NOTE:
Use a new cover with an integral gasket and
oil seal.
• Fit the cover with the centring cap.
• Tighten the bolts.
• Remove the centring cap.
 CAUTION:
Keep to the torque settings without fail. Use
Special Tool 21‐540.
95. Fit the crankshaft pulley/vibration damper.
   Immobilise the engine.

96. Fit the water pump with a new gasket.

NOTE:
The upper edge of the cover must be a
maximum of 0,13 mm below the mating face
of the cylinder head cover.
97. Fit the upper timing chain cover.

98. Connect the crankcase breather (PCV) pipe.

1. Press it into the exhaust manifold.
2. Attach the bracket to the cylinder head.
3. Connect it to the inlet manifold.
99. Fit the cylinder head cover with a new gasket (11
bolts and 4 nuts).

100. Attach the engine mounting bracket with the

engine mounting.
101. Attach the CKP sensor.
102. Attach the oil filter.

103. Attach the alternator and bracket.

104. Attach the inlet manifold bracket.

 105. Attach the EGR system.

106. Install the brackets for the air conditioning

compressor and the exhaust.

107. Detach the engine from the assembly stand.

108. Attach the engine mounting bracket with the

engine mounting.

109. Finishing operations.

   Fill up with engine oil.

Cylinder Head ‐ Remove and Install (21

Scorpio 1995 (10/1994-06/1998)
164 0)
 Print

Removal and Installation

Special Tools

15‐030A Universal flange‐

holding wrench
 21‐202 Socket, spark plug

21‐226 Pliers, spark plug

connectors

21‐540 Angle gauge

24‐003 Removing and fitting

tool, radiator hose clip

Materials
Never‐Seeze ESE‐M1244‐A
M6 x 60 bolt
Silicone grease A960‐M1C171‐AA
Coolant ESD‐M97B‐49A
Remove
1. General instructions
   Use special tool 24‐003 when removing coolant and
ventilation hoses if necessary.
2. Standard preparatory work.
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
• Remove the battery cover (one nut).
CAUTION:
Disconnect the battery earth lead.

WARNING:
Wrap a thick cloth around the coolant
expansion tank cover before opening the
cooling system when the engine is at
operating temperature in order to prevent
scalding.
3. Open the coolant reservoir.
4. Remove the resonator with the intake pipes.
1. Detach the crankcase ventilation hose.
2. Release the two hose clips.
3. Disconnect the intake air temperature (IAT) sensor
multiplug.
4. Disconnect the multiplug from the mass air flow
(MAF) sensor.
5. Disconnect the resonator from the air cleaner (two
spring band clamps).
5. Detach the engine undershield.
   Raise the vehicle.
6. Detach the oil filter.
7. Pull off the crankshaft position sensor (CKP sensor)
connector.

8. Disconnect the oil pressure switch plug.

9. Disconnect the crankcase breather (PCV) hose.

WARNING:
Danger of scalding when the engine is at
operating temperature.
10. Drain off the coolant.
• Lower the vehicle.
• Tighten the drain plug again.

11. Detach the ignition coil cover (ten bolts).

12. Detach the components on the right‐hand side of
the engine compartment:
1. Unhook the throttle cable and remove it.
2. Disconnect the coolant hose from the thermostat
housing.
3. Disconnect the coolant hose from the heater.
   Vacuum lines:
4. To evaporative emission system valve (EVAP).
5. From the variable intake system (VIS) control
motor.
6. To the solenoid (VIS+EGR).
7. To the brake servo.
WARNING:
Escaping fuel. Observe safety regulations
regarding the handling of fuel.
8. Disconnect the fuel pipes.
13. Disconnect the multiplugs.
• Detach the ignition coil cover.
1. Ignition coils.
2. Idle speed control (ISC) valve.
3. Throttle position (TP) sensor.
4. Coolant temperature display sender
5. Engine coolant temperature (ECT) sensor.
6. Injectors.
7. Withdraw the injector wiring rail.
8. Camshaft position (CMP) sensor.
 CAUTION:
Do not pull on the cable when removing the
spark plug connectors. Remove the high‐
tension lead from the ignition coil to prevent
kinks in the lead if necessary. Turn the spark
plug connectors slightly before removing
them in order to loosen the seal.
CAUTION:
Remove the spark plug connectors in a
straight line in relation to the spark plugs
(use special tool 21‐226 for offset spark plug
connectors).
14. Remove the spark plugs.
1. Disconnect the spark plug connectors.
2. Remove the ignition coils (two bolts for each).
3. Remove the spark plugs.

15. Detach the components on the left‐hand side of the

engine:
1. Dipstick tube.
2. Pull the vacuum hoses off the exhaust gas
recirculation (EGR) tubes.
3. Heat shield.
4. Exhaust gas recirculation valve (EGR valve)
5. Disconnect the catalytic converter from the exhaust
manifold.
 16. Remove the cylinder head cover
(eleven bolts, four nuts).
   Remove the gasket.
17. Remove the upper timing gear cover.
   Remove the gasket.

NOTE:
The chain guide rail must be renewed during
assembly.
18. Detach the upper chain guide rail.

19. Loosen the camshaft sprockets.

20. Set the camshaft sprockets to the marks.

 21. Remove the camshaft sprockets with the timing
chain.

22. Remove the chain tensioner arm.

1. Remove the retaining ring with a pair of pliers.
2. Withdraw the chain tensioner pivot with a bolt
(M6).
3. Remove the chain tensioner arm from the housing.

23. Slacken the chain guide bolt.

24. Remove the chain tensioner plunger.

CAUTION:
Do not re‐use the plunger.

   Tie the timing chain up to one side.

 25. Remove the camshafts.
• Detach the chain guide bracket with the front
bearing caps.
• Remove the hydraulic tappets and keep them in
order.

CAUTION:
Only reuse cylinder head bolts which have an
integral washer.
26. Cylinder head bolts, distinguishing features
1. New cylinder head bolts with integral washer.
2. Old cylinder head bolts with separate washer.

CAUTION:
Before the bolts are released, the cylinder
head must have cooled to at least 30 °C.
27. Detach the cylinder head.
NOTE:
Bolt‐slackening sequence. Release the three
auxiliary bolts first.
 28. Drain off the engine oil.
   Tighten the drain plug with a new seal ring.

Fit the cylinder head

29. General instructions
   Use special tool 24‐003 when installing the coolant
and ventilation hoses if necessary.
30. Preparatory measures.
   The mating faces of the cylinder head and cylinder
block must be dry and clean.
31. Turn the crankshaft until the piston of cylinder
no. 1 is at 25 mm before TDC.

CAUTION:
Do not use old cylinder head bolts which
have a separate washer.
32. The new bolts with integral washer may be reused
providing that 174.3 mm distance is not exceeded and
the cylinder head bolts show no signs of damage.
1. New cylinder head bolts.
2. Old cylinder head bolts.
 NOTE:
The cylinder head gasket and the cylinder
head are guided into the correct installation
position by guide sleeves.
33. Fit a new cylinder head gasket, position the
cylinder head and tighten in the sequence indicated.

34. Tighten the cylinder head bolts in two stages.

35. Tighten the auxiliary cylinder head bolts.

Install the camshafts

36. Turn the crankshaft until the piston of cylinder
no. 1 is at approx. 25 mm before TDC.
   Position of the crankshaft belt pulley/vibration
damper.
 37. Install the camshafts.
CAUTION:
Before the camshafts are installed, the
piston of cylinder no. 1 must be at a point
approx. 25 mm before TDC.
CAUTION:
After installation of the camshafts, it is
imperative to wait 15 minutes before the
engine is turned.
• Oil the bearings.
1. Fit the hydraulic tappets.
2. Fit the camshafts so that none of the cams is at full
lift.
NOTE:
R is the inlet side, L is the exhaust side.

3. Fit the camshaft bearing caps so that the position

markings can be read from the rear.
• Fit the chain guide bracket with the front bearing
caps.

Install the timing chain

38. Bring the camshafts and crankshaft to TDC.

CAUTION:
Fully and partially released plungers
(whether new or used) must not be fitted.
39. Check the new oil‐filled plunger of the chain
tensioner.
1. Plunger latched.
2. Plunger partly released.
3. Plunger fully released (the detent ring is visible).

CAUTION:
Only use a new latched plunger.

40. Install the oil‐filled plunger of the chain tensioner.

41. Tighten the chain guide bolt.

42. Install the chain tensioner.

1. Insert the chain tensioner.
2. Insert the pivot.
3. Fit the circlip.

43. Fit the camshaft timing pulley (inlet side) with the
timing chain at the top.
NOTE:
The timing chain must be taut on the long
side.
   If necessary, turn the camshaft slightly.

NOTE:
The timing chain may sag slightly between
the camshaft timing sprockets.
44. Fit the camshaft timing pulley (exhaust side) with
the timing chain at the top.

NOTE:
If the chain tensioner arm does not reach the
plunger, the plunger must be released using
an auxiliary tool.
45. Release the oil‐filled plunger of the chain
tensioner.
   Press the chain tensioner arm down by hand and
unlatch the oil‐filled plunger.
46. Fabricate an auxiliary tool.
   Use a 120 mm length of 2,5 mm welding rod.

47. Secure the camshaft sprockets.

48. Clip the new chain guide rail in the bracket at the
top.

NOTE:
If it is necessary to correct the valve timings
(timing chain must be released) a new
plunger must be fitted for the chain
tensioner.
49. Checking the valve timings.
   Turn the engine in the normal direction of rotation
and line up the sprockets on the mark.

50. Additional check.

• Turn the engine in the normal direction of rotation
to the next TDC position.
• The markings on the camshaft sprockets must be
exactly opposite each other at the height of the
cylinder head top edge.
 NOTE:
Bolt tightening sequence.

51. Fit the upper timing gear cover with a new

gasket.
NOTE:
The upper edge of the cover should be
located at no more than 0,13 mm below the
cylinder head cover mating face.
52. Fit the cylinder head cover with a new gasket
(eleven bolts, four nuts) and tighten the bolts in two
stages.

53. Install the components on the left‐hand side of the

engine.
1. Fit the catalytic converter to the exhaust manifold.
2. Fit the exhaust gas recirculation (EGR) valve in the
bracket.
3. Fit the dipstick tube.
4. Fit the exhaust manifold heat shield.
5. Connect the vacuum hoses to the exhaust gas
recirculation (EGR) pipes.
 CAUTION:
Use a blunt object to apply the silicone
grease (e.g. a plastic cable tie) so as not to
damage the spark plug connector seal.
CAUTION:
Push on the spark plug connectors in a
straight line in relation to the spark plugs.
NOTE:
Coat the inside of the spark plug connectors
with silicone grease (A960‐M1C171‐AA) down
to a depth of 5‐10 mm.
54. Fit the spark plugs, ignition coils and spark plug
connectors.
1. Spark plug
2. Ignition coils (two bolts)
3. Spark plug connectors

55. Connect the multiplugs.

1. Ignition coils.
2. ISC valve
3. TPS
4. Coolant temperature display sender
5. ECT sensor
6. Injectors.
7. CMP sensor
8. Injector wiring rail.

56. Install the components on the right‐hand side of

the engine compartment.
• Connect the fuel pipes.
   Vacuum hoses:
1. To the brake servo.
2. To the variable intake system (VIS) control motor.
3. To the solenoid (VIS+EGR).
4. To evaporative emission system valve (EVAP).
5. Fit the throttle cable and the speed control cable
and secure them.
6. Heater coolant hose.
7. Coolant hose to thermostat housing.
57. Fit the ignition coil cover.

58. Raise the vehicle.

59. Connect the crankcase breather hose.

60. Connect the oil pressure switch plug.

61. Fit a new oil filter.

62. Connect the crankshaft position (CKP) sensor
multiplug.
63. Fit the engine undershield.

64. Fit the resonator with the intake pipes.

• Lower the vehicle.
1. Install the crankcase ventilation hose.
2. Tighten the two hose clips.
 3. Fit the resonator to the air cleaner (two spring band
clips).
4. Push on the MAF multiplug.
5. Push on the IAT sensor multiplug.
65. Finishing operations:
• Top up the engine oil.
• Top up the coolant.
• Connect the battery earth lead.
• Check the routing of the vacuum hoses and the
wiring and secure them using cable ties as required.
• Enter the radio keycode and reprogramme the preset
radio stations.
• Set the clock.
• Carry out a road test to enable the PCM (EEC IV) to
collect data.
• Check the fluid levels after the road test and correct
them as necessary.

Valve Seat ‐ Cut (one) (valve removed)

Scorpio 1995 (10/1994-06/1998)
(21 231 9)
 Print

Removal and Installation

Proprietary Tools
Valve seat cutter (stopped in valve guide)
Cutters, 30°, 45°, 70° and 75°
Rework
1. Position of the angles on the valve seat ring
(exhaust valve).
1. Upper correction angle (70°)
2. Valve seat angle (45°)
3. Lower correction angle (30°)
4. Valve seat width

2. Position of the angles on the valve seat ring (inlet

valve).
1. Upper correction angle (75°)
2. Valve seat angle (45°)
3. Lower correction angle (30°)
4. Valve seat width
 NOTE:
Only use tools which locate securely in the
valve guide.
NOTE:
The procedure is shown using a proprietary
tool. Follow the instructions of the tool
manufacturer.
3. Insert the locating pin in the valve guide and
tighten.
4. Put the twist grip onto the valve seat cutter.

NOTE:
Avoid chatter marks.

5. Cutting procedure.
NOTE:
Do not remove more than 0,1 mm of
material. Otherwise, the cylinder head must
be renewed.
• Put the 45° cutter with twist grip onto the locating
pin and turn evenly in clockwise direction with light
pressure of about 2 kg.
• Repeat this procedure until an even seat surface is
produced.
6. Check the valve seat width and contact.
• Mark the valve seat ring with a pencil at four equal
intervals around the circumference .
• Insert the valve and turn it through 90°.
• The valve seat width, the position of the valve seat
surface on the valve and the evenness of the contact
surface can be determined from the spread of the
pencil marks.
• Repeat the cutting procedure if necessary.
7. Correct the position and width of the valve seat
surface.
NOTE:
The valve seat surface should lie centrally
on the seating surface of the valve seat
ring.
• The valve seat width and the position of the valve
seat surface can be changed by cutting the correction
angles as in sub‐operation
• By cutting the lower correction angle (30°), the
valve seat surface is reduced and moved in the
direction of the valve stem.
• By recutting the upper correction angle (70° or
75°), the valve seat surface is reduced and moved in
the direction of the valve head.

Valve Guide ‐ Ream (one) (valve

Scorpio 1995 (10/1994-06/1998)
removed) (21 233 4)
 Print

Removal and Installation

Special Tools

21‐212 Mounting plate

Proprietary Tools
Adjustable reamer Ø 7 ‐ 7,5 mm
Workshop Equipment
Dial indicator gauge
with magnet holder
Rework
1. Install the mounting plate and dial indicator gauge.
2. Insert a 7,0 mm Ø drill between the valve seat
ring and valve head.
3. Check the valve stem / valve guide clearance.
• Permitted valve stem / valve guide clearance
measured at valve head: inlet 0,06 ‐ 0,21 mm,
exhaust 0,12 ‐ 0,29 mm.
NOTE:
The dial indicator gauge must be at right
angles to the valve stem.
• Put the feeler of the dial indicator gauge onto the
valve head edge.
• Measure the valve stem clearance by moving the
valve from side to side.
• If necessary, renew the valve, and/or rework the
valve guide as in sub‐operation
4. Remove the dial indicator gauge, mounting plate
and drill.
CAUTION:
After reaming the valve guide, re‐cut the
valve seat as in Operation Number 21 231 9
and renew the valve.
NOTE:
Lubricate with drilling oil.

5. Ream the valve guide.

NOTE:
The specified clearance must be reached to
prevent the valve from seizing.
• Ream the valve guide in several stages with an
adjustable reamer to the appropriate oversize (see
Technical Data).

General Specifications Scorpio 1995 (10/1994-06/1998)

 Print

Specifications
Engine Data
2,5 TCI Diesel Engine
Engine management EDC
Emission standard 94 EEC/12
Fuel Diesel
Engine code SCD
Injection sequence 1‐3‐4‐2
Bore mm 92
Stroke mm 94
Cubic capacity effective cc 2498
Compression ratio 20,2 ‐ 21,7 : 1
Compression pressure at starter motor speed bar 24 ‐ 26
Power output (EEC) kW 92
Power output (EEC) at rev/min 4200
Power output (DIN) kW 92
Power output (DIN) PS 125
Power output (DIN) at rev/min 4200
Torque (EEC/DIN) Nm 293
Torque (EEC/DIN) at rev/min 2000
Idle speed rev/min 875 ± 50
Continuous engine speed rev/min 4200
Maximum engine speed rev/min 4750
Dimensions
Cylinder block and main bearing mm
housings
Number of main bearings 5
Main bearing inside ∅, front, standard 63,043 ‐ 63,088
Main bearing inside ∅, front, 1st undersize
62,793 ‐ 62,838
0,25
Main bearing inside ∅, front, 2nd undersize
62,543 ‐ 62,588
0,50
Main bearing shell width, front 31,750 ‐ 32,250
Main bearing clearance (radial), front 0,043 ‐ 0,103
Front main bearing, depth from front face 6
Main bearing inside ∅ ‐ main bearing housing,
63,050 ‐ 63,093
standard
Main bearing inside ∅ ‐ main bearing housing,
62,800 ‐ 62,843
1st undersize 0,25
Main bearing inside ∅ ‐ main bearing housing,
62,550 ‐ 62,593
2nd undersize 0,50
Main bearing shell width ‐ main bearing
29,750 ‐ 30,000
housing
Main bearing clearance (radial) ‐ main
0,030 ‐ 0,073
bearing housing
Main bearing inside ∅, rear, standard 70,050 ‐ 70,065
Main bearing inside ∅, rear, 1st undersize
69,800 ‐ 69,815
0,25
Main bearing inside ∅, rear, 2nd undersize
69,550 ‐ 69,565
0,50
Main bearing shell width, rear 31,750 ‐ 32,250
Main bearing clearance (radial), rear 0,050 ‐ 0,085
Camshaft bearing inside ∅, front 53,540 ‐ 53,590
Camshaft bearing inside ∅, centre 53,540 ‐ 53,590
Camshaft bearing inside ∅, rear 53,540 ‐ 53,590
Camshaft bearing clearance (radial) 0,030 ‐ 0,095
Dimensions
Cylinder liners mm
Cylinder liner ∅, class A 92,000 ‐ 92,010
Cylinder liner protrusion 0,00 ‐ 0,05
Thickness of shims 0,15 / 0,17 / 0,20 / 0,23 / 0,25
Dimensions
Crankshaft mm
Main bearing journal ∅, front, standard 62,985 ‐ 63,000
Main bearing journal ∅, front, 1st undersize
62,735 ‐ 62,750
0,25
Main bearing journal ∅, front, 2nd undersize
62,485 ‐ 62,500
0,50
Main bearing journal ∅  ‐   main bearing
63,005 ‐ 63,020
housing, standard
Main bearing journal ∅  ‐   main bearing
62,755 ‐ 62,770
housing, 1st undersize 0,25
Main bearing journal ∅  ‐   main bearing
62,505 ‐ 62,520
housing, 2nd undersize 0,50
Main bearing journal ∅, rear, standard 79,980 ‐ 80,000
Main bearing journal ∅, rear, 1st undersize
79,730 ‐ 79,750
0,25
Main bearing journal ∅, rear, 2nd undersize
79,480 ‐ 79,500
0,50
Big‐end bearing journal ∅, standard 53,940 ‐ 53,955
Big‐end bearing journal ∅, 1st undersize 0,25 53,690 ‐ 53,705
Big‐end bearing journal ∅, 2nd undersize 0,50 53,440 ‐ 53,440
Crankshaft end float 0,08 ‐ 0,23
Thickness of thrust washers, standard 2,311 ‐ 2,362
Thickness of thrust washers, 1st oversize 2,411 ‐ 2,462
Thickness of thrust washers, 2nd oversize 2,511 ‐ 2,562
Connecting rod bearing inside ∅, big‐end ‐
53,977 ‐ 54,016
standard
Connecting rod bearing inside ∅, big‐end ‐ 1st
53,727 ‐ 53,766
undersize 0,25
Connecting rod bearing inside ∅, big‐end ‐
53,477 ‐ 53,516
2nd undersize 0,25
Bearing shell width 22,750 ‐ 23,250
Connecting rod bearing clearance (radial),
0,022 ‐ 0,076
big‐end
Bearing inner ∅, small end 30,035 ‐ 30,050
Dimensions
Pistons mm
Piston ∅ (measured at right‐angles to the
91,935 ‐ 91,945
piston pin bore), class A
Piston ∅ (measured at right‐angles to the
91,945 ‐ 91,955
piston pin bore), class B
Piston clearance (initial installation), class A 0,055 ‐ 0,075
Piston protrusion at TDC 0,530 ‐ 0,820
Piston ring gap (fitted), upper compression
0,25 ‐ 0,50
ring
Piston ring gap (fitted), lower compression
0,20 ‐ 0,35
ring
Piston ring gap (fitted), oil control ring 0,25 ‐ 0,58
Piston ring clearance in piston groove, upper
0,080 ‐ 0,130
compression ring
Piston ring clearance in piston groove, lower
0,070 ‐ 0,102
compression ring
Piston ring clearance in piston groove, oil
0,040 ‐ 0,072
control ring
Ring gap positions: the piston ring gaps must
be evenly distributed around the
circumference of the piston. This also applies
to the elements of the oil control ring.
Stagger the ring gaps at intervals of 120°.
Piston pin type ”Floating" in piston and connecting rod
Piston pin retention Circlips
Piston pin ∅, class A 29,990 ‐ 29,993
Piston pin ∅, class B 29,993 ‐ 29,996
Piston pin clearance (radial), class A 0,039 ‐ 0,042
Piston pin clearance (radial), class B 0,057 ‐ 0,060
Dimensions
Cylinder head mm
Number of cylinder heads 4
Height of cylinder heads 89,950 ‐ 90,050
Height of end spacers 89,92 ‐ 90,000
Thickness of cylinder head gasket with piston
(Number of notch marks), 1,42 (0)
protrusion of 0.53 ‐ 0.62 mm
Thickness of cylinder head gasket with piston
1,52 (2)
protrusion of 0.63 ‐ 0.72 mm
Thickness of cylinder head gasket with piston
1,62 (1)
protrusion of 0.73 ‐ 0.82 mm
Dimensions
Camshaft mm
Valve timings ‐ inlet opens BTDC 26 °C/S
Valve timings ‐ exhaust closes ATDC 36 °C/S
Cam lift (camshaft) ‐ inlet 7,019
Cam lift (camshaft) ‐ exhaust 7,303
Thickness of thrust plate 3,950 ‐ 4,050
Camshaft end float 0,050 ‐ 0,200
Bearing journal ∅, front 53,495 ‐ 53,510
Bearing journal ∅, centre 53,450 ‐ 53,470
Bearing journal ∅, rear 53,480 ‐ 53,500
Bearing journal ∅, 1st undersize 0,25 mm 53,245 ‐ 53,260
Engine Oil
Viscosity / Ambient Name Specification
temperature
Recommended engine oil:
Ford Super Multigrade Engine ACEA A2‐96/B2‐96 or A3‐
SAE 15W40 / ‐15 to over 40°C
Oil 96/B3‐96 or API/SH/CD EC
Alternative engine oils:
SAE 5W40 / below ‐20 to over Ford Formula S Synthetic ACEA A3‐96/B3‐96 or
40°C Engine Oil API/SH/CD EC
Ford XR + High‐performance ACEA A3‐96/B3‐96 or
SAE 10W40 / ‐20 to over 40°C
High‐Lubricity Engine Oil API/SH/CD EC
Only for diesel engines: if engine oils with these specifications are not available, only use
engine oils which conform to specification API/SH/CD EC and CCMC PD2 or better.
Dimensions
Engine Lubrication bar
Oil pressure (minimum) , at idle speed 1,5
Oil pressure (oil temperature approx. 100°C) at 4000 rev/min 4,0
Pressure relief valve opening pressure 6,38
Lubricants, Adhesives and Sealers
Description Ford Specification
Coolant ESD‐M97B‐49A
Transmission fluid (MT 75) ESD‐M2C186‐A
Lubricant ‐ cylinder liner (bottom), connecting rod bolts, crankshaft SAE 15W40 API SG/CD
rear oil seal, hydraulic tappets (engine oil)
Lubricant for main and camshaft bearings, big‐end bearings, oil SQM‐2C‐9002‐AA Hypoi
pump spigot, vacuum pump spigot, timing gears d oil SAE90
SAE 15W40 ‐ API
Lubricant for M12 cylinder head bolts
SG/CD (engine oil)
SQM‐2C‐9002‐AA Hypoi
Lubricant for M14 cylinder head bolts
d oil SAE90
Lubricant for O‐rings, crankshaft thrust washers ESD‐M1C220‐A
Cylinder liner adhesive Loctite 277 WSK‐M2G351‐A7
Adhesive for oil dipstick tube, fuel injection pump studs, oilway
WSK‐M2G349‐A1
blanking plugs, piston cooling nozzles
Adhesive for coolant temperature sensors, crankshaft
WSK‐M2G349‐A7
pulley/vibration damper nut (Loctite 510)
Adhesive for pressure relief valve, cylinder block plugs WSK‐M2G348‐A5
Sealer for sump SLM‐4G9111‐A
Sealer for injectors ESEAM‐1C1014
Sealer ‐ timing cover to engine block SPM‐2G9121‐A
Ford hypoid oil SQM‐2C9002‐AA
Capacity
Litres
Engine oil, initial fill with filter 7,3
Engine oil, incl. filter change 6,6
Engine oil, excl. filter change 6,0
Coolant 7,0
Timing Belt Tension
Description
Belt tension, new (N) 332 ‐ 375
Setting of automatic belt tensioner (X) 85
Follow the instructions
to adjust the belt
tension.
Torques
General Nm lbf.ft
Hood hinge bolts 23 17
Front axle transverse brace to side members 80 59
Front axle/engine crossmember to side members, M12 80 59
Front axle/engine crossmember to side members, M10 47 35
Torques
Starter motor Nm lbf.ft
Starter motor to transmission intermediate flange 35 26
Heat shield bracket to starter motor 12 9
Torques
Inlet and exhaust manifold Nm lbf.ft
Inlet manifold to cylinder heads 32 24
Exhaust manifold to cylinder heads 32 24
Front exhaust pipe to turbocharger 45 33
Front to rear exhaust pipe 45 33
Torques
Fuel system Nm lbf.ft
Gear to fuel injection pump 88 65
Injectors 69 51
Fuel injection pipes to injectors and fuel injection pump 17 13
Fuel return pipe to fuel injection pump 27 20
Torques
Alternator Nm lbf.ft
Alternator bracket to cylinder block 47 35
Alternator to bracket ‐ lower position 28 21
Alternator to bracket ‐ upper position 47 35
Torques
Transmission Nm lbf.ft
Transmission intermediate flange to engine (M8) 27 20
Transmission intermediate flange to engine (M10) 44 32
Transmission intermediate flange to sump 37 27
Transmission housing to transmission intermediate flange 44 32
Transmission mounting bracket 44 32
Starter motor to transmission intermediate flange 35 26
Torques
Coolant circuit Nm lbf.ft
Radiator and intercooler to crossmember 23 17
Coolant collecting pipe to cylinder heads 12 9
Coolant pump to cylinder block 25 18
Coolant pipe bracket to cylinder block 27 20
Coolant expansion tank to engine 5 4
Torques
Steering Nm lbf.ft
Steering intermediate shaft to steering shaft 24 18
Power steering pump pulley 31 23
Power steering pump to bracket 21 16
Torques
Oil circuit Nm lbf.ft
Oil intake pipe bracket to cylinder block 27 20
Oil feed connection of main bearing housing in cylinder block 47 35
Sump blanking plug 35 26
Oil pipes to extension of oil filter intermediate housing 33 24
Sump to cylinder block 12 9
Oil pump to cylinder block 27 20
Rocker arm oil feed pipe to cylinder heads 13 10
Oil pipe extension to cylinder block 25 18
Rocker arm oil feed pipe to connector 23 17
Oil feed pipe to hollow retaining screw in main bearing housing 33 24
Vacuum pump oil feed pipe 23 17
Bracket of vacuum pump oil feed pipe to cylinder block 27 20
Oil filter intermediate housing to cylinder block 60 44
Oil pressure switch 32 24
Torques
Turbocharger Nm lbf.ft
Oil feed pipe to turbocharger 27 20
Heat shield to turbocharger, nuts 10 7
Heat shield to turbocharger, bolts 12 9
Torques
Vacuum pump Nm lbf.ft
Vacuum pump to cylinder block 28 21
Vacuum pump connector to cylinder block 54 40
Torques
Engine mounting Nm lbf.ft
Engine mounting to front axle/engine support bar 50 37
Right‐hand engine mounting bracket to cylinder block 47 35
Left‐hand engine mounting bracket to cylinder block 47 35
Torques
Cylinder block Nm lbf.ft
Engine mounting bracket to cylinder block 47 35
Mounting bracket 21‐031B to engine mounting bracket 47 35
Fix cylinder liners with clamps 30 22
Main bearing housings 42 31
Hollow retaining screws ‐ main bearing housings to engine block 47 35
Big‐end bearing caps, 1st stage 29 21
Big‐end bearing caps, 2nd stage 605 446
Oil seal and main bearing housing to transmission intermediate
12 9
flange
Camshaft thrust plate to cylinder block 29 21
Timing cover to cylinder block 12 9
Crankshaft pulley/vibration damper to crankshaft 196 145
Flywheel to crankshaft, 1st stage 20 15
Flywheel to crankshaft, 2nd stage 755 557
Clutch to flywheel 27 20
Fuel injection pump to cylinder block 30 22
Fuel filter retaining plate to cylinder block, M8 27 20
Fuel filter retaining plate to cylinder block, M10 47 35
Clamp bolt of automatic belt tensioner eccentric adjuster 47 35
Automatic belt tensioner bracket to cylinder block 69 51
Air conditioning compressor 25 18
Engine lifting eye 47 35
Crankshaft position sensor (CKP sensor) to transmission intermediate
12 9
flange
Torques
Cylinder heads Nm lbf.ft
Glow plugs 14 10
Cylinder head bolts M14, inner, 1st stage 30 22
Cylinder head bolts M14, inner, 2nd stage 705 520
Cylinder head bolts M14, inner, 3rd stage 705 520
Cylinder head bolts M12, outer, 1st stage 30 22
Cylinder head bolts M12, outer, 2nd stage 855 631
Pipe flange to EGR valve 27 20
Rocker shaft to cylinder heads 27 20
Cylinder head cover 15 11
Torques
Retorque cylinder head bolts Nm lbf.ft
‐1805 ‐1805
Cylinder head bolts M14, inner, 1st stage
(undo) (undo)
Cylinder head bolts M14, inner, 2nd stage 30 22
Cylinder head bolts M14, inner, 3rd stage 1305 1305
Cylinder head bolts M12, outer, 1st stage 90 66

