0G4969PMNL 4.2 liter GAS Ford ENGINE PARTS MANUAL
4.2L Diesel Engine Table of Contents Quick Reference Guide... 1 Cylinder Block And Related Parts... 2 Timing Cover... 3 Cylinder Head... 4 Camshaft... 6 Timing Components... 7 Crankshaft, Piston, & Connecting Rod... 8 Balance Shaft... 10 Valve Cover... 11 Oil Pump... 12 Oil Pan... 13 PCV System... 14 Water Pump... 15 Thermostat... 16 FEAD... 17 Intake Manifold... 18 Exhaust Manifold... 20 EGR System... 22 Throttle Body Gaskets... 23 Ignition... 24 NOTE The information in this manual is known to be accurate as of the date of release shown on the cover. However, engineering changes can occur without notice. To obtain the proper parts, please be sure to use the serial number of the unit being serviced when ordering from this manual. All other parts not shown in this manual can be found in the Owner's Manual for the unit being serviced. Owner's Manuals can be found at: www.generac.com Legend A/R AS REQUIRED STD STANDARD SIZE O.S. OVERSIZE U.S. UNDERSIZE NA Not Available
4.2L Gas Engine Quick Reference Guide ENGINE SIZE: 4.2 Liter FUEL: LP/NG MAKE: Ford ENGINE P/N: 0G4969 (raw) 0G5962 (CPL make) 0G8279 (Industrial make) quick reference ENGINE PARTS Description Part Number Special Notes Scheduled Maintenance Kit 0G596200PM Air Filter, Spark Plug, Oil Filter Oil Filter 0E7080 Oil capacity - See owner's manual Air Cleaner Element V-Belt 0C8127 See owner's manual Thermostat 0G49690203 192 Degrees / Coolant capacity - See owner's manual Thermostat Housing Gasket 0G5511 Qty. 2 Starter Motor See owner's manual Spark Plug 0G49690110 Spark plug gap, see owner's manual Spark Plug Wires See owner's manual ENGINE IDENTIFICATION The engine identification tag can be located on the left side valve cover facing the flywheel end of the generator LEFT VALVE COVER SECONDARY ENGINE PART NUMBER ENGINE SERIAL NUMBER 1
4.2L Gas Engine Cylinder Block And Related Parts HP2 0G49690644 PLUG, SCREW IN WATER JACKET 2 6397 0G49690104 DOWEL, TIMING COVER TO BLOCK 2 HP1 0G49690106 PLUGS, OIL GALLEY 4 6026 0E96180118 CUP PLUG, 38.30MM 8 6A335 0G49690107 CUP PLUG, REAR OF BLOCK 2 6266 0G49690108 CUP PLUG, REAR OF BLOCK, BAL.SHFT, CMSHFT. 2 6A008 0E96180108 DOWEL, CYLINDER HEAD TO BLOCK 4 6345 0G49690109 BOLT, MAIN WITH STUD 6 2
4.2L Gas Engine Timing Cover 6019 0G49690645 TIMING COVER 1 6020 0G49690111 GASKET, TIMING COVER 1 6700 0G49690103 SEAL, TIMING COVER 1 6C315 0G49690113 SENSOR, CRANKSHAFT POSITION. 1 HB1 0G49690114 BOLT, M6 X 21.5 1 HB2 0G49690115 BOLT, M5 X 20MM 1 HM1 0G49690116 STUD, M8 XM8X1.25 2 HS1 0G49690117 BOLT, M8 X 1.25 1 3
4.2L Gas Engine Cylinder Head 4
