2000 Ford Ranger

2000-01 ENGINES 4.0L V6 - VIN X

2000-01 ENGINES

4.0L V6 - VIN X

ENGINE IDENTIFICATION

NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL
PROCEDURES article in GENERAL INFORMATION.

Engine may be identified by Vehicle Identification Number (VIN). See ENGINE IDENTIFICATION
CODES table. VIN is stamped on a metal tab attached to left side of instrument panel, and is visible through the
windshield. VIN is also stamped on the Safety Certification Decals (on driver's front door lock panel) and on
the Engine Identification Label (on valve cover). The eighth character of VIN identifies the engine, and tenth
character indicates model year. All label numbers are necessary for determining correct parts for specific
engine. DO NOT remove labels at any time.

ENGINE IDENTIFICATION CODES

Engine Code
4.0L SFI X

ADJUSTMENTS
VALVE CLEARANCE

NOTE: Information on valve clearance check is not available from manufacturer.

Engine uses nonadjustable hydraulic roller lifters and nonadjustable rocker arms. If lifters are excessively worn
or noisy, repair or replace as necessary.

TROUBLE SHOOTING

NOTE: To trouble shoot mechanical components, see appropriate table in TROUBLE

SHOOTING article in GENERAL INFORMATION.

REMOVAL & INSTALLATION

CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION before disconnecting
battery.

NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and
fuel lines before removal. Also place mating marks on hood and other major

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assemblies before removal.

FUEL PRESSURE RELEASE

To release fuel pressure, disconnect negative battery cable. Remove fuel cap to release fuel tank pressure.
Remove relief valve cap from fuel rail. Connect fuel pressure gauge to fuel rail, and release fuel into a suitable
container.

COOLING SYSTEM BLEEDING

WARNING: When engine is operating, DO NOT remove radiator cap under any
conditions. Failure to follow instruction could damage cooling
system or engine, and cause personal injury. Always wrap protective
material around radiator cap to avoid injury from hot coolant.

1. Fill cooling system with 50/50 mixture of coolant and water. Pause several minutes for circulation. Fill
radiator to filler neck seat. Install radiator cap fully, then back off to first stop.
2. Set heater controls to maximum heat. Start engine and operate at 2000 RPM for approximately 3-4
minutes. Turn engine off. Use a protective rag, and carefully remove radiator cap. Add coolant to filler
neck seat.
3. Install radiator cap fully, then back off to first stop. Start engine and allow to operate at 2000 RPM until
upper radiator hose is warm. Check heater output. Turn engine off. Use protective rag, and carefully
remove radiator cap. Add coolant to filler neck seat if necessary.
4. Tightly install radiator cap. Remove small cap (large cap is for windshield washer reservoir) on coolant
recovery reservoir. Add 1.1 qt. (1.0L) of 50/50 mixture of coolant and water to reservoir. Install reservoir
cap.

ENGINE

Removal

1. Disconnect negative battery cable. Mark hood hinges and remove hood. Discharge A/C system using
approved refrigerant recovery/recycling equipment. Remove air cleaner tube and assembly. Drain cooling
system and engine oil.
2. Remove upper and lower radiator hoses. Disconnect radiator fan shroud and position over fan. Remove
radiator and fan shroud. Using Fan Clutch Nut Wrench (T96T-6312-A) and Fan Clutch Holder (T96T-
6312-B) remove cooling fan. Remove accessory drive belt.
3. Disconnect A/C manifold tube from compressor (if equipped) and plug openings. Unbolt A/C bracket and
position compressor, power steering pump and bracket assembly aside.
4. Remove generator and bracket assembly. Disconnect heater hoses from water pump and intake manifold.
Disconnect control cables from throttle body. Disconnect necessary vacuum connections. Disconnect
necessary wiring harness connections and ground cables.
5. On Ranger, disconnect A/C manifold tube from condenser and receiver-drier, and plug openings. On all
models, disconnect and/or remove necessary A/C lines and components. Relieve fuel pressure. See FUEL
PRESSURE RELEASE. Using Spring Lock Coupling Remover (T81P-19623-G1) for 3/8" line or

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(T81P-19623-G2) for 1/2" line, disconnect fuel supply and return lines. See Fig. 1. Disconnect Powertrain
Control Module (PCM).
6. Raise and support vehicle. Remove A/C manifold bracket. Remove starter. On models with automatic
transmission, disconnect flexplate from torque converter through starter opening. Remove transmission
cooler line-to-engine bolts. On all models, disconnect transmission wiring harness connectors.
7. Remove transmission-to-engine bolts. Disconnect exhaust pipes from exhaust manifolds. Lower vehicle.
Support transmission. Remove transmission. See appropriate TRANSMISSION REMOVAL &
INSTALLATION article in TRANSMISSION SERVICING. Remove right and left top engine mount
nuts. Attach engine hoist and remove engine from vehicle.

Installation

To install, reverse removal procedure. Evacuate and recharge A/C system (if equipped). Check and top off all
fluid levels. Fill and bleed air from cooling system. See COOLING SYSTEM BLEEDING.

Fig. 1: Disconnecting Fuel Lines

Courtesy of FORD MOTOR CO.

INTAKE MANIFOLDS

Removal (Upper)

1. Disconnect negative battery cable. Remove air cleaner outlet tube. Remove splash shield to expose
throttle linkage. Remove control cable(s) and bracket from throttle body.
2. Disconnect necessary vacuum hoses. Disconnect necessary wiring harness and ground connections.
Disconnect heater hose locating bracket and transmission dipstick tube, position aside.

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3. Disconnect spark plug wires and harness connectors from coil pack. Remove coil pack and EGR valve (if
equipped). Remove oil dipstick tube. Remove EGR manifold tube, EGR transducer and EGR solenoid (if
equipped). Remove upper intake manifold retaining bolts. Remove upper intake manifold and gasket.

