GENERAL SPECIFICATIONS
| Item | Specification |
|---|---|
| Lubricants and Sealants | |
| SAE 5W-20 Premium Synthetic Blend Motor Oil (XO-5W20-QSP) or equivalent | WSS-M2C930-A |
| Silicone Brake Caliper Grease and Dielectric Compound XG-3-A or equivalent | ESE-M1C171-A |
| Thread Sealant with Teflon® TA-24 | WSK-M2G350-A2 |
| Silicone Gasket and Sealant F7AZ-19554-EA | WSE-M4G323-A4 |
| Motorcraft Silicone Gasket Remover ZC-30 | |
| Motorcraft Metal Surface Prep ZC-31 | |
| Metal Surface Cleaner ZC-21 | WSE-M5B392-A |
GENERAL SPECIFICATIONS
| Item | Specification |
|---|---|
| Engine | |
| Displacement | 3.9L |
| Number of cylinders | 6 |
| Bore | 96.82 mm (3.81 in) |
| Stroke | 88.0 mm (3.46 in) |
| Firing order | 1-4-2-5-3-6 |
| Oil pressure (hot 2,500 RPM) | 275.8-861.8 kPa (40-125 psi) |
| Oil Capacity | 4.73 L (5.0 quarts) total |
| Compression ratio | 9.35: 1 |
| Cylinder Head and Valve Train | |
| Cylinder head gasket surface flatness | 0.18 mm (0.007 in) |
| Combustion chamber volume (cc) | 61.5-64.5 |
| Valve arrangement (front to rear) | LH: E, I, E, I, E, I RH: I, E, I, E, I, E |
| Valve guide bore diameter intake and exhaust | 7.015-7.044 mm (0.276-0.277 in) |
| Valve stem diameter - intake (standard) | 6.975-6.995 mm (0.2746-0.2754 in) |
| Valve stem diameter - exhaust (standard) | 6.949-6.970 mm (0.2735-0.2744 in) |
| Valve stem diameter - intake (oversize) | 9.075-9.055 mm (0.3573-0.3565 in) |
| Valve stem diameter - exhaust (oversize) | 9.063-9.043 mm (0.3568-0.3560 in) |
| Valve stem diameter - intake (oversize) | 9.456-9.436 mm (0.3723-0.3715 in) |
| Valve stem diameter - exhaust (oversize) | 9.444-9.424 mm (0.3718-0.3710 in) |
| Valve stem-to-guide clearance - intake | 0.020-0.069 mm (0.0008-0.0027 in) |
| Valve stem-to-guide clearance - exhaust | 0.045-0.095 mm (0.0018-0.0037 in) |
| Valve head diameter - intake | 47.27 mm (1.86 in) |
| Valve head diameter - exhaust | 37.1 mm (1.46 in) |
| Valve face runout | 0.05 mm (0.002 in) |
| Valve face angle | 45.675 degrees |
| Valve seat width | 1.5-2.0 mm (0.06-0.08 in) |
| Valve seat runout (T.I.R.) | 0.076 mm (0.003 in) |
| Valve seat angle | 44.75 degrees |
| Valve spring free length | 50.7 mm |
| Valve spring squareness | 1.2 mm |
| Valve spring compression pressure (valve open, without damper) | 1000 N (224 lb) @ 29.2 mm (1.16 in) |
| Valve spring compression pressure (valve closed, without damper) | 350 N (79 lb) @ 40.7 mm (1.62 in) |
| Valve spring installed height | 40.7 mm (1.62 in) |
| Valve spring installed pressure | 350 N (79 lb) @ 40.7 mm (1.62 in) |
| Rocker arm ratio | 1.73: 1 |
| Hydraulic Roller Lifter | |
| Diameter (Std) | 22.195-22.212 mm (0.8738-0.8745 in) |
| Clearance-to-bore | 0.018-0.068 mm (0.0007-0.0027 in) |
| Service limit | 0.127 mm (0.005 in) |
| Hydraulic leakdown rate | 20-100 seconds |
| Collapsed lash adjuster gap - intake | 2.15-4.69 mm (0.089-0.189 in) |
| Collapsed lash adjuster gap - exhaust | 2.15-4.69 mm (0.089-0.189 in) |
| Camshaft | |
| Theoretical valve lift @ 0 lash - intake | 10.78 mm (0.424 in) |
| Theoretical valve lift @ 0 lash - exhaust | 11.41 mm (0.449 in) |
