Fulltext TSBs

Technical Service Bulletins

TSB
96-8-6
  • ENGINE – 4.6L – DIFFERENCES BETWEEN ROMEO AND WINDSOR BUILT ENGINES – SERVICE TIP
Publication Date: APRIL 8, 1996

FORD:
1996 CROWN VICTORIA
LINCOLN-MERCURY:
1996 GRAND MARQUIS
LIGHT TRUCK:
1997 F-150

This TSB article is being republished in its entirety to include F-150 vehicles and revise the Engine Identification text.

ISSUE:

The Windsor Engine Plant, along with the Romeo Engine Plant, is producing a 4.6L 2V engine for some vehicles. There are several differences between the Windsor 4.6L 2V engine and the Romeo 4.6L 2V engine and many parts are not interchangeable.

ACTION:

When servicing a 4.6L engine, it is important that the engine is properly identified as being either a Windsor 4.6L 2V engine or a Romeo 4.6L 2V engine. Failure to use the correct service procedures or service parts may result in improper repairs. Refer to following Service Publications for engine procedures and specifications, and the Engine Identification which lists four ways to identify the engines.

SERVICE PUBLICATIONS

The 1996 Town Car, Crown Victoria/Grand Marquis Service Manual contains the service procedures and specifications for the Romeo built 4.6L 2V engine. The 1997 Town Car, Crown Victoria/Grand Marquis Service Manual will contain the service procedures and specifications for the Windsor built 4.6L 2V engine, as well as the Romeo 4.6L 2V engine. The 1997 Light Truck Service Manual will contain much of the service procedures and specifications for the Windsor built 4.6L 2V engine.

ENGINE IDENTIFICATION

ENGINE BUILD CODE LABEL

The engine build code label on the RH cam cover, as follows:

PASSENGER CAR

  • 6G 804 AA or AB – Romeo 4.6L 2V engine
  • 6G 808 AA or AB – Romeo 4.6L 2V engine with oil cooler
  • 6G 866 AA or AB – Romeo 4.6L 2V engine Natural Gas Vehicle (NGV)
  • 6G 926 AA – Windsor 4.6L 2V engine

LIGHT TRUCK

  • 6G 840 AA – Romeo 4.6L 2V engine
  • 6G 870 AA – Windsor 4.6L 2V engine
  • 6G 871 AA – Windsor 4.6L 2V engine

VIN NUMBER

The engine code in the 8th position of the VIN, as follows:

  • W for the Romeo 4.6L 2V engine
  • 6 for the Windsor 4.6L 2V engine
  • 9 for the Romeo 4.6L 2V NGV engine

EXTERNAL DIFFERENCES

Cam cover fasteners (bolts)

  • The RH cam cover on the Romeo 4.6L 2V engine has eleven (11) bolts (Figure 1)


    Figure 1 – Article 96-8-6

  • The RH cam cover on the Windsor 4.6L 2V engine has fourteen (14) bolts (Figure 2)


    Figure 2 – Article 96-8-6

Also, there is the letter “W” embossed on each Windsor engine cam cover, in the area of the camshaft sprockets.

INTERNAL DIFFERENCES

  • Main Bearings – the Windsor built 4.6L has larger main bearing caps than the Romeo built 4.6L. Also, the Windsor built engine uses dowels between the main bearing caps and the block (Figure 3). The Romeo built 4.6L uses jack screws between the main bearing caps and the block (Figure 4).


    Figure 3 – Article 96-8-6




    Figure 4 – Article 96-8-6

  • Connecting Rods – the Windsor built 4.6L engine uses a larger connecting rod and has a full floating piston pin with two (2) retainers (Figure 5). The Romeo built 4.6L engine uses a press fit piston pin without retainers (Figure 6).


    Figure 5 – Article 96-8-6




    Figure 6 – Article 96-8-6

  • Camshaft Sprockets – the Windsor built 4.6L engine uses an interference fit between the camshaft sprocket and camshaft to secure the camshaft sprocket, and has individual camshaft bearing caps. The Romeo built 4.6L engine uses a bolt and spacer to secure the camshaft sprocket.
  • Head Casting – the Romeo built 4.6L engine has an oil feed reservoir and utilizes a ladder style cam cap. The Windsor built 4.6L engine has no oil feed reservoir in the head and uses single cam caps. Refer to the 1997 F-150 Service Manual, Volume 1, Pages 303-01B-5 and 6.

NOTE:THE WINDSOR BUILT 4.6L ENGINE WILL BE PART OF THE FORD ENGINE EXCHANGE PROGRAM. DEALERS WILL BE NOTIFIED REGARDING THE DETAILS OF THE PROGRAM.

OTHER APPLICABLE ARTICLES:

NONE

SUPERSEDES:

96-4-7

WARRANTY STATUS:

Information Only

OASIS CODES:

499000