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Ford TSG-416 Engine

General Technical Data

Engine Specifications

Engine Model ............... Ford TSG-416
Engine Type ............... 4-cycle inline 4-cylinder SOHC liquid-cooled multi-fuel engine
Number of Cylinders ............... 4
Cylinder Arrangement ............... In-line
Engine Bore, in (mm) ............... 3.23 (82.1)
Engine Stroke, in (mm) ............... 2.97 (75.5)
Displacement, cu.in (L) ............... 98 (1.6)
Rated Engine Power, hp (kW) ............... 52-63 (39-47) at 3600 rpm
Rated Engine Speed, rpm ............... 2500-3600
Peak Torque ............... 126 Nm (93 lb-ft) at 3200 rpm
Idle Speed ............... 800-900 rpm
Operating Speed ............... 1500-3600 rpm
Max Intermittent Speed, rpm ............... 4000
Max Continuous Speed, rpm ............... 3600
Compression Ratio ............... 9.5:1
Firing Order ............... 1-3-4-2
Cylinder Block Type ............... Cast iron
Cylinder Head Type ............... Aluminum alloy
Lubrication System ............... Full-pressure
Oil Pump Type ............... Rotor-type gear-driven
Oil Filter Type ............... Full-flow spin-on
Cooling System ............... Liquid-cooled centrifugal pump
Water Pump Type ............... Belt-driven centrifugal
Air Cleaner Type ............... Dry heavy-duty element
Starting System ............... Electric starter motor
Electrical System ............... 12V negative ground
Alternator Rating, amp ............... 70-95

Fuel System

Fuel Injection Type ............... Electronic Fuel Injection (EFI)
Fuel Control Type ............... Electronic Engine Control Module
Gasoline Specification ............... 87 AKI or 89 AKI unleaded gasoline
Liquefied Petroleum Gas Rating ............... HD-5 Propane
Natural Gas Energy Content ............... 1050 BTU/ft3
Fuel Pressure Range Gasoline, psi (kPa) ............... 39.1-56.5 (270-390)
LPG Inlet Pressure Range, in-H2O (kPa) ............... 4.0-11.0 (1.0-2.7)
Natural Gas Inlet Pressure, in-H2O (kPa) ............... 7.0-11.0 (1.7-2.7)
Fuel Filter Type ............... Inline high-pressure spin-on canister
Fuel Pump Type ............... Electric high-pressure fuel pump
Throttle Body Type ............... Electronic drive-by-wire system
Oxygen Sensor Configuration ............... Heated upstream sensor
Governor System Type ............... Electronic digital speed governor
Governed Speed Regulation ............... Isochronous +/- 0.5 percent
Manifold Vacuum at Idle, in-Hg (kPa) ............... 18-22 (61-74)
Air-Fuel Ratio Control ............... Closed-loop feedback system
Emissions Certification ............... CARB and EPA certified industrial package

Dimensions and Weight

Overall Length, in (mm) ............... 24.1 (610)
Overall Width, in (mm) ............... 18.9 (480)
Overall Height, in (mm) ............... 24.7 (625)
Dry Weight, lbs (kg) ............... 275 (125)
Wet Weight, lbs (kg) ............... 298 (135)

Maintenance Data

Service Information

Cylinder Compression Pressure, psi (kPa) ............... 140 (965.0)
Oil Pressure Minimum at Idle, psi (kPa) ............... 15 (103.4)
Oil Pressure at Rated Speed, psi (kPa) ............... 40-60 (275.8-413.7)
Thermostat Opening Temperature, F (C) ............... 190 (88.0)
Thermostat Full Open Temperature, F (C) ............... 212 (100.0)
Spark Plug Type ............... Motorcraft AGSF-32PM
Spark Plug Gap, in (mm) ............... 0.052-0.056 (1.32-1.42)
Intake Valve Clearance, Cold, in (mm) ............... 0.006-0.008 (0.15-0.20)
Exhaust Valve Clearance, Cold, in (mm) ............... 0.010-0.012 (0.25-0.30)

Engine Oil and Coolant

Engine Oil Type .................. SAE 10W-30, SAE 5W-30
API Service Classifications ......................... SL or SM
Engine Oil Capacity with Filter, qt (L) ............... 4.25 (4.0)
Engine Oil Capacity without Filter, qt (L) ............... 3.70 (3.5)
Coolant Capacity Engine Only, qt (L) ............... 3.5 (3.3)

