The cylinder heads are installed in such a way that the intake manifold is located between them, and the exhaust manifolds are located on the outer sides of the manifolds.
The cylinder block is made of cast iron. At the bottom of the block is an oil pan, stamped from sheet steel or cast from aluminum alloy.
Aluminum alloy pistons connected to the crankshaft by I-section connecting rods.
The crankshaft rotates in four bearings, axial play is regulated by thrust half rings mounted on the third main bearing.
Pressure lubrication is carried out by a double-rotor oil pump.
Main settings
| Engine | 2,4 V6 | 2,8 V6 | 2,9 V6 | 2,9 V6 | 2,9 V6 |
| Designation | AKC | BRC | BRD | BRE | |
| cylinder diameter, (mm) | 84,00 | 93,00 | 93,00 | 93,00 | 93,00 |
| piston stroke, (mm) | 72,00 | 68,50 | 71,99 | 71,99 | 71,99 |
| Volume, (see3) | 2394 | 2792 | 2933 | 2933 | 2933 |
| Compression ratio | 9,5 | 9,2 | 9,5 | 9,0 | 9,0 |
| compression pressure, (MPa) | 1,15 – 1,25 | ||||
| Rated power: | |||||
| - kW at rpm. | 96 at 5800 | 110 at 5800 | 110 at 5700 | 107 at 5500 | 107 at 5500 |
| – HP at rpm | 131 at 5800 | 150 at 5800 | 150 at 5700 | 146 at 5500 | 146 at 5500 |
| Max Torque (Nm at rpm) | 193 at 3000 | 216 at 3000 | 233 at 3000 | 222 at 3000 | 226 at 3000 |
Cylinder head
The head is made of a special aluminum alloy.
| Designation: | |
| – engine 4.8 dm3 | H |
| – engine 2.8 dm3 | EN |
| – engine 2.9 dm3 (BRC) | F |
| – engine 2.9 dm3 (BRD and BRE) | K |
| Valve seats: | |
| – the angle of the working chamfer of the valves | 44,30 – 45,00° |
| - width of the working chamfer of the valve seat | 1.61 - 2.33 mm |
Regrinding of the lower plane of the cylinder head is not provided.
Valves
Inlet valve sizes
| Name | V6 2.4 in3 and 2.9 BRC | V6 2.8 in.3 | V6 2.9 in.3 |
| Plate diameter, mm | 39,67 – 40,00 | 41,85 – 42,24 | 41,85 – 42,24 |
| Valve length, mm | 106,2 – 106,9 | 105,25 – 106,96 | 104,7 – 105,4 |
| Rod diameter, mm: | |||
| – standard | 8,025 – 8,043 | 8,025 – 8,043 | 8,025 – 8,043 |
| – enlarged by 0.2, 0.4, 0.6 and 0.8 mm | |||
Gap of the rod in the guide: 0.020 - 0.063 mm.
Exhaust valve sizes
| Name | V6 2.4 in3 and 2.9 BRC | V6 2.8 in.3 | V6 2.9 in.3 |
| Plate diameter, mm | 33,83 – 34,21 | 35,83 – 36,21 | 41,85 – 42,24 |
| Valve length, mm | 106,1 – 107,1 BRC 106,8 – 107,8 | 105,20 – 106,20 | 104,6 – 105,6 |
| Rod diameter, mm: | |||
| – standard | 7,999 – 8,017 | 7,999 – 8,017 | 7,999 – 8,017 |
| – enlarged by 0.2, 0.4, 0.6 and 0.8 mm | |||
Identification of valve stem seals by color
| Standard size | White |
| 0.2 mm enlarged | Red |
| 0.4 mm enlarged | Blue |
| 0.6 mm enlarged | Green |
| 0.8 mm enlarged | Black |
Valve clearance (with a cold engine)
| Inlet valve | 0.35 mm |
| Exhaust valve | 0.40 mm |
Gap of the rod in the guide: 0.046 - 0.089 mm.