Installation (Upper)

Clean and inspect mounting surfaces. Position NEW gasket on mounting studs. Install upper intake manifold,
and tighten bolts in sequence to specification. See Fig. 2. See TORQUE SPECIFICATIONS. To complete
installation, reverse removal procedure.

Fig. 2: Upper Intake Manifold Tightening Sequence

Courtesy of FORD MOTOR CO.

Removal (Fuel Injection Supply)

1. With upper intake manifold removed. Relieve fuel pressure. See FUEL PRESSURE RELEASE.
Disconnect crank shaft position (CKP) sensor, engine coolant temperature (ECT) sensor, and water
temperature indicator unit.
2. Disconnect fuel inject electrical connectors. Disconnect and remove oil pressure sensor. Disconnect fuel
supply and return lines.
3. Disconnect vacuum line and remove vacuum line harness. Remove bolts and fuel injector supply
manifold. Remove valve covers. See VALVE COVERS. Drain cooling system.

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Installation (Fuel Injection Supply)

Install fuel injection supply manifold gaskets. Install fuel injection supply manifold. Tighten bolts in sequence
to specification. See Fig. 3. See TORQUE SPECIFICATIONS. To complete installation, reverse removal
procedure.

Fig. 3: Fuel Injection Supply Manifold Tightening Sequence

Courtesy of FORD MOTOR CO.

Removal (Lower)

With upper intake manifold removed. Disconnect upper radiator hose from manifold. Relieve fuel pressure. See
FUEL PRESSURE RELEASE. Using Spring Lock Coupling Remover (T81P-19623-G1) for 3/8" line or
(T81P-19623-G2) for 1/2" line, disconnect fuel supply and return lines. See Fig. 1. Remove valve covers. See
VALVE COVERS. Drain cooling system. Remove lower intake manifold retaining bolts. Remove lower intake
manifold and gasket.

Installation (Lower)

Clean gasket mating surfaces. Install intake manifold gaskets. Apply silicone sealer at 4 corners of cylinder
block sealing surface. Install lower intake manifold within 15 minutes of silicone sealer application. Tighten
bolts in sequence to specification. See Fig. 4. See TORQUE SPECIFICATIONS.

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Fig. 4: Lower Intake Manifold Tightening Sequence

Courtesy of FORD MOTOR CO.

EXHAUST MANIFOLDS

Removal

Disconnect negative battery cable. On right manifold, remove heater hose support bracket. Disconnect heater
hoses. On left manifold, remove oil dipstick tube. Remove EGR manifold tube and EGR valve, (if equipped).
Remove EGR transducer vacuum hoses, (if equipped). Remove EGR-to-intake manifold tube, (if equipped).
Remove power steering hoses from power steering pump (if necessary). On both manifolds, disconnect exhaust
pipe at exhaust manifold. Remove exhaust manifold retaining nuts. Remove exhaust manifold and gasket.

Installation

Clean all mating surfaces. Lightly oil all bolt/stud threads before installation. Install exhaust manifold on
cylinder head, and tighten bolts in sequence to specification. See Fig. 5. See TORQUE SPECIFICATIONS.
To complete installation, reverse removal procedure. Fill and bleed cooling system if necessary. See
COOLING SYSTEM BLEEDING.

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Fig. 5: Exhaust Manifold Tightening Sequence

Courtesy of FORD MOTOR CO.

VALVE COVERS

Removal

1. Disconnect negative battery cable. Remove intake air tube and throttle body splash shield. Remove spark
plug wires. Disconnect necessary vacuum hoses. Remove wiring as necessary. Remove engine harness
clips.
2. If removing rear valve cover, drain cooling system. Remove upper radiator hose. Remove ignition coil
and alternator. Disconnect heater water hose. Disconnect throttle cable.
3. If removing left valve cover, remove upper intake manifold. See INTAKE MANIFOLDS. Remove A/C
compressor with hoses attached. Position A/C compressor and harness aside.
4. Remove PCV hose and breather. Keeping in removal order, remove valve cover attaching bolts and load
distribution washers. Remove valve covers.

Installation

CAUTION: Failure to use NEW valve cover gaskets and valve cover load distribution
washers will result in oil leaks.

Clean all gasket surfaces. Position NEW gasket in place. Install valve cover. Install valve cover load
distribution washers in their original location. Install valve cover bolts and tighten in sequence to specification.
See TORQUE SPECIFICATIONS. See Fig. 6. To complete installation, reverse removal procedure.

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Fig. 6: Valve Cover Bolt Tightening Sequence

Courtesy of FORD MOTOR CO.

CYLINDER HEAD

NOTE: On Explorer and Mountaineer, discharge A/C system using approved refrigerant
recovery/recycling equipment. Remove A/C manifold line from compressor, and
plug openings.

Removal

1. Disconnect negative battery cable. Drain cooling system. Release fuel pressure. See FUEL PRESSURE
RELEASE. Remove upper and lower intake manifolds. See INTAKE MANIFOLDS. Remove exhaust
manifold. See EXHAUST MANIFOLDS.
2. Remove valve covers. See VALVE COVERS. Remove spark plugs. Remove accessory drive belt. If
removing left cylinder head, remove A/C compressor with hoses attached, and position aside (if
equipped). Remove power steering pump bracket with power steering pump attached, and position aside.

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CAUTION: If rocker arm shafts are not loosened gradually, shafts may become
bent or damaged.

3. If removing right cylinder head, remove generator and bracket. Remove Ignition coil and bracket as an
assembly. Remove Spark plugs. On all cylinder heads, disconnect exhaust pipe at exhaust manifold.
Remove rocker arm shaft bolts evenly by loosening bolts 2 turns at a time. Remove rocker arm shaft
assembly.
4. Mark push rod location for installation reference, and remove push rods. Remove and discard cylinder
head bolts. Remove cylinder head(s) and gaskets.

Inspection

Check dowels in cylinder block, and replace if necessary. Check cylinder head warpage. Resurface cylinder
head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. DO
NOT machine more than .010" (.25 mm) from original cylinder head surface.

