Page 11
022-6
Engine-Technical Data
LUBRICATION SYSTEM
CRANKSHAFT
Crankshaft
mm
in.
Maximum variation in
straightness (runout)
0.10
0.004
Axial play (end float)
0.08-0.28
0.003-0.011
Maximum out-of-round
of journals
0.05
0.002
Radius of main journal
fillet
2.2-2.5
0.09--Q.10
Main bearing oil
clearance
0.020-0.062
0.0008-0.0024
Big-end bearing oil
clearance
0.026-0.062
0.0010-0.0024
Crankpin diameter
standard
51.981-52.000
2.0465-2.0472
first undersize
51.731-51.750
2.0367-2.0374
second undersize
51.481-51.500
2.0268-2.0276
third undersize
51.237-51.250
2.0172-2.0177
fourth undersize
50.987-51.000
2.0074-2.0079
Main journal diameter
standard
57.981-58.000
2.2827-2.2835
first undersize
57.731-57.750
2.2729-2.2736
second undersize
57.481-57.500
2.2630-2.2638
third undersize
57.237-57.250
2.2534-2.2539
fourth undersize
56.987-57.000
2.2436-2.2441
Color markings, main and big-end bearing shells
standard
first oversize
thin-red
thin-yellow
thin-white
thick-blue
thick-green
thick-brown
LUBRICA nON SYSTEM
second oversize
Lubrication System
Oil pressure at 2000
rpm, engine temp. 80 D C
(176 D F)
at least 2.7 bar
(39 psi)
Oil pressure relief valve
opening pressure
3.6-5.3 bar
(52-77 psi)
Waming light on
pressure
below 0.3--0.5
bar
(4.4-7.3 psi)
Oil pump end noat
0.03--0.08 mm
(0.0012-D.0031
in.)
Page 12
Engine-Technical Data
022-7
LH FUEL INJECTION
89092
Fuel Injection
LH Coolant Temperature Sensor Resistance
89091
7.
8.
9.
10,
11.
12.
1.
2.
3.
4.
5.
Fuel tank
Fuel pump
Fuel filter
Fuel distribution
Pressure regulator
6, LH control unit
Fuel injector
Coolant temperature sensor
Throttle plate
Th rottle switch
AIC valve
Air mass meter
Tem peratu re
Resistance (Ohms, ±10%)
14,000
9,000
5,800
3,800
3,000
System
YearlModel
Identification
2,600
LH 2.2
1985-1988 tu rbo
1986-1987
normally aspirated
Three wire AIC idle valve,
metal air mass meter with
sealed mixture adjustment
screw
2,000
1989 and later
turbo
Two wire AIC idle valve,
plastic air mass meter
without mixture adjustment
LH 2.4
1988-1990
normally aspirated
LH 2.4.2
1991 and later
normally aspirated
1,700
320
Three wire AIC idle valve,
si milar plastic ai r mass meter
without mixture adjustment
Fuel Pump
Fuel Pump Delivery Volume
(minimum)
Fuel system pressure -
900 ml (30 oz.) in 30 seconds
fuel pump running, engine off
normally aspirated models
3.0 bar (43.5 psi)
turbo models
2.5±0.05 bar (36.3±0.7 psi)
Fuel system pressure -
engine idling
normally aspirated models
2.4 bar (34.8 psi)
turbo models
1.9 bar (27.6 psi)
Residual fuel pressure
all models
0.1-0.2 bar (1.5-3.0 psi)
below system pressure,
minimum after 10 minutes
LH FUEL INJECTION
Page 13
022-8
Engine-Technical Data
COOLING SYSTEM
'-'
89093-S2I1591
89094-S5207
Fuel Injection
Fuel injector resistance
Cooling System
Oxygen Sensor Specifications
Oxygen sensor voltage
at idle (engine wann)
0.4-1 volt
Oxygen sensor
preheater resistance
approx. 4 Ohms
LH 2.2
LH 2.4
LH 2.4.2
Test tenninals
Resistance
(Ohms)
1 and 2
20±2
2 and 3
20±2
1 and 3
40±4
1 and 2
812
1 and 2
10-15
2 and 3
10-15
850±50 rpm
Idle speed (adjustable
only on LH 2.2 injection)
Idle %CO (adjustable only on LH 2.2 injection)
nonnally aspirated
0.5-1.5%
turbo
0.9-1,6%
Dashpot Adjustment
Specifications (LH 2,2)
10 liters (10.5 qts,)
Pennissible coolant leakage
1 qt. over 60,000 miles (1
Iiter/lOO,OOO km)
Coolant thennoswitch closing
temperature
AIC Valve Resistance
Fuel System
Cooling system capacity
Coolant thermoswitch opening
temperatu re
Coolant type
Phosphate-free 50% mixture
anti-freeze 50% water
Coolant temperature sender
resistance
51 .2±4.3 Ohms at 90°C
(194 C F)
Cooling system test pressure
(maximum)
1,2 bar (17.4 psi.)
