Engine - 4.0L (SOHC): Removal & Installation Ford Ranger II

REMOVAL AND INSTALLATION

1. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-268732) article.
2. Disconnect the accelerator cable from the throttle body (TB).
3. If equipped, disconnect the speed control actuator cable from the TB.
4. Disconnect the throttle position (TP) sensor electrical connector.
5. Detach the wiring harness retainer.
6. Disconnect the idle air control motor electrical connector.
7. Disconnect the EGR valve vacuum hose connector.
8. Disconnect the exhaust manifold-to-EGR valve tube from the EGR valve. To install, tighten to 34 Nm (25 lb-ft).
9. Disconnect the evaporative emissions (EVAP) purge valve-to-intake manifold hose from the intake manifold.
10. Disconnect the EGR vacuum regulator solenoid electrical connector.
11. Disconnect the EGR vacuum regulator solenoid vacuum connector.
12. Disconnect the brake booster vacuum hose from the intake manifold.
13. Disconnect the RH spark plug wires from the ignition coil.
14. Detach the RH spark plug wire retainer from the intake manifold and position the spark plug wires aside.
15. Disconnect the ignition coil electrical connector.
16. Detach the wiring harness retainer from the ignition coil bracket.
17. Detach the accelerator cable retainer from the ignition coil bracket.
18. Disconnect the radio interference capacitor electrical connector.
19. Remove the 4 bolts and position the ignition coil and bracket aside. To install, tighten the lower rear bolt to 28 Nm (21 lb-ft). To install, tighten the lower front bolt to 23 Nm (17 lb-ft). To install, tighten the 2 upper bolts to 8 Nm (71 lb-in).
20. Disconnect the vacuum harness main vacuum connector from the intake manifold.
21. Remove the wiring harness-to-cowl bracket nut.
22. Disconnect the 3 PCM electrical connectors.
23. Remove the wiring harness ground wire stud bolt and position the wiring harness aside. To install, tighten to 10 Nm (89 lb-in).
24. Detach the knock sensor electrical connector from the intake manifold.
25. Loosen the bolts and lift up the intake manifold. To install, tighten to 10 Nm (89 lb-in).
26. Remove the heated PCV fitting bolts and detach the heated PCV fitting from the intake manifold. To install, tighten to 8 Nm (71 lb-in).
27. Remove the intake manifold.
28. Inspect the intake manifold gaskets. Install new gaskets if necessary.
29. To install, reverse the removal procedure.

1. Detach the accelerator cable from the throttle body (TB) and the accelerator cable bracket.
2. Detach the exhaust manifold-to-EGR valve tube from the EGR valve. To install, tighten to 34 Nm (25 lb-ft).
3. Disconnect the evaporative emission (EVAP) purge valve-to-intake manifold tube from the intake manifold.
4. Detach the EVAP purge valve-to-intake manifold tube retainer.
5. Disconnect the differential pressure feedback EGR sensor electrical connector.
6. Detach the wiring harness retainer from the differential pressure feedback EGR sensor.
7. Remove the differential pressure feedback EGR sensor.
8. Disconnect the camshaft position (CMP) sensor electrical connector.
9. Disconnect the EGR vacuum regulator solenoid electrical connector.
10. Disconnect the EGR vacuum regulator solenoid vacuum connector.
11. Remove the bolts and the EGR vacuum regulator solenoid. To install, tighten to 10 Nm (89 lb-in).
12. Disconnect the wiring harness electrical connectors.
13. Remove the bolt and position the wiring harness connectors and bracket aside. To install, tighten to 6 Nm (53 lb-in).
14. Disconnect the LH spark plug wires from the ignition coil.
15. Detach the LH spark plug wire retainer from the ignition coil bracket.
16. Detach the LH spark plug wire retainer from the valve cover stud bolt.
17. Disconnect the ignition coil electrical connector.
18. Detach the wiring harness retainer from the ignition coil bracket.
19. Disconnect the radio interference capacitor electrical connector.
20. Detach the accelerator cable bracket from the ignition coil.
21. Remove the 4 bolts and position the ignition coil and bracket aside. To install, tighten the lower rear bolt to 28 Nm (21 lb-ft). To install, tighten the lower front bolt to 23 Nm (17 lb-ft). To install, tighten the 2 upper bolts to 8 Nm (71 lb-in).
22. Disconnect the PCV hose from the PCV valve.
23. Disconnect the PCV valve electrical connector.
24. Disconnect the 3 LH fuel injector electrical connectors.
25. Detach the wiring harness retainer from the LH valve cover stud bolt.
26. Loosen the bolts and remove the LH valve cover. To install, tighten to 10 Nm (89 lb-in).
27. Clean the sealing surfaces and inspect the LH valve cover gasket. Install a new gasket if necessary.
28. To install, reverse the removal procedure.

