GENERAL SPECIFICATIONS
| Item | Specification |
|---|---|
| Engine - 4.0L SOHC | |
| Displacement | 4.0L (244 cu in) |
| 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 |
| Minimum oil pressure at 2,000 RPM (engine at normal operating temperature) | 103 kPa (15 psi) |
| Engine weight (without accessory drive components or flexplate or flywheel) | 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 cc ± 2.068-2.018 cc |
| Valve arrangement (front to rear) | LH=I-E-I-E-I-E RH=E-I-E-I-E-I |
| Valve guide bore diameter | 7.00-7.018 mm (0.2756-0.2762 in) |
| Valve stem diameter intake | 6.965-6.98 mm (0.274-0.275 in) |
| Valve stem diameter exhaust | 6.95-6.965 mm (0.274 in) |
| Valve stem-to-guide clearance exhaust | 0.035-0.068 mm (0.001-0.003 in) |
| Valve stem-to-guide clearance intake | 0.020-0.053 mm (0.001-0.002 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 (exhaust and intake) | 1.556-2.404 mm (0.06-0.094 in) 1.273-2.121 mm (0.05-0.083 in) |
| Valve seat runout (TIR maximum) | 0.059 mm (0.002 in) |
| Valve seat angle | 45 degrees |
| Valve spring free length intake | 43.1 mm (1.7 in) |
| Valve spring free length exhaust | 43.1 mm (1.7 in) |
| Valve spring squareness | ± 1.5 deg |
| Valve spring compression pressure intake (at specified height) (lb) | 275-305 N.m at 35.9-36.7 mm (202.84-224.968 lb-ft at 1.413-1.445 in) |
| Valve spring compression pressure exhaust (at specified height) (lb) | 275-305 N.m at 35.9-36.7 mm (202.84-224.968 lb-ft at 1.413-1.445 in) |
| Valve spring installed height intake | 39.86-40.86 mm (1.569-1.608 in) |
| Valve spring installed height exhaust | 39.86-40.68 mm (1.569-1.608 in) |
| Valve spring installed pressure | 320 newtons |
| Roller follower ratio | 1.98:1 |
| Camshaft | |
| Theoretical valve lift @ 0 lash | 12 mm (0.47 in) |
| Lobe lift intake | 6.584 mm (0.259 in) |
| Lobe lift exhaust | 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) |
| Journal bore inside diameter | 28.0-28.03 mm (1.102-1.104 in) |
| Journal to bearing clearance a | 0.04-0.095 mm (0.002-0.004 in) |
| Runout | 0.05 mm (0.002 in) |
| End play | 0.075-0.185 mm (0.0003-0.007 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 | 60.634-60.620 mm (2.387-2.387 in) |
| Head gasket surface flatness | 0.1 mm (0.004 in) overall |
| Head gasket surface finish (RMS) | 60-150 |
| 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 STD | 100.380-100.400 mm (3.952-3.9528 in) |
| Piston diameter - coded 0.5 | 100.880-100.900 mm (3.972 in) |
| Piston diameter - coded 1.0 | 101.350-101.370 mm (3.990-3.991 in) |
| Piston-to-cylinder bore clearance | 0.030-0.060 mm (0.0012-0.0023 in) |
| Piston top ring end gap | 0.200-0.450 mm (0.008-0.018 in) |
| Piston bottom ring end gap | 0.450-0.700 mm (0.018-0.028 in) |
| Piston top ring groove width | 1.64-1.66 mm (0.0645-0.0654 in) |
| Piston bottom ring groove width | 1.79-1.81 mm (0.0705-0.0713 in) |
| Piston oil ring groove width | 3.5-3.53 mm (0.1378-0.1399 in) |
| Piston top ring width | 1.578-1.598 mm (0.062-0.063 in) |
| Piston bottom ring width | 1.728-1.74 mm (0.068-0.069 in) |
| Piston top ring-to-groove clearance | 0.050-0.082 mm (0.002-0.003 in) |
| Piston bottom ring-to-groove clearance | 0.050-0.082 mm (0.002-0.003 in) |
| Piston pin bore diameter (red) | 24.007-24.010 mm (0.9451-0.9452 in) |
| Piston pin bore diameter (blue) | 24.010-24.013 mm (0.9452-0.9453 in) |
| Piston pin diameter (red) | 23.994-23.997 mm (0.9446-0.9447 in) |
| Piston pin diameter (blue) | 23.997-24.000 mm (0.9447-0.9449 in) |
| Piston pin length | 72.0-72.8 mm (2.835-2.866 in) |
| Piston pin-to-piston pin fit | 0.01-0.016 mm (0.0004-0.0006 in) |
| Piston pin-to-connecting rod clearance | Press fit -0.018 to -0.042 mm (-0.0007 to -0.0017 in) |
| Connecting rod pin bore diameter | 23.958-23.976 mm (0.943-0.944 in) |
| Connecting rod length | 145.965-146.035 mm (5.746-5.749 in) |
| Connecting rod maximum allowed bend | 0.0125 mm (0.00049 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 | 56.82-56.84 mm (2.2370-2.2378 in) |
| Connecting rod bearing-to-crankshaft clearance | 0.022-0.064 mm (0.0008-0.0025 in) |
| Connecting rod side clearance (assembled to crankshaft) | 0.092-0.268 mm (0.0036-0.0106 in) |
GENERAL SPECIFICATIONS
a Tighten camshaft bearing cap bolts to 15 N.m (11 lb-ft) when measuring journal clearance.
