Engine - 4.0L SOHC: Other Ford Ranger I

Material

MATERIAL SPECIFICATION

Scheme 1220

1. Remove the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-204985) .
2. Remove the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
3. Using the special tool, remove the crankshaft pulley bolt.
4. Using the special tool, remove the crankshaft pulley.

Scheme 1221

Scheme 1222

1. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
2. Using the special tool, install the crankshaft pulley.
3. Using the special tool, install a new crankshaft pulley bolt. Tighten the bolt in two stages: Stage 1: Tighten the bolt to 50 Nm (37 lb-ft). Stage 2: Tighten the bolt an additional 90 degrees.
4. Install the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
5. Install the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-204985) .

Scheme 1223

MATERIAL SPECIFICATION

Scheme 1224

1. Remove the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-204984-S29677217772005111600000) .
2. Using the special tool, remove the crankshaft front oil seal.

MATERIAL SPECIFICATION

Scheme 1225

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Scheme 1237

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
2. Remove the crankshaft front oil seal. For additional information, refer to «CRANKSHAFT FRONT OIL SEAL»(ref-204984-S08312908352005111600000) .
3. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-204985) .
4. On A/C equipped vehicles, remove the A/C line bracket bolt and position the A/C line aside.
5. Remove the lower cylinder block cradle-to-engine front cover bolts.
6. Lower the vehicle.
7. Remove the bolt and the wiring harness routing clip.
8. Remove the accessory bracket bolts and position the bracket aside.
9. Remove the drivebelt tensioner.
10. Disconnect the generator wiring and position the wiring aside.
11. Remove the generator mounting bracket.
12. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
13. Remove the wiring anchors and position the wiring aside.
14. Remove the wiring harness retainer and position the wiring aside.
15. Move the lower bypass hose clamp off of the coolant pump outlet.
16. Release the hose clamp and remove the lower heater water hose.
17. Release the hose clamp and remove the lower radiator hose.
18. Remove the bolts and the engine front cover. Discard the gasket.

Scheme 1238

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Scheme 1253

1. Clean and inspect the sealing surfaces. Install a new gasket.
2. Apply silicone gasket and sealant to the oil pan and the engine block mating surfaces.
3. Apply silicone gasket and sealant to the front cover in two places.
4. Install the engine front cover.
5. Connect the coolant bypass hose clamp.
6. Install the lower radiator hose and clamp.
7. Install the lower heater water hose and clamp.
8. Position the wiring harness and install the bolt.
9. Secure the wiring anchors.
10. Connect the CKP sensor electrical connector.
11. Install the generator mounting bracket.
12. Connect the generator wiring.
13. Install the drivebelt tensioner.
14. Install the accessory bracket bolts.
15. Install the routing clip and bolt.
16. Raise and support the vehicle.
17. Install the cylinder block cradle-to-engine front cover bolts.
18. On A/C equipped vehicles, install the A/C line bracket and bolt.
19. Drain the engine oil.
20. Lower the vehicle.
21. Install crankshaft front oil seal. For additional information, refer to «CRANKSHAFT FRONT OIL SEAL»(ref-204984-S08312908352005111600000) .
22. Fill the engine with clean engine oil.
23. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204997) .
24. Fill the engine with coolant. For additional information, refer to «ENGINE COOLING»(ref-204985) .