Scheme 342

1. For additional information, refer to the procedures in this article.

REMOVAL

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-268709) article.
2. Remove the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-268733) article.
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-268742) article.
4. Using the special tool to hold the crankshaft pulley, remove the bolt and washer.
5. Install the crankshaft pulley bolt 2 to 3 turns. Using the special tools and the two 8-mm bolts, remove the crankshaft pulley. Discard the crankshaft pulley bolt and washer.

Scheme 343

Scheme 344

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 to hold the crankshaft pulley, install a new crankshaft pulley bolt and washer. Tighten the bolt in 2 stages. Stage 1: Tighten to 45 Nm (33 lb-ft). Stage 2: Tighten an additional 85 degrees.
4. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-268742) article.
5. Install the fan shroud. For additional information, refer to «ENGINE COOLING»(ref-268733) article.

INSTALLATION

1. Using the special tools, install a new crankshaft front seal.
2. Install the crankshaft pulley. For additional information, refer to «Crankshaft Pulley»(ref-268722-S41747269282007102600000) in this article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-268709) article.
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-268774) article.
3. Remove the crankshaft front seal. For additional information, refer to «Crankshaft Front Seal»(ref-268722-S01320116222007102600000) in this article.
4. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-268733) article.
5. Remove the nut and detach the A/C hose bracket from the front cover.
6. Remove the 5 cylinder block cradle-to-front cover bolts.
7. Remove the bolts and position the A/C compressor and power steering bracket aside.
8. Remove the nut and disconnect the generator wiring terminal.
9. Disconnect the 2 generator electrical connectors.
10. Remove the bolt and the accessory drive belt tensioner.
11. Remove the bolts and the generator bracket.
12. Disconnect the crankshaft position (CKP) sensor electrical connector.
13. Detach the wiring harness retainer.
14. Detach the wiring harness anchors and position the wiring harness aside. Discard the anchors.
15. Remove the bolt and detach the wiring harness from the LH cylinder head.
16. Position the bypass hose clamp off of the coolant pump outlet.
17. Disconnect the heater hose from the coolant pump.
18. Disconnect the lower radiator hose from the coolant pump.
19. Remove the 5 bolts, the 5 stud bolts, the engine front cover and the gasket. Discard the gasket.

1. Clean and inspect the gasket mating surfaces. Use silicone gasket remover and metal surface prep and a plastic scraping tool. Follow the directions on the packaging.
2. Position the front cover gasket.
3. Apply silicone gasket and sealant to the oil pan and engine block mating surfaces.
4. Apply silicone gasket and sealant to the front cover in 2 places.
5. Position the engine front cover and install the 5 bolts and 5 stud bolts. Tighten to 19 Nm (14 lb-ft).
6. Install the 5 cylinder block cradle-to-front cover bolts. Tighten bolts without washers to 14 Nm (10 lb-ft).
7. Attach the wiring harness to the LH cylinder head and install the bolt. Tighten to 10 Nm (89 lb-in).
8. Position the bypass hose clamp.
9. Connect the lower radiator hose to the coolant pump.
10. Connect the heater hose to the coolant pump.
11. Install new wiring harness anchors and position the CKP sensor wiring.
12. Attach the wiring harness retainer.
13. Connect the CKP sensor electrical connector.
14. Position the power steering and A/C compressor bracket and install the bolts. Tighten to 42 Nm (31 lb-ft).
15. Position the generator bracket and install the bolts. Tighten to 42 Nm (31 lb-ft).
16. Position the accessory drive belt tensioner and install the bolt. Tighten to 47 Nm (35 lb-ft).
17. Connect the generator electrical connectors.
18. Attach the generator terminal and install the nut. Tighten to 8 Nm (71 lb-in).
19. Position the A/C tube bracket and install the nut. Tighten to 20 Nm (15 lb-ft).
20. Drain the engine oil. Install the drain plug when finished. Tighten to 26 Nm (19 lb-ft).
21. Install the crankshaft front seal. For additional information, refer to «Crankshaft Front Seal»(ref-268722-S01320116222007102600000) in this article.
22. Fill the engine with clean engine oil.
23. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-268774) article.
24. Fill the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-268733) article.

1. Remove the hydraulic chain tensioner. To install, tighten to 44 Nm (32 lb-ft).
2. Remove and discard the O-ring seal.
3. To install, reverse the removal procedure.

1. Remove the intake manifold. For additional information, refer to «Intake Manifold»(ref-268722-S10681386672007102600000) in this article.
2. Remove the thermostat housing. For additional information, refer to «ENGINE COOLING»(ref-268733) article.
3. Remove the hydraulic chain tensioner. To install, tighten to 44 Nm (32 lb-ft).
4. Remove and discard the O-ring seal.
5. To install, reverse the removal procedure.