| Lobe lift - intake | 6.223 mm (0.245 in) |
| Lobe lift - exhaust | 6.575 mm (0.259 in) |
| Allowable lobe lift loss | 0.127 mm (0.005 in) |
| Journal diameter | 52.082-52.108 mm (2.0505-2.0515 in) |
| Camshaft journal bore inside diameter - intake | 47.097 mm (1.8542 in) |
| Camshaft journal bore inside diameter - exhaust | 39.739 mm (1.5645 in) |
| Camshaft journal-to-bearing clearance | 0.025-0.076 mm (0.001-0.003 in) |
| Camshaft bearing runout | 0.127 mm (0.0005 in) |
| End play | 0.025-0.150 mm (0.001-0.006 in) |
| Cylinder Block | |
| Cylinder bore diameter | 96.82 mm (3.81 in) |
| Cylinder bore maximum out-of-round limit | 0.025 mm (0.001 in) |
| Cylinder bore maximum taper | 0.050 mm (0.002 in) |
| Cylinder bore maximum out-of-round service limit | 0.127 mm (0.005 in) |
| Cylinder bore maximum taper service limit | 0.254 mm (0.010 in) |
| Main bearing bore inside diameter | 68.905 mm (2.713 in) 68.885 mm (2.712 in) |
| Camshaft bearing bore inside diameter | |
| Head gasket surface flatness | 0.008 mm (0.003 in) in 152.0 mm (6.00 in) |
| Crankshaft | |
| Main bearing journal diameter (journals 1, 2, 3) | 63.978-63.998 mm (2.5188-2.5196 in) |
| Main bearing journal maximum taper | 0.016 mm (0.0006 in) diameter or 0.008 mm (0.0003 in) radius MAX between any 2 measurement points |
| Main bearing journal maximum out-of-round | 0.0008 mm MAX in 45 degrees, 0.016 mm (0.006 in) TOTAL |
| Main bearing journal-to-cylinder block clearance - desired | 0.025-0.035 mm (0.001-0.0014 in) |
| Main bearing journal-to-cylinder block clearance - allowable | 0.013-0.058 mm (0.0005-0.0023 in) |
| Connecting rod journal diameter | 58.682-58.702 mm (2.3103-2.3111 in) |
| Connecting rod journal maximum taper | 0.016 mm D or 0.008 mm R MAX between any 2 measurement points |
| Connecting rod journal maximum out-of-round | 0.008 mm (0.0003 in) MAX in 45 degrees, 0.015 mm (0.0006 in) TOTAL |
| Crankshaft maximum end play | 0.010-0.20 mm (0.0004-0.008 in) |
| Piston (1) and Connecting Rod | |
| Piston diameter - coded red (before coating) | 96.795-96.782 mm (3.81082-3.81031 in) |
| Piston diameter - coded blue (before coating) | 96.808-96.795 mm (3.81133-3.81082 in) |
| Piston diameter - coded yellow (before coating) | 96.821-96.808 mm (3.81184-3.81133 in) |
| Piston-to-cylinder bore clearance (uncoated clearance) | 0.018-0.044 mm (0.0007-0.0017 in) |
| Piston ring end gap - compression (top, in gauge) | 0.17-0.33 mm (0.0067-0.0130 in) |
| Piston ring end gap - compression (bottom, in gauge) | 0.3-0.55 mm (0.0118-0.0217 in) |
| Piston ring end gap - oil ring (steel rail, in gauge) | 0.15-0.65 mm (0.0059-0.0256 in) |
| Piston ring groove width - compression (top) | 1.535-1.52 mm (0.0604-0.0598 in) |
| Piston ring groove width - compression (bottom) | 1.54-1.52 mm (0.0606-0.0598 in) |
| Piston ring groove width - oil | 3.05-3.03 mm (0.1200-0.1193 in) |
| Piston ring width - compression (top) | 1.47-1.49 mm (0.0578-0.0587 in) |
| Piston ring width - compression (bottom) | 1.47-1.49 mm (0.0578-0.0587 in) |
| Piston ring width - oil ring | Side seal - snug fit |
| Piston ring-to-groove clearance - 1st ring | 0.030-0.065 mm (0.0012-0.0026 in) |
