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Ford ESG-642 Engine

General Technical Data

Engine Specifications

Engine Model ............... Ford ESG-642
Engine Family ............... Essex V6
Engine Type ............... 4-cycle V-type 6-cylinder overhead valve liquid-cooled gasoline
Number of Cylinders ............... 6
Cylinder Arrangement ............... V-6 configuration with 90-degree bank angle
Engine Bore, in (mm) ............... 3.81 (96.8)
Engine Stroke, in (mm) ............... 3.74 (95.0)
Displacement, cu.in (L) ............... 256 (4.2)
Intermittent Power (Gasoline), hp (kW) ............... 146 (109) at 3600 rpm
Continuous Power (Gasoline), hp (kW) ............... 125 (93) at 3600 rpm
Intermittent Power (Natural Gas), hp (kW) ............... 120 (89) at 3600 rpm
Continuous Power (Natural Gas), hp (kW) ............... 102 (76) at 3600 rpm
Intermittent Power (LPG), hp (kW) ............... 131 (98) at 3600 rpm
Continuous Power (LPG), hp (kW) ............... 114 (85) at 3600 rpm
Peak Torque (Gasoline, Intermittent), lb-ft (Nm) ............... 247 (335) at 2200 rpm
Peak Torque (Gasoline, Continuous), lb-ft (Nm) ............... 213 (289) at 2200 rpm
Peak Torque (Natural Gas, Intermittent), lb-ft (Nm) ............... 198 (268) at 2200 rpm
Peak Torque (Natural Gas, Continuous), lb-ft (Nm) ............... 170 (230) at 2200 rpm
Peak Torque (LPG, Intermittent), lb-ft (Nm) ............... 224 (304) at 2200 rpm
Peak Torque (LPG, Continuous), lb-ft (Nm) ............... 194 (263) at 2200 rpm
Idle Speed, rpm ............... 700-850
Maximum Governed Speed, rpm ............... 3600
Compression Ratio ............... 9.3:1
Firing Order ............... 1-4-2-5-3-6
Cylinder Block Material ............... Cast iron with 4 main bearing caps
Cylinder Head Material ............... Cast aluminum with integral valve seats
Intake Manifold Material ............... Cast aluminum
Valvetrain Config ............... Overhead valve pushrod actuated, 2 valves per cylinder
Camshaft Drive ............... Chain driven with hydraulic tensioner
Lifter Type ............... Roller lifter lifters
Balance Shaft ............... Counter-rotating balance shaft mounted internally
Crankshaft Material ............... Nodular iron balance-weighted
Lubrication System ............... Full-pressure wet sump system
Oil Pump Type ............... High-flow gear driven
Oil Filter Type ............... Full-flow, spin-on cartridge type
Cooling System ............... Liquid-cooled centrifugal pump bypass type
Water Pump Drive ............... Serpentine accessory drive belt driven
Ignition System Type ............... Distributorless coil pack electronic ignition
Starting System ............... Electric starter motor
Electrical System ............... 12V negative ground

Fuel System

Fuel Injection Type ............... Multi-port electronic fuel injection manifold delivery
Gasoline Fuel Specification ............... 87 AKI octane or 87 RON/MON
Natural Gas Fuel Specification ............... 1050 BTU/FT3 dry pipeline gas
Liquefied Petroleum Gas Specification ............... ASI-Grade HD-5 propane
Fuel Control Architecture ............... Electronic engine management system for multi-fuel monitoring
Throttle Control ............... Drive-by-wire electronic throttle body actuator
Governor System ............... Electronic programmable governing four speed system
Fuel Rail Operating Pressure Gasoline, psi (kPa) ............... 35.0-45.0 (241.0-310.0)
Fuel Injector Resistance, ohms ............... 11.0-14.0
Fuel Filter Micron Rating, microns ............... 10.0 nominal filter rating
LPG Regulator Inlet Pressure Range, psi (bar) ............... 30.0-312.0 (2.07-21.51)
LPG Delivery Pressure To Throttle, in H2O (kPa) ............... -0.5 to -1.5 (-0.12 to -0.37)
Natural Gas Regulator Inlet Pressure, psi (bar) ............... 10.0-15.0 (0.69-1.03)
Natural Gas Delivery Pressure, in H2O (kPa) ............... 4.0-6.0 (1.00-1.49)
Manifold Absolute Pressure Range, in Hg (kPa) ............... 10.0-30.0 (33.8-101.3)
Air-Fuel Ratio Control ............... Closed-loop utilizing exhaust oxygen sensor feedback
Oxygen Sensor Type ............... Heated exhaust oxygen sensor multi-wire
Fuel Shutoff Valve Valve Type ............... 12V direct current solenoids automatic shutdown
Fuel System Safety Controls ............... Low pressure cutoff and high temperature protection integrations

