TSG-416 Service Manual (Sec. 2)
Contents
1. Exhaust Manifold Installation NOTE All contact surfaces must be clean and free from any old gasket material Install a new gasket and exhaust manifold Install nuts Tighten to 11 Ib ft 15 Nm Connect exhaust at outlet flange Tighten flange nuts to xx Ib ft xx Nm Dou sies oon o c 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 Coolant Flow Control Module 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 Hydraulic Tensioner FPPO4135 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 04136 13 Using tool 15 030A to lock camshaft sprocket remove bolt CAUTION Duri2. 3 Install lash adjusters 4 Install roller followers Bearing Caps aan Roller Follower 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 Ib ft 8 10 Nm H l Hol SE S D ES CS Sion F SIA rn 1772 i aaa FPP04133 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 0304 install bolt and tighten to 52 59 Ib ft 70 80 Nm Locking Tool 15 030A FPP04132 9 Install valve cover Refer to Valve Cover Installation on page 10 02 12 TSG 416 ENGINE PRELIMINARY Valve Stem Seal Removal NOTE Ifthe 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 pr
3. Outer Bolts FPP04139 FPP04141 CAUTION Do not apply oil to shaft or seal Sealing lip along with all contact surfaces must be free of oil 30 Tighten remaining oil pump housing bolts to 15 Ib ft 20 Nm 25 Place oil pump and gasket onto crankshaft 26 Install pulley bolt and tighten to 92 Ib ft 125 Nm Pulley Bolt FPP04142 Remaining Bolts FPP04140 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 35 Install oil deflector 32 Install bolts and tighten to 7 Ib ft 10 Nm 36 Install oil pick up tube Oil Pick up Tube Water Pump Oil Deflector 33 Install water pump pulley 34 Install bolts and tighten to 9 Ib ft 12 Nm 37 Tighten nuts to 14 Ib ft 19 Nm Tighten bolt to 7 Ib ft 9 5 Nm 38 Apply WSEM A4 sealer Loctite 5910 to the 4 positions as shown 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 42 Install the oil pan drain plug Tighten to 18 Ib ft
4. repaired or replaced 1 Assemble gasket onto oil pump housing guiding it with 2 outer bolts FPP04139 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 Ib ft 125 Nm Pulley Bolt FPP04140 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 Ib ft 20 Nm Outer Bolts FPPO4141 7 Tighten remaining oil pump housing bolts to 15 Ib ft 20 Nm FPP04142 Remaining Bolts 02 22 TSG 416 ENGINE PRELIMINARY Crankshaft Rear Oil Seal Removal Crankshaft Rear Oil Seal Installation 1 Remove flywheel refer to xx 1 Install new rear seal and retainer using tool 21 046 2 Remove oil pan refer to xx 3 Remove bolts and rear oil seal retainer Special Tool Rear Oil Seal gt 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 Camshaft Follower Hydraulic Lash Adjuster Removal Adjuster Installation NOTE All components mu
5. t 02 43 TSG 416 ENGINE PRELIMINARY SUBASSEMBLIES 3 Check the engine block for warpage cracks or any other damage 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 FPP04162 4 Coolant and oil galleries must be free of dirt and deposits FPP04161 5 Refer to Section 01 for cleaning amp servicing cylinder block and core plug installation 2 Remove oil gallery plugs 6 Reinstall 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 Ring Expander FPP04163 4 Piston Assembly NOTE Apply a light coat of clean engine oil contact surfaces 2 Install piston rings using a suitable pisto