| Piston ring-to-groove clearance - 2nd ring | 0.030-0.070 mm (0.0012-0.0028 in) |
| Piston pin bore diameter | 23.012-23.012 mm (0.9060-0.9061 in) |
| Piston pin diameter | 23.000-23.003 mm (0.9055-0.9056 in) |
| Piston pin length | 63.55-63.05 mm (2.5096-2.4823 in) |
| Piston pin-to-piston fit | 0.009-0.017 mm (0.0004-0.0007 in) |
| Connecting rod-to-pin clearance | Press fit 8 kilo newtons (1,800 lb) |
| Connecting rod pin bore diameter | 22.98-22.941 mm (0.9047-0.9032 in) |
| Connecting rod length (center-to-center) | 154.66-154.74 mm (6.08896-6.09211 in) |
| Connecting rod maximum allowed bend | 0.04 per 25 mm (0.0016 per in) |
| Connecting rod maximum allowed twist | 0.05 per 25 mm (0.002 per in) |
| Connecting rod bearing bore diameter | 61.635-61.655 mm (2.4266-2.4274 in) |
| Connecting rod bearing-to-crankshaft clearance - desired | 0.025-0.035 mm (0.001-0.0014 in) |
| Connecting rod bearing-to-crankshaft clearance - allowable | 0.022-0.069 mm (0.00086-0.0027 in) |
| Connecting rod side clearance - standard | 0.11-0.49 mm (0.0047-0.0193 in) |
| Connecting rod side clearance - service limit | 0.49 mm MAX (0.0193 in MAX) |
| Balance Shaft | |
| Journal diameter | 52.108-52.082 mm (2.0515-2.0505 in) |
| Bore inside diameter | 55.689-55.664 mm (2.192-2.191 in) |
| Maximum runout | 0.025 mm (0.001 in) |
| End play | 0.075-0.200 mm (0.003-0.008 in) |
| (1) When installing new pistons, measure the cylinder bore as described in ENGINE SYSTEM-GENERAL INFORMATION. Install the service piston matched to the piston bore diameter above. | |
| (1) | When installing new pistons, measure the cylinder bore as described in ENGINE SYSTEM-GENERAL INFORMATION. Install the service piston matched to the piston bore diameter above. |
GENERAL SPECIFICATIONS
| Item | Specification |
|---|---|
| Engine | |
| Displacement | 4.2L |
| Number of cylinders | 6 |
| Bore | 96.82 mm (3.81 in) |
| Stroke | 95.0 mm (3.8 in) |
| Firing order | 1-4-2-5-3-6 |
| Oil pressure (hot 2,500 RPM) | 40-125 psi |
| Oil capacity | 5.0 quarts total |
| Compression ratio | |
| Cylinder Head and Valve Train | |
| Cylinder head gasket surface flatness | 0.18 mm (0.007 in) |
| Combustion chamber volume | 61.5-64.5 |
| Valve arrangement (front to rear) | LH: E, I, E, I, E, I RH: I, E, I, E, I, E |
| Valve guide bore diameter - intake and exhaust | 7.015-7.044 mm (0.276-0.277 in) |
| Valve stem diameter - intake (standard) | 6.975-6.995 mm (0.2746-0.2754 in) |
| Valve stem diameter - exhaust (standard) | 6.949-6.970 mm (0.2735-0.2744 in) |
| Valve stem diameter - oversize (intake) | 9.075-9.055 mm (0.3573-0.3565 in) |
| Valve stem diameter - oversize (exhaust) | 9.063-9.043 mm (0.3568-0.3560 in) |
| Valve stem diameter - oversize (intake) | 9.456-9.436 mm (0.3723-0.3715 in) |
| Valve stem diameter - oversize (exhaust) | 9.444-9.424 mm (0.3718-0.3710 in) |
| Valve stem-to-guide clearance - intake | 0.020-0.069 mm (0.0008-0.0027 in) |
| Valve stem-to-guide clearance - exhaust | 0.045-0.095 mm (0.008-0.0037 in) |
| Valve head diameter - intake | 47.27 mm (1.86 in) |
| Valve head diameter - exhaust | 37.1 mm (1.46 in) |
