PDF associated:
/Inside_Sealing_Ford_4.6L_5.4L_V8.pdf
Inside Sealing Ford 4 6L 5 4L Who For shop owners and technicians What Tips for engine sealing repairs and upgrades Where Visit www felpro only com for more information Why Leverage the expertise of Federal Mogul s Fel Pro engineering team to grow your engine sealing business Highlights Identifying head and block combinations Head sealing recommendations Eliminating intake manifold sealing concerns Avoiding spark plug complications Known by many names and offered in an uncommon and often confusing number of variations the Ford 4 6L 5 4L engine platform was the first to bring the performance and efficiency benefits of overhead cam V8 and V10 configurations to the mass market And give Ford s engineers credit for they accomplished in a mass production design what only the likes of Mercedes Lexus and BMW had previously achieved on a much smaller scale Introduced as a 4 6L two valve SOHC design for the 1991 Lincoln Town Car Ford s Modular engine more on the name later remains the company s automotive workhorse powering virtually all rear wheel drive passenger cars as well as pickups vans work trucks taxis police cruisers and more The 4 6L took the place of Ford s venerable 302 ci engine while the 5 4L Modular replaced the 351W Windsor engine The engines were initially produced in Romeo Mich but production later expanded to Windsor Ont What to call these popular and very reliable engines Versions used in Ford trucks have been marketed under the Triton name while DOHC versions used in Lincoln models for many years carried the InTech badge The name Modular is a misnomer by the way Many automotive professionals assume the name refers to Ford s original plans to interchange parts across multiple engine designs with the engine Common Leaks The most commonly encountered sealing needs on Ford 4 6L and 5 4L engines are 1 head gasket leaks resealing after internal engine repairs 2 intake manifold leaks 3 valve cover leaks and 4 oil pan leaks Fel Pro Solutions 1 PermaTorqueMLS multi layer steel head gaskets 2 PermaDryPlus intake manifold gaskets 3 PermaDry valve cover gaskets 4 PermaDry oil pan gaskets Exploring Opportunity in Ford s Modular Workhorse Ford 4 6L 5 4L Engine Models Engines in Service 4 6L Car Truck 1995 2004 4 6 million 5 4L Car Truck 1997 2008 3 6 million FPO EOM 156 www felpro only com 1 Continued on page 3 Ford 4 6L 5 4L OHC Engines By John Gurnig Field Test Technician Perhaps due to the misconcep tion that Modular means less complexity engine rebuilders are often amazed by the many varia tions and resulting com plications represented within the Ford 4 6L 5 4L platform One common cause of confusion is the fact that the SOHC en gines making up by far the largest percentage of units built are available in multiple block designs An other factor is Ford s use of two production facilities each with its own block variations Three different Romeo blocks emerged between 1991 and 1996 while two versions of the Windsor block were introduced between 1996 and 1999 At least five head designs have been used including Power Improved versions with square intake ports larger valves and heart shaped chambers These PI as opposed to NPI or Non Power Improved heads are available across multiple applications but with seemingly little rhyme or reason perhaps deter mined by the marketing folks As a result anyone consulting an engine parts or gasket catalog for these engines will face many op tions depending on which block and heads they have Bottom line Be abso lutely certain what s on the engine stand by checking the VIN code and casting numbers There s simply no other way to guarantee what Ford or someone else put into the chassis And while this guessing game can come back to bite you in the gaskets seals area it s even worse when you start ordering internal engine parts Here are a few pointers to help you comb through the vast matrix of head con figurations Romeo NPI heads feature oval ports with an F5AE cast ing number PI heads feature square ports with 1L2E and 2L2E casting numbers Note that PI heads have small er combustion chambers than NPI heads Windsor NPI heads feature oval ports with F65EBB and F75E casting numbers PI heads also have square ports as well as XL3E and 2L1E cast ing numbers PI heads have smaller combus tion chambers than NPI heads Head Sealing Go Blue When it comes to head sealing there s only one appropriate choice for 4 6L and 5 4L engines multi layer steel MLS is the OE technology and with the exception of a few re ported issues related to the high pressure oil running through the heads has been extremely reliable When these engines enter the aftermarket repair cycle however the choice of MLS gasket deserves special attention The best choice for trouble free sealing in the aftermarket repair environment is the Fel Pro PermaTorqueMLS gasket which features multiple layers of full hard stainless steel to accom modate casting motion an exclusive extra strong stopper layer for a supe rior primary combustion seal precision engineered embossed sealing beads to seal leak paths at all critical areas and an ad vanced new non stick blue rubber coating that seals minor surface imperfec tions and can be used with finishes of up to 75 Ra One last note These engines are equipped with torque to yield head bolts so you ll need to throw away the old ones and order a fresh Fel Pro set from