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TSG-416 ENGINE - PRELIMINARY
INDEX
Subject Page
General Information
Special Tools............................................................................................................................................. 02 - 3
Description ................................................................................................................................................ 02 - 5
Component Location ................................................................................................................................. 02 - 6
Engine Repair
Valve Cover - Removal ........................................................................................................................... 02 - 10
Valve Cover - Installation ........................................................................................................................ 02 - 10
Camshaft- Removal................................................................................................................................. 02 - 11
Camshaft - Installation............................................................................................................................. 02 - 12
Valve Stem Seal - Removal .................................................................................................................... 02 - 13
Valve Stem Seal - Installation ................................................................................................................. 02 - 14
Intake Manifold - Removal....................................................................................................................... 02 - 15
Intake Manifold - Installation.................................................................................................................... 02 - 15
Exhaust Manifold - Removal ................................................................................................................... 02 - 16
Exhaust Manifold - Installation ................................................................................................................ 02 - 16
Cylinder Head - Removal ........................................................................................................................ 02 - 17
Cylinder Head - Installation ..................................................................................................................... 02 - 19
Oil Pump - Removal ................................................................................................................................ 02 - 21
Oil Pump - Installation ............................................................................................................................. 02 - 22
Crankshaft Rear Oil Seal - Removal ....................................................................................................... 02 - 23
Crankshaft Rear Oil Seal - Installation .................................................................................................... 02 - 23
Camshaft Follower / Hydraulic Lash Adjuster - Removal ........................................................................ 02 - 24
Camshaft Follower / Hydraulic Lash Adjuster - Installation ..................................................................... 02 - 24
Oil Pan - Removal ................................................................................................................................... 02 - 25
Oil Pan - Installation ................................................................................................................................ 02 - 25
Pick-up Tube / Deflector - Removal ........................................................................................................ 02 - 26
Pick-up Tube / Deflector - Installation ..................................................................................................... 02 - 26
Crankshaft Main Bearings - Removal...................................................................................................... 02 - 27
Crankshaft Main Bearings - Installation................................................................................................... 02 - 27
Connecting Rod Bearings - Removal ...................................................................................................... 02 - 28
Connecting Rod Bearings - Installation ................................................................................................... 02 - 28
Piston - Removal ..................................................................................................................................... 02 - 29
Piston - Installation .................................................................................................................................. 02 - 30
Flywheel - Removal................................................................................................................................. 02 - 31
Flywheel - Installation.............................................................................................................................. 02 - 31
Timing Chain and Sprockets - Removal.................................................................................................. 02 - 32
Timing Chain and Sprockets - Installation............................................................................................... 02 - 33
Oil Level Indicator - Removal .................................................................................................................. 02 - 35
Oil Level Indicator - Installation ............................................................................................................... 02 - 35
Oil Filter and Adapter - Removal ............................................................................................................. 02 - 36
Oil Filter and Adapter - Installation .......................................................................................................... 02 - 36
Disassembly .................................................................................................................................................. 02 - 37
Subassemblies
Cylinder Block ......................................................................................................................................... 02 - 44
Piston - Disassembly............................................................................................................................... 02 - 45
Piston - Assembly.................................................................................................................................... 02 - 45
Cylinder Head - Disassembly .................................................................................................................. 02 - 46
Cylinder Head - Assembly....................................................................................................................... 02 - 47
Assembly ....................................................................................................................................................... 02 - 48
Specifications................................................................................................................................................ 02 - 58
02
02-1
TSG-416 ENGINE - PRELIMINARY
NOTE: For engine diagnosis, refer to Section 01.
02-2
TSG-416 ENGINE - PRELIMINARY
GENERAL INFORMATION
Special Tools
Valve Spring Compressor
T81P-6513-A or Equivalent
Seal Remover
T92C-6700-CH or Equivalent
Piston Ring Compressor
D81L-6002-C or Equivalent
Dial Indicator with Bracketry
TOOL-4201-C or Equivalent
Camshaft Bearing Set
T65L-6250-A or Equivalent
Connecting Rod Guide Tool
T93P-6136-A or Equivalent
Crankshaft Damper Remover
T58P-6316-D or Equivalent
Cylinder Ridge Reamer
T64L-6011-EA or Equivalent
Vibration Damper Remover
Adapter
T82L-6316-B or Equivalent
Feeler Gauge
D81L-4201-A or Equivalent
02-3
Special Tools
TSG-416 ENGINE - PRELIMINARY
Impact Slide Hammer
T50T-100-A or Equivalent
Valve Seal Tool 21-024 or
Equivalent
Pound/Inch Torque Wrench
Purchase from Local Tool
Dealer
Extra space
Extra space Spring Tester
303-006 or
TOOL-6513-DD or Equivalent
Valve Clearance Measuring
Tool 100-002 or
TOOL-6505-E or Equivalent
Extra space
Spring Testing Fixture
21-024 or Equivalent
Extra space
02-4
TSG-416 ENGINE - PRELIMINARY
Description
The 1.6L 4 cylinder Zetec Rocam engine has been developed with the highest technology. Its main characteristics are:
• electronic controlled multipoint sequential injection
• roller finger follower camshaft
• intake manifold made of aluminum
• high resistance aluminum cylinder head
• steel oil pan.
Cylinder Head
The Zetec Rocam engine cylinder head is entirely made of aluminum which improves the thermal characteristics and reduces weight. The assembly is attached using a multi layer steel gasket and 12 bolts.
Oil Pan
The Zetec Rocam engine oil pan is made of steel. The gasket must always be replaced whenever the oil pan is removed.
Engine ID
Fuel System
The electronic fuel injection (EFI) system is electronically controlled by an ECM module which carefully controls fuel-air mixture along with spark timing, depending on information received from various sensors.
Intake Manifold
The intake manifold is made of aluminum. It consists of two pieces.
FPP04115
Engine Identification Number
The engine identification number is marked on the right side of the cylinder block as shown.
02-5
Component Location
TSG-416 ENGINE - PRELIMINARY
Oil Level Indicator
Camshaft Position
(CMP) Sensor
Positive Crankcase
Ventilation (PCV)
Valve
Cylinder Head
Assembly
Timing Chain
Tensioner Arm
Chain Guide
Water Pump
Coolant Flow
Control Module
Oil Pressure Switch
Cylinder Block
Crankshaft Position (CKP) Sensor
Piston Assembly
02-6
Component Location
TSG-416 ENGINE - PRELIMINARY
Throttle Body
TMAP
Sensor
PCV Hose
Intake Manifold
Exhaust
Manifold
Gasket
02-7
Component Location
TSG-416 ENGINE - PRELIMINARY
Gasket
Oil Deflector
Main Bearing Cap
Crankshaft Sprocket
Oil Pump
Oil Pan
Oil Pick-up tube
Main Bearings - Lower
Rear Seal Retainer
Crankshaft
Main Bearings - Upper
Cylinder Block
Timing Chain
02-8
Component Location
TSG-416 ENGINE - PRELIMINARY
Spark Plug Wires
DIS Ignition Coil
PCV Valve
Valve Cover
PCV Hose
Camshaft Sprocket
Tension Arm
Bearing Caps
Camshaft
Roller Follower
Lash Adjuster
Cylinder Head
Chain Guide
Timing Chain
Valve Assembly
Hydraulic Tensioner
Gasket
02-9
TSG-416 ENGINE - PRELIMINARY
ENGINE REPAIR
Valve Cover - Removal
1. Remove any necessary wiring and vacuum hoses.
Mark connections and routing as necessary to assure they are returned as they were removed.
