GENERAL SPECIFICATIONS
| Item | Specification |
|---|---|
| Engine | |
| Displacement | 4.0L (244 CID) |
| Number of cylinders | 6 |
| Bore | 100.4 mm (3.953 in) |
| Stroke | 84.4 mm (3.32 in) |
| Firing order | 1-4-2-5-3-6 |
| Oil pressure minimum at 2,000 rpm (engine at normal operating temperature) | 103 kPa (15 psi) |
| Engine weight (without accessory drive components or flexplate) | 189 kg (417 lb) |
| Cylinder Head and Valve Train | |
| Cylinder head gasket surface flatness | 0.08 mm (0.003 in) total |
| Combustion chamber volume | 65.197 ± 2.068-2.018 cc |
| Valve arrangement (front to rear) - LH | I-E-I-E-I-E |
| Valve arrangement (front to rear) - RH | E-I-E-I-E-I |
| Valve guide bore diameter | 7.00-7.018 mm (0.276 in) |
| Valve stem diameter - intake | 6.965-6.98 mm (0.274-0.275 in) |
| Valve stem diameter - exhaust | 6.95-6.965 mm (0.27-0.274 in) |
| Valve stem-to-guide clearance - intake | 0.020-0.053 mm (0.001-0.002 in) |
| Valve stem-to-guide clearance - exhaust | 0.035-0.068 mm (0.001-0.003 in) |
| Valve head diameter - intake | 45.9-46.1 mm (1.807-1.815 in) |
| Valve head diameter - exhaust | 38.9-39.1 mm (1.531-1.539 in) |
| Valve face runout | 0.03 mm (0.001 in) |
| Valve face angle | 45 degrees |
| Valve seat width - intake | 1.273-2.121 mm (0.05-0.083 in) |
| Valve seat width - exhaust | 1.556-2.404 mm (0.061-0.095 in) |
| Valve seat runout | 0.059 mm (0.002 in) |
| Valve seat angle | 45 degrees |
| Valve spring free length | 43.1 mm (1.7 in) |
| Valve spring squareness | ± 1.5 degrees |
| Valve spring compression pressure @ specified height (lbs) | 275-305 N @ 35.9-36.7 mm (202.84-224.968 lb @ 1.413-1.445 in) |
| Valve spring installed height | 39.86-40.86 mm (1.569-1.609 in) |
| Valve spring installed pressure | 320 N (72 lb) |
| Roller follower ratio | 1.98:1 |
| Camshaft | |
| Theoretical valve lift @ 0 lash | 11.93 mm (0.472 in) |
| Lobe lift | 6.584 mm (0.259 in) |
| Allowable lobe lift loss | 0.127 mm (0.005 in) |
| Journal diameter | 27.935-27.96 mm (1.099-1.101 in) |
| Camshaft journal bore inside diameter | 28.0-28.03 mm (1.102-1.104 in) |
| Camshaft journal-to-bearing clearance | 0.04-0.095 mm (0.002-0.004 in) |
| Runout | 0.05 mm (0.002 in) |
| End play | 0.075-0.185 mm (0.003-0.007 in) |
| Cylinder Block | |
| Cylinder bore diameter | 100.4 mm (3.953 in) |
| Cylinder bore maximum taper | 0.025 mm (0.001 in) |
| Cylinder bore maximum out-of-round | 0.025 mm (0.001 in) |
| Main bearing bore inside diameter | 60.620-60.634 mm (2.387-2.387 in) |
| Head gasket surface flatness | 0.1 mm (0.004 in) overall |
| Crankshaft | |
| Main bearing journal diameter | 56.980-57.0 mm (2.243-2.244 in) |
| Main bearing journal maximum taper | 0.008 mm (0.0003 in) |
| Main bearing journal maximum out-of-round | 0.008 mm (0.0003 in) |
| Main bearing journal-to-cylinder block clearance | 0.008-0.062 mm (0.0003-0.0024 in) |
| Connecting rod journal diameter | 53.98-54.0 mm (2.125-2.126 in) |
| Connecting rod journal maximum taper | 0.008 mm (0.0003 in) |
| Connecting rod journal maximum out-of-round | 0.008 mm (0.0003 in) |
| Crankshaft maximum end play | 0.05-0.32 mm (0.002-0.0126 in) |
| Main Bearings | |
| Clearance to crankshaft | 0.021-0.039 mm (0.0008-0.0015 in) |
| Clearance to crankshaft allowable | 0.013-0.048 mm (0.0005-0.002 in) |
| Bearing wall thickness | 1.8-1.806 mm (0.0709-0.0711 in) |
| Piston and Connecting Rod | |
| Piston diameter - coded standard | 100.380-100.400 mm (3.952-3.9528 in) |
| Piston diameter - coded 0.5 | 100.880-100.900 mm (3.971-3.972 in) |
| Piston diameter - coded 1.0 | 101.390-101.400 mm (3.991-3.992 in) |
| Piston-to-cylinder bore clearance | 0.030-0.050 mm (0.0012-0.002 in) |
| Piston ring end gap - top | 0.200-0.450 mm (0.008-0.018 in) |
| Piston ring end gap - bottom | 0.40-0.60 mm (0.016-0.024 in) |
| Piston ring groove width - top | 1.23-1.25 mm (0.0484-0.0492 in) |