Valve springs
The same springs are used for intake and exhaust valves.
| free length: | |
| – engine 2.4 dm3 | 55.12 mm |
| – engine 2.8 dm3 | 52.50 mm |
| – engine 2.9 dm3 (BRC) | 52.50 mm |
| – engine 2.9 dm3 (BRD and BRE) | 53.00 mm |
Engine block
The engine block is cast iron. The cylinders are made directly in the cylinder block.
| Designation: | |
| – engine 2.4 dm3 | D |
| – engine 2.8 dm3 | E |
| – engine 2.9 dm3 | F |
| Main bearing bed diameter: | |
| – standard | 60.620 – 60.640 mm |
| - enlarged | 61.000 – 61.020 mm |
| Camshaft bearing bed diameter: | |
| - front | 47.025 - 47.060 mm |
| - front center | 46.645 - 46.680 mm |
| - rear center | 46.265 - 46.300 mm |
| - rear | 45.885 - 45.920 mm |
Cylinder diameters (mm)
| Engine | 2.4 dm3 | 2.8 and 2.9 dm3 |
| Nominal standard diameters: | ||
| – group 1 | 84,000 – 84,010 | 93,010 – 93,020 |
| – group 2 | 84,010 – 84,020 | 93,020 – 93,030 |
| – group 3 | 84,020 – 84,030 | 93,030 – 93,040 |
| – group 4 | 84,030 – 84,040 | 93,040 – 93,050 |
| - official | 84,030 – 84,040 | 93,040 – 93,050 |
| enlarged diameters: | ||
| – group A | 84,510 – 84,520 | 93,520 – 93,530 |
| - group B | 84,520 – 84,530 | 93,530 – 93,540 |
| - group C | 84,530 – 84,540 | 93,540 – 93,550 |
| Repair dimensions: | ||
| - with a tolerance of 0.5 | 84,530 – 84,540 | 93,540 – 93,550 |
| – with a tolerance of 1.0 | 85,030 – 85,040 | 94,040 – 94,050 |
Crank mechanism
Crankshaft
The steel crankshaft is supported by four bearings.
Measurement should be carried out using Plastigage measuring rods.
| Axial play | 0.08 - 0.20 mm |
| Main bearing journal diameters | 56.980 - 57.00 mm |
| Clearance in main bearings | 0.008 – 0.062 mm |
| Diameters of connecting rod journals | 53.980 – 54.000 mm |
| Clearance in connecting rod bearings | 0.006 - 0.064 mm |
| Support bearing width (3rd) | 26.39 - 26.44 mm |
| Permissible reduction in the diameter of the main and connecting rod journals (except for engine 2.8 dm3) | 0.254 mm |
Flywheel
The flywheel is fixed to the crankshaft flange with six bolts.
Connecting rods
The connecting rods are forged from steel and have an I-beam profile in cross section. The piston pin is pressed into the connecting rod head.
| Connecting rod head bore diameter | 23.958 - 23.976 mm |
| Pin tension in the connecting rod head | 0.018 - 0.039 mm |
| Heating temperature of the connecting rod head during pin installation | 250°- 300°С |
| Connecting rod bore diameter | 56.820 - 56.840 mm |
| Permissible non-perpendicularity of the axis of the holes relative to the axis of the connecting rod: | |
| - head hole | 0.10 mm |
| - base hole | 0.15 mm |
Pistons
Installation Method: The arrow on the bottom of the piston must point towards the front of the engine (towards the drive of the gas distribution system).
Piston dimensions (mm)
| Engine | 2.4 dm3 | 2.8 and 2.9 dm3 |
| Nominal standard diameters: | ||
| – group 1 | 83,962 – 83,972 | 92,972 – 92,982 |
| – group 2 | 83,972 – 83,982 | 92,982 – 92,992 |
| – group 3 | 83,982 – 83,992 | 92,992 – 93,002 |
| – group 4 | 83,992 -84,002 | 93,002 – 93,012 |
| - official | 83,978 – 84,002 | 93,000 – 93,020 |
| Repair dimensions: | ||
| - with a tolerance of 0.5 | 84,478 – 84,502 | 93,500 – 93,520 |
| – with a tolerance of 1.0 | 84,978 – 85,002 | 94,000 – 94,020 |
| Clearance of new pistons in cylinders | 0,028 – 0,048 | 0,020 – 0,050 |
Piston pins
Pins made of steel and heat treated, pressed into the connecting rod heads (hot mounting at head temperature 250°–300°С) and rotate in the piston hubs.