TURBOCHARGER
speed at which dash pot rod touches
throttle lever
nonnallyaspirated
2500±100 rpm
turbo
2600±100 rpm
89095-S5865
TURBOCHARGER
Turbocharger basic boost
pressure
bar
psi
All except 1987 and later SPG
models
0.3510,03
5.010.4
1987 and later SPG models
0.4010.03
5.810.4
I
Page 14
Electrical System-Technical Data
023-1
023 Electrical System-Technical Data
Electrical System
023-1
ELECTRICAL SYSTEM
i
[
I
II
II
I
!
i
' - - -
J
1
Charging System
TIghtening Torques
Nm
ft-Ib (in-I b)
Alternator
Ignition distributor holddown bolt
15
11
rated speed
1900 rpm
minimum brush length
5 mm (0.2 in.)
Knock sensor to engine
block
20
15
Solenoid to starter
4.5-5.5
(40-49 in-Ib)
Starter field winding strap
and battery cable to
solenoid
(62--80 in-Ib)
7-9
Output test values
36 amps
@ 1500 rpm
54 amps
@ 1900 rpm
80 amps
@ 6000 rpm
all other fasteners
M5 bolt
5
(44 in-Ib)
M6 bolt
10
(89 in-Ib)
M8 bolt
20
15
M10 bolt
40
30
Ignition System
Ignition system type
Charging System
Alternator
rated output
14 volts
ELECTRICAL SYSTEM
Page 15
023-2
Electrical System-Technical Data
I
I
I
L
Ignition System
1985 and later, turbo
basic Hall ignition
1986 and later, non-turbo
EZK ignition-Hall-effect with
knock sensor
Ignition firing order
1-3-4-2 (no. 1 cylinder next to
firewall)
Ignition timing (vacuum hose
discon nected)
Turbo
16°BTDC @ 850 rpm
Non-turbo
14°BTDC @ 850 rpm
Ignition coil
primary winding resistance*
0.5-<:>.9 Ohms
secondary winding resistance*
7200-8200 Ohms
Spark plug wires and rotor
ignition rotor resistance
1000 Ohms
coil high tension lead
resistance (complete with
end connectors)
500-1500 Ohms
spark plug lead resistance
(complete with end
connectors)
2000-4000 Ohms
'Measure with all wires disconnected from call. See 340 Ignition System for testing
information
ELECTRICAL SYSTEM
Page 16
Transmission-Technical Data
024-1
024 Transmission-Technical Data
Transmission
024-1
TRANSMISSION
Tightening Torques
Nm
ft-Ib (in-Ib)
Tightening Torques
Nm
ft·lb (in-Ib)
ATF pressure tap (automatic
transmission)
5-7
(44--62 in-Ib)
Shift rod clamp bolt
(manual transmission)
30---35
22-26
ATF sump pan bolts
(automatic transmission)
8-12
(71-106 in-Ib)
All other fasteners
M5 bolt
5
(44 in-Ib)
ATF sump pan drain plug
(automatic transmission)
5-8
(44-71 in-Ib)
M6 bolt
10
(89 in-Ib)
M8 bolt
20
15
ATF cooler connection nut
(automatic transmission)
13-16
10-12
M10 bolt
40
30
Clutch slave cylinder mounting
screws
6-14
(53-124 in-Ib)
Gearbox drain plug (manual
transmission)
39-59
29-44
Selector cable setscrew
tightening torque
(automatic transmission)
2.5
(22 in-Ib)
TRANSMISSION
(~~~i~?i;:~:t~~~:~:;~
....:..... ;........•...