| Valve face runout | 0.05 mm (0.002 in) |
| Valve face angle | 45.675 degrees |
| Valve seat width | 1.5-2.0 mm (0.06-0.08 in) |
| Valve seat runout (T.I.R.) | 0.076 mm (0.003 in) |
| Valve seat angle | 44.75 degrees |
| Valve spring free length | 50.7 mm (1.99 in) |
| Valve spring squareness | 1.2 mm (0.0472 in) |
| Valve spring compression pressure (valve open, without damper) | 1,000 N (224 lb) @ 29.2 mm (1.16 in) |
| Valve spring compression pressure (valve closed, without damper) | 350 N (79 lb) @ 40.7 mm (1.62 in) |
| Valve spring installed height | 40.7 mm (1.62 in) |
| Valve spring installed pressure | 350 N (79 lb) @ 40.7 mm (1.62 in) |
| Rocker arm ratio | 1.73: 1 |
| Hydraulic Roller Lifter | |
| Diameter (standard) | 22.195-22.212 mm (0.8738-0.8745 in) |
| Clearance-to-bore | 0.018-0.068 mm (0.0007-0.0027 in) |
| Service limit | 0.127 mm (0.005 in) |
| Hydraulic leakdown rate | 20-100 seconds |
| Collapsed lash adjuster gap (intake and exhaust) | 2.15-4.69 mm (0.089-0.189 in) |
| Camshaft | |
| Theoretical valve lift @ 0 lash - intake | 10.78 mm (0.4244 in) |
| Theoretical valve lift @ 0 lash - exhaust | 11.41 mm (0.4492 in) |
| Lobe lift - intake | 6.223 mm (0.24 in) |
| Lobe lift - exhaust | 6.575 mm (0.26 in) |
| Allowable lobe lift loss | 0.127 mm (0.005 in) |
| Journal diameter | 52.082-52.108 mm (2.0505-2.0515 in) |
| Camshaft journal bore inside diameter - intake | 47.097 mm (1.8542 in) max. 47.072 mm (1.85 in) min. |
| Camshaft journal bore inside diameter - exhaust | 39.739 mm (1.5645 in) max. 39.714 mm (1.56 in) min. |
| Camshaft journal-to-bearing clearance | 0.025-0.076 mm (0.001-0.003 in) |
| Camshaft bearing runout | 0.127 mm (0.005 in) |
| End play | 0.025-0.150 mm (0.001-0.006 in) |
| Cylinder Block | |
| Cylinder bore diameter | 96.812 mm (3.81 in) |
| Cylinder bore maximum out-of-round limit | 0.025 mm (0.001 in) |
| Cylinder bore maximum taper | 0.050 mm (0.002 in) |
| Cylinder bore maximum out-of-round service limit | 0.127 mm (0.005 in) |
| Cylinder bore maximum taper service limit | 0.254 mm (0.010 in) |
| Main bearing bore inside diameter | 68.905 mm (2.713 in) 68.885 mm (2.712 in) |
| Camshaft bearing bore inside diameter - No. 1 | 55.689-55.664 mm (2.192-2.191 in) |
| Camshaft bearing bore inside diameter - No. 2 and No. 3 | 55.308-55.283 mm (2.177-2.176 in) |
| Camshaft bearing bore inside diameter - No. 4 | 55.684-55.664 mm (2.192-2.191 in) |
| Head gasket surface flatness | 0.08 mm (0.003 in) in 152.0 mm (6.00 in) |
| Crankshaft | |
| Main bearing journal diameter (journals 1, 2, 3) | 63.978-63.998 mm (2.5188-2.5196 in) |
| Main bearing journal maximum taper | 0.016 mm (0.0006 in) diameter or 0.008 (0.0003 in) radius MAX between any 2 measurement points |
| Main bearing journal maximum out-of-round | 0.008 mm (0.0003 in) MAX in 45 degrees, 0.016 mm (0.006 in) TOTAL |
| Main bearing journal-to-cylinder block clearance - desired | 0.025-0.035 mm (0.001-0.0014 in) |
| Main bearing journal-to-cylinder block clearance - allowable | 0.013-0.058 mm (0.0005-0.0023 in) |
| Connecting rod journal diameter | 58.682-58.702 mm (2.310-2.311 in) |