Installation

NOTE: Always use NEW cylinder head bolts when installing cylinder heads.

1. Ensure all bolt holes in cylinder block are clean. Install gaskets and cylinder heads. Install NEW cylinder
head bolts. Tighten cylinder head bolts in sequence to specification. See Fig. 7. See TORQUE
SPECIFICATIONS.
2. Install lower intake manifold. See INTAKE MANIFOLDS. Tighten lower intake manifold bolts in
sequence to specification. See Fig. 4. See TORQUE SPECIFICATIONS.
3. Coat push rods with Oil Conditioner (D9AZ-19579-D) and install in original position. Install rocker arm
shaft assembly to cylinder head. Guide rocker arms onto push rods.
4. Tighten rocker arm bolts evenly to specification. To complete installation, reverse removal installation.
Fill and bleed cooling system. See COOLING SYSTEM BLEEDING.

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Fig. 7: Cylinder Head Bolt Tightening Sequence

Courtesy of FORD MOTOR CO.

CRANKSHAFT FRONT OIL SEAL

Removal & Installation

CAUTION: DO NOT reuse crankshaft pulley bolt.

1. Disconnect negative battery cable. Remove fan blade and fan shroud. Remove accessory drive belts.
Remove crankshaft damper retaining bolt. Using Crankshaft Damper Remover (T74P-6316-A), remove
crankshaft damper. Carefully pry seal from timing chain cover. DO NOT damage timing chain cover or
crankshaft.
2. To install, lubricate seal lip with engine oil. Using Timing Chain Cover Aligner (T74P-6019-A) and
Crankshaft Front Seal Installer (T90T-6701-A), install front crankshaft seal. Apply silicone sealer to
crankshaft keyway.

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3. Coat crankshaft damper sealing surface with engine oil. Install crankshaft damper. Tighten to
specification. See TORQUE SPECIFICATIONS. Install accessory drive belts.

TIMING CHAIN COVER

NOTE: It is necessary to remove oil pan to properly reseal timing chain cover. It is
necessary to remove engine to remove oil pan.

Removal

CAUTION: Fan clutch nut has left-hand threads. Remove nut by turning
clockwise as viewed from front of engine.

1. Remove oil pan. See OIL PAN. Remove air intake tube. Drain cooling system. Remove accessory drive
belt. Using Fan Clutch Pulley Holder (T84T-6312-C) and Fan Clutch Nut Wrench (T84T-6312-D),
remove fan and clutch assembly. See Fig. 15.
2. Remove fan shroud. Remove accessory drive belt tensioner. Remove lower radiator hose. Remove power
steering pump with bracket and A/C compressor attached (if equipped), and position aside.
3. Remove generator with bracket, and position aside. Remove water pump pulley. Remove water pump
attaching bolts, and remove pump. Remove gasket. Using Crankshaft Damper Remover (T74P-6316-A),
remove crankshaft damper.
4. Remove crankshaft position sensor. Remove timing chain cover bolts (note bolt location for installation
reference). Remove cover and gasket.

Installation

1. Clean timing chain cover mating surfaces. Apply sealing compound to gasket surfaces. Place NEW
timing chain cover gasket into position. Replace crankshaft seal. Position timing chain cover on engine.
Insert bolts in their original location.
2. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Apply silicone sealer to crankshaft
keyway. To complete installation, reverse removal procedure. Install oil pan. See OIL PAN. Fill or top
off all fluids. Fill and bleed air from cooling system. See COOLING SYSTEM BLEEDING.

TIMING CHAIN & SPROCKETS

NOTE: It is necessary to remove oil pan to properly reseal timing chain cover. It is
necessary to remove engine to remove oil pan.

Removal

1. Position No. 1 piston at TDC of compression stroke. Remove timing chain cover. See TIMING CHAIN
COVER. Remove oil pan. See OIL PAN.
2. Ensure all timing marks are aligned. See Fig. 8. Check camshaft end play. If end play is not within
specification, replace camshaft thrust plate. See CAMSHAFT table under ENGINE SPECIFICATIONS.
3. Retract timing chain tensioner and install packaging clip from new tensioner or one that you have

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fabricated. Remove camshaft sprocket retaining bolt and crankshaft sprocket Woodruff key. Remove
tensioner and guide rail. Replace worn parts as necessary. Remove crankshaft, camshaft sprockets and
timing chain as an assembly.
4. If crankshaft sprocket is difficult to remove, carefully pry off with a pair of screwdrivers positioned
evenly on sprocket.

Installation

1. Install guide rail to cylinder block, with pin inserted into oil hole of block. Install 2 tensioner retaining
bolts. Ensure timing marks are aligned. See Fig. 8. If camshaft thrust plate was removed, install thrust
plate so that it covers main oil gallery. See Fig. 9.
2. Install crankshaft, camshaft sprocket and timing chain as an assembly. Install tensioner with clip in place
to lock tensioner in retracted position. See Fig. 8. Install camshaft sprocket bolt and tighten to
specification. See TORQUE SPECIFICATIONS.

CAUTION: Ensure tensioner side of timing chain is held inward, and guide side
is straight and tight. Ensure clip is removed from tensioner before
installing timing chain cover.

3. Remove clip from tensioner. Rotate crankshaft 2 revolutions clockwise, and recheck timing marks. To
complete installation, reverse removal procedure. Fill and bleed cooling system. See COOLING
SYSTEM BLEEDING.

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Fig. 8: Identifying Timing Chain & Components

Courtesy of FORD MOTOR CO.

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Fig. 9: Installing Camshaft Thrust Plate

Courtesy of FORD MOTOR CO.

VALVE LIFTERS

Removal

CAUTION: If rocker arm shafts are not loosened gradually, shafts may be bent or
damaged.

Remove lower intake manifold. See INTAKE MANIFOLDS. Note original location of push rods and lifters
during removal for installation reference. Gradually loosen rocker shaft and remove rocker shaft. Remove push
rods and lifters.

