Engine - 4.0L SOHC: Overhaul Ford Ranger I

Assembly

Note. Prior to assembly, coat all of the valve train components with clean engine oil.

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1. Install the camshaft.
2. Position the camshaft bearing caps, the oil supply tube, and the bolts.
3. Tighten the camshaft bearing cap bolts in two stages in the sequence shown. Stage 1: Tighten to 6 Nm (53 lb-in). Stage 2: Tighten to 16 Nm (12 lb-ft).
4. Install the valve.
5. Using the special tool, install the valve stem seals.
6. Position the valve spring and the valve spring retainer.
7. Install the special tool between the valve spring coils to prevent valve stem seal damage.
8. Using the special tool to compress the valve spring, install the valve spring retainer keys.
9. Repeat the procedure until all of the valves are installed.
10. Install the spark plugs.
11. Install the camshaft roller followers only when the cylinder head is installed in the vehicle and the timing procedure has been carried out.

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All Vehicles

Note. Before engine assembly, use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

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1. Install the upper crankshaft main bearings and the thrust bearing. Lubricate the crankshaft main bearings with clean engine oil.
2. Install the crankshaft.
3. Apply silicone gasket and sealant to the rear main bearing cap to cylinder block parting line.
4. Install the crankshaft lower main bearings in the main bearing caps.
5. Install the main bearing caps.
6. Tighten the main bearing cap bolts in two stages in the sequence shown. Tighten bolts to 35 Nm (26 lb-ft). Tighten bolts an additional 57 degrees.
7. Lubricate the piston rings with clean engine oil.
8. Make sure that the piston rings are correctly spaced. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION - RANGER»(ref-204976) .
9. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.
10. Using the special tool, install the pistons.
11. Check the clearance of each connecting rod bearing. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION - RANGER»(ref-204976) .
12. Rotate the crankshaft until the piston is at the bottom of its stroke.
13. Loosen the first nut until the face is approximately 2 mm (0.08 in) over the end of the bolt.
14. Tap the bolt on the nut until it can be removed by hand.
15. Repeat previous two steps for the opposite bolt.
16. Install the new bolts making certain that the bolt head is parallel to the sideward face of the connecting rod.
17. Install the connecting rod cap in the original position.
18. Install and tighten the connecting rod nuts finger tight.
19. Tighten the connecting rod nuts simultaneously in two stages: Stage 1: Tighten 20 Nm (15 lb-ft). Stage 2: Tighten 90 degrees.
20. Repeat previous four steps for the remaining connecting rods.
21. Rotate crankshaft until No.1 piston is at top dead center.
22. Install the oil pump.
23. Install the jackshaft.
24. Install the jackshaft thrust plate and bolts.
25. Install the oil pump drive.
26. Attach the rear cassette and sprocket to the bolt. Do not tighten at this time.
27. Install the rear cassette and bolt.
28. Install the front cassette and bolt.
29. Position the jackshaft sprocket and chain.
30. Install the chain guide.
31. Install the chain tensioner.
32. Install the bolt. Do not tighten at this time.
33. While holding the front jackshaft sprocket bolt secure, tighten the rear bolt to 20 Nm (15 lb-ft).
34. Install the special tool on the rear of the jackshaft.
35. Tighten the rear bolt an additional 90 degrees.
36. Tighten the front bolt in two stages. Stage 1: Tighten to 45 Nm (33 lb-ft). Stage 2: Tighten 90 degrees.
37. Remove the special tool and install the rear jackshaft plug.
38. Position the front cover gasket and install the front cover.
39. Apply silicone gasket and sealant to the front cover in four places.
40. Apply silicone gasket and sealant to the rear main bearing cap as shown. Position the ladder frame gasket.
41. Loosen the ladder frame inserts.
42. Position the ladder frame and gasket assembly.
43. Install and hand-tighten the fifteen bolts and two nuts.
44. Install and hand-tighten the bolts.
45. Using a straightedge, align the transmission face of the ladder frame with the rear face of the cylinder block.
46. Tighten the fifteen bolts and two nuts.
47. Tighten the bolts.
48. Tighten the inserts.
49. Install new seals on the two silver bolts and position them in the ladder frame.
50. Position the six remaining bolts.
51. Tighten the ladder frame bolts in two stages. Stage 1: Tighten to 15 Nm (11 lb-ft). Stage 2: Tighten to 33 Nm (24 lb-ft).
52. Measure the step between the rear face of the cylinder block and the transmission face of the ladder frame.
53. Repair all assemblies that exceed underflush specification by installing shims on one or both sides of the ladder frame.
54. Install the oil pump screen cover and tube.
55. Install the gasket, and the oil pan.
