Ford 4.6L (2V) SPECIFICATIONS General Specifications Item Specifications Silicone Gasket and Sealant F7AZ-19554-EA WSE-M4G323-A4 Premium Engine Coolant VC-4A, VC-5 in Oregon, CXC-10 in Canada ESE-M97B44-A Super Premium 5W-20 Motor Oil XO-5W20-QSP WSS-M2C153-H Thread lock 262 E2FZ-19554-B WSK-M2G351-A6 Metal Surface Cleaner F4AZ-19A536-RA or equivalent WSE-M5B392-A Engine Specifications Description Specification General Specifications Displacement 4.6L (2V) (281 CID) Number of Cylinders 8 Bore and Stroke 90.2 x 90.0 mm (3.55 x 3.54 inch) Firing Order 1-3-7-2-6-5-4-8 Oil Pressure (HOT 1500 RPM) 138-310 kpa (20-45 psi) Cylinder Head and Valve Train Head gasket face flatness 0.10 mm (0.004 inch) max overall 0.050 mm (0.002 inch) total (in head bolt sealing area) 0.025 mm ( 0.001 inch) per 25x25. Combustion Chamber Volume (cc) 43.9±1.5 cm 3 Valve Seats Width intake 1.3-1.5 mm (0.051-0.060 inch) Width exhaust 1.3-1.5 mm (0.051-0.060 inch) Angle 45 degrees Runout (T.I.R.) Recommended 0.025 mm (0.001 inch) max 0.050 mm (0.002 inch) Valve Arrangement (Front-to-Rear) c (Left hand): E-I-E-I-E-I-E-I (Right hand): I-E-I-E-I-E-I-E Valve Stem to Guide Clearance Intake 0.020-0.069 mm (0.00078-0.00272 inch) Exhaust 0.046-0.095 mm (0.0018-0.0037 inch) Valve Head Diameter Intake 44.37-44.63 mm (1.75-1.76 inch) Exhaust 35.88-36.14mm (1.41-1.43 inch) Gauge diameters 42.5 and 34 mm (1.67-1.34 inch) Valve Face Runout Limit 0.05 mm (0.002 inch) Valve Face Angle 45.5 degrees Valve Stem Diameter (Std) Intake 6.975-6.995 mm (0.2754-0.2746 inch) Exhaust 6.975-6.995 mm (0.2754-0.2746 inch) Valve Springs Compression pressure (N (lb) @ spec length) Intake 720.0-800.0 N @ 28.80 mm (161.9 lb @ 1.13 inch) Exhaust 720.0-800.0 N @ 28.80 mm (161.9 lb @ 1.13 inch) Free length (approximate) 51.77-54.97 mm (2.04-2.16 inch) Installed Height Installed pressure (N (lb-ft) @ spec length) Intake 42.3-42.9 mm (1.67-1.69 inch) Exhaust 42.3-42.9 mm (1.67-1.69 inch) Intake 283.0-321.0 N @ 42.56 mm (63.61 lb @ 1.68 inch)
Exhaust 283.0-321.0 N @ 42.56 mm (63.61 lb @ 1.68 inch) Service limit 10% pressure loss Roller Follower Ratio (intake) 2.02 : 1 Ratio (exhaust) 2.03 : 1 Hydraulic Lash Adjuster Diameter (std) 16.000-15.988 mm (0.6299-0.6294 inch) Clearance to bore 0.018-0.069 mm (0.000709-0.002717 inch) Hydraulic leakdown rate b 5-25 seconds Collapsed lash adjuster gap desired 0.45-0.85 mm (0.02-0.03 inch) Camshaft Lobe Lift Intake 7.11038 mm (0.28 inch) Exhaust 7.4794 mm (0.30 inch) Allowable lobe lift loss 0 mm (0.0 in) Theoretical Valve Lift @ Zero Lash Intake 13.00 mm (0.51 inch) Exhaust 13.75 mm (0.54 inch) End Play 0.027-0.190 mm (0.001-0.007 inch) Service limit 0.190 mm (0.007480 inch) Journal to Bearing Clearance 0.025-0.076 mm (0.00098-0.002992 inch) Service limit 0.100 mm (0.003937 inch) max Journal Diameter (All) 26.962-26.936 mm (1.0615-1.0605 inch) Bearing Inside Diameter (All) 27.012-26.987 mm (1.0635-1.0625 inch) Front Bearing Location c Cylinder block Head gasket face flatness 0.15 mm (0.006 inch) max overall Head gasket surface finish b 0.050 mm (0.002 inch) per 150x150 0.025 mm (0.001 inch) per 25x25 Main Bearing Bore Diameter 72.400-72.424 mm (2.8504-2.8513 inch) Crankshaft Main Bearing Journal Diameter 67.482-67.504 mm (2.66-2.661 inch) Connecting Rod Journal Diameter 52.983-53.003 mm (2.085941-2.086728 inch) Crankshaft Free End Play 0.075-0.377 mm (0.003-0.015 inch) Crankshaft Runout to Rear Face of Block 0.050 mm (0.01969 inch) max Connecting Rod Bearings Clearance to Crankshaft Desired 0.027-0.069 mm (0.0010629-0.0027165 inch) Allowable 0.027-0.069 mm (0.0010629-0.0027165 inch) Bearing Wall Thickness (Std) d 2.442-2.453 mm (0.096-0.097 inch) Main Bearings Clearance to Crankshaft Desired 0.025-0.044 mm (0.001-0.002 inch) Allowable 0.025-0.050 mm (0.00098-0.00197 inch) Bearing Wall Thickness (Std) f 1.919-1.925 mm (0.0756-0.0757 inch) Connecting Rod Pin bore diameter 22.012-22.024 mm (0.86661-0.86708 inch) Crankshaft bearing bore diameter 56.866-56.886 mm (2.23881-2.23960 inch) Length (center-to-center) 150.7 mm (5.933 inch) Alignment (Bore-To-Bore Max. Diff.) e Twist 0.050 per 25 mm (0.00197 per 0.9843 inch) Bend 0.038 per 25 mm (0.00150 per 0.9843 inch) Side Clearance (Assembled to Crank) Standard 0.125-0.475 mm (0.005-0.019 inch) Service limit 0.50 mm (0.01969 inch) max
Cylinder Bore and Piston Cylinder Bore Diameter f Surface finish (RMS) 0.2-0.6 Microns Out-of-round limit 0.20 mm (0.007874 inch) Out-of-round service limit 0.70 mm (0.027559 inch) Taper service limit 0.70 mm (0.027559 inch) Piston Diameter g 0.028 mm (0.0010 inch) Coded Red 1 90.185-90.205 mm (3.55-3.551 inch) Coded Blue 2 90.195-90.215 mm (3.55-3.551 inch) Coded Yellow 3 90.205-90.225 mm (3.551-3.552 inch) Coated Piston-to-Bore Clearance -0.005-0.025 mm (-0.002/+0.001 inch) Pin Bore Diameter h 21.008-22.014 mm (0.866-0.867 inch) Ring Groove Width Compression (top) 1.530-1.550 mm (0.06-.061 inch) Compression (bottom) 1.520-1.540 mm (0.06-0.061 inch) Oil ring 3.030-3.050 mm (0.12-0.12 inch) Piston Pin Length 61.601-62.030 mm (2.42523-2.44212 inch) Diameter 22.0010-22.0030 mm (0.87-0.871 inch) Pin to Piston Fit -0.005/+0.0135 mm (-0.0002/+0.0005 inch) Pin to Rod Clearance Standard 0.009-0.0235 mm (0.0004-0.00092 inch) Service limit 0.035 mm (0.001378 inch) Piston Ring Compression (top) 0.050-0.090 mm (0.002-0.004 inch) Compression (bottom) 0.030-0.080 mm (0.00118-0.00315 inch) Oil ring Snug fit Ring Gap i Compression (top) 0.130-0.280 mm (0.005-0.011 inch) Compression (bottom) 0.300-0.550 mm (0.0018-0.0022 inch) Oil ring (steel rail) 0.150-0.650 mm (0.006-0.0256 inch) Piston to Deck 0.035-0.565 mm (0.001-0.022 inch) Piston Ring Thickness Compression (top) 1.480-1.500 mm (0.058-0.059 inch) Compression (bottom) 1.470-1.490 mm (0.0587-0.0586 inch) Oil ring N/A Lubrication System Oil Capacity (Quarts U.S.) 5 ± 0.25 j a Newly installed refers to the condition of the "NEW" drive belt before the engine has made no more than one rotation and before the belt has had a chance to stretch or seat into the pulley grooves. b Time necessary for plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in tappet. c Distance front edge of bearing is installed below front face of cylinder block. d 0.050 Undersize add 0.025 to standard thickness. e Pin bore and crank bearing bore must be parallel and in same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 101.5 mm on each side of rod centerline. f Cylinder bore diameter measured at 31 mm (1.24 inch) from top of block. Red 90.200-90.210 Blue 90.210-90.220 Yellow 90.220-90.230 g Measured at 31.5 mm from top of block. Measured at 43 mm from top of piston, at 90 degrees to the piston pin.