Inspection

Inspect lifter for damage. Ensure roller rotates smoothly. Measure lifter O.D. and cylinder block lifter bore I.D.
Replace components if oil clearance is not within specification. See VALVE LIFTERS table under ENGINE
SPECIFICATIONS.

Installation

Lubricate lifter and cylinder block bore with Oil Conditioner (D9AZ-19579-D) or heavy engine oil. Install lifter
in original location, with alignment tab in locating groove of bore. See Fig. 10. Ensure lifters slide freely in
bore. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See

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TORQUE SPECIFICATIONS.

Fig. 10: Installing Hydraulic Lifters

Courtesy of FORD MOTOR CO.

CAMSHAFT POSITION SYNCHRONIZER

CAUTION: Synchro Positioner (T95T-12200-A) is required to properly install

synchronizer. See Fig. 11. Failure to use Synchro Positioner during
installation will cause fuel injection to be out of time and may cause
engine damage.

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Fig. 11: Exploded View Of CMP Synchronizer Assembly

Courtesy of FORD MOTOR CO.

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Removal

CAUTION: DO NOT rotate crankshaft while synchronizer is removed from engine.

1. Disconnect negative battery cable. Remove upper intake manifold. See REMOVAL (UPPER) under
INTAKE MANIFOLDS. Position crankshaft to TDC of cylinder No. 1 compression stroke.
2. Note position of electrical connector on CMP sensor. Disconnect harness connector from CMP sensor.
Remove CMP sensor screws and CMP sensor from synchronizer. Remove synchronizer hold-down bolt
and CMP synchronizer.

Installation

1. Install Synchro Positioner (T95T-12200-A) on synchronizer housing. See Fig. 12. Rotate synchronizer
shaft until vane on shaft aligns with slot on synchro positioner. Rotate synchro positioner until engaged
into notch in housing. Dip drive gear in engine oil.

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Fig. 12: Installing Synchro Positioner On Synchronizer Assembly (Typical)

Courtesy of FORD MOTOR CO.

2. Install camshaft synchronizer assembly so that camshaft synchronizer drive gear engagement occurs
when Synchro Positioner is pointing 60 degrees counterclockwise of crankshaft centerline. As
synchronizer is inserted into engine, synchronizer shaft will rotate.
3. Install hold-down clamp and tighten bolt to specification. See TORQUE SPECIFICATIONS. Install
CMP sensor to synchronizer and tighten to specification. Ensure CMP sensor electrical connector is in
original position. Reconnect wiring to CMP sensor. To complete installation on Explorer and
Mountaineer models, reverse removal procedure. On all models, connect negative battery cable.

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CAMSHAFT

NOTE: It is necessary to remove oil pan to properly reseal timing chain cover. It is
necessary to remove engine to remove oil pan.

Removal

Remove radiator. Remove oil pump. See OIL PUMP. Remove camshaft position sensor. Remove camshaft
synchronizer. See CAMSHAFT POSITION SYNCHRONIZER. Remove lifters. See VALVE LIFTERS.
Remove timing chain. See TIMING CHAIN. Remove camshaft thrust plate. Remove camshaft.

Inspection

Inspect components for damage. Check camshaft journal diameter, lobe lift and oil clearance. Replace
components if damaged or not within specification. See CAMSHAFT table under ENGINE
SPECIFICATIONS.

Installation

1. Lubricate camshaft lobes and bearing surfaces with Oil Conditioner (D9AZ-19579-D). Install camshaft
carefully to prevent damaging bearings and journal surfaces. Install thrust plate so it covers main oil
gallery. See Fig. 9.
2. Ensure camshaft end play is within specification. See CAMSHAFT table under ENGINE
SPECIFICATIONS. To complete installation, reverse removal procedure. Tighten nuts and bolts to
specification. See TORQUE SPECIFICATIONS. Fill and bleed cooling system. See COOLING
SYSTEM BLEEDING.

CRANKSHAFT REAR OIL SEAL

Removal

1. On Explorer M/T, clutch disc and pressure plate. Remove 6 of 8 bolts. Loosen 2 remaining bolts, leave in
place. Press flywheel off crankshaft. Install 2 bolts in threaded hole of flywheel. Remove 2 remain bolts
from crankshaft. Remove flywheel. On Ranger M/T, remove disc and pressure plate. Install flywheel
holding tool. Remove bolts. Remove flywheel. On A/T models, remove bolts. Remove flywheel.
2. Rear main bearing oil seal is a one-piece seal. Remove transmission. See appropriate TRANSMISSION
REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Punch hole in metal portion
of seal with an awl. Remove seal using a slide hammer.

Installation

1. To install, lubricate seal and mating surfaces with engine oil. Install seal on crankshaft, with spring side
toward crankshaft. Using Crankshaft Rear Oil Seal Replacer (T95T-6701-A), install seal into position
until seal is firmly seated.
2. On Explorer M/T, position flywheel onto crankshaft. Install and tighten bolts to specification. On Ranger
M/T, position flywheel onto crankshaft. Install bolts in sequence and tighten to specification. See Fig. 13.
On A/T models, position flywheel onto crankshaft. Install bolts in 2 steps, in sequence to specification.

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See Fig. 14. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Fig. 13: Flywheel Tightening Sequence, (Ranger M/T)

Courtesy of FORD MOTOR CO.

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Fig. 14: Flywheel Tightening Sequence, (A/T Models)

Courtesy of FORD MOTOR CO.

WATER PUMP

Removal

1. Remove negative battery cable. Drain cooling system. Disconnect lower radiator hose and heater return
hose from water pump. Using Fan Clutch Pulley Holder (T96T-6312-B) and Fan Clutch Nut Wrench
(T96T-6312-A), remove radiator fan and clutch assembly. See Fig. 15.
2. Remove accessory drive belt. Remove power steering pump with bracket and A/C compressor (if
equipped), and position aside. Remove generator bracket with generator, and position aside. Remove
accessory drive belt tensioner. Remove water pump pulley. Remove water pump retaining bolts. Remove
water pump and gasket.