56. Install the oil filter adapter.
57. Install the oil filter.
58. Install the water pump.
59. Install the cylinder head gasket.
60. Install the cylinder head and tighten the bolts in the sequence shown in two stages. Stage 1: Tighten to 12 Nm (9 lb-ft). Stage 2: Tighten to 25 Nm (18 lb-ft).
61. Install the two 8 mm bolts.
62. Tighten the bolts in the sequence shown in two stages. Stage 1: Rotate 90 degrees. Stage 2: Rotate an additional 90 degrees.
63. Using the special tool, install the crankshaft pulley.
64. Tighten the bolt in two stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Rotate an additional 90 degrees.
65. Install the RH rear camshaft bolt.
66. Install the bolt.
67. Install the LH front camshaft bolt.
68. Install the bolt.
69. Turn the crankshaft one revolution clockwise.
70. Install the special tool.
71. Install the special tools on the front of the RH cylinder head.
72. Install the special tools on the rear of the RH cylinder head.
73. Install the special tool.
74. Tighten the bolts. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). Tighten the camshaft bolt.
75. Remove the special tool and install the RH camshaft tensioner.
76. Remove the special tools from the RH cylinder head.
77. Install the special tools on the front of the LH cylinder head.
78. Install the special tools on the rear of the LH cylinder head.
79. Install the special tool.
80. Tighten the bolts. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). Tighten the camshaft bolt.
81. Remove the special tool and install the LH camshaft tensioner.
82. Remove the special tools from the LH cylinder head.
83. Remove the special tool.
84. Using the special tool, install the roller followers in their original position.
85. Install the gasket and the LH exhaust manifold.
86. Install the gasket and the RH exhaust manifold.
87. Install the knock sensor.
88. Install the oil level indicator tube.
89. Install the thermostat housing. Install the housing into the bypass hose. Install the bolts. Position the bypass hose clamp.
90. Install the fuel injectors. Lubricate the fuel injector O-ring seals with engine oil.
91. Install the gasket and the RH valve cover.
92. Install the gasket and the LH valve cover.
93. Install the fuel injection supply manifold.
94. Install the lower fuel line bracket.
95. Connect the EGR valve to exhaust manifold tube to the exhaust manifold.
96. Install the fuel charging wiring.
97. Connect the six fuel injector electrical connectors.
98. Connect the water temperature indicator sender unit and the Engine Coolant Temperature (ECT) sensor electrical connectors.
99. Connect the Crankshaft Position (CKP) sensor electrical connector.
100. Connect the differential pressure feedback EGR transducer.
101. Connect the Camshaft Position (CMP) sensor electrical connector.
102. Attach the wiring harness retainer and install the heater tube bracket assembly.
103. Install the bolts.
104. Position the intake manifold close to the installed position.
105. Install the heated Positive Crankcase Ventilation (PCV) fitting.
106. Install the intake manifold.
107. Connect and attach the electrical connector.
108. Connect the vacuum hoses.
109. Install the coil and ignition wire. Install the bolt.
110. Install the bolts.
111. Connect the spark plug wires to the spark plugs.
112. Connect the Exhaust Gas Recirculation (EGR) vacuum regulator.
113. Connect the radio ignition interference capacitor electrical connector.
114. Connect the ignition coil electrical connector.
115. Connect the EGR valve-to-exhaust manifold tube to the EGR valve.
116. Connect the Idle Air Control (IAC) valve electrical connector and connect the EGR valve vacuum hose.
117. Connect the Throttle Position (TP) sensor electrical connector.
118. Install the generator mounting bracket. Install the generator mounting bracket bolts. Install the drive belt tensioner bolt.
119. Install the accessory bracket and tighten the bolts.
120. Rotate the drive belt tensioner counterclockwise and install the drive belt.
121. Install the Lifting Eyes.
122. Install the Spreader Bar to the Lifting Eyes.
123. Attach an appropriate engine crane to the engine and remove the engine from the engine stand. Vehicles Equipped With An Automatic Transmission
124. Install the spacer plate. All Vehicles
125. Position the flexplate or flywheel and install the bolts. Tighten the bolts in the sequence shown in two stages. Stage 1: Tighten the bolts to 13 Nm (10 lb-ft). Stage 2: Tighten the bolts to 71 Nm (52 lb-ft). Vehicles Equipped With A Manual Transmission
126. Lubricate the transmission input shaft pilot bearing, using front axle grease.
127. Adjust the clutch pressure plate. Using a suitable press, press downward on the fingers until the adjusting ring moves freely. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
128. Using the special tool, position the clutch disc on the flywheel.
129. Position the pressure plate and install the bolts. Tighten the bolts in a star pattern sequence.

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