Description and Operation Scorpio 1995 (10/1994-06/1998)

 Print

Description and Operation

Changes introduced on '97¼ MY vehicles

 Increase in power output from 85 kW (115 PS) to 92 kW (125 PS)

 Increase in torque from 270 Nm to 293 Nm
 New engine code: SCD
 Modified cylinder surfaces
 Modified piston ring groove
 Different drive belt adjustment
 Modified coolant pump
 Modified thermostat housing
 New swirl chamber inserts
1. Location of vehicle serial number/engine code
1. Serial number
2. Engine code

2. Location of engine serial number

3. Alternator
• From '97¼ model year, 120 Amp Nippon Denso
alternators will be used.
• The vacuum pump is located on the front side of the
alternator. This results in better cooling of the diode
plate and prevents any loss of power caused by the
alternator getting hot.
• The routing of the vacuum pipe and of the oil feed
pipe has been changed accordingly.
• This combination is available as a conversion kit for
all previous models.
4. Positive crankcase ventilation
• The positive crankcase ventilation system is a
completely closed system.
   All the combustion gases blowing past the piston
 rings and into the crankcase are passed back into the
air intake through a pipe from the cylinder head cover
via a positive crankcase ventilation valve integrated in
the oil separator.
   The positive crankcase ventilation feed pipe into the
air intake pipe has been moved away from the air
cleaner and into a position close to the turbocharger.
This prevents increased contamination of the mass air
flow meter (MAF).
• The positive crankcase ventilation valve near the
inlet manifold will be omitted from '97¼ model year
onwards.
Positive crankcase ventilation
Item Description
Screw connection on cylinder head
1
cover
Oil separator with integrated positive
2
crankcase ventilation valve
3 Oil return hose to sump
4 Screw connection in the sump
5 Air intake pipe
6 Mass air flow meter (MAF)
7 Air cleaner
5. Turbocharger
• The direct connection for the boost pressure
regulator will be omitted from '97¼ model year
onwards.
• It is actuated by an electric solenoid valve which is
controlled by the PCM.
6. Routing of drive belt.
• From '97¼ model year onwards, no idler pulley will
be used on engines of vehicles without air conditioning.
The drive belt is therefore shorter.
• It is adjusted as described in Operation No. 21 134
0, steps to

Routing of drive belt

Item Description
1 Alternator with vacuum pump
2 Idler pulley
3 Crankshaft pulley/vibration damper
4 Automatic belt tensioner
5 Power steering pump
6 Tensioning pulley
7 Coolant pump
8 Idler pulley
7. Cylinder head gasket
• A new, one‐piece, multi‐layer steel cylinder head
gasket will be fitted from '97¼ model year onwards.
• When fitted, it is possible to identify the type of
gasket used from the front side of cylinder head 1.
1. Multi‐part cylinder head gasket
2. One‐piece cylinder head gasket
3. Shortened spacers
• The cylinder head gaskets are available in three
different thicknesses. They are identified by the
number of notches.
   1,41 mm: no notch
   1,51 mm: two notches
   1,61 mm: one notch
• When using the one‐piece cylinder head gasket, it is
no longer necessary to retighten the cylinder head
bolts after 20 000 km.

8. Engine management
• New Bosch engine management module (PCM)
• Mass air flow meter (MAF)
• PCM‐controlled fan motors
• New electronically controlled injection pump
• PCM‐controlled boost pressure
• Modified EGR system
• Power reduction when engine overheats
• Electronic accelerator pedal
• Speed control (optional)

Engine Assembly ‐ Dismantle and

Reassemble (engine assembly removed) Scorpio 1995 (10/1994-06/1998)
(21 134 8)
 Print

Removal and Installation

Special Tools

14‐046 Remover, crankshaft

main bearing

15 033 02A Installer,

crankshaft main bearing
15‐105A Engine mounting
bracket

16‐067 Locator for clutch disc

21‐002 Splined head socket,

cylinder head bolts

21‐003 Cylinder head locating

studs

21‐031B Mounting bracket

21‐037B Pilot bearing

remover

21‐044A Installer/aligner,
pilot bearing/clutch plate

21‐051 Oil seal remover

21‐068A Engine lifting bracket

21‐128 Cylinder head guide

studs

21‐153B Remover for

vibration damper

21‐168 Crankshaft
immobilising tool

21‐175 Wrench for M14

cylinder head bolts
21‐176 Installer, radial oil
seal

21‐177 Flywheel locating

studs

21‐178 Installer, radial oil

seal

21‐179 Separator, sump

21‐181 Remover, cylinder

liner

21‐182 Cylinder liner

clamping bolts

21‐183 Measuring fixture,

cylinder liner protrusion

21‐185 Remover/installer,
crankshaft main bearing

21‐186 Crankshaft guide

sleeve

21‐540 Bolt tightening angle

gauge

23‐018 Dial indicator fixture

for fuel injection pump timing

23‐043 Wrench for injectors

23‐044 Remover, injection

pump timing pulley

24‐003 Remover/installer,
cooling hose clamp
Proprietary Tools
Description
Oil filter wrench
Dial indicators
Magnetic fixture
Internal gauge
Micrometer screw 50 ‐ 75 mm
Micrometer screw 75 ‐ 100 mm
Feeler gauges
Piston ring compressor
Workshop Equipment
Description
Assembly stand
Workshop press
Workshop hoist
Materials
Description
Obtainable through:
Replacement Services
Limited, 30 Euston
Plastigage
Street, Freemans
Industrial Estate,
Leicester LE2 7ST.
Copper oil seals for
Obtainable through:
injectors: 1,5 mm
Bosch authorised
thick with an internal
dealerships
diameter of 17,5 mm
Adhesive Loctite 277 WSK‐M2G351‐A7
Engine Oil SAE 15W40
Ford hypoid oil SAE 90 SQM‐2C9002‐AA
Lubricant ESD‐M1C220‐A
Sealer SLM‐4G9111‐A
Sealer ESEAM‐1C1014
Sealer SPM‐2G9121‐A
Adhesive WSK‐M2G349‐A7
Dismantle
1. General note.
   If necessary, use Special Tool 24‐003 when
removing coolant or vent hoses.
2. Remove the right‐hand engine mounting bracket.
3. Mount the engine on an assembly stand.
1. Fit Special Tool 15‐105A (three bolts).
2. Attach Special Tool 21‐031B to Special Tool 15‐
105A.
• Mount the engine on an assembly stand with the aid
of a workshop hoist and Special Tool 21‐068A.

NOTE:
Escaping oil.

4. Detach the turbocharger oil return hose.

1. Disconnect the oil return hose.
2. Remove the connector.
NOTE:
Escaping oil.

5. Remove the oil filter.

6. Remove the oil filter intermediate housing.

NOTE:
Remove the two blanking plugs and do not
screw them in again.
7. Drain off the engine oil.

8. Remove the left‐hand engine mounting bracket.

9. Remove the alternator with the vacuum pump.
• Disconnect the vacuum pump hose.
• Disconnect the vacuum pump oil feed pipe.
• Unscrew the bolts.

10. Remove the alternator bracket with the idler

pulley.

11. Remove the automatic belt tensioner with the

mounting plate.

12. Remove the power steering pump bracket.

13. Disconnect the hoses.
1. Withdraw the oil dipstick.
2. Positive crankcase ventilation hose
3. Oil separator return hose
4. Wiring loom retaining clip

14. Disconnect the plugs.

1. Engine coolant temperature sensor (ECT sensor)
2. Coolant temperature gauge sender
3. Detach the wiring loom retaining clip.
4. Oil pressure switch.
• Undo the cable ties.

15. Pull off the connectors and detach the wiring

loom.
1. Fuel shut‐off valve electrical connector
2. Fuel heater plug
3. Fuel injection pump timing adjusting valve
connector.
4. Detach the wiring loom retaining clip.

16. Detach the connectors from the fuel filter

mounting plate and disconnect them.
1. Crankcase position sensor (CKP sensor).
2. Plug of the injector needle lift sensor (NLS).
17. Detach the fuel return pipe and left‐hand engine
lifting eye.

18. Remove the fuel filter mounting plate complete

with the fuel heater, oil separator, oil feed pipe bracket
and wiring loom.

19. Detach the oil feed pipes from the connector.

1. Vacuum pump oil feed pipe
2. Rocker arm oil feed pipe
3. Oil feed pipe bracket

NOTE:
Escaping fuel. Close off the openings in the
injection pump and the injectors with
suitable plugs.
20. Disconnect the leak‐off hoses and remove the
injection pipes.

21. Detach the coolant pipe bracket.

22. Remove the coolant pump.
1. Disconnect the coolant hose.
2. Pull the hose out of the clip.
3. Remove the bolts (x4).

23. Disconnect the oil feed pipe from the turbocharger.

NOTE:
Stop it from turning.

24. Unscrew the turbocharger oil feed pipe from the

main bearing housing hollow retaining screw.

25. Remove the exhaust manifold with the

turbocharger.
1. Detach the pipe flange from the exhaust gas
recirculation valve (EGR valve).
2. Remove the exhaust manifold.
26. Remove the intake manifold with the EGR valve.
   Take off the intake/exhaust manifold gasket.

27. Remove the coolant collection tube with the

thermostat housing.
   Take off the gaskets.

28. Remove the rocker arm oil feed pipe.

29. Remove the cylinder head cover.

   Take off the gasket.

NOTE:
Keep the rocker shafts and push rods in
order.
30. Remove the rocker shafts.
1. Rocker shafts.
2. Push rods.
31. Remove the injectors with the special tool.
   Cut through the old seals and remove them.
32. Remove the glow plugs.

NOTE:
Bolt‐slackening sequence.

33. Unscrew and remove the cylinder head outer bolts

(M12).

NOTE:
Bolt‐slackening sequence.

NOTE:
Keep the cylinder heads and end spacers in
order.
34. Unscrew and remove the cylinder head inner bolts
(M14) and thrust elements.
• Remove the end spacers on the side.
• Remove each cylinder head in turn working from the
flywheel end of the engine.
• Remove the cylinder head gasket.
35. Remove the hydraulic tappets and aligning clips.

36. Remove the crankshaft pulley/vibration damper

bolt.
NOTE:
If necessary reverse the locking tooth of the
immobilising tool.
1. Fit the special tool.
2. Crankshaft pulley/vibration damper nut.

37. Remove the crankshaft pulley/vibration damper.

38. Remove the timing cover.

   Remove the TDC marker (if present) and the coolant
pump hose retaining clip.

CAUTION:
Take care not to damage the mating faces.
The timing cover will be bent if any other
tools are used.
39. Separate the timing cover from the cylinder block
using the special tool.
   Remove any sealer residues.
40. Remove the crankshaft front oil seal from the
timing cover with a suitable tool.
41. Remove the injection pump timing pulley nut.

42. Remove the injection pump timing pulley.

43. Remove the injection pump.

NOTE:
The gear wheel is under spring pressure.
Movable vanes can drop out.
44. Remove the vacuum pump.
45. Remove the vacuum pump connector.

NOTE:
The rotor can drop out.

46. Remove the oil pump.

47. Remove the camshaft.
• Remove the camshaft thrust plate.
• Carefully pull the camshaft out of the cylinder block.

NOTE:
Clutch disc.

48. Remove the clutch.

49. Remove the oil pipe connector.

50. Detach the CKP sensor.

51. Remove the flywheel.

CAUTION:
Do not remove the flywheel yet.

• Slacken the flywheel bolts.

• Remove three bolts.
• Remove Special Tool 21‐168.

52. Remove the flywheel (cont.).

• Screw the special tools into the flywheel.
• Remove the remaining bolts.
• Remove the flywheel.
• Remove the special tools.
• Remove the O‐ring from the flywheel.
53. Remove the crankshaft rear oil seal.
1. Take out the thrust washers.
2. Prise out the oil seal.

54. Remove the crankshaft pilot bearing.

55. Remove the transmission intermediate flange with

the oil seal/main bearing housing.
• Remove the O‐ring of the camshaft bearing.
• Remove the O‐ring of the oil seal/main bearing
housing.

56. Remove the oil seal/main bearing housing.

57. Detach the sump.

 CAUTION:
Take care not to damage the mating faces.

58. Separate the sump from the cylinder block.

   Remove any sealer residues.

59. Remove the oil intake pipe and bracket.

CAUTION:
Take care not to damage the cylinder liners.

60. Remove the carbon from the upper edges of the

cylinder bores.
   Remove the carbon ring from the top of the cylinder
bore with a proprietary scraper.

61. Remove the pistons with the connecting rods.

NOTE:
Keep the big‐end bearing shells and caps in
order.
• Remove the big‐end bearing caps.
NOTE:
Mark the pistons and cylinder liners.

• Press out the pistons with the connecting rods and

big‐end bearing shells.

62. Fit the special tool for guiding the crankshaft.

63. Slacken or remove the main bearing housing
hollow retaining screws.
1. Remove the oil pressure switch.
2. Remove the oil feed connection.
CAUTION:
Only slacken the hollow screw.

3. Slacken the hollow retaining screw.

64. Remove the main bearing housings.

CAUTION:
Prevent the crankshaft from dropping out
with a block of wood.
• Move the engine block so that it is vertical.
• Mark the installation position of the main bearing
housings in relation to the cylinder block using a
centre punch.
• Remove the hollow retaining screw.
• Push the crankshaft through until the main bearing
housings are accessible.
• Turn the cylinder block until it is horizontal.
NOTE:
Keep the main bearing housings and bearing
shells in order.
• Remove the main bearing housings.

65. Guide the crankshaft carefully out of the cylinder

block using the special tool.

66. Remove the pressure relief valve from the cylinder

block.
 67. Measure the cylinder liners.
• Clean the cylinder liners.
• Measure the cylinder liner bore at the top, in the
middle and at the bottom using a proprietary internal
gauge.
• Change the cylinder liners if necessary.

68. Remove the cylinder liners.

NOTE:
Mark the position of the cylinder liners in
relation to the cylinder block.
CAUTION:
It is essential to make sure that the special
tool is seated correctly.
   Withdraw the cylinder liners.

Assemble
69. General note.
• If necessary, use Special Tool 24‐003 when installing
coolant and vent hoses.
• All self‐locking nuts, gaskets and seals must be
renewed.
70. Preparations.
• Clean all the mating faces thoroughly.
• Clean the piston cooling oil spray nozzles in the main
bearing housings, the oilways and the pressure relief
valve.
• Renew all seals and gaskets.
71.
NOTE:
Measure the cylinder liner protrusion
separately for each cylinder.
72. Measure the cylinder liner protrusion and
determine the required shim.
NOTE:
The support and guiding surfaces of the
cylinder liner and cylinder block must be free
of dirt and oil.
• Insert the cylinder liner without the shim and O‐
rings.
• Measure the difference between the cylinder liner
and the cylinder block using the special tool and a
proprietary dial gauge.
• Choose a suitable shim according to the difference
and the specified oversize.
   Available shims: 0,15 mm; 0,17 mm; 0,20 mm;
0,23 mm; 0,25 mm.
73. Fit the cylinder liners.
CAUTION:
Extreme care and cleanliness are essential.
Do not damage the shim.
1. Fit a suitable shim (as determined in the previous
step) onto the cylinder liner.
2. Fit new O‐rings.
3. Fit a new oil proof O‐ring.
4. Apply adhesive (WSK‐M2G351‐A7) to the upper
guide surfaces of the cylinder liner.
• Apply engine oil (SAE 15W40) to the lower guiding
surfaces for the cylinder liners on the cylinder block.
NOTE:
Note the position mark when refitting the
original cylinder liners.
• Fit the cylinder liners.

CAUTION:
The adhesive takes approx. two hours to
harden.
74. Clamp the cylinder liners.
   Fit the cylinder head thrust elements using the
special tools and tighten them.

75. Measure the crankshaft main bearing shells in the

cylinder block.
• Measure the bearing shells using a proprietary
internal gauge.
• If necessary renew the main bearing shells (see
following steps).
76. Pull the main bearing shells out of the cylinder
block.

NOTE:
The oil bores in the crankshaft bearing shells
and crankshaft bearing seats must line up.
Note the installation depth of the front face.
77. Draw the crankshaft main bearing shells into the
cylinder block.
   Measure the main bearing shells after installation.

78. Measure the main bearing shell in the oil seal/main

bearing housing and remove it if necessary.
• Measure the main bearing shell.
• Press out the main bearing shell using the special
tool and a proprietary workshop press.

NOTE:
Position of the main bearing shell oil bore in
relation to the oil bore in the oil seal/main
bearing housing.
79. Install the main bearing shell in the oil seal/main
bearing housing.
NOTE:
The main bearing shell must not protrude.

• Press in the new main bearing shell using the special

tool on a proprietary workshop press until the special
tool reaches the stop.
• After installation, measure the main bearing shell in
accordance with the following step.
80. Measure the main bearing shells in their housings
and renew them as necessary.
NOTE:
There are notch marks. Do not assemble
the main bearing housings back to front.
1. Lay the main bearing shells dry in the housing to
which they belong and assemble the housing.
2. Measure the bearing shells using a proprietary
internal gauge.
• Renew the bearing shells if necessary.
81. Measure the camshaft bearing shells in the
cylinder block and renew them as necessary.

82. Measure the main bearing journal running

surfaces with a proprietary micrometer.
   Repeat the test at an angle of 90°.

83. Measure the running surfaces of the camshaft

journals using a proprietary micrometer.

84. Install the pressure relief valve in the cylinder

block.
   Coat the sliding faces of the pressure relief valve
with engine oil (SAE 15W40).

85. Insert the crankshaft.

• Coat all the main bearing shells and main bearing
journals with Ford hypoid oil (SQM‐2C9002‐AA).
• Carefully guide the crankshaft into the cylinder block
using the special tool.
86. Install the main bearing housings.
NOTE:
Notch marks on the main bearing housing
halves.
NOTE:
Aim the piston cooling oil splash nozzles at
the preceding cylinder.
• Fit the main bearing housings with the corresponding
lubricated main bearing shells.
NOTE:
The hole in the main bearing housing must
point upwards; the notch marks must line up.
• Turn the bearing housings into position.
87. Fit the crankshaft in the cylinder block.
• Turn the engine block so that it is vertical.
NOTE:
The bores for the hollow retaining screws in
the cylinder block and in the main bearing
housings must line up.
• Install the main bearing housings using their own
weight and light blows from a brass drift.

88. Fit the main bearing housing hollow retaining

screws.
NOTE:
Use new seals.

1. Oil pressure switch.

2. Oil feed connection for main bearing housings
3. Hollow retaining screw

89. Remove the special tool.

90. Check the piston ring gaps.

   Renew the piston rings on reaching the specified
maximum wear.
91. Dismantle and assemble the pistons and
connecting rods.
NOTE:
The piston pin ”floats" in the piston and
connecting rod.
• Remove the circlips and drive out the piston pin.
• Check that the piston, piston pin and connecting rod
dimensions are as specified and renew as necessary.
• Insert the piston pin in the piston and connecting rod
and fit the circlips.
1. Fit the trapezoid compression ring with the TOP
marking uppermost.
2. Fit the tapered‐face compression ring with the
chamfer facing downwards.
3. Assemble and fit the oil control ring.

92. Install the piston with the connecting rod.

• Lubricate the pistons and cylinder liners with engine
oil (SAE 15W40).
• Spread the piston ring gaps evenly around the
circumference. This also applies to the elements of the
oil control ring.
• Compress the piston rings using a proprietary piston
ring compressor.
• Press the piston into the cylinder liner with the
handle of a hammer, guiding the connecting rod on to
the big‐end bearing journal.
NOTE:
The combustion chamber in the piston and
the matching numbering on the connecting
rod should face towards the camshaft side.
• Make sure the corresponding bearing shells are clean
and dry and place them in the connecting rod.
93. Preparation for measuring the big‐end bearing
clearance.
NOTE:
The following steps must be carried out
exactly as described.
• Measure each big‐end bearing area separately with a
length of Plastigage thread.
• In each case, only fit the bearing cap to be
measured, and tighten it to the specified torque.
• The measurement should be made as close as
possible to the TDC position of that bearing.
• The big‐end bearing shells and journals must be
clean and oil free.
• Lay a length of Plastigage thread across the bearing
journal.
 94. Measure the big‐end bearing clearance.
• Install the unoiled big‐end bearing cap with the
matching bearing shell and torque it down in two
stages.
NOTE:
The numbers on the connecting rod and
bearing cap must match and must both
point towards the camshaft side.
• Remove the big‐end bearing cap.

95. Compare the width of Plastigage thread with the

Plastigage scale.
• The scale reading corresponds to the bearing
clearance.
• Renew the big‐end bearing shells and regrind the
bearing journals as necessary.

NOTE:
The corresponding numbers on the
connecting rods and the bearing caps point
towards the camshaft side.
96. Fit the big‐end bearing caps.
• Lubricate the big‐end bearing shells and journals
with Ford hypoid oil (SQM‐2C9002‐AA).
• Tighten the big‐end bearing shells and the matching
bearing shells in two stages.

NOTE:
The two new O‐rings must be correctly
seated.
97. Install the oil intake pipe and bracket.

NOTE:
Installation position of the oil splash nozzle.
The pattern of the bolt holes governs the
direction of the jet for piston cooling.
98. Fit the oil seal/main bearing housing to the
transmission intermediate flange.
99. Fit the sump.
• Apply sealer (SLM‐4G9111‐A) to the cylinder block.
• Locate the sump in place and tighten the bolts finger
tight.

100. Fit the transmission intermediate flange with the

oil seal/main bearing housing.
• Fit new O‐rings for the oil seal/main bearing housing
and the camshaft bearing.
• Apply high‐temperature grease (ESD‐M1C220‐A) to
the camshaft bearings and O‐rings.
• Centre the transmission intermediate flange with
the locating sleeves and attach it.

NOTE:
Tightening sequence.

101. Tighten the sump bolts.

102. Tighten the retaining plugs.

103. Fit a new crankshaft pilot bearing.

NOTE:
The sealing lip must remain dry.

NOTE:
Moisten the outer edge of the oil seal with
engine oil (SAE 15W40).
104. Fit the crankshaft rear oil seal.
• Draw in the new oil seal evenly using the special tool
and two flywheel bolts.
• Remove the special tool.
105. Fit the flywheel.
• Apply high‐temperature grease (ESD‐M1C220‐A) to
the thrust washers and lay them in the oil seal/main
bearing housing with the lubricating groove facing
outwards.
• Screw in the special tools.
NOTE:
The locating sleeve and hole must line up.