Installation

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Clean all gasket surfaces. Apply sealer to both sides of NEW gasket, and position gasket on water pump. Install
water pump. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See
TORQUE SPECIFICATIONS. Fill and bleed cooling system. See COOLING SYSTEM BLEEDING.

Fig. 15: Removing Fan Clutch

Courtesy of FORD MOTOR CO.

OIL PAN

NOTE: It is necessary to remove oil pan to properly reseal timing chain cover.

Removal

1. Disconnect the battery ground cable.

2. Remove the air cleaner outlet tube.
3. Remove the two bolts, lift the fan shroud out of the lower retaining clips and drape it over the fan.
4. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
5. Remove the front tires and wheels.
6. Remove the front inner splash shields.
7. Drain the engine oil and reinstall the drain plug.

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Fig. 16: Identifying Oil Drain Plug

Courtesy of FORD MOTOR CO.

8. For 4WD vehicles, disconnect the front driveshaft CV joint and position aside.

Fig. 17: Identifying Front Driveshaft Bolts

Courtesy of FORD MOTOR CO.

9. Remove the four motor mount nuts.

10. Lower the vehicle.
11. Attach the Lifting Eyes to the engine. Raise and support the engine with the 3-Bar Engine Support Kit.
12. Raise and support the vehicle.
13. Disconnect the axle vent tube.

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Fig. 18: Identifying Axle Vent Tube

Courtesy of FORD MOTOR CO.

14. Support the axle with a suitable jack.

Fig. 19: Supporting Axle With Jack

Courtesy of FORD MOTOR CO.

NOTE: Front driveshaft removed for clarity.

Fig. 20: Identifying Left Front Axle-To-Frame Bolt

Courtesy of FORD MOTOR CO.

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15. Remove the left front axle-to-frame bolt.

NOTE: Front driveshaft removed for clarity.

Fig. 21: Identifying Axle-To-Frame Bolts

Courtesy of FORD MOTOR CO.

16. Remove the two axle-to-frame bolts. Lower the axle to just rest on the lower control arms.
17. On all vehicles, remove the starter motor. For additional information, refer to STARTER MOTOR .
18. Remove the bolts.

Fig. 22: Identifying Bolts

Courtesy of FORD MOTOR CO.

19. Remove the bolts and the nuts.

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Fig. 23: Identifying Bolts & Nuts

Courtesy of FORD MOTOR CO.

20. Remove the oil pan and the gasket.

Fig. 24: Identifying Oil Pan & Gasket

Courtesy of FORD MOTOR CO.

Installation

1. On all vehicles, clean and inspect the sealing surfaces.

2. Apply a bead of silicone rubber in six places. Use Silicone Gasket and Sealant F7AZ-19554-EA or
equivalent meeting Ford specification WSE-M4G323-A4.

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Fig. 25: Identifying Silicone Rubber Application Points

Courtesy of FORD MOTOR CO.

NOTE: Use a straightedge to maintain the rear oil pan edge-to-rear cylinder block
edge alignment.

Fig. 26: Identifying Oil Pan & Gasket

Courtesy of FORD MOTOR CO.

3. Position the gasket and the oil pan.

4. Install the bolts and nuts and tighten in the sequence shown in illustration. See Fig. 27. See TORQUE
SPECIFICATIONS.

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Fig. 27: Oil Pan Tightening Sequence

Courtesy of FORD MOTOR CO.

5. Install the bolts.

Fig. 28: Identifying Bolts

Courtesy of FORD MOTOR CO.

6. Install the starter motor. For additional information, refer to STARTER MOTOR .

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NOTE: Front driveshaft removed for clarity.

Fig. 29: Identifying Axle-To-Frame Bolts & Nuts

Courtesy of FORD MOTOR CO.

7. For 4WD vehicles, raise the axle and install the two axle-to-frame bolts and nuts.

NOTE: Front driveshaft removed for clarity.

Fig. 30: Identifying Left Front Axle-To-Frame Bolt & Nut

8. Install the left front axle-to-frame bolt and nut.

9. Remove the jack from the axle.
10. Connect the axle vent tube.

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Fig. 31: Identifying Axle Vent Tube

Courtesy of FORD MOTOR CO.

11. Connect the front driveshaft CV joint.

Fig. 32: Identifying Front Driveshaft Bolts

Courtesy of FORD MOTOR CO.

12. Lower the vehicle.

13. Lower the engine onto the mounts and remove the 3-Bar Engine support Kit. Remove the Lifting Eyes.
14. Raise and support the vehicle.
15. Install the four motor mount nuts.
16. Install the front inner fender splash shields.
17. Install the front tires and wheels.
18. Install a new oil filter and lower the vehicle.
19. Position the fan shroud and install the two bolts.
20. Install the air cleaner outlet tube.
21. Fill the engine with Super Premium SAE 5W-30 Motor Oil X0-5W30-QSP or equivalent meeting Ford
specification WSS-M2C153-G.

OVERHAUL

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CYLINDER HEAD

Cylinder Head

1. Clean head gasket mating surface. Clean carbon from combustion chambers. Use care not to damage
surfaces. Check cylinder head for cracks, burrs, nicks and warpage.
2. Check cylinder head warpage. Resurface cylinder head if warpage exceeds specification. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS. DO NOT machine more than .010" (.25
mm) from original cylinder head surface.

Valve Springs

CAUTION: DO NOT install valve spring spacers unless necessary. Using more
spacers than required can result in spring breakage or worn
camshaft lobes.

1. Measure valve spring installed height from surface of cylinder head spring pad to underside of spring
retainer. If installed height is greater than specification, a shim can be installed between cylinder head and
valve spring to obtain correct height. See VALVES & VALVE SPRINGS table under ENGINE
SPECIFICATIONS.
2. Inspect valve spring free length and pressure. Replace valve spring if free length and pressure are not
within specification. See VALVES & VALVE SPRINGS table.

