AfterMarketNews Auto Care Pro AutoProJobs Auto-Video.com Brake&Frontend BodyShopBusiness Counterman EngineBuilder Fleet Equipment ImportCar Motorcycle & Powersports News Servicio Automotriz Shop Owner Tire Review Tech Shop Tomorrow's Tech Underhood Service

Inside The Bosch Xperience Mobile Technician Training

Robert Bosch LLC has been bringing technician training straight to the shop this year with its Bosch Xperience mobile tour, and when it rolled into The Swedish Solution in Orange Village, Ohio, a team of editors from Babcox Media had to check it out. In...

Read more...

Oklahoma Shops Organize To Join Auto Care Association

The auto shops in Tulsa, Okla., are organizing an effort to all join the Automotive Service Association in order to improve the overall service levels of the city. ABC Channel 8 in Tulsa, Okla., has the details: Randy Calley of Same Day Auto Repair...

Read more...

Service Adviser Pay Program Tips That Work

If you are looking to drive up your profits, you need to ensure you have service advisers that have the right attitude, aptitude and ethics. They will need to have the natural talent to sell, they will need to be well trained, and they will need to have...

Read more...

Mercedes-Benz: Installation guidelines for Smart Car front wheel bearing

The typical solution for replacing the front wheel hub on a 2008-‘13 Mercedes-Benz Smart Car is a front wheel hub assembly, including a front wheel hub and knuckle. However, with a wheel hub-only ­solution for the Mercedes Smart Car, like the one offered...

Read more...

Kia: Uncovering Unperformed Maintenance

While some vehicle problems will motivate the customer to make an appointment, an equal amount of Kia repair opportunities will be discovered as the vehicle is being serviced. If you’re not already doing so, always encourage your customers to keep...

Read more...

The Evolving Oil Change Market

The only constant in the oil change business is change itself, especially if you’re trying to maintain an inventory of engine oil for all makes and models of vehicles. Since Volkswagen began ­requiring application-specific engine oil in the mid-1990s,...

Read more...

Speed Sensor Diagnostics: The 'If’s' of Sensors and Speed Explained

If all of the wheel speed sensors are generating a speed signal, and they all agree, the wheel speed sensor (WSS) is not an issue, but something else might be, possibly an intermittent wiring fault in one of the WSS circuits. If one of the WSS...

Read more...

What is Brake Noise? The Basics of Diagnosing NVH

What does your shop do when a brake noise complaint enters the service bays? Does it end up hurting productivity for the rest of the day as a technician randomly applies lubes, pastes and sprays to the brake system hoping that the problem will be...

Read more...

How Does a Dual Clutch Transmission Work?

Dual clutch transmissions are like ­having two manual transmissions shifting together while being controlled like an automatic transmission. This is the transmission of the future because it is lighter than an automatic and is just as ­efficient...

Read more...

Snap-on Offers Top 14.2 Reasons To Upgrade To Latest Diagnostic Software Release

Keeping the diagnostic tools up-to-date is critical, because without the latest vehicle coverage, professional technicians simply cannot service as many vehicles in a day. Snap-on Software Upgrade 14.2 supercharges the Snap-on family of diagnostic tools...

Read more...

Tell Us Your Top 5 Tools and Win!

Send in your list of your five favorite tools and equipment that help you most in the shop, and you could be chosen to win a $25 gift card for Bass Pro Shops. From scan tools to flashlights, impact wrenches to on-car brake lathes or computer systems...

Read more...

Snap-on Facebook Community Tops 500,000

The Snap-on Nation Facebook community recently reached a major milestone, surpassing the 500,000 mark. “Whether you want to get helpful tips, provide useful suggestions or learn about the latest and greatest tools, the Snap-on Facebook page is the...

Read more...

Home Emissions ‘Exploring’ Service Needs On The Ford 4.0L V6 Engine

Print Print Email Email

to 2010 Mazda B4000, 2005 to 2010 Ford Mustang and 2005 to 2009 Land Rover LR3.

Rated at a rather anemic 210 horsepower, the 4.0L SOHC V6 is not exactly a high output engine. It also has an unusual overhead cam drive setup.