• Fit the flywheel in place using a new O‐ring.

• Coat the underside of the bolt heads with engine oil
(SAE 15W40) and screw in three bolts.
• Unscrew the special tools.
106. Tighten the flywheel bolts.
• Engage Special Tool 21‐168 in the flywheel teeth.
• Screw in the remaining bolts.
• Tighten the bolts in two stages working diagonally.

107. Check the crankshaft end float.

• Set up a dial indicator.
• Measure the end float by lifting the flywheel as
shown.
• Correct the end float as necessary using thrust
washers at the oil seal/main bearing housing.
108. Fit the CKP sensor with a new O‐ring.

109. Centre the clutch disc on the pressure plate.

110. Fit the clutch.

• Fit the clutch pressure plate with the centred clutch
disc.
• Tighten the bolts uniformly, working diagonally.
• Remove the special tool.

111. Install the camshaft.

• Lubricate the camshaft bearing and running faces
with Ford hypoid oil (SQM‐2C9002‐AA).
• Carefully guide the camshaft into the cylinder block.
• Secure the camshaft in the cylinder block with the
thrust plate.

112. Check the camshaft end float.

• Set up a proprietary dial indicator.
• Measure the end float by lifting the camshaft with a
screwdriver.
• Adjust the end float as necessary by renewing the
thrust plate.
113. Fit the oil pump.
• Fit a new O‐ring and coat it thinly with engine oil.
NOTE:
Install the rotor with the dot mark pointing
towards the pump.
• Coat the oil pump spigot with Ford hypoid oil (SQM‐
2C9002‐AA) and install the oil pump.

114. Install the vacuum pump.

• Lubricate the moving internal parts of the vacuum
pump and vacuum pump spigot with Ford hypoid oil
(SQM‐2C9002‐AA).
NOTE:
The teeth on the crankshaft, vacuum pump
and camshaft gear wheels must be aligned
so that each single dot is in between the
corresponding two dots.
• Lubricate the new vacuum pump O‐ring with engine
oil and install the vacuum pump with the O‐ring.
• Fit the vacuum pump connector with new seals.
115. Fit the injection pump.
NOTE:
The Woodruff key on the injection pump shaft
must be at 11 o'clock. If necessary, fit the
gear wheel in order to turn the injection
pump shaft.
   Put the injection pump in place using a new gasket
and screw on the nuts (x3) finger‐tight. Tighten the
one bolt that is easily accessible.

116. Fit the injection pump gear wheel.

NOTE:
The tooth with the B mark on the injection
pump gear wheel must be exactly in between
the two dot marks on the camshaft gear
wheel.
   Lubricate the timing gears with Ford hypoid oil
(SQM‐2C9002‐AA).

117. Fit the timing cover with the TDC marker (if
equipped) and the clip for the coolant pump hose.
• Fit the new crankshaft O‐ring.
• Apply a thin coating of sealer (SPM‐2G9121‐A) to
the cylinder block mating face.
1. Bolts M6
2. Bolt M8
 NOTE:
The oil seal should be unoiled and fitted with
care.
118. Fit the crankshaft front oil seal.

119. Fit the crankshaft pulley/vibration damper.

NOTE:
Apply adhesive (WSK‐M2G349‐A7) to the
thread of the crankshaft nut.
1. Install the crankshaft pulley/vibration damper.
2. Detach the special tool.

120. Unscrew the rear timing adjustment blanking

plug from the injection pump.

121. Screw the special tool into the injection pump.

122. Fit the dial indicator to the special tool and

tighten it.

Engines with a cast iron transmission adaptor plate only

 123. Turn the injection pump towards the cylinder
block.
124. Set cylinder no. 1 to TDC using Special Tool 21‐
183 and the dial indicator.
125. Adjust the injection pump timing.
• Turn the crankshaft approx. 30° anti‐clockwise until
the pointer on the dial gauge for injection timing
adjustment on Special Tool 23‐018 reaches its
maximum deflection.
• Zero the timing dial indicator.
• Turn the crankshaft clockwise until cylinder no. 1 is
at TDC.
Engines with a cast iron transmission adaptor plate only
126. Adjust the injection pump timing (cont.).
   Align the single hole (5 mm) in the flywheel with the
lower hole in the cast iron transmission adaptor plate.

Engines with an aluminium transmission adaptor plate only

NOTE:
Check that the fixed TDC mark on the timing
cover and the movable TDC mark on the
crankshaft vibration damper are in the
correct position.
127. Turn the injection pump towards the cylinder
block.
128. Set cylinder no. 1 to TDC using Special Tool 21‐
183 and the dial indicator.

Engines with an aluminium transmission adaptor plate only

NOTE:
Bearing clearances. The crankshaft must not
be turned back for TDC setting.
129. Adjust the injection pump timing.
• Turn the crankshaft through approx. 45° anti‐
clockwise.
NOTE:
The pointer on the timing dial indicator on
Special Tool 23‐018 must not move any
more.
• Zero the timing dial indicator.
• Turn the crankshaft clockwise until cylinder no. 1 is
at TDC.
130. Adjust the injection pump timing (cont.).
• Turn the injection pump until the injection timing dial
gauge displays the following value
   up to 97 MY¼: 0,65 mm ± 0,02 mm
   from 97 MY¼: 0,55 mm ± 0,02 mm
• Tighten the injection pump nuts to 30 Nm (x3).
• Check the setting on the timing dial indicator by
turning the crankshaft back and forth to the TDC
position for cylinder no. 1; repeat the adjustment
procedure if necessary.
• Remove Special Tool 23‐018 with the dial indicator
and screw in the blanking plug with a new oil seal.
NOTE:
The adhesive used to stick the cylinder liners
must have had two hours to harden.
131. Remove the cylinder liner thrust elements.

132. Insert the hydraulic tappets and aligning clips.

   Coat the tappets with engine oil (SAE 15W40).

133. Measure the piston protrusion and determine the

size of cylinder head gasket required.
• Measure the piston protrusion of each individual
cylinder at TDC using the special tool and a proprietary
dial indicator.
• Measure the difference between the piston crown
and the cylinder block.
NOTE:
One measurement should be made for each
cylinder on the axis of the piston pin at a
distance of 5 mm from the edge of the
piston.
• The largest measurement determines the choice of
cylinder head gasket:
NOTE:
The thickness of the cylinder head gasket is
identified by the number of notch marks.
   If the piston protrusion is 0,53 to 0,62 mm, choose a
1,42 mm thick cylinder head gasket (no notches).
   If the piston protrusion is 0,63 to 0,72 mm, choose a
1,52 mm thick cylinder head gasket (two notches).
   If the piston protrusion is 0,73 to 0,82 mm, choose a
1,62 mm thick cylinder head gasket (one notch).
   
 NOTE:
Shared multi‐layer cylinder head gasket for
all cylinder heads.
134. Fit the new cylinder head gasket.
1. Indicator of cylinder head gasket thickness
2. Writing faces upwards.
3. Screw in the special tools.

135. Fit the cylinder heads.

NOTE:
Make sure that the thrust elements are
positioned correctly. With used cylinder
heads take the imprint as a guide.
• Guide the cylinder heads over the special tools and
fit them.
• Coat the undersides of the cylinder head bolt heads
and the threads with Ford hypoid oil (SQM‐2C9002‐
AA).
1. Fit the end spacer.
2. Lay the thrust elements in place and screw in the
inner M14 cylinder head bolts.
136. Fit the cylinder heads (cont.).
NOTE:
Make sure that the pressure pads are
positioned correctly. With used cylinder
heads take the imprint as a guide.
• Coat the undersides of the cylinder head bolt heads
and the threads with Ford hypoid oil (SQM‐2C9002‐
AA).
1. Transfer the special tools and fit the cylinder
heads.
2. Screw in the outer M12 cylinder head bolts.
3. Fit the end spacer.
• Lay the thrust elements in place and screw in the
inner M14 cylinder head bolts.
• Unscrew the special tools and screw in the outer
M12 cylinder head bolts.
NOTE:
Do up the retaining nuts lightly to align the
cylinder heads.
137. Fit the inlet manifold without a gasket.
 NOTE:
Bolt‐tightening sequence.

138. Pre‐tighten the inner M14 cylinder head bolts.

NOTE:
Retighten all the cylinder head bolts after
approx. 30 minutes' running time as
described in Operation No. 21 161 0.
NOTE:
Bolt‐tightening sequence.

139. Tighten the inner M14 cylinder head bolts in two

stages.
 NOTE:
Retighten all the cylinder head bolts after
approx. 30 minutes' running time as
described in Operation No. 21 161 0.
NOTE:
Bolt tightening sequence.

140. Tighten the outer M12 cylinder head bolts on the

injection side in two stages.

NOTE:
Retighten all the cylinder head bolts after
approx. 30 minutes' running time as
described in Operation No. 21 161 0.
NOTE:
Bolt‐tightening sequence.

141. Tighten the outer M12 cylinder head bolts on the

exhaust side in two stages.
142. Remove the inlet manifold.

NOTE:
Fit the injector with the NLS in cylinder no. 1.

143. Install the injectors and glow plugs.

• Fit new copper oil seals (with a thickness of 1,5 mm
and an internal diameter of 17,5 mm) to the injectors.
• Apply sealer (ESEAM‐1C1014) to the injector
threads.
 CAUTION:
Do not turn the engine for 15 minutes.

144. Fit the rocker shafts.

NOTE:
Rotate the crankshaft to 20° before TDC.

NOTE:
Keep to the removal sequence.

1. Insert the push rods.

2. Coat the nuts with Ford hypoid oil (SQM‐2C9002‐
AA) and tighten them.
145. Fit the cylinder head cover with a new gasket.

146. Fit the rocker arm oil feed pipe using new seals.

147. Fit the coolant collection pipe with the

thermostat housing and new gaskets.

NOTE:
The inlet and exhaust manifolds have a
shared gasket.
148. Fit the inlet manifold with the new inlet/exhaust
manifold gasket.
149. Fit the coolant pump.
1. Install the coolant pump with a new gasket.
2. Fit the coolant hose.
3. Guide the hose into the clip.

150. Install the exhaust manifold with the

turbocharger.
1. Tighten the exhaust manifold nuts.
2. Attach the pipe flange to the EGR valve with a new
gasket.

NOTE:
Stop it from turning.

151. Connect the oil feed pipe to the main bearing

housing hollow retaining screw.

152. Connect the oil feed pipe to the turbocharger

using new oil seals.
153. Attach the coolant pipe bracket.

154. Fit the injector pipes and the leak‐off pipes.

155. Connect the oil feed pipes to the connector using

new oil seals.
1. Rocker arm oil feed pipe
2. Vacuum pump oil feed pipe
3. Bracket of oil feed pipe

NOTE:
Retaining clip for CKP sensor cable.

156. Install the fuel filter mounting plate complete

with the fuel heater, oil separator, oil feed pipe bracket
and wiring loom.

157. Attach the fuel return pipe and the left‐hand

engine lifting eye.
158. Connect the plugs and fit them to the fuel filter
mounting plate.
1. CKP sensor plug
2. NLS plug

159. Fit the wiring loom and connect the plugs.

1. Fuel shut‐off valve electrical connector
2. Fuel heater plug
3. Plug of timing adjustment valve
4. Attach the wiring loom retaining clip.

160. Connect the plugs.

1. Engine coolant temperature (ECT) sensor
connector.
2. Coolant temperature gauge sender connector.
3. Fit the wiring loom retaining clip.
4. Oil pressure switch connector.
• Secure the lead using cable ties.

161. Connect the hoses.

1. Insert the oil dipstick.
2. Crankcase ventilation hose
3. Attach the wiring loom retaining clip.
4. Oil separator oil return hose to sump.
162. Install the alternator bracket with the idler pulley.

163. Install the automatic belt tensioner with the

retaining plate.

164. Install the alternator with the vacuum pump.

• Screw in the bolts.
• Connect the vacuum pump hose.
• Connect the vacuum pump oil feed pipe.

165. Install the right‐hand engine mounting bracket.

166. Detach the engine from the assembly stand.

• Lift the engine off the assembly stand with the
workshop hoist and Special Tool 21‐068A and place it
down.
1. Detach Special Tool 21‐031B.
2. Detach Special Tool 15‐105A.
 167. Install the oil filter intermediate housing.
   Coat the new O‐ring with engine oil (SAE15W40).

168. Install the oil filter.

   Coat the rubber seal of the new oil filter with engine
oil (SAE15W40). Screw on the oil filter finger‐tight.
169. Fit the turbocharger oil return hose to the
cylinder block.
NOTE:
The connector must point in the direction of
the turbocharger oil return hose.
1. Fit the connector.
2. Connect the oil return hose to the connector.

170. Fit the left‐hand engine mounting bracket.

171. Finishing operations.

   Turn the engine over three times to check there is
no contact between the pistons and the valves.

Cylinder Heads (all) ‐ Remove and Install

Scorpio 1995 (10/1994-06/1998)
(21 164 0)
 Print

Removal and Installation

Special Tools

21‐002 Splined head socket,

cylinder head bolts

21‐003 Cylinder head locating

studs

21‐128 Cylinder head guide

studs

21‐175 Wrench for M14

cylinder head bolts
 21‐183 Measuring fixture,
cylinder liner protrusion

21‐540 Bolt tightening angle

gauge

23‐043 Wrench for injectors

Materials
Description
Copper seals for
injectors: 1,5 mm Obtainable through:
thick and with an Bosch authorised
inside diameter of dealerships
17,5 mm.
Ford hypoid oil SQM‐2C9002‐AA
Sealer ESEAM‐1C‐1014‐A
Coolant ESD‐M97B‐49A
Proprietary Tools
Description
Dial indicator
Remove
1. Preparatory measures:
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
• Detach the battery cover.
CAUTION:
Disconnect the battery negative lead.

WARNING:
Danger of scalding if the engine is warm.

• Open the coolant expansion tank.

2. Raise the vehicle.
3. Remove the front engine undershield.
 WARNING:
Danger of scalding if the engine is warm.

4. Drain off the coolant.

   Screw the screw plug back in again once the coolant
has been drained off.
5. Lower the vehicle.

6. Remove the coolant expansion tank.

1. Detach the hose from the coolant collection pipe.
2. Detach the two hoses.
3. Disconnect the plug from the engine coolant level
sensor (ECL sensor) (if equipped).
4. Remove the bolts.

7. Remove the turbocharger heat shield.

   Unclip the hoses.

8. Remove the air hose between the inlet manifold and

the intercooler.

9. Detach the intake pipe from the turbocharger.

10. Detach the coolant hose and disconnect the
vacuum hose.

11. Detach the heater hose from the coolant collecting

pipe.

12. Disconnect the two vacuum hoses.

13. Disconnect the hoses.

1. Coolant hose
2. Intercooler air hose

14. Detach the front exhaust pipe from the

turbocharger.
15. Detach the turbocharger oil feed pipe.

16. Remove the exhaust manifold and turbocharger.

1. Detach the pipe flange from the exhaust gas
recirculation valve (EGR valve).
2. Detach the exhaust manifold and remove it.

17. Remove the coolant collection pipe with the

thermostat housing.
   Disconnect the coolant hose.

18. Remove the intake manifold and EGR valve.

   Remove the intake/exhaust gasket.

19. Remove the rocker arm oil feed pipe.

1. Oil supply to oil feed pipe.
2. Rocker arm oil feed pipe.
20. Pull out the plugs of the engine coolant
temperature sensor (ECT sensor) and coolant
temperature sender unit.

21. Disconnect the glow plug connectors.

22. Remove the left‐hand injector pipes.

   Release and remove the retaining clip.

23. Remove the right‐hand injector pipes.

24. Remove the cylinder head cover and hoses.

• Withdraw the oil dipstick.
1. Disconnect the leak‐off hoses.
2. Detach the crankcase ventilation hose.
3. Remove the bolts.
25. Pull off the connector for the injector needle lift
sensor (NLS).

NOTE:
Keep the rocker shafts and push rods in
order.
26. Remove the rocker shafts.
1. Rocker shafts.
2. Push rods.

27. Remove the injectors.

   Cut through the old oil seals and dispose of them.
28. Remove the glow plugs.

NOTE:
Bolt‐slackening sequence.

29. Remove the outer M12 cylinder head bolts.

 NOTE:
Bolt‐slackening sequence.

30. Unscrew the inner cylinder head bolts (M14) and

remove the thrust elements.
NOTE:
Keep the cylinder heads and end spacers in
order.
• Remove the end spacers on the side.
• Working from the flywheel end, remove the cylinder
heads one after the other.
• Remove the cylinder head gasket.

Install
31. Measure the piston protrusion and determine the
size of cylinder head gasket required.
• Measure the piston protrusion for each individual
cylinder in the TDC position using the special tool and
a proprietary dial indicator.
• Measure the difference between the piston crown
and the cylinder block.
NOTE:
One measurement should be made for each
cylinder on the axis of the piston pin at a
distance of 5 mm from the edge of the
piston.
• The largest measurement determines the choice of
cylinder head gasket:
NOTE:
The thickness of the cylinder head gasket is
identified by the number of notch marks.
   If the piston protrusion is 0,53 to 0,62 mm, choose a
1,42 mm thick cylinder head gasket (no notches).
   If the piston protrusion is 0,63 to 0,72 mm, choose a
1,52 mm thick cylinder head gasket (two notches).
   If the piston protrusion is 0,73 to 0,82 mm, choose a
1,62 mm thick cylinder head gasket (one notch).
   
NOTE:
Shared multi‐layer cylinder head gasket for
all the cylinder heads.
32. Fit the new cylinder head gasket.
1. Indicator of cylinder head gasket thickness
2. Writing faces upwards.
3. Screw in the special tools.
33. Fit the cylinder heads.
NOTE:
Correct position of the thrust elements. With
used cylinder heads, take the imprint as a
guide.
• Guide the cylinder heads over the special tools and
put them in place.
• Coat the undersides of the cylinder head bolt heads
and the threads with Ford hypoid oil (SQM‐2C9002‐
AA).
1. Fit the end spacer.
2. Put the thrust elements in place and screw in the
inner (M14) cylinder head bolts.
34. Fit the cylinder heads (cont.).
NOTE:
Make sure that the pressure pads are
positioned correctly. With used cylinder
heads take the imprint as a guide.
• Coat the undersides of the cylinder head bolt heads
and the threads with Ford hypoid oil (SQM‐2C9002‐
AA).
1. Transfer the special tools and put the cylinder
heads in place.
2. Screw in the outer M12 cylinder head bolts.
3. Fit the end spacer.
• Lay the thrust elements in place and screw in the
inner M14 cylinder head bolts.
• Unscrew the special tools and screw in the outer
M12 cylinder head bolts.
NOTE:
Do up the retaining nuts lightly to align the
cylinder heads.
35. Fit the inlet manifold without a gasket.
 NOTE:
Bolt‐tightening sequence.

36. Pretighten the inner (M14) cylinder head bolts.

NOTE:
Retighten all the cylinder head bolts after
approx. 30 minutes' running time as
described in Operation No. 21 161 0.
NOTE:
Bolt‐tightening sequence.

37. Tighten the inner M14 cylinder head bolts in two

stages.
 NOTE:
Retighten all the cylinder head bolts after
approx. 30 minutes' running time as
described in Operation No. 21 161 0.
NOTE:
Bolt tightening sequence.

38. Tighten the outer (M12) cylinder head bolts on the

injection side in two stages.

NOTE:
Retighten all the cylinder head bolts after
approx. 30 minutes' running time as
described in Operation No. 21 161 0.
NOTE:
Bolt‐tightening sequence.

39. Tighten the outer M12 cylinder head bolts on the

exhaust side in two stages.
40. Remove the inlet manifold.

NOTE:
Install the injector with the NLS in cylinder
no. 1.
41. Install the injectors.
• Fit new copper oil seals (with a thickness of 1,5 mm
and an internal diameter of 17,5 mm) on the injectors.
• Apply sealer (ESAM‐1C‐1014‐A) to the injector
threads.
• Tighten the injectors with the new oil seals.
42. Install the glow plugs.
 CAUTION:
Do not turn the engine for 15 minutes.

43. Install the rocker shafts.

NOTE:
Rotate the crankshaft to 20° before TDC.

NOTE:
Keep to the installation sequence.

1. Insert the push rods.

2. Coat the nuts with Ford hypoid oil (SQM‐2C9002‐
AA) and tighten them.
44. Connect the connector of the injector NLS and
press it into the bracket.

45. Install the cylinder head cover and the hoses.

1. Install the cylinder head cover using a new gasket.
2. Fit the crankcase ventilation hose on the cylinder
head cover.
3. Connect the leak‐off hoses.
• Insert the oil dipstick.

46. Fit the right‐hand injector pipes.

47. Fit the left‐hand injector pipes.

   Fit the retaining clip.
48. Connect the glow plug connectors.

49. Connect the plugs to the ECT sensor and coolant

temperature sender unit.

50. Install the rocker shaft oil feed pipe with new oil
seals.
1. Rocker shaft oil feed pipe.
2. Oil supply oil feed pipe.

NOTE:
The inlet and exhaust manifolds have a
shared gasket.
51. Install the inlet manifold with a new inlet/exhaust
manifold gasket.

52. Fit the coolant collection pipe and thermostat

housing using new gaskets.
   Connect the coolant hose.
 53. Install the exhaust manifold with turbocharger.
1. Exhaust manifold nuts.
2. Attach the pipe flange to the EGR valve.

54. Install the turbocharger oil feed pipe using new

seals.

55. Connect the front exhaust pipe to the turbocharger

using a new gasket.

56. Connect the hoses.

1. Intercooler air hose
2. Coolant hose

57. Connect the two vacuum hoses.

58. Connect the heater hose to the coolant collector
pipe.

59. Fit the coolant hose and connect the vacuum hose.

60. Connect the intake pipe to the turbocharger.

61. Fit the air hose between the inlet manifold and the
intercooler.

62. Attach the turbocharger heat shield.

   Clip the hoses in place.
 63. Fit the coolant expansion tank.
1. Screw in the bolts.
2. Connect the plug for the ECL sensor (if equipped).
3. Connect the hoses.
4. Connect the coolant hose to the coolant collecting
pipe.

NOTE:
Retighten the cylinder head bolts at operating
temperature as described in Operation No. 21
161 0.
64. Finishing operations.
• Fill up with coolant (ESD‐M97B‐49A).
• Connect the battery negative lead.
• Fit the battery cover.
• Check the routing of the vacuum hoses and the
wiring and secure them using cable ties as required.
• Remove the air from the cooling system.
• Check the fluid levels and rectify as necessary.
• Check the engine and cooling system for leaks
(visual check).
• Enter the radio keycode.
• Reprogram the preset radio stations.
• Reset the clock.
65. Raise the vehicle.
66. Fit the front engine undershield.
67. Lower the vehicle.
68. Carry out a road test to enable the PCM to gather
data.

