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Ford 2722E Engine

The Ford 2722E (commonly known as the Dover 90) is a heavy-duty, 4.15-liter, 4-cylinder in-line diesel engine. Produced as part of the Ford 2720 industrial and marine range, this naturally aspirated, direct-injection engine is highly regarded for its industrial-grade durability and extensive use in marine propulsion, auxiliary power units, and Ford Cargo trucks. Key design refinements of the Dover generation over the older Dorset series include a robust cast aluminum front timing cover, enlarged intake and exhaust ports, and highly durable straight-cut timing gears.

The cylinder head utilizes an overhead valve (OHV) design. The vertical valves are mounted in-line and operated via pushrods and rocker arms driven by a camshaft located in the cylinder block. The camshaft itself is gear-driven directly from the crankshaft. For standard workshop adjustment, valve clearance (both inlet and exhaust) must be set between 0.38 mm and 0.46 mm. Bore: 107 mm (4.212 inches). Stroke: 115 mm (4.524 inches). Total Displacement: 4.150 liters (254 cubic inches).

Fuel delivery relies on the direct injection principle, where fuel is injected directly into a combustion chamber formed in the piston crown. The mechanical system is anchored by a block-mounted, in-line fuel injection pump utilizing an individual pumping element for each cylinder. A mechanical governor is integrated directly into the pump housing to maintain steady engine RPM against variable load demands. Fuel lines consist of a flexible braided supply line feeding the high-pressure steel injector pipes.

Lubrication is managed via a pressure-fed system driven by an internal oil pump. The system features a full-flow, spin-on disposable oil filter cartridge. A dedicated external oil delivery pipe feeds oil directly from the main filter housing to the fuel injection pump housing to maintain constant pump lubrication. Depending on the application, sumps can feature different configurations and dipping positions to compensate for installation inclination angles.

The engine uses a liquid-cooled architecture utilizing an engine-driven fresh water pump. In marine variants, cooling is executed via a dual-circuit configuration featuring a cupro-nickel heat exchanger cooled by raw water via a gear-driven rubber impeller pump. Most industrial and marine fresh water pumps feature two distinct ports, although certain specialized 2722E builds use a single-port pump housing.

General Technical Data

Engine Specifications

Engine Model ............... Ford 2722E (Dover Series)
Engine Type ............... 4-cycle inline 4-cylinder direct injection liquid-cooled diesel
Number of Cylinders ............... 4
Cylinder Arrangement ............... In-line
Engine Bore, in (mm) ............... 4.22 (107.18)
Engine Stroke, in (mm) ............... 4.52 (114.90)
Displacement, cu.in (L) ............... 255 (4.15)
Rated Engine Power, hp (kW) ............... 80-90 (60-66)
Rated Engine Speed, rpm ............... 2500-2600
Peak Torque, lb-ft (Nm) ............... 195-210 (265-285) at 1600 rpm
Idle Speed, rpm ............... 700-800
Max No-Load Speed, rpm ............... 2800-2950
Aspiration Type ............... Naturally Aspirated
Compression Ratio ............... 16.1:1
Firing Order ............... 1-3-4-2
Cylinder Block Type ............... Cast iron
Cylinder Head Type ............... Cast iron
Crankshaft Material ............... Forged steel
Main Bearings Number ............... 5
Lubrication System ............... Full-pressure
Oil Pump Type ............... Gear-driven
Oil Filter Type ............... Full-flow, spin-on
Cooling System ............... Liquid-cooled
Water Pump Type ............... Belt-driven, centrifugal
Timing Gears Type ............... Straight cut
Timing Gear Cover Material ............... Cast aluminum
Exhaust Manifold Type ............... Dry or water-cooled
Electrical System, V ............... 12 or 24
Alternator Output, A ............... 55-70