Valve Stem Oil Seals

Different types of valve stem oil seals are used on intake and exhaust valves. Use Valve Stem Seal Installer
(T90T-6571-A) to install NEW valve stem seals. Ensure seal bottoms on valve guide. Oversized seals must be
installed when using oversized valves.

Valve Guides

CAUTION: Always grind valve seat after valve guide has been reamed or service
bushing has been installed.

1. Valve guides must be reamed for an oversize valve if valve stem oil clearance exceeds specification. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valves are available in .008" (.20 mm)
and .016" (.41 mm) oversize.
2. If oversize valves or oversize valve stem seals are not available, valve guide may be reamed to use a
service bushing. Always use reamers in proper sequence (smallest first).

Valve Seat

Ensure valve seat angle, seat width and seat runout are within specification. See CYLINDER HEAD table
under ENGINE SPECIFICATIONS. Valve seats must be ground when valve guide is reamed or replaced.
Replacement information is not available from manufacturer.

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Valves

1. Grind valve face to 44-degree angle. Ensure head diameter, valve face runout, stem diameter and valve
margin are within specification. See VALVES & VALVE SPRINGS table under ENGINE
SPECIFICATIONS.
2. Oversize valves are available in .008" (.20 mm) and .016" (.41 mm). When servicing valve stem tip, DO
NOT remove more than .010" (.25) from end of valve stem.

Valve Seat Correction Angles

Grind valve seat to 45-degree angle. If seat is too wide after grinding, use a 30-degree stone to lower seat, or a
60-degree stone to raise seat. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

CYLINDER BLOCK ASSEMBLY

Piston & Rod Assembly

Ensure pistons and rods are installed in cylinder from which they were removed. Note direction of connecting
rod installation on piston before removal. Ensure arrow on piston dome is facing front of engine, and
connecting rod oil squirt hole is pointed toward center of engine. See Fig. 33.

Fitting Pistons

Measure cylinder bore out-of-round, taper and piston-to-cylinder bore clearance. Measure with components at
about 70°F (21°C). If measurements are not within specification, hone or bore cylinders and fit suitable pistons.
See CYLINDER BLOCK and PISTONS, PINS & RINGS tables under ENGINE SPECIFICATIONS.

Piston Rings

1. Select rings for bore diameter. Place ring in cylinder bore in which it will be installed. Using piston to
square ring in bore, place ring below normal ring wear area. Measure ring end gap. If gap is too small, file
material from end of ring. If ring gap exceeds specification, try another ring set. See PISTONS, PINS &
RINGS table under ENGINE SPECIFICATIONS.
2. Check side clearance of rings after installing on piston. Ensure clearance is within specification around
entire circumference. Replace piston and/or rings if clearance is not within specification. See PISTONS,
PINS & RINGS table. Ensure rings are properly spaced on piston before installing pistons into cylinder.
See Fig. 34.

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Fig. 33: Positioning Piston & Rod Assembly

Courtesy of FORD MOTOR CO.

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Fig. 34: Positioning Piston Ring End Gaps

Courtesy of FORD MOTOR CO.

Rod Bearings

1. Use Plastigage to check rod bearing clearance. If proper oil clearance cannot be obtained with standard
bearings, try a combination of undersize bearings. DO NOT use any bearing combination other than
listed. See UNDERSIZE MAIN & ROD BEARING COMBINATIONS table.
2. If use of bearing combinations does not bring clearance within specification, machine or replace
crankshaft as necessary. Always replace bearings in pairs. See CRANKSHAFT, MAIN &
CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

UNDERSIZE MAIN & ROD BEARING COMBINATIONS (1)

Use Lower Bearing - In.

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Excess Bearing Clearance - In. (mm) Use Upper Bearing - In. (mm) (mm)
.0-.0005 (.0-.013) .001 (.025) (2)

.0005-0010 (.013-.025) .001 (.025) .001 (.025)

.0010-.0015 (.025-.039) .002 (.050) .001 (.025)
.0015-.0020 (.039-.050) .002 (.050) .002 (.050)
(1) DO NOT use any bearing combination other than listed. If use of bearing combinations does not
bring clearance within specification, machine or replace crankshaft as necessary.
(2) Use standard bearing.

Crankshaft & Main Bearings

1. When checking main bearing clearance in vehicle, position a jack under adjoining bearing counterweight
being checked. Remove only one main bearing cap at a time.
2. Use Plastigage to check main bearing clearance. If proper oil clearance cannot be obtained with standard
bearings, try a combination of undersize bearings. DO NOT use any bearing combination other than
listed. See UNDERSIZE MAIN & ROD BEARING COMBINATIONS table.
3. If use of bearing combinations does not bring clearance within specification, machine or replace
crankshaft as necessary. Always replace bearings in pairs. See CRANKSHAFT, MAIN &
CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
4. To install thrust bearing, tighten main bearing cap bolts finger tight. Pry crankshaft forward while prying
thrust bearing cap rearward. Tighten bearing caps in sequence to specification. See TORQUE
SPECIFICATIONS. See Fig. 35.
5. Mount dial indicator, and pry on crankshaft to check crankshaft end play. Replace thrust bearing, and
inspect crankshaft thrust faces if end play is not within specification. See CRANKSHAFT, MAIN &
CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

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Fig. 35: Main Bearing Bolt Tightening Sequence

Courtesy of FORD MOTOR CO.

Cylinder Block

CAUTION: DO NOT machine more than .010" (.25 mm) of material from original
cylinder-to-block head surface.

1. Using a feeler gauge and straightedge, check cylinder block head gasket surface for warpage. Check
cylinder bore for wear, taper, out-of-round and piston fit. See CYLINDER BLOCK table under
ENGINE SPECIFICATIONS.
2. Install all main bearing caps and tighten to specification before honing cylinder bore. See TORQUE
SPECIFICATIONS. Ensure bearing caps are installed in their original location, with arrow on cap
pointing toward front of engine.

