Page 752 of 3229

Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel -
Lubricants, Fluids, Sealers and AdhesivesDescriptionDescription and part number.
‘T’ joi nts  - ladder frame to engi ne blocks ealantThree bond TB 1215J
Oi l pan to bl ock s ealantThree bond TB 1215J
Cams haft  l adder s eal antLocti te 518 (8510302)
Engine Oi lSAE 5W -30 oils  conforming to Ford W SS-M2C13B specificat ion or ACEA A1 orB1
C apacities
ItemCapacity (liters/pints/US quarts)
Dry fi ll  i ncludi ng fi lt er6.5/11.4/6.7Service fil l5.9/10.4/6.2
Amount of oil required t o bri ng level from t he lower t o t he upper mark on t he dips tick1.5/2.6/1.6
C ylinder Head Gasket Selection
Piston ProtusionT hickness of Compressed GasketNumber of holes at ' a'Number of holes at 'b'0.55 to 0.60 mm1.25 ± 0.04 mm11
0.61 to 0.65 mm1.30 ± 0.04 mm22
0.66 to 0.70 mm1.35 ± 0.04 mm330.71 to 0.75 mm1.40 ± 0.04 mm44
'a' and 'b' = Thi ckness  identi fi cat ion
General Specification
ItemSpecificationType2.2 l it re, i nl ine 4, t urbocharged and int ercool ed dies el  engine, t win overheadcamshaft , 4 valves  per cyl inder
Cyli nder arrangementInl ine 4Cyli nder numberi ngNo.1 from gearbox end
Bore - nominal85.0 mm (3.346 i n)
St roke96.0 mm (3.779 i n)Capaci ty2179 cm³ (132.9 in³)
Firing order1 - 3 - 4 - 2
Compres s ion rati o16.6:1Di recti on of rotat ionClockwi s e viewed at  FEAD
Maximum permi s sable cyl inder headwarp0.03mm (0.00118 i n)
Maximum pow er
All  markets  except  Bel gi um118 kW  (160 ps ) @ 4000rpmBelgi um s peci fi cat ion110 kW  (150 ps ) @ 4000rpm
Maximum t orque400 Nm (295 l b-ft ) @ 2000rpm
Engine oil pressure*:At  1750 rev/min1.6 bar/160 kPa/23 l b/i n²
At  4000 rev/min3.1 bar/310 kPa/45 l b/i n²
Balance shaft to crankshaftclearance**:
Mi ni mum0.01mm
Maximum0.07mm* Prior to checking the engine oil pressure, a road test of 6 miles (10 kilometres) must be carried out. Do notattempt to attain normal engine operating temperature by allowing the engine to idle.
**If the backlash betw een the balance shaft and crankshaft is less than 0.01 mm or greater than 0.07 mm then thebalance shaft assembly must be replaced.
Torque SpecificationsDescriptionNmlb-ft
Acces s ory drive belt  i dler bol t4835
Acces s ory drive belt  t ensi oner bolt4835Camshaft pulley bolt
St age 12015
St age 260°60°Cams haft  t imi ng belt  cover bolt s65
Cams haft  t imi ng chai n t ens ioner bolt s75
Crankshaft pulley bolt:St age 17052
St age 260°60°
Cranks haft rear s eal retai ner pl at e97Coolant outl et  el bow97
Cyli nder head bolt sAA
Di ps t ick t ube bol t107Engine i ns ulat or lower11081
Engine i ns ulat or lower heat  s hiel d107
Engine i ns ulat or lower li nk bracket s11081Engine i ns ulat or upper11081 
     
        
        Page 908 of 3229

Publi s hed: 11-May-2011
Engine Cooling - I6 3.2L Petrol -
Lubricants, Fluids, Sealers and AdhesivesItemSpecification
Anti -freezeTexaco Ext ended Li fe Coolant  (XLC) or any glycol bas ed anti -freezecontaini ng no met hanol wit h only Organic Acid Technology (O AT) corrosi oni nhi bit ors
Anti -freeze concentrati on - W i ll  provi de frostprot ect ion to -40°C (-40°F)50%
Speci fi c gravit y of cool ant  at  20°C (68°F), t oprot ect  agains t  fros t down to -40°C (-40°F)1.068
Amount of anti-freeze to use for 50%concentration:4.0 li ters
C apacitiesItemCapacity (liters/pints/US quarts)
Cooli ng sys t em capacit y8.0/14.0/8.5
General Specification
ItemSpecificationCooling fan:
St andard fi t - Single fan500W
Hot  cli mate - Twin fan750WCooli ng sys t em t ypePress uris ed, t hermos t at icall y cont rol led wi th remot e header t ank
Expans ion tankSeeber wit h i nt egrat ed level s ens or
Radiat orVal eo 28mm core wit h i ntegrat ed drain cock and repl aceable lower pinThermos t atW ax element
St arts  to open90° C
Full y open100° C
Torque Specifications
DescriptionNmlb-ftCoolant expans ion t ank bol t107
Coolant pump bolt s1713
Coolant pump pull ey bol ts107Radiat or bolt s65
Radiat or drain pl ug76
Thermos t at  hous ing bolt s107W at er inlet  pi pe bol ts1713
W at er inlet  pi pe drain nipple75
W at er out let  t o bl ock bolt107 
     