| Diameter (mm): | |
| - marking in red | 23,994 – 23,997 |
| - marked in blue | 23,997 – 24,000 |
| Clearance in piston hubs | 0.008 - 0.014 mm |
| Tension in the connecting rod head | 0.018 - 0.042 mm |
Piston rings
Each piston has three rings: two sealing and one oil scraper.
| O-ring lock clearance (installed in the cylinder): | |
| – engine 2.4 and 2.9 dm3 | 0.3 - 0.5 mm |
| – engine 2.8 dm3 | 0.38 - 0.58 mm |
| Clearance of the lock of an oil scraper ring | 0.40 - 1.40 mm |
| Location of ring locks: | |
| – sealing | by 150° (in opposite directions) in relation to the oil scraper lock |
| – oil scraper | the expanding spring lock is installed in accordance with the direction of the arrow on the bottom of the piston; the locks of the upper and lower plates are set 25 mm to the right and left of the direction of the arrow |
Gas distribution system
The camshaft is located in the cylinder block, drives the valves through pushers and valve levers, and is driven by a gear or chain drive.
Valve clearance (cold): | |
| - inlet | 0.35 mm |
| – graduation | 0.40 mm |
Distribution phases
| Engine | 2.4 dm3 and 2.9 BRC | 2.8 dm3 | 2.9 in.3 BRD and BRE |
| OZD | 24°before TDC | 26°30' before TDC | 30°before TDC |
| ZZD | 64°after BDC | 69°30' after BDC | 66°after BDC |
| OZW | 66°before BDC | 75°30' before BDC | 76°before BDC |
| ZZW | 22°after TDC | 22°30' after TDC | 20°after TDC |
OZD and ZZD - opening and closing of the intake valve, respectively;
OZW and ZZW - opening and closing of the exhaust valve, respectively;
TDC and BDC are top and bottom dead center respectively.
Camshaft
The camshaft rotates in four bearings.
| Camshaft bearing diameters: | |
| - front | 43.903 - 43.923 mm |
| - front center | 43.522 - 43.542 mm |
| - rear center | 43.141 - 43.161 mm |
| - rear | 42.760 - 42.780 mm |
| Inner diameters of bearing bushes: | |
| - front | 43.948 - 43.968 mm |
| - front center | 43.567 - 43.587 mm |
| - rear center | 43.186 - 43.206 mm |
| - rear | 42.805 - 42.825 mm |
| Camshaft end play | 0.02 - 0.10 mm |
| Camshaft Thrust Flange Thickness: | |
| - red | 3.960 - 3.985 mm |
| – blue | 3.986 - 4.011 mm |
| Camshaft gasket thickness: | |
| - red | 4.075 - 4.100 mm |
| - blue | 4.101 - 4.125 mm |
| Cam lift: | |
| - inlet: | |
| engine 2.4 dm3 | 6.72 mm |
| engine 2.8 dm3 | 6.70 mm |
| engine 2.9 dm3 (BRC) | 6.72 mm |
| engine 2.9 dm3 (BRD and BRE) | 6.54 mm |
| - graduation | 6.6mm |
| engine 2.4 dm3 | 6.72 mm |
| engine 2.8 dm3 | 6.60 mm |
| engine 2.9 dm3 (BRC) | 6.72 mm |
| engine 2.9 dm3 (BRD and BRE) | 6.54 mm |
| Jaw height: | |
| - inlet: | |
| engine 2.4 dm3 | 36.08 - 36.25 mm |
| engine 2.8 dm3 | 35.995 - 36.165 mm |
| engine 2.9 dm3 (BRC) | 36.08 - 36.25 mm |
| engine 2.9 dm3 (BRD and BRE) | 36.22 - 36.41 mm |
| - graduation: | |
| engine 2.4 dm3 | 36.08 - 36.25 mm |
| engine 2.8 dm3 | 35.895 - 36.065 mm |
| engine 2.9 dm3 (BRC) | 36.08 - 36.25 mm |
| engine 2.9 dm3 (BRD and BRE) | 36.22 - 36.41 mm |
Lubrication system
Pressurized lubrication is provided by a rotary oil pump housing a bypass valve.