6. 25 Nm 43 Install flywheel using special locking tool 21 168 40 Align oil pan with rear portion of engine block Flywheel Straight Edge Oil Pan 41 Tighten oil pan bolts in 3 steps in the sequence shown 44 Lubricate bolt threads with clean engine oil and enough for gasket settlement tighten to 49 Ib ft 67 Nm Sib ft 7 Nm 45 Check flywheel runout at clutch disc surface 7 lb ft 10 Nm maximum runout 0 005 in 0 13 mm Dial Indicator Tightening Sequence 02 54 TSG 416 ENGINE PRELIMINARY 46 Check flywheel runout at gear surface 50 Install oil filter support with new filter Tighten bolts to 15 Ib ft 20 Nm maximum runout 0 024 in 0 6 mm Cil Filter Indicator FPP04152 47 Install valve cover and gasket Tighten bolts to 7 Ib ft 9 Nm FPP04092 CMP Sensor CKP Sensor 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 Ib ft 13 17 Nm 52 Install crankshaft position sensor and tighten to 3 Ib ft 4 Nm 02 55 TSG 416 ENGINE PRELIMINARY 53 Install intake manifold and gasket Tighten bolts and 55 Apply sealer WSK M2G 349 A4 Loctite 648 to lower end of oil level indicator tube Install immediately and tighten bolt to 15 Ib ft 20 Nm nuts to 6 Ib ft 8 Nm Intake Manifold Oil Level
7. Rotate bearing out from between crankshaft and cylinder block Lower Bearing Stud amp Nut 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 Ib 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 Connecting Rod Bearings Installation NOTE Make sure bearing bore of connecting rod and 1 Remove oil pan Refer to Ol Pan Removal on cap and bearing journal are clean Lubricate wear page 25 surfaces with clean engine oil 2 Remove pick up tube and deflector Refer to Pick up Tube Deflector Removal page 26 1 Insert upper bearing into connecting rod 3 Remove spark plug for cylinder being serviced 2 Insert low
8. for gasket settlement has been applied 5lb ft 7 Nm 7 b ft 10 Nm 1 Apply WSEM A4 sealer Loctite 5910 to the 4 positions as shown Sealer Rope an Tightening Sequence 10 15mm 02 25 TSG 416 ENGINE PRELIMINARY Pick up Tube Deflector Removal 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 Oil Deflector 004087 Tube Deflector Installation zg N gt 02 26 Install oil deflector Install pick up tube Install 4 nuts and tighten to 14 Ib ft 19 Nm Install bolt and tighten to 7 Ib ft 9 5 Nm Install oil pan Refer to Oil Pump Installation on page 22 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 amp deflector Refer to Pick up Tube Deflector Removal on page 26 NOTE Replace one bearing ata time leaving the other bearings securely fastened Note location of studs for deflector installation Stud Positions FPP04145 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
9. iaia 02 44 Pistons Disasse pne i em 02 45 Piston Assembly cider liaud cedet ee dna e T I er ne 02 45 Cylinder Head Disassembly e 02 46 Cylinder Head Assembly en lan asien 02 47 CIIJIb AME 02 48 Specificatlons iii iaia u Su EE sassa 02 58 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 Cylinder Ridge Reamer T64L 6011 EA or Equivalent Connecting Rod Guide Tool T93P 6136 A or Equivalent Vibration Damper Remover Adapter T82L 6316 B or Equivalent Crankshaft Damper Remover T58P 6316 D or Equivalent Feeler Gauge D81L 4201 A or Equivalent 02 3 Special Tools TSG 416 ENGINE PRELIMINARY FPP10000 Impact Slide Hammer Valve Seal Tool 21 024 or T50T 100 A or Equivalent Equivalent FPP10035 Pound Inch Torque Wrench Extra space Purchase from Local Tool Dealer Spring Tester Extra space 303 006 or TOOL 6513 DD or Equivalent FPP10034 Valve Clearance Measuring Extra space Tool 100 002 or TOOL 6505 E or Equi
10. with clean engine oil 4 Install connecting rod caps with bearings lubricate wear surface and tighten bolts in 2 steps Step 1 9 Ib ft 12 5 Nm Step 2 22 Ib ft 30 Nm 41 94 222 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 TSG 416 ENGINE PRELIMINARY Flywheel Removal 3 Check flywheel runout at clutch disc surface 4 Remove bolts maximum runout 0 005 in 0 13 mm 2 Remove flywheel 3 Dial 4 Indicator Flywheel 4 Check flywheel runout at gear surface maximum runout 0 024 in 0 6 mm Flywheel Installation Indicator 1 Install flywheel using special locking tool 21 168 2 Lubricate bolt threads with clean engine oil and tighten to 49 Ib ft 67 Nm Flywheel Locking Tool T84P 6375 A 21 168 FPP04150 02 31 TSG 416 ENGINE PRELIMINARY Timing Chain and Sprockets Removal 8 Remove the hydraulic tensioner 1 2 Hydraulic 3 Tensioner 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 th
