Section 03-01C: Engine, 7.5L MFI
1996 F-250, F-350, F-Super Duty Chassis Cab and Motorhome Workshop Manual
SPECIFICATIONS

SPECIFICATIONS

 
General Specifications
Bore and StrokeFiring OrderOil Pressure Hot @ 2000 rpm kPa (psi)Engine Type and Number of Cylinder
4.36 x 3.8515426378276-606 (40-88)O.H.V. V-8



Cylinder Head And Valve Train
Combustion Chamber Volume C.C.bValve Guide Bore DiameterValve Seal Widtha
IntakeExhaustIntakeExhaust
89.5-92.50.3433-0.34430.3433-0.34430.060-0.0800.060-0.080
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 MaximumValve Arrangement Front to RearGasket Surface Flatnessc
0.002RT I-E-I-E-I-E-I-E
LT E-I-E-I-E-I-E-I		0.003 in Any 6 In.
0.006 Overall
c Gasket surface finish — RMS 60-150.


Cylinder Head And Valve Train (Continued)
Rocker Arm Lift Ratio to 1Push Rod Runout TIR MaximumValve Tappet or LifterCollapsed Tappet Gap (Clearance)
Standard DiameterClearance to BoreaHydraulic Lifter Leak-Down RatebAllowableDesired
1.730.0150.8740-0.87450.0007-0.002710 to 50 Seconds for 1/16 Travel0.075-0.1750.100-0.150
a Service limit — 0.005.
b Time required for plunger to leak-down 0.0625 in. 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		Valve Spring Out of Square Maximum
IntakeaExhaustIntakeExhaustIntakeExhaust
76-84 @ 1.81
218-240 @ 1.33		76-84 @ 1.81
218-240 @ 1.33		2.062.061.78-1.841.78-1.845/64 (0.078)
a Service limit — 10% loss of pressure.


CYLINDER HEAD AND VALVE TRAIN (Continued)
Valve Stem to Guide ClearanceaValve Head DiameterbValve Face Runout TIR Maximum
IntakeExhaustIntakeExhaust
0.0010-0.0027 0.0010-0.0027 2.075-2.090 1.646-1.661 0.002
a Service clearance — 0.0055.
b Valve face angle — 44°.


CYLINDER HEAD AND VALVE TRAIN (Continued)
StandardValve Stem Diameter
0.015 Oversize		0.030 Oversize
IntakeExhaustIntakeExhaustIntakeExhaust
0.3415-0.34230.3415-0.34230.3565-0.35730.3565-0.35730.3715-0.37230.3715-0.3723



Camshaft
Lobe LiftaCamshaft End PlayCamshaft Journal to Bearing Clearanceb
IntakeExhaustEnd PlayService Limit
0.2520.2780.001-0.0060.0090.001-0.003
a Maximum allowable lift loss — 0.005.
b Service limit — 0.006.


Camshaft Drive
Camshaft Journal Diameter — Standarda
No. 1No. 2No. 3No. 4No. 5
2.1238-
2.1248		2.1238-
2.1248		2.1238-
2.1248		2.1238-
2.1248		2.1238-
2.1248
a Camshaft journal runout — 0.005 TIR maximum.


Camshaft Bearing Inside Diameter
No. 1No. 2No. 3No. 4No. 5
2.1258-
2.1268		2.1258-
2.1268		2.1258-
2.1268		2.1258-
2.1268		2.1258-
2.1268



Camshaft Drive (Continued)
Camshaft Front Bearing Location bTiming Chain Deflection Inches Maximum
0.040-0.0600.500
b Distance in inches that front edge of the bearing is installed below the front face of the cylinder block.


Cylinder Block
Cylinder Bore DiameteraMain Bearing Bore DiameterDistributor Shaft Bearing Bore DiameterHead Gasket Surface FlatnessHead Gasket Surface FinishTappet Bore Diameter
4.3600-4.36363.1922-3.19340.5160-0.51750.003 in Any 6 In. 0.006 OverallRMS 90-1500.8752-0.8767
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.


Crankshaft And Flywheel
Main Bearing Journal DiameteraMain Bearing Journal Runout TIR MaximumbMain Bearing Thrust Face Runout TIR MaximumMain Bearing Journal Taper Maximum Per InchThrust Bearing Journal LengthMain and Rod Bearing Journal Finish RMS MaximumMain Bearing Thrust Face Finish RMS Maximum
2.9994-3.00020.0020.0010.00051.124-1.1261225 Front — 23 Rear
a Maximum out-of-round — 0.0006.
b Service limit — 0.005.