Scheme 1254

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Scheme 1267

1. Remove the valve covers. For additional information, refer to «VALVE COVER - RH»(ref-204984-S02255971572005111600000) and «VALVE COVER - LH»(ref-204984-S37839882192005111600000) .
2. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-204984-S01911419402005111600000) .
3. Remove the fuel supply manifold. For additional information, refer to «FUEL SYSTEMS»(ref-142378-S26708405812002073100000) .
4. Remove the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
5. Remove the thermostat housing. For additional information, refer to «ENGINE COOLING»(ref-204985) .
6. Remove the roller followers. For additional information, refer to «ROLLER FOLLOWERS»(ref-204984-S24291439952005111600000) .
7. Turn the crankshaft clockwise to position the number one cylinder at TDC.
8. Install the special tool.
9. Using the special tool, loosen the RH camshaft sprocket bolt.
10. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools and install the special tools on the front of the RH cylinder head.
11. Raise and support the vehicle.
12. Remove the RH wheel and tire. For additional information, refer to «WHEELS & TIRES»(ref-204955) .
13. Remove the RH lower splash shield.
14. Remove the RH camshaft tensioner.
15. Lower the vehicle.
16. Install the special tools on the rear of the RH cylinder head.
17. Install the special tool.
18. Tighten the bolts. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). Tighten the camshaft bolt.
19. Remove the special tool.
20. Install the RH camshaft tensioner.
21. Raise the vehicle.
22. Install the RH lower splash shield.
23. Install the RH wheel and tire. For additional information, refer to «WHEELS & TIRES»(ref-204955) .
24. Lower the vehicle.
25. Remove the special tools from the RH cylinder head.
26. Remove the LH camshaft tensioner.
27. Install the special tools on the front of the LH cylinder head and tighten the top two clamp bolts to 10 Nm (89 lb-in).
28. Loosen the LH camshaft sprocket bolt.
29. Loosen the top two clamp bolts on the special tool to allow the camshaft sprocket to rotate freely.
30. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools, and install the special tools on the rear of the LH cylinder head.
31. Install the special tool.
32. Tighten the bolts. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). Tighten the camshaft bolt.
33. Remove the special tool.
34. Install the LH camshaft tensioner.
35. Remove all of the special tools.
36. Install the roller followers. For additional information, refer to «ROLLER FOLLOWERS»(ref-204984-S24291439952005111600000) .
37. Install the thermostat housing. For additional information, refer to «ENGINE COOLING»(ref-204985) .
38. Install the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
39. Install the fuel supply manifold. For additional information, refer to «FUEL SYSTEMS»(ref-142378-S26708405812002073100000) .
40. Install the lower intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-204984-S01911419402005111600000) .
41. Install the valve covers. For additional information, refer to «VALVE COVER - LH»(ref-204984-S37839882192005111600000) and «VALVE COVER - RH»(ref-204984-S02255971572005111600000) .

Scheme 1268

Scheme 1269

1. Remove the wheel and tire. For additional information, refer to «WHEELS & TIRES»(ref-204955) .
2. Remove the lower splash shield.
3. Remove the RH camshaft tensioner.
4. To install, reverse the removal procedure.

Scheme 1270

1. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-204984-S01911419402005111600000) .
2. Remove the thermostat housing. For additional information, refer to «ENGINE COOLING»(ref-204985) .
3. Remove the LH camshaft tensioner.
4. To install, reverse the removal procedure.

Scheme 1271

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Scheme 1278

1. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-204984-S01911419402005111600000) .
2. Remove valve covers. For additional information, refer to «VALVE COVER - RH»(ref-204984-S02255971572005111600000) and «VALVE COVER - LH»(ref-204984-S37839882192005111600000) .
3. Remove the fuel supply manifold. For additional information, refer to «FUEL SYSTEMS»(ref-142378-S26708405812002073100000) .
4. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-204984-S38019862582005111600000) .
5. Remove the thermostat housing. For additional information, refer to «ENGINE COOLING»(ref-204985) .
6. Remove all of the roller followers. For additional information, refer to «ROLLER FOLLOWERS»(ref-204984-S24291439952005111600000) .
7. Turn the crankshaft clockwise to position number one cylinder at TDC.
8. Remove the LH camshaft chain tensioner.
9. Remove the LH camshaft sprocket bolt. Install the special tools to hold the camshaft sprocket. Loosen but do not remove the bolt.
10. Remove the tool and bolt.
11. Hold the crankshaft from turning and loosen the jackshaft sprocket bolt.
12. Remove the primary chain tensioner.
13. Remove the primary chain and sprocket.
14. Remove the camshaft drive cassette. Remove the chain guide bolts. Remove the sprockets. Lift the chain and guide up and out of the cylinder head.
15. Clean all surfaces. Clean all debris from engine.

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Scheme 1284

Scheme 1285

1. Install the chain guide through the cylinder head.
2. Install the chain.
3. Install the new chain guide bolts.
4. Install the lower chain sprocket and the camshaft sprocket.
5. Install, but do not tighten the camshaft sprocket bolt.
6. Install the primary chain and gear.
7. Install the primary drive chain tensioner.
8. Hold the crankshaft from turning and tighten the jackshaft sprocket bolt in two stages. Stage 1: Tighten bolts to 45 Nm (33 lb-ft). Stage 2: Tighten bolts an additional 90 degrees.
9. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-204984-S38019862582005111600000) .
10. Time the engine. For additional information, refer to «TIMING DRIVE COMPONENTS - CAMSHAFT TIMING»(ref-204984-S02828196272005111600000) .

TIMING DRIVE COMPONENTS - CAMSHAFT DRIVE CASSETTE, RH

Note. For Timing Drive Components - Camshaft Drive Cassette, RH service information, see ENGINE under DISASSEMBLY.