11. 1 1 2 to 1 3 4 turns after first 2 Remove oil filter contact 3 Remove 3 bolts 3 Install filter adapter to block 4 Remove adapter and gasket 4 Install 3 bolts and tighten to 15 Ib ft 20 Nm 02 36 TSG 416 ENGINE PRELIMINARY DISASSEMBLY 3 Loosen the tensioner pulley and remove the drive belt 1 Install engine on an engine stand Tension Pulley FPPO4154 Generator FPP01527 2 Drain the engine oil NOTE Record drive belt routing and direction of travel 4 Disconnect wiring at generator for use during assembly 5 Remove the generator 6 Remove the generator support Water Pump Generator FPP02537 02 37 TSG 416 ENGINE PRELIMINARY 7 Remove oil level indicator tube 10 Remove the coolant flow control module 8 Remove the return connector 28 Coolant Flow Oil Level Indicator IECH Control Module Coolant Return Connector e fu S ug NIT l 11 Remove the intake manifold assembly NOTE Record routing of wiring harnesses and vacuum tubes so they may be returned to their original positions Intake Manifold during assembly Assembly 20 9 Remove vacuum hoses wiring Wiring Harness Vacuum Hose 02 38 TSG 416 ENGINE PRELIMINARY 12 Remove the oil filter and support assembly 16 Remove the valve cover assembly PCV Valve CMP Sensor Valve Cover 13 Remove oil pressure switch 14 Remove crankshaft posit
12. 2 24 Camshaft Follower Hydraulic Lash Adjuster Installation i 02 24 Oil Pan le LEE 02 25 Oil Pan Installation ie la ek Fede uv edo dau ede ege ed 02 25 Pick up Tube Deflector Removal 02 26 Pick up Tube Deflector Installation s enne 02 26 Crankshaft Main Bearings Removal i 02 27 Crankshaft Main Bearings Installation i 02 27 Connecting Rod Bearings 02 28 Connecting Rod Bearings Installation 02 28 Biston Semi val ote edt dE rere De EDU ER tet red aa edens ad solar ceed wet Mas aree EMO eh 02 29 Piston Installation iiie el na a ea 02 30 Flywlieel Removal radarin a dte i ed e ara tdi eee 02 31 Flywheel Installation nn ai 02 31 Timing Chain and Sprockets 02 32 Timing Chain and Sprockets Installation U ennemis 02 33 Oil Level Indicator r 02 35 Oil Level Indicator Installation 02 35 Oil Filter and Adapter Removal 02 36 Oil Filter and Adapter Installation 02 36 gt gaa EE 02 37 Subassemblies Cylinder Blok uuu asan bivani el VR ia ei ii
13. C205 A API classification SJ Service Oil fill 4 2 Liter 4 44 quarts capacity including filter Oil filter Type X56E 6714 D1A COOLING SYSTEM Thermostat Type Wax element Commences opening 82 2 C 180 F Fully open 94 5 C 202 F Coolant 50 Motorcraft Super Plus 2000 plus 50 clear water Ford Specification WSS M97B44 D or ESE M97B44 A 02 58
14. Indicator Tube Assembly jr teo 54 Install coolant flow control module and gasket Tighten bolts to 7 Ib ft 10 Nm 56 Apply sealer WSK M2G 349 A7 Loctite 243 to threads of coolant return connector Install and tighten to 15 Ib ft 20 Nm Coolant Flow Control Module Coolant Return Connector 02 56 TSG 416 ENGINE PRELIMINARY 57 Install generator support Tighten bolts to Ib ft Nm Generator Support 04157 58 Install generator and electrical connectors Tighten bolts to Ib ft Nm FPP04167 Generator Electrical Connector NOTE Drive belt must be installed in the same direction of rotation as when removed 59 Pry tensioner pulley as shown and install drive belt Tension Pulley Of 4 PS FPPO4155 60 Install engine wiring and vacuum hoses Wiring Harness Vacuum Hose 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 ELECTRICAL SYSTEM GENERAL SPECIFICATIONS Polarity Negative to earth ground Generator Drive Belt Tension 8K Poly Belt Tension is within specification if the tensioner is with