Unlike most other OHC V6 and V8 engines that drive both overhead cams directly from the crankshaft with a belt or chain, this engine has an intermediate jackshaft in the middle of the block where a pushrod cam would normally be located. the 4.0l sohc engine was found under the hood of many ford and related suvs and light trucks, as well as 2005-’10 mustangs.

A short timing chain on the front of the engine connects the crankshaft to the intermediate jackshaft. A second, longer timing chain behind the first chain connects the front of the jackshaft to the overhead cam on the left side of the engine.

A third timing chain in the back of the engine connects the rear of the jackshaft to the overhead cam in the right cylinder head. There is also a balance shaft in the crankcase of engines used in 4×4 trucks, which is driven by a fourth chain directly off the crankshaft.

Why Ford designed the cam drives this way is anyone’s guess. It probably allowed the engine to be shorter and more compact. But one of the unintended consequences of this fore-and-aft split cam drive arrangement is that it makes the timing chains, guides and tensioners VERY difficult to replace — which makes for an expensive repair when a chain guide or tensioner fails on one of these engines (a common problem on high mileage engines, especially if the owner has ­neglected regular oil changes).

TIMING CHAIN PROBLEMS
Some of the early engines up through 2002 in the Ranger and Explorer have had a timing chain rattle problem due to the poor design of the original teflon chain guides. The noise is most noticeable when a cold engine is first started, and is usually loudest from 2400 to 3000 rpm.

The same noise problem can also develop in 2003 and newer high-mileage engines as a result of chain guide wear. In some instances, the guide may break and disintegrate and spew debris into the oil pan. This may also cause one of the timing chains to break (typically the front left chain).

Fortunately, the 4.0L SOHC is not an interference engine so a timing chain failure won’t bend the valves. But it does create an expensive repair for the vehicle owner.

Ford issued a TSB for the timing rattle problem and released a redesigned “‘cassette”‘ (the timing chain, gears, guide and tensioner assembly) for the left front timing chain. This timing chain cassette can be replaced without having to pull the engine out of the vehicle.

But, if the engine has a bad rear chain or guide, or a chain guide has failed and throws debris into the crankcase, you will have to remove the engine to make the required repairs. That includes removing the flywheel and flexplate so that the rear cam drive cassette can be replaced, and pulling the oil pan so any debris in the oil pan and oil pickup screen can be cleaned out.

You’ll also need a special tool kit (Ford or aftermarket) to hold the cams and tension the timing chains, and to prevent the crankshaft from rotating while you’re doing the cam drives. You’ll also need the proper puller to get the harmonic balancer off the crankshaft. one of the unintended consequences of the 4.0l’s fore-and-aft split cam drive arrangement is that it makes the timing chains, guides and tensioners very difficult to replace and an expensive repair when a chain guide or tensioner fails.  courtesy: cloyes gears

The redesigned Ford primary timing chain service kit includes an improved chain tensioner and chain guide, chain, jackshaft and sprockets. Kit number 2U3Z-6D256-AA is for balance shaft engines in 1999 to 2001 4×4 Explorer/Mountaineer, 2001 to 2002 4×4 Sport/Sport Trac and all 2002 Explorer/Mountaineer (except engine codes 2G-960-AA and 2G-964-AA). Kit number 2U3Z-6D256-BA is for non-balance shaft engines in 1999 to 2001 2WD Explorer/Mountaineer and 2001 to 2002 2WD Sport/Sport Trac, and all 2001 to 2002 Ranger.

ENGINE SERVICE
If the head gasket is leaking, replacing the left head gasket can be done with the engine in the vehicle (assuming there is enough room to pull the head). But if the right head has to come off, the only way to remove the head is with the engine out of the vehicle because of the rear cam drive on the right head.

At this point, some might argue that it’s cheaper and easier to simply find a good used engine and replace the old motor rather than repair it. This might be a viable alternative IF you can find a good used low-mileage 4.0L SOHC V6 that can be swapped into your customer’s vehicle. a short timing chain on the front of the engine connects the crankshaft to the ­intermediate jackshaft.

But by the time many of these engines end up in a salvage yard, they don’t have a lot of miles left in them. A better option if your customer is willing to spend the money would be to install a remanufactured engine. A reman engine from a reputable supplier should be completely reconditioned to original specifications and come with an extended warranty.