| Piston ring groove width - bottom | 1.52-1.54 mm (0.0598-0.0606 in) |
| Piston ring groove width - oil ring | 3.01-3.03 mm (0.1185-0.1193 in) |
| Piston ring width - top | 1.175-1.190 mm (0.0463-0.0469 in) |
| Piston ring width - bottom | 1.475-1.490 mm (0.0581-0.0587 in) |
| Piston ring-to-groove clearance - top | 0.040-0.075 mm (0.0016-0.0030 in) |
| Piston ring-to-groove clearance - bottom | 0.030-0.065 mm (0.0012-0.0026 in) |
| Piston pin bore diameter | 23.958-23.976 mm (0.943-0.944 in) |
| Piston pin diameter (red) | 23.994-23.997 mm (0.9446-0.9448 in) |
| Piston pin diameter (blue) | 23.997-24.000 mm (0.9448-0.9449 in) |
| Piston pin length | 72.0-72.8 mm (2.835-2.866 in) |
| Piston pin-to-piston fit | 0.01-0.016 mm (0.0004-0.0006 in) |
| Piston pin-to-connecting rod clearance | 0.01-0.016 mm (0.0004-0.0006 in) |
| Connecting rod pin bore diameter | 23.958-23.976 mm (0.943-0.944 in) |
| Connecting rod length (center-to-center) | 145.965-146.035 mm (5.747-5.749 in) |
| Connecting rod maximum allowed bend | 0.013 mm (0.0005 in) per 25.4 mm (1.000 in) |
| Connecting rod maximum allowed twist | 0.038 mm (0.0015 in) per 25.4 mm (1.000 in) |
| Connecting rod bearing bore diameter | 56.82 mm-56.84 mm (2.237 in-2.238 in) |
| Connecting rod bearing-to-crankshaft clearance | 0.022-0.064 mm (0.0008-0.0025 in) |
| Connecting rod side clearance | 0.092-0.268 mm (0.0036-0.0106 in) |
GENERAL SPECIFICATIONS
TORQUE SPECIFICATIONS
| Description | Nm |
|---|---|
| A/C line fitting nuts | 15 |
| A/C tube bracket nut | 10 |
| Accessory drive bracket bolts | 42 |
| Accessory drive belt tensioner bolt | 47 |
| Balance shaft bolts | 29 |
| Balance shaft chain guide bolts | 10 |
| Balance shaft chain tensioner bolts | 29 |
| Battery cable retainer bracket-to-frame nut | 15 |
| Battery cable-to-engine front cover bracket nut | 20 |
| Battery cable-to-power distribution box nut | 12 |
| Camshaft bearing cap bolts a | |
| Camshaft sprocket bolt | 85 |
| Camshaft sprocket bolt (w/SST) | 61 |
| Cassette-to-cylinder block bolt | 19 |
| Cassette-to-cylinder head bolt, RH | 10 |
| Cassette-to-cylinder head bolt, LH | 12 |
| Connecting rod bolts a | |
| Coolant expansion tank bolts | 7 |
| Coolant pump bolts | 10 |
| Coolant pump pulley bolts | 25 |
| Crankshaft pulley bolt a | |
| Crossmember bolts | 103 |
| Cylinder block cradle bolts (inside) a | |
| Cylinder block cradle bolts (outside) | 14 |
| Cylinder block cradle nuts (outside) | 10 |
| Cylinder block cradle inserts | 3 |
| Cylinder block cradle Torx bolts | 8 |
| Cylinder head bolts a | |
| Electrical harness-to-rear of engine bolts | 47 |
| Engine front cover bolts | 19 |
| Engine lifting eye bolts (service) | 37 |
| Engine support insulator bracket bolts | 80 |
| Engine support insulator nuts | 90 |
| Engine support insulator through bolt | 103 |
| Exhaust manifold nuts | 22 |
| Exhaust manifold studs | 12 |
| Exhaust manifold-to-converter nuts | 40 |
| Exhaust manifold-to-EGR system module tube fittings | 34 |
| Flexplate bolts a | |
| Front axle housing bolts | 66 |
| Front stabilizer bar bracket bolts | 55 |
| Fuel rail bolts | 24 |
| Fuel supply tube bracket-to-valve cover bolt | 6 |
| Fuel supply tube-to-fuel rail bolts | 6 |
| Generator bracket bolts | 42 |
| Generator wire nut | 9 |
| Ground strap-to-RH cylinder head bolt | 10 |
| Ground wire nut | 9 |
| Heater hose tube bracket front bolt | 34 |
| Heater hose tube bracket rear bolt | 23 |
| Hood hinge bolts | 12 |
| Hydraulic camshaft tensioner | 44 |
| Ignition coil bracket bolts | 10 |
| Intake manifold bolts | 11 |
| Jackshaft chain guide bolts | 19 |
| Jackshaft chain tensioner bolts | 9 |
| Jackshaft front sprocket bolt a | |
| Jackshaft rear sprocket bolt a | |
| Jackshaft thrust plate bolt | 11 |
| Knock sensor (KS) bolt | 20 |
| Main bearing cap bolts | 97 |
| Oil cooler hose bracket bolt | 25 |
