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1,256 Posts
Discussion Starter · #1 ·
Remember to measure actuals and not use book specs in building an engine !!!!! These are references only.

Piston, Engine
Piston
Piston diameter
Coated grade 1 88.990-89.010 mm (3.5035-3.5043 inch)
Coated grade 2 88.998-89.022 mm (3.5039-3.5048 inch)
Coated grade 3 89.010-89.030 mm (3.5043-3.5051 inch)
Uncoated grade 1 88.970-88.980 mm (3.50275-3.50314 inch)
Uncoated grade 2 88.978-88.992 mm (3.50306-3.50362 inch)
Uncoated grade 3 89.010-89.030 mm (3.50432-3.50511 inch)

Piston-to-bore clearance
0.012 to 0.022 mm (0.0005-0.0009 inch)

Pin bore diameter (piston)
21.008-21.012 mm (0.8270-0.8272 inch)

Piston Ring, Engine
Ring groove width
Compression (top) 1.230-1.245 mm (0.0484-0.0490 inch)
Compression (bottom)1.530-1.545 mm (0.0602-0.0608 inch)
Oil ring 3.030-3.055 mm (0.1192-0.1203 inch)

Piston pin
Length 60.51-60.08 mm (2.382-2.365 inch)
Diameter 21.011-21.013 mm (0.0013 inch)

Pin-to-piston clearance
-0.005 to +0.001 mm (0.0001-0.00003 inch)

Pin-to-rod clearance
Standard 0.004-0.020 mm (0.0001-0.0007 inch)
Service limit 0.035 mm (0.0013 inch)

Piston Ring-To-Groove Clearance
Compression (top) 0.040-0.075 mm (0.0015-0.0029 inch)
Compression (bottom) 0.040-0.085 mm (0.0015-0.0033 inch)
Oil ring Snug Fit

Piston ring gap g
Compression (top)-gauge diameter 0.100-0.250 mm (0.0039-0.0098 inch)
Compression (bottom)-gauge diameter 0.27-0.42 mm (0.0106-0.0165 inch)
Oil ring (steel rail)-gauge diameter 0.15-0.65 mm (0.0059-0.0255 inch)
Compression (top)-service limit 0.50 mm (0.0196 inch) max.
Compression (bottom)-service limit 0.65 mm (0.0255 inch) max.
Oil ring (steel rail)-service 1imit 0.90 mm (0.0354 inch) max.
g Specification 82.4 mm (3.2441 inch) diameter gauge.

Piston Pin, Engine
Piston pin bore diameter
21.017-21.031 mm (0.827-0.828 inch)

Crankshaft bearing bore diameter
53.015-53.035 mm (2.0872-2.0879 inch)

Length (center to center) 138.06-138.14 mm (5.435-5.438 inch)
Alignment (bore to bore max. difference) e
Twist 0.050 mm per 25 (0.0019 per 0.984 inch)
Bend 0.038 mm per 25 (0.0014 per 0.984 inch)

Side clearance (assembled to crank)
Standard 0.100-0.30 mm (0.0039-0.0118 inch)
Service limit 0.35 mm (0.0013inch) max.
e Pin bore and crank bearing bore must be parallel and in same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 101.5 mm on each side of rod centerline.

Crankshaft, Engine
Crankshaft
Main bearing journal diameter 62.968-62.992 mm (2.479-2.480 inch)

Connecting rod journal diameter
49.970-49.990 mm (1.967-1.968 inch)

Crankshaft free end play
0.110-0.232 mm (0.004-0.009 inch)

Crankshaft runout to rear face of cylinder block
0.050 mm (inch) max. (0.001 inch)

Lower cylinder block bolts and studs
Stage 1: Tighten fasteners 1-8 to 25 Nm (18 ft. lbs.).
Stage 2: Tighten fasteners 9-16 to 40 Nm (30 ft. lbs.).
Stage 3: Tighten fasteners 1-16 90 degrees.
Stage 4: Tighten fasteners 17-22 to 25 Nm (18 ft. lbs.).

Main bearings
Clearance to crankshaft-desired
0.025-0.045 mm (0.0009-0.0017 inch)

Clearance to crankshaft-allowable
0.025-0.050 mm (0.0009-0.0019 inch)

Bearing wall thickness-grade 1 2.497 mm (0.0983 inch)

Bearing wall thickness-grade 2 2.501 mm (0.0985 inch)

Bearing wall thickness-grade 3 2.505 mm (0.0986 inch

Connecting Rod Bearing

Connecting rod bearings
Clearance to crankshaft
0.028-0.066 mm (0.001-0.0025 inch)

Bearing wall thickness (std.) d 1.503 mm (0.059 inch)
Connecting Rod

Piston pin bore diameter
21.017-21.031 mm (0.827-0.828 inch)

Crankshaft bearing bore diameter
53.015-53.035 mm (2.0872-2.0879 inch)

Length (center to center) 138.06-138.14 mm (5.435-5.438 inch)
Alignment (bore to bore max. difference) e
Twist 0.050 mm per 25 (0.0019 per 0.984 inch)
Bend 0.038 mm per 25 (0.0014 per 0.984 inch)

Side clearance (assembled to crank)
Standard 0.100-0.30 mm (0.0039-0.0118 inch)
Service limit 0.35 mm (0.0013inch) max.