·11111
Page 17
024-2
Transmission-Technical Data
4 65
1.
2.
3.
4.
Torque convertor
Front clutch
Rearclutch
Front band
5. Rearband
6. One way clutch
7. Govemor
Automatic Transmission
Type
Borg Wamer 37
ATF volume (transmission)
8.0 I (8.5 U.S. qts.)
ATF
Ford specification M2C-33F
(alternate Ford specification G)
AfT final drive capacity
125 I (1.3 U,S. qts.)
AfT final drive grade of oil
SAE EP800r75API-GL-40rAP
I-GL5
Alternate grade
SAE 10W·30 engine oil
General stall speed (APC
solenoid unplugged)
2250-2700 rpm
Line pressure at idle
(gear selector in D)
4.2-4.9 bar
(61-71 psi)
89100-S6605
1.
2.
3.
4.
5.
Pressure plate
Housing
Diaphragm spring
Pivot rings
Release bearing
6.
7.
8.
9.
Slave cylinder
Master cylinder
Clutch pedal
Clutch fluid reservoir
Manual Transmission
Clutch type
Fichtel & Sachs
Clutch diameter
non-turbo
204 mm (8 in,)
turbo
216 mm (8.5 in,)
Clutch adjustment
automatic
(non-adjustable)
Manual transmission oil
capacity
3.0 I (3.5 U.S. qts.)
Grade of oil
SAE 10W-30 SF/CC, SF/CD, SG
Altemate grade of oil
SAE EP 75 API-GL-4 or API GL·5
Clutch/brake master
cylinder fluid
DOT 4 brake fluid
TRANSMISSION
Page 18
Brakes-Technical Data
025-1
025 Brakes-Technical Data
Brakes
025-1
BRAKES
Front Brake Disc Applications
Model year and Model
Disc type
1985 through 1987900
Solid
1985 and 1986 900s
Solid
1985 Turbo
Solid
1987900s
Ventilated
1986 through 1987 Turbo,
including convertible
Ventilated
1988 and later
All Ventilated
Front Brake
Disc
Solid disc
89102
Tightening Torques
Nm
ft-Ib (in-Ib)
ABS hydraulic unit to bulkhead
26±4
19±3
Front caliper mounting bolt to
guide pin (1988 models and
later)
30-35
22-26
Front caliper to steering
member (1985 to 1987)
110-130
81-96
Front pad carrier to steering
member (1988 models and
later)
70-110
52--81
Rear caliper to axle (1985 to
1987)
70-90
Rear caliper to pad carrier
(pins) (1988 models and later)
25-30
18-22
Rear pad carrierto axle (1988
models and later)
40-54
30--40
Ventilated
disc
Ventilated
(1986·1987)
and later)
disc (1988
Thickness
(new)
12.7 mm
(0.50 in.)
20mm
(0.787 in.)
23.5 mm
(0.93 in.)
Thickness
(wear limit)
11.2 mm
(0.441 in.)
18mm
(0.709 in.)
21.5mm
(0.85 in.)
Brake surface
lateral runout
(maximum)
0.1 mm
(0.004 in.)