General Specifications Scorpio 1995 (10/1994-06/1998)

 Print

Specifications
Engine Data
General
Emission standard 93EEC
Identification code BRG
Firing order 1‐4‐2‐5‐3‐6
Bore mm 93,03
Stroke mm 71,99
Cubic capacity cm3 2936
Compression ratio 9,0 : 1
Power output (EEC) kW 107
PS 145
at rev/min 5500
Torque (EEC) Nm 168
at rev/min 2500
 Continuous
Max. permissible engine speed 5800
rev/min
Intermittent
5800
rev/min
Spark plugs AGRF 32C1
Dimensions
Cylinder block
Cast mark F
Cylinder bore diameter, standard class 1 mm 93,010 ‐ 93,020
Cylinder bore diameter, standard class 2 mm 93,020 ‐ 93,030
Cylinder bore diameter, standard class 3 mm 93,030 ‐ 93,040
Cylinder bore diameter, standard class 4 mm 93,040 ‐ 93,050
Cylinder bore diameter, oversize class A mm 93,520 ‐ 93,530
Cylinder bore diameter, oversize class B mm 93,530 ‐ 93,540
Cylinder bore diameter, oversize class C mm 93,540 ‐ 93,550
Cylinder bore diameter, service standard mm 93,040 ‐ 93,050
Cylinder bore diameter, oversize 0,5 mm 93,540 ‐ 93,550
Cylinder bore diameter, oversize 1,0 mm 94,040 ‐ 94,050
Installed main bearing shells, vertical Ø, standard mm 57,008 ‐ 57,042
Installed main bearing shells, vertical Ø, undersize
mm 56,754 ‐ 56,788
0,254
Centre main bearing width mm 22,610 ‐ 22,660
Number of main bearings 4
Main bearing parent bore diameter, standard mm 60,620 ‐ 60,634
Main bearing parent bore diameter, oversize 0,38 mm 61,000 ‐ 61,014
Camshaft bearing parent bore diameter, front mm 47,025 ‐ 47,060
Camshaft bearing parent bore diameter (without
mm 46,645 ‐ 46,680
bearing bushes), middle 1
Camshaft bearing parent bore diameter, middle 2 mm 46,265 ‐ 46,300
Camshaft bearing parent bore diameter, rear mm 45,885 ‐ 45,920
Dimensions
Crankshaft
Main bearing journal diameter, standard mm 56,980 ‐ 57,000
Main bearing journal diameter, undersize 0,254 mm 56,726 ‐ 56,746
Main bearing journal to shell clearance mm 0,008 ‐ 0,056
Centre main bearing shoulder width, standard mm 26,390 ‐ 26,440
Centre main bearing shoulder width, oversize 0,38 mm 26,771 ‐ 26,821
Flanged bearing shell width, standard mm 26,190 ‐ 26,260
Flanged bearing shell width, oversize 0,38 mm 26,570 ‐ 26,640
End float mm 0,080 ‐ 0,240
Big‐end bearing journal diameter, standard mm 53,980 ‐ 54,000
Big‐end bearing journal diameter, undersize 0,254 mm 53,726 ‐ 53,746
Big‐end bearing journal to shell clearance mm 0,006 ‐ 0,064
Dimensions
Pistons
Piston diameter, standard 1 mm 92,972 ‐ 92,982
Piston diameter, standard 2 mm 92,982 ‐ 92,992
Piston diameter, standard 3 mm 92,992 ‐ 93,002
Piston diameter, standard 4 mm 93,002 ‐ 93,012
Piston diameter, service standard mm 93,000 ‐ 93,020
Piston diameter, service oversize 0,5 mm 93,500 ‐ 93,520
Piston diameter, service oversize 1,0 mm 94,000 ‐ 94,020
Piston clearance in bore (unused) mm 0,028 ‐ 0,048
Piston ring gaps (fitted), top mm 0,030 ‐ 0,050
Piston ring gaps (fitted), middle mm 0,030 ‐ 0,050
bottom 0,400 ‐ 1,400
Ring gap position, top (from the expander ring gap) 150°
150° from the
expander ring gap
Ring gap position, middle
(opposite the top
compression ring)
25 mm from the
Lower oil control ring, top intermediate ring
expander ring gap
opposite the
Expander marked side of
the piston
25 mm from the
expander ring gap
Lower intermediate ring
(opposite the top
intermediate ring)
Dimensions
Piston Pins
Pin diameter, red mm 23,994 ‐ 23,997
Pin diameter, blue mm 23,997 ‐ 24,000
Clearance in piston mm 0,005 ‐ 0,011
Interference fit in small‐end bore mm 0,018 ‐ 0,042
Dimensions
Connecting rods
Bore diameter (without bearing shells), big end mm 56,820 ‐ 56,840
Bore diameter (without bearing shells), small end mm 23,958 ‐ 23,976
Fitted big‐end bearing shells, vertical inside diameter,
mm 54,006 ‐ 54,046
standard
Fitted big‐end bearing shells, vertical inside diameter,
mm 53,752 ‐ 53,792
oversize
Dimensions
Cylinder head
Cast mark K
Upper correction angle (production), inlet/exhaust 75° / 65°
Service correction cutter 75° / ‐
Lower correction angle (production), inlet 18°
Service correction cutter 15°
Stem bore (inlet and exhaust valve), oversize 0,2 mm 8,263 ‐ 8,288
Stem bore (inlet and exhaust valve), oversize 0,4 mm 8,463 ‐ 8,488
Stem bore (inlet and exhaust valve), oversize 0,6 mm 8,663 ‐ 8,688
Stem bore (inlet and exhaust valve), oversize 0,8 mm 8,863 ‐ 8,888
Dimensions
Camshaft
Single roller chain
Drive
3/8''
Valve timing, inlet opens BTDC 30°
Valve timing, inlet closes ABDC 66°
Valve timing, exhaust opens BBDC 76°
Valve timing, exhaust closes ATDC 20°
Cam lift, inlet mm 6,54
Cam lift, exhaust mm 6,54
Cam length (between heel and toe), inlet mm 36,215 ‐ 36,405
Cam length (between heel and toe), exhaust mm 36,215 ‐ 36,405
Thickness of camshaft thrust plate mm 4,020 ‐ 4,050
Camshaft end float mm 0,065 ‐ 0,165
Number of camshaft bearings 4
Bearing diameter ‐ camshaft bearing journal, front mm 43,903 ‐ 43,923
Bearing diameter ‐ camshaft bearing journal, middle 1 mm 43,522 ‐ 43,542
Bearing diameter ‐ camshaft bearing journal, middle 2 mm 43,141 ‐ 43,161
Bearing diameter ‐ camshaft bearing journal, rear mm 42,760 ‐ 42,780
Bearing bush inside diameter, front mm 43,948 ‐ 43,968
Bearing bush inside diameter, middle 1 mm 43,567 ‐ 43,587
Bearing bush inside diameter, middle 2 mm 43,186 ‐ 43,206
Bearing bush inside diameter, rear mm 24,805 ‐ 42,825
Dimensions
Valves
Valve tappet diameter mm 22,200 ‐ 22,212
Tappet clearance in housing mm 0,023 ‐ 0,060
Free valve spring height mm 53
Spring force, valve open N 800 ‐ 867
Spring force, valve closed N 417 ‐ 467
Dimensions
Inlet valve
Valve head diameter mm 41,85 ‐ 42,24
Valve length mm 104,65 ‐ 105,35
Valve stem diameter, standard mm 8,025 ‐ 8,043
Valve stem diameter, oversize 0,2 mm 8,225 ‐ 8,243
Valve stem diameter, oversize 0,4 mm 8,425 ‐ 8,443
Valve stem diameter, oversize 0,6 mm 8,625 ‐ 8,643
Valve stem diameter, oversize 0,8 mm 8,825 ‐ 8,843
Valve stem clearance in guide mm 0,020 ‐ 0,063
Valve lift, at zero valve clearance mm 9,54
Part number 86
Viton oil control ring
TM 6571 AB
Dimensions
Exhaust valve
Valve head diameter mm 35,83 ‐ 36,21
Valve length mm 104,60 ‐ 105,60
Valve stem diameter, standard mm 7,999 ‐ 8,017
Valve stem diameter, oversize 0,2 mm 8,199 ‐ 8,217
Valve stem diameter, oversize 0,4 mm 8,399 ‐ 8,417
Valve stem diameter, oversize 0,6 mm 8,599 ‐ 8,617
Valve stem diameter, oversize 0,8 mm 8,799 ‐ 8,817
Valve stem clearance in guide mm 0,046 ‐ 0,089
Valve lift at zero valve clearance mm 9,54
 Part number 86
Viton oil control ring
TM 6571 AB
Dimensions
Oil pump
Rotor/housing clearance mm 0,154 ‐ 0,304
Inner/outer rotor clearance mm 0,050 ‐ 0,200
Rotor end float at mating face mm 0,035 ‐ 0,100
Lubricants, Adhesives and Sealers
Description Ford
Specification
Sealer for vibration damper bolt, joint between the cylinder head
ventilation plenum and the cylinder block, cylinder head cover flange SPM‐2G‐3121‐A
mating faces
Sealer, crankshaft main bearing caps to the cylinder block, sump to
cylinder block, coolant pump and timing cover to cylinder block (Loctite ESKM‐4G‐269‐A
518)
Sealer for contact faces of the cylinder block and cylinder heads and the
SPM‐4G‐9112‐F
inlet manifold flange (Wellseal)
Spark plug thread lubricant (Never Seeze) ESE‐M1244‐A
High‐temperature grease for torque converter guide bore ESDM‐1C220‐A
Silicone grease A960‐M1C171‐AA
Motor oil
Ambient temperature Designation Specification
‐10 to above 40 degrees Ford Multigrade Super Motor
SAE 20W50 API/SG/CD
Centigrade Oil
‐15 to above 40 degrees Ford Multigrade Super Motor
SAE 15W40 API/SH/CD
Centigrade Oil
‐20 to above 40 degrees Ford Multigrade Super Motor
SAE 10W30 API/SH/CD EC
Centigrade Oil
‐20 to above 40 degrees XR+ High Performance High
SAE 10W40 API/SH/CD EC
Centigrade Lubricity Engine Oil
‐30 to above 40 degrees Ford Formula S Synthetic
SAE 5W50 API/SG/CD
Centigrade Engine Oil
‐30 to above 40 degrees Synthetic/Semi‐synthetic
SAE 5W40 API/SH/CD EC
Centigrade Engine Oil
40 to below ‐30 degrees Ford Multigrade Super Motor
SAE 5W30 API/SG/CD
Centigrade Oil
Engine oil of specification SAE 5W30 API/SG/CD is only approved for northern European
markets.
If other types of engine oil are used, these must conform at least to the respective API
SG/CD viscosity class.
Capacity
Description Litres
Engine oil, initial fill 4,8
Oil change excl. filter 4,0
Oil change, incl. filter 4,5
Old style, production fitted big‐end bolts (part number 78TM‐6214‐A2A) (see
illustration 1)
Identification Method of To engine number: Strength Remarks
tightening class
Torque to 30 1100 ‐ 1300
KX110 TCA 8000, TLC 0029, TSC 0044. ‐
Nm N/mm2
Later big‐end bearing bolts (part number 97JM‐6214‐AB) (see illustration 2)
Identification Method of To engine number: Strength Remarks
tightening class
Torque to 20
Nm and then 900 ‐ 1050
KX900 TCA 8000, TLC 0029, TSC 0044. ‐
angle, a N/mm2
further 90°
Big‐end bearing bolts developed especially as replacement parts (not illustrated)
Identification Method of From engine number Strength Remarks
tightening class
White paint Only
Torque to 30 1100 ‐ 1300
mark on the TCA 8000, TLC 0029, TSC 0044. available as
Nm N/mm2
bolt head spare parts
Torques
General Nm lbf.ft.
Engine hood hinges 23 17
Wiring loom clip bracket 10 7
Torques
Inlet Manifold Nm lbf.ft
Inlet manifold, stage 1 6 4
Inlet manifold, stage 2 12 9
Inlet manifold, stage 3 18 13
Inlet manifold, stage 4 23 17
after a 15 min. warm‐up at 1000 rev/min Stage 5 23 17
Fuel rail to inlet manifold 12 9
Intake air temperature (IAT) sensor. 15 11
Inlet air plenum chamber to inlet manifold 9 7
Torques
Exhaust manifold Nm lbf.ft
Exhaust manifold to cylinder head 28 21
Heat shield to exhaust manifold 9 7
Exhaust pipe to exhaust manifold 47 35
Exhaust pipe to catalytic converter 45 33
Torques
Alternator Nm lbf.ft
Alternator bracket 25 18
Alternator to bracket 25 18
Torques
Transmission Nm lbf.ft
Flange bolts (all) 44 32
Torque converter to drive plate 44 32
Starter motor to transmission 44 32
Torques
Air conditioning system Nm lbf.ft
Belt tensioner for drive belt of air conditioning compressor 41 30
Air conditioning compressor to cylinder block 44 32
Torques
Coolant circuit Nm lbf.ft
Coolant pump 9 7
Belt pulley to coolant pump 25 18
Thermostat housing/bypass connector 10 7
Engine coolant temperature (ECT) sensor 15 11
Coolant temperature sender unit 6 4
Coolant drain plug 23 17
Torques
Steering Nm lbf.ft
Power steering pump to bracket 25 18
Power steering pump pulley 25 18
Intermediate shaft to steering shaft 18 13
Torques
Oil circuit Nm lbf.ft
Oil intake pipe to oil pump 11 8
Oil pump to cylinder block 19 14
Oil pump cover 11 8
Sump, stage 1 5 4
Sump, stage 2 8 6
Oil baffle 19 14
Oil drain plug 25 18
Oil pressure switch 27 20
Oil filter 15 11
Bracket ‐ oil dipstick tube 44 32
Torques
Front axle Nm lbf.ft
Transverse brace to front axle 80 59
Front axle to side member 80 59
Suspension arm to spindle carrier 83 61
Link rod to stabiliser bar 47 35
Track rod to spindle carrier 63 46
Lower engine mounting to crossmember 50 37
Torques
Cylinder block Nm lbf.ft
Camshaft sprocket 64 47
Camshaft thrust plate 11 8
Chain guide to cylinder block 11 8
Timing chain tensioner to cylinder block 10 7
Vibration damper bolt to crankshaft, stage 1 45 33
Vibration damper bolt to crankshaft, stage 2 85° 85°
Timing cover to cylinder block 19 14
Main bearing caps 97 72
Big‐end bearing caps (connecting rods and big‐end bearing bolts,
30 22
identification codes 6AA and KX 110 respectively)
Big‐end bearing caps (connecting rods and big‐end bearing bolts,
20 15
identification codes 5AB and KX 900 respectively), stage 1
Big‐end bearing caps, stage 2 90° 90°
Spark plugs 32 24
Distributor retaining plate 19 14
Flywheel pressure plate to crankshaft, stage 1 30 22
Flywheel pressure plate to crankshaft, stage 2 85° 85°
Clutch pressure plate to flywheel 23 17
Bracket with engine mounting bracket to cylinder block 50 37
Torques
Cylinder Head Nm lbf.ft
Thermostat housing/bypass connector 10 7
Cylinder head (internal Torx bolts), stage 1 38 28
Cylinder head (internal Torx bolts), stage 2 73 54
Cylinder head (internal Torx bolts), stage 3 90° 90°
Cylinder head cover 7 5
Rocker shaft, stage 1 32 24
Rocker shaft, stage 2 90° 90°
Exhaust manifold to cylinder head 28 21
Heat shield to exhaust manifold 9 7

Engine ‐ Dismantle and Assemble (21

Scorpio 1995 (10/1994-06/1998)
134 8)
 Print

Removal and Installation

Special Tools

21‐036A Remover for pilot

bearing

21‐044A Installer/Aligner,
Pilot Bearing/Clutch Plate

21‐059C Installer for radial

seal

21‐064 Mounting bracket

21‐092A Inlet manifold

wrench

21‐137 Oil seal

installer/aligner

21‐144 Inlet manifold wrench

21‐147 Remover, vibration

damper

21‐168 Crankshaft locking

tool
 21‐226 Pliers, spark plug
connector

21‐540 Bolt tightening angle

gauge

Workshop Equipment
Description
Assembly stand
Materials
Description
Obtainable
through: Replacement
Services Limited, 30
Euston
Plastigage
Street, Freemans
Industrial
Estate, Leicester, LE2
7ST.
M8 threaded rod
Spark plug thread
lubricant (Never ESE‐M1244‐A
Seeze)
Loctite 518 ESKM‐4G‐269‐A
Wellseal SPM‐4G‐9112‐H
Sealer SPM‐2G‐3121‐A
Silicone grease A960‐M1C171‐AA
Proprietary Tools
Description
Oil filter strap wrench
Dial indicator
Magnetic fixture
Micrometer screw
Piston ring pliers
Piston ring compressor
V‐belt tension gauge
Dismantle
1. Remove the heat shield from the right‐hand exhaust
manifold.
2. Remove the bracket with the right‐hand engine
mounting bracket (four bolts).
3. Detach the right‐hand exhaust manifold.

4. Attach the engine to the assembly stand.

• Attach the mounting bracket.
• Attach the engine to the assembly stand.
• Drain off the engine oil.
• Withdraw the oil dipstick.

CAUTION:
Do not pull the cable when removing the
spark plug connector. If necessary, remove
the ignition cables from the ignition coil to
avoid kinking the cables. Turn the spark plug
connector slightly before removing to loosen
the seal.
CAUTION:
Pull off the spark plug connectors in line with
the spark plugs (for bent spark plug
connectors use Special Tool 21‐226).
5. Remove the distributor arc shield.
1. Pull off all spark plug connectors.
2. Remove the arc shield.
6. Remove the distributor cap (two bolts).
7. Remove the distributor and the spark plugs.

8. Remove the alternator (two bolts).

9. Detach the alternator bracket.

10. Remove the coolant pump belt pulley.

11. Remove the intake air plenum chamber with the

throttle housing.
CAUTION:
Do not use a steel scraper.

• Remove the gaskets.

• Pull the positive crankcase ventilation (PCV) hose
and valve from the cylinder head cover.

12. Detach the fuel rail (four bolts).

13. Remove the injectors.

14. Remove the cylinder head covers (eight bolts and
extended washers on each).
   Remove the gaskets.

15. Detach the two rocker shafts.

NOTE:
Do not mix up the rocker shafts and the push
rods.
   Withdraw the push rods in the correct sequence and
keep them in order.

16. Detach the inlet manifold.

• Disconnect the connecting hose running to the
thermostat housing.
NOTE:
Bolt‐slackening sequence.

• Detach the inlet manifold (seven bolts, one nut).

• Remove the gasket.

NOTE:
Bolt‐slackening sequence.

17. Remove the cylinder heads.

   The cylinder head bolts may only be used once.
18. Remove the oil pressure switch.

19. Detach the crankshaft pulley/vibration damper.

• Lock the flywheel.
• Remove the bolt.

20. Detach the crankshaft pulley/vibration damper

(continued).
• Screw in the bolt by 15 turns.
• Attach the special tool and pull off the crankshaft
pulley/vibration damper.
• Remove the bolt and the Woodruff key.

21. Detach the flywheel.

1. Six bolts.
2. Pressure plate.
3. Flywheel.
4. Adaptor plate.
22. Detach the oil filter.

23. Remove the crankshaft pilot bearing.

 CAUTION:
Oil sludge and abraded particles must not get
into the engine.
24. Remove the sump downwards (18 bolts/six nuts).

CAUTION:
Take care not to damage the cylinder liners.

25. Remove the carbon from the upper edges of the

cylinder bores.

26. Remove the hydraulic tappets.

• Place a suitable drain tray under the cylinder block.
• Place the cylinder block in the vertical position.
NOTE:
Do not mix up the tappets when removing
and installing them and do not dismantle
them. They are only available as a single part
for servicing.
• Press out the hydraulic tappets with a bent piece of
brass wire.

27. Detach the oil baffle.

 28. Detach the oil pump with the intake pipe.
   Remove the oil pump drive shaft.

29. Detach the coolant pump.

30. Detach the timing cover.

   Remove the oil seal from the timing cover.
31. Remove the camshaft chain drive complete.
CAUTION:
The oil‐filled plunger of the chain tensioner is
spring‐loaded.
1. Chain tensioner (two bolts)
2. Camshaft sprocket
3. Timing chain
4. Crankshaft sprocket
5. Chain guide (two bolts)

32. Remove the camshaft.

1. Detach the thrust plate (two bolts).
2. Carefully withdraw the camshaft with the sprocket
bolt.
• Swivel the engine.

CAUTION:
Do not damage the crankshaft bearing
journal.
33. Remove the pistons.
• Detach the big‐end bearing caps.
• Remove the bearing shells from the big‐end bearing
caps and the connecting rods and mark them.
• Press out the pistons with the connecting rods.
 34. Remove the crankshaft.
NOTE:
Four special bolts for securing the oil baffle.

• Detach the main bearing caps.

• Lift out the crankshaft.
• Remove the rear oil seal.
• Remove the bearing shells and mark them for reuse.

Assemble
35. Preparatory measures.
   Thoroughly clean all mating and bearing surfaces
and re‐usable parts and check them for damage.
Measure the cylinder bores
NOTE:
Machine or renew the cylinder block as
necessary.
36. Measure the cylinder bores.
• Measure the dimensions A, B, and X ‐ Y compare
them with the values given in the Technical Data.
• Ovality = X ‐ Y
• Conicity = A ‐ B

Measure the piston diameter

 NOTE:
Piston classification, if a piston has to be
renewed.
37. Measure the piston diameter.
• Measure the piston diameter at the top of the piston
pin bore.

CAUTION:
Do not mix up the piston rings. Refit the
piston rings in the same position as before.
38. Check the piston ring gaps.
   The figures indicated in the Technical Data are for a
gauge ring used in production. The figures measured
in the cylinder can exceed these by 0,15 mm.

39. Measure the diameter of the main and big‐end

bearing journals.
• Repeat each measurement at 90°.
• Re‐work or renew the crankshaft if necessary.

Measure the bearing clearance

40. Paint marks on the main bearing caps.
• If the parent bore in the cylinder block has standard
dimensions, it does not have a mark.
• Bearing caps for a 0,38 mm oversize parent bore
have a white paint mark.

41. Paint marks on the main and big‐end bearing

shells.
• Standard bearing shells do not have a mark.
• Bearing shells for an oversize cylinder block and an
undersize crankshaft are marked on the back as
appropriate (see Parts Microfiche).
• If a repair is carried out in production, the bearing
shells are provided with paint marks as shown.
42. Paint marks on the main and big‐end bearing
journals.
• Main bearing journals with the standard diameter are
not marked.
• In the case of bearing journals with 0,25 mm
undersize, the first counterweight on the crankshaft
has a green paint mark.
• Big‐end bearing journals with the standard diameter
are not marked.
• In the case of big‐end bearing journals with 0,25 mm
undersize, the first crankshaft web in relation to the
big‐end bearing journal is marked with a green spot.
CAUTION:
Do not damage the crankshaft bearings
during fitting.
43. Fit the crankshaft.
• Fit the main bearing shells in the cylinder block.
• Fit the crankshaft without lubrication.

44. Measure the crankshaft main bearing clearance.

• Measure the clearance of the bearings in turn in
numerical order (1 ‐ 4). The numbering starts at the
timing chain end.
• Lay a length of Plastigage thread on the bearing
journal across the bearing.

45. Measure the crankshaft main bearing clearance

(continued).
• Fit the bearing cap with the associated bearing shell
and tighten it.
CAUTION:
The crankshaft must not be turned during the
measuring operation. Do not hit the bearing
caps.
• Detach the bearing caps.

NOTE:
If the measured bearing clearance is outside
the specification of 0,008 ‐ 0,062 mm, then
the bearing shells should be renewed and the
measurement procedure repeated from step
46. Measure the crankshaft main bearing clearance
(continued).
• Compare the Plastigage thread with the Plastigage
scale.
• The reading corresponds to the bearing clearance.
 47. Fit the crankshaft.
• Coat all main bearing journals, all bearing shells,
the threads of all bolts and all bolt contact faces with
oil.
• Arrange the bearing shells and fit the crankshaft.
• Apply a thin coat of sealer (Loctite 518, ESKM‐4G‐
269‐A) to the contact faces of the rear main bearing
caps.
• Fit the main bearing caps with the associated
bearing shells.
NOTE:
The arrows point to the timing chain end.
The numbering starts at the timing chain
end.
• Tighten the bolts.

48. Check the crankshaft end float.

• Set up a dial indicator.
• Measure the end float by lifting the crankshaft with
the aid of a screwdriver.
• Correct the end float as necessary by fitting new
flanged bearing shells.

49. Fit the pistons with the connecting rods.

CAUTION:
The upper piston rings are coated with
molybdenum. This coating must not be
damaged.
NOTE:
The tapered face ring must be fitted so that
the ”TOP" mark faces the piston crown.
• Fit the piston rings on to the pistons using
proprietary piston ring pliers.
• Lubricate the piston and cylinder bore with engine
oil.
• Distribute the ring gaps evenly around the
 circumference (see Technical Data).
50. Fit the pistons with the connecting rods
(continued).
• Compress the piston rings with a proprietary piston
ring compressor.
NOTE:
The front mark on the piston (arrow) must
point in the direction of travel. The
numbering on the connecting rods starts at
the timing chain end.
• Fit the pistons. The associated big‐end bearing
journal must be at BDC.
• Place the appropriate bearing shells in the
connecting rod and bearing cap.
• Fit the bearing caps.

51. Identification of the big‐end bearing bolts and

connecting rods used.
Only engines with connecting rods and big‐end bearing journals with the
respective identification codes 6AA and KX110.
52. Measure the big‐end bearing clearance.
• Measure the big‐end bearing clearance as described
in sub‐operations to
• Renew the bearing shell(s) as necessary.
NOTE:
Check whether the connection rods have the
specified end float.
53. Fit the big‐end bearing caps.
• Lubricate the bearing shells, bearing journals and the
threads and mating surfaces of the connecting rod
nuts with oil.
NOTE:
The connecting rods and their bearing caps
have the same numbers.
• Fit the big‐end bearing caps with the bearing shells
and tighten them.
Only engines with connecting rods and big‐end bearing journals with the
respective identification codes 5AB and KX900.
NOTE:
Use the old bolts to measure the bearing
clearance.
54. Measure the big‐end bearing clearance.
• Measure the big‐end bearing clearance as described
in sub‐operations to .
• Renew the bearing shell(s) as necessary.
NOTE:
Check whether the connection rods have the
specified end float.
NOTE:
Use new bolts.

55. Install the big‐end bearing caps.

• Lubricate the bearing shells, bearing journals and the
threads and mating surfaces of the connecting rod
nuts with oil.
NOTE:
The connecting rods and their bearing caps
have the same numbers.
• Install the big‐end bearing caps with the bearing
shells. Use Special Tool 21‐540 during tightening.
NOTE:
The oil seal points outwards.

56. Install the crankshaft pilot bearing.

57. Fit the crankshaft rear oil seal.

• Lubricate the crankshaft running face and oil seal lip
with oil.
• Support the special tool in a vice.
• Insert the oil seal with the open side upwards and
drive it in carefully as far as it will go using the handle
of a hammer.
• Fit the special tool with the oil seal to the engine.
• Drive in the oil seal evenly as far as it will go.
• Swivel the engine.
 58. Install the camshaft.
• Lubricate the camshaft bearings, the camshaft and
the thrust plate with oil.
• Screw in the timing sprocket bolt half way and fit the
camshaft.
NOTE:
The oil bore in the thrust plate must be at the
bottom.
• Fit the thrust plate.
• Take out the sprocket bolt.

59. Check the camshaft end float.

Install the chain drive.

60. Attach the chain guide.
61. Align the camshaft and crankshaft in relation to
one another.
   The recesses on both crankshaft journals must be
opposite one another.

62. Preload the chain tensioner.

   Press the spring and the oil‐filled plunger into the
chain tensioner and fit the oil‐filled plunger in the
sliding block.
63. Preload the chain tensioner (continued).
   Press the oil‐filled plunger and sliding block right
into the chain tensioner and hold it in this position.

NOTE:
A locking clip is supplied with new chain
tensioners. If necessary, fabricate a locking
clip from welding rod.
64. Preload the chain tensioner (continued).
   Immobilise the sliding block in this position with a
locking clip.

65. Fit the camshaft chain drive.

NOTE:
The dots on the sprockets must be exactly
opposite each other on the inside.
1. Crankshaft sprocket.
2. Crankshaft Woodruff key.
3. Camshaft sprocket.
4. Timing chain.
5. Chain tensioner.
6. Remove the locking clip after tensioner has been
fitted.
66. Fit the timing cover.
• Fit the timing cover with a gasket and tighten the
bolts finger tight.
• Centre the timing cover using the special tool and
align it to the sump mating face.
• Tighten the nine bolts.
• Remove the special tool.

67. Fit the new crankshaft front oil seal.

• Lubricate the oil seal lip and the crankshaft with oil.
• Insert the oil seal lip as far as it will go.
• Remove the bolt and the special tool.
68. Fit the adaptor plate in place and attach the
flywheel.
CAUTION:
Use new bolts.

• Immobilise the crankshaft in the cylinder block.

1. Place the adaptor plate on the guide sleeves.
2. Flywheel.
3. Pressure plate.
4. Bolts.
69. Attach the oil filter.
   Lubricate the oil seal with clean engine oil.
70. Install the belt pulley/crankshaft vibration damper.
• Immobilise the flywheel.
• Lubricate the hole in the crankshaft pulley/vibration
damper with oil.
• Press the crankshaft pulley/vibration damper home
onto the crankshaft over the Woodruff key using the
bolt.
• Remove the bolt, apply sealer (SPM‐2G‐3121‐A) and
re‐tighten it.

71. Fit the coolant pump.

• Apply sealer (specification ESKM‐4G‐269‐A) to the
sealing surfaces of the coolant pump and the timing
cover.
• Fit the coolant pump with an oil seal.

72. Fit the driveshaft and the oil pump with the
intake pipe.
NOTE:
The short pointed end of the shaft points
towards the distributor.
1. Set the retaining ring in its correct position on the
drive shaft and fit the shaft.
• Fill the oil pump with oil through the intake pipe
and turn it by hand.
2. Fit the oil pump.
 73. Fit the oil baffle.