TORQUE SPECIFICATIONS
| Description | Nm |
|---|---|
| A/C compressor and power steering bracket bolts | 42 |
| A/C compressor manifold bolt | 20 |
| A/C hose bracket nut | 20 |
| Accessory drive belt tensioner bolt | 47 |
| Camshaft bearing cap bolts a | |
| Camshaft sprocket bolt | 85 |
| Camshaft sprocket bolt (w/SST) | 61 |
| Cassette and sprocket-to-jackshaft bolt a | |
| Cassette-to-cylinder head bolt, LH | 12 |
| Cassette-to-cylinder head bolt, RH | 10 |
| Cassette-to-engine block bolt | 19 |
| Connecting rod nuts a | |
| Coolant pump bolts | 10 |
| Crankshaft pulley bolt a | |
| Cylinder block cradle nuts (outside) | 10 |
| Cylinder block cradle bolts (outside) | 14 |
| Cylinder block cradle bolts (inside) a | |
| Cylinder block cradle Torx® bolts | 8 |
| Cylinder block cradle inserts | 3 |
| Cylinder head bolts a | |
| EGR vacuum regulator bolts | 10 |
| Engine front cover bolts | 19 |
| Engine support insulator bracket bolts | 62 |
| Engine support insulator-to-engine bracket nuts | 110 |
| Engine support insulator-to-frame nuts | 103 |
| Exhaust manifold nuts | 22 |
| Exhaust manifold studs | 12 |
| Exhaust manifold-to-dual converter Y-pipe nuts | 40 |
| Exhaust manifold-to-EGR valve tube | 34 |
| Fan shroud bolts | 10 |
| Flexplate bolts a | |
| Flywheel bolts a | |
| Front axle bolts | 66 |
| Front axle dampener bolts | 70 |
| Fuel rail bolts | 23 |
| Fuel tube bracket-to-RH cylinder head bolt | 28 |
| Generator bracket bolts | 42 |
| Generator terminal nut | 8 |
| Ground wire-to-cowl bolt | 10 |
| Ground wire-to-engine bolt | 25 |
| Heated PCV fitting-to-intake manifold bolts | 8 |
| Heater tube assembly front bolt | 28 |
| Heater tube assembly rear bolt | 23 |
| Hydraulic camshaft tensioner | 44 |
| Ignition coil bracket lower front bolt | 23 |
| Ignition coil bracket lower rear bolts | 28 |
| Ignition coil bracket upper bolts | 8 |
| Intake manifold bolts | 10 |
| Jackshaft chain guide bolts | 19 |
| Jackshaft chain tensioner bolts | 9 |
| Jackshaft front sprocket bolt a | |
| Jackshaft rear sprocket bolt a | |
| Jackshaft thrust plate bolts | 11 |
| Knock sensor (KS) bolt | 25 |
| Main bearing cap bolts a | |
| Oil filter | 13 |
| Oil filter adapter bolt | 57 |
| Oil level indicator tube bracket bolt | 10 |
| Oil pan bolts | 11 |
| Oil pan drain plug | 26 |
| Oil pressure switch | 14 |
| Oil pump bolts | 19 |
| Oil pump drive assembly hold down bolt | 19 |
| Oil pump screen cover and pickup tube bolt | 10 |
| PCM ground wire nut | 10 |
| Power steering fluid cooler nuts | 80 |
| Rear cassette bolt | 18 |
| Spark plug | 20 |
| Thermostat housing bolts | 11 |
| Torque converter-to-flexplate nuts | 47 |
| Transmission cooler tube bracket bolt | 47 |
| Transmission fluid level indicator nut | 23 |
| Transmission-to-cylinder block cradle bolts | 47 |
| Transmission-to-engine bolts | 47 |
| Valve cover bolts | 10 |
| Wiring harness bracket-to-RH cylinder head bolt | 28 |
| Wiring harness bracket-to-transmission nut | 10 |
| Wiring harness electrical connector bracket bolt | 6 |
| Wiring harness ground wire stud bolt | 10 |
| Wiring harness shield bolt | 10 |
| Wiring harness retainer bolt | 10 |
| Wiring harness retainer nut | 10 |
TORQUE SPECIFICATIONS
a Refer to the procedure in this article.
The 4.0L SOHC engine consists of the following
- Single overhead camshafts
- Sequential multiport 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 article.
Induction System - The sequential multi-point 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 341
For engine mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION article. For driveability concerns, refer to the INTRODUCTION - GASOLINE ENGINES article.
See also:
• AUTOMATIC TRANSMISSION - 5R44E AND 5R55E