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1. Remove the camshaft roller followers. For additional information, refer to «ROLLER FOLLOWERS»(ref-204984-S24291439952005111600000) .
2. Position the piston at Top Dead Center (TDC).
3. Remove the spark plug and apply compressed air in the cylinder to hold both valves in position.
4. Using the special tool to compress the valve spring, remove the valve spring retainer keys, the valve spring and the retainer.
5. Inspect the components. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION - RANGER»(ref-204976) .

Scheme 1288

Scheme 1289

Scheme 1290

1. Position the valve spring and the valve spring retainer.
2. Install the special tool between the valve spring coil to prevent valve stem seal damage.
3. Using the special tool to compress the valve spring, install the valve spring retainer keys.
4. Install the camshaft roller followers. For additional information, refer to «ROLLER FOLLOWERS»(ref-204984-S24291439952005111600000) .
5. Install the spark plug.
6. Repeat all steps for each cylinder being serviced.

Scheme 1291

MATERIAL SPECIFICATION

MATERIAL SPECIFICATION

Scheme 1292

1. Remove the camshaft roller followers. For additional information, refer to «ROLLER FOLLOWERS»(ref-204984-S24291439952005111600000) .
2. Remove the hydraulic lash adjusters.
3. To install, reverse the removal procedure.

Scheme 1293

MATERIAL SPECIFICATION

MATERIAL SPECIFICATION

Scheme 1294

Scheme 1295

1. Remove the camshaft roller followers. For additional information, refer to «ROLLER FOLLOWERS»(ref-204984-S24291439952005111600000) .
2. Remove the LH camshaft chain tensioner. For additional information, refer to «TIMING DRIVE COMPONENTS - HYDRAULIC CHAIN TENSIONER, LH»(ref-204984-S28918743682005111600000) .
3. Remove the bolt and the camshaft sprocket.
4. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube.
5. Remove the camshaft.

MATERIAL SPECIFICATION

Scheme 1296

1. Remove the camshaft roller followers. For additional information, refer to «ROLLER FOLLOWERS»(ref-204984-S24291439952005111600000) .
2. Remove the RH camshaft chain tensioner. For additional information, refer to «TIMING DRIVE COMPONENTS - HYDRAULIC CHAIN TENSIONER, RH»(ref-204984-S22318518892005111600000) .
3. Using the special tool, remove the bolt and the camshaft sprocket.
4. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube.
5. Remove the camshaft.

MATERIAL SPECIFICATION

Scheme 1297

Scheme 1298

1. Raise and support the vehicle.
2. Drain the engine oil.
3. Remove the bolts and the oil pan.
4. To install, reverse the removal procedure.

Scheme 1299

1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-204984-S42664671972005111600000) .
2. Remove the oil pump screen cover and tube.
3. To install, reverse the removal procedure.

Scheme 1300

1. Remove the clutch. For additional information, refer to «CLUTCHES»(ref-153163) .
2. Remove the bolts and the flywheel.

MATERIAL SPECIFICATION

MATERIAL SPECIFICATION

MATERIAL SPECIFICATION

Scheme 1301

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Scheme 1303

1. Remove the spark plugs.
2. Using the special tool, remove the camshaft roller followers.
3. Using the special tool to compress the valve spring, remove the valve spring retainer keys, the valve spring and the retainer.
4. Remove the valve.
5. Repeat the procedure until all of the valves are removed.
6. Remove the valve stem seals.
7. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube.
8. Remove the camshaft.
9. Inspect the cylinder head. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-204976) .

MATERIAL SPECIFICATION

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Scheme 1305

1. Remove the connecting rod bearings from the connecting rod and caps.
2. Remove the piston rings. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-204976) .
3. Using the special tool, press the piston pin out of the connecting rod and piston assembly.
4. Remove the connecting rod from the piston.
5. Clean and inspect the connecting rod and piston. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION - RANGER»(ref-204976) .

Scheme 1306

1. Install the large chamfered side of the connecting rod bearing bore facing toward the engine front on the RH bank connecting rod and facing toward the rear of the engine on LH bank connecting rod.
2. Position the piston pin in the bore aligned with the connecting rod bore.
3. Gradually heat the pin bore side of the connecting rod to approximately 232°C-316°C (467°F-626°F) and immediately install the piston pin.
4. Using the special tool, press the piston pin into the piston and connecting rod assembly.
5. Install the piston rings. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION - RANGER»(ref-204976) .

Scheme 1307

MATERIAL SPECIFICATION