Scheme 345

Scheme 346

1. For additional information, refer to the procedures in this article.

Note. Lubricate the camshaft journal bearing surfaces on the cylinder head, the camshaft journals and the camshaft bearing caps with clean engine oil.

1. Remove the valve springs. For additional information, refer to «Valve Springs»(ref-268722-S31399118452007102600000) in this article.
2. Remove the valve seals.

1. Using the special tool, install the valve seal.
2. Install the valve springs. For additional information, refer to «Valve Springs»(ref-268722-S31399118452007102600000) in this article.

1. Remove the camshaft roller followers. For additional information, refer to «Camshaft Roller Follower»(ref-268722-S07100374202007102600000) in this article.
2. Remove the hydraulic lash adjusters.
3. To install, reverse the removal procedure.

Scheme 347

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-268709) article.
2. Detach the differential feedback pressure EGR sensor from the exhaust manifold-to-EGR valve tube.
3. Remove the exhaust manifold-to-EGR valve tube.
4. Remove the exhaust manifold-to-dual converter Y-pipe nuts.
5. Remove the 6 nuts, the LH exhaust manifold and the gasket. Discard the nuts and the gasket.
6. Remove and discard the 6 LH exhaust manifold studs.

1. Clean and inspect the LH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-268738) article.
2. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
3. Position a new gasket and the exhaust manifold and install 6 new nuts. Tighten to 22 Nm (16 lb-ft).
4. Position the dual converter Y-pipe and install the nuts. Tighten to 40 Nm (30 lb-ft).
5. Install the exhaust manifold-to-EGR valve tube. Tighten to 34 Nm (25 lb-ft).
6. Attach the differential pressure feedback EGR sensor to the exhaust manifold-to-EGR valve tube.

Scheme 348

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-268709) article.
2. Remove the exhaust manifold-to-dual converter Y-pipe nuts.
3. Remove the nuts, the RH exhaust manifold and the gasket. Discard the nuts and the gasket.
4. Remove and discard the 6 RH exhaust manifold studs.

1. Clean and inspect the RH exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-268738) article.
2. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
3. Position a new gasket and the RH exhaust manifold and install 6 new nuts. Tighten to 22 Nm (16 lb-ft).
4. Position the dual converter Y-pipe and install the nuts. To install, tighten to 40 Nm (30 lb-ft).

Scheme 349

1. For additional information, refer to the procedures in this article.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-268709) article.
2. Remove the drain plug and drain the engine oil. To install, tighten to 26 Nm (19 lb-ft).
3. Remove the bolts, the oil pan and the gasket. Discard the gasket. To install, tighten to 11 Nm (8 lb-ft).
4. Clean and inspect the sealing surfaces.
5. To install, reverse the removal procedure.
6. Fill the engine with clean engine oil.

1. Remove the oil pan. For additional information, refer to «Oil Pan»(ref-268722-S17222968592007102600000) in this article.
2. Remove the bolt and the oil pump screen and pickup tube. To install, tighten to 10 N.m (89 lb-in).
3. To install, reverse the removal procedure.

1. Remove the clutch. For additional information, refer to «CLUTCH»(ref-268748) article.
2. Remove the bolts and the flywheel.

1. Position the flywheel and install the bolts. Tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten to 13 Nm (10 lb-ft). Stage 2: Tighten to 50 Nm (37 lb-ft). Stage 3: Tighten an additional 90 degrees.
2. Install the clutch. For additional information, refer to «CLUTCH»(ref-268748) article.

Scheme 350

1. Remove the flexplate or flywheel. For additional information, refer to «Flexplate»(ref-268722-S24982284482007102600000) or «Flywheel»(ref-268722-S35317911552007102600000) in this article.
2. Remove the crankshaft spacer plate.
3. Remove the crankshaft spacer.
4. If necessary, remove the speedy sleeve using 2 screwdrivers or small pry bars.
5. Using the special tool, remove the crankshaft rear seal.

Scheme 351

Scheme 352

Scheme 353

1. Lubricate the crankshaft rear seal with clean engine oil.
2. Install the special tools.
3. Position the crankshaft rear seal.
4. Using the special tool, install the crankshaft rear seal.
5. Install the crankshaft spacer.
6. Install the spacer plate.
7. Install the flexplate or flywheel. For additional information, refer to «Flexplate»(ref-268722-S24982284482007102600000) or «Flywheel»(ref-268722-S35317911552007102600000) in this article.

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSMISSION - 5R44E AND 5R55E»(ref-268740) article.
2. Remove the bolts and the flexplate.

1. Install the flexplate. Tighten the bolts in 3 stages in the sequence shown. Stage 1: Tighten to 13 Nm (10 lb-ft). Stage 2: Tighten to 50 Nm (37 lb-ft). Stage 3: Tighten an additional 90 degrees.
2. Install the transmission. For additional information, refer to «AUTOMATIC TRANSMISSION - 5R44E AND 5R55E»(ref-268740) article.