        
        Page 937 of 3229

Publi s hed: 11-May-2011
Engine Cooling - TD4 2.2L Diesel -
Lubricants, Fluids, Sealers and AdhesivesItemSpecification
Anti -freezeTexaco Ext ended Li fe Coolant  (XLC) or any glycol bas ed anti -freezecontaini ng no met hanol wit h only Organic Acid Technology (O AT) corrosi oni nhi bit ors
Anti -freeze concentrati on - W i ll  provi de frostprot ect ion to -40°C (-40°F)50%
Speci fi c gravit y of cool ant  at  20°C (68°F), t oprot ect  agains t  fros t down to -40°C (-40°F)1.068
Amount of anti-freeze to use for 50%concentration:4.25 li ters
C apacitiesItemCapacity (liters/pints/US quarts)
Cooli ng sys t em capacit y8.5/15.0/9.0
General Specification
ItemSpecificationCoolant pump21.5 li ter/mi n : 2.8 bar
Cooli ng fan750W /600W
Cooli ng sys t em t ypePress uri s ed, t hermos tat icall y cont roll ed wi th remote header t ankExpans ion tankSeeber wit h int egrated level  s ensor
Pres s ure cap rati ng145 kPa (21lb/i n²)
Radiat orVal eo 28mm core wit h i nt egrat ed drain cock and repl aceable l ower pi nThermos t atW ax element
St arts  to open83°C (181°F)
Full y open91°C (200°C)
Torque Specifications
DescriptionNmlb-ftA/C condens er t o radiator107
Automat ic trans mi ss i on fl uid cooler66
Coolant manifold t o t hermos tat  hous ing pipe.86Coolant expans ion t ank bol t107
Coolant pump bolt s1713
Cyli nder block s ealing pl ug4231Radiat or bolt s65
Radiat or drain pl ug76
Thermos t at  hous ing bolt s86W iri ng harnes s s upport  bracket .86 
     
        
        Page 2913 of 3229

193
Wheels and tyres
R
• Avoid tyre/vehicle  damage by removing  
the traction devices as soon as the  
conditions allow.
TYRE GLOSSARY
Terms used
lbf/in² or psi  
Pounds per square inch,   an imperial unit of  
measure for pressure. 
kPa 
Kilo Pascal, a metric unit of measure for  
pressure. 
Cold tyre pressure 
The air pressure in a tyre which has been  
standing in excess of th  ree hours, or driven for  
less than one mile. 
Maximum inflation pressure 
The maximum pressure to which the tyre  
should be inflated. This pressure is given on  
the tyre side wall in lbf/in² (psi) and kPa. 
Note:   This pressure is the maximum allowed  
by the tyre manufacturer.   It is not the pressure  
recommended for use.  See   TECHNICAL  
SPECIFICATIONS   (page 194). 
Kerb weight 
The weight of a standa  rd vehicle, including a  
full tank of fuel, any   optional equipment fitted,  
and with the correct coolant and oil levels. 
Gross vehicle weight 
The maximum permissible weight of a vehicle  
with driver, passengers, load, luggage, 
equipment, and towbar load. 
Accessory weight 
The combined weight (in excess of those items  
replaced) of items available as factory installed  
equipment.  Production options weight 
The combined weight of options installed  
which weigh in excess of   1.4 kg (3 lb) more  
than the standard items that they replaced, and  
are not already considered in kerb or accessory 
weights. Items such as heavy duty brakes, high  
capacity battery, special trim etc. 
Vehicle capacity weight 
The number of seats multiplied by 68 kg (150  
lb) plus the rated amount of load/luggage. 
Maximum loaded vehicle weight 
The sum of kerb wei  ght, accessory weight,  
vehicle capacity weig  ht, plus any production  
option weights. 
Rim 
The metal support for a ty  re, or tyre and tube,  
upon which the tyre beads are seated. 
Bead 
The inner edge of a tyre th  at is shaped to fit to  
the rim and form an air tight seal. The bead is  
constructed of   steel wires which are wrapped,  
or reinforced, by the ply cords.