Dimensions and Weight

Overall Height, in (mm) ............... 30.3 (770)
Overall Length, in (mm) ............... 29.6 (755)
Overall Width, in (mm) ............... 26.7 (680)
Dry Weight, lbs (kg) ............... 403 (183)
Total Weight With Fluid, lbs (kg) ............... 435 (197)

Maintenance Data

Service Information

Oil Pressure at Low Idle, psi (kPa) ............... 15.0-25.0 (103.0-172.0)
Oil Pressure at 2500 rpm, psi (kPa) ............... 40.0-60.0 (275.0-413.0)
Cooling System Pressure Cap Rating, psi (kPa) ............... 14.0-16.0 (96.0-110.0)
Thermostat Opening Temperature, F (C) ............... 180.0 (82.2)
Thermostat Full Open Temperature, F (C) ............... 202.0 (94.4)
Standard Spark Plug ............... AWSF-42PP double platinum
Spark Plug Gap, in (mm) ............... 0.052-0.056 (1.32-1.42)

Engine Oil and Coolant

Engine Oil Type .................. SAE 5W-20, 5W-30
API Service Classifications ......................... SG/SH/SJ
Engine Oil Capacity with Filter, qt (L) ............... 6.0 (5.68)
Engine Oil Capacity without Filter, qt (L) ............... 5.5 (5.20)
Cooling System Capacity (Engine Only), qt (L) ............... 7.5 (7.10)
Cooling System Capacity with Radiator, qt (L) ............... 14.5 (13.72)

Service Intervals

Change engine oil ............... Every 200 hours
Replace oil filter ............... Every 200 hours
Replace fuel filter ............... Every 500 hours
Inspect air filter ............... Every 50 hours
Replace air filter ............... Every 250 hours
Change coolant ............... Every 2000 hours
Valve-lash adjustment ............... Every 500 hours
Check fuel system ............... Every 1000 hours
Replace spark plug ............... Every 1000 hours
Compression test ............... Every 1000 hours
Belt inspection ............... Every 100 hours