| Connecting rod journal maximum taper | 0.016 mm D or 0.008 mm R between any 2 measurement points |
| Connecting rod journal maximum out-of-round | 0.008 mm (0.0003 in) MAX in 45 degrees, 0.016 mm (0.006 in) Total |
| Crankshaft maximum end play | 0.10-0.20 mm (0.004-0.008 in) |
| Piston and Connecting Rod | |
| Piston diameter - coded red (before coating) | 96.795-96.782 mm (3.81082-3.81031 in) |
| Piston diameter - coded blue (before coating) | 96.808-96.795 mm (3.81133-3.81082 in) |
| Piston diameter - coded yellow (before coating) | 96.821-96.808 mm (3.81184-3.81133 in) |
| Piston-to-cylinder bore clearance (uncoated clearance) | 0.018-0.044 mm (0.00071-0.00173 in) |
| Piston ring end gap - compression (top, in gauge) | 0.17-0.33 mm (0.0067-0.0130 in) |
| Piston ring end gap - compression (bottom, in gauge) | 0.3-0.55 mm (0.0118-0.0217 in) |
| Piston ring end gap - oil ring (steel rail, in gauge) | 0.15-0.65 mm (0.006-0.026 in) |
| Piston ring groove width - compression (top) Piston ring groove width - compression (bottom) | 1.535-1.52 mm (0.0603-0.0598 in) |
| Piston ring groove width - oil | 3.05-3.03 mm (0.12001-0.11929 in) |
| Piston ring width - compression (top and bottom) | 1.460-1.490 mm (0.05748-0.05866 in) |
| Piston ring width - oil ring | Side seal, snug fit |
| Piston ring-to-groove clearance - 1st ring | 0.030-0.065 mm (0.0012-0.00315 in) |
| Piston ring-to-groove clearance - 2nd ring | 0.030-0.070 mm (0.0012-0.0028 in) |
| Piston pin bore diameter | 23.014-23.018 mm (0.90606-0.90622 in) |
| Piston pin diameter | 23.000-23.003 mm (0.90551-0.90563 in) |
| Piston pin length | 63.55-63.05 mm (2.5096-2.4823 in) |
| Piston pin-to-piston fit | 0.011-0.018 mm (0.00043-0.00071 in) |
| Connecting rod-to-pin clearance | Press fit 8 kilo newtons (1,800 lb) |
| Connecting rod pin bore diameter | 22.94-22.98 mm (0.90315-0.90472 in) |
| Connecting rod length (center-to-center) | 154.66-154.74 mm (6.08896-6.09211 in) |
| Connecting rod maximum allowable bend | 0.04 per 25 mm (0.0016 per in) |
| Connecting rod maximum allowable twist | 0.059 per 25 mm (0.002 per in) |
| Connecting rod bearing bore diameter | 61.635-61.655 mm (2.4266-2.4274 in) |
| Connecting rod bearing-to-crankshaft clearance - desired | 0.025-0.035 mm (0.001-0.0014 in) |
| Connecting rod bearing-to-crankshaft clearance - allowable | 0.022-0.069 mm (0.00086-0.0027 in) |
| Connecting rod side clearance (assembled to crank) - standard | 0.11-0.49 mm (0.0047-0.01929 in) |
| Connecting rod side clearance (assembled to crank) - service limit | 0.49 mm (0.0193 in) max. |
| Balance Shaft | |
| Journal diameter | 52.108-52.082 mm (2.0515-2.0505 in) |
| Bore inside diameter | 55.689-55.664 mm (2.192-2.191 in) |
| Maximum runout | 0.025 mm (0.001 in) |
| End play | 0.075-0.200 mm (0.003-0.008 in) |
GENERAL SPECIFICATIONS
TORQUE SPECIFICATIONS
| Description | Nm | Lb-ft | Lb-in |
|---|---|---|---|
| Crankshaft pulley bolt | 160 | 118 | |
| Front subframe bolts | 90 | 66 | |
| Exhaust manifold nuts | 25 | 18 | |
| Suction/discharge manifold and tube assembly bolt | 20 | 15 | |
| Inspection cover plate bolt | 10 | 89 | |