Valve Cover - Installation
1. Contact surfaces must be clean and free of oil.
2. Install a new gasket and valve cover.
CMP Sensor
PCV Valve
Wiring Harness
Valve Cover
Vacuum Hose
2.
3.
4. Remove DIS coil and set aside - refer to Section 03.
5. Remove bolts.
6. Remove valve cover and gasket.
3. Install bolts. Tighten to 7 lb.ft. (9 Nm). (?any sequence ?).
4. Install DIS coil - refer to Section 03.
5.
6.
7. Reconnect any wiring and vacuum hoses removed.
02-10
Camshaft- Removal
TSG-416 ENGINE - PRELIMINARY
5. Remove camshaft, lower bearings, roller followers and lash adjusters.
NOTE: Store components to ensure assembly in the same order as they were removed.
1. Remove valve cover -- Refer to“Valve Cover -
Removal” on page 10.
2. Using tool 15-030A to lock camshaft sprocket, remove bolt.
Bearing Caps
Camshaft
Roller
Follower
Lash
Adjuster
Locking Tool
15-030A
CAUTION: During camshaft removal, the camshaft sprocket and chain must remain engaged and the chain tensioned in order to keep timing links aligned. If chain is allowed to slacken or disengage with sprocket, the oil pump will have to be removed, and the timing chain realigned - refer to timing chain assembly xxx.
3. Separate camshaft sprocket and chain from camshaft while maintaining tension on the chain.
4. Remove bolts and camshaft bearing caps evenly in the sequence shown.
6. ?
7. ?
Refer to Section 01 for camshaft and bearing service.
1
5
9
8
4
2
6
10
7
3
02-11
TSG-416 ENGINE - PRELIMINARY
Camshaft - Installation
NOTE: All components must be clean and assembled in the same positions as removed. Lubricate contact surfaces with clean engine oil.
1.
2.
3. Install lash adjusters.
4. Install roller followers.
7. Install camshaft sprocket with chain onto camshaft while maintaining tension on the chain.
CAUTION: The camshaft sprocket and chain must remain engaged and the chain tensioned in order to keep timing links aligned. If chain is allowed to slacken or disengage with sprocket, the oil pump will have to be removed, and the timing chain realigned - refer to timing chain assembly xxx.
8. Using tool 15-030A, install bolt and tighten to 52-59 lb.ft. (70-80 Nm).
Bearing Caps
Camshaft
Roller
Follower
Lash
Adjuster
Locking Tool
15-030A
NOTE: The chamfer on the camshaft bearing caps must be facing the chain housing. Rotate camshaft so keyway will align with sprocket.
5. Carefully install camshaft, bearings, caps and bolts finger tight.
6. Tighten bolts in the sequence shown in 3 steps to 6-
7 lb.ft. (8-10 Nm).
9. Install valve cover -- Refer to“Valve Cover -
Installation” on page 10.
9
7
1
5
3
10
8
2
6
4
02-12
TSG-416 ENGINE - PRELIMINARY
Valve Stem Seal - Removal
NOTE: If the valve or valve seat has not been damaged, the valve spring, seal, retainer or keys may be replaced by holding the affected valve closed using compressed air.
Use an appropriate air line tool installed in the spark plug hole. A minimum of 965 kPa (140 psi) line pressure is required. If air pressure does not hold the valve shut, the valve is damaged or burned and the cylinder head must be removed and serviced.
1. Remove valve cover -- Refer to“Valve Cover -
Removal” on page 10.
2. Rotate the camshaft so the roller follower for the valve to be serviced is on the heel of the cam.
3. Using a suitable valve spring compressor tool, compress and hold down the valve spring. Slide out the roller follower over the lash adjuster.
5. Turn on air supply and pressurize cylinder. Air pressure may rotate the crankshaft until the piston reaches the bottom of the stroke.
Rotunda
Pressurization Kit
014-00705
6. Using a suitable valve spring compressor, compress the valve spring and remove the keys and retainer.
Remove and discard the stem seal.
Roller Follower
Lash Adjuster
Key
Retainer
Spring
Valve Seal
FPP04076
4. Replace spark plug for cylinder being serviced with an air line adapter. Mark location so spark plug is returned to the same cylinder.
CAUTION: The crankshaft may rotate when air pressure is applied. Remove all objects from fan area such as lights, extension cords, etc.
7. If air pressure has forced the piston to the bottom of the cylinder, any removal of air pressure will allow the valve(s) to drop into the cylinder. Wrap a rubber band, tape or string around the end of the valve stem in such a way to prevent the valve from falling in and to allow enough travel to check the valve for binds.
8. Inspect the valve stem for damage. Rotate the valve and check the stem tip for eccentric movement.
Move the valve up and down through normal travel in the valve guide and check the stem for any binding. If the valve has been damaged, it will be necessary to remove the cylinder head as outlined in this section.
02-13
TSG-416 ENGINE - PRELIMINARY
Valve Stem Seal - Installation
NOTE: All components must be clean and assembled in the same positions as removed. Lubricate contact surfaces with clean engine oil.
CAUTION: Valve stem seal can be cut by grooves in valve stem. A damaged seal will leak causing oil burning and valve fouling.
1. Carefully slide oil seal over valve stem.
2. Install new valve seal using special tool 21-024
(optional T95P-6565A) ??protective cap??.
4. Release air pressure and remove air adapter. Install spark plug in proper cylinder.
5. Grease contact surfaces of roller follower with Ford
Multi-purpose Grease D0AZ-19584-AA, or equivalent, meeting Ford specification ESR-
M1C159-A.
6. Using spring compressor, compress and hold down the valve and spring. Slide the roller finger follower into place over valve and lash adjuster. Release spring.
Special Tool 21-024
Roller Follower
Lash Adjuster
NOTE: Apply a small amount of Ford Multi-purpose
Grease D0A2-19584-AA, or equivalent, meeting Ford specification ESR-M1C159-A to valve spring retainer key to hold in place during installation.
3. With cylinder pressurized and using a suitable spring compressor tool, install valve spring, retainer and locks.
FPP04076
7. Install valve cover -- Refer to“Valve Cover -
Installation” on page 10.
Key
Retainer
Spring
02-14
TSG-416 ENGINE - PRELIMINARY
TMAP Sensor
Electronic Throttle Body
Intake Manifold
Gasket
PCV Hose
Bolt
Gasket
Intake Manifold - Removal
1. Remove any necessary wiring and vacuum hoses.
Mark connections and routing as necessary to assure they are returned as they were removed.
2. Relieve fuel pressure.
3. Disconnect fuel lines from fuel rail.
4. Disconnect air intake tube.
5.
6.
7. Remove bolts, nuts and intake manifold assembly.
Intake Manifold - Installation
NOTE: All contact surfaces must be clean and free from any old gasket material.
1. Install a new gasket and intake manifold assembly.
2. Install bolts and nuts. Tighten to 6 lb.ft. (8 Nm).
3.
4.