your supplier John Gurnig runs the Fel Pro Field Test Garage in Skokie Ill Mastering the Model Matrix John Gurnig Note the design differences between a PI head left and an NPI head right 2 Intake Manifold The complex assortment of head and block variations carries through to the selection of the correct replacement intake manifold gaskets Intake manifold design has changed almost every year over the life of the 4 6L 5 4L platform so it obviously is very important to be conscious of the ap plication you re working on In addition while these engines have proved to be very reliable throughout the years the intake manifold has been a rare exception Between 1996 and 2001 the two valve SOHC en gines featured a problem atic nylon composite intake manifold that experienced many failures at the front coolant crossover A re vised OE design featuring an aluminum front coolant crossover was introduced in 2001 Fel Pro offers its innova tive PermaDryPlus intake manifold gaskets for sev eral of these applications These gaskets feature a strong aluminized steel carrier rather than O E style plastic designs and advanced FKM fluoroelas tomer coating that stand up to engine vibration and are impervious to engine fluids and thermal stress Each PermaDryPlus intake manifold gasket also features integral compres sion limiters to eliminate potential damage related to overtorquing Valve Cover Engine profes sionals are best served by selecting an OE style molded rubber valve cover gasket These engines have not been problematic from a valve cover sealing standpoint though Fel Pro engineers have heard some reports of valve cover seepage ruin ing the spark plug boots Remember though that suppliers molded rub ber compounds can vary dramatically By relying on a leading product line such as Fel Pro PermaDry gaskets you re getting the best rubber composition for the real world operating conditions of each engine application Oil Pan Fel Pro offers advanced composition PermaDry oil pan gas kets for all Ford 4 6L 5 4L engine applications PermaDry gaskets feature exclusive material chem istries that stand up to the extreme thermal cycles vibration and other chal lenges associated with oil pan sealing Each gasket features precisely aligned sealing beads that help eliminate leak paths in all critical areas including hard to seal corners Spark Plugs That s right spark plugs The Fel Pro product team offers a tip of the hat to Federal Mogul s Champion spark plug engineers who have developed and introduced a much needed problem solving plug design for millions of Ford 4 6L 5 4L and 6 8L engines The innovative Champion Double Platinum Power spark plug p n 7989 utilizes a one piece high thread design that replac es two piece OE and or aftermarket plugs utilized in these engines When servicing the engines professionals and do it yourselfers often find that plugs can separate during removal potentially leaving the base trapped within the engine s cylinder head and adding an hour or more per plug to the repair The Champion one piece de sign solves this problem Sealing Upgrades Repair Tips from Fel Pro 3 Figure 2 Fel Pro PermaDry valve cover gasket Figure 1 Fel Pro PermaDryPlus intake manifold gasket family to eventually include four six eight 10 and 12 cylinder versions According to Ford however Modular refers to the plant equipment and processes used in production of the millions of 4 6 5 4L engines that have hit the streets over the past 18 plus years The 4 6L 5 4L platform now includes SOHC and DOHC versions used in a broad range of passenger car light truck and SUV applications while the 6 8L V10 has been offered in two and three valve SOHC designs for E Series vans F Series Super Duty trucks and the Excursion SUV It s safe to say most automotive professionals have encountered these engines in everything from taxis emergency vehicles and RVs to Crown Victorias driven back and forth from church on Sunday Exploring Opportunity in Ford s Modular Workhorse Continued from page 1 4 Only Fel Pro offers 100 application specific sealing solution components for Ford 4 6L and 5 4L engines Each Fel Pro gasket and seal for these applications features the best material and design for the aftermarket performance environment Ford 4 6L 5 4L Parts Check Exhaust System Exhaust Manifold Gasket Sets Exhaust Pipe Gaskets Leak Repair EGR Gaskets Intake Manifold Gasket Sets Oil Filter Adapter Gaskets Oil Pan Gasket Sets Plenum Gasket Sets Rear Main Seal Sets Timing Cover Sets Valve Cover Gasket Sets Cooling System Thermostat Housing Gaskets Water Outlet Gaskets Water Pump Gaskets Engine Repair Conversion Gasket Sets Head Bolt Sets Head Sets Head Gaskets Repair Sleeve Tool Repair Sleeves Valve Stem Seal Sets Fuel System EGR Gaskets Fuel Injector O Ring Sets Plenum Gasket Sets Idle Air Control Gaskets Throttle Body Gaskets Repair Type Repair Type Premium materials available Make sure you get every Fel Pro Inside Sealing e mail newsletter Sign up for FREE monthly e mail alerts at www felpro only com The Best Book Is Back More than 400 new engine applications Accurate specs for each cylinder head verified by Federal Mogul engineers Individual data listings and diagrams for every covered engine Head bolt requirements and part numbers included www felpro only com Federal Mogul s popular Fel Pro Torque Tables cylinder head specifications guide is now available Download this invaluable reference tool today at
