ITEM SPECIFICATION
| Item | Specification | Fill Capacity |
|---|---|---|
| Motorcraft® Metal Surface Prep ZC-31-A | ||
| Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft® SAE 5W-30 Super Premium Motor Oil CXO-5W30- LSP12 (Canada); or equivalent | WSSM2C929-A | 4.7L (5 qt) with filter change |
| Silicone Brake Caliper Grease and Dielectric Compound XG-3-A | ESE-M1C171-A | |
| Silicone Gasket and Sealant TA-30 | WSEM4G323-A4 | |
| Silicone Gasket Remover ZC-30 |
ITEM SPECIFICATION
| 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° |
| 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° |
| 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° |
| Valve spring compression pressure intake (at specified height) (lb) | 275-305 Nm 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 Nm 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 N |
| 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 (1) | 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) |
| (1) Tighten camshaft bearing cap bolts to 15 Nm (133 lb-in) when measuring journal clearance. | |
| (1) | Tighten camshaft bearing cap bolts to 15 Nm (133 lb-in) when measuring journal clearance. |
ITEM SPECIFICATION
TORQUE SPECIFICATIONS
| Description | Nm | Lb-ft | Lb-in |
|---|---|---|---|
| A/C compressor and power steering bracket bolts | 42 | 31 | |
| A/C compressor manifold bolt | 20 | 177 | |
| A/C tube bracket nut | 20 | 177 | |
| Accessory drive belt tensioner bolt | 47 | 35 | |
| Camshaft bearing cap bolts (1) | |||
| Camshaft sprocket bolt | 85 | 63 | |
| Camshaft Sprocket Holding Tool top clamp bolts (1) | |||
| Cassette and sprocket-to-jackshaft bolt (1) | |||
| Cassette-to-cylinder head bolt, LH | 12 | 106 | |
| Cassette-to-cylinder head bolt, RH | 10 | 89 | |
| Cassette-to-engine block bolt | 19 | 168 | |
| Connecting rod nuts (1) | |||
| Coolant pump bolts | 10 | 89 | |
| Crankshaft Position (CKP) sensor bolts | 10 | 89 | |
| Crankshaft pulley bolt (1) | |||
| Cylinder block cradle nuts (outside) | 10 | 89 | |
| Cylinder block cradle bolts (outside) | 14 | 124 | |
| Cylinder block cradle bolts (inside) (1) | |||
| Cylinder block cradle Torx bolts | 10 | 89 | |
| Cylinder block cradle set screws | 3 | 27 | |
| Cylinder head bolts (1) | |||
| EGR vacuum regulator bolts | 10 | 89 | |
| Engine front cover bolts | 19 | 168 | |
| Engine Lifting Bracket bolt (1) | |||
| Engine support insulator bracket bolts | 62 | 46 | |
| Engine support insulator-to-engine bracket nuts | 110 | 81 | |
| Engine support insulator-to-frame nuts | 103 | 76 | |
| Exhaust manifold nuts | 22 | 16 | |
| Exhaust manifold studs | 12 | 106 | |
| Exhaust manifold-to-dual converter Y-pipe nuts | 40 | 30 | |
| Exhaust manifold-to-EGR valve tube | 34 | 25 | |
| Fan shroud bolts | 10 | 89 | |
| Flexplate bolts (1) | |||
| Flywheel bolts (1) | |||
| Front axle bolts | 66 | 49 | |
| Fuel rail bolts | 23 | 17 | |
| Generator bracket bolts | 42 | 31 | |
| Generator terminal nut | 12 | 106 | |
| Ground wire-to-cowl nut | 10 | 89 | |
| Ground wire-to-engine bolt | 25 | 18 | |
| Heated PCV fitting-to-intake manifold bolts | 8 | 71 | |
| Heater tube assembly front bolt | 28 | 21 | |
| Heater tube assembly rear bolt | 23 | 17 | |
| Hood bolts | 12 | 106 | |
| Hydraulic timing chain tensioner | 44 | 32 | |
| Ignition coil bracket lower front bolt | 23 | 17 | |
| Ignition coil bracket lower rear bolts | 28 | 21 | |
| Ignition coil bracket upper bolts | 8 | 71 | |
| Intake manifold bolts | 10 | 89 | |
| Jackshaft chain guide bolts | 19 | 168 | |
| Jackshaft chain tensioner bolts | 9 | 80 | |
| Jackshaft front sprocket bolt (1) | |||
| Jackshaft rear sprocket bolt (1) | |||
| Jackshaft thrust plate bolts | 11 | 97 | |
| Knock Sensor (KS) bolt | 20 | 177 | |
| Main bearing cap bolts (1) | |||
| Oil filter | 13 | 115 | |
| Oil filter adapter bolt | 57 | 42 | |
| Oil level indicator tube bracket bolt | 10 | 89 | |
| Oil pan bolts | 11 | 97 | |
| Oil pan drain plug | 26 | 19 | |
| Oil pressure switch | 14 | 124 | |
| Oil pump bolts | 19 | 168 | |
| Oil pump drive assembly hold down bolt | 19 | 168 | |
| Oil pump screen cover and pickup tube bolt | 10 | 89 | |
| Rear cassette bolt | 18 | 159 | |
| Spark plug | 15 | 133 | |
| Thermostat housing bolts | 11 | 97 | |
| Torque converter-to-flexplate nuts | 47 | 35 | |
| Transmission cooler tube bracket bolt | 47 | 35 | |
| Transmission fluid level indicator nut | 23 | 17 | |
| Transmission-to-cylinder block cradle bolts | 47 | 35 | |
| Transmission-to-engine bolts | 47 | 35 | |
| Valve cover bolts | 10 | 89 | |
| Wiring harness bracket-to-RH cylinder head bolt | 28 | 21 | |
| Wiring harness bracket-to-transmission nut | 10 | 89 | |
| Wiring harness electrical connector bracket bolt | 6 | 53 | |
| Wiring harness ground wire stud bolt | 10 | 89 | |
| Wiring harness shield bolt | 10 | 89 | |
| Wiring harness retainer bolt | 10 | 89 | |
| Wiring harness retainer nut | 10 | 89 | |
| (1) Refer to the appropriate procedure(s). | |||
| (1) | Refer to the appropriate procedure(s). |
TORQUE SPECIFICATIONS
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.