5. Connect air intake tube.
6. Connect fuel lines to fuel rail.
7. Install any wiring and vacuum hoses that were removed. Connect and route as they were removed.
02-15
TSG-416 ENGINE - PRELIMINARY
Exhaust Manifold
Gasket
Outlet Flange
Exhaust Manifold - Removal
1. Remove any necessary wiring and vacuum hoses.
Mark connections and routing as necessary to assure they are returned as they were removed.
2. Disconnect exhaust at outlet flange.
3.
4.
5. Remove nuts, exhaust manifold and gasket.
Exhaust Manifold - Installation
NOTE: All contact surfaces must be clean and free from any old gasket material.
1. Install a new gasket and exhaust manifold.
2. Install nuts. Tighten to 11 lb.ft. (15 Nm).
3.
4.
5. Connect exhaust at outlet flange.
6. Tighten flange nuts to xx lb.ft. (xx Nm).
7. Install any wiring and vacuum hoses that were removed. Connect and route as they were removed.
02-16
TSG-416 ENGINE - PRELIMINARY
Cylinder Head - Removal
1. Drain engine oil - refer to Operator Handbook.
2. Drain engine coolant - refer to Section 05.
3. Remove any necessary wiring and vacuum hoses.
Mark connections and routing as necessary to assure they are returned as they were removed.
4. Remove valve cover -- Refer to“Valve Cover -
Removal” on page 10.
5. Remove spark plugs and wires.
6. Remove the coolant flow control module - refer to
Section 05.
12.Rotate camshaft sprocket using tool 15-030A until the 2 copper links on timing chain are at 12 o’clock.
Copper Links
12 O’clock
Coolant Flow
Control Module
Timing Mark
7. Remove bolts and nuts holding intake manifold to cylinder head. Move aside.
8. Remove heat shield ??.
9. Remove nuts at exhaust manifold. Move aside.
10.Remove oil level indicator tube bolt at cylinder head.
11.Remove timing chain hydraulic tensioner.
13.Using tool 15-030A to lock camshaft sprocket, remove bolt.
CAUTION: During cylinder head removal, the timing chain must be held up with a wire with constant tension in order to keep timing links aligned at crankshaft. If chain is allowed to slacken or disengage with sprocket, the oil pump will have to be removed, and the timing chain realigned - refer to timing chain assembly xxx.
14.Remove camshaft sprocket from chain while maintaining tension on the chain using a wire.
15.Remove the M11 cylinder head bolts in 3 phases in the sequence shown.
Hydraulic
Tensioner
1
7
9
5
3 M8
4
6
10
8
2
M8
02-17
TSG-416 ENGINE - PRELIMINARY
CAUTION: Be careful to avoid the bolts falling into the timing chain compartment.
16.Remove 2 M8 bolts, cylinder head and gasket.
M8 Bolts
Cylinder Head
Gasket
Dowels
17.Carefully remove cylinder head and gasket while maintaining tension on timing chain.
Gasket
Timing Chain
02-18
TSG-416 ENGINE - PRELIMINARY
Cylinder Head - Installation
NOTE: The contact surface of the cylinder head and block must be clean and free of oil. Use new cylinder head bolts and lubricate the threads.
1. Rotate crankshaft so all pistons are below top dead center (TDC).
CAUTION: During cylinder head installation, the timing chain must be held up with a wire with constant tension in order to keep timing links aligned at crankshaft. If chain is allowed to slacken or disengage with sprocket, the oil pump will have to be removed, and the timing chain realigned - refer to timing chain assembly xxx.
2. Carefully install dowels, a new gasket and cylinder head to the engine block while maintaining tension on the timing chain.
3. Install new bolts using the sequence shown in the following 3 steps:
• Step 1 - tighten M11 bolts to 29.5 lb.ft. (40 Nm)
• Step 2 - tighten M8 bolts to 11 lb.ft. (15 Nm) + 45°
• Step 3 - tighten M11 bolts additional 120°
10
4 2
6
8 M8
M8 Bolts
Gasket
Dowels
Cylinder Head
7
5 1 3
9
M8
Tightening Sequence
4. Carefully install sprocket into timing chain aligning timing mark with 2 copper links.
Copper Links
12 O’clock
CAUTION: Be careful to avoid the bolts falling into the timing chain compartment.
Timing Mark
02-19
TSG-416 ENGINE - PRELIMINARY
5. Using tool 15-030A, install camshaft sprocket bolt.
Tighten to 92 lb.ft. (125 Nm).
11.Install the coolant flow control module - refer to
Section 05.
Coolant Flow
Control Module
Locking Tool
15-030A
6. Install hydraulic tensioner and tighten to 30 lb.ft. (40
Nm).
Hydraulic
Tensioner
12.Install spark plugs and wires - refer to Section 03.
13.Install valve cover -- Refer to“Valve Cover -
Removal” on page 10.
14.Install and route any wiring and vacuum hoses removed.
15.Fill engine with correct type and quantity of coolant - refer to Section 05.
16.Fill engine with correct type and quantity of engine oil - refer to Operator Handbook.
7. Install oil level indicator bolt. Tighten to 15 lb.ft. (20
Nm).
8. Install exhaust manifold and nuts. Tighten nuts to 11 lb.ft. (15 Nm).
9. Install heat shield ??.
10.Install bolts and nuts holding intake manifold to cylinder head. Tighten to nuts and bolts to 13 lb.ft.
(18 Nm).
02-20
TSG-416 ENGINE - PRELIMINARY
Oil Pump - Removal
CAUTION: The oil pump, pulley and sealer are provided as an assembly kept together by a clip (no.
BF9A-6606-AA). Do not remove clip until oil pump is installed. If pulley is pushed out of the oil pump prior to oil pump installation, it will have to be
??repaired?? or replaced.
1. Remove drive belt - refer to xx.
2.
3. Remove water pump - refer to Section 05.
4. Insert retaining clip # BF9A-6606-AA between crankshaft pulley and oil pump to prevent pulley axial movement.
Retaining Clip
BF9A-6606-AA
Oil Pump
5. Remove crankshaft pulley bolt.
NOTE: Identify oil pump bolts so they may be returned to their original positions.
6. Remove 6 oil pump bolts, oil pump and gasket.
02-21
TSG-416 ENGINE - PRELIMINARY
Oil Pump - Installation
NOTE: Contact surfaces of the oil pump and block must be clean and free of oil.
CAUTION: The oil pump, pulley and sealer are provided as an assembly kept together by a clip (no.
BF9A-6606-AA). Do not remove clip until oil pump is installed. If pulley is pushed out of the oil pump prior to oil pump installation, it will have to be
??repaired?? or replaced.
1. Assemble gasket onto oil pump housing guiding it with 2 outer bolts.
4. Remove clip.
5. Install oil pump housing bolts finger tight.
CAUTION: The oil pump housing must be positioned during tightening of the oil pump housing bolts, so that the sealing flange of the oil pump housing is within ± 0.008 in. (0.20 mm) of the block bottom sealing flanges.
6. Tighten 2 outer oil pump housing bolts to 15 lb.ft. (20
Nm).
Outer Bolts
Oil Pump
Gasket
CAUTION: Do not apply oil to shaft or seal. Sealing lip along with all contact surfaces must be free of oil.
2. Place oil pump and gasket onto crankshaft.
3. Install pulley bolt and tighten to 92 lb.ft. (125 Nm).
7. Tighten remaining oil pump housing bolts to 15 lb.ft.
(20 Nm).
