Page 1 of 5 Section 03-01C: Engine, 4.0L V-6 IN-VEHICLE SERVICE Workshop Manual Camshaft SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Sensor Adjusting Wrench T94T-12270-A Removal NOTE: It is necessary to replace oil pan gasket (6710) when removing and installing engine front cover (6019). On Ranger and Explorer vehicles, it is necessary to remove the engine (6007) to remove the oil pan (6675). On Aerostar, it is necessary to remove the transmission to properly reseal oil pan. 1. On Ranger and Explorer vehicles, remove engine as outlined in this section. 2. On Aerostar vehicles, remove radiator (8005) as outlined in Section 03-03 and remove transmission as outlined in Group 07. 3. Remove the upper and lower intake manifolds as outlined in this section. 4. Remove the engine front cover as outlined in this section. 5. Remove the oil pan as outlined in this section. 6. Remove the hold-down clamp (12270), screw and oil pump drive shaft from the rear of the cylinder block (6010). 7. NOTE: Ranger and Explorer vehicles have a CID sensor mounted on top of the oil pump drive assembly. Sensor Adjusting Wrench T94T-12270-A is designed for easy access to the hold-down clamp screw. For Ranger and Explorer vehicles, disconnect the engine wiring harness connector at the CID sensor. 8. Remove the valve covers (6582) and rocker arm shaft (6563) assemblies as outlined in this section. Lift out the push rods (6565) and place in a marked rack so they can be installed in the same location. 9. Remove the valve tappets (6500). Refer to tappet removal and installation procedure in this section. 10. Push the timing chain/belt tensioner (6K254) into the retracted position, and install the retaining clip. 1 6256 Camshaft Sprocket 2 Camshaft Timing Mark (Part of 6256) 3 6K297 Timing Chain Guide 4 Crankshaft Timing Mark (Part of 6306) 5 6306 Crankshaft Sprocket 6 6K254 Timing Chain/Belt Tensioner 11. Remove the camshaft sprocket attaching bolt and remove the camshaft sprocket (6256) from the camshaft. 12. Remove the camshaft thrust plate (6269). 13. Remove the camshaft (6250) carefully from the cylinder block, avoiding any damage to the camshaft bearings.

Page 2 of 5 Installation 1. Oil the camshaft journals and cam lobes with SAE 50 Service SG engine oil or equivalent meeting Ford specification ESE-M2C39-F. Insert the camshaft key. 2. Install the camshaft in the cylinder block, being careful to avoid damaging the bearing surfaces. 3. Install the thrust plate as shown so that it covers the main oil gallery. Tighten the attaching screws to 9-13 Nm (7-10 lb-ft). 4. Turn the camshaft and crankshaft (6303) as necessary to align the timing marks. Install the camshaft sprocket, install the attaching bolt and tighten to 60-68 Nm (44-50 lb-ft). 1 6256 Camshaft Sprocket 2 Camshaft Timing Mark (Part of 6256) 3 6K297 Timing Chain Guide 4 Crankshaft Timing Mark (Part of 6306) 5 6306 Crankshaft Sprocket 6 6K254 Timing Chain/Belt Tensioner 5. Check the camshaft for correct end play. Refer to Section 03-00. End play should be 0.065-0.165mm (0.0025-0.0064 inch). Remove the clip from the timing chain tensioner. 6. Position the valve tappets in their original locations as outlined. Apply SAE 50 Service SG or equivalent oil meeting Ford specification ESE-M2C39-F to both ends of the push rods. Install the push rods in the same locations as removed. 7. Install the intake manifolds as outlined in this section. 8. Install the rocker arm shaft assemblies. Tighten the rocker arm stand bolts evenly and in sequence to 6-8 Nm (53-71 lb-in). Refer to Rocker Arm, Installation in this section. 9. Install the valve covers as outlined. 10. Install the engine front cover as an assembly. Refer to Engine Front Cover, Installation, in this section. 11. Install the oil pump drive, hold-down clamp and screw. For Ranger and Explorer vehicles refer to Installation, Ranger and Explorer below.