Service Specifications

Cylinder Bore Inside Diameter, in (mm) ............... 3.780-3.784 (96.000-96.702)
Cylinder Bore Service Limit, in (mm) ............... 3.815 (96.90)
Cylinder Bore Out-of-Round Maximum, in (mm) ............... 0.0005 (0.013)
Cylinder Bore Taper Maximum, in (mm) ............... 0.001 (0.025)
Main Bearing Journal Diameter, in (mm) ............... 2.519-2.520 (64.00-64.02)
Main Bearing Clearance, in (mm) ............... 0.0011-0.0027 (0.028-0.068)
Connecting Rod Journal Diameter, in (mm) ............... 2.310-2.311 (58.68-58.70)
Connecting Rod Bearing Clearance, in (mm) ............... 0.0011-0.0026 (0.028-0.066)
Connecting Rod Center-to-Center Length, in (mm) ............... 6.090-6.094 (154.7-154.8)
Connecting Rod Side Clearance, in (mm) ............... 0.006-0.014 (0.152-0.356)
Crankshaft End Play, in (mm) ............... 0.004-0.008 (0.102-0.203)
Piston to Cylinder Bore Clearance, in (mm) ............... 0.0014-0.0022 (0.036-0.056)
Piston Pin Bore Inside Diameter, in (mm) ............... 0.9054-0.9057 (22.997-23.005)
Piston Pin Diameter, in (mm) ............... 0.9052-0.9054 (22.992-22.997)
Piston Pin to Piston Pin Bore Clearance, in (mm) ............... 0.0002-0.0005 (0.005-0.013)
Piston Pin to Con Rod Bushing Clearance, in (mm) ............... 0.0003-0.0007 (0.008-0.018)
Top Ring Groove Width, in (mm) ............... 0.059-0.061 (1.50-1.55)
Second Ring Groove Width, in (mm) ............... 0.059-0.061 (1.50-1.55)
Oil Ring Groove Width, in (mm) ............... 0.118-0.120 (3.00-3.05)
Top Ring Side Clearance, in (mm) ............... 0.0031 (0.080)
Second Ring Side Clearance, in (mm) ............... 0.0031 (0.080)
Oil Ring Side Clearance, in (mm) ............... 0.0039 (0.100)
Top Ring End Gap, in (mm) ............... 0.010-0.020 (0.254-0.508)
Second Ring End Gap, in (mm) ............... 0.014-0.024 (0.356-0.610)
Oil Ring End Gap, in (mm) ............... 0.015-0.045 (0.381-1.143)
Cylinder Head Deck Flatness Maximum, in (mm) ............... 0.003 per 6.0 in (0.076 per 152.4 mm)
Cylinder Block Deck Flatness Maximum, in (mm) ............... 0.005 overall (0.127 overall)
Intake Valve Stem Outer Diameter, in (mm) ............... 0.274-0.275 (6.96-6.98)
Exhaust Valve Stem Outer Diameter, in (mm) ............... 0.273-0.274 (6.93-6.96)
Valve Guide Inside Diameter, in (mm) ............... 0.275-0.277 (7.00-7.04)
Intake Valve Stem to Guide Clearance, in (mm) ............... 0.0010-0.0027 (0.025-0.069)
Exhaust Valve Stem to Guide Clearance, in (mm) ............... 0.0018-0.0035 (0.046-0.089)
Valve Face Angle ............... 45.0 degrees
Valve Seat Angle ............... 45.0 degrees
Valve Margin Thickness, in (mm) ............... 0.031 (0.79)
Valve Spring Free Length, in (mm) ............... 1.98 (50.3)
Camshaft Journal Outer Diameter, in (mm) ............... 1.998-1.999 (50.75-50.77)
Camshaft Journal Bearing Clearance, in (mm) ............... 0.001-0.003 (0.025-0.076)
Camshaft End Play, in (mm) ............... 0.001-0.007 (0.025-0.178)
Cam Lobe Lift (Intake), in (mm) ............... 0.260 (6.60)
Cam Lobe Lift (Exhaust), in (mm) ............... 0.268 (6.81)
Valve Lifter Bore Inside Diameter, in (mm) ............... 0.874-0.876 (22.22-22.25)
Valve Lifter Guide Clearance, in (mm) ............... 0.0007-0.0021 (0.018-0.053)
Balance Shaft Journal Diameter (Front), in (mm) ............... 2.124-2.125 (53.96-53.98)
Balance Shaft Journal Diameter (Rear), in (mm) ............... 1.624-1.625 (41.26-41.28)
Balance Shaft Bearing Clearance (Front), in (mm) ............... 0.0015-0.0035 (0.038-0.089)
Balance Shaft Bearing Clearance (Rear), in (mm) ............... 0.0015-0.0035 (0.038-0.089)
Balance Shaft End Play Clearance, in (mm) ............... 0.002-0.006 (0.051-0.152)

