1996 Bronco/F-Series

Engine Specifications
Bore and Stroke	Firing Order	Oil Pressure Hot @ 2000 rpm kPa (PSI)	Engine Type and Number of Cylinders
4.00 x 3.98	153624	275 (40-60)	O.H.V. I-6

Cylinder Head And Valve Train
Combustion Chamber Volume C.C.^b	Valve Guide Bore Diameter		Valve Seat Width^a
Combustion Chamber Volume C.C.^b	Intake	Exhaust	Intake	Exhaust
65.4-68.4	0.3433-0.3443	0.3433-0.3443	0.060-0.080	0.070-0.090

^b Compression pressure (psi) of the lowest cylinder must be at least 75% of the highest to be within specification.
^a Valve seat angle — 45°.

Cylinder Head And Valve Train (Continued)
Valve Seat Runout TIR Maximum	Valve Arrangement Front to Rear	Gasket Surface Flatness^c	Rocker Arm Fulcrum Thread Diameter Std.^a
0.002	E-I-E-I-E-I- E-I-E-I-E-I	0.006 in any 6 inches 0.010 overall	5/16-18

CYLINDER HEAD AND VALVE TRAIN (Continued)
Rocker Arm Lift Ratio to 1	Push Rod Runout TIR Maximum	Valve Tappet or Lifter			Collapsed Tappet Gap (Clearance)
Rocker Arm Lift Ratio to 1	Push Rod Runout TIR Maximum	Standard Diameter	Clearance to Bore^a	Hydraulic Lifter Leak-down Rate^b	Allowable	Desired
1.61	0.015	0.8740-0.8745	0.0007-0.0027	10 to 50 seconds for 1/16 travel	0.100-0.200	0.125-0.175

^a Service limit —0.005.
^b Time required for plunger to leak down .0625 under load of 50 lbs. using leak-down fluid in tappet.

CYLINDER HEAD AND VALVE TRAIN (Continued)
Valve Spring Compression Pressure Lbs. @ Specified Height		Valve Spring Free Length (Approximate)		Valve Spring Assembled Height^a		Valve Spring Out of Square
Intake^b	Exhaust	Intake	Exhaust	Intake	Exhaust	Valve Spring Out of Square
66-74 @ 1.640 166-184 @ 1.240	66-74 @ 1.470 166-184 @ 1.070	1.96	1.78	1.61-1.67	1.44-1.50	5/64 (.078)

^a Pad to retainer.
^b Service limit — 10% loss of pressure.

CYLINDER HEAD AND VALVE TRAIN (Continued)
Valve Stem to Guide Clearance^a		Valve Head Diameter^b		Valve Face Runout TIR Maximum
Intake	Exhaust	Intake	Exhaust	Valve Face Runout TIR Maximum
0.0010-0.0027	0.0010-0.0027	1.769-1.793	1.548-1.572	0.0020

^a Service clearance — 0.0055 maximum.
^b Valve face angle — 45°.

CYLINDER HEAD AND VALVE TRAIN (Continued)
Valve Stem Diameter
Standard		.015 Oversize		.030 Oversize
Intake	Exhaust	Intake	Exhaust	Intake	Exhaust
0.3415-0.3423	0.3415-0.3423	0.3565-0.3573	0.3565-0.3573	0.3715-0.3723	0.3715-0.3723

Camshaft
Lobe Lift^a		Camshaft End Play		Camshaft Journal to Bearing Clearance^b
Intake	Exhaust	End Play	Service Limit	Camshaft Journal to Bearing Clearance^b
0.249-0.247^c	0.249-0.247^c	0.001-0.007	0.009	0.001-0.003

^a Maximum allowable lift loss — 0.005.
^b Service clearance — 0.006.
^c F-150 4x2 w/2.47:1 or 2.75:1 axle ratio and manual transmission (49S).

Camshaft Drive
Camshaft Journal Diameter — Standard^a
No. 1	No. 2	No. 3	No. 4
2.017- 2.018	2.017- 2.018	2.017- 2.018	2.017- 2.018

Camshaft Bearing Inside Diameter
No. 1	No. 2	No. 3	No. 4
2.019- 2.020	2.019- 2.020	2.019- 2.020	2.019- 2.020

Camshaft Drive (Continued)
Camshaft Front Bearing Location^c	Assembled Gear Face Runout^b
Camshaft Front Bearing Location^c	Crankshaft	Camshaft
0.020-0.035	0.005	0.005

^c Distance in inches that front edge of the bearing is installed below the front face of the cylinder block.
^b Gear backlash — 0.004-0.010.

Cylinder Block
Cylinder Bore Diameter^a	Main Bearing Bore Diameter^b	Distributor Shaft Bearing Bore Diameter	Head Gasket Surface Flatness	Head Gasket Surface Finish	Tappet Bore Diameter
4.0000-4.0048	2.5902-2.5910	0.5155-0.5165	0.003 in any 6 inches 0.006 overall	RMS 60-150	0.8752-0.8767

^a Maximum out-of-round 0.0015, service limit — 0.005, maximum taper service limit — 0.010, cylinder bore surface finish RMS 18-38, bore taper service limit — 0.010.
^b Crankshaft to rear face of block runout. TIR maximum 0.005.