| Minimum oil pressure (at 80°С): | |
| – at 750 rpm. | 0.1 MPa |
| – at 2000 rpm. | 2.5 MPa |
| bypass valve opening pressure (at 1000 rpm.) | 0.40 - 0.47 MPa |
| Pressure of ignition of a control bulb of pressure of oil | 0.03 MPa - 0.06 MPa |
| The volume of engine oil in the engine, dm3: | |
| - with filter replacement | 4,25 |
| – without filter replacement | 4,00 |
Oil pump
The rotary oil pump, with an internal arrangement of teeth, is put in action from a camshaft.
| Gap of a gear with an internal arrangement of teeth relative to the housing | 0.150 - 0.300 mm |
| Gap between gear teeth | 0.05 - 0.20 mm |
| Axial gear clearance | 0.003 - 0.100 mm |
Cooling system
The closed antifreeze cooling circuit contains a radiator, an expansion tank, a coolant pump, a thermostat and a fan.
Radiator and expansion tank
The crossflow radiator has tanks made of artificial material. The expansion tank is made of transparent material and is marked with maximum and minimum coolant levels.
| Opening pressure of the overpressure valve in the plug of the expansion tank | 120 - 150 kPa |
Coolant pump
The centrifugal coolant pump, located on the front cover of the cylinder block, is driven by a V-belt along with the generator.
Thermostat
| Opening start temperature | 79°- 83°С |
| Full opening temperature | 102±3°С |
Coolant
| Quantity | 8.6 in.3 |
| Type | special antifreeze mixture Ford SSM 97 B 9103 A (50%) and distilled water (50%) form protection up to -30°С |
| Replacement frequency | every 60,000 km or every two years |
Tightening torques
| Main bearing cap bolts | 90 - 104 Nm |
| Connecting rod bolts | 26 - 33 Nm |
| crankshaft pulley bolt | 115 – 130 Nm |
| Camshaft Gear Bolt | 42 – 50 Nm |
| Camshaft Thrust Flange Bolts | 17 - 21 Nm |
| flywheel bolts | 67 - 70 Nm |
| Bolts of fastening of a damper to a cranked shaft: | |
| – 1st stage | 40 – 50 Nm |
| – 2nd stage | tighten by 90° |
| Oil pump mounting bolts | 14 - 17 Nm |
| Oil pump cover bolts | 9 – 13 Nm |
| Oil pan bolts: | |
| – 1st stage | 4 – 6 Nm |
| – 2nd stage | 7 – 10 Nm |
| Oil drain plug in the oil pan | 21 – 28 Nm |
| Oil pressure sensor | 12 – 15 Nm |
| oil cooler | 20 – 40 Nm |
| Rocker axle bolts | 62 – 70 Nm |
| Cylinder head bolts (Torx): | |
| – 1st stage | 35 – 40 Nm |
| – 2nd stage | 70 – 75 Nm |
| – 3rd stage (after 10 - 20 minutes) | tighten by 90° |
| Cover of system gas distribution to the block of cylinders | 17 - 21 Nm |
| Gas distribution cover to intermediate flange | 13 - 17 Nm |
| Intermediate flange to cylinder block | 17 - 21 Nm |
| Intake manifold | 17 - 21 Nm |
| An exhaust manifold | 21 – 25 Nm |
| Spark plug | 20 – 28 Nm |
| thermostat housing | 17 - 21 Nm |
| Cylinder head cover bolts | 6 – 8 Nm |
Visitor comments