Connecting rod cap bolts
Stage 1: Tighten to 23 Nm (17 ft. lbs.).
Stage 2: Tighten to 43 Nm (32 ft. lbs.).
e Pin bore and crank bearing bore must be parallel and in same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 101.5 mm on each side of rod centerline.
d 0.250 mm Undersize-Add 0.125 mm to standard or grade 2 thickness.
 

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Premium Member
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1,256 Posts
Discussion Starter · #2 ·
Older listing of build tooling, replacement and performance parts used in the 3L duratec. SOme of these oare related to the Contour re-engine project from 2.5L to the 3L also availalbe in the Escapes. Prices are several years old.

It should be noted that in 2008 Ford pulled replacement pistons and rods from the market and only support short block assemblies to repair lower ends repairs. If you wish to do your own work you must get pistons custom made. Diamond Racing pistons is one option and have made 2.5 and 3L duratec pistons before.

These are references only and a current IPC should be consulted if you are building an engine.

Engine:
3.0L short block, NEW. Build date is from 04/01/03 and is the same part# for Sable, Taurus, Escape.

4F1Z-6009-BA List $1800 plus

Seals and gaskets:
- Fel-Pro Part# 61006 SE TB gasket, $1.59
- Fel-Pro Part# 61006 SVT TB Gasket
- Fel-Pro Part# 70149 EGR gasket
- Fel-Pro Part# 9038PT 2.5L Left Hand Head Gasket
- Fel-Pro Part# 9039PT 2.5L Right Hand Head Gasket
- Fel-Pro Part# 9540PT 3L Left Hand Head Gasket
- Fel-Pro Part# 9541PT 3L Right Hand Head Gasket
- Fel-Pro Part# CS9038 2.5L lower conversion Kit (includes oil pan gasket, oil seals etc.), $72
- Fel-Pro Part# ES72159 Head bolt set, 2.5L 2 req., $16.92ea
- Fel-Pro Part# HS9038PT Head gasket set, conversional $231.15
- Fel-Pro Part# MS92586 3L Plastic Oval Port Intake Manifold Set
- Fel-Pro Part# MS95715 Exhaust Manifold Gasket (53mm x 32mm)
- Fel-Pro Part# MS95726 Intake manifold gasket set, $30.15
- Fel-Pro Part# OS30675R Oil pan set , $35.27
- Fel-Pro Part# SS72873-1 Valve Stem Seals (Viton)
- Fel-Pro Part# TCS45966 Camshaft rear seal gasket set, $6.95
- Fel-Pro Part# TCS45967 Crankshaft front seal, $14.55
(Includes 2.5L head gaskets that are not needed.)
- Fel-Pro Part# VS50462 Valve cover set, $32.59

- BCA part# 3909 Crankshaft oil seal, $13.32
- BCA part# 5277 Crankshaft oil seal (teflon), $16.76
- BCA part# 99363 Crankshaft oil seal (redi-sleeve), $33.50
- BCA part# 88187 Harmonic balancer sleeve, $4.18
- BCA part# 482041N Oil seal, front timing cover, $7.67
- BCA part# 99187 Oil seal, front timing cover (redi-sleeve), $22.58
- Spectra Premium #1719 non-SVT radiator, $138.41

Clevite 77 bearings:
- CB-1772P Rod bearing, available in standard, -.25MM, -.50MM, and -.75MM.
- MS-2207 Mains (not yet available)

Federal Mogul:
- 7262M- Standard Grade Main bearings (also available in non standard grade)
- 6-4395A- standard grade rod bearings (also available in non standard grade)

