TSG-416 Service Manual (Sec. 2)

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TSG-416 Service Manual (Sec. 2) | Manualzz

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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