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3. Use ONLY a spring-loaded type cylinder hone. After honing, thoroughly clean bore with detergent and
water solution. Rinse solution from bore thoroughly with clean water. Wipe bore clean with lint-free
cloth. Lubricate cylinder bores with engine oil.

ENGINE OILING
ENGINE LUBRICATION SYSTEM

Engine lubrication system is a force-feed type. Oil is supplied under full pressure to crankshaft, connecting
rods, camshaft bearings and valve lifters. See Fig. 36. A controlled volume of oil is supplied to rocker arms and
push rods. All other moving parts are lubricated by splash or gravity flow. Oil flows through oil filter before
entering main oil gallery.

Crankcase Capacity

Crankcase capacity is 5 qts. (4.75L) with oil filter.

Oil Pressure

Oil pressure with engine at normal operating temperature is 40-60 psi (2.8-4.2 kg/cm2 ) at 2000 RPM.

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Fig. 36: Cross-Sectional View Of Engine Oiling Circuit

Courtesy of FORD MOTOR CO.

OIL PUMP

Removal & Disassembly

Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove oil pump attaching bolts.
Remove oil pump and oil pump drive shaft. Disassemble oil pump. Note direction of component installation for
reassembly reference.

Inspection

Inspect components for damage. Measure rotor end play and outer rotor-to-housing clearance. Measure relief

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valve-to-bore clearance and relief valve spring tension. Replace oil pump assembly if measurements are not
within specification. See OIL PUMP SPECIFICATIONS table.

NOTE: Oil pump is serviced as an assembly only. Replace assembly if measurements

are not within specifications. See OIL PUMP SPECIFICATIONS table.

OIL PUMP SPECIFICATIONS

Application In. (mm)
Outer Rotor-To-Housing Clearance .006-.020 (.02-.51)
Rotor End Play .0014-.0044 (.036-.112)
Shaft-To-Housing Clearance .0015-.0030 (.038-.076)
Relief Valve Spring Tension (1)

Relief Valve-To-Bore Clearance .0015-.0030 (.038-.076)

(1) Spring tension is 13.6-14.7 lbs. @ 1.39" (6.2-6.7 kg @ 35 mm).

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure components are installed in original location. To
install, prime oil pump with engine oil. Rotate oil pump drive shaft to distribute oil within pump body.
2. Insert oil pump drive shaft into engine block, with pointed end of oil pump drive shaft inward. Pointed
end is closest to pressed-on retainer ring. See Fig. 37.
3. Position NEW gasket in place and install oil pump. To complete installation, reverse removal procedure.
Tighten bolts to specification. See TORQUE SPECIFICATIONS.

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Fig. 37: Installing Oil Pump

Courtesy of FORD MOTOR CO.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
A/C Mounting Bracket Bolts 35 (47)
Bellhousing-To-Engine Bolt 30-40 (40-55)
Camshaft Position Synchronizer 22 (30)
Camshaft Sprocket Bolt 47 (64)
Camshaft Thrust Plate Bolt 8 (11)
Connecting Rod Bearing Cap Bolts 18-24 (25-32)

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Connecting Rod Nut

Step 1 15 (20)
Step 2 Additional 90 Degrees
Crankshaft Pulley-To-Crankshaft Bolt (1)
Step 1 33 (45)
Step 2 Additional 90 Degrees
Cylinder Head Bolt (1) (2)
Step 1 25 (34)
Step 2 53 (72)
Step 3 Additional 90 Degrees
Engine Front Cover Bolt 13-15 (17-21)
Engine Mount-To-Crossmember Nut 65-97 (88-132)
Engine Mount-To-Engine Bolt 44-59 (60-80)
Exhaust Manifold Bolt (3) 20 (27)
Explorer 15-18 (20-25)
Ranger
Left-Hand Side 16 (22)
Right-Hand Side 15-18 (20-25)
Fan Clutch 30-100 (40-135)
Flexplate-To-Torque Converter Bolt 22-30 (30-41)
Flywheel-To-Crankshaft Bolt
M/T Models (4)
Explorer 75-85 (102-115)
Ranger 54-67 (73-91)
A/T Models (5)
Step 1 10 (13)
Step 2 52 (71)
Fuel Injection Supply Manifold Bolts (6) 11 (15)
Generator Mounting Bracket Bolts
Except 2001 Explorer 35 (47)
2001 Explorer 30-40 (40-55)
Main Bearing Cap Bolt (7)
Step 1 25 (35)
Step 2 72 (97)
Oil Drain Plug 19(26)
Oil Filter Adapter 42 (57)
Oil Level Sensor 15 (20)
Oil Level Indicator Tube 18 (25)
Oil Pan Baffle Bolts
Explorer 15 (20)

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Ranger 13-15 (17-20)

Oil Pump Retaining Bolt 13 (17)
Power Steering Bracket Bolt 30-40 (41-54)
Rocker Arm Assembly Bolt (8)
Step 1 24 (33)
Step 2 Additional 90 Degrees
Starter Bolt 16-20 (22-27)
Transmission Crossmember Bolt 65-87 (88-118)
Upper Intake Manifold Bolts (9) 17 (23)
Water Pump Pulley 17-20 (23-27)
INCH Lbs. (N.m)
Camshaft Position Sensor Screw 23-30 (2.5-3.5)
Lower Intake Manifold Bolts/Nuts (10)
Step 1 27 (3)
Step 2 89 (10)
Step 3 115 (13)
Step 4 (11)

Oil Pan Bolt/Nut (12) 71 (8)

Oil Pan-To-Transmission Bolt 62-89 (7-10)
Timing Chain Tensioner Bolts 89 (10)
Valve Cover Bolt (13) 62 (7)
Water Pump Bolt 71-108 (8-12)
(1) DO NOT reuse bolts.

(2) Tighten in sequence. See Fig. 7.