Crankshaft And Flywheel
Main Bearing Journal Diameter^a	Main Bearing Journal Runout TIR Maximum^b	Main Bearing Thrust Face Runout TIR Maximum	Main Bearing Journal Taper Maximum Per Inch	Thrust Bearing Journal Length	Main and Rod Bearing Journal Finish RMS Maximum	Main Bearing Thrust Face Finish RMS Maximum
2.3982-2.3990	0.002	0.001	0.0005	1.1990-1.2010	12	35 Front 25 Rear

^a Maximum out-of-round — 0.0006.
^b Service limit — 0.005.

CRANKSHAFT AND FLYWHEEL (Continued)
Connecting Rod Journal Diameter^a	Connecting Rod Journal Taper Per Inch Maximum	Crankshaft Free End Play^b	Flywheel Clutch Face Runout Assembled	Flywheel Ring Gear Lateral Runout TIR		Flywheel Clutch Face Runout
Connecting Rod Journal Diameter^a	Connecting Rod Journal Taper Per Inch Maximum	Crankshaft Free End Play^b	Flywheel Clutch Face Runout Assembled	Std. Trans.	Auto. Trans.	Flywheel Clutch Face Runout
2.1228-2.1236	0.0006	0.004-0.008	0.010	0.040	0.060	0.010

^a Maximum out-of-round — 0.0006.
^b Service limit — 0.012.

CRANKSHAFT AND FLYWHEEL (Continued)
Connecting Rod Bearing to Crankshaft Clearance Selective Fit			Main Bearing to Crankshaft Clearance Selective Fit
Desired	Allowable	Bearing Wall Thickness Std.^a	Desired	Allowable	Bearing Wall Thickness Std.^a
0.0008-0.0015	0.0009-0.0027	0.0752-0.0757	0.008-0.0015	0.0009-0.0028	0.0951-0.0956

^a For 0.002 undersize add 0.001 to standard wall thickness.

Connecting Rod, Piston And Rings
Piston Pin Bore or Bushing I.D.	Rod Bearing Bore I.D.^a	Rod Length Center to Center	Connecting Rod Alignment Maximum Total Difference		Rod to Crankshaft Assembled Side Clearance^c
Piston Pin Bore or Bushing I.D.	Rod Bearing Bore I.D.^a	Rod Length Center to Center	Twist^b	Bend^b	Rod to Crankshaft Assembled Side Clearance^c
0.9734-0.9742	2.2750-2.2758	6.2082-6.2112	0.024	0.012	0.006-0.013

^a Connecting rod bearing bore maximum out-of-ground — 0.006.
^c Service limit — 0.018.
^b Pin bushing and crankshaft bore must be parallel and in same vertical plane within specified total difference when measured at the ends of an 8-inch long bar, 4 inches on each side of rod centerline.

CONNECTING ROD, PISTON AND RINGS (Continued)
Length	Diameter			To Piston Pin Bore Clearance^a	To Connecting Rod Bushing Clearance
Length	Standard	.001 Oversize	.002 Oversize	To Piston Pin Bore Clearance^a	To Connecting Rod Bushing Clearance
3.150-3.170	0.9749-0.9754	0.9760-0.9763	0.9770-0.9773	0.0003-0.0005^b	Interference Fit

CONNECTING ROD, PISTON AND RINGS (Continued)
Ring Width Compression		Side Clearance Compression^a			Ring Gap Compression
Top	Bottom	Top	Bottom	Oil	Top	Bottom	Oil^b
0.0774-0.0781	0.0770-0.0780	0.0019-0.0036	0.002-0.004	Snug	0.010-0.020	0.010-0.020	0.010-0.035

^a Service limit — 0.002 maximum increase in clearance.
^b Steel rail.

Piston
Diameter^a			Piston to Bore Clearance^b	Piston Pin Bore Diameter
Coded Red	Coded Blue	.003 Oversize	Selective Fit	Piston Pin Bore Diameter
3.9982-3.9988	3.9994-4.0000	4.0008-4.0014	0.0010-0.0018	0.9754-0.9757

^a Measured at the piston pin bore centerline at 90° to the pin.
^b Rebuild specification only.

Piston
Ring Groove Width Compression
Top	Bottom	Oil
0.080-0.081	0.080-0.081	0.188-0.189

Lubrication System
Relief Valve Spring Pressure Lbs. @ Specified Length	Driveshaft to Housing Clearance	Relief Valve to Housing Clearance	Rotor Assembly End Clearance	Outer Race to Housing Clearance	Inner to Outer Rotor Tip Clearance^b
20.6-22.6 @ 2.49	0.0015-0.0030	0.0015-0.0030	0.004 Maximum	0.001-0.013	0.012 Maximum

^b With feeler gauge inserted 1/2 inch minimum and rotor removed from pump housing.

Engine Oil Capacity^a
U.S Quarts	Imperial Quarts	Liters
5	4.2	4.7

^a Add 1 U.S. quart (or equivalent in imperial quarts or liters) when replacing filter.