15. S coil and set aside refer to Section 03 Remove bolts no a a Reconnect any wiring and vacuum hoses removed o RON Remove valve cover and gasket 02 10 TSG 416 ENGINE PRELIMINARY Camshaft Removal 5 Remove camshaft lower bearings roller followers NOTE Store components to ensure assembly in the same order as they removed 1 Remove valve cover Refer to Valve Cover Removal on page 10 Bearing Caps 2 Using tool 15 030A to lock camshaft sprocket Cm Roller remove bolt gt i Follower Locking Tool 15 030A FPP04132 6 7 Refer to Section 01 for camshaft and bearing service 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 Dog 12 2 RE CS Bon puo LL A FTA FPP04133 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
16. TSG 416 ENGINE PRELIMINARY INDEX Subject Page General Information Special TOONS 02 3 DesScrtiptiOli ET 02 5 Gomponerit EOGAUOE zoo n i coe tpa ht oed ce E bk h a cit eger ou tear cet naval dene bp eee 02 6 Engine Repair Valve ee E CET 02 10 Valve Cover Installation 02 10 Gamishaft Removal etd iege E 02 11 Camshaft Installationy TL M ERES 02 12 Valve Stem Seal Removal 02 13 Valve Stem Seal Installation 02 14 Intake Manifold Removal rr 02 15 Intake Manifold Installation eene e nn enne nnn 02 15 Exhaust Manifold Hemoval 02 16 Exhaust Manifold Installation 02 16 ie nnzgar oEdcui 02 17 Cylinder Head Installation 2 2 2 1 01 0 r 02 19 er artuum mS 02 21 Oil Pump Installation 02 22 Crankshaft Rear Oil Seal r 02 23 Crankshaft Rear Oil Seal Installation nn 02 23 Camshaft Follower Hydraulic Lash Adjuster Remowval sese 0
17. ce and tighten bolts in 2 steps Step 1 9 Ib ft 12 5 Nm Step 2 22 Ib ft 30 Nm 41 94 10 Install a new rear seal and retainer using tool 21 046 Special Tool FPP04143 Rear Seal Retainer 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 8 Bolts Cylinder Head 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 Ib ft 40 Nm Step2 tighten M8 bolts to 11 Ib ft 15 Nm 45 Step 3 tighten M11 bolts additional 120 Tightening Sequence 16 Install the chain guide and the tensioner arm from the top of the engine Install bolts finger tight Tensioner Arm Chain Guide FPP04153 17 Install crankshaft sprocke
18. e 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 tim ing mark Markthe single chain link that is positioned on the crankshaft sprocket timing mark FPP04135 9 Using tool 15 030A to lock camshaft sprocket Copper Links remove bolt and camshaft sprocket Timing Mark Locking Tool 15 030A FPP04132 Copper Link 02 32 TSG 416 ENGINE PRELIMINARY 10 Remove timing chain and crankshaft sprocket 11 Remove tensioner arm and chain guide if necessary Crankshaft Sprocket Timing Chain 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 Installthe if removed chain guide and the tensioner arm from the top of the engine Install bolts finger tight Tensioner Arm Chain Guide FPP04153 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 Mark 12 O clock Position FPP04084 Coppered Link 4 Insert camshaft sprocket into chain and assemble to camshaft Position camshaft key at 12 o clock and align timing mar
19. er bearing into cap CAUTION Do not scratch journal with connecting 4 Rotate crankshaft until connecting rod and bearing rod bolts to be serviced is placed at the bottom of its stroke 5 Remove two connecting rod nuts 3 Install cap and bolts Tighten bolts in 2 steps 6 Remove connecting rod cap with lower bearing Step 1 9 Ib ft 12 5 Nm Step 2 22 Ib 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 Bearing 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 6 Remove 2 bolts connecting rod cap and lower bearing 1 Remove oil pan Refer to Oil Pan Removal on page 25 2 Remove pick up tube and deflector Refer to Pick up 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 cutte