Pulley Bolt
Remaining Bolts
02-22
TSG-416 ENGINE - PRELIMINARY
Crankshaft Rear Oil Seal - Removal
1. Remove flywheel - refer to xx.
2. ??Remove oil pan - refer to xx.??
3. Remove bolts and rear oil seal retainer.
Crankshaft Rear Oil Seal - Installation
1. Install new rear seal and retainer using tool 21-046.
Special Tool
21-046
Rear Oil Seal and Retainer
Rear Seal Retainer
2. ??Install oil pan - refer to xx.??
3. Install flywheel - refer to xx.
02-23
TSG-416 ENGINE - PRELIMINARY
Camshaft Follower / Hydraulic Lash
Adjuster - Removal
1. Remove valve cover -- Refer to“Valve Cover -
Removal” on page 10.
2. Rotate the camshaft so the roller follower for the valve to be serviced is on the heel of the cam.
3. Using a suitable valve spring compressor tool, compress and hold down the valve spring. Slide out the roller follower over the lash adjuster.
Camshaft Follower / Hydraulic Lash
Adjuster - Installation
NOTE: All components must be kept clean and lubricated with clean engine oil.
Roller Follower
Special Tool 21-024
Lash Adjuster
4. Lift out the hydraulic lash adjuster.
FPP04076
1. Rotate the camshaft so the roller follower for the valve to be serviced is on the heel of the cam.
2. Install the hydraulic lash adjuster.
3. Using a suitable valve spring compressor tool, compress and hold down the valve spring. Slide in the roller follower over the lash adjuster.
4. Install valve cover -- Refer to“Valve Cover -
Removal” on page 10.
02-24
Oil Pan - Removal
1. Remove bolts.
2. Remove oil pan.
TSG-416 ENGINE - PRELIMINARY
2. Install the oil pan and bolts finger tight.
3. Align oil pan with rear portion of engine block.
Gasket
Straight Edge
Block
Oil Pan
Oil Pan
FPP04088
3. Remove all gasket material from pan.
CAUTION: Be careful not to contact surfaces.
Oil Pan - Installation
CAUTION: The contact surfaces of oil pan, gasket and block must be free of oil. Do not wait more than
5 minutes to install the oil pan gasket after sealer has been applied.
1. Apply WSEM-A4 sealer (Loctite 5910) to the 4 positions as shown.
4. Tighten oil pan bolts in 3 steps in the sequence shown:
• enough for gasket settlement
• 5 lb.ft. (7 Nm)
• 7 lb.ft. (10 Nm)
Front of Engine
4 places
Sealer Rope
3-5mm
60° ± 3°
10-15mm
02-25
Tightening Sequence
TSG-416 ENGINE - PRELIMINARY
Pick-up Tube
Oil Deflector
Pick-up Tube / Deflector - Removal
1.
2.
3. Remove oil pan -- Refer to“Oil Pump - Removal” on page 21.
4. Remove 4 nuts and1 bolt.
5. Remove pick-up tube.
6. Remove oil deflector.
Pick-up Tube / Deflector - Installation
1. Install oil deflector.
2. Install pick-up tube.
3. Install 4 nuts and tighten to 14 lb.ft. (19 Nm).
4. Install bolt and tighten to 7 lb.ft. (9.5 Nm).
5. Install oil pan -- Refer to“Oil Pump - Installation” on page 22.
6.
7.
02-26
TSG-416 ENGINE - PRELIMINARY
Crankshaft Main Bearings - Removal
NOTE: To check bearing clearances or to select new bearings, refer to Section 01.
1. Remove oil pan -- Refer to“Oil Pan - Removal” on page 25.
2. Remove pick-up tube & deflector -- Refer to“Pick-up
Tube / Deflector - Removal” on page 26.
NOTE: Replace one bearing at a time, leaving the other bearings securely fastened. Note location of studs for deflector installation.
Stud Positions
Lower Bearing
Cap
Stud & Nut
Bolt
3. Remove first main bearing cap bolts.
4. Remove cap and lower bearing.
5. Press on end of upper bearing without tang to start it out.
6. Rotate bearing out from between crankshaft and cylinder block.
Crankshaft Main Bearings - Installation
NOTE: All components must be clean and dried with compressed air or a lint free cloth. Lubricate bearing to crankshaft contact surfaces with clean engine oil.
1. Place upper bearing on crankshaft and rotate into place. Oil holes must align.
2. Place lower bearing into cap.
NOTE: Main bearing cap arrow must point to the front of the engine.
3. Install bearing cap.
CAUTION: Use new main bearing cap bolts.
4. Lightly oil new main bearing bolts or studs and install in same positions as removed. Alternately tighten in
3 steps to 70 lb.ft. (95 Nm).
5. Check crankshaft end play as outlined in Section 01.
6. Install pick-up tube and deflector -- Refer to“Pick-up
Tube / Deflector - Installation” on page 26.
7. Install oil pan -- Refer to“Oil Pan - Installation” on page 25.
02-27
TSG-416 ENGINE - PRELIMINARY
Connecting Rod Bearings - Removal
1. Remove oil pan -- Refer to“Oil Pan - Removal” on page 25.
2. Remove pick-up tube and deflector -- Refer to“Pickup Tube / Deflector - Removal” on page 26.
3. Remove spark plug for cylinder being serviced.
4. Rotate crankshaft until connecting rod and bearing to be serviced is placed at the bottom of its stroke.
5. Remove two connecting rod nuts.
6. Remove connecting rod cap with lower bearing.
Connecting Rod Bearings - Installation
NOTE: Make sure bearing bore of connecting rod and cap and bearing journal are clean. Lubricate wear surfaces with clean engine oil.
1. Insert upper bearing into connecting rod.
2. Insert lower bearing into cap.
CAUTION: Do not scratch journal with connecting rod bolts.
3. Install cap and bolts. Tighten bolts in 2 steps:
• Step 1 - 9 lb.ft. (12.5 Nm)
• Step 2 - 22 lb.ft. (30 Nm) (41-94°???)
4. Install deflector and pick-up tube -- Refer to“Pick-up
Tube / Deflector - Installation” on page 26.
5. Install oil pan -- Refer to“Oil Pan - Installation” on page 25.
5
4
3
2
1
Lower
Bearing
Cap
Bolts
FPP04072
7. Push piston and connecting rod assembly up into bore.
8. Remove upper bearing from connecting rod.
NOTE: For bearing service refer to Section 01.
02-28
TSG-416 ENGINE - PRELIMINARY
Piston - Removal
1. Remove oil pan -- Refer to“Oil Pan - Removal” on page 25.
2. Remove pick-up tube and deflector -- Refer to“Pickup Tube / Deflector - Removal” on page 26.
3. Remove cylinder head assembly -- Refer to“Cylinder
Head - Removal” on page 17.
CAUTION: Never cut into the ring travel area in excess of 0.8mm (1/32 inch) when removing ridges.
4. Turn crankshaft until piston to be removed is at the bottom of its travel and place a cloth on the piston head to collect the cuttings.
5. Remove any ridge and/or deposits from the upper end of the cylinder bores using a ridge cutter. follow the instructions furnished by the tool manufacturer.
6. Remove 2 bolts, connecting rod cap and lower bearing.
Cap
Lower
Bearing
Cylinder Ridge
Reamer
T64L-6011-EA
Bolts
FPP04072
CAUTION: Avoid damage to the crankshaft journal or the cylinder wall when removing the piston and rod.
