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Ford KSG-416 Engine

General Technical Data

Engine Specifications

Engine Model ............... Ford KSG-416
Engine Family ............... Kent Crossflow Industrial Series
Displacement, cu.in (L) ............... 97.6 (1.6)
Number of Cylinders ............... 4
Cylinder Configuration ............... Inline vertical
Cycle Type ............... 4-stroke overhead valve
Engine Bore, in (mm) ............... 3.188 (80.98)
Engine Stroke, in (mm) ............... 3.056 (77.62)
Brake Horsepower Intermittent, hp (kW) ............... 63 (47) at 3600 rpm
Continuous Power Rating, hp (kW) ............... 52 (39) at 3000 rpm
Peak Torque, lb-ft (Nm) ............... 95 (129) at 2400 rpm
Aspiration Type ............... Naturally aspirated
Compression Ratio ............... 9.0:1
Firing Order ............... 1-2-4-3
Max No-Load Speed, rpm ............... 3800
Idle Speed, rpm ............... 700-750
Cylinder Block Material ............... Cast iron
Cylinder Head Material ............... Cast iron
Number of Main Bearings ............... 5
Crankcase Ventilation System ............... Closed positive crankcase ventilation
Camshaft Drive Type ............... Timing chain
Direction of Rotation ............... Counter-clockwise viewed from flywheel end
Lubrication System ............... Full-pressure circulation
Oil Pump Type ............... Eccentric twin-rotor gear-driven
Oil Filter Type ............... Full-flow, spin-on cartridge
Cooling System ............... Forced liquid circulation with bypass thermostat
Water Pump Type ............... Belt-driven centrifugal impeller
Air Cleaner Type ............... Heavy-duty dry dual-stage element
Ignition System ............... Solid state distributor or electronic ignition
Starting System ............... Electric starter motor
Electrical System ............... 12V

Fuel System

Primary Fuel Type ............... Gasoline unleaded 87 octane minimum
Secondary Fuel Capability ............... Liquefied petroleum gas liquefied propane gas
Tertiary Fuel Capability ............... Natural gas
Carburetor Type ............... Single barrel downdraft industrial type
LPG Regulator Variant ............... Secondary single stage converter regulator
Fuel Pump Type ............... Mechanical diaphragm style camshaft driven
Fuel Pump Delivery Pressure, psi (kPa) ............... 3.5-5.0 (24.1-34.5)
Fuel Filter Rating, microns ............... 10 inline paper element
Air Fuel Ratio Gasoline, ratio ............... 14.7:1
Air Fuel Ratio LPG, ratio ............... 15.5:1
Air Fuel Ratio Natural Gas, ratio ............... 17.2:1
Governor System Type ............... Mechanical velocity or electronic governor options
Governor Regulation Percentage ............... 3-5 percent stable state regulation
Choke Control Mechanism ............... Automatic electric thermostatic coil or manual cable
Fuel Inlet Thread Size, in ............... 0.125 internal pipe thread
Main Jet Orifice Diameter Gasoline, in (mm) ............... 0.052 (1.32)
Idle Jet Orifice Diameter Gasoline, in (mm) ............... 0.022 (0.56)
LPG Vaporizer Capacity, hp (kW) ............... 100 (74.6)
Natural Gas Inlet Pressure Minimum, in H2O (kPa) ............... 7.0 (1.74)
Natural Gas Inlet Pressure Maximum, in H2O (kPa) ............... 11.0 (2.74)
Solonoid Shutoff Voltage, V ............... 12 direct current

Dimensions and Weight

Overall Length, in (mm) ............... 22.4 (570)
Overall Width, in (mm) ............... 18.9 (480)
Overall Height, in (mm) ............... 25.6 (650)
Dry Weight, lbs (kg) ............... 295 (134)
Wet Weight, lbs (kg) ............... 325 (147.5)

Maintenance Data

Service Information

Compression Pressure Minimum, psi (bar) ............... 150 (10.3)
Oil Pressure at Low Idle, psi (kPa) ............... 15 (103.4)
Oil Pressure at 2000 rpm, psi (kPa) ............... 40-60 (275.8-413.7)
Oil Pressure Relief Valve Opening, psi (kPa) ............... 65 (448.2)
Cooling System Radiator Cap Pressure, psi (kPa) ............... 13 (89.6)
Thermostat Start To Open Temperature, F (C) ............... 190 (87.8)
Thermostat Fully Open Temperature, F (C) ............... 212 (100.0)
Spark Plug Gap, in (mm) ............... 0.030 (0.76)
Breaker Point Gap, in (mm) ............... 0.025 (0.64)
Ignition Timing (Gasoline), deg BTDC ............... 8
Ignition Timing (LPG), deg BTDC ............... 12
Drive Belt Deflection Tension, in (mm) ............... 0.50 (12.7)
Intake Valve Clearance (Cold), in (mm) ............... 0.014 (0.36)
Exhaust Valve Clearance (Cold), in (mm) ............... 0.022 (0.56)