20. essure 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 Roller Follower Lash Adjuster 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 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 Bee Retainer Spring Valve Seal FPP04073 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 f
21. ication 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 gee E I Retainer Spring FPP04073 02 14 TSG 416 ENGINE PRELIMINARY TMAP Sensor Electronic Throttle Body EN fa 1 Intake Manifold PCV Hose Gasket Intake Manifold Removal Intake Manifold Installation NOTE All contact surfaces must be clean and free from 1 Remove any necessary wiring and vacuum hoses any old gasket material Mark connections and routing as necessary to assure they are returned as they were removed Install a new gasket and intake manifold assembly Relieve fuel pressure Install bolts and nuts Tighten to 6 Ib ft 8 Nm Disconnect fuel lines from fuel rail Disconnect air intake tube Connect air intake tube Connect fuel lines to fuel rail Doc fF N Remove bolts nuts and intake manifold assembly NO a F WN gt Install any wiring and vacuum hoses that were removed Connect and route as they were removed 02 15 TSG 416 ENGINE PRELIMINARY Exhaust Manifold Outlet Flange Exhaust Manifold Removal 1 N Remove any necessary wiring and vacuum hoses Mark connections and routing as necessary to assure they are returned as they were removed Disconnect exhaust at outlet flange Remove nuts exhaust manifold and gasket
22. in Tensioner Arm Coolant Flow Control Module Oil Pressure Switch Cylinder Block Crankshaft Position CKP Sensor Water Pump Chain Guide Piston Assembly FPP04128 02 6 TSG 416 ENGINE PRELIMINARY Component Location Intake Manifold Exhaust Manifold o gt o 02 7 TSG 416 ENGINE PRELIMINARY Component Location Oil Pick up tube Oil Deflector Main Bearings Lower Main Bearing Cap Rear Seal Retainer Crankshaft Sprocket Crankshaft Main Bearings Upper Cylinder Block Timing Chair 02 8 TSG 416 ENGINE PRELIMINARY Component Location Spark Plug Wires DIS Ignition Coil PCV Valve Valve Cover PCV Hose Camshaft Sprocket 0 Bearing Caps yp Tension Arm Camshaft Roller Follower Lash Adjuster Cylinder Head L Chain Guide Valve Assembl Timing Chain idc ee Hydraulic Tensioner 02 9 TSG 416 ENGINE PRELIMINARY ENGINE REPAIR Valve Cover Installation Valve Cover Removal 1 Contact surfaces must be clean and free of oil 2 Install a new gasket and valve cover 1 Remove any necessary wiring and vacuum hoses Mark connections and routing as necessary to assure they are returned as they were removed CMP Sensor PCV Valve Wiring Harness Valve Cover Vacuum Hose 3 Install bolts Tighten to 7 Ib ft 9 Nm any sequence Install DIS coil refer to Section 03 Remove DI
23. in the indicator markings Engine Type 4 cylinder 4 stroke spark ignition 90 Overhead Valve OHV chain driven overhead camshaft operating the valves via roller cam followers Liter CID 1 6 97 5 IGNITION Bore mm inch 82 070 mm 3 23 in Spark Ford Part Number XS6F 12405 A1A NGK TR6B 10 Plug Gap 0 95 1 05 mm Firing 1 3 4 2 Order Stroke mm 75 480 mm 2 97 in inch Number of 4 cylinders Compression 95 1 Ratio CRANKSHAFT Main journal standard diameter 2 243 2 244 56 980 57 000 mm FUEL SYSTEM Main journal undersize diameter 2 233 2 234 56 726 56 746 LPG Liquefied Petroleum Gas na Type Width main journal bearing shell Fuel EN589 European USA Specification Pin Journal standard NG Natural Gas Type ITEM Nm FT LB LB IN Fuel 38 7 MJ m UK 39 0 MJ m3 USA ied nb Specification Oil Pan Drain 25 18 221 3 GAS Gasoline petrol Plug Type Electronic Fuel Injection Fuel Unleaded 87 or 89 Octane Gasoline blends Spark Plugs 13 17 9 6 12 5 115 150 5 Specification not to exceed 10 Ethanol by volume Octane Index of 87 or 89 Oil Filter 11 15 8 11 97 4 132 7 Fuel Pump Part ZU1L 9350 AA Pressure 40 psi Normal psi Max LUBRICATION SYSTEM Max Oil Hot 2500 rpm 275 79 413 69 kPa 40 60 Pressure psi Oil Type SAE 5W30 WSS M2