| Oil cooler insert | 57 |
| Oil filter | 13 |
| Oil filter adapter bolt | 57 |
| Oil filter adapter insert | 33 |
| Oil level indicator tube bracket bolt | 10 |
| Oil pan bolts | 11 |
| Oil pan drain plug | 26 |
| Oil pressure switch | 13 |
| Oil pump bolts | 19 |
| Oil pump drive bolt | 19 |
| Oil pump screen cover and tube bolts | 10 |
| Power steering fluid reservoir bolt | 7 |
| Power steering fluid reservoir-to-power steering pump hose bracket bolt | 11 |
| Power steering pressure hose bracket bolt | 11 |
| Power steering pump bolts | 25 |
| Power steering pump pulley bolts | 25 |
| Radiator fan shroud bolts | 7 |
| Spark plugs | 20 |
| Stabilizer bar bracket bolts | 70 |
| Starter B terminal nut | 12 |
| Starter S terminal nut | 6 |
| Thermostat housing bolts | 11 |
| Transmission cooler tube bracket nut | 23 |
| Transmission-to-cylinder block cradle bolts | 47 |
| Valve cover bolts | 10 |
| Wiring harness-to-front cover bracket nut | 20 |
| Wiring harness-to-RH cylinder head bracket bolt | 47 |
| Wiring harness-to-throttle body bracket nut | 9 |
TORQUE SPECIFICATIONS
a Refer to the appropriate procedures.
The 4.0L SOHC engine consists of the following
- Single overhead camshafts
- Sequential multi-port fuel injection (SFI)
- Distributorless ignition system
- Aluminum cylinder heads
- Cast-iron, 60-degree V cylinder block
- Jackshaft
- Unique engine timing configuration
The 4.0L engine is a 2-valve-per-cylinder, overhead camshaft engine. The engine features a jackshaft located in the cylinder block above the crankshaft and driven by the crankshaft via a sprocket and chain assembly. The jackshaft drives the 2 camshafts via 2 timing chain cassettes, the LH located on the front of the engine and the RH located on the rear of the engine. The oil pump is driven by the crankshaft via a sprocket and chain. The piston assembly is an aluminum piston with a powdered metal connecting rod. The engine uses a distributorless ignition system.
Identification - Always refer to these labels when installation of new parts is necessary, or when checking engine calibrations. The engine parts often differ within a cubic inch displacement (CID) family. Verification of the identification codes will make sure that the correct parts are obtained. These codes contain all the pertinent information relating to the dates, optional equipment and revisions. The Ford Master Parts Catalog contains a complete listing of the codes and their application
Code Information - The engine code information label, located on the side of the valve cover and the front side of the valve cover, contains the
- engine build date.
- engine plant code.
- engine code.
Exhaust Emission Control System - Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered in the Introduction - Gasoline Engines .
Induction System - The sequential multi-port fuel injection (SFI) provides the fuel/air mixture needed for combustion in the cylinders. The 6 solenoid-operated fuel injectors
- are mounted in the cylinder heads.
- meter fuel to the air intake stream in accordance with engine demand.
- are positioned so their tips direct fuel just ahead of the engine intake valves.
PCV System - All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the intake manifold.
Lubrication System - The engine lubrication system operates as follows
- Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan.
- Oil is pumped through the oil filter on the right front side of the cylinder block.
- Oil enters the main gallery where it is distributed to the crankshaft main journals and to the cylinder head.
- From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod, piston and piston ring assembly.
Scheme 1
For basic engine mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION . For driveability concerns, refer to the Introduction - Gasoline Engines .
See also:
• AUTOMATIC TRANSAXLE/TRANSMISSION - 5R55S