4.2L Gas Engine Cylinder Head 6049 0G49690152 CYLINDER HEAD, BARE 2 6049 0G49690153 CYLINDER HEAD, COMPLETE 2 6051 0G49690154 GASKET, HEAD RH 1 6051 0G49690155 GASKET, HEAD LH 1 6065 0G49690156 BOLT, HEAD, M11X1.5X132MM 8 6065 0G49690157 BOLT, HEAD, M11X1.5X81MM 8 6057 0G49690158 SEAT, INTAKE VALVE 6 6057 0G49690159 SEAT, EXHAUST VALVE 6 6505 0G49690160 VALVE, EXHAUST 6 6507 0G49690161 VALVE, INTAKE 6 6026 0E96180118 PLUG, CUP, 38.30MM (NOT SHOWN) 8 6510 0G49690163 GUIDE, VALVE 12 6513 0G49690164 SPRING, VALVE 12 6514 0G49690165 RETAINER 12 6518 0D34540183 KEY 24 6A527 0G49690166 BOLT, ROCKER ARM 12 6A528 0G49690167 FULCRUM 12 6564 0G49690168 ROCKER ARM 12 6565 0G49690169 ROD, PUSH 12 6571 0G49690170 SEAL, VALVE STEM 12 5
4.2L Gas Engine Camshaft 6250 0G49690118 CAMSHAFT 1 6C341 0G49690119 PLATE, CAMSHAFT THRUST 1 6265 0G49690120 SPACER 1 6269 0G49690121 PLATE, CAMSHAFT THRUST 1 HM1 0G49690122 BOLT, CAMSHAFT 1 HM2 0G49690123 BOLT, CAMSHAFT THRUST PLATE(M6X1.0X19MM) 2 6500 0G49690124 LIFTER, HYDRAULIC ROLLER 12 6K564 0G49690125 GIRDLE, LIFTER 2 6
4.2L Gas Engine Timing Components 6K254 0G49690102 TENSIONER 1 HB1 0E96180111 BOLT, CHAIN TENSIONER (M6X1.0X16.5) 1 6255 0G49690127 GEAR, DISTRIBUTOR DRIVE 1 6256 0G49690128 GEAR, CAMSHAFT, TIMING 1 6268 0G49690129 CHAIN, TIMING 1 6279 0G49690130 BOLT, CAMSHAFT TIMING GEAR 1 6269 0G49690121 PLATE, THRUST 1 6A303 0G49690132 GEAR, BALANCE SHAFT DRIVE 1 6A304 0G49690133 GEAR, BALANCE SHAFT DRIVEN 1 6C341 0G49690119 CAMSHAFT THRUST PLATE 1 7
4.2L Gas Engine Crankshaft, Piston, & Connecting Rod 8
4.2L Gas Engine Crankshaft, Piston, & Connecting Rod 6303 0G49690134 CRANKSHAFT 1 6D309 0G49690135 KIT, MAIN BEARING, STD. 1 6D309 0G49690360 KIT, MAIN BEARING,(.010/25MM) A/R 6D309 0H09230224 KIT, MAIN BEARING(.020/50MM) A/R 6D309 0H09230209 KIT, MAIN BEARING(.030/75MM) A/R 6700 0G49690103 SEAL, CRANKSHAFT, FRONT 1 6701 0G49690136 SEAL, CRANKSHAFT, REAR 1 6306 0G49690137 GEAR, CRANKSHAFT TIMING 1 6108 0G4969A100 PISTON & PIN 6 6135 0G49690141 PIN, PISTON 6 6B316 0G49690139 KEY, WOODRUFF 1 6148 0G49690142 RINGSET, KIT RE-RINGS TWO PISTONS 3 6200 0G49690143 ROD, CONNECTING 6 6211 0G49690144 BEARING, ROD 12 6214 0D34540120 BOLT, ROD 12 9
4.2L Gas Engine Balance Shaft 6A311 0G49690145 SHAFT, BALANCE 1 6A333 0G49690146 BEARING 1 HM1 0G49690123 BOLT, M6X1.0X19MM 2 10
4.2L Gas Engine Valve Cover 6582 0G4969A101 COVER, VALVE, RH 1 6582 0G4969A102 COVER, VALVE, LH 1 6584 0G49690173 GASKET, VALVE COVER 2 6766 0F19600109 CAP, OIL FILLER 1 6A892 0G49690175 GROMMET 1 6C519A 0G49690176 GROMMET, VALVE COVER BOLT 10 6C519B 0G49690177 GROMMET, VALVE COVER BOLT 10 6K562 0G49690178 BUSHING 10 11
4.2L Gas Engine Oil Pump 6C639 0G49690179 PUMP, OIL, INCLUDES SEAL 1 6C639 0G49690180 SEAL, OIL PUMP 1 6019 0G49690645 COVER, TIMING 1 6A618 0G49690182 SHAFT, INTERMEDIATE 1 6622 0G49690183 PICK UP, OIL PUMP 1 6626 0G49690184 GASKET, PICK UP TO BLOCK 1 12
4.2L Gas Engine Oil Pan 6675 0G49690185 OIL PAN 1 6A835 0G49690186 TRAY, WINDAGE 1 HN1 0G49690187 NUT, M8 WINDAGE TRAY TO MAIN STUD 6 6723 0G4969A103 SEAL, OIL PAN REAR 1 6734 0F97650187 GASKET, DRAIN PLUG 1 HB1 0G49690317 BOLT, M6X1.0X22.5, OIL PAN/DIP STICK TUBE A/R,1 HM1 0G4969A105 BOLT, M6X1.0X35.5, OIL PAN A/R 6750 0G49690191 DIPSTICK 1 6754 0G49690192 TUBE, DIPSTICK 1 13