24. ine oil 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 Stud Positions FPP04145 5 Tighten main bearing cap bolts studs in sequence shown and in three steps to 70 Ib ft 95 Nm Front of Engine 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 Hammer Handle Piston Ring Compressor Tool CAUTION Use new connecting rod cap bolts and lubricate threads with clean engine oil 9 Install connecting rod caps with bearings lubricate wear surfa
25. ion CKP sensor CKP Sensor 02 39 TSG 416 ENGINE PRELIMINARY 18 Remove 3 bolts and the water pump pulley NOTE When removing oil pan always keep the engine in its normal upright position to avoid contamination 20 Remove bolts gasket and oil pan Oil Pan 1 i i FPP04089 21 Turn the engine over 180 22 Remove 4 nuts 1 bolt oil pick up tube and oil deflector Oil Pick up Tube T Oil Deflector gt A 1 i 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 02 40 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 tim ing mark Mark the single chain link that is positioned on the crankshaft sprocket timing mark Copper Links Copper Link 27 Remove the hydraulic tensioner Hydraulic Tensioner FPP04135 28 Using tool 15 030A to lock camshaft sprocket remove bolt and camshaft sprocket L
26. k between 2 coppered links on drive chain Coppered Links 12 O clock Position 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 Ib ft 8 Tighten hydraulic tensioner to 27 32 Ib ft 36 44 24 28 Nm Nm Tensioner Arm Chain Guide Hydraulic Tensioner FPP04135 FPP04153 7 Using locking tool tighten camshaft sprocket 9 oil pan water pump bolt to 52 59 Ib ft 70 80 Nm 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 Locking Tool 12 15 030A 43 14 15 FPP04132 02 34 TSG 416 ENGINE PRELIMINARY Oil Level Indicator FPP04098 Oil Level Indicator Removal Oil Level Indicator Installation 1 1 Apply sealer WSK M2G 349 A4 Loctite 648 to 2 Remove bolt lower end of oil level indicator tube 2 Install tube immediately into bore 3 Install bolt and tighten to 15 Ib ft 20 Nm 4 3 Remove oil level indicator amp tube 02 35 TSG 416 ENGINE PRELIMINARY Gasket Oil Filter FPP04092 Oil Filter and Adapter Removal Oil Filter and Adapter Installation NOTE Place oil drain pan under oil filter to catch oil drainage 1 Install a new gasket 2 Lubricate oil seal on a new filter and install to 1 adapter Tighten
27. n ring expander FPP04164 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 6 Remove all valve components using a suitable valve NOTE Store components to ensure assembly in the Spring cormprossor same order as they were removed 1 Remove bolts and camshaft bearing caps evenly in the sequence shown Retainer Spring Valve Seal al OR T CS D WC a CS Se A G Ka p ci k Loosening Sequence FPP04133 Cylinder Head Remove camshaft Remove roller followers Remove lash adjusters Remove spark plugs Refer to Section 01 for m N servicing valve components valve guide and valve seat y e camshaft and bearing service Bearing Caps cylinder head cleaning and inspection CH SD Follower 02 46 TSG 416 ENGINE PRELIMINARY Cylinder Head Assembly 5 Check that spring installed height is 35 2 1mm NOTE All components must be clean and assembled in the same positions as removed Lubricate contact surfaces with clean engine oil Spring 1 Check that valves move freely in valve guides I