Fit the sump.

74. Apply sealer (Loctite 518, ESKM‐4G‐269‐A) as
detailed below.
• To the gap at the cylinder block/timing cover
mating face.
• To the groove in the rear main bearing cap.
75. Fit the sump with a new one‐piece gasket.
• Fit the gasket over the studs on the cylinder block.
NOTE:
The knobs on the sump must engage in the
corresponding holes in the gasket.
• Fit the sump and screw on the nuts.
• Tighten the nuts and bolts in two stages.
76. Fit the oil drain plug using a new seal.

77. Tighten the sump nuts and bolts.

1. Start ‐ stage 1.
2. Start ‐ stage 2.

NOTE:
Fit the hydraulic tappets in the correct
sequence.
NOTE:
Hydraulic tappets that are new or contain no
oil should be pumped up manually in oil
before installation until they cannot be
compressed any more.
78. Fit the hydraulic tappets.

Install the cylinder heads

79. Fit new cylinder head gaskets.
• The cylinder block and cylinder head mating faces
must be dry and clean.
• The gaskets are marked ”TOP FRONT" and are
guided into place with the locating sleeves.
• The left and right‐hand gaskets are different.
80. Fit the cylinder heads.
   The cylinder heads are guided into locating sleeves.

CAUTION:
Use new bolts.

81. Pre‐tighten the cylinder head bolts.

• Lubricate the head and thread of the cylinder head
bolts with oil, and fit them.
• Pre‐tighten the cylinder head bolts in two stages and
in the indicated sequence.
CAUTION:
The cylinder head bolts must not be
retorqued.
82. Tighten the cylinder head bolts.
   Wait five minutes after the second stage and then
tighten the bolts a further 90°.
 83. Fit the oil pressure switch.

Install the inlet manifold.

84. Fit the gasket.
• Apply sealer (Wellseal, SPM‐4G‐9112‐H) to the joints
between the cylinder block and cylinder heads at the
inlet manifold flange.
• Fit the gasket.
• Apply sealer (SPM‐4G‐9112‐H) to the four overlength
parts of the gasket (inlet manifold of the cylinder
heads)

85. Fit the inlet manifold (seven bolts, one nut).

   Tighten the inlet manifold in four stages as
illustrated.

86. Fit the distributor.

• Set cylinder no. 1 to TDC.
 1. Align the notches on the distributor base and the
cylinder block.
2. The distributor rotor points towards the notch on the
edge of the distributor.
• Press the distributor down and engage the pinion.
• Crank the engine and bring the distributor into
engagement with the oil pump drive assembly.
3. Position of the distributor rotor (cylinder no. 1 in
TDC position) with the distributor installed.
4. Secure the distributor with the retaining plate (one
bolt).
87. Fit the rocker shafts.
• Lubricate the push rods with oil and fit them.
CAUTION:
Do not under any circumstances adjust the
rocker arms.
• Fit the rocker shafts and screw in the bolts.
• Screw in the bolts. Use Special Tool 21‐540 to
tighten them.

88. Fit the fuel rail (four bolts).

NOTE:
Use new rubber seals at the injectors.

89. Fit the injectors.

Attach the cylinder head covers

NOTE:
Stick the gaskets in place with the adhesive‐
coated side facing the cylinder head cover.
90. Apply sealer (SPM‐2G‐3121‐A) to the joints in the
cylinder cover flanges.
   Arrange the gaskets in position.
91. Fit the cylinder head covers (eight bolts and
washers each).

92. Fit the inlet air plenum chamber and throttle

housing.
   Insert the positive crankcase ventilation (PCV) hose
into the left‐hand cylinder head cover.

93. Attach the belt pulley to the coolant pump.

94. Fit the alternator bracket.

95. Fit the alternator.

 NOTE:
Apply lubricant (ESE‐M1244‐A) to the spark
plug threads.
96. Fit the spark plugs.
   Tightening torque : 32 Nm
97. Fit the distributor cap and HT leads.

CAUTION:
Use a blunt object (e.g. a plastic cable tie) to
apply the silicone grease, to avoid damaging
the spark plug connector seal.
CAUTION:
Push on the spark plug connectors, keeping
them in line with the spark plugs.
NOTE:
Coat the inside of the spark plug connector
with silicone grease (A960‐M1C171‐AA) to a
depth of 5‐10 mm.
98. Fit the distributor arc shield.
1. Push the arc shield on and ensure that it engages
correctly.
2. Join the spark plug connectors.
NOTE:
Use new gaskets.

99. Top up the engine oil and insert the dipstick.

100. Remove the engine from the assembly stand.
101. Fit the right‐hand exhaust manifold.

102. Fit the heat shield to the right‐hand exhaust

manifold.
103. Fit the bracket with the engine mounting
bracket on the cylinder block (four bolts).
 NOTE:
Bolt‐tightening sequence.

104. Retorque the inlet manifold bolts.

• After installation, allow the engine to run for 15
minutes at 1000 rev/min.
• Tighten the bolts.
• Tighten the nuts using Special Tool 21‐092 A.

Cylinder Heads ‐ Remove and Install (21

Scorpio 1995 (10/1994-06/1998)
164 0)
 Print

Removal and Installation

Special Tools

21‐092 A Inlet manifold

wrench

21‐144 Inlet manifold wrench

21‐226 Pliers, spark plug

connector

21‐540 Bolt tightening angle

gauge

23‐027 A Fuel pipe remover

24‐003 Remover/installer,
radiator hose clip

Materials
Description
Coolant
Sealer SPM‐4G‐9112‐H
Sealer SPM‐2G‐3121‐A
Silicone grease A960‐M1C171‐AA
Remove
1. General notes.
   If necessary, use remover and installer 24‐003 to
remove and install coolant or ventilation hoses.
2. Preparatory measures.
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
• Detach the battery cover (one nut).
CAUTION:
Disconnect the battery negative lead.

WARNING:
If the engine is warm, wrap a thick cloth
around and over the coolant expansion tank
cap before opening it, to prevent the risk of
scalding.
• Open the coolant expansion tank.
3. Raise the vehicle.
4. Detach the engine undershield.

WARNING:
Danger of scalding if the engine is warm.

5. Drain off the coolant.

   Tighten the drain plug again.

6. Lower the vehicle.

7. Detach the upper part of the air cleaner housing.
1. Remove the intake pipes from the throttle housing
(two hose clamps).
2. Unclip the upper part of the air cleaner housing
(four clips).
3. Pull off the positive crankcase ventilation (PCV)
hose.
8. Disconnect the expansion tank connecting hose and
the upper coolant hose from the thermostat housing.

9. Disconnect the heater coolant hose from the

thermostat housing.

10. Disconnect the vacuum hoses.

1. Brake servo.
2. From the air plenum chamber.
3. From the fuel pressure regulator.
4. Manifold absolute pressure sensor (MAP sensor).

11. Disconnect both vacuum hoses from the throttle

housing.

12. Detach the throttle cable.

1. Disconnect the kickdown switch plug.
2. Remove the clip.
3. Unhook the cable.
 WARNING:
Escaping fuel. Observe the safety regulations
for working with fuel.
13. Disconnect the fuel pipes.
   Fit the special tool in the slots.

14. Disconnect the engine wiring loom.

1. Disconnect the injector plugs.
• Separate the following plugs:
2. From the distributor
3. Right‐hand heated oxygen sensor (HO2S) plug
4. From the intake air temperature sensor (IAT
sensor).
5. Remove the wiring loom clip.
15. Disconnect the engine wiring loom (continued).
• Separate the following plugs:
1. From the idle speed control (ISC) valve.
2. From the throttle position sensor (TPS).
3. From the coolant temperature sender unit.
4. From the engine coolant temperature (ECT) sensor.
16. Disconnect the oil pressure switch plug.
CAUTION:
Do not pull the cable when removing the
spark plug connector. If necessary, remove
the ignition cables from the ignition coil to
avoid kinking the cables. Turn the spark plug
connector slightly before removing to loosen
the seal.
CAUTION:
Pull off the spark plug connectors in line with
the spark plugs (for bent spark plug
connectors use Special Tool 21‐226).
17. Disconnect the ignition wiring and detach the
distributor cap.

CAUTION:
Do not use a steel scraper.

18. Remove the air plenum chamber with the throttle

body.
• Remove the gaskets.
• Disconnect the engine breather hose with the valve
from the cylinder head cover.

19. Disconnect the fuel rail (four bolts).

20. Remove the injectors.

21. Remove the cylinder head covers (eight bolts and
washers each).
   Remove the gaskets.

22. Remove the two rocker shafts.

NOTE:
Do not mix up the rocker shafts and push
rods.
   Withdraw the push rods in the correct sequence and
keep them in order.

23. Detach the inlet manifold.

• Disconnect the connecting hose running to the
thermostat housing.
NOTE:
Bolt‐slackening sequence.

• Detach the inlet manifold (seven bolts, one nut).

• Remove the gasket.

NOTE:
Bolt‐slackening sequence.

24. Remove the cylinder heads.

    The cylinder head bolts may only be used once.
Install
25. Fit the new cylinder head gaskets.
• The cylinder block and cylinder head mating faces
must be dry and clean.
• The gaskets are marked ”TOP FRONT" and are
guided into place with the locating sleeves.
• The left and right‐hand gaskets are different.
26. Fit the cylinder heads.
   The cylinder heads are guided into locating sleeves.
27. Pre‐tighten the cylinder head bolts.
CAUTION:
Use new bolts.

• Lubricate the heads and threads of the cylinder head

bolts with oil and fit them.
• Pre‐tighten the cylinder head bolts in two stages and
in the indicated sequence.

CAUTION:
The cylinder head bolts must not be
retorqued.
28. Tighten the cylinder head bolts.
   Wait five minutes after the second stage and then
tighten the bolts a further 90°.

Install the inlet manifold.

 29. Install the gasket.
• Apply sealer (Wellseal, SPM‐4G‐9112‐H) to the joints
between the cylinder block and cylinder heads at the
inlet manifold flange.
• Fit the gasket.
• Apply sealer (SPM‐4G‐9112‐H) to the four overlength
parts of the gasket (inlet manifold of the cylinder
heads)

NOTE:
Bolt‐tightening sequence.

30. Fit the inlet manifold (seven bolts, one nut).

   Tighten the inlet manifold bolts in four stages.

31. Attach the rocker shafts.

• Lubricate the push rods with oil
and fit them.
CAUTION:
Do not move the rocker
arm adjusting bolts.
• Fit the rocker shafts and screw in
the bolts.
• Tighten the bolts.

32. Fit the fuel rail (four bolts).

NOTE:
Use new seal rings on the injectors.

33. Fit the injectors.

Fit the cylinder head covers.

 NOTE:
Stick the gaskets in place with the adhesive‐
coated side facing the cylinder head cover.
34. Apply sealer (SPM‐2G‐3121‐A) to the joints in the
cylinder head cover flanges.
   Lay the gaskets in place.

35. Fit the cylinder head covers (eight bolts and

washers each).

36. Fit the inlet air plenum chamber and throttle

housing.
   Put the positive crankcase ventilation (PCV) hose in
place in the left cylinder head cover.

CAUTION:
Use a blunt object (e.g. a plastic cable tie) to
apply the silicone grease, to avoid damaging
the spark plug connector seal.
CAUTION:
Push on the spark plug connectors, keeping
them in line with the spark plugs.
NOTE:
Coat the inside of the spark plug connector
with silicone grease (A960‐M1C171‐AA) to a
depth of 5‐10 mm.
37. Fit the distributor cap and connect the HT leads.
38. Connect the oil pressure switch plug.
39. Connect the engine wiring loom.
• Lower the vehicle.
• Connect the plugs following the cylinder sequence.
40. Connect the engine wiring loom (continued).
• Join the multiplugs on the right‐hand side.
1. Distributor
2. Right‐hand HO2S
3. IAT sensor
4. Fit the wiring loom clamp.

41. Connect the engine wiring loom (continued).

• Connect the multiplugs on the left‐hand side:
1. ISC valve
2. TPS
3. Coolant temperature gauge sensor
4. ECT sensor

42. Connect the fuel pipes.

43. Attach the throttle cable.
1. Hook the cable in place.
2. Secure it with a clip.
3. Connect the kickdown switch plug.

44. Connect both vacuum hoses to the throttle

housing.

45. Connect the vacuum hoses.

1. Brake servo.
2. Air plenum chamber.
3. Fuel pressure regulator.
4. MAP sensor

46. Connect the heater coolant hose to the thermostat

housing.

47. Connect the expansion tank connecting hose and

the upper coolant hose to the thermostat housing.
 48. Attach the upper part of the air cleaner housing.
1. Fit the intake pipes on the throttle housing (two
hose clamps).
2. Clip the upper part of the air cleaner housing in
place (four clips).
3. Attach the PCV hose.

49. Connect the battery negative lead.

50. Top up the coolant.
51. Retorque the inlet manifold bolts.
• After installation, allow the engine to run for 15
minutes at 1000 rev/min.
NOTE:
Bolt‐tightening sequence.

• Tighten the bolts.

• Tighten the nuts using Special Tool 21‐092 A.

52. Finishing operations:

• Check the fluid levels and rectify as necessary.
• Check the routing of the vacuum hoses and the
wiring and secure them using cable ties as required.
• Change the engine oil.
• Enter the radio keycode.
• Reprogramme the preset radio stations.
• Reset the clock.
• Carry out a road test to allow the PCM to re‐learn
values.
• Check the engine and cooling system for leaks
(visual check).
• Attach the engine undershield.

General Specifications Scorpio 1995 (10/1994-06/1998)

 Print

Specifications
Engine Data
General V6 24V Cosworth
Engine management EEC V module
Emission standard 96 EEC
Super 95 RON
Fuel
unleaded
Engine code BOB
Firing order 1‐4‐2‐5‐3‐6
Bore mm 93,0
Stroke mm 72,0
Cubic capacity cm3 2935
Compression ratio 9,7:1
Compression pressure bar 14
Power output (EEC) kW 151,4
at rev/min 6000
Power output (DIN) kW 154,5
(PS) 210
at rev/min 6000
Torque (EEC) Nm 281
at rev/min 4250
Torque (DIN) Nm 286,6
at rev/min 4250
Idle speed rev/min N=730, D=650
Max. engine speed rev/min 6150, 6250
Dimensions
Cylinder block
Number of main bearings 4
Cylinder bore Ø, class 1 mm 93,01 ‐ 93,02
Cylinder bore Ø, class 2 mm 93,02 ‐ 93,03
Cylinder bore Ø, class 3 mm 93,03 ‐ 93,05
Main bearing shells, inside diameter mm 60,620 ‐ 60,640
Dimensions
Crankshaft
Main bearing journal Ø, class 1 mm 56,980 ‐ 57,000
Main bearing journal end float mm 0,08 ‐ 0,32
Dimensions
Connecting rod
Bore diameter, big end mm 56,820 ‐ 56,840
Bore diameter, small end mm 23,958 ‐ 23,976
130,515 ‐
Connecting rod, distance between bores mm
130,585
Big‐end bearing clearance (radial)
Dimensions
Pistons
Piston Ø, class 2 mm 92,985 ‐ 92,995
Piston Ø, class 3 mm 92,995 ‐ 93,005
Piston ring groove, upper compression ring mm 0,41 ‐ 0,48
Piston ring groove, lower compression ring mm 1,73 ‐ 1,79
Piston ring gap (fitted)
Upper compression ring mm 0,4 ‐ 0,65
Lower compression ring mm 0,9 ‐ 1,1
Oil control ring mm 0,3 ‐ 0,6
Top ring max. clearance mm 0,20
Compression ring max. clearance mm 0,10
Piston ring clearance: excessive piston ring clearance
is identifiable by high oil consumption and sometimes
also by blue exhaust smoke.
Piston Pins
Piston pin diameter mm 24,013 ‐ 24,019
Ring gap position: the piston ring gaps must be spread
evenly around the circumference of the piston. This
also applies to the elements of the oil control ring.
Stagger the ring gaps at intervals of 120°.
Dimensions
Camshafts
Number of camshafts 4
Number of camshaft bearings 4/4
Drive 2 timing chains
Camshaft bearing, inside diameter mm 34,5 ‐ 34,52
Camshaft bearing, inside diameter mm 28,0 ‐ 28,21
Max cam lift, inlet mm 9,5
Max cam lift, exhaust mm 9,5
Bearing journal diameter mm 34,439 ‐ 34,460
Bearing journal diameter mm 27,939 ‐ 27,960
Valve timing, inlet opens BTDC 8°
Valve timing, inlet closes ABDC 62°
Valve timing, exhaust opens BBDC 56°
Valve timing, exhaust closes ATDC 14°
Valve timings, overlap 22°
Dimensions
Valves
Valve tappet diameter mm 34,9659 ‐ 34,975
Valve head Ø, inlet mm 34
Valve head Ø, exhaust mm 30
Valve length, inlet mm 105,59
Valve length, exhaust mm 104,15
Valve stem Ø, inlet mm 6,90 ‐ 6,94
Valve stem Ø, exhaust mm 6,90 ‐ 6,94
Valve spring length, fitted mm 32,0
Valve spring length, not fitted mm 40,4
Dimensions
Cylinder Heads
Valve tappet bore diameter mm 35,000 ‐ 35,015
Valve guide bore diameter mm 7,0 ‐ 7,015
Valve seat angle 45°0" ‐ 45°15"
Cylinder head mating face, maximum distortion
mm 0,06
diagonally or along length
Cylinder head mating face, maximum distortion across
mm 0,02
width
Rework to a maximum depth of mm 0,13
Thickness of cylinder head gasket mm 1,2
Lubricants, Adhesives and Sealers
Ford
Specification
Coolant ESD‐M97B49‐A
No. 4 rear crankshaft main bearing cover only ESK‐M4G269
Lubricant for spark plug threads (Never Seeze) ESE‐M1244‐A
Timing chain housing on cylinder block and on cylinder head (M8x60 only) ESK‐M4G269
WSK‐M2G 349‐
Timing chain tensioner housing on cylinder head
A7
WSK‐M2G 349‐
Right‐hand timing chain guide on cylinder block
A7
WSK‐M2G 349‐
Intermediate shaft bearing plate
A7
Sump on cylinder block, rubber gasket ends ESK‐M4G269
Locking compound ESK‐M4G247‐A
Capacity
Litres
Engine oil incl. filter 4,5
Engine oil excl. filter 4,2
Coolant 9,5
Engine oil
Ambient temperature Designation Specification
Ford Multigrade Super Motor
‐10 to above 40 degrees C SAE 20W50 API/SG/CD
Oil
Ford Multigrade Super Motor
‐15 to above 40 degrees C SAE 15W40 API/SH/CD
Oil
Ford Multigrade Super Motor
‐20 to above 40 degrees C SAE 10W30 API/SH/CD EC
Oil
XR+ high‐performance high‐
‐20 to above 40 degrees C SAE 10W40 API/SH/CD EC
lubricity oil
Ford Formula S synthetic
‐30 to above 40 degrees C SAE 5W50 API/SG/CD
engine oil
Semi‐synthetic/synthetic
‐30 to above 40 degrees C SAE 5W40 API/SH/CD EC
engine oil
Ford Multigrade Super Motor
40 to below ‐30 degrees C SAE 5W30 API/SG/CD
Oil
Specification SAE 5W30 API/SG/CD engine oil is only approved for northern European
countries.
If other makes of engine oil are used, make sure these are of the required API SG/CD
viscosity class or better.
Torques
General Nm lbf.ft
Wheel nuts 85 63
Torques
Intake system Nm lbf.ft
Inlet manifold cover 4 3
Bracket for speed control cable 9 7
Inlet manifold to cylinder head 16 12
Torques
Exhaust Nm lbf.ft
Catalytic converters to bracket (between the catalytic converters) 23 17
Catalytic converter bracket to transmission crossmember 47 35
Catalytic converter bracket to transmission 23 17
Catalyst to exhaust manifold 47 35
EGR valve, pipe to intake air plenum chamber 9 7
EGR valve, pipe to inlet manifold 9 7
EGR valve, bracket to cylinder head 19 14
Heat shields to exhaust manifold 9 7
Torques
Alternator Nm lbf.ft
Bracket for alternator/power steering pump to cylinder block 44 32
Alternator to bracket 25 18
Tensioning pulley for alternator/power steering pump 44 32
Torques
Driveshaft Nm lbf.ft
Driveshaft to differential 66 49
Driveshaft centre to floor assembly 21 15
Torques
Transmission Nm lbf.ft
Ground lead to transmission 44 32
Transmission crossmember to floor assembly 36 27
Torques
Air conditioning system Nm lbf.ft
Tensioning pulley for air conditioning compressor 41 30
A/C compressor to bracket 25 18
A/C compressor to cylinder block 44 32
Torques
Coolant circuit Nm lbf.ft
Coolant pump to timing chain housing 12 9
Bracket for the coolant pipe to the oil cooler 9 7
Coolant pump pulley 19 14
Thermostat housing bracket 9 7
Thermostat housing connector 9 7
Coolant pipe bracket to cylinder head 19 14
Coolant pipe clamp to cylinder head 9 7
Torques
Steering Nm lbf.ft
Power steering pump to bracket 25 18
Power steering pump pulley 25 18
Intermediate shaft to steering shaft 18 13
Torques
Engine mounting Nm lbf.ft
Engine mounting nuts 50 37
Torques
Front axle Nm lbf.ft
Transverse brace to front axle 80 59
Front axle to side member 80 59
Suspension arm to spindle carrier 83 61
Link rod to stabiliser bar 47 35
Track rod to spindle carrier 63 46
Torques
Oil circuit Nm lbf.ft
Sump M6x20 12 9
Sump M6x45 12 9
Sump M6x115 12 9
Oil pump 20 15
Oil drain plug 24 18
Oil baffle plate 21 15
Oil filter to oil cooler (after contact) 270° 270°
Oil cooler to oil pick‐up pipe 33 24
Oil filter connector 35 26
Torques
Cylinder block Nm lbf.ft
Main bearing caps 97 72
Big‐end bearing cap, (big‐end bearings and connecting rod bolts 6AA
30 22
or KX 110)
Big‐end bearing cap, (big‐end bearings and connecting rod bolts 5AB
20 15
or KX 900), stage 1
Big‐end bearing caps, stage 2 90° 90°
Camshaft bearing caps 10 7
Right‐hand timing chain guide 12 9
Timing chain housing to cylinder block M8 19 14
Crankshaft pulley/vibration damper, stage 1 45 33
Crankshaft pulley/vibration damper, stage 2 90° 90°
Crankcase breather connector to sump 9 7
Clamping sleeve bolt (crankcase breather) 9 7
Oil pressure switch 20 15
Intermediate shaft bearing plate 12 9
Intermediate shaft sprocket 50 37
Clamping piece for oil pump drive assembly bearing bracket 19 14
CKP sensor bracket to cylinder block 9 7
CKP sensor to bracket 9 7
CKP sensor wiring clamp 12 9
Drive plate to crankshaft 68 50
Torques
Cylinder Head Nm lbf.ft
CMP sensor to cylinder head 9 7
Camshaft sprockets 72 53
Upper chain guides 19 14
Left‐hand timing chain guide 9 7
Timing chain tensioner housing 9 7
Timing chain tensioner threaded plug 13 10
Right‐hand chain guide retaining bolt 9 7
Cylinder head bolts, stage 1 50 37
Cylinder head bolts, stage 2 (or 2 x 90°) 180° 180°
Cylinder head bolt in timing chain housing 19 14
Cylinder head covers 7 5
Fuel rails 9 7
Fuel pipe bracket 9 7
Spark plugs 20 15
Cylinder head heat shield 9 7
Engine lifting eyes to cylinder head 19 14
Ignition coil bracket M6 9 7
Ignition coil bracket M8 19 14
Oil dipstick tube to cylinder head 9 7

Engine Assembly ‐ Dismantle and

Scorpio 1995 (10/1994-06/1998)
Assemble (21 134 8)
 Print

Removal and Installation

Special Tools

15‐053 Slide hammer

21‐002 Splined head socket,

cylinder head bolts

21‐051 Oil seal remover

21‐059C Installer for oil seal

21‐064 Mounting bracket

21‐128 Cylinder head guide

studs

21‐135 Flywheel immobilising

tool

21‐137 Oil seal

installer/aligner

21‐147 Vibration damper

remover

21‐187 Mounting stand with

geared drive

21‐540 Angle gauge

Proprietary Tools
Description
Oil filter wrench
Universal strap wrench
Magnetic fixture
Dial indicator
Piston ring compressor
Angled torx key T30
4,5 mm Allen key
3/16" Allen key
Handle with Torx T25 or T27 bit
Materials
Description
Plastigage
obtainable from: Replacement Services
Limited, 6 Euston Street, Freemans Industrial
Estate, Leicester LE2 7ST
Timing chain/sump sealer
ESK‐M4G269
Locking compound
ESK‐M4G247‐A
Dismantle
1. General instruction.
   All parts should be set aside in order.
2. Attach the engine to the assembly stand.
• Drain off the engine oil.
• Screw in the oil drain plug and tighten it to 24 Nm.

3. Detach the exhaust gas recirculation (EGR) valve.

1. Slacken the nut.
2. Detach the EGR pipes.
3. Remove the exhaust gas recirculation (EGR) valve.

4. Disconnect the plug from the ignition coil.

1. Ignition coil plug.
2. HT lead.
5. Detach the ignition coil bracket.

6. Remove the right‐hand inlet manifold.

1. Disconnect the positive crankcase ventilation (PCV)
hose and the vacuum hose.
2. Disconnect the plug from the idle air control (IAC)
valve.
3. Disconnect the two vacuum hoses.
4. Disconnect the multiplug from the intake air
temperature sensor (IAT sensor).
5. Remove the connecting hoses.
6. Remove the bolts and pull the inlet manifold off
the intake air plenum chamber (six bolts).

7. Remove the air intake plenum chamber.

1. Remove the EGR valve from the air intake plenum
chamber (two bolts):
2. Disconnect the plug from the throttle position (TP)
sensor.
3. Remove the variable resonance induction system
(VRIS).
4. Detach the intake air plenum chamber from the
left‐hand inlet manifold and lift it out.

8. Remove the left‐hand inlet manifold.

1. Disconnect the vacuum hose.
2. Disconnect the PCV valve from the cylinder head
cover.
3. Remove the six bolts.

9. Detach the PCV bracket.

10. Remove the fuel rails.
   Disconnect the six fuel injection plugs.

11. Disconnect the plugs and detach the thermostat

housing bracket.
• Engine coolant temperature (ECT) sensor plug.
• Temperature gauge sender unit plug.
• Thermostat housing bracket.