7. Push piston assembly out the top of the cylinder with the handle end of a hammer.
Piston Assembly
Upper Bearing
NOTE: Make sure all caps are marked so that they can be installed in their original positions.
8. Remove upper bearing from connecting rod.
NOTE: For piston and bearing service - refer to Section
01.
02-29
TSG-416 ENGINE - PRELIMINARY
Piston - Installation
NOTE: Crankshaft journal should be at its lowest point.
All components should be clean and dried with compressed air or a lint free cloth.
1. Set piston ring gaps as follows:
• lower oil ring gap aligned with piston pin.
• center ring gap at 90° from the oil ring gap.
• top ring gap at 180° from the oil ring gap.
2. Lubricate piston, bearing wear surface, crankshaft journal and cylinder wall with clean engine oil.
3. Carefully install pistons with bearings into cylinder bores using a piston ring compressor and a hammer handle. Avoid damage to the crankshaft bearing journals. The arrow of the piston must point to the front of the engine. The connecting rod has the cylinder number identified in the base.
4. Install connecting rod caps with bearings (lubricate wear surface) and tighten bolts in 2 steps:
• Step 1 - 9 lb.ft. (12.5 Nm)
• Step 2 - 22 lb.ft. (30 Nm) (41-94°???).
Lower
Bearing
Hammer Handle
Cap
Piston Ring
Compressor Tool
CAUTION: Use new connecting rod cap bolts and lubricate threads with clean engine oil.
Bolts
FPP04072
5. ??Check connecting rod side clearance??.
6. Install cylinder head assembly -- Refer to“Cylinder
Head - Installation” on page 19.
7. Install pick-up tube and deflector -- Refer to“Pick-up
Tube / Deflector - Installation” on page 26.
8. Install oil pan -- Refer to“Oil Pan - Installation” on page 25.
02-30
Flywheel - Removal
1. Remove bolts.
2. Remove flywheel.
3.
4.
Flywheel
TSG-416 ENGINE - PRELIMINARY
3. Check flywheel runout at clutch disc surface:
• maximum runout 0.005 in. (0.13 mm)
Dial
Indicator
Dowel
4. Check flywheel runout at gear surface:
• maximum runout 0.024 in. (0.6 mm)
Dial
Indicator
Flywheel - Installation
1. Install flywheel using special locking tool 21-168.
2. Lubricate bolt threads with clean engine oil and tighten to 49 lb.ft. (67 Nm).
Flywheel Locking
Tool T84P-6375-A
(??21-168??)
02-31
TSG-416 ENGINE - PRELIMINARY
Timing Chain and Sprockets - Removal
1.
2.
3.
4. Remove oil pump assembly -- Refer to“Oil Pump -
Removal” on page 21.
5. Remove valve cover -- Refer to“Valve Cover -
Removal” on page 10.
6. oil pan, water pump, ???
7. Check to see if coppered links on the timing chain are still visible. If not, identify them as follows:
• Turn engine until timing mark on camshaft sprocket is at 12 o’clock.
• Mark the two chain links left and right of that timing mark.
• Mark the single chain link that is positioned on the crankshaft sprocket timing mark.
Copper Links
8. Remove the hydraulic tensioner.
Hydraulic
Tensioner
9. Using tool 15-030A to lock camshaft sprocket, remove bolt and camshaft sprocket.
Timing Mark
Locking Tool
15-030A
Copper Link
Timing Mark
02-32
TSG-416 ENGINE - PRELIMINARY
10.Remove timing chain and crankshaft sprocket.
11.Remove tensioner arm and chain guide if necessary.
Crankshaft Sprocket
2. Install crankshaft sprocket with key at 12 o’clock position.
3. Assemble drive chain through chain housing cavity from top of engine and onto crankshaft sprocket.
Align timing mark with coppered link on drive chain.
Timing Chain
Timing Mark
12 O’clock Position
Tensioner Arm
Coppered Link
Chain Guide
Camshaft Sprocket
Timing Chain and Sprockets - Installation
NOTE: All components must be clean and dried with compressed air or a lint free cloth. Lubricate with clean engine oil.
1. Install the (if removed) chain guide and the tensioner arm from the top of the engine. Install bolts finger tight.
4. Insert camshaft sprocket into chain and assemble to camshaft. Position camshaft key at 12 o’clock and align timing mark between 2 coppered links on drive chain.
12 O’clock Position
Coppered Links
Tensioner Arm
Chain Guide
Timing Mark
5. Install camshaft sprocket bolt and hydraulic tensioner finger tight.
02-33
TSG-416 ENGINE - PRELIMINARY
6. Tighten guide and tensioner arm bolts to 18-21 lb.ft.
(24-28 Nm).
8. Tighten hydraulic tensioner to 27-32 lb.ft. (36-44
Nm).
Tensioner Arm
Chain Guide
Hydraulic
Tensioner
7. Using ?? locking tool ??, tighten camshaft sprocket bolt to 52-59 lb.ft. (70-80 Nm).
Locking Tool
15-030A
9. oil pan, water pump, ???
10.Install valve cover -- Refer to“Valve Cover -
Installation” on page 10.
11.Install oil pump assembly -- Refer to“Oil Pump -
Installation” on page 22.
12.
13.
14.
15.
02-34
TSG-416 ENGINE - PRELIMINARY
Oil Level Indicator
Tube
Sealer
Oil Level Indicator - Removal
1.
2. Remove bolt.
3. Remove oil level indicator & tube.
Oil Level Indicator - Installation
1. Apply sealer WSK-M2G 349-A4 (Loctite 648) to lower end of oil level indicator tube.
2. Install tube immediately into bore.
3. Install bolt and tighten to 15 lb.ft. (20 Nm).
4.
02-35
TSG-416 ENGINE - PRELIMINARY
Gasket
Adapter
Oil Filter
Oil Filter and Adapter - Removal
NOTE: Place oil drain pan under oil filter to catch oil drainage.
1.
2. Remove oil filter.
3. Remove 3 bolts.
4. Remove adapter and gasket.
Oil Filter and Adapter - Installation
1. Install a new gasket.
2. Lubricate oil seal on a new filter and install to adapter. Tighten 1 1/2 to 1 3/4 turns after first contact.
3. Install filter/adapter to block.
4. Install 3 bolts and tighten to 15 lb.ft. (20 Nm).
5.
02-36
DISASSEMBLY
1. Install engine on an engine stand.
TSG-416 ENGINE - PRELIMINARY
3. Loosen the tensioner pulley and remove the drive belt.
Tension Pulley
Generator
2. Drain the engine oil.
NOTE: Record drive belt routing and direction of travel for use during assembly.
4. Disconnect wiring at generator.
5. Remove the generator.
6. Remove the generator support.
Water
Pump
FPP01527
Crankshaft
Idler
Generator
FPP02537
02-37
7. Remove oil level indicator tube.
8. Remove the ?return connector?.
TSG-416 ENGINE - PRELIMINARY
10.Remove the coolant flow control module.
Oil Level Indicator
Coolant Flow
Control Module
Coolant Return
Connector
NOTE: Record routing of wiring harnesses and vacuum tubes so they may be returned to their original positions during assembly.
9. Remove any vacuum hoses and wiring.
11.Remove the intake manifold assembly.