28. ng 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 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 17 Carefully remove cylinder head and gasket while maintaining tension on timing chain Gasket FPP04138 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
29. nstalled Height 2 Install intake and exhaust valves 3 Install new valve seals using special tool 21 024 optional T95P 65654 FPP04165 Special Tool 21 024 6 Install lash adjusters Roller Follower Lash Adjuster FPPO4134 4 Usinga suitable spring compressor tool install valve springs retainers and locks 7 Installroller followers NOTE The chamfer on the camshaft bearing caps must ptm be facing the chain housing I Retainer 8 Carefully install camshaft bearings camshaft and bearing caps with bolts finger tight Spring NOTE Rotate camshaft so key is at 12 O clock position 9 Tighten bolts in the sequence shown in 3 steps to 6 Valve Seal 7 Ib ft 8 10 Nm aR 9 Sony d ab Cylinder Head e LI Tightening Sequence FPP04133 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 amp 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 Upper Main Bearings A USD Thrust Washers SD w I 1 1 be gt 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 eng
30. ocking Tool 15 030A FPP04132 29 Remove timing chain and crankshaft sprocket 30 Remove tensioner arm and chain guide Crankshaft Sprocket Timing Chain 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 32 Remove 2 M8 bolts cylinder head and gasket M8 Bolts Cylinder Head 33 Remove crankshaft rear seal retainer Oil Seal Retainer 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 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 6 Front of Engine 36 Carefully remove the crankshaft and install it vertically on the flywheel to avoid warp running out Crankshaft FPPO4160 37 Remove the 5 upper main bearings and the 2 thrust washers Upper Main Bearings A USD Thrust Washers gut
31. or 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 4 Release air pressure and remove air adapter Install NOTE All components must be clean and assembled in spark plug Mproper cy inder the same positions as removed Lubricate contact 5 Grease contact surfaces of roller follower with Ford surfaces with clean engine oil Multi purpose Grease D0AZ 19584 AA or CAUTION Valve stem seal can be cut by grooves in equivalent meeting Ford specification ESR valve stem A damaged seal will leak causing oil M1C159 A burning and valve fouling 6 Using spring compressor compress and hold down 1 Carefully slide oil seal over valve stem the valve and spring Slide the roller finger follower 2 Install new valve seal using special tool 21 024 into place a d lash Adusien REIEaSE optional T95P 6565A protective cap spring Special Tool 21 024 Lash Adjuster FPP04134 FPP04076 7 Install valve cover Refer to Valve Cover NOTE Apply a small amount of Ford Multi purpose Installation on page 10 Grease D0A2 19584 AA or equivalent meeting Ford specif
32. r follow the instructions furnished by the tool manufacturer Cylinder Ridge Reamer T64L 6011 EA 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 FPP10048 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 Hammer Handle Piston Ring Compressor Tool FPP04149 CAUTION Use new connecting rod cap bolts and lubricate threads