Torque Limits — 4.9L (300 CID) I-6 Engine
1/4-20	5/16-18	5/16-24	3/8-16	3/8-24	7/16-14	7/16-20	1/2-13	9/16-18
8-12 (6-9)	17-24 (12-18)	19-27 (14-20)	30-43 (22-32)	37-51 (27-38)	55-75 (40-55)	55-81 (40-60)	75-109 (55-80)	116-162 (85-120)

Note: All values are in Nm (lb-ft) unless otherwise noted. Oil threads with engine oil unless the threads require oil or water-resistant sealer. The standard torque limits listed are applicable for all functions not listed in the special torque chart.

Pipe Threads
1/8-27	1/4-18	3/8-18	1/2-14
7-11 (5-8)	17-24 (12-18)	30-44 (22-33)	34-47 (25-35)

Torque Specifications
Description	Nm	Lb-Ft	Lb-In
Connecting Rod Nut	55-61	40-45	—
Cylinder Front Cover	16-24	12-18	—
Cylinder Head Bolts	^a	^a	—
Damper to Crankshaft	177-203	130-150	—
EGR Valve to Intake Manifold	18-26	13-19	—
EGR Transducer	16-24	12-18	—
Flywheel to Crankshaft	102-115	75-85	—
Flywheel Attaching Bolts 1st Stage	12-15	9-11	—
2nd Stage	68-74	50-55	—
Main Bearing Cap Bolts	82-94	60-69	—
Manifold to Cylinder Head — Intake^a	30-43	22-32	—
Manifold to Cylinder Head — Exhaust^a	30-43	22-32	—
Upper Intake Manifold to Lower Intake Manifold	16-24	12-18	—
Exhaust Manifold-to-Muffler Inlet Pipe	34-49	25-36	—
Oil Filter Insert to Cylinder Block	20-48	15-35	—
Oil Filter to Cylinder Block	1/2 turn after gasket contacts sealing surface — oiled gasket
Oil Inlet Tube to Pump	14-20	10-15	—
Oil Pan Drain Plug	21-33	15-25	—
Wiring Harness Bracket Nut	8-13	6-10	—
Oil Pan to Cylinder Block^a	20-23	15-17	—
Oil Pump to Cylinder Block	16-24	12-18	—
Oil Inlet Tube to Main Bearing Cap	30-43	22-32	—
Oil Level Indicator Tube Retaining Nut	20-24	15-17	—
Oil Pressure Sensor	11-24	8-18	—
Pulley to Damper Bolt	48-67	35-50	—
Rocker Arm Bolt	24-31	17-23	—
Spark Plug to Cylinder Head	14-20	10-15	—
Valve Rocker Arm Cover	8-14	—	70-120
Valve Push Rod — Cover to Cylinder Block	1.7-2.8	—	15-25
Water Outlet Housing	16-24	12-18	—
Water Pump to Block/Front Cover	16-24	12-18	—
Thermactor Pump Pulley to Pump Hub	9-12	7-9	—
Throttle Body Attaching Nuts	19-27	14-20	—
Camshaft Thrust Plate to Cylinder Block	16-24	12-18	—
Distributor Clampdown	24-33	17-25	—
Intake Manifold Vacuum Fittings	8-13	6-10	—
Timing Pointer to Front Cover	16-24	12-18	—
Thermactor Air Manifold to Cylinder Head (Nut and Ferrule Assembly)	19-22	14-16	—
Thermactor Air Check Valve to Thermactor Air Manifold	22-26	16-19	—
Water Pump Pulley Screw	17-23	13-17	—
Power Steering Pump Brace	24-31	18-23	—
Pressure Plate and Cover Assembly to Flywheel	27-39	20-29	—
Secondary Air Injection Pump	30-40	41-54	—
Generator/Thermactor Pump Bracket to Engine (All Except Bottom Bolt)	30-40	22-30	—
Generator/Thermactor Pump Bracket to Engine (Bottom Bolt)	53-72	40-53	—
EGR Tube Assembly (Both Ends)	34-47	25-35	—
Delta PFE Transducer	16-24	12-18	—
Generator Pivot Bolt	22-28	16-21	—
Thermactor Pump Pivot Bolt	28-42	21-31	—
Generator Adjusting Bolt	22-28	16-21	—
Thermactor Pump Attaching Bolt	30-40	22-30	—
Air Conditioning Compressor to Mounting Bracket — Short Bolt	30-40	22-30	—
Air Conditioning Compressor to Mounting Bracket — Long Bolt	28-42	21-31	—
Power Steering Pump to Mounting Bracket Bolts	40-55	30-40	—
Power Steering Pump/Air Conditioning Compressor Bracket to Cylinder Head Bolts	40-55	30-40	—
Power Steering Pump/Air Conditioning Compressor Bracket to Block Bolts and Nuts	55-70	40-50	—
Fan Blade to Fan Clutch Bolts	16-24	12-18	—
Fan Clutch to Water Pump	41-135	30-100	—
Water Pump Pulley Bolt	17-23	13-17	—
Thermactor Pulley Bolt	9-12	22-30	—

SPECIFICATIONS