Ford part numbers:
- 2S7Z-6513-AA ST220 Valve Springs (measured 161-163 lb/in)
- 3F1Z-6564-AA New Roller Finger Followers
- 3M4Z-6675-BA Upgraded Oil Pan Set
(2 drain back channels and better lower baffles - comes with gasket and hardware)
- 4F1Z-6065-AA Head Bolts
- F3LY-6214-A Connecting Rod Bolts, need 12
- F5AZ-6700-A 3.0 Front Crankshaft Seal
- F5AZ-6701-A 3.0 Rear Crankshaft Seal
- F5DZ-9E936-AE SVT TB Gasket
- F5RZ-2A411-A 2.5L UIM Plastic Retainer Grommet with Brass Insert Sleeve
- F5RZ-2L181-AA 2.5L UIM Plastic Retainer Grommet
- F5RZ-6020-A 2.5 Right Front Timing Cover Gasket
- F5RZ-6020-B 2.5 Center Front Timing Cover Gasket
- F5RZ-6020-C 2.5 Left Front Timing Cover Gasket
- F5RZ-6345-C Lower cylinder block retaining bolts, need 4
- F5RZ-6345-D need 8
- F5RZ-6345-E need 5
- F5RZ-6584-B 2.5 Right Valve Cover Gasket
- F5RZ-6584-C 2.5 Left Valve Cover Gasket
- F5RZ-9439-B 2.5 Lower Intake Manifold Gasket
- F5RZ-9H486-BA 2.5 Upper Intake Manifold Gasket
- F5RZ-17285-AA MTX-75 Speedo Gear
- F6DZ-6345-CA need 5
- F6DZ6505A Valve-exhaust
- F6DZ6507A Valve-intake
- F6RZ-9K313-BC Fuel vapor hose
- F7RZ-4211-AC Differential Bearings (2 req)
- W701-512-S301 TTY Crank Pulley Bolt
- XF1Z-6051-BA 3.0 Right Head Gasket
- XF1Z-6051-DA 3.0 Left Head Gasket
- XS4Z-7201-CD Upgraded Shifter Tower (03+)
- XS8Z-7230-DD 1-2 Shifter Fork, Roller Bearings (02+)
- XW4Z-9448-AA Duratec Exhaust Manifold Gasket (50mm x 26mm)
- YF1Z-6148-BA Piston rings, $30.03 (does 2 pistons)
- YF1Z-6513-FA Duratec Valve Springs (rated 153 lb/in per manual)
- YL8Z-6622-BA 01+ Upgraded Oil Pickup (req 01+ main studs)
- YL8Z-6687-AA 01+ Upgraded Windage Tray (req 01+ main studs)
- YS2Z-7230-BA 5-R Shifter Fork, Revised (00)
- YS4Z-7230-AD 3-4 Shifter Fork, Modified Oil Scraper (01+)
- YS4Z-7K453-FA Shifter Retaining Clip

Motor mount/Powersteering bracket parts
(needed for mid '98 and previous years to fit to the 3L block):
1S7Z3A732AA Bracket, $32.72
W704693S309 Long Bolts, $5.22 each
W704694S309 Short Bolts, $3.53 each

ARP bolts:
- 253-4701 ARP Head Studs
- 253-5402 ARP Main stud kit

K&N Filters:
K&N Filters
Tapered Conical - DB x DT x L
RF-1045 (5.5 x 4 x 8) = 720cfm
RC-4630 (5.5 x 4.5 x 6.5) = 615cfm
RE-0950 (6 x 4.625 x 6) = 605cfm
RE-0920 (6 x 4.625 x 9) = 900cfm
RU-3530 (5.375 x 4.375 x 7) = 645cfm (3.75" flange)
Straight Conical - D x L
RU-1785 (5 x 8.5) = 800cfm

Miscellaneous parts:
- Stant Part# 13396 160 Degree T-Stat
- Bosch# 13246 L1H1 Wideband O2 Sensor

Tools:
Rotunda Tool Set - Essential
T94P-6136-AH Connecting Rod Guides
T94P-6256-AH Camshaft Seal Protector
T94P-6256-BH Camshaft Seal Replacer
T94P-6256-DH Camshaft Damper Replacer
T94P-6312-AH Water Pump Pulley Remover/Replacer
T94P-6312-BH Water Inlet Tube Replacer
T94P-6510-BH Valve Guide Replacer Adapter
T94P-6510-CH Valve Stem Seal Replacer
T94P-6256-CH Camshaft Alignment Triming Tool
T94P-6510-AH Valve Stem Seal Remover
T94P-6510-DH Valve Guide Replacer Adapter
T94P-6565-AH Valve Spring Compressor Adapter
T94P-4451-AH Measuring Fixture
T94P-4451-BH Differential Shim Selection Tool Adapter
T94P-7025-BH Multi-Bearing Cup Replacer
T94P-7025-CH Differential Drive Shaft Seal Replacer
T94P-7025-DH Selector Shaft Bearing Remover/Replacer
T94P-7025-EH Pinion Spline Socket
T94P-7025-FH Gear Lever Aligning Tool
T94P-7025-GH Differential Bearing Cone Replacer
T94P-7025-HH Selector Shaft Seal Remover/Replacer
T94P-2100-AH Sub Frame Alignment Pin Set
T94P-6000-AH Power Train Alignment Gauge Set
T94P-70010-AH Transmission Range Sensor Tool
 
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