Intake Manifold
Assembly
Wiring Harness
Vacuum Hose
02-38
TSG-416 ENGINE - PRELIMINARY
12.Remove the oil filter and support assembly.
Gasket
16.Remove the valve cover assembly.
PCV Valve
CMP Sensor
Valve Cover
Oil Filter Assembly
13.Remove oil pressure switch.
14.Remove crankshaft position (CKP) sensor.
CKP Sensor
Oil Pressure Switch
17.Loosen the crankshaft pulley bolt.
Crankshaft Pulley
15.Remove the flywheel and flywheel plate.
Flywheel
Bolt
Plate
02-39
TSG-416 ENGINE - PRELIMINARY
18.Remove 3 bolts and the water pump pulley.
22.Remove 4 nuts, 1 bolt, oil pick-up tube and oil deflector.
Pulley
Water Pump
Oil Pick-up Tube
Oil Deflector
19.Remove 3 bolts, water pump and gasket.
Gasket
Water Pump
NOTE: When removing oil pan, always keep the engine in its normal upright position to avoid contamination.
20.Remove bolts, gasket and oil pan.
23.Insert retaining clip # BF9A-6606-AA between crankshaft pulley and oil pump to prevent pulley axial movement.
24.Remove crankshaft pulley bolt.
NOTE: Identify oil pump bolts so they may be returned to their original positions.
25.Remove 6 oil pump bolts, and oil pump.
Retaining Clip BF9A-6606-AA
Gasket
Oil Pump
Oil Pan
21.Turn the engine over 180°.
FPP04089
02-40
Gasket
TSG-416 ENGINE - PRELIMINARY
26.Check to see if coppered links on the timing chain are still visible. If not, identify them as follows:
• Turn engine until timing mark on camshaft sprocket is at 12 o’clock.
• Mark the two chain links left and right of that timing mark.
• Mark the single chain link that is positioned on the crankshaft sprocket timing mark.
Copper Links
28.Using tool 15-030A to lock camshaft sprocket, remove bolt and camshaft sprocket.
Locking Tool
15-030A
Timing Mark
29.Remove timing chain and crankshaft sprocket.
30.Remove tensioner arm and chain guide.
Crankshaft Sprocket
Timing Chain
Timing Mark
Tensioner Arm
Copper Link
27.Remove the hydraulic tensioner.
Hydraulic
Tensioner
Chain Guide
Camshaft Sprocket
02-41
TSG-416 ENGINE - PRELIMINARY
CAUTION: Keep cylinder head in the vertical position during removal to avoid warping and damage to the sealing surfaces.
31.Remove the M11 cylinder head bolts in 3 phases in the sequence shown.
33.Remove crankshaft rear seal retainer.
Oil Seal Retainer
1
7
9
5
3 M8
4
6 10
8
2
M8
32.Remove 2 M8 bolts, cylinder head and gasket.
M8 Bolts
Cylinder Head
FPP04078
NOTE: Mark piston and cap so they may be returned to their original positions.
34.Remove 2 bolts, lower connecting rod bearing and cap. Push piston assembly out of the engine block.
Repeat for other three cylinders.
Bolts
Cap
Lower
Bearing
Gasket
Dowels
02-42
TSG-416 ENGINE - PRELIMINARY
NOTE: Keep caps and bearings in order so they may be returned to their original positions.
35.Remove bolts, caps and crankshaft lower main bearings in the sequence shown.
36.Carefully remove the crankshaft and install it vertically on the flywheel to avoid warp running-out.
Crankshaft
Caps
Flywheel
Lower Bearings
Crankshaft
1
2
5
6
Front of Engine
9
10
8
7
4
3
37.Remove the 5 upper main bearings and the 2 thrust washers.
Upper Main Bearings
Thrust Washers
02-43
TSG-416 ENGINE - PRELIMINARY
SUBASSEMBLIES
Clean crankcase and all subassemblies of all foreign material. Scrape or wire brush RTV sealant from mating surfaces. Surfaces must be kept oil free for good adhesion of fresh RTV seal (during reassembly).
NOTE: For cleaning and service information on crankcase, cylinder head, camshaft, crankshaft and bearings, Refer to Section 01.
Discard gaskets and O-Rings and replace with new ones unless otherwise instructed.
Cylinder Block
1. Remove the core plugs, if necessary.
3. Check the engine block for warpage, cracks or any other damage.
4. Coolant and oil galleries must be free of dirt and deposits.
5. Refer to Section 01 for cleaning & servicing cylinder block and core plug installation.
6. Reinstall oil gallery plugs.
2. Remove oil gallery plugs.
Oil Gallery Plugs
02-44
TSG-416 ENGINE - PRELIMINARY
Piston - Disassembly
NOTE: Store components to ensure assembly with the same rod and installation in the same cylinders from which they were removed. Refer to Section 01 for piston inspection and servicing.
1. Remove the connecting rod bearing from the connecting rod and cap.
2. Remove the piston rings using a suitable piston ring expander.
Piston - Assembly
NOTE: Apply a light coat of clean engine oil contact surfaces.
1. Assemble piston to connecting rod using ?????????
2. Install piston rings using a suitable piston ring expander.
Ring Expander
Tool
3. Remove piston pin???????????????????
4.
NOTE: Check piston ring end gap and side clearance - refer to Section 01.
3. Install bearings into connecting rods and caps. Make sure lock slots align.
CAUTION: Make sure bearings and connecting rod bore are clean. foreign material under the inserts will distort the bearing and cause a failure.
02-45
TSG-416 ENGINE - PRELIMINARY
Cylinder Head - Disassembly
NOTE: Store components to ensure assembly in the same order as they were removed.
1. Remove bolts and camshaft bearing caps evenly in the sequence shown.
6. Remove all valve components using a suitable valve spring compressor.
1
5
9
8
4
Key
Retainer
Spring
Valve Seal
2
6 10
7
Loosening Sequence
3
2. Remove camshaft.
3. Remove roller followers.
4. Remove lash adjusters.
5. Remove spark plugs.
Bearing Caps
Camshaft
Roller
Follower
Lash
Adjuster
Cylinder Head
Valve
Refer to Section 01 for:
• servicing valve components, valve guide and valve seat.
• camshaft and bearing service.
• cylinder head cleaning and inspection.
02-46
TSG-416 ENGINE - PRELIMINARY
Cylinder Head - Assembly
NOTE: All components must be clean and assembled in the same positions as removed. Lubricate contact surfaces with clean engine oil.
1. Check that valves move freely in valve guides.
2. Install intake and exhaust valves.
3. Install new valve seals using special tool 21-024
(optional T95P-6565A).
5. Check that spring installed height is 35.2 ± 1mm.
Spring
Installed
Height
Special Tool 21-024
6. Install lash adjusters.
Bearing Caps
Camshaft
Roller
Follower
Lash
Adjuster
4. Using a suitable spring compressor tool, install valve springs, retainers and locks.
Key
Retainer
Spring
Valve Seal
7. Install roller followers.
NOTE: The chamfer on the camshaft bearing caps must be facing the chain housing.
8. Carefully install camshaft bearings, camshaft and bearing caps with bolts finger tight.
NOTE: Rotate camshaft so key is at 12 O’clock position.
9. Tighten bolts in the sequence shown in 3 steps to 6-
7 lb.ft. (8-10 Nm).