Engine Oil and Coolant

Engine Oil Type .................. SAE 5W-30, 10W-30
API Service Classifications ......................... SG, SH, or SJ
Engine Oil Capacity Without Filter, qts (L) ............... 3.5 (3.3)
Engine Oil Capacity With Filter, qts (L) ............... 4.0 (3.8)
Cooling System Fluid Capacity, qts (L) ............... 6.5 (6.2)

Service Intervals

Change engine oil ............... Every 100 hours
Replace oil filter ............... Every 100 hours
Replace fuel filter ............... Every 500 hours
Inspect air filter ............... Every 50 hours
Replace air filter ............... Every 250 hours
Change coolant ............... Every 1000 hours
Valve-lash adjustment ............... Every 300 hours
Check fuel system ............... Every 1000 hours
Replace spark plug ............... Every 500 hours
Compression test ............... Every 1000 hours
Belt inspection ............... Every 100 hours

Service Specifications

Cylinder Bore Inside Diameter, in (mm) ............... 3.1878-3.1888 (80.970-80.996)
Cylinder Bore Maximum Out of Round, in (mm) ............... 0.0005 (0.0127)
Cylinder Bore Maximum Taper, in (mm) ............... 0.0010 (0.0254)
Cylinder Liner Outside Diameter, in (mm) ............... 3.3795 (85.839)
Cylinder Liner Overall Length, in (mm) ............... 5.875 (149.225)
Crankshaft Main Journal Diameter, in (mm) ............... 2.1250-2.1256 (53.975-53.990)
Crankshaft Main Journal Out of Round Max, in (mm) ............... 0.0003 (0.0076)
Main Bearing Bore Inner Diameter, in (mm) ............... 2.271-2.272 (57.683-57.709)
Crankshaft Main Bearing Clearance, in (mm) ............... 0.0008-0.0026 (0.020-0.066)
Crankpin Journal Diameter, in (mm) ............... 1.9370-1.9376 (49.199-49.215)
Crankpin Bearing Oil Clearance, in (mm) ............... 0.0008-0.0022 (0.020-0.056)
Crankshaft Axial End Play, in (mm) ............... 0.003-0.011 (0.076-0.279)
Connecting Rod Side Clearance, in (mm) ............... 0.004-0.010 (0.102-0.254)
Connecting Rod Small End Bore I.D, in (mm) ............... 0.8126-0.8133 (20.640-20.658)
Connecting Rod Big End Bore I.D, in (mm) ............... 2.0600-2.0605 (52.324-52.337)
Piston To Cylinder Bore Clearance, in (mm) ............... 0.0018-0.0024 (0.046-0.061)
Piston Pin Bore Inside Diameter, in (mm) ............... 0.8122-0.8125 (20.630-20.638)
Piston Pin Outer Diameter, in (mm) ............... 0.8120-0.8123 (20.625-20.632)
Piston Pin To Piston Pin Bore Clearance, in (mm) ............... 0.0002-0.0004 (0.005-0.010)
Piston Pin To Connecting Rod Bushing Clearance, in (mm) ............... 0.0001-0.0003 (0.003-0.008)
Top Ring Groove Width, in (mm) ............... 0.080-0.081 (2.032-2.057)
Second Ring Groove Width, in (mm) ............... 0.080-0.081 (2.032-2.057)
Oil Ring Groove Width, in (mm) ............... 0.189-0.190 (4.801-4.826)
Top Ring Side Clearance, in (mm) ............... 0.0020-0.0040 (0.051-0.102)
Second Ring Side Clearance, in (mm) ............... 0.0016-0.0036 (0.041-0.091)
Oil Ring Side Clearance, in (mm) ............... 0.0015-0.0035 (0.038-0.089)
Top Ring End Gap, in (mm) ............... 0.009-0.014 (0.229-0.356)
Second Ring End Gap, in (mm) ............... 0.009-0.014 (0.229-0.356)
Oil Ring End Gap, in (mm) ............... 0.015-0.030 (0.381-0.762)
Intake Valve Stem Outer Diameter, in (mm) ............... 0.3110-0.3120 (7.899-7.925)
Exhaust Valve Stem Outer Diameter, in (mm) ............... 0.3100-0.3110 (7.874-7.899)
Intake Valve Stem To Guide Clearance, in (mm) ............... 0.0010-0.0025 (0.025-0.064)
Exhaust Valve Stem To Guide Clearance, in (mm) ............... 0.0020-0.0035 (0.051-0.089)
Valve Guide Inner Diameter, in (mm) ............... 0.3130-0.3140 (7.950-7.976)
Intake Valve Head Diameter, in (mm) ............... 1.410-1.420 (35.814-36.068)
Exhaust Valve Head Diameter, in (mm) ............... 1.240-1.250 (31.496-31.750)
Intake Valve Seat Contact Width, in (mm) ............... 0.060-0.080 (1.524-2.032)
Exhaust Valve Seat Contact Width, in (mm) ............... 0.070-0.090 (1.778-2.286)
Valve Seat Angle, deg ............... 45
Valve Margin Thickness, in (mm) ............... 0.031 (0.787)
Valve Spring Free Length, in (mm) ............... 1.820 (46.228)
Camshaft Journal Diameter (Number 1), in (mm) ............... 1.6860-1.6867 (42.824-42.842)
Camshaft Journal Diameter (Number 2), in (mm) ............... 1.6560-1.6567 (42.062-42.080)
Camshaft Journal Diameter (Number 3), in (mm) ............... 1.6260-1.6267 (41.300-41.318)
Camshaft Journal Clearance, in (mm) ............... 0.0010-0.0030 (0.025-0.076)
Camshaft Housing Block Bore I.D (Number 1), in (mm) ............... 1.786-1.787 (45.364-45.390)
Camshaft Housing Block Bore I.D (Number 2), in (mm) ............... 1.756-1.757 (44.602-44.628)
Camshaft Housing Block Bore I.D (Number 3), in (mm) ............... 1.726-1.727 (43.840-43.866)
Camshaft Axial End Play, in (mm) ............... 0.002-0.006 (0.051-0.152)
Cam Lobe Lift (Intake), in (mm) ............... 0.285 (7.239)
Cam Lobe Lift (Exhaust), in (mm) ............... 0.285 (7.239)
Tappet Lifter Body Outer Diameter, in (mm) ............... 0.5425-0.5430 (13.780-13.792)
Tappet Lifter To Block Bore Clearance, in (mm) ............... 0.0006-0.0021 (0.015-0.053)
Rocker Arm Shaft Outer Diameter, in (mm) ............... 0.6238-0.6245 (15.845-15.862)
Rocker Arm Bore Inner Diameter, in (mm) ............... 0.6253-0.6261 (15.883-15.903)
Rocker Arm To Shaft Clearance, in (mm) ............... 0.0008-0.0023 (0.020-0.058)