| Torque converter nuts | 36 | 27 | |
| Engine-to-transaxle bolts | 50 | 37 | |
| Engine support insulator bracket-to-transaxle bolts | 63 | 46 | |
| Flywheel-to-crankshaft bolts | 80 | 59 | |
| Coolant pump extension tube bolt | 25 | 18 | |
| Tensioner pulley bracket bolts | 25 | 18 | |
| Idler pulley bolt | 47 | 35 | |
| Heater tube bolt | 10 | 89 | |
| Power steering pump bracket (small) bolts | 25 | 18 | |
| Power steering pump bracket (large) bolts | 48 | 35 | |
| Upper intake manifold bolts (1) | |||
| Fuel injection supply manifold bolts | 10 | 89 | |
| Camshaft synchronizer assembly bolt | 25 | 18 | |
| Crankshaft position (CKP) sensor nuts | 6 | 53 | |
| Oil pickup tube and screen bolts | 25 | 18 | |
| Spark plugs | 15 | 11 | |
| Exhaust manifold studs | 8 | 71 | |
| Oil pressure sender | 27 | 20 | |
| Oil pan baffle nuts | 32 | 24 | |
| Oil pan drain plug | 26 | 19 | |
| Oil pan-to-transmission mounting bolt | 45 | 33 | |
| RH motor mount-to-bracket bolt | 90 | 66 | |
| RH motor mount-to-subframe nut | 90 | 66 | |
| LH motor mount bolt | 90 | 66 | |
| LH motor mount-to-subframe nut | 90 | 66 | |
| Rear motor mount-to-bracket nut | 63 | 46 | |
| Rear motor mount-to-subframe nut | 90 | 66 | |
| Engine roll restrictor bolts | 63 | 46 | |
| Engine harness ground bolts | 10 | 89 | |
| Oil level indicator tube and bracket bolt | 10 | 89 | |
| Valve cover bolts | 10 | 89 | |
| Valve cover stud bolts | 10 | 89 | |
| Accelerator cable bracket bolt | 10 | 89 | |
| Accelerator cable bracket nut | 10 | 89 | |
| Exhaust gas recirculation (EGR) tube nuts | 40 | 30 | |
| EGR system module bolts | 25 | 18 | |
| Coolant bypass tube bolt | 10 | 89 | |
| Oil pickup tube and screen nut | 48 | 35 | |
| Lower intake manifold bolts (1) | |||
| Rocker arm-to-cylinder head bolt(s) (1) | |||
| Tappet guide plate bolts | 12 | 9 | |
| Cylinder head bolts (1) | |||
| Oil bypass filter-to-oil pump and filter body (1) | |||
| Oil cooler mounting bolt | 35 | 26 | |
| Oil pump and filter body-to-engine front cover bolts (small) | 10 | 89 | |
| Oil pump and filter body-to-engine front cover bolts (large) | 25 | 18 | |
| Camshaft thrust plate bolts | 12 | 9 | |
| Balance shaft bolts | 12 | 9 | |
| Crankshaft main bearing cap bolts (1) | |||
| Connecting rod cap bolts (1) | |||
| Timing chain tensioner bolts | 12 | 9 | |
| Engine front cover bolts (1) | |||
| Coolant pump bolts (1) | |||
| Coolant pump nuts (1) | |||
| Camshaft position (CMP) sensor drive gear bolt | 45 | 33 | |
| Coolant pump pulley bolts | 11 | 8 | |
| (1) Refer to the procedure in this article. | |||
| (1) | Refer to the procedure in this article. |
TORQUE SPECIFICATIONS
The 3.9L and 4.2L engines have
- a V-block with 6 cylinders and splayed crankpins.
- a distributorless ignition system.
- a multiport, sequential fuel injection (SFI) system.
- a variable-length induction system (intake manifold runner control).
- overhead valves.
- hydraulic valve tappets for automatic lash adjustment.
- connecting rod parting faces that are unique with an interference fit.
- an engine dynamic balance shaft.
Refer to ENGINE SYSTEM-GENERAL INFORMATION.