CRANKSHAFT AND FLYWHEEL (Continued)
Connecting Rod Journal DiameteraConnecting Rod Journal Taper Per Inch MaximumCrankshaft Free End Playb
2.4992-2.50000.00060.004-0.008
a Maximum out-of-round — 0.0006.
b Service limit— 0.012.


CRANKSHAFT AND FLYWHEEL (Continued)
Connecting Rod Bearing to Crankshaft Clearance Selective FitMain Bearing to Crankshaft Clearance Selective Fit
DesiredAllowableBearing Wall Thickness Std.aDesiredAllowableBearing Wall Thickness Std.a
0.0008-0.00150.0008-0.00250.0757-0.0762Main Bearing Cap
2, 3, 4, 5:
0.0009-0.0027
Main Bearing Cap 1:
0.0004-0.0022		Main Bearing Cap
2, 3, 4, 5:
0.0009-0.0027
Main Bearing Cap 1:
0.0004-0.0022		0.0955-0.0960
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.aRod Length Center of CenterConnecting Rod Alignment Maximum Total DifferenceRod to Crankshaft Assembled Side Clearancec
TwistbBendb
1.0386-1.03932.6522-2.65306.6035-6.60650.0240.0120.010-0.020
a Connecting rod bearing bore maximum out-of-round — 0.0004.
c Service limit — 0.023.
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)
LengthDiameterTo Piston Pin Bore ClearanceaTo Connecting Rod Bushing Clearance
Standard.001 Oversize
3.290-3.3101.0398-1.04031.0410-1.04130.0002-0.0005Interference Fit
a Selective Fit.


CONNECTING ROD, PISTON AND RINGS (Continued)
Ring WidthSide ClearanceaRing Gap
CompressionCompressionOilCompression (In Gauge)Oil
TopBottomTopBottomTopBottom
0.0773-0.07830.0773-0.07830.0012-0.00220.0012-0.0022Snug0.010-0.0150.011-0.0210.010-0.030
a Service limit — 0.002 maximum increase in clearance.


Piston
DiameteraPiston to Bore Clearance Selective FitPiston Pin Bore Diameter
Coded RedCoded Blue.003 Oversize
4.3585-4.35954.3595-4.36054.3605-4.36150.0014-0.00221.0401-1.0406
a Measured at the piston pin bore centerline at 90° to the pin.


Ring Groove Width Compression
TopBottomOil
0.0795-0.08050.0795-0.08050.1586-0.1596



PISTON (Continued)
Piston Bore DiameterI.D. Code of Service Piston Required
110.744-110.774mm (4.3600-4.3612 In.)
110.774-110.805mm (4.3612-4.3624 In.)
110.805-110.835mm (4.3624-4.3636 In.)		Red
Blue
Yellow

When replacing pistons, measure cylinder bore. Refer to Section 03-00. Install service piston matched in piston bore diameter above.




Lubrication System
Relief Valve Spring Pressure Lbs. @ Specified LengthDriveshaft to Housing ClearanceRelief Valve to Housing ClearanceRotor Assembly End ClearanceOuter Race to Housing ClearanceInner to Outer Rotor Tip Clearance
20.6-22.6
@ 2.49		0.0015-0.00300.0015-0.00300.004 Maximum0.001-0.0130.012



Engine Oil Capacitya
U.S. Qts.Imperial Qts.Liters
54.24.7
a Add 1 U.S. quart (or equivalent in Imperial quarts or liters) when replacing filter.


Drive Belt Tension
Tensioning MethodBelt TypeNew Belt Tension (0 Min. Operation)Used Belt Tension (Greater Than 5 Min. Operation)Min. Tension After 5 Min. Operation
(A/C and P/S Belt) Automatic6K Poly-V BeltTension OK If Tensioner Within Indicator Marks. 418 N (94 Lb.) Min.Same As NewSame As New
(Alt and Air Pump Belt) Manual6K Poly-V Belt711-889 N
(160-200 Lb.)		489-578 N
(110-130 Lb.)		467 N (105 Lb.)