h If applicable, measured vertically, +0.030-0.050 mm (0.001-0.002 inch) measured horizontally (oval pin bore). i Specification in 90.200 mm diameter gauge. j With installation of a new filter. DRIVE BELT TENSION Belt type Belt tension 6 Rib (fixed) a N/R- Automatic tensioner a "Fixed" refers to systems with manually-adjusted centers which are bolted in place and considered fixed. Torque Specifications Description Nm Lb-Ft Lb-In Main bearing cap adjusting bolts a EGR sensor bracket 10 89 Belt idler pulley 25 18 Oil filter 15 11 Oil filter adapter insert 58 43 Camshaft sprocket bolt a Connecting rod bolt a Engine mount nuts 150 111 Engine mount-to-cylinder block bolts 70 52 Exhaust manifolds a Engine front cover bolts a Drive belt tensioner bolts 25 18 A/C muffler 20 15 Battery cable support brackets 20 15 Cylinder head bolt a Pulley-to-crankshaft bolt a EGR valve to intake manifold 25 18 EGR valve tube to exhaust manifold fittings 40 30 Intake manifold-to-cylinder head bolt 25 18 Main bearing cap bolt a Oil filter adapter bolts 25 18 Oil level indicator tube bolt 10 89 Oil pump screen cover and tube-to-oil pump bolt 10 89 Oil pan-to-cylinder block bolt a Flywheel 80 59 Oil pan-to-engine front cover bolts a Oil pump-to-cylinder block bolt 10 89 Oil pump screen cover and tube-to-main bearing cap stud spacer bolt 25 18 Water pump pulley bolts 25 18 Cam cover bolt a Water pump-to-cylinder block bolt 25 18 Water bypass tube 25 18 EGR tube nuts (2 req'd) 40 30 Power steering pump to engine 25 18 Power steering reservoir bolts 10 89 Water outlet connector bolts 25 18 Camshaft cap cluster to cylinder head bolts 10 89 Torque converter nuts 25 18 Timing chain tensioner bolts 25 18 Transmission filler tube bolt 47 35 A/C compressor bolts 25 18 Ignition coil bolts 6 53 Generator brace bolts 10 89
Primary timing chain guide-to-engine bolts 10 89 Accelerator cable bracket bolts 10 89 Rear seal retainer bolts 10 89 Pressure plate bolts 2 47 Spark plugs 18 13 Sensor assembly crankshaft timing bolt 10 89 Sensor assembly camshaft timing bolt 10 89 Fuel rail studs 10 89 Engine coolant sensor 15 11 Exhaust manifold stud to cylinder head 10-13 7-10 Throttle body adaptor bolts a Throttle body bolts 10 89 Idle air control valve 10 89 RFI capacitor nut 10 89 Generator bolts 25 18 Oil pan drain plug 14 10 Water bypass tube bracket bolt 25 18 Subframe bolts 115 85 Battery lead to generator 10 89 EGR vacuum regulator solenoid bracket 10 89 Pipe plug water drain 20 15 Spacer screen and cover assembly to main bearing cap stud 25 18 Wiring harness retainer nut 10 89 Oil pressure switch a A/C muffler stud to cylinder head 10 89 Connector EGR tube to exhaust manifold 50 37 T3650 gear ratios 3.38,2.00, 1.32, 1.00,.62 Intake manifold: composite, cast No. 1L2E-DL Cylinder heads: cast No. RF1L2E-6090-D22D (or D24D) Combustion chambers: 42.45cc Valves: 1.752/1.417 inches Rockers: roller type, w/1.81:1 ratio Camshaft lift:.505/.534-inch lift Duration (I/E) @.050" 186/194 Compression ratio: 9.74:1 Pistons: hypereutectic w/.145-inch dish Romeo was Feb '01-'04 Windsor was 99-01 Romeo uses bolt-on cam gears. Windsor uses press-on cam gears. Romeo has 11 bolts on the valve covers. Windsor has 13 bolts on the valve covers Stock PI head flow rate.