Fuel System

Fuel Injection Pump Type ............... Inline mechanical
Injection Pump Manufacturer ............... Minimec / Simms / Bosch
Governor Type ............... Mechanical / Hydraulic
Fuel Injection Timings ............... 20 deg BTDC
Fuel Injector Type ............... Multi-hole nozzle
Injector Opening Pressure, psi (bar) ............... 2900-3190 (200-220)
Fuel Lift Pump Type ............... Mechanical plunger
Fuel Feed Pressure, psi (bar) ............... 5.8-8.7 (0.4-0.6)
Fuel Filter Type ............... Dual element spin-on paper cartridge
Maximum Fuel Return Line Pressure, psi (bar) ............... 2.9 (0.2)
Recommended Fuel Type ............... ASTM D975 Class 2D / BS2869 Class A1

Dimensions and Weight

Overall Length, in (mm) ............... 33.4 (850)
Overall Width, in (mm) ............... 24.8 (630)
Overall Height, in (mm) ............... 32.3 (820)
Dry Weight, lbs (kg) ............... 925-1050 (420-475)

Maintenance Data

Service Information

Compression Pressure at Cranking Speed, psi (bar) ............... 360-400 (24.8-27.6)
Compression Variation between Cylinders, psi (bar) ............... 43.5 (3.0)
Minimum Oil Pressure at Idle, psi (bar) ............... 14.5 (1.0)
Normal Operating Oil Pressure, psi (bar) ............... 36.3-58.0 (2.5-4.0)
Normal Operating Coolant Temperature, F (C) ............... 170-190 (77-88)
Maximum Allowed Coolant Temperature, F (C) ............... 205 (96)
Thermostat Opening Temperature, F (C) ............... 165 (74)
Thermostat Fully Open Temperature, F (C) ............... 187 (86)
Intake Valve Clearance (Cold), in (mm) ............... 0.0150 (0.380)
Exhaust Valve Clearance (Cold), in (mm) ............... 0.0180 (0.460)

Engine Oil and Coolant

Engine Oil Type .................. SAE 30, SAE 10W-30, SAE 15W-40
API Service Classifications ......................... CC or CD
Engine Oil Capacity with Filter, qt (L) ............... 9.6 (9.1)
Engine Oil Capacity without Filter, qt (L) ............... 8.6 (8.1)
Cooling System Capacity, qt (L) ............... 12.7 (12.0)

Service Intervals

Change oil and filter ............... Every 150 hours
Inspect air cleaner ............... Every 100 hours
Replace air cleaner ............... Every 500 hours
Replace fuel filter ............... Every 300 hours
Valve clearance adjustment ............... Every 400 hours
Fuel system inspection ............... Every 600 hours
Change coolant ............... Every 1000 hours
Compression test ............... Every 600 hours
Belt inspection ............... Every service cycle