33. st be kept clean and 1 Remove valve cover Refer to Valve Cover lubricated with clean engine oil 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 Roller Follower Special Tool 21 024 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 FPPO4134 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 Lift outthe hydraulic lash adjuster 4 Install valve cover Refer to Valve Cover Removal on page 10 02 24 TSG 416 ENGINE PRELIMINARY Oil Pan Removal 2 Install the oil pan and bolts finger tight 4 Remove bolts 3 Align oil pan with rear portion of engine block 2 Remove oil pan Straight Edge Oil Pan Oil Pan FPP04088 3 Remove all gasket material from pan CAUTION Be careful not to contact surfaces Oil Pan Installation 4 Tighten oil pan bolts in 3 steps in the sequence CAUTION The contact surfaces of oil pan gasket shown and block must be free of oil Do not wait more than 5 minutes to install the oil pan gasket after sealer enough
34. stall 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 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 Remove drive belt refer to xx 1 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
35. t 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 12 O clock Position Timing Mark FPP04084 Coppered Link 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 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 Ib ft 24 28 Nm Tensioner Arm Chain Guide FPPO4153 22 Using locking tool tighten camshaft sprocket bolt to 52 59 Ib ft 70 80 Nm Locking Tool 15 030A FPP04132 23 Tighten hydraulic tensioner to 27 32 Ib ft 36 44 Nm Hydraulic Tensioner FPP04135 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 FPP04166 Do Not Remove Clip Until Installed 02 51 TSG 416 ENGINE PRELIMINARY 24 Assemble gasket onto oil pump housing guiding it 29 Tighten 2 outer oil pump housing bolts to 15 Ib ft 20 with 2 outer bolts Nm
36. 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 Cylinder Head M8 Bolts CAUTION Be careful to avoid the bolts falling into the timing chain compartment 3 Install new bolts using the sequence shown in the following 3 steps Step 1 tighten M11 bolts to 29 5 Ib ft 40 Nm Step 2 tighten M8 bolts to 11 Ib ft 15 Nm 45 Step 3 tighten M11 bolts additional 120 Tightening Sequence 4 Carefully install sprocket into timing chain aligning timing mark with 2 copper links Copper Links 12 O clock 04136 02 19 TSG 416 ENGINE PRELIMINARY 5 Using tool 15 030A install camshaft sprocket bolt Tighten to 92 Ib ft 125 Nm Locking Tool 15 030A FPP04132 6 Install hydraulic tensioner and tighten to 30 Ib ft 40 Nm Hydraulic Tensioner FPPO4135 7 Install oil level indicator bolt Tighten to 15 Ib ft 20 Nm 8 Install exhaust manifold and nuts Tighten nuts to 11 Ib 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 Ib ft 18 Nm 11 Install the coolant flow control module refer to Section 05 Coolant Flow Control Module 12 Install spark plugs and wires refer to Section 03 13 In
37. valent Spring Testing Fixture Extra space 21 024 or Equivalent 02 4 TSG 416 ENGINE PRELIMINARY Description Cylinder Head The 1 6L 4 cylinder Zetec Rocam engine has been The Zetec Rocam engine cylinder head is entirely made developed with the highest technology Its main of aluminum which improves the thermal characteristics characteristics are and reduces weight The assembly is attached using a electronic controlled multipoint sequential injection multtlayersieel gasket and 12 Bols roller finger follower camshaft Oil Pan e intake manifold made of aluminum The Zetec Rocam engine oil pan is made of steel The high resistance aluminum cylinder head gasket must always be replaced whenever the oil pan is removed Steeloil pan 3 iz FPP04115 Engine Identification Number The engine identification number is marked on the right side of the cylinder block as shown 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 02 5 TSG 416 ENGINE PRELIMINARY Component Location Positive Crankcase Ventilation PCV Valve Camshaft Position Oil Level Indicator CMP Sensor Cylinder Head Assembly Timing Cha
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