9
7
1
5
3
Valve
Cylinder Head
10
8
2
6
Tightening Sequence
4
02-47
TSG-416 ENGINE - PRELIMINARY
ASSEMBLY
NOTE: All components must be clean and dried with compressed air or a lint free cloth. For information on bearings & piston inspection and selection - Refer to
Section 01.
1. Install upper main bearings and thrust washers to cylinder block. Lubricate the wear surfaces with clean engine oil. Make sure oil holes align.
NOTE: The main bearing caps are numbered and must be assembled to corresponding numbers. The arrow on the main bearing caps must point to the front of the engine.
CAUTION: Use new main bearing cap bolts.
4. Install main bearing caps in the same positions as removed.
NOTE: Check the position of studs as shown.
Upper Main Bearings
Stud Positions
Thrust Washers
2. Carefully install the crankshaft onto the upper bearings.
3. Assemble the lower main bearings into caps.
Lubricate the wear surfaces and the bolt threads with clean engine oil.
5. Tighten main bearing cap bolts/studs in sequence shown and in three steps to 70 lb.ft. (95 Nm).
Front of Engine
Caps
Lower Bearings
9
10
5
6
1
2
4
3
8
7
Crankshaft
NOTE: Check crankshaft end play as outlined in
Section 01.
02-48
TSG-416 ENGINE - PRELIMINARY
6. Set piston ring gaps as follows:
• lower oil ring gap aligned with piston pin.
• center ring gap at 90° from the oil ring gap.
• top ring gap at 180° from the oil ring gap.
7. Lubricate piston, bearing wear surface, crankshaft journal and cylinder wall with clean engine oil.
8. Carefully install pistons with bearings into cylinder bores using a piston ring compressor and a hammer handle. Avoid damage to the crankshaft bearing journals. The arrow of the piston must point to the front of the engine. The connecting rod has the cylinder number identified in the base.
10.Install a new rear seal and retainer using tool 21-
046.
Special Tool
21-046
Piston Ring
Compressor Tool
Hammer Handle
Rear Seal Retainer
CAUTION: Use new connecting rod cap bolts and lubricate threads with clean engine oil.
9. Install connecting rod caps with bearings (lubricate wear surface) and tighten bolts in 2 steps:
• Step 1 - 9 lb.ft. (12.5 Nm)
• Step 2 - 22 lb.ft. (30 Nm) (41-94°???).
NOTE: Rear seal retainer comes on a plastic sleeve.
Link plastic sleeve to crankshaft (?? 34mm ??) and push retainer to crankshaft. Plastic pins at rear side of retainer must fit to corresponding block bores. Remove plastic sleeve when done.
11.Turn engine 180° to prepare for cylinder head installation.
NOTE: The contact surface of the cylinder head and block must be clean and free of oil. Use new cylinder head bolts and lubricate the threads.
12.Rotate crankshaft so all pistons are below top dead center (TDC).
13.Install dowels and new cylinder head gasket to the engine block.
14.Carefully install the cylinder head onto the gasket.
M8 Bolts
Cylinder Head
Cap
Bolts
Lower
Bearing
Gasket
Dowels
02-49
TSG-416 ENGINE - PRELIMINARY
15.Install new bolts using the sequence shown in the following 3 steps:
• Step 1 - tighten M11 bolts to 29.5 lb.ft. (40 Nm)
• Step 2 - tighten M8 bolts to 11 lb.ft. (15 Nm) + 45°
• Step 3 - tighten M11 bolts additional 120°
17.Install crankshaft sprocket with key at 12 o’clock position.
18.Assemble drive chain through chain housing cavity from top of engine and onto crankshaft sprocket.
Align timing mark with coppered link on drive chain.
Timing Mark
12 O’clock Position
10
4 2
6
8 M8
Coppered Link
7
5 1 3
9
M8
Tightening Sequence
16.Install the chain guide and the tensioner arm from the top of the engine. Install bolts finger tight.
19.Insert camshaft sprocket into chain and assemble to camshaft. Position camshaft key at 12 o’clock and align timing mark between 2 coppered links on drive chain.
Coppered Links
12 O’clock Position
Tensioner Arm
Chain Guide
Timing Mark
20.Install camshaft sprocket bolt and hydraulic tensioner finger tight.
02-50
TSG-416 ENGINE - PRELIMINARY
21.Tighten guide and tensioner arm bolts to 18-21 lb.ft.
(24-28 Nm).
23.Tighten hydraulic tensioner to 27-32 lb.ft. (36-44
Nm).
Tensioner Arm
Chain Guide
Hydraulic Tensioner
22.Using locking tool, tighten camshaft sprocket bolt to
52-59 lb.ft. (70-80 Nm).
CAUTION: The oil pump, pulley and sealer are provided as an assembly kept together by a clip (no.
BF9A-6606-AA). Do not remove clip until oil pump is installed. If pulley is pushed out of the oil pump prior to oil pump installation, it will have to be
??repaired?? or replaced. (?can this pump be rebuilt?)
Clip
Locking Tool
15-030A
Do Not Remove Clip Until Installed!
02-51
TSG-416 ENGINE - PRELIMINARY
24. Assemble gasket onto oil pump housing guiding it with 2 outer bolts.
29.Tighten 2 outer oil pump housing bolts to 15 lb.ft. (20
Nm).
Oil Pump
Outer Bolts
Gasket
CAUTION: Do not apply oil to shaft or seal. Sealing lip along with all contact surfaces must be free of oil.
25.Place oil pump and gasket onto crankshaft.
26.Install pulley bolt and tighten to 92 lb.ft. (125 Nm).
30.Tighten remaining oil pump housing bolts to 15 lb.ft.
(20 Nm).
Pulley Bolt
Remaining Bolts
27.Remove clip.
28.Install oil pump housing bolts finger tight.
CAUTION: The oil pump housing must be positioned during tightening of the oil pump housing bolts, so that the sealing flange of the oil pump housing is within ± 0.008 in. (0.20 mm) of the block bottom sealing flanges.
02-52
TSG-416 ENGINE - PRELIMINARY
31.Install water pump.
32.Install bolts and tighten to 7 lb.ft. (10 Nm).
Gasket
Water Pump
35.Install oil deflector.
36.Install oil pick-up tube.
Oil Pick-up Tube
Oil Deflector
33.Install water pump pulley.
34.Install bolts and tighten to 9 lb.ft. (12 Nm).
Pulley
Water Pump
37.Tighten nuts to 14 lb.ft. (19 Nm). Tighten bolt to 7 lb.ft. (9.5 Nm).
38.Apply WSEM-A4 sealer (Loctite 5910) to the 4 positions as shown.
4 places
Sealer Rope
3-5mm
60° ± 3°
10-15mm
CAUTION: The contact surfaces of oil pan, gasket and block must be free of oil. Do not wait more than
5 minutes to install the oil pan gasket after sealer has been applied.
02-53
TSG-416 ENGINE - PRELIMINARY
39.Install the oil pan and bolts finger tight.
40.Align oil pan with rear portion of engine block.
42.Install the oil pan drain plug. Tighten to 18 lb.ft. (25
Nm).
43.Install flywheel using special locking tool 21-168.
Flywheel
Straight Edge
Block
Dowel
Oil Pan
41.Tighten oil pan bolts in 3 steps in the sequence shown:
• enough for gasket settlement
• 5 lb.ft. (7 Nm)
• 7 lb.ft. (10 Nm)
44.Lubricate bolt threads with clean engine oil and tighten to 49 lb.ft. (67 Nm).