0.1 mm
(0.004 in.)
0.08 mm
(0.003 in.)
Rear Brake Disc
Thickness (new)
9.0 mm (0.354 in.)
Thickness (wear limit)
7.0 mm (0.276 in.)
Brake surface lateral runout
(maXimum)
0.1 mm (0.004 in.)
52--86
ABS Specification
ABS wheel speed sensor air
gap
All other fasteners
M5 bolt
5
(44 in-Ib)
M6 bolt
10
(89 in-Ib)
M8 bolt
20
15
Ml0 bolt
40
30
0.65 mm (0.026 in.)
BRAKES
Page 19
Steering and Wheel Alignment-Technical Data
026-1
026 Steering and Wheel AlignmentTechnical Data
Steering and Wheel Alignment
026-1
STEERING AND WHEEL ALIGNMENT
Tightening Torques
Nm
ft-Ib (in-I b)
Lower control arm bearing bracket
(front or rear) to body
M12 dry joint
70-95
52-70
M121ubricaled joint (waxed nut)
45-55
33-41
Lower control arm bracket to body
25~5
18-26
Power steering rack to body
60-80
44-59
lug nuts
90-110
lug bolts
105-125
66-81
77-92
Steering column to steering rack
(clamping bolt, self-locking nut)
20-27
15-20
Steering column to body
(bolts, use with Loctite)
20-27
15-20
Steering wheel to steering column
(self-locking nut)
25-28
18-21
Universal joint to pinion shaft
(clamping bolt and self-locking nut)
25~4
18-25
Power steering hose fittings
20~4
15-25
Tie rod end to tie rod
60-80
44-59
Upper control arm bearing bracket
(front or rear) to body
40-55
30-41
Road wheel to wheel hub
All olher fasteners
Tightening Torques
Nm
ft-Ib (in-Ib)
M5 bolt
5
(44 in-Ib)
M6 bolt
10
(89 in-Ib)
M8 bolt
20
40
30
M10 bolt
15
Ball joinl to control arm (upper or
lower)
40-55
29-41
Ball joint to control arm bolts (selflocking nuls)
40-55
29-41
Steering and Wheel Alignment Specifications
Ball joint to steering swivel member
(self-locking nut)
35-50
26~7
Chassis Ride Height
(measured between top of wheel rim and fender/hood gap)
Except sport chassis
Bearing bracket to control arm
(locknut and lock washer)
243 mm (9.56 in.)
Sport chassis
lower control arm bracket to
control arm
75-90
55-66
upper control arm bracket to
control arm
55-70
41-52
Coil spring seat to control arm
55-110
41-81
with 15 in. wheel
with 16 in. wheel
230 mm (9.06 in.)
217 mm (8.54 in.)
STEERING AND WHEEL ALIGNMENT
Page 20
026-2
Steering and Wheel Alignment-Technical Data
Wheel Alignment Specifications
Measurement
Model
except sport
chassis
sport chassis
Front
caster
2°±0.5
2°±0.25
camber
0.5°±0.5
0.25°±0.25
toe-in
2±1 mm
(0.08±0.04 in.)
1.5±0.5 mm
(0.06±0.02 in)
Swivel pin inclination
11.5°±1
11.5°±1
Steering angle-outer
wheel
20°
20°
Steering angle-inner
wheel
20.75°±0.50
20.75°±0.50
toe-in
4±1 mm
(0.16±0.04 in.)
4±1 mm
(0.16±0.04 in.)
camber
-0.5°±0.25
-0.5°±0.25
Rear wheels (nonadjustable)
Ball joint wear limit
maximum radial play
1 mm
0.040 in.
maximum axial play
2mm
0.078 in.
75 cl
0.8 qt
Power Steering Fluid
GM power steering
fluid (GM 9985010),
Texaco TL4634 or
equivalent
STEERING AND WHEEL ALIGNMENT