Service Intervals

Change engine oil ............... Every 150 hours
Replace oil filter ............... Every 150 hours
Replace fuel filter ............... Every 450 hours
Inspect air filter ............... Every 100 hours
Replace air filter ............... Every 500 hours
Change coolant ............... Every 1000 hours
Valve-lash adjustment ............... Every 1000 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) ............... 3.2323-3.2331 (82.100-82.120)
Cylinder Bore Max Wear Limit, in (mm) ............... 3.2354 (82.180)
Cylinder Out of Round Max, in (mm) ............... 0.0004 (0.010)
Cylinder Bore Taper Limit Max, in (mm) ............... 0.0004 (0.010)
Main Crankshaft Journal Diameter, in (mm) ............... 2.2441-2.2449 (57.000-57.020)
Main Crankshaft Bearing Clearance, in (mm) ............... 0.0007-0.0021 (0.018-0.054)
Connecting Rod Journal Diameter, in (mm) ............... 1.8465-1.8472 (46.900-46.920)
Connecting Rod Bearing Clearance, in (mm) ............... 0.0006-0.0022 (0.016-0.056)
Crankshaft End Play, in (mm) ............... 0.0028-0.0094 (0.070-0.240)
Connecting Rod Side Clearance, in (mm) ............... 0.0043-0.0094 (0.110-0.240)
Piston Outer Diameter, in (mm) ............... 3.2307-3.2315 (82.060-82.080)
Piston to Cylinder Wall Clearance, in (mm) ............... 0.0008-0.0024 (0.020-0.060)
Piston Pin Bore Inside Diameter, in (mm) ............... 0.7874-0.7876 (20.000-20.006)
Piston Pin to Piston Pin Bore Clearance, in (mm) ............... 0.0002-0.0004 (0.005-0.011)
Top Ring End Gap, in (mm) ............... 0.0079-0.0157 (0.200-0.400)
Second Ring End Gap, in (mm) ............... 0.0118-0.0197 (0.300-0.500)
Oil Ring End Gap, in (mm) ............... 0.0079-0.0197 (0.200-0.500)
Top Ring Side Clearance, in (mm) ............... 0.0016-0.0031 (0.040-0.080)
Second Ring Side Clearance, in (mm) ............... 0.0012-0.0028 (0.030-0.070)
Oil Ring Side Clearance, in (mm) ............... 0.0012-0.0028 (0.030-0.070)
Cylinder Head Deck Surface Flatness, in (mm) ............... 0.0020 (0.050)
Cylinder Block Deck Surface Flatness, in (mm) ............... 0.0030 (0.076)
Intake Valve Stem Outer Diameter, in (mm) ............... 0.2740-0.2748 (6.960-6.980)
Exhaust Valve Stem Outer Diameter, in (mm) ............... 0.2732-0.2740 (6.940-6.960)
Valve Guide Inner Diameter, in (mm) ............... 0.2756-0.2764 (7.000-7.020)
Intake Valve Stem to Guide Clearance, in (mm) ............... 0.0008-0.0024 (0.020-0.060)
Exhaust Valve Stem to Guide Clearance, in (mm) ............... 0.0016-0.0031 (0.040-0.080)
Valve Face Angle, deg ............... 45
Valve Seat Angle, deg ............... 45
Valve Spring Free Length, in (mm) ............... 1.7600 (44.700)
Camshaft Bearing Journal Diameter, in (mm) ............... 1.0236-1.0244 (26.000-26.020)
Camshaft Bearing Oil Clearance, in (mm) ............... 0.0010-0.0028 (0.025-0.070)
Camshaft End Play, in (mm) ............... 0.0031-0.0071 (0.080-0.180)

Tightening Torques

Cylinder Head Bolts (Step One), Nm (lb-ft) ............... 30 (22)
Cylinder Head Bolts (Step Two), Nm (lb-ft) ............... 60 (44) + 90 deg turn
Main Bearing Cap Bolts, Nm (lb-ft) ............... 50 (37) + 90 deg turn
Connecting Rod Cap Bolts, Nm (lb-ft) ............... 25 (18) + 90 deg turn
Flywheel Receptacle Assembly Bolts, Nm (lb-ft) ............... 85 (63)
Crankshaft Damper Pulley Central Bolt, Nm (lb-ft) ............... 115 (85)
Camshaft Sprocket Gear Fastener, Nm (lb-ft) ............... 60 (44)
Camshaft Thrust Bearing Screws, Nm (lb-ft) ............... 11 (8)
Timing Belt Tensioner Bracket Bolts, Nm (lb-ft) ............... 25 (18)
Engine Oil Pump Assembly Fasteners, Nm (lb-ft) ............... 23 (17)
Oil Pan Structural Peripheral Bolts, Nm (lb-ft) ............... 11 (8)
Oil Pan Main Drain Plug, Nm (lb-ft) ............... 28 (21)
Valve Cover Perimeter Sealing Nuts, Nm (lb-ft) ............... 9 (7)
Intake Manifold Flange Fastener Set, Nm (lb-ft) ............... 23 (17)
Exhaust Manifold Flange Holding Nuts, Nm (lb-ft) ............... 25 (18)
Water Pump Assembly Shell Screws, Nm (lb-ft) ............... 23 (17)
Thermostat Housing Attachment Fasteners, Nm (lb-ft) ............... 11 (8)
Spark Plug Secondary Screw Threads, Nm (lb-ft) ............... 15 (11)
Engine Mount Main Structural Fasteners, Nm (lb-ft) ............... 80 (59)
Starter Motor Housing Mounting Bolts, Nm (lb-ft) ............... 40 (30)
Alternator Pivot Adjustment Mounting Bolt, Nm (lb-ft) ............... 48 (35)
Fuel Rail Mechanical Fasteners, Nm (lb-ft) ............... 20 (15)
Throttle Body Base Sealing Studs, Nm (lb-ft) ............... 10 (7)
Crankshaft Position Sensor Bracket Screw, Nm (lb-ft) ............... 9 (7)
Camshaft Position Sensor Small Stud Bolt, Nm (lb-ft) ............... 9 (7)
Knock Sensor Main Cylinder Block Fastener, Nm (lb-ft) ............... 20 (15)
Oxygen Sensor Exhaust Header Fitting, Nm (lb-ft) ............... 45 (33)
Oil Pressure Sender Unit Block Thread, Nm (lb-ft) ............... 15 (11)
Coolant Temperature Sensor Hex Fitting, Nm (lb-ft) ............... 18 (13)
Flywheel Housing Rear Structure Bolts, Nm (lb-ft) ............... 48 (35)
Timing Belt Outer Protection Cover Bolts, Nm (lb-ft) ............... 9 (7)
Front Crankshaft Oil Seal Carrier Screws, Nm (lb-ft) ............... 11 (8)
Rear Crankshaft Oil Seal Fasteners, Nm (lb-ft) ............... 11 (8)

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