Torque Specifications
DescriptionNmLb-FtLb-In
Frame Bracket Attaching Bolt Lock Nuts58-7734-57—
Nut, Insulator-to-Support Mounting Bracket (F-250, F-350 and F-Super Duty)109-14980-109—
Insulator-to-Engine Bolts81-10960-80—
Insulator-to-Support Bracket Nuts (F-Super Duty Motorhome Chassis)96-12771-94—
Nut and Washer Assembly, Insulator-to-Support Bracket (F-250, F-350 and F-Super Duty)88-11865-87—
Nut, Support Bracket-to-Frame58-7743-57—
Rocker Arm Seat Bolts25-3418-25—
Cylinder Head Attaching Bolts — in Sequence:
  Step 1		  
95-108		  
70-80		—
  Step 2136-149100-110—
  Step 3176-189130-140—
Muffler Inlet Pipe Stud Nuts34-4925-36—
Water Pump-to-Engine Front Cover Bolts16-2412-18—
Camshaft Sprocket Capscrew54-6840-50—
Engine Front Cover-to-Cylinder Block Attaching Screws16-2412-18—
Engine Front Cover-to-Oil Pan Bolts8-12—71-105
Crankshaft Vibration Damper-to-Crankshaft Attaching Bolt95-12270-90—
Camshaft Thrust Plate-to-Cylinder Block Bolts11-15—90-135
Flywheel-to-Crankshaft Mounting Bolts103-11575-85—
Oil Pump-to-Cylinder Block Attaching Bolts, Nut30-4322-32—
Oil Pump Screen Cover and Tube-to-Oil Pump Bolts16-2412-18—
Oil Pump Screen Cover and Tube-to-Main Bearing Cap Nut30-4322-32—
Oil Lever Indicator Tube Nut13-2410-18—
Engine Rear Plate Bolts54-7540-55—
Engine Lifting Eye Bolts54-7540-55—
Oil Pan-to-Cylinder Block Attaching Bolts
  1/4-20		  
11-16		  
8-12		—
Crankshaft Main Bearing Cap Bolts129-14295-105—
Connecting Rod Bearing Cap Nuts61-6845-50—
Exhaust Manifold Bolts and Studs34-4725-35—
Lock Nut, Spark Plug Heat Shield13-2410-18—
Bolt, 3/8-16 x 2.75, Exhaust52-6538-48—
Crankshaft Pulley Bolts54-7140-53—
Fan Blade-to-Fan Clutch Bolts16-2412-18—
Alternator/Air Pump Bracket-to-Head Bolt (7/16 Inch)54-7140-53—
Fan Clutch-to-Water Pump Pulley16-2412-18—
Generator/Air Pump Bracket-to-Head, Block and Water Pump Bolts (3/8 inch)41-5430-40—
Generator Adjusting Arm Bolts41-5430-40—
EGR Valve-to-Exhaust Manifold Tube34-6525-48—
Generator Pivot Bolt54-7140-53—
Generator Locking Bolt
(Med. and Lg. Frame Alt.)		41-5430-40—
Generator Locking Bolt
(Sm. Frame Alt.)		41-5430-40—
Air Pump Pivot Bolt/Idler Bracket Pivot Bolt41-5430-40—
Air Pump Locking Bolt/Idler Bracket Locking Bolt41-5430-40—
Non Air Pump Idler Torque40-5530-40—
Air Pump Pulley Bolts12-159-11—
AC/PS Bracket-to-Water Pump Stud Nut41-5430-40—
AC/PS Bracket-to-Head Bolts54-7140-53—
PS Pump-to-Bracket Bolts41-5430-40—
Drive Belt Tensioner Bolt68-9250-68—
Exhaust Air Supply Manifold Lube Bolt53-7239-53—
Valve and Bracket Assembly Exhaust Air Supply Bolt19-2514-18—
Exhaust Air Supply Check Valve Lube Bolt19-2514-18—
AC Compressor Bolts24-3118-23—
AC Idler Bolts24-3118-23—
Oil Gallery Plugs, 3/8-1831-3823-28—
Valve Cover Bolts, 1/4-2012-159-11—
PCV Valve Body13-2610-19—
Oil Filter Mounting Insert61-20345-150—
Engine Oil Cooler Bolt54-8840-65—
Engine Oil Cooler Hose Clamp3-4—27-35
Radiator Lower Hose Clamp1.6-2.8—15-25
Oil Pressure Sender11-248-18—
Spark Plug7-145-10—
Upper Intake Manifold-to-Lower Intake Manifold Bolts16-2412-18—
Lower Intake Manifold-to-Cylinder Head Bolts and Nuts — in Sequence:   
  Step 111-168-12—
  Step 216-3012-22—
  Step 330-4722-35—



Torque Limits

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 below are applicable
for all functions not listed in the special torque chart.
1/4-205/16-185/16-243/8-163/8-247/16-147/16-201/2-139/16-18
8-12
(6-9)		16-24
(12-18)		19-27
(14-20)		30-43
(22-32)		37-52
(27-38)		54-75
(40-55)		54-75
(40-55)		75-108
(55-80)		115-163
(85-120)



Pipe Threads
1/8-271/4-183/8-181/2-14
7-11 (5-8)11-16 (8-12)16-24 (12-18)16-24 (12-18)