12. Remove the coolant pipe.

13. Remove the coolant pipe (continued).

14. Detach the connector, the coolant hose and the

thermostat housing (three bolts).
 15. Remove the crankshaft position (CKP) sensor and
the clamps.
1. Crankshaft position (CKP) sensor.
2. CKP sensor wiring clamp
3. Camshaft position (CMP) sensor wiring clamp
4. CKP sensor bracket
5. CKP sensor.

16. Disconnect the plug from the CMP sensor and

remove the oil pressure switch.
1. CMP sensor plug
2. Oil pressure switch.
   Remove the wiring loom.

17. Remove the exhaust manifold heat shields (left‐

hand side shown).

18. Remove the cylinder head heat shields (left‐hand

side shown).

19. Pull out the dipstick tube and detach the lifting
eye.
20. Remove the PCV connector (left‐hand side shown).

21. Detach the two cylinder head covers (left‐hand

side shown).

22. Set the engine to TDC.

23. Remove the upper chain guide (left‐hand side

shown).

NOTE:
The chain tensioner is locked once there is an
audible click and when it has reached its
stop.
24. Remove the right and left‐hand chain tensioners.
1. Remove the chain tensioner blanking plug (4,5 mm
Allen key).
NOTE:
Use the TORX T30 angled socket.

NOTE:
On '95¼ MY vehicles built prior to
15.04.1997 (build code VP), use the 3/16"
Allen key and the handle with a Torx T25 or
T27 bit.
• Lock the chain tensioner by rotating it clockwise.
2. Unscrew the bolts.
25. Remove the chain guide bolt.
   Prise out the blanking plug.

NOTE:
Undo the camshaft sprocket bolts ten turns.

26. Remove the camshaft sprockets.

NOTE:
Hold the timing chain to prevent it falling in.

27. Remove the camshaft sprockets (continued).

• Lightly tap on the drive plates to loosen them from
the camshaft sprockets.
• Remove the camshaft sprocket bolts.
• Remove the camshaft sprockets, drive plates and
thrust washers and lay them aside in order.

CAUTION:
Turn the camshaft before loosening to make
sure none of the cams are at full lift.
NOTE:
Loosening sequence: working diagonally from
the outside inwards.
NOTE:
Remove the camshaft bearing caps and the
camshafts and lay them aside in order.
28. Remove the camshaft bearing caps and take out
the camshafts.
 NOTE:
Bolt‐slackening sequence.

29. Remove the cylinder heads.

• Remove the cylinder head bolts with special tool 21
002.
• Remove the bolt from the timing chain housing.
• Remove the cylinder heads and the cylinder head
gaskets.

30. Detach the coolant pump pulley.

   Use a universal strap wrench to stop the coolant
pump pulley from turning.
31. Detach the coolant hose.

32. Remove the crankshaft pulley/vibration damper.

• Immobilise the flywheel with locking tool 21‐135.
• Unscrew the bolt approximately 20 mm.
• Pull off the crankshaft pulley/vibration damper.
• Remove the bolt.
• Remove the immobilising tool.

33. Detach the coolant pump.

34. Remove the oil filter connector.
1. Oil filter
2. Oil cooler
3. Oil filter connector

NOTE:
Bolt‐slackening sequence.

NOTE:
Remove the sump downwards so that
abraded particles and sludge cannot fall into
the engine.
35. Remove the sump.

NOTE:
The left‐hand chain guide attached to the
timing chain housing.
36. Detach the timing chain housing (eight bolts).
1. Seven bolts at the front, one at the top of the
back.
2. Remove the crankshaft oil seal with remover 21‐
051.
3. Lift the left‐hand timing chain away from the chain
guides and remove the timing chain housing.

37. Remove the timing chain.

• Remove the timing chain sprocket together with the
timing chain out towards the front.
• Take the crankshaft Woodruff key out of the groove.
• Remove the chain guides.
 38. Remove the pressure pad from the oil pump drive
bearing housing and draw out the oil pump drive
bearing housing.

39. Remove the oil pump driving sprocket using an M6

bolt.

NOTE:
Left‐hand thread.

40. Detach the intermediate shaft timing sprocket.

• Use a universal strap wrench to stop the timing
sprocket from turning.
• Remove the spacer washer.

41. Remove the bearing plate and withdraw the

intermediate shaft.

42. Detach the oil baffle plate and the oil pump.
 43. Withdraw the driving shaft from the oil pump.

CAUTION:
Do not damage the cylinder bores.

44. Remove the pistons.

• Remove the carbon from the upper edge of the
cylinder bores.
• Detach the big‐end bearing caps.
• Remove the pistons and connecting rods.

45. Remove the crankshaft.

   Detach the main bearing caps.

46. Take out the crankshaft.

   Remove the oil seal.

Assemble
47. Preparatory measures.
   All mating faces and reusable parts should be
thoroughly cleaned and checked for damage.
Measure the cylinder bores
 48. Measure the cylinder bores.

Measure the pistons and piston rings.

49. Measure the pistons.

CAUTION:
Do not mix up the piston rings. They should
be refitted in the same positions.
NOTE:
Carry out the measurement at the top end of
the run‐in cylinder bore.
50. Measure the piston ring gaps.
• If necessary renew the piston rings.
• See technical data for piston ring gaps.

NOTE:
Measure the clearance with the ring
protruding from the groove.
51. Measure the piston ring clearance.
 52. Measure the diameter of the main and big‐end
bearing journals.
• In each case, repeat the measurement 90° around
the circumference.
• Rework or renew the crankshaft if necessary.

Measure the main bearing clearance.

53. General notes.
NOTE:
Measure each bearing individually with a
length of Plastigage thread.
• Fit the main bearing cap of the bearing which is to be
measured and tighten it to the specified torque.
• The bearing shells/journals and the crankshaft must
be clean and free of oil.
• The measuring point should be near the respective
dead centre position.
• The crankshaft must not be turned during the
measuring operation.
• Measure the bearing clearances one after the other in
numerical order.
54. Measure the crankshaft main bearing clearance.
   Lay a length of Plastigage thread on the bearing
journal across the bearing.

NOTE:
The main bearing cap numbering starts at
the timing chain end, to which the arrows
also point.
• Fit the main bearing caps with the associated bearing
shells and tighten them.
• Remove the main bearing caps.

55. Compare the Plastigage thread with the Plastigage

scale.
   If the reading does not correspond to the specified
bearing clearance, renew the bearing shells as
necessary and repeat the operation from step
 NOTE:
Installation position of the studs.

NOTE:
The main bearing cap numbering starts at
the timing chain end, to which the arrows
also point.
56. Install the crankshaft.
• Coat the crankshaft main bearing journals, bearing
shells, and all bolt threads and bolt contact faces with
engine oil.
• Fit the crankshaft.
• Fit the rear main bearing cap using sealer (ESK‐
M4G269).
• Fit the main bearing caps with the associated bearing
shells.
• Tighten the bolts.
57. Check the crankshaft end float.
• Set up a dial indicator.
• Check the end float by lifting the crankshaft.
58. If necessary, correct the end float with thrust half
rings on main bearing no. 3.

NOTE:
The numbering on the connecting rods starts
at the timing chain end. The arrow on the
piston crown points towards the timing chain
end.
59. Fit the pistons.
• Lubricate the pistons and cylinder bores with engine
oil.
• Arrange the piston ring gaps at 120° intervals.
• Compress the piston rings with a proprietary piston
ring compressor.
• Insert the appropriate bearing shells clean and oil‐
free in the connecting rods and the connecting rod
bearing caps.
• Press the pistons into the cylinders using the handle
of a hammer, guiding the connecting rods on to the
big‐end bearing journals. The appropriate big‐end
bearing journal must be at BDC.
 60. Identifying used connecting rod bolts and
connecting rods.
Measure the big‐end bearing clearance.
Only for engines with connecting rods and connecting rod bolts 6AA or KX110.
61. Measure the big‐end bearing clearance.
   Carry out the same procedure as for measuring the
main bearing clearance.
NOTE:
The connecting rods and their bearing caps
have the same numbers.
62. Fit the big‐end bearing caps.
• Lubricate the bearing shells, big‐end bearing journals
and the bolt threads and bolt contact faces with engine
oil.
• Fit the associated big‐end bearing caps with the
bearing shells and secure them.
Only for engines with connecting rods and connecting rod bolts 5AB or KX900
NOTE:
Use the old bolts to measure the bearing
clearance.
63. Measure the big‐end bearing clearance.
   Carry out the same procedure as for measuring the
main bearing clearance.
NOTE:
The connecting rods and their bearing caps
have the same numbers.
NOTE:
Use new bolts.

64. Fit the big‐end bearing caps.

• Lubricate the bearing shells, big‐end bearing journals
and the bolt threads and bolt contact faces with engine
oil.
• Fit the associated bearing caps and bearing shells
and secure them.
65. Fit the oil pump drive shaft in the hexagonal drive.

66. Fit the oil pump and oil baffle.

NOTE:
Coat the thread with locking compound (ESK
M4G247‐A).
67. Fit the oil pump drive intermediate shaft.

NOTE:
Left‐hand thread.

68. Fit the intermediate shaft sprocket.

• Press on the spacer washer (the chamfered side
faces the cylinder block).
• Use a universal strap wrench to stop the sprocket
from turning.

NOTE:
Turn the intermediate shaft so that the oil
pump drive can click in place.
69. Fit the oil pump drive pinion and the oil pump
drive bearing housing with a new oil seal.
70. Fit the pressure pad of the oil pump drive bearing
housing.

NOTE:
The chamfer points towards the cylinder
block.
71. Sprocket must be installed facing the correct way.

72. Fit the timing chain housing gasket using sealer

(WSK‐M4G320‐A).
73. Fit the right‐hand timing chain.
• Coat the chain guide bolts with locking compound
(ESK‐M4G247‐A).
• Attach the chain guides.
• Fit the crankshaft Woodruff key in the groove.
• Lay the timing chain on the sprocket and push them
together onto the crankshaft.

NOTE:
The left‐hand chain guides are attached to
the timing chain housing.
74. Fit the timing chain housing.
• Lay the left‐hand timing chain on the sprocket and fit
the timing chain housing.
• Align the timing chain housing using the special tool.
• Screw in the timing chain housing bolts finger tight.
• Hold the chain tight.
• Check that the special tool is accessible.
NOTE:
Ensure that the timing chain housing and
cylinder block mating faces are flush.
• Tighten the eight bolts on the timing chain housing
(one on the back at the top).
• Remove the special tool.
75. Install the crankshaft front oil seal.
1. Special tool
2. Spacer sleeve
3. Crankshaft pulley/vibration damper bolt.
76. Fit the sump gaskets.
   Apply sealer (ESK‐M4G269) at the ends of the new
gaskets and at the points where the timing chain
housing and engine block meet.

NOTE:
Tightening sequence and different bolt
lengths.
77. Fit the sump.
• Bolts five and six: M6 x 115
• Bolts 23 and 24: M6 x 45
• All other bolts: M6 x 20

78. Fit the oil filter connector.

1. Oil filter connector with a new seal.
2. Oil cooler
3. New oil filter.

79. Fit the coolant pump with a new gasket.

80. Fit the coolant pump pulley.
   Use a universal strap wrench to stop the pulley from
turning.
81. Fit the coolant hose.

NOTE:
The stepped side of the disc faces the
cylinder block.
82. Fit the crankshaft pulley/vibration damper.
• Immobilise the flywheel with locking tool 21‐135.
• Fit a new O‐ring and tighten the new bolt.
• Remove the immobilising tool.

83. Fit the crankshaft rear oil seal.

• Insert a new oil seal into the special tool.
• Fit the oil seal.

NOTE:
FRONT TOP marking.

84. Fit the cylinder head gaskets.

• Apply sealer (ESK‐M4G269) in the timing chain
housing area.
• Cut through the left‐hand cylinder head gasket,
remove the corners and smooth off any sharp edges.

85. Insert the studs into the cylinder block.

86. Fit the cylinder heads (left‐hand side shown.
• Fit the cylinder heads.
• Guide the timing chains through the timing chain
housing and secure them to prevent them from falling
in.

NOTE:
The cylinder head bolts may only be reused
twice. Mark them with a punch mark on the
bolt head when they are reused.
87. Fit the left‐hand cylinder head (continued).
• Insert the cylinder head bolts and tighten them to
the first stage in the indicated sequence.
• Screw in the timing chain housing bolt.

NOTE:
Tightening sequence (see sub‐operation ).

88. Tighten the cylinder head bolts.

89. Set the crankshaft to the TDC marking for cylinder

no. 1.
 NOTE:
The wider contact areas of camshaft bearing
caps 1 and 5 and A and E point towards the
middle.
90. Identification of the camshaft baring caps.
91. Fit the hydraulic tappets.
NOTE:
Tightening sequence: evenly, working
diagonally from the inside outwards.
92. Install the camshafts for the right‐hand cylinder
head.
• The inlet cams on camshaft 1 must be vertical at
cylinder no. 1.
• The exhaust cams on camshaft 2 must be vertical
at cylinder no. 1.
• Fit the camshaft bearing caps.
93. Install the camshafts for the left‐hand cylinder
head.
• The inlet cams on camshaft 3 must be vertical at
cylinder no. 6.
• The exhaust cams on camshaft 4 must be vertical
at cylinder no. 4.
• Fit the camshaft bearing caps.
NOTE:
The drive plate follower must engage in the
bore on the camshaft sprocket.
94. Camshaft components.
95. Set the camshafts to the timing marks.
• Push on the thrust washers and drive plates, screw
in the bolts a few turns.
• Set the camshafts to the timing marks.
• Remove the drive plates.

NOTE:
Engine is set to TDC.

NOTE:
Do not rotate the camshafts.

96. Attach the camshaft sprockets.

• Pull the timing chain tight on the driving run (the
opposite side to the chain tensioner), and working
from this side attach the camshaft sprockets (do not
yet tighten the bolts).
NOTE:
The left and right‐hand chain tensioners are
different (thin left‐hand inner spacer and
thick right‐hand inner spacer). The chain
tensioner must be locked before installation.
97. Fit the right and left‐hand chain tensioners
1. Screw in the bolts.
   Tension the timing chain according to step
2. Screw in chain tensioner blanking plugs (4,5 mm).

NOTE:
The chain tensioner is released once there is
an audible click and when it has reached its
stop.
CAUTION:
Make sure the recess at the end of the timing
chain tensioner tappet is seated in the guide.
98. Tighten the timing chains.
NOTE:
Use the TORX T30 angled socket.

NOTE:
On '95¼ MY vehicles built prior to
15.04.1997 (build code VP), use the 3/16"
Allen key and the handle with a Torx T25 or
T27 bit.
   Twist the chain tensioner anti‐clockwise to release it.
 99. Carefully turn the engine through two rotations
and check the valve timings.
   If necessary, follow steps to to correct the valve
timings.

100. Fit the upper chain guides.

101. Fit the right‐hand chain guide bolt.

• Screw in the chain guide bolt.
• Fit the blanking plug in the bore using a new O‐ring

102. Fit the two cylinder head covers (left‐hand side

shown).

103. Fit the PCV connector (left‐hand side shown).

104. Fit the oil dipstick tube and engine lifting eye.
   Insert the oil dipstick.

105. Fit the cylinder head heat shields (left‐hand side

shown).

106. Fit the exhaust manifold heat shields (left‐hand

side shown).

107. Connect the CMP sensor multiplug and fit the oil
pressure switch.
   Route the wiring loom.
1. Camshaft position (CMP) sensor.
2. Oil pressure switch.
   Connect the oil pressure switch multiplug.

108. Fit the CKP sensor and the clips.

1. CKP sensor.
2. CKP sensor wiring clip.
3. Bracket for CKP sensor.
4. CMP sensor wiring clip.
5. CKP sensor plug.
109. Fit the thermostat housing.
• Guide in the thermostat housing and attach the
coolant hose.
• Fit the three thermostat housing bolts.
• Fit the connector.

110. Fit the coolant pipe.

111. Fit the coolant pipe (continued)

112. Connect the plugs and fit the thermostat housing

bracket.
• Engine coolant temperature (ECT) sensor plug.
• Temperature gauge sender unit plug.
• Thermostat housing bracket.

113. Fit the fuel rails.

   Connect the six fuel injection valve multiplugs.
114. Fit the left‐hand inlet manifold with a new gasket.
1. Fit the six bolts.
2. Insert the PCV valve into the cylinder head cover.
3. Connect the vacuum hose.
   Move the wiring and hoses for the inlet air plenum
chamber and the right‐hand inlet manifold into
installation position.

115. Fit the air intake plenum chamber.

1. Push the air intake plenum chamber onto the left
hand inlet manifold.
2. Attach the VRIS.
3. Connect the TP sensor plug.
4. Attach the EGR valve to the inlet manifold (two
bolts).

116. Attach the right‐hand inlet manifold with a new

gasket.
1. Push the inlet manifold onto the air intake plenum
chamber and fit the six bolts.
2. Fit the connecting hoses.
3. Connect the IAT sensor multiplug.
4. Push on the two vacuum hoses.
5. Connect the IAC valve multiplug.
6. Push on the PCV hose and the vacuum hose.

117. Fit the bracket for the PCV hose.

118. Fit the ignition coil bracket.

 119. Connect the ignition coil plug.
1. Ignition coil connector
2. HT leads

120. Fit the EGR valve.

1. Connect the EGR pipes.
2. Fit the EGR valve bracket.
3. Tighten the nut.

121. Fit the inlet manifold cover.

122. Detach the engine from the assembly stand.

Cylinder Heads ‐ Remove and Install

Scorpio 1995 (10/1994-06/1998)
(All) (21 164 0)
 Print

Removal and Installation

Special Tools

21‐002 Splined head socket,

cylinder head bolts
 21‐226 Pliers, spark plug
connectors

21‐540 Angle gauge, bolt

tightening

24‐003 Installer/remover,
coolant hose clamp

Proprietary Tools
4,5 mm Allen key
3/16" Allen key
Angled T30 TORX socket
Scraper
Handle with Torx T25 or T27 bit
Workshop straight‐edge 400x5 mm
Feeler gauges
Materials
Silicone grease A960‐M1C171‐AA
Sealer (ESK‐M4G269)
Remove
1. General notes.
NOTE:
Throughout the whole operation cover the
engine openings to make sure that nothing
falls into them.
• Lay components aside in the right order.
• The position of ancillary components is described
looking from the transmission to the engine.
• The hydraulic lines are not separated.
NOTE:
If necessary, use remover/installer 24‐003
when removing and installing coolant or vent
hoses.
2. Standard preparatory measures:
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
• Detach the battery cover
CAUTION:
Disconnect the battery negative lead.

• If necessary, cut the cable ties and renew them on

installation.
WARNING:
Wrap a thick cloth around the coolant
expansion tank cover before opening the
cooling system when the engine is at
operating temperature in order to prevent
scalding.
• Open the coolant expansion tank.
• Raise the vehicle.
• Detach the engine undershield.
• Drain the engine oil by removing the drain plug, and
screw the plug back in with a new seal.
• Drain the coolant by removing the radiator drain
plug, and screw the plug back in with a new seal.
3. Fit the air conditioning multi‐groove belt.
• Take the pressure off the belt by turning the
tensioning pulley clockwise.
• Remove the multi‐groove belt.

4. Remove the alternator/power steering multi‐groove

belt.
• Take the pressure off the belt by turning the
tensioning pulley clockwise.
• Remove the multi‐groove belt.
• Lower the vehicle.

5. Remove the intake system cover.

6. Remove the air cleaner.

1. Disconnect the mass air flow (MAF) sensor
multiplug.
2. Remove the intake hose.
3. Remove the bolt from the intake pipe.
4. Remove the positive crankcase ventilation (PCV)
hose.
5. Remove the two rubber retainers.
• Pull the air cleaner off the intake pipe and pull it
upwards out of the grommets on the body.

7. Detach the cables.

1. Unhook the throttle cable and detach it from the
bracket.
2. Unhook the cable of the speed control system.
3. Detach the bracket for the speed control system
cable.
 8. Remove the right‐hand inlet manifold.
1. Disconnect the multiplug from the intake air
temperature sensor (IAT sensor).
2. Disconnect the plug from the idle air control (IAC)
valve.
3. Disconnect the two vacuum hoses.
4. Remove the PCV hose and the vacuum hose.
5. Remove the connecting hoses.
6. Remove the bolts and pull the inlet manifold off
the intake air plenum chamber (six bolts).

9. Remove the air intake plenum chamber.

1. Remove the EGR valve from the air intake plenum
chamber (two bolts).
2. Disconnect the plug from the throttle position (TP)
sensor.
3. Remove the variable resonance induction system
(VRIS).
4. Detach the intake air plenum chamber from the
left‐hand inlet manifold and lift it out.

10. Remove the left‐hand inlet manifold.

1. Disconnect the vacuum hose.
2. Disconnect the PCV valve from the cylinder head
cover.
3. Remove the brake servo vacuum line.
4. Remove the six bolts.

CAUTION:
Do not pull on the cable when removing the
spark plug connectors. Remove the high‐
tension lead from the ignition coil to prevent
kinks in the lead if necessary. Turn the spark
plug connectors slightly before removing
them in order to loosen the seal.
CAUTION:
Remove the spark plug connectors in a
straight line in relation to the spark plugs
(use special tool 21‐226 for offset spark plug
connectors).
11. Detach the hose and pull off the spark plug
connectors.
• Detach the PCV hose from the cylinder head cover
and disconnect it.
• Pull off the spark plug connectors (right‐hand side
shown).
• Detach the bracket for the vacuum lines from the
ignition coil.
12. Disconnect the plugs.

13. Detach the coolant hoses.

1. To the radiator.
2. To coolant expansion tank.

14. Remove the ignition coil.

15. Remove the power steering pump pulley and

detach the coolant hose from its bracket.

16. Remove the power steering pump (five bolts) and

remove the upper bolt from the bracket.
   Raise the vehicle.
17. Remove the drive belt tensioning pulley for the
alternator/power steering pump.

18. Disconnect the alternator and remove the power

steering pressure switch (PSP switch) connector.

19. Remove the alternator.

1. Undo the upper bolt.
2. Remove the lower bolt.

20. Remove the bracket for the alternator/power

steering pump.
   Swivel the alternator upwards and remove the
bracket.

21. Remove the PCV hoses (left‐hand side shown).

22. Remove the bolt from the coolant pipe for the oil
cooler.

23. Detach the exhaust manifold from the catalytic

converter.

24. Disconnect the camshaft position (CMP) sensor

plug and remove the dipstick.
   Lower the vehicle.

25. Remove the heat shields (left‐hand side shown).

26. Disconnect the plug of the heated oxygen sensor

(HO2S) and unclip it from the engine mounting, and
remove the left‐hand engine lifting eye.
27. Remove the fuel rails.
   Disconnect the fuel injection valve plugs.

28. Disconnect the plugs and detach the thermostat

housing bracket.
• Thermostat housing bracket.
• Temperature gauge sender unit plug.
• Engine coolant temperature (ECT) sensor plug.

29. Remove the coolant pipe.

30. Remove the coolant pipe (continued).

31. Detach the thermostat housing.

   Take off the connector.
32. Remove the thermostat housing (continued).
   Detach the thermostat housing from the coolant
hose and remove it.

33. Remove the hoses, the engine lifting eye and the
coolant line.
NOTE:
The hoses have different diameters.

1. Pull off the EGR vacuum hose.

2. Remove the engine lifting eye (two bolts).
3. Remove the coolant line.
4. Detach the coolant hose.

34. Detach the EGR valve from the exhaust manifold

(two bolts).

35. Detach the exhaust manifold from the catalytic

converter (left‐hand side shown).

WARNING:
Escaping fuel. Observe safety regulations
regarding the handling of fuel.
36. Remove the PCV bracket from the cylinder head
cover and disconnect the fuel lines.
37. Remove the cylinder head covers (left‐hand side
shown).

38. Remove the upper chain guides (left‐hand side

shown).

39. Remove the timing chain guide on the right‐hand

cylinder head.
• Evenly prise out the blanking plug with a
screwdriver.
• Remove the chain guide bolt.

40. Set the engine to TDC.

NOTE:
The chain tensioner is immobilised after an
audible click and when it has reached its
stop.
41. Slacken the timing chains.
• Remove the blanking plug from the chain tensioner
using a 4,5 mm Allen key.
NOTE:
Use the TORX T30 angled socket.

NOTE:
On '95¼ MY vehicles built prior to
15.04.1997 (build code VP), use the 3/16"
Allen key and the handle with a Torx T25 or
T27 bit.
• Lock the timing chain tensioner by turning its tappet
 clockwise.
NOTE:
Undo the camshaft sprocket bolts ten turns.

42. Remove the camshaft sprockets.

NOTE:
Hold the timing chain to prevent it falling in.

43. Remove the camshaft sprockets (continued).

• Lightly tap on the drive plates to loosen them from
the camshaft sprockets.
• Remove the camshaft sprocket bolts.
• Remove the camshaft sprockets, the drive plates and
thrust washers and lay them to one side in order.

CAUTION:
Turn the camshaft before loosening to ensure
that none of the cams are at full lift.
NOTE:
Loosening sequence: working diagonally from
the outside inwards.
NOTE:
Remove the camshaft bearing caps and the
camshafts.
44. Remove the camshaft bearing caps and take out
the camshafts and hydraulic tappets.
45. Detach the cylinder heads.
• Remove the cylinder head bolts with special tool 21
002.
• Guide the timing chains and the chain guides out
through the timing chain housing.

Install
46. Preparatory measures.
 CAUTION:
Do not damage the cylinder bore.

• Remove the carbon from the upper edge of the

cylinder bore.
NOTE:
During cleaning take care not to damage the
mating faces.
• Clean the mating faces of all ancillary components
with a scraper, check them for damage and renew
them as necessary.
• Clean the threaded bores and dry them.
• Renew all gaskets and self‐locking nuts.
Check the cylinder head distortion.
NOTE:
The straight‐edge needs to be at least 400
mm long and 5 mm wide.
47. Check the cylinder head mating face for distortion.
• Permissible distortion at the mating face between
combustion chambers: along the length 0,02 mm,
across the width and diagonally 0,06 mm.
• Lay the straight‐edge across all of the mating faces
between the combustion chambers and check each
one in three different places.
• In three different places lay the straight‐edge along
the cylinder head in the region of the combustion
chambers, and check each of the mating faces
between the combustion chambers.
• Lay the straight‐edge diagonally across the cylinder
head and check all mating faces between the
combustion chambers.
• If necessary rework the cylinder head as described in
step
48. Note ‐ reworking the cylinder head.
NOTE:
Make sure that the average peak‐to‐valley
height Rz stays at a value of 0,0135 mm
after reworking.
   The cylinder head must only be reworked to a
maximum depth of 0,13 mm. In doing this,
measurement ”a" must be no less than 141,9 mm.