Page 3 of 5 12. Install oil pan as outlined in this section. 13. Install engine front cover as outlined in this section. 14. On Ranger and Explorer vehicles, install engine as outlined in this section. 15. On Aerostar vehicles, install transmission as outlined in this section. 16. On Aerostar, install the radiator. 17. Fill the cooling system to the proper level with the specified coolant and bleed the cooling system as outlined in Section 03-03. 18. Fill the crankcase with the specified quantity and grade of oil. 19. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Connect the battery ground cable (14301) to the battery. 20. Run the engine at fast idle speed and check for coolant, fuel, vacuum and oil leaks. Installation, Ranger and Explorer SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number CID Testing Wiring Harness T94T-50-B 1. After performing Steps 1-11 above, rotate crankshaft until TDC mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC). This position is 34mm (1.34 inches) counterclockwise from the Top Dead Center (TDC) mark. 2. Position No. 1 cylinder to 26 ATDC between compression and ignition stroke. (Both intake and exhaust valves must be closed with TDC mark on vibration damper at pointer.) 3. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CID sensor with SM-2C 1013-A oil. Do not get oil above mounting flange.

Page 4 of 5 1 12K073 CID Sensor 2 E853103-S O-Ring 3 6846 Oil Pump Drive Assembly 4 6007 Engine 5 12270 Hold-Down Clamp 6 E602550 Screw A Tighten to 17-21 Nm (13-15 Lb-Ft) B Maximum Level for Pre-Oiling Drive Gear C Minimum Level for Pre-Oiling Drive Gear 4. NOTE: Normal CID sensor rotation is clockwise viewed from top of CID sensor. Align the CID sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window. 5. Position the sensor above its hole at right angles to the block rear face. 6. Install the assembled CID sensor and oil pump drive gear into the engine. As the assembly is pushed into place, the camshaft gear will rotate the sensor vane clockwise toward the center of the window. 7. Rotate the CID sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. Connect the CID Testing Wiring Harness T94T-50-B to the CID Sensor. 9. Connect the CID Testing Wiring Harness leads: a. Red harness wire to battery positive terminal. b. Black harness wire to battery negative terminal. c. Voltmeter positive lead to harnesses white lead. d. Voltmeter negative lead to battery negative terminal.

Page 5 of 5 1 T94T-50-B CID Testing Wiring Harness 2 White Lead 3 Red Lead 4 Positive Terminal (Part of 10655) 5 10655 Battery 6 Red Lead (Part of 007-00407) 7 007-00407 Rotunda Digital Volt-Ohmmeter or Equivalent 8 Black Lead (Part of 007-00407) 9 Negative Terminal (Part of 10655) 10 Black Lead 11 Connector (Attaches to CID Sensor) 10. Rotate engine two revolutions to take up slack in timing chain and return No. 1 cylinder to its compression stroke. 11. Verify that No. 1 cylinder is on its compression stroke (both valves closed). 12. NOTE: No. 1 cylinder must be at 26 degrees After Top Dead Center (ATDC) to set CID sensor. Continue to rotate the crankshaft until the new 26 degrees ATDC mark lines up with the timing pointer. 13. NOTE: The voltmeter will register battery voltage whenever the CID sensor closes and makes a complete circuit. Rotate the CID sensor and stop at the exact point where the sensor switches from 0 to 12 volts on the voltmeter. 14. NOTE: The final movement to set the CID sensor must be in a COUNTERCLOCKWISE direction. Rotate the CID sensor clockwise past the CID switching point (from 12 to 0 volts). 15. Rotate the CID sensor counterclockwise and stop at the exact point the voltmeter switches from 0 to 12 volts. 16. Tighten the CID sensor hold-down bolt to 17-21 Nm (13-15 lb-ft) using Sensor Adjusting Wrench T94T-12270-A. 17. Disconnect the testing wiring harness and the voltmeter and proceed with Step 12 of Installation above.