Tightening Torques

Cylinder Head Bolts (Step 1), lb-ft (Nm) ............... 37.0 (50.0)
Cylinder Head Bolts (Step 2), lb-ft (Nm) ............... 45.0 (61.0)
Cylinder Head Bolts (Step 3), lb-ft (Nm) ............... 59.0 (80.0)
Cylinder Head Bolts (Step 4), lb-ft (Nm) ............... 73.0 (99.0)
Main Bearing Cap Bolts (Step 1), lb-ft (Nm) ............... 35.0 (48.0)
Main Bearing Cap Bolts (Step 2), lb-ft (Nm) ............... 75.0 (102.0)
Connecting Rod Cap Bolts (Step 1), lb-ft (Nm) ............... 18.0 (25.0)
Connecting Rod Cap Bolts (Step 2), lb-ft (Nm) ............... 32.0 (43.0)
Flywheel to Crankshaft Fasteners, lb-ft (Nm) ............... 59.0 (80.0)
Crankshaft Damper Pulley Center Bolt, lb-ft (Nm) ............... 115.0 (155.0)
Camshaft Thrust Plate Retaining Bolts, lb-ft (Nm) ............... 9.0 (12.0)
Camshaft Sprocket Gear Center Bolt, lb-ft (Nm) ............... 44.0 (60.0)
Balance Shaft Retaining Flange Bolts, lb-ft (Nm) ............... 9.0 (12.0)
Balance Shaft Driven Gear Center Bolt, lb-ft (Nm) ............... 15.0 (20.0)
Rocker Arm Fulcrum Attaching Bolts, lb-ft (Nm) ............... 24.0 (32.0)
Valve Rocker Arm CoverFasteners, lb-in (Nm) ............... 80.0 (9.0)
Intake Manifold Lower to Cylinder Head (Step 1), lb-in (Nm) ............... 36.0 (4.0)
Intake Manifold Lower to Cylinder Head (Step 2), lb-in (Nm) ............... 72.0 (8.0)
Intake Manifold Lower to Cylinder Head (Step 3), lb-ft (Nm) ............... 15.0 (20.0)
Intake Manifold Upper Upper Section Fasteners, lb-in (Nm) ............... 89.0 (10.0)
Exhaust Manifold Attaching Nuts (Step 1), lb-ft (Nm) ............... 8.0 (11.0)
Exhaust Manifold Attaching Nuts (Step 2), lb-ft (Nm) ............... 16.0 (22.0)
Oil Pan to Cylinder Block Attaching Bolts, lb-in (Nm) ............... 106.0 (12.0)
Oil Pan Oil Drain Plug, lb-ft (Nm) ............... 20.0 (27.0)
Oil Pump Assembly Housing to Block Fasteners, lb-ft (Nm) ............... 18.0 (25.0)
Oil Pump Screen Pickup Tube Flange Bolt, lb-in (Nm) ............... 106.0 (12.0)
Water Pump to Front Cover Fasteners, lb-in (Nm) ............... 89.0 (10.0)
Engine Front Cover Timing Chain Bolts, lb-in (Nm) ............... 106.0 (12.0)
Spark Plug, lb-ft (Nm) ............... 15.0 (20.0)
Knock Sensor Electrical Device Fastener, lb-ft (Nm) ............... 14.0 (19.0)
Camshaft Position Sensor Attaching Bolt, lb-in (Nm) ............... 89.0 (10.0)
Crankshaft Position Sensor Attaching Bolt, lb-in (Nm) ............... 89.0 (10.0)
Fuel Rail Mechanical Attachment Fasteners, lb-in (Nm) ............... 89.0 (10.0)
Engine Mount Lower Bracket to Block Bolts, lb-ft (Nm) ............... 48.0 (65.0)
Starter Motor Housing Mounting Bolts, lb-ft (Nm) ............... 18.0 (25.0)
Alternator Assembly Lower Bracket Fixing Bolt, lb-ft (Nm) ............... 35.0 (48.0)
Thermostat Housing Water Outlet Cover Fasteners, lb-in (Nm) ............... 89.0 (10.0)
Flywheel Housing to Block Outer Shield Bolts, lb-ft (Nm) ............... 33.0 (45.0)
Ignition Coil Pack Assembly Mount Brackets, lb-in (Nm) ............... 53.0 (6.0)

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