Intake... in (CFM).050" 25.100" 51.150" 76.200" 102.250" 124.300" 138.350" 149.400" 153.450" 155.500" 156.550" 159.600" 160 Exhaust... in (CFM).050" 24.100" 49.150" 68.200" 84.250" 96.300" 107.350" 116.400" 123.450" 130.500" 133.550" 136.600" 138 99+ PI cam spec 200, 209 @.050 duration.504,.531 lift 114 LSA 4.6-liter SOHC and DOHC Aluminum block weight (bare): 86 lbs. Iron block weight (bare): 154 lbs. Assembled cylinder head weight: 44 lbs.* Displacement: 4.6 liters/281 cubic inches Bore: 3.552 inches Stroke: 3.543 inches Bore spacing: 3.937 inches Main journal dia.: 2.657 inches Rod journal dia.: 2.086 inches Rod length: 5.933 inches Deck height: 8.937 inches *Assembled 302 iron head weighs approx. 55 lbs. 2001 4.6 SOHC 260HP Mustang Engine Throttle body: 65mm (2.560 inches) Intake manifold: composite, cast No. 1L2E-DL Cylinder heads: cast No. RF1L2E-6090-D22D (or D24D) Combustion chambers: 42.45cc Valves: 1.752/1.417 inches Rockers: roller type, w/1.81:1 ratio
Camshaft lift:.505/.534-inch lift Compression ratio: 9.74:1 Pistons: hypereutectic w/.145-inch dish Will Fit, Won't Fit Blocks--When it comes to 2V 4.6 engines, you'll find there are as many as 12 different castings, but the basic architecture is the same so any heads will bolt up. For performance applications we recommend finding a 1996-up block because these (Romeo and Windsor) have cross-bolts used on all five main caps. Windsor blocks use dowels, and most Romeo blocks use jackscrews; neither has proven to be stronger than the other. Ford Racing Power Improved heads (PN M-6049-D46)--will physically bolt to any 4.6 block, but ports are designed to match 1996-98 4.6 intake manifolds or Ford Racing High-Flow intakes. Ford racing heads must also be used with a Ford Racing computer for proper engine calibration. Ford Racing intake manifolds (PN M-9444-D46/E46)-- physically fit all 4.6 engines but will only match the cylinder head port shape of 1996-98 4.6 engines. The manifold kit is similar to the Bullitt intake but not identical. Weight is approximately 35 pounds (stock plastic manifold is 15 pounds). Bullitt intake--this unit is made of cast aluminum and features a rear inlet and 15-inch runners (stock intake feeds from the top/center and has 17.5-inch runners). The Bullitt intake will fit all 1999+ 4.6 engines, however, there can be some interference problems with the valve covers on 1999-00 engines. Weight is approximately 35 pounds, whereas the stock, plastic manifold weighs 15 pounds. Horsepower increase is minimal on stock or mildly modified engines but well worth the effort on supercharged or nitrous-injected engines. Crankshafts--The stock crank in 1991-95 Romeo-built SOHC engines is the F1AE casting that is made from nodular iron. It has six, knife-edged counterweights (the front one measuring.960 to.980 inch), and the flywheel flange has six holes. Beginning in 1996, Romeo engines used a similar crank that carries cast No. F65E. This crank also has a six-bolt flange, but the front counterweight measures.920 to.940 inch. Therefore, you