Tightening Torques

Cylinder Head Bolts (1-Stage), lb-ft (Nm) ............... 30 (40.7)
Cylinder Head Bolts (2-Stage), lb-ft (Nm) ............... 55 (74.6)
Cylinder Head Bolts (3-Stage), lb-ft (Nm) ............... 70 (94.9)
Main Bearing Cap Bolts, lb-ft (Nm) ............... 65 (88.1)
Connecting Rod Cap Nut, lb-ft (Nm) ............... 35 (47.5)
Flywheel Retaining Crankshaft Bolts, lb-ft (Nm) ............... 55 (74.6)
Crankshaft Front Pulley Center Bolt, lb-ft (Nm) ............... 80 (108.5)
Camshaft Sprocket Locking Bolt, lb-ft (Nm) ............... 32 (43.4)
Camshaft Thrust Push Plate Bolt, lb-ft (Nm) ............... 10 (13.6)
Rocker Arm Shaft Support Bracket Bolts, lb-ft (Nm) ............... 30 (40.7)
Rocker Arm Adjusting Screw, lb-ft (Nm) ............... 15 (20.3)
Valve Cylinder Head Cover Screws, lb-ft (Nm) ............... 5 (6.8)
Cylinder Front Cover Timing Case M6 Fastener, lb-ft (Nm) ............... 7 (9.5)
Cylinder Front Cover Timing Case M8 Fastener, lb-ft (Nm) ............... 15 (20.3)
Oil Pan Sump Perimeter Drain Bolts, lb-ft (Nm) ............... 8 (10.8)
Oil Pan Main Center Sump Drain Plug, lb-ft (Nm) ............... 22 (29.8)
Oil Pump Assembly Housing Bolts, lb-ft (Nm) ............... 15 (20.3)
Intake Manifold To Cylinder Head Fasteners, lb-ft (Nm) ............... 17 (23.1)
Exhaust Manifold To Cylinder Head Fasteners, lb-ft (Nm) ............... 17 (23.1)
Water Pump Assembly Mounting Housing Screws, lb-ft (Nm) ............... 15 (20.3)
Water Outlet Thermostat Housing Attaching Bolts, lb-ft (Nm) ............... 15 (20.3)
Distributor Base Clamp Down Holding Bolt, lb-ft (Nm) ............... 14 (19.0)
Spark Plug Installation, lb-ft (Nm) ............... 18 (24.4)
Oil Pressure Sender Unit, lb-ft (Nm) ............... 12 (16.3)
Coolant Temperature Indicator Switch, lb-ft (Nm) ............... 15 (20.3)
Fuel Pump Mechanical Mounting Bracket Nut, lb-ft (Nm) ............... 14 (19.0)
Flywheel Housing Ring Assembly To Block Bolts, lb-ft (Nm) ............... 45 (61.0)
Starter Motor Mounting Flange Securing Bolts, lb-ft (Nm) ............... 35 (47.5)
Alternator Pivot Mounting Long Pivot Bolt, lb-ft (Nm) ............... 30 (40.7)
Alternator Adjusting Arm Linkage Slotted Bolt, lb-ft (Nm) ............... 18 (24.4)
Engine Support Front Mounting Foot Inserts, lb-ft (Nm) ............... 40 (54.2)
Engine Support Rear Plate Adapter Fasteners, lb-ft (Nm) ............... 45 (61.0)

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