49. Prepare the left‐hand cylinder head for installation.

• Cut the cylinder head gasket at the indicated cut
points.
• Cut off any protruding corners and smooth off any
sharp edges.
 NOTE:
FRONT TOP marking.

50. Fit the cylinder head gasket.

• Apply sealer (ESK‐M4G269) in the timing chain
housing area.

NOTE:
Secure the timing chains against falling in.

NOTE:
Use new bolts.

51. Fit the cylinder heads (left‐hand side shown).

   Guide the timing chains and the chain guides
through the timing chain housing and fit the exhaust
manifold into the catalytic converter.

52. Cylinder head tightening sequence.

53. Tighten the cylinder head bolts.

   Fit the additional bolts as described in step
54. Set the engine to TDC.

NOTE:
The wider contact areas of camshaft bearing
caps 1 and 5 and A and E point towards the
middle.
55. Identification of the camshaft bearing caps.
56. Fit the hydraulic tappets.
NOTE:
Tightening sequence: evenly, working
diagonally from the inside outwards.
NOTE:
The camshafts are numbered from right to
left.
57. Install the camshafts for the right‐hand cylinder
head.
• The inlet cams on camshaft 1 must be vertical at
cylinder no. 1.
• The exhaust cams on camshaft 2 must be vertical
at cylinder no. 1.
• Fit the camshaft bearing caps.
58. Install the camshafts for the left‐hand cylinder
head.
• The inlet cams on camshaft 3 must be vertical at
cylinder no. 6.
• The exhaust cams on camshaft 4 must be vertical
at cylinder no. 4.
• Fit the camshaft bearing caps.
 NOTE:
The drive plate follower must engage in the
bore on the camshaft sprocket.
59. Camshaft components.

60. Fit the chain guide for the right‐hand cylinder

head.
• Screw in the chain guide bolt.
• Press in the blanking plug with a new seal.

61. Set the camshafts to the timing marks.

• Push on the thrust washers and drive plates and
secure them with bolts against falling in.
• Rotate the camshafts to the timing marks.
• Remove the drive plates.

NOTE:
Engine must be set to TDC.

NOTE:
Do not rotate the camshafts.

62. Fit the camshaft sprockets together with the drive

plates.
NOTE:
The timing chain must be tight between the
camshaft sprockets.
• Pull the timing chain tight on the driving run (the
opposite side to the chain tensioner), and working
from this side attach the camshaft sprockets (do not
yet tighten the bolts).
CAUTION:
Make sure the recess at the end of the timing
chain tensioner tappet is seated in the guide.
NOTE:
The chain tensioner is released after an
audible click and when it has reached its
stop.
63. Tighten the timing chains.
NOTE:
Use the TORX T30 angled socket.
 NOTE:
On '95¼ MY vehicles built prior to
15.04.1997 (build code VP), use the 3/16"
Allen key and the handle with a Torx T25 or
T27 bit.
• Twist the chain tensioner anti‐clockwise to release it.
• Screw the blanking plug (4,5 mm Allen key) into the
chain tensioner.
NOTE:
Wait at least 15 minutes before turning the
engine.
64. Turn the engine through two rotations and check
the valve timings.
   If necessary, follow steps to to correct the valve
timings.

65. Fit the upper chain guides (left‐hand side shown).

66. Fit the cylinder head covers (left‐hand side shown).

67. Attach the PCV bracket to the cylinder head cover

and connect the fuel pipes.
 68. Attach the exhaust manifolds to the catalytic
converter (left‐hand side shown).

69. Attach the EGR valve to the exhaust manifold (two

bolts).

70. Attach the hoses, the coolant line and the right‐
hand engine lifting eye.
NOTE:
The hoses have different diameters.

1. Fit the coolant hose.

2. Attach the coolant lines.
3. Attach the engine lifting eye (two bolts).
4. Push on the EGR valve vacuum hoses.

71. Fit the thermostat housing.

• Lubricate the coolant hose and the oil seals with
liquid soap.
• Move the thermostat housing into installation
position and at the same time insert and attach the
coolant hose.

72. Fit the thermostat housing (continued).

73. Fit the coolant pipe.

74. Fit the coolant pipe (continued).

75. Connect the plugs and fit the thermostat housing

bracket.
• ECT sensor plug.
• Temperature gauge sender unit plug.
• Thermostat housing bracket

76. Fit the fuel rails.

   Connect the fuel injection valve multiplugs.

77. Attach the engine lifting eye, connect the HO2S

plug and clip it on to the engine mounting.
78. Fit the heat shields (left‐hand side shown).

79. Connect the CMP sensor multiplug and attach the

dipstick.
   Raise the vehicle.

80. Attach the exhaust manifold to the catalytic

converter.

81. Screw in the oil cooler coolant line bolt.

82. Fit the positive crankcase ventilation hoses (left‐

hand side shown).
83. Fit the bracket for the alternator/power steering
pump.

84. Fit the alternator.

1. Screw in and tighten the lower bolt.
2. Screw in the upper bolt.

85. Connect the alternator and the PSP switch plug.

86. Fit the tensioning pulley for the alternator/power

steering pump.
   Lower the vehicle.

87. Insert the upper bolt of the bracket and fit the
power steering pump (five bolts).
88. Fit the power steering pump pulley and attach the
coolant hose to the bracket.

89. Fit the ignition coil.

90. Attach the coolant hoses.

1. To the radiator.
2. To coolant expansion tank.

91. Connect the plugs.

CAUTION:
Use a blunt object to apply the silicone
grease (e.g. a plastic cable tie) so as not to
damage the spark plug connector seal.
CAUTION:
Push on the spark plug connectors in a
straight line in relation to the spark plugs.
NOTE:
Coat the inside of the spark plug connectors
with silicone grease (A960‐M1C171‐AA) down
to a depth of 5‐10 mm.
92. Push on the spark plug connectors and attach the
vacuum hoses.
• Attach the bracket for the vacuum lines to the
ignition coil.
• Push on the spark plug connectors (right‐hand side
shown).
• Connect the PCV hose and attach it to the cylinder
head cover.
93. Fit the left‐hand exhaust manifold.
1. Fit the six bolts.
2. Fit the brake servo vacuum line.
3. Insert the PCV valve into the cylinder head cover.
4. Connect the vacuum hose.
   Locate the wiring and hoses for the air intake
plenum chamber and the right‐hand inlet manifold in
installation position.

94. Fit the air intake plenum chamber.

1. Push the air intake plenum chamber onto the left
hand inlet manifold.
2. Attach the VRIS.
3. Connect the TP sensor plug.
4. Attach the EGR valve to the inlet manifold (two
bolts).

95. Attach the right‐hand inlet manifold.

1. Push the inlet manifold onto the air intake plenum
chamber and fit the six bolts.
2. Fit the connecting hoses.
3. Connect the IAT sensor multiplug.
4. Push on the two vacuum hoses.
5. Connect the IAC valve multiplug.
6. Push on the PCV hose and the vacuum hose.

96. Attach the cables.

1. Fit the bracket for the speed control system cable.
2. Hook the speed control system cable in place.
3. Attach the throttle cable to the bracket and hook it
in place.

97. Adjust the throttle cable.

1. Pull off the clip from the throttle cable.
2. Pull the throttle cable out a few notches.
• Fully depress the accelerator pedal once and push
the clip back in place.
• Check whether the throttle valve opens fully when
the accelerator pedal is fully depressed, and repeat the
adjustment if necessary.
98. Fit the air cleaner.
• Push the air cleaner into the grommets on the body
and onto the intake pipe.
1. Fit the two rubber retainers.
2. Attach the PCV hose.
3. Insert the bolt for the intake pipe.
4. Fit the intake hose.
5. Connect the MAF plug.
• Raise the vehicle.

99. Fit the intake system cover.

100. Fit the multi‐groove belt for the alternator/power

steering pump.
• Take the pressure off the belt by turning the
tensioning pulley clockwise.
• Fit the multi‐groove belt.

101. Fit the air conditioning multi‐groove belt.

• Take the pressure off the belt by turning the
tensioning pulley clockwise.
• Fit the multi‐groove belt.

102. Standard finishing operations.

• Renew the oil filter.
• Attach the engine undershield (left‐hand side
shown).
• Connect the battery negative lead.
• Attach the battery cover.
• Enter the radio keycode.
• Reprogramme the preset radio stations.
• Reset the clock.
• Check the routing of hoses and wiring and secure
them with cable ties if necessary.
• Top up the engine oil.
• Fill up with coolant and close the coolant expansion
tank.
• Screw in the coolant expansion tank filler plug.
• Carry out a road test to enable the PCM to collect
 data.
• After the road test check the fluid levels and correct
them if necessary.

General Specifications Scorpio 1995 (10/1994-06/1998)

 Print

Specifications
General
Engine management EEC V
Emission standard 96 EC
Engine code Y5A
Firing order 1‐3‐4‐2
Bore mm 89,6
Stroke mm 91
Cubic capacity cc 2295
Compression ratio 10,0:1
Engine power (EC rating) kW 108
Engine power (EC rating) PS 147
Engine power (EC rating), at rev/min 5600
Torque (EC rating) Nm 202
Torque (EC rating), at rev/min 4500
Idle speed rev/min 875
Engine speed, max. continuous rev/min 6150
Engine speed, max. intermittent rev/min 6375
Spark plugs AGPR22P1
Spark plug gap mm 1,0
Dimensions
Cylinder block
Cast mark 2,3
Cylinder bore diameter, standard class 1 mm 89,60 ‐ 89,61
Cylinder bore diameter, standard class 2 mm 89,61 ‐ 89,62
Number of main bearings 5
Thrust bearing width (without thrust half washers)
mm 21,17 ‐ 21,23
standard
Fitted main bearing shells
Vertical inner diameter, standard mm 55,003 ‐ 55,030
Vertical inner diameter, 1st undersize 0,02 mm 54,993 ‐ 55,020
Vertical inner diameter, 2nd undersize 0,25 mm 54,753 ‐ 54,780
Vertical inner diameter, 3rd undersize 0,50 mm 54,503 ‐ 54,530
Vertical inner diameter, 4th undersize 0,75 mm 54,253 ‐ 54,280
Main bearing parent bore diameter, standard mm 59,287 ‐ 59,300
Main bearing parent bore diameter, oversize 0,40 mm 59,687 ‐ 59,700
Crankshaft
End float mm 0,093 ‐ 0,303
Main bearing journal diameter, standard mm 54,98 ‐ 55,00
Main bearing journal diameter, undersize (green) mm 54,73 ‐ 54,75
Bearing shell to main bearing journal clearance mm 0,011 ‐ 0,048
Big end journal diameter, standard mm 50,89 ‐ 50,91
Big end journal diameter, undersize 0,25 (green) mm 50,64 ‐ 50,66
Thrust half washer thickness, standard mm 2,301 ‐ 2,351
Thrust half washer thickness, oversize 0,38 mm
mm 2,491 ‐ 2,541
(yellow)
Thrust bearing journal width, standard mm 26,025 ‐ 26,075
Thrust bearing journal width, oversize 0,38 (yellow) mm 26,405 ‐ 26,455
Connecting rod
Bore diameter, big end mm 53,89 ‐ 53,91
Bore diameter, small end mm 20,589 ‐ 20,609
Fitted big‐end bearing shells
Vertical inner diameter, standard mm 50,916 ‐ 50,950
Vertical inner diameter, 1st undersize 0,025 mm 50,892 ‐ 50,926
Vertical inner diameter, 2nd undersize 0,25 mm 50,666 ‐ 50,700
Vertical inner diameter, 3rd undersize 0,50 mm 50,416 ‐ 50,450
Vertical inner diameter, 4th undersize 0,75 mm 50,166 ‐ 50,200
Vertical inner diameter, 5th undersize 1,00 mm 49,916 ‐ 49,950
Big‐end bearing journal to shell clearance mm 0,006 ‐ 0,060
Big‐end bearing end float mm 0,090 ‐ 0,3610
Uncoated pistons (unused)
Piston diameter, class 1 mm 89,560 ‐ 89,570
Piston diameter, class 2 mm 89,570 ‐ 89,580
Coated pistons (unused)
Piston diameter, class 1 mm 89,580 ‐ 89,610
Piston diameter, class 2 mm 89,590 ‐ 89,620
Piston clearance in cylinder bore (unused, uncoated
mm 0,03 ‐ 0,05
piston)
Piston clearance in cylinder bore (unused, coated
mm ‐0,01 ‐ +0,03
piston)
Piston pin length mm 63,0 ‐ 63,8
Interference fit in small‐end bore mm 0,016 ‐ 0,042
Piston ring gap (installed), top mm 0,3 ‐ 0,46
Piston ring gap (installed), middle mm 0,5 ‐ 0,76
Piston ring gap (installed), bottom mm 0,15 ‐ 0,71
Set the ring gaps at 90° to each
other around the piston
Ring gap positions
circumference; this also applies to
each part of the oil scraper ring.
Cylinder head with valve seat inserts*
Cast mark 2,3
Upper correction angle, inlet valve (production) ° 30
Upper correction angle, exhaust valve (production) ° 30
Valve seat angle ° 44,5 ‐ 45,5
Valve seat width, inlet mm 1,18 ‐ 2,02
Valve seat width, exhaust mm 1,35 ‐ 2,19
Lower correction angle, inlet (production) ° 75
Lower correction angle, exhaust (production) ° 75
Valve stem guide diameter, inlet mm 7,063 ‐ 7,094
Valve stem guide diameter, exhaust mm 7,063 ‐ 7,094
Camshaft bearing parent bore diameter mm 26,00 ‐ 26,03
Camshafts
Number of camshaft bearings, each camshaft 5
Drive Single roller chain
Camshaft end float mm 0,02 ‐ 0,26
Cam lift, inlet mm 9,4
Cam lift, exhaust mm 8,75
Valve timing, inlet opens BTDC °CS 9
Valve timing, inlet closes ABDC °CS 51
Valve timing, exhaust opens BBDC °CS 48
Valve timing, exhaust closes ATDC °CS 12
Camshaft bearing journal diameter mm 25,96 ‐ 25,98
Valves
Valve timing DOHC
Valve clearance adjustment Hydraulic tappets
Hydraulic tappet diameter mm 30
Hydraulic tappet clearance in housing mm 0,025 ‐ 0,071
Inlet valve length mm 111,67 ‐ 112,13
Exhaust valve length mm 111,37 ‐ 111,83
Valve head diameter, inlet mm 33,5
Valve head diameter, exhaust mm 30,0
Valve stem diameter, standard inlet mm 7,025 ‐ 7,043
Valve stem diameter, standard exhaust mm 6,999 ‐ 7,017
Valve stem diameter, oversize 0,2 inlet mm 7,225 ‐ 7,243
Valve stem diameter, oversize 0,2 exhaust mm 7,199 ‐ 7,217
Valve stem diameter, oversize 0,4 inlet mm 7,425 ‐ 7,443
Valve stem diameter, oversize 0,4 exhaust mm 7,399 ‐ 7,417
Inlet valve stem guide clearance mm 0,020 ‐ 0,069
Exhaust valve stem guide clearance mm 0,046 ‐ 0,095
Free valve spring height mm 43,6
Spring height (compressed) mm max. 26,5
Valve spring inner diameter mm 17,2
Valve spring coil diameter mm 3,7
Number of turns 7,4
Lubrication
Oil pressure at 800 rev/min (with SAE 10W/30 and
bar 1,60
80°C oil temperature)
Oil pressure at 2000 rev/min (with SAE 10W/30 and
bar 3,10
80°C oil temperature)
Pressure relief valve opens at bar 3,70 ‐ 4,60
Oil control light comes on at bar 0,30 ‐ 0,50
Oil pump rotor/housing clearance mm 0,154 ‐ 0,304
Inner/outer rotor clearance mm 0,05 ‐ 0,20
Rotor end float at mating face mm 0,039 ‐ 0,104
Balancer shaft housing
Balancer shaft end float mm 0,050 ‐ 0,100
Balancer shaft radial clearance mm 0,022 ‐ 0,074
Distance plate for balancer shaft housing
Range of adjustment Available shims Colour coding
0,26 ‐ 0,29 mm 0,15 mm Silver
0,30 ‐ 0,44 mm 0,30 mm Pale blue
0,45 ‐ 0,59 mm 0,45 mm Red
0,60 ‐ 0,75 mm 0,60 mm Black
0,76 ‐ 0,90 mm 0,75 mm Green
Lubricants, Adhesives and Sealers
Description Ford
Specification
Coolant ESD‐M97B49‐A
Sealer, coolant temperature sensor, coolant pump angle connector, oil
WSK‐M2G349‐A7
pressure switch (Loctite 243)
Sealer for rear oil seal carrier to balancer shaft housing WSE‐M4G323‐A6
Lubricant for O‐ring of crankshaft position/speed sensor (CPS) WSD‐M1C226‐A
Power steering fluid SQM‐2C‐9010‐A
Lubricant for spark plug threads, HO2S sensor (`Never Seez') ESE‐M1244‐A
High‐temperature grease ESDM‐1C220‐A
Silicone grease A960‐M1C171‐AA
Capacity
Description Litres
Engine oil, initial fill, with filter 5,1
Engine oil, oil change incl. filter (every 15,000 km) 4,25
Engine oil, oil change excl. filter 3,75
Engine oil
Ambient temperature Designation Specification
Ford Super Multigrade Engine
‐10 to above 40°C SAE 20W50 API/SG/CD
Oil
Ford Super Multigrade Engine
‐15 to above 40°C SAE 15W40 API/SH/CD
Oil
Ford Super Multigrade Engine
‐20 to above 40°C SAE 10W30 API/SH/CD EC
Oil
Ford XR+ High‐performance
‐20 to above 40°C SAE 10W40 API/SH/CD EC
High‐lubricity Engine Oil
Ford Formula S Synthetic
‐30 to above 40°C SAE 5W50 API/SG/CD
Engine Oil
Synthetic/Semi‐synthetic
‐30 to above 40°C SAE 5W40 API/SH/CD EC
Engine Oil
Ford Super Multigrade Engine
+40° to below ‐30°C SAE 5W30 API/SG/CD
Oil
The engine oil to specification SAE 5W30 API/SG/CD has only been approved for use in
northern European territories
If engine oils of other brands are used, it is imperative to ensure that these conform to API
SG/CD or better in the particular viscosity class.
Torques
General Nm lbf.ft
Front axle reinforcing bar 80 59
Air conditioning compressor 47 35
Air baffle ‐ fan motors 11 8
Hood hinges 23 17
EGR valve to bracket 24 18
EGR tube to exhaust manifold 75 55
EGR tube bracket to exhaust manifold 23 17
Transmission crossmember to body 36 27
Transmission crossmember to automatic transmission 62 46
Driveshaft to rear axle 66 49
Driveshaft centre bearing 21 15
Starter motor to automatic transmission 44 32
Automatic transmission to engine (flange bolts) 44 32
Starter motor bracket to cylinder block 44 32
Torque converter to engine drive plate 44 32
Earth lead to automatic transmission 44 32
Oil dipstick tube bracket to automatic transmission 44 32
Oil pipes to automatic transmission 25 18
Oil pipe bracket to automatic transmission 44 32
Engine mounting bracket to cylinder block 47 35
Engine mounting nuts 50 37
Torques
Steering Nm lbf.ft
Intermediate shaft to steering shaft 18 13
Steering gear ‐ 1st stage 15 11
Steering gear ‐ 2nd stage 90° 90°
Power steering pump to bracket 25 19
Power steering pump pulley 25 19
Torques
Exhaust system Nm lbf.ft
Front to rear exhaust pipe 47 35
Front exhaust pipe bracket to transmission crossmember 47 35
Catalytic converter to exhaust manifold 47 35
Catalytic converter bracket to automatic transmission 44 33
Catalytic converter bracket to body 47 35
Front catalytic converter bracket 24 18
Torques
Cylinder block Nm lbf.ft
Main bearing 97 72
Big end bearing, 1st stage 7 5
Big end bearing, 2nd stage 16 12
Big end bearing, 3rd stage 90° 90°
Balancer shaft housing to cylinder block, 1st stage 5 4
Balancer shaft housing to cylinder block, 2nd stage 17 13
Crankshaft rear oil seal carrier 15 11
Crankshaft pulley/vibration damper, 1st stage 52 38
Crankshaft pulley/vibration damper, 2nd stage 85° 85°
Clutch Disk and Pressure Plate 29 21
Flywheel 87 64
Lower timing chain cover 11 9
Crankshaft position/speed sensor 4 3
Torques
Cylinder Head Nm lbf.ft
Cylinder head bolts, 1st stage 10 7
Cylinder head bolts, 2nd stage 35 26
Cylinder head bolts, 3rd stage 90° 90°
Cylinder head bolts, 4th stage 90° 90°
Auxiliary cylinder head bolts 38 28
Camshaft bearing caps 24 18
Timing chain top guide 12 9
Timing chain bottom guide 26 19
Camshaft sprockets 59 44
Timing chain upper cover 11 8
Cylinder head cover, 1st stage 3 2
Cylinder head cover, 2nd stage 9 7
Camshaft position sensor (CMP sensor) 5 4
Spark plugs 18 13
DIS ignition coils 10 7
Ignition coil cover 5 4
Studs for exhaust manifold 14 10
Engine oil dipstick tube bracket 24 18
Engine lifting eye, rear right 25 18
Engine lifting eye, front left 47 35
Inlet manifold 22 16
Fuel rail 23 17
Throttle housing 10 7
Idle speed control valve 10 7
Engine coolant temperature sensor (ECT sensor) 27 20
Torques
Oil circuit Nm lbf.ft
Oil intake tube to balancer shaft housing 12 9
Sump to balancer shaft housing 12 9
Oil drain plug 24 18
Oil pressure switch 27 20
Oil filter connector 57 42
Oil pump 11 8
Oil pump sprocket 21 15
Oil pump cover 10 7
Oil pump sprocket 21 15
Oil pump drive chain upper guide 26 19
Oil pump drive chain lower guide 12 9
Oil pump drive chain tensioner 12 9
Torques
Balancer shaft housing Nm lbf.ft
Balancer shaft bearing caps to housing 12 9
Sprockets to shaft stub 19 14
Torques
Coolant circuit Nm lbf.ft
Coolant pump 23 17

Engine ‐ Dismantle and Assemble (21

Scorpio 1995 (10/1994-06/1998)
134 8)
 Print

Removal and Installation

Special Tools
15‐030A Universal flange‐
holding wrench

16‐067 Locator for clutch disc

17‐055‐02 Depth gauge for

cylinder head reworking

21‐031B Engine mounting

bracket

21‐036A Remover for pilot

bearing

21‐044A Installer/centring
pin, pilot bearing

21‐107 Pliers, hydraulic

tappets

21‐125 Extractor, balancer

shaft end float measurement

21‐141 Installer, crankshaft

rear oil seal

21‐146C Engine mounting

plate

21‐147 Vibration damper

remover

21‐167 Wrench for cylinder

head bolts

21‐168 Crankshaft locking

tool
 21‐202 Socket, spark plugs

21‐214 Installer, vibration

damper

21‐226 Pliers, spark plug

connectors

21‐540 Bolt tightening angle

gauge

Proprietary Tools
Piston ring compressor
Piston ring pliers
Dial indicator
Measuring fixture
External micrometer gauge
Internal gauge
E8 Torx wrench
E10 Torx wrench
T20 Torx wrench
T25 Torx wrench
T30 Torx wrench
T55 Torx wrench
Twist drill, 2,5 mm diameter
Steel straight‐edge
Oil filter strap wrench
Workshop Equipment
Assembly stand with
21‐187
geared drive
Materials
Engine oil
Spark plug thread
lubricant (`Never ESE‐M1244‐A
Seez')
Lubricant, crankshaft
position sensor (CKP WSD‐M1C226‐A
sensor)
Sealer, coolant
temperature sensor,
coolant pump angle WSK‐M2G349‐A7
connector, oil pressure
switch (Loctite 243)
Obtainable from:
Replacement Services
Limited, 30, Euston
Plastigage
Street, Freemans
Industrial Estate,
Leicester, LE2 7ST
Sealer for crankshaft
WSE‐M4G323‐A6
rear oil seal carrier
Bolt M6 X 60
Silicone grease A960‐MC171‐AA
Dismantle
1. Attach the engine to the assembly stand.
• Drain off the engine oil.
• Detach the oil filter.
• Undo the oil dipstick tube and pull it out.
 CAUTION:
Do not pull on the cable when removing the
spark plug connectors. Remove the high‐
tension lead from the ignition coil to prevent
kinks in the lead if necessary. Turn the spark
plug connectors slightly before removing
them in order to loosen the seal.
CAUTION:
Remove the spark plug connectors in a
straight line in relation to the spark plugs
(use special tool 21‐226 for offset spark plug
connectors).
2. Remove the cylinder head cover.
1. Remove the ignition coil cover (10 bolts).
2. Pull off the spark plug caps, remove the coils and
spark plugs.
3. Remove the camshaft position sensor (CMP sensor).
4. Remove the cylinder head cover (four nuts, 11
bolts).
   Remove the gaskets.
 NOTE:
Lock the flywheel.

3. Unscrew and remove the crankshaft pulley/vibration

damper bolt.

4. Remove the crankshaft pulley/vibration damper.

5. Remove the timing chain covers (seven bolts for the

top, 16 bolts for the bottom).
   Remove the gasket.

6. Dismantle the oil pump chain drive.

NOTE:
Do not remove the bolt.

1. Loosen the oil pump sprocket bolt.

NOTE:
Wrap adhesive tape around the twist drill
flutes.
2. Press the chain tensioner together, lock it with a
twist drill (2,5 mm diameter) and remove it.
3. Remove the chain guide.
   Take off the chain.
7. Remove the timing chain.
1. Remove the chain guide.
NOTE:
Hold the flange with the special tool. Tie the
chain up with wire to stop it from falling into
the timing chain housing.
2. Undo the camshaft sprockets and remove them.
3. Remove the chain tensioner.
• Remove the lock washer.
• Extract the pivot bolt using an M6 bolt.
• Take out the chain tensioner and hydraulic plunger.
4. Remove the chain guide bolt and pull the chain
guide up and out together with the chain.
 8. Remove the camshafts.
NOTE:
Store the bearing caps, camshafts and
hydraulic tappets in sequence.
NOTE:
Front bearing cap with chain guide bracket.