may find an interference problem when installing an F1AE crank in a 1996-up block. All Windsor engines came with the F65E crank, but some had a six-bolt flange, and some came with eight. The most desirable crankshaft is the forged steel unit found in 1996-03 Cobra engines (cast No. F2LE-AG). The Cobra crank can be used in iron-block SOHC engines as long as the eight-bolt flywheel is used (SOHC passenger-car cranks have a six-bolt pattern). Note: Windsor engines may have a different crank (cast No. F65E), which has a smaller front counterweight (.920 inch thick versus.940 inch on the F1AE) so any Windsor engines must be built using the F65E crankshaft or an interference problem may occur between the counterweight and the main area in the block. Connecting Rods--All 4.6 engines (except the 2003 Cobra) were fitted with powdered metal rods that have cracked caps. Generally, passenger car engines from the Romeo plant got press-fit piston pins, while Windsor engines got floating pins. Rods can be interchanged, but we recommend using aftermarket steel rods in any performance applications. Pistons--Ford used three different pistons in the 4.6 engines.
The 1991-99 Romeo pistons have a 10.5cc dish and a 1.5mm/1.5mm/3.0mm ring package, and the pin was press fit to the connecting rod. The 1996-99 Windsor (non-power Improved) pistons have the same dish and ring dimensions but are of the floating type with circlips holding the pins in place. Lastly, Windsor PI engines have different pistons with a larger (18.5cc) dish to reduce compression, on the PI engines, due to the closed chamber heads. Therefore, it must be noted that a rise in compression (to about 10.5:1) will result when PI heads are installed on a 1991-98 engine. 4V heads on a 2V block--this swap is a direct bolt-on, however there are no advantages over using the aluminum block other than availability and/or cost. Note: there are a variety of chain tensioners that may differ depending on where the block was produced. 2V heads on a 4V block--this swap is a direct bolt-on. Advantages include lighter weight and ability to replace the sleeves and increase the bore size 3.70 inches. Front Covers--Because the Modular engines are used in so many applications, there are quite a few styles of front covers. Passenger car covers differ from truck covers and van covers are similar only to themselves. Likewise, the Mustang covers are different altogether and even from year-toyear. Some covers used 8mm bolts, while others use 10mm bolts. So it's important to keep the cover with the block. When building an engine from scratch, the only way to ensure that you have the proper cover is to trial fit. Then you must be certain that the engine accessories will attach. Underdrive Pulleys--Aftermarket pulleys are popular among Mustang owners. The 1996-98 pulleys are of one design, but like most other parts on the Mod engines, they changed with time. The 1999 design is different, and sometime during the 2001 production run, Ford changed the water pump design again, requiring a different offset in the water pump pulley. Therefore, there are many distinct water pump underdrive pulleys depending on whether you have a 1996-98, a 1999-early 2001 or a late 2001-present engine.