45.Check flywheel runout at clutch disc surface:
• maximum runout 0.005 in. (0.13 mm)
Dial
Indicator
Front of Engine
Tightening Sequence
02-54
TSG-416 ENGINE - PRELIMINARY
46.Check flywheel runout at gear surface:
• maximum runout 0.024 in. (0.6 mm)
50.Install oil filter support with new filter. Tighten bolts to
15 lb.ft. (20 Nm).
Oil Filter
Support
Gasket
Dial
Indicator
47.Install valve cover and gasket. Tighten bolts to 7 lb.ft. (9 Nm).
CMP Sensor
PCV Valve
51.Install oil pressure switch and tighten to 15 lb.ft. (20
Nm).
CKP Sensor
Oil Pressure Switch
Valve Cover
48.Apply grease WSD-M13P8-A1 (? kluberpaste?
HEL46-450 ? anti-seize? ) or equivalent to spark plug threads.
49.Install spark plugs and tighten to 10-13 lb.ft. (13-17
Nm).
52.Install crankshaft position sensor and tighten to 3 lb.ft. (4 Nm).
02-55
TSG-416 ENGINE - PRELIMINARY
53.Install intake manifold and gasket. Tighten bolts and nuts to 6 lb.ft. (8 Nm).
Intake Manifold
Assembly
55.Apply sealer WSK-M2G 349-A4 (Loctite 648) to lower end of oil level indicator tube. Install immediately and tighten bolt to 15 lb.ft. (20 Nm).
Oil Level
Indicator
Tube
Sealer
54.Install coolant flow control module and gasket.
Tighten bolts to 7 lb.ft. (10 Nm).
Coolant Flow
Control Module
56.Apply sealer WSK-M2G 349-A7 (Loctite 243) to threads of coolant return connector. Install and tighten to 15 lb.ft. (20 Nm).
Coolant Return
Connector
02-56
TSG-416 ENGINE - PRELIMINARY
57.Install generator support. Tighten bolts to? lb.ft. (?
Nm).
59.Pry tensioner pulley as shown and install drive belt.
Tension Pulley
Generator Support
58.Install generator and electrical connectors. Tighten bolts to? lb.ft. (? Nm).
60. Install engine wiring and vacuum hoses.
Wiring Harness
Generator
Electrical Connector
Vacuum Hose
NOTE: Drive belt must be installed in the same direction of rotation as when removed.
61.Fill engine with clean engine oil of the correct type and quantity.
NOTE: Ford Power Products industrial engines are designed to perform with engine oils that are licensed by the American Petroleum Institute (API) and oils carrying the most current API classification should be used.
02-57
TSG-416 ENGINE - PRELIMINARY
SPECIFICATIONS
Engine Type:
GENERAL SPECIFICATIONS
4 cylinder, 4 stroke spark ignition 90°
Overhead Valve (OHV) chain driven, overhead camshaft operating the valves via roller cam followers.
Liter/CID:
Bore: mm (inch)
Stroke: mm
(inch)
Number of cylinders:
Compression
Ratio:
1.6 / 97.5
82.070 mm (3.23 in.)
75.480 mm (2.97 in.)
4
9.5 : 1
LPG
Type:
Fuel
Specification:
NG
Type:
Fuel
Specification:
GAS
Type:
Fuel
Specification:
Fuel Pump
Pressure
Normal:
Max:
FUEL SYSTEM
Liquefied Petroleum Gas
EN589 (European) (USA)
Natural Gas
38.7 MJ/m
3
(UK) 39.0 MJ/m
3
(USA)
Gasoline (petrol)
Electronic Fuel Injection
Unleaded 87 or 89 Octane (Gasoline blends not to exceed 10% Ethanol by volume Octane
Index of 87 or 89).
(Part #ZU1L-9350-AA)
40 psi
?? psi
Max. Oil
Pressure:
Oil Type:
Service Oil fill capacity
(including filter):
Oil filter Type:
LUBRICATION SYSTEM
Hot@2500 rpm: 275.79 - 413.69 kPa (40-60 psi)
SAE 5W30 WSS-M2C205-A (API classification: SJ)
4.2 Liter (4.44 quarts)
X56E-6714-D1A
Thermostat:
Coolant
COOLING SYSTEM
Type: Wax element
Commences opening: 82.2°C (180°F)
Fully open:94.5°C (202°F)
50% Motorcraft Super Plus 2000 plus 50% clear water
Ford Specification: WSS-M97B44-D or ESE-
M97B44-A
Polarity:
Generator Drive
Belt Tension (8K
Poly Belt):
ELECTRICAL SYSTEM
Negative to earth (ground)
Tension is within specification if the tensioner is within the indicator markings
Spark
Plug
IGNITION
Ford Part Number: XS6F-12405-A1A (NGK TR6B-10)
Gap: 0.95 - 1.05 mm
Firing
Order
1-3-4-2
CRANKSHAFT
Main journal-standard diameter
Main journal-undersize diameter
2.243 - 2.244
(56.980 - 57.000 mm)
2.233 - 2.234
(56.726 - 56.746)
Width-main journal bearing shell
Pin Journal standard
ITEM
Oil Pan Drain
Plug
Spark Plugs
Oil Filter
Nm
25
13-17
11-15
FT. LB.
18
9.6-12.5
8-11
LB. IN.
221.3
115-150.5
97.4-132.7
02-58
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Table of contents
- 3 Special Tools
- 5 Description
- 6 Component Location
- 10 Valve Cover - Removal
- 10 Valve Cover - Installation
- 11 Camshaft- Removal
- 12 Camshaft - Installation
- 13 Valve Stem Seal - Removal
- 14 Valve Stem Seal - Installation
- 15 Intake Manifold - Removal
- 15 Intake Manifold - Installation
- 16 Exhaust Manifold - Removal
- 16 Exhaust Manifold - Installation
- 17 Cylinder Head - Removal
- 19 Cylinder Head - Installation
- 21 Oil Pump - Removal
- 22 Oil Pump - Installation
- 23 Crankshaft Rear Oil Seal - Removal
- 23 Crankshaft Rear Oil Seal - Installation
- 24 Camshaft Follower / Hydraulic Lash Adjuster - Removal
- 24 Camshaft Follower / Hydraulic Lash Adjuster - Installation
- 25 Oil Pan - Removal
- 25 Oil Pan - Installation
- 26 Pick-up Tube / Deflector - Removal
- 26 Pick-up Tube / Deflector - Installation
- 27 Crankshaft Main Bearings - Removal
- 27 Crankshaft Main Bearings - Installation
- 28 Connecting Rod Bearings - Removal
- 28 Connecting Rod Bearings - Installation
- 29 Piston - Removal
- 30 Piston - Installation
- 31 Flywheel - Removal
- 31 Flywheel - Installation
- 32 Timing Chain and Sprockets - Removal
- 33 Timing Chain and Sprockets - Installation
- 35 Oil Level Indicator - Removal
- 35 Oil Level Indicator - Installation
- 36 Oil Filter and Adapter - Removal
- 36 Oil Filter and Adapter - Installation
- 37 Disassembly
- 44 Cylinder Block
- 45 Piston - Disassembly
- 45 Piston - Assembly
- 46 Cylinder Head - Disassembly
- 47 Cylinder Head - Assembly