1. Remove the bearing caps.

2. Take out the camshafts and hydraulic tappets.
3. Remove the three bolts from the cylinder head.
CAUTION:
Only use cylinder head bolts with an integral
washer.
9. Cylinder head bolts, distinguishing features
1. New cylinder head bolts with integral washer
2. Old cylinder head bolts with separate washer

Remove cylinder head

 NOTE:
Lay the cylinder head down only on a soft
surface.
NOTE:
Bolt‐slackening sequence.

10. Detach the cylinder head.

• Pull off the connectors from the oil pressure switch
and the crankshaft position sensor (CKP sensor).
• Lift the cylinder head and lay it down on a soft
surface.

11. Remove the components of the oil and coolant

circulation systems.
1. Take off the cylinder head gasket.
2. Oil pressure switch
3. Crankshaft position (CKP) sensor.
4. Oil pump sprocket.
5. Remove the oil pump.
   Remove the gasket.
6. Detach the coolant pump.
   Take out the seal.
12. Detach the clutch assembly.

NOTE:
Do not re‐use the bolts.

13. Detach the flywheel.

   Remove Special Tool 21‐168.

14. Remove the sump (14 bolts) and balancer shaft

housing (17 bolts).
NOTE:
The sump and balancer shaft housing must
be removed from below, so that no sludge or
abraded particles can enter the engine.
1. Remove the sump.
2. Remove the oil intake pipe.
3. Remove the balancer shaft housing and gasket.
15. Remove the crankshaft rear oil seal carrier.
• Remove the gasket.
• Drive out the oil seal on a flat surface.
 NOTE:
Store the bearing caps and shells in
sequence.
NOTE:
Do not damage the cylinder bores.

16. Remove the pistons and connecting rods.

• Remove the Woodruff key and take off the crankshaft
sprocket.
• Remove the carbon from the upper edge of the
cylinder bore.
17. Remove the crankshaft pilot bearing.
 NOTE:
Store the bearing caps, shells and thrust half
washers in sequence.
18. Remove the crankshaft.
Assemble
 19. Thoroughly clean all sealing surfaces and re‐
useable parts, check them for damage and renew as
necessary.
20. Measure the cylinder bores.
NOTE:
Measurements which fall both in the top part
of one bore range and in the lower part of
the next range above should be taken to be
in the smaller range.

21. Measure the diameter of the main and big‐end

journals.
   Repeat the measurement at 90° intervals.

22. Check the piston ring gaps.

   The values given in the General Specifications
apply to a gauge ring which is used in production.
The figures measured in the cylinder can exceed
these by 0,15 mm.

NOTE:
Piston ring clearance must be measured with
the piston ring proud of the piston surface.
23. Measure the piston ring clearance.

Check cylinder head evenness

 NOTE:
The steel straight‐edge must be at least 500
mm long and 5 mm wide.
24. Check the cylinder head for distortion.
• Maximum allowable distortion over the combustion
chamber steps: Across the cylinder head: 0,05 mm.
Lengthways and diagonally along the cylinder head:
0,10 mm.
• Lay the steel straight‐edge across all the combustion
chamber steps and check each at three points.
• Lay the steel straight‐edge lengthways at three
different points along the cylinder head and check at
each combustion chamber step.
• Lay the steel rule diagonally over the cylinder head
and check at each combustion chamber step.
• Rework the cylinder head as described in the
following operation if necessary.
25. Notes on re‐working the cylinder head.
NOTE:
Keep the average peak‐to‐valley height (Rz)
at 0,0135 mm on re‐working.
• The cylinder head may be reworked to a maximum
of 0,20 mm (by milling or surface grinding).
Measurement ”a" must not be less than 13,80 mm
(see step ) and measurement ”b" must not be less
than 147,25 mm.

NOTE:
Remove any carbon deposit where the
measurement is to be made.
26. Measurement point in the combustion chamber for
measurement ”a".

Check oil pump

NOTE:
The oil pump can only be renewed as a unit.

27. Dismantle the oil pump.

 28. Check the radial clearance between the outer rotor
and the oil pump housing.

29. Reassemble the oil pump.

CAUTION:
Do not damage the bearing running
surfaces of the crankshaft during
installation.
NOTE:
Lay the bearing shells which have a
groove and hole, free of oil, into the
cylinder block.
30. Fit the crankshaft without lubrication.

Measure main bearing clearance

CAUTION:
The crankshaft must not be turned during the
measuring operation.
31. Measure the main bearing clearance.
   Lay a length of Plastigage thread on the bearing
journal across the bearing.

NOTE:
The bearing cap numbering starts at the
timing chain end.
NOTE:
Measure the bearing clearance in numerical
sequence (one to five).
32. Measure the main bearing clearance (cont.).
   Put the bearing cap with its corresponding bearing
shell in place with the arrow pointing towards the
timing chain end, and secure it.
NOTE:
Do not strike the bearing caps.

   Remove the bearing cap.

 33. Measure the main bearing clearance (cont.).
• Compare the Plastigage thread with the Plastigage
scale.
• The reading corresponds to the bearing clearance.
NOTE:
If the bearing clearance does not fall in
range, then the bearing shells should be
changed and the measurement procedure
repeated from step

NOTE:
Put the thrust half washers in place with the
grooves outwards.
NOTE:
Lay the bearing shells which have the groove
and hole in place in the cylinder block.
34. Install the crankshaft.
   Oil the crankshaft bearing shells and thrust half
washers.
Measure crankshaft end float
35. Measure the crankshaft end float.
• Measure the end float by lifting the crankshaft.
• Correct the end float if necessary using thrust half
washers at the third main bearing.

36. Install the crankshaft pilot bearing.

NOTE:
Do not damage the running surfaces of the
cylinders and bearings.
NOTE:
Coat the running surfaces of the cylinders
with engine oil.
NOTE:
The arrows point to the timing chain end of
the engine.
37. Fit the pistons and connecting rods.
38. Measure the big‐end bearing clearance as
described in steps to

NOTE:
Coat the bearing shells and crankshaft with
engine oil.
 39. Fit the pistons and connecting rods (continued).
   
Install crankshaft rear oil seal

40. Install the crankshaft rear oil seal

NOTE:
Use a new gasket.

NOTE:
Do not tighten the bolts yet.

1. Put the oil seal carrier, new gasket and bolts in

place ready for installation.
2. Install the oil seal using the special tool and two
vibration damper bolts.
NOTE:
The oil seal carrier must not lie flush with the
cylinder block.
3. Fit the oil seal carrier so that it is proud of the
cylinder block by up to 0,46 mm on both sides.
4. Tighten the bolts.
   Remove the special tool.
41. Apply sealer (WSE‐M4G323‐A6) to the contact
faces of the cylinder block and the oil seal carrier.
 42. Fit the balancer shaft housing and sump.
NOTE:
Use a new gasket.

CAUTION:
Do not wipe away any sealer which leaks out.

1. Lay the gasket in place ready for installation.

• Press the semi‐circular elastomer section into the
groove.
• Hold the gasket in position by bending the tabs.
• Apply sealer (WSE‐M4G‐323‐A6) as described in step
to both metal to elastomer joints on the gasket.
2. Install the balancer shaft housing.
3. Install the oil intake pipe.
4. Fit the sump.
NOTE:
Use a new seal.

5. Fit the oil drain plug.

Measure balancer shaft housing clearance shims
 NOTE:
Bring the surfaces flush using adjustment
shims (see General Specifications) when
fitting the transmission.
43. Measure the step between the cylinder block and
the balancer shaft housing.

44. Fit the components of the oil and coolant circuits.

NOTE:
Use a new seal.

1. Water pump
NOTE:
Use a new gasket.

2. Oil pump
NOTE:
Do not tighten the sprocket.

3. Oil pump sprocket.

NOTE:
Apply lubricant (WSD‐M1C226‐A) to the seal

4. CKP sensor.
NOTE:
Coat the first three turns of the thread with
sealer (WSK‐M2G349‐A7).
5. Oil pressure switch
6. Lay a new cylinder head gasket in place.
 CAUTION:
Use new bolts.

NOTE:
There is only one installation position.

45. Fit the flywheel.

46. Move the crankshaft so that the first cylinder is
about 25 mm before TDC.

Install cylinder head

CAUTION:
Do not reuse old cylinder head bolts which
have a separate washer.
47. The new bolts with integral washer may be reused
providing that the distance of 174,3 mm is not
exceeded and the cylinder head bolts show no signs of
damage.
1. New cylinder head bolts
2. Old cylinder head bolts

NOTE:
The cylinder head is positively located on
the cylinder block by two guide sleeves.
48. Move the cylinder head into its installation
position.
49. Tighten the cylinder head bolts in the sequence
indicated using socket 21‐167.

NOTE:
Tighten them in two stages.

50. Tighten the cylinder head bolts in the sequence

indicated using socket 21‐167 (cont.).
 51. The intake and exhaust camshafts are marked by
two identification rings between the fourth and fifth
cams.
1. Intake camshaft
2. Exhaust camshaft

52. Install the camshafts.

CAUTION:
After tightening the camshafts the crankshaft
must not be turned for one quarter of an
hour.
1. Put in three cylinder head bolts.
2. Coat the hydraulic tappets with engine oil and put
them in place.
NOTE:
Fit the camshafts so that none of the cams is
at full lift.
3. Coat the camshafts with engine oil and put them in
place.
4. Put the bearing caps in place and tighten the bolts.
CAUTION:
A fully or partially released plunger (whether
new or used) must not be fitted.
53. Check the new chain tensioner plunger.
1. Plunger latched.
2. Plunger partly released.
3. Plunger fully released (the detent ring is visible).

Install timing chain

 54. Install the chain tensioner plunger.
NOTE:
The only copper coloured link must be at
the bottom of the chain guide.
55. Insert the timing chain with the chain guide.

NOTE:
The copper link must be across the single
mark on the rear sprocket.
56. Fit the timing chain at the bottom.
• Slide on the sprocket.
• Lay the timing chain around the inner sprocket.
• Fit the Woodruff key in the crankshaft.
• Tie the chain with wire to stop it from slipping into
the timing chest.

NOTE:
Apply thread locking compound (WSK‐
M2349‐A7) to the thread of the lower bolt.
57. Tighten the chain guide bolts (2,0 DOHC 16V
shown).

58. Install the chain tensioner.

1. Move the chain tensioner into position ready for
installation.
2. Insert the pin.
3. Fit the circlip.
59. Fit the timing chain at the top.
NOTE:
The copper coloured chain link must lie
directly across the marking on the sprocket.
NOTE:
The timing chain must be taut on the long
side.
   If necessary, turn the camshaft slightly.

60. Fit the timing chain at the top (continued).

NOTE:
The copper coloured link must lie directly
across the marking on the sprocket.
NOTE:
The timing chain may sag slightly between
the camshaft sprockets.
   Screw in the bolts of both camshaft timing
sprockets.

61. Fit a new timing chain upper guide.

62. Release the chain tensioner plunger.

• Press the chain tensioner arm down by hand and
unlatch the oil‐filled plunger.
• If the chain tensioner arm does not reach the oil‐
filled plunger, the plunger must be released using an
auxiliary tool.
 63. Fabricate an auxiliary tool.
   Use 2,5 mm diameter welding rod cut to a length of
about 220 mm.

64. Tighten the camshaft sprocket bolts.

65. Check the valve timing.

• Turn the engine in the normal direction of rotation
through two complete revolutions and set it to the
markings.
• If it is necessary to correct the valve timing, i.e.
release the timing chain, a new oil‐filled plunger must
also be fitted for the chain tensioner.

66. Check the valve timing (continued).

• Turn the crankshaft in the normal running direction
until the second cylinder is at TDC.
• The markings on the camshaft sprockets must be
opposite one another on the level of the top edge of
the cylinder head.

Install oil pump chain drive

67. Fit the oil pump chain drive.
NOTE:
The copper coloured links must be across the
markings on the crankshaft sprocket and the
balancer shaft sprocket. To do this turn the
crankshaft so that the second cylinder is at
TDC.
1. Chain
2. Chain guide
3. Fit the chain guide and pull out the twist drill.
4. Tighten the oil pump sprocket bolt.

NOTE:
Use new gaskets.

68. Fit the timing chain cover.

 NOTE:
The top edge must lie flush with the cylinder
head top edge.
1. Upper timing chain cover
NOTE:
Take out the centring cap after tightening the
bolts.
2. Lower timing chain cover.
   Tighten the cover bolts.
69. Install the crankshaft pulley/vibration damper.

NOTE:
Lock the crankshaft

70. Tighten the crankshaft pulley/vibration damper

bolt.
 NOTE:
Use new gaskets.

71. Fit the cylinder head cover.

NOTE:
Bolt‐tightening sequence.

1. Fit the cylinder head cover.

NOTE:
Apply lubricant (ESE‐M1244‐A) to the spark
plugs.
CAUTION:
Use a blunt object to apply the silicone
grease (e.g. a plastic cable tie) so as not to
damage the spark plug connector seal.
CAUTION:
Push on the spark plug connectors in a
straight line in relation to the spark plugs.
NOTE:
Coat the inside of the spark plug connectors
with silicone grease (A960‐M1C171‐AA) down
to a depth of 5‐10 mm.
2. Fit the spark plugs, ignition coils and ignition cables.
3. Fit the CMP sensor and connector.
 4. Fit the ignition coil cover.
Install clutch
72. Centre the clutch disc on the clutch pressure plate.

73. Secure the clutch.

1. Put the clutch pressure plate and the centralised
clutch disc in position ready for installation.
2. Tighten the bolts uniformly, working diagonally.
3. Remove the special tool.

74. Finishing operations.

• Attach the oil filter.
• Fill up with engine oil.
• Detach the engine from the assembly stand.

Cylinder Head ‐ Remove and Install (21

Scorpio 1995 (10/1994-06/1998)
163 0)
 Print

Removal and Installation

Special Tools

15‐030A Universal flange‐

holding wrench

17‐055‐02 Depth gauge for

cylinder head reworking

21‐107 Pliers for hydraulic

tappets

21‐167 Wrench for cylinder

head bolts

21‐202 Socket, spark plugs

21‐226 Pliers, spark plug

connectors
 21‐540 Bolt tightening angle
gauge

24‐003 Remover/installer,
cooling hose clamp

Proprietary Tools
Steel straight‐edge (at least 500 mm long
and 5 mm wide)
Depth gauge
Brass drift
Feeler gauge
Materials
Lubricant (Never‐
ESE‐M1244‐A
Seeze)
Bolt M6 X 60
Silicone grease A960‐M1C171‐AA
Remove
1. General note.
   Use Special Tool 24‐003 to remove coolant or
ventilation lines if necessary.
2. Preparatory measures.
• Make a note of the radio keycode.
• Make a note of the preset radio stations.
• Detach the battery cover.
CAUTION:
Disconnect the battery negative lead.

   Withdraw the automatic transmission dipstick.

WARNING:
Wrap a thick cloth around the coolant
expansion tank cover before opening the
cooling system when the engine is at
operating temperature in order to prevent
scalding.
   Unscrew the lid from the coolant expansion tank.
3. Raise the vehicle.
4. Remove the engine undershield.
 WARNING:
There is a risk of scalding when the engine is
warm.
5. Drain off the coolant.

6. Lower the vehicle.

7. Remove the air intake pipe.
1. Disconnect the multiplug from the intake air
temperature sensor (IAT sensor).
2. Detach the air intake pipe from the air cleaner
housing (two clips).
3. Disconnect the mass air flow (MAF) sensor plug.
4. Detach the air intake pipe.
5. Lift the resonator (push‐fit) and remove the air
intake pipe complete.

8. Detach the accelerator cable.

1. Pull off the retaining clip from above.
2. Detach the accelerator cable.
9. Disconnect the crankcase breather hose.

10. Disconnect the vacuum hoses and vacuum line.

1. Vacuum hoses
2. Vacuum line to the brake servo.
11. Detach the earth lead from the bulkhead.

12. Detach the main wiring loom plug.

13. Detach the coolant hoses from the thermostat
housing.
   Unclip the coolant hose.

14. Remove the three‐part exhaust manifold

heatshield.
15. Disconnect the two vacuum hoses.

16. Detach the exhaust gas recirculation valve (EGR

valve) and the EGR pipe.
1. Disconnect the vacuum hose.
2. Detach the EGR pipe.
3. Detach the EGR pipe bracket.
4. Detach the EGR valve from the bracket.

17. Disconnect the valve with the crankcase breather

hose and unclip it.
NOTE:
Only loosen the bolt.

18. Detach the oil dipstick tube bracket.

   Withdraw the oil dipstick.
19. Detach the catalytic converter from the exhaust
manifold.

20. Remove the ignition coil cover.

CAUTION:
Do not pull on the cable when removing the
spark plug connectors. Remove the high‐
tension lead from the ignition coil to prevent
kinks in the lead if necessary. Turn the spark
plug connectors slightly before removing
them in order to loosen the seal.
CAUTION:
Remove the spark plug connectors in a
straight line in relation to the spark plugs
(use special tool 21‐226 for offset spark plug
connectors).
21. Disconnect the spark plug connectors and remove
the ignition coils.

22. Remove the spark plugs.

23. Disconnect the plug of the camshaft position
sensor (CMP sensor).
24. Remove the cylinder head cover (eleven bolts, four
nuts).
   Remove the gasket.

25. Remove the upper timing chain cover.

26. Set the crankshaft to the TDC position of cylinder

no. 1.
   The marking on the crankshaft pulley/vibration
damper should lie vertically uppermost.

27. Remove the upper chain guide.

 NOTE:
Use the special tool to stop them from
turning.
28. Remove the camshaft sprockets.

29. Undo the top bolt of the timing chain guide.

CAUTION:
Secure the lock washer to prevent it from
dropping down.
NOTE:
Secure the timing chain to prevent it from
falling into the valve body assembly.
30. Remove the chain tensioner.
1. Remove the lock washer.
2. Extract the chain tensioner pivot bolt using an M6
x 60 bolt.

CAUTION:
Do not re‐use the chain tensioner hydraulic
plunger.
31. Withdraw the chain tensioner hydraulic plunger.

NOTE:
Remove the camshaft bearing caps and the
camshafts in order.
32. Remove the camshafts.
1. Remove the bracket of the timing chain guide.
2. Remove the camshaft bearing caps.
   Remove the camshafts.
33. Remove the hydraulic tappets using Special Tool
21‐107.

CAUTION:
The cylinder head must be cooled down to at
least 30 °C before the bolts are loosened.
34. Remove the three bolts.

CAUTION:
Only reuse cylinder head bolts which have an
integral washer.
35. Distinguishing features of cylinder head bolts with
integral washer.
1. New cylinder head bolts with integral washer.
2. Old cylinder head bolts with separate washer.

CAUTION:
Do not reuse the cylinder head bolts.

NOTE:
It is essential that the cylinder head is put
down on a soft surface.
NOTE:
Bolt‐slackening sequence.

36. Detach the cylinder head.

• Pull out the plugs for the oil pressure switch and the
crankshaft position sensor (CKP sensor).
• Lift off the cylinder head and put it down on a soft
surface.
• Remove the cylinder head gasket.

37. General instructions

   Use special tool 24‐003 to install coolant or
ventilation lines if necessary.
 NOTE:
Renew the seals, circlips and self‐locking
nuts.
38. Thoroughly clean all mating faces and reusable
components and check them for damage.
NOTE:
The steel straight‐edge must be at least 500
mm long and 5 mm wide.
39. Check the cylinder head for distortion.
• Maximum allowable distortion over the combustion
chamber steps: Across the cylinder head: 0,05 mm.
Lengthways and diagonally along the cylinder head:
0,10 mm.
• Lay the steel straight‐edge across all the combustion
chamber steps and check each at three points.
• Lay the steel straight‐edge lengthways along the
cylinder head and check at each combustion chamber
step.
• Lay the steel straight‐edge diagonally along the
cylinder head and check at each combustion chamber
step.
• If necessary, re‐work the cylinder head as described
in sub‐operation
40. Notes on re‐working the cylinder head.
NOTE:
Keep the average peak‐to‐valley height (Rz)
at 0,0135 mm on re‐working.
   Re‐work the cylinder head to a maximum of 0,20
mm (by milling or surface grinding). Measurement ”a"
must not be less than 16,55 mm (see sub‐operation )
and measurement ”b" must not be less than 147,45
mm.

NOTE:
Remove any carbon deposit where the
measurement is to be made.
41. Measurement point in the combustion chamber for
measurement ”a".

42. Set the piston of cylinder no. 1 to 25 mm before

TDC.
 43. Fit the cylinder head (shown without ancillary
components).
1. Fit the guide sleeves.
2. Lay a new cylinder head gasket in place.
3. Fit the cylinder head.

CAUTION:
Do not use old cylinder head bolts which have
a separate washer.
44. The new bolts with integral washer may be reused
providing that 174.3 mm distance is not exceeded and
the cylinder head bolts show no signs of damage.
1. New cylinder head bolts
2. Old cylinder head bolts

NOTE:
Bolt‐tightening sequence.

45. Tighten the cylinder head bolts using socket 21‐

167.
 NOTE:
Tighten them in two stages.

NOTE:
Bolt‐tightening sequence.

46. Tighten the cylinder head bolts using socket 21‐

167.

47. Screw in the three bolts and tighten them.

48. Make sure that the piston of cylinder no. 1 is

approx. 25 mm before TDC.
   Position of the crankshaft pulley/vibration damper.

49. Lubricate the new hydraulic tappets with engine oil

and insert them.

50. Camshaft, distinguishing features

NOTE:
The intake and exhaust camshafts are
marked by two identification rings between
the fourth and fifth cams.
1. Intake camshaft
2. Exhaust camshaft
 CAUTION:
After tightening the camshafts, the
crankshaft must not be turned for a quarter
of an hour.
51. Install the camshafts.
   Lubricate the bearing points with engine oil.
NOTE:
Lubricate the camshafts with engine oil and
fit them so that none of the cams is at full
lift.
NOTE:
Install the timing chain guide bracket with
the front camshaft bearing caps.
   Install the camshaft bearing caps. The position
markings are legible from the rear.
52. Set the camshafts and the crankshaft at the TDC
position for cylinder no. 1.
   The marking on the crankshaft pulley/vibration
damper should be vertically uppermost.

CAUTION:
A fully or partially released chain tensioner
plunger (whether new or used) must not be
fitted.
53. Check the new chain tensioner plunger.
1. Plunger latched
2. Plunger partially released
3. Plunger fully released (the detent ring is visible).

CAUTION:
Only use a new and latched chain tensioner
plunger.
54. Install the chain tensioner plunger.

55. Tighten the top bolt of the timing chain guide.

 CAUTION:
Secure the lock washer to prevent it from
dropping down.
56. Install the chain tensioner.
1. Insert the pivot bolt using an M6 x 60 bolt.
2. Install the lock washer.
   Unscrew the M6 x 60 bolt.

NOTE:
The timing chain must be taut on the long
side.
CAUTION:
The camshaft sprockets must engage in the
camshaft groove.
NOTE:
Copper chain links must line up with the
markings on the sprockets.
57. Fit the camshaft sprocket with the timing chain
(in the TDC position).
   If necessary, turn the camshaft slightly.
NOTE:
The timing chain may sag slightly between
the camshaft sprockets.
NOTE:
Copper chain links must line up with
markings on the sprockets.
58. Fit the camshaft sprocket with the timing chain
(in the TDC position).
59. Screw in the bolts of the camshaft sprockets
finger tight.

60. Release the chain tensioner plunger with a light

tap on the chain tensioner with the brass drift.

NOTE:
Use the special tool to stop them from
turning.
61. Tighten the camshaft sprocket bolts.
 62. Set the crankshaft to the TDC position of cylinder
no. 2.
NOTE:
If it is necessary to correct the valve
timings, i.e. release the timing chain, a new
chain tensioner plunger must also be fitted
as described in sub‐operations , and
63. Check the valve timing.
   The marks on the camshaft sprockets must be
opposite one another at the level of the top edge of
the cylinder head.

64. Check the valve timing (continued).

   Turn the crankshaft a further revolution in the
normal running direction and set it to the mark.

65. Install a new chain guide at the top.

NOTE:
Use a new gasket.

NOTE:
Align the top edge of the upper cover with
the cylinder head mating face (the maximum
downward misalignment is 0,13 mm).
66. Install the upper timing chain cover.
 NOTE:
Bolt‐tightening sequence.

67. Install the cylinder head cover using a new gasket

(eleven bolts, four nuts).
68. Connect the CMP sensor plug.

NOTE:
Apply lubricant (ESE‐M1244‐A) to the spark
plug threads.
69. Install the spark plugs.

CAUTION:
Use a blunt object to apply the silicone
grease (e.g. a plastic cable tie) so as not to
damage the spark plug connector seal.
CAUTION:
Push on the spark plug connectors in a
straight line in relation to the spark plugs.
NOTE:
Coat the inside of the spark plug connectors
with silicone grease (A960‐M1C171‐AA) down
to a depth of 5‐10 mm.
70. Install the ignition coils and connect the spark plug
connectors.
71. Install the ignition coil cover.
72. Attach the catalytic converter to the exhaust
manifold using a new gasket.

73. Fit the valve with crankcase breather hose and clip
it into place.
74. Fit the oil dipstick tube bracket.
   Insert the oil dipstick.

75. Fit the EGR valve and the EGR pipe.

1. Attach the EGR valve to the bracket.
2. Fit the EGR pipe bracket.
3. Fit the EGR pipe.
4. Connect the vacuum hose.

76. Fit the three‐part exhaust manifold heatshield.

• Loosely fit the parts in the order shown.
• Tighten the bolts.
77. Connect the two vacuum hoses.
78. Attach the coolant hoses to the thermostat
housing.
   Clip the coolant hose into place.

79. Fit the main wiring loom plug.

80. Connect the vacuum hoses and the vacuum line.

1. Vacuum hoses
2. Vacuum line to the brake servo.
81. Attach the earth lead to the bulkhead.

82. Attach the throttle cable.

1. Hook the accelerator cable in place.
2. Push the circlip into place.
83. Connect the crankcase breather hose.

84. Install the air intake pipe.

1. Attach the air intake pipe to the air cleaner
housing (two clips).
2. Fit the air intake pipe.
3. Move the resonator into the installation position
(push‐fit).
4. Connect the IAT sensor plug.
5. Connect the MAF sensor plug.

85. Standard finishing operations.

• Top up the coolant.
• Fix the wiring and hoses in place with cable ties.
• Connect the battery negative lead.
• Bleed the cooling system.
• Bring the engine up to operating temperature and
check it for leaks (visual check).
• Check the fluid levels and rectify as necessary.
• Enter the radio keycode.
• Reprogramme the preset radio stations.
• Reset the clock.
86. Raise the vehicle.
87. Fit the engine undershield.

88. Lower the vehicle.

89. Carry out a road test to enable the PC module
(EEC V) to collect data.