(3) Tighten in sequence. See Fig. 5.

(4) Tighten in sequence. See Fig. 13.

(5) Tighten in sequence. See Fig. 14.

(6) Tighten in sequence. See Fig. 3.

(7) Tighten in sequence. See Fig. 35.

(8) Tighten bolts evenly, 2 turns at a time.

(9) Tighten in sequence. See Fig. 2.

(10) Tighten in sequence. See Fig. 4.

(11) Tighten bolts/nuts to 12 Ft. Lbs. (16 N.m).

(12) Tighten in sequence. See Fig. 27.

(13) Tighten in sequence. See Fig. 6.

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ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS
Application Specification
Displacement 245 Cu. In. (4.0L)
Bore 3.94" (100 mm)
Stroke 3.31" (84 mm)
Compression Ratio 9.0:1
Fuel System SFI

CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Application In. (mm)
Crankshaft
End Play
Standard .0020-.0125 (.05-.32)
Service Limit .0125 (.32)
Main Bearings
Journal Diameter 2.2433-2.2441 (56.980-
57.000)
Journal Out-Of-Round .0006 (.015)
Journal Taper (1) .0006 (.015)

Journal Runout (Max.) .002 (.05)

Oil Clearance
Desired .0008-.0015 (.020-.038)
Allowable .0005-.0022 (.013-.055)
Connecting Rod Bearings
Journal Diameter 2.1252-2.1260 (53.980-
54.000)
Journal Out-Of-Round .0003 (.008)
Journal Taper (1) .0003 (.008)

Oil Clearance
Desired .0003-.0024 (.008-.061)
Allowable .0005-.0022 (.013-.056)
(1) Specification listed is per 1" (25.4 mm).

CONNECTING RODS SPECIFICATIONS

CONNECTING RODS

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Application In. (mm)

Bore Diameter
Pin Bore .9217-.9236 (23.411-23.459)
Crankpin Bore 2.2370-2.2378 (56.820-56.840)
Center-To-Center Length 5.7467-5.7494 (145.966-146.035)
Maximum Bend (1) .0005 (.013)
Maximum Twist (1) .0015 (.038)
Side Play
Standard .0036-.0106 (.091-.269)
Service Limit .014 (.36)
(1) Specification listed is measured at the ends of an 8" (203 mm) bar, 4" (102 mm) on each side of rod
center line.

PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS

PISTONS, PINS & RINGS

Application In. (mm)
Pistons
Clearance .0008-.0019 (.020-.048)
Diameter (1) 3.9524-3.9531 (100.390-100.409)

Pin Bore Diameter .9450-.9452 (24.003-24.008)

Pins
Diameter
Red Pin .9446-.9448 (23.993-23.998)
Blue Pin .9448-.9449 (23.998-24.000)
Length 2.84-2.87 (72.1-72.9)
Piston Fit .0003-.0006 (.008-.015)
Rod Fit Press Fit
Rings
No. 1 & 2
End Gap .015-.023 (.38-.58)
Side Clearance .0020-.0033 (.051-.084)
No. 3 (Oil)
End Gap (Steel Rail) .015-.055 (.38-1.40)
Side Clearance Snug Fit
(1) Measure at piston pin bore, 90 degrees to pin.

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK
Application In. (mm)

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Cylinder Bore
Standard Diameter 3.9527-3.9543 (100.398-100.439)
Maximum Taper .010 (.25)
Maximum Out-Of-Round
Standard .0015 (.038)
Service Limit .005 (.13)
Maximum Deck Warpage (1)

(1) .003" (.08mm) within a 6" (152 mm) area or .006" (.15 mm) overall.

ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS

Application Specification
Face Angle 44°
Face Runout .002" (.051 mm)
Head Diameter
Intake 1.71" (43.5 mm)
Exhaust 1.36" (34.5 mm)
Stem Diameter
Intake .3159-.3167" (8.024-8.044 mm)
Exhaust .3149-.3156" (8.998-8.016 mm)
Valve Margin .031" (.79 mm)
Valve Springs
Free Length 1.91" (48.5 mm)
Installed Height 1.58-1.61" (40.1-40.9 mm)
Out-Of-Square .078" (1.98 mm)
Lbs. @ In. (kg @ mm)
Pressure
Closed 60-68 @ 1.59 (27-31 @ 37.8)
Open 138-149 @ 1.22 (63-68 @ 31.0)

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD
Application Specification
Maximum Warpage (1) .003" (.08 mm)
Valve Seats
Seat Angle 45°
Seat Width .060-.079" (1.52-2.00 mm)
Maximum Seat Runout .0015" (.038 mm)
Valve Guides

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Valve Guide Bore I.D. .3174-.3184" (8.062-8.087 mm)

Valve Stem-To-Guide Oil Clearance
Intake .0008-.0025" (.020-.064 mm)
Exhaust .0018-.0035" (.046-.089 mm)
(1) Specification listed is within 6" (152 mm). Overall warpage is .006" (.15 mm). DO NOT machine
more than .010" (.25 mm) from original gasket surface.

CAMSHAFT SPECIFICATIONS

CAMSHAFT
Application In. (mm)
Camshaft Bearing I.D.
No. 1 1.951-1.952 (49.56-49.58)
No. 2 1.937-1.938 (49.20-49.23)
No. 3 1.922-1.923 (48.82-48.84)
No. 4 1.907-1.908 (48.44-48.46)
End Play .002-.013 (.051-.318)
Journal Runout .005 (.13)
Lobe Lift Wear Limit .005 (.13)
Oil Clearance
Standard .0010-.0026 (.025-.066)
Service Limit .006 (.15)
Valve Lift .4024 (10.220)

VALVE LIFTERS SPECIFICATIONS

VALVE LIFTERS
Application In. (mm)
Lifter Diameter .8742-.8755 (22.205-22.238)
Oil Clearance
Standard .0005-.0022 (.013-.056)
Service Limit .005 (.13)

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