4.2L Gas Engine PCV System 6762A 0G49690200 ELBOW 1 6767B 0G4969A112 CONNECTOR 1 14
4.2L Gas Engine Water Pump 8501 0G49690201 PUMP, WATER 1 8507 0G49690202 GASKET, WATER PUMP 1 HB1 0G49690208 BOLT, M6 X20MM A/R HB2 0G49690345 BOLT, M8 X 1.25 X 35MM A/R HN1 0G49690346 NUT, M8X1.25 A/R HT1 0G49690315 STUD, M8 X 1.25 A/R 15
4.2L Gas Engine Thermostat 8575 0G49690203 THERMOSTAT 1 8592 0G49690205 HOUSING, THERMOSTAT 1 8548 0G49690207 TUBE, BYPASS 1 HB1 0G49690208 BOLT, M6 X 20MM 2 16
4.2L Gas Engine FEAD 6B209 0G49690210 TENSIONER 1 HB1 0G4969A106 BOLT, M8 X 35MM A/R 17
4.2L Gas Engine Intake Manifold 18
4.2L Gas Engine Intake Manifold 9424A 0G4969A108 MANIFOLD, INTAKE, UPPER 1 9A474 0G49690217 CONNECTOR, VACUUM TUBE 1 9Y450 0F8286F241 BOLT, UPR/INT MAN. TO LWR/INT 8 HD1 0G49690220 CLAMP, HOSE 1 9H486 0G49690222 GASKET, UPR/INT TO LWR/INT. 6 9424 0G49690223 MANIFOLD, INTAKE, LOWER 1 HM2 0G49690225 BOLT, M6 X 1.0 X 22.5 (NOT SHOWN) 3 9F955 0G49690226 BUSHING 2 HS1 0G49690227 SCREW 2 HS2 0G49690228 SCREW & WASHER 8 HS3 0G49690229 SCREW 6 HM1 0G49690230 PLUG 4 HP1 0G49690231 PLUG 1 9439A 0G49690233 9439 A GASKET, LWR INTAKE MAN. TO HEAD (LH) 1 9439B 0G49690234 9439 B GASKET, LWR INTAKE MAN. TO HEAD (RH) 1 9A424 0G49690236 SEAL, INTAKE MANIFOLD, REAR 1 9A425 0G49690235 SEAL, INTAKE MANIFOLD, FRONT 1 9461 CONTACT PARTS 8555 CONTACT PARTS NOT SERVICED 19
4.2L Gas Engine Exhaust Manifold 20
4.2L Gas Engine Exhaust Manifold 9430A 0G49690237 MANIFOLD, EXHAUST, RH 1 9430B 0G49690238 MANIFOLD, EXHAUST, LH 1 9448 0G49690239 GASKET, EXH. MANIFOLD TO HEAD 2 HB1 0F7316C199 BOLT, M6 X 14 (NOT SHOWN) 3 HN1 0F97650223 NUT, M8 X 1.25 12 HT1 0G49690243 STUD, M8 X 19MM-M8 X 35MM 4 HT2 0F73160240 STUD, M8 X 19-M8 X 21.7 8 21
4.2L Gas Engine EGR System 9E470 0G49690247 TUBE, CONNECTING 1 9D476 0F7316C183 GASKET 1 HS1 0F8286E275 SCREW, M6X16MM 2 22
4.2L Gas Engine Throttle Body Gaskets 9E936 0G49690262 GASKET, THROTTLE BODY 1 9F670 0G49690268 GASKET, IDLE AIR BY PASS VALVE 1 23
4.2L Gas Engine Ignition 24
4.2L Gas Engine Ignition 12297 0G49690369 SEPERATOR, IGN. WIRE, 3-WIRE, PIN MOUNT A/R 12297 0G49690370 SEPERATOR, IGN. WIRE, 2-WIRE, PIN MOUNT A/R 12405 0G49690110 PLUGS, SPARK 6 12A362 0G49690293 SYNCHRONIZER 1 6B288 0G49690140 SENSOR, CAMSHAFT 1 12143 0G49690296 O RING 1 12390 0G49690297 GEAR, SYNCHRONIZER DRIVE 1 25
Part No. 0G4969PMNL rev. A / Printed in USA 04/26/10 2010 Generac Power Systems, Inc. All rights reserved. Specifications are subject to change without notice No reproduction allowed in any form without prior written consent from Generac Power Systems, Inc. Generac Power Systems, Inc. S45 W29290 Hwy. 59 Waukesha, WI 53189 1-888-GENERAC (1-888-436-3722) generac.com