Service Specifications

Cylinder Bore Diameter, in (mm) ............... 4.2197-4.2205 (107.180-107.200)
Cylinder Bore Maximum Wear Limit, in (mm) ............... 4.2256 (107.330)
Cylinder Bore Out-of-Round, in (mm) ............... 0.0020 (0.050)
Cylinder Bore Taper Limit, in (mm) ............... 0.0020 (0.050)
Crankshaft Main Journal Diameter, in (mm) ............... 2.9992-3.0000 (76.180-76.200)
Crankshaft Main Bearing Clearance, in (mm) ............... 0.0022-0.0043 (0.057-0.110)
Crankpin Standard Diameter, in (mm) ............... 2.4992-2.5000 (63.480-63.500)
Connecting Rod Bearing Clearance, in (mm) ............... 0.0018-0.0035 (0.045-0.090)
Crankshaft End Play, in (mm) ............... 0.0020-0.0100 (0.050-0.250)
Piston to Cylinder Bore Clearance, in (mm) ............... 0.0035-0.0047 (0.090-0.120)
Piston Pin Bore Diameter, in (mm) ............... 1.4998-1.5002 (38.095-38.105)
Piston Pin Diameter, in (mm) ............... 1.4995-1.4997 (38.087-38.093)
Piston Pin to Piston Clearance, in (mm) ............... 0.0001-0.0005 (0.002-0.012)
Top Ring Groove Width, in (mm) ............... 0.0961-0.0969 (2.440-2.460)
Second Ring Groove Width, in (mm) ............... 0.0953-0.0961 (2.420-2.440)
Oil Ring Groove Width, in (mm) ............... 0.1878-0.1886 (4.770-4.790)
Top Ring End Gap, in (mm) ............... 0.0157-0.0217 (0.400-0.550)
Second Ring End Gap, in (mm) ............... 0.0118-0.0177 (0.300-0.450)
Oil Ring End Gap, in (mm) ............... 0.0118-0.0217 (0.300-0.550)
Cylinder Head Flatness, in (mm) ............... 0.0039 (0.100)
Cylinder Block Top Surface Flatness, in (mm) ............... 0.0039 (0.100)
Intake Valve Stem Diameter, in (mm) ............... 0.3720-0.3728 (9.450-9.470)
Exhaust Valve Stem Diameter, in (mm) ............... 0.3713-0.3720 (9.430-9.450)
Intake Valve Guide Internal Diameter, in (mm) ............... 0.3740-0.3752 (9.500-9.530)
Exhaust Valve Guide Internal Diameter, in (mm) ............... 0.3740-0.3752 (9.500-9.530)
Intake Valve Stem-to-Guide Clearance, in (mm) ............... 0.0012-0.0031 (0.030-0.080)
Exhaust Valve Stem-to-Guide Clearance, in (mm) ............... 0.0020-0.0039 (0.050-0.100)
Camshaft Journal Diameter, in (mm) ............... 2.1232-2.1244 (53.930-53.960)
Camshaft Bearing Clearance, in (mm) ............... 0.0016-0.0039 (0.040-0.100)
Camshaft End Play, in (mm) ............... 0.0031-0.0071 (0.080-0.180)

Tightening Torques

Cylinder Head Bolts (Stage 1), lb-ft (Nm) ............... 40 (54)
Cylinder Head Bolts (Stage 2), lb-ft (Nm) ............... 70 (95)
Cylinder Head Bolts (Stage 3), lb-ft (Nm) ............... 110 (150)
Main Bearing Cap Bolts, lb-ft (Nm) ............... 115 (156)
Connecting Rod Cap Nuts, lb-ft (Nm) ............... 75 (102)
Flywheel Bolts, lb-ft (Nm) ............... 85 (115)
Crankshaft Damper / Pulley Bolt, lb-ft (Nm) ............... 220 (298)
Camshaft Thrust Plate Bolts, lb-ft (Nm) ............... 35 (48)
Camshaft Gear Bolt, lb-ft (Nm) ............... 55 (75)
Rocker Arm Shaft Bracket Bolts, lb-ft (Nm) ............... 45 (61)
Rocker Arm Adjusting Screw Locknuts, lb-ft (Nm) ............... 25 (34)
Timing Gear Cover Bolts, lb-ft (Nm) ............... 18 (24)
Oil Pan Sump Drain Plug, lb-ft (Nm) ............... 35 (48)
Oil Pan Sump Retaining Bolts, lb-ft (Nm) ............... 15 (20)
Fuel Injector Clamp Bolts, lb-ft (Nm) ............... 18 (24)
Fuel Injection Pump Drive Gear Nut, lb-ft (Nm) ............... 60 (81)
Fuel Injection Pump Mounting Bolts, lb-ft (Nm) ............... 18 (24)
Fuel High Pressure Pipe Union Nuts, lb-ft (Nm) ............... 22 (30)
Intake Manifold Bolts, lb-ft (Nm) ............... 22 (30)
Exhaust Manifold Bolts, lb-ft (Nm) ............... 25 (34)
Water Pump Mounting Bolts, lb-ft (Nm) ............... 18 (24)
Thermostat Housing Bolts, lb-ft (Nm) ............... 18 (24)
Oil Pump Assembly Bolts, lb-ft (Nm) ............... 18 (24)
Starter Motor Mounting Bolts, lb-ft (Nm) ............... 35 (48)
Alternator Mounting Bracket Bolts, lb-ft (Nm) ............... 35 (48)
Glow Plug (If Equipped), lb-ft (Nm) ............... 15 (20)

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