Some suppliers offer a three-year or 36,000-mile warranty with their reman engines. That’s a better deal than the 30 day guarantee many salvage yards offer (which doesn’t include labor!).

If the engine in your customer’s vehicle has a timing chain rattle problem, and the engine has less than 100,000 miles on it, doing an oil change and using a light viscosity, pure synthetic oil can sometimes quiet the noise.

The lighter oil will flow to the timing chain more quickly following a cold start and reduce the noise somewhat. However, if the engine has a lot of miles on it (more than 100,000) or changing motor oils makes no difference, replacing the timing chain cassette(s) will likely be necessary to quiet the engine.

As we mentioned earlier, this is a rather involved repair procedure so always refer to the Ford service literature for the step-by-step details. If you try to wing it as you go, you’ll likely be in for some unpleasant surprises along the way.

The jackshaft drive gear and cam drive gear retaining bolts are TTY (torque-to-yield) and should not be reused. If you don’t replace these bolts with new ones, there’s a risk of breakage. The rear jackshaft bolt is also covered by a small circular plug on the back of the engine. It looks like a freeze plug but isn’t.

The front left chain ­tensioner can be tricky to extract because of its close proximity to the thermostat housing and coolant sensors. You may have to remove the thermostat housing if you can’t get the tensioner out with a wrench or deep socket.

The left (front) and right (rear) cam drive cassettes for this engine are different, and the design and quality of the parts can vary depending on the supplier. Some aftermarket suppliers buy their cam drive cassettes from the same original equipment supplier that Ford uses, while others do not. Since this is a labor-intensive repair that should only have to be done once, don’t try to save money on a no-name part. Go with the genuine Ford replacement parts or parts from a quality-brand aftermarket company.

Other “fun” parts to replace on this engine include the heated PCV valve on the back of the left valve cover. It’s out of sight and hard to reach with little clearance between the engine and firewall.

DIAGNOSTICS
If the Check Engine light is on and you’re doing misfire diagnostics on a 2006 and up Explorer, a new scan tool PID that’s available on these ­models is the actual burn time of each individual spark plug. By comparing the spark durations, you can quickly see if a spark plug is fouled or a cylinder has low compression because the burn time for that cylinder will be longer. If you see a cylinder with a shorter burn time, it would tell you that cylinder is running lean or the spark plug gap in that cylinder is worn or set too wide.

On some 2005-’10 Mustangs with automatic transmissions, there can be an annoying vibration at idle, especially when the A/C is on. The problem is not the engine, but an exhaust ­vibration. Ford TSB 05-8-6 says the cure is to install a damper kit to dampen the annoying vibration. The kit is P/N 5R3Z-5F240-A.

MAINTENANCE
The original equipment spark plugs are platinum with a 100,000-mile service interval. Make sure you install the correct replacement plugs because the ones for the 4.0L OHV pushrod engine are shorter and won’t position the electrode the correct distance into the combustion chamber.

Though Ford diehards tend to stick with the original Motorcraft brand spark plugs, any brand of spark plug will work in these engines provided the plug manufacturer has a listing for the engine application. The plug gap is 0.054” on most applications.

The crankcase oil capacity on the 4.0L SOHC V6 is 5 quarts, usually 5W-30 for the older vehicles and 5W-20 for the newer ones. Refer to the vehicle owner’s manual for the recommended viscosity. 

The following two tabs change content below.

Larry Carley

Larry Carley has more than 30 years of experience in the automotive aftermarket, including experience as an ASE-certified technician, and has won numerous awards for his articles. He has written 12 automotive-related books and developed automotive training software, available at www.carleysoftware.com.
Latest articles from our other sites:

Fel-Pro Introduces Three Exclusive Head Gasket Sets For Popular Subaru Engines

Federal-Mogul Motorparts’ Fel-Pro Gaskets brand has introduced three PermaTorque MLS multi-layer-steel head gasket sets for a variety of popular 2.5L engines used in late-model Subaru passenger vehicles....More

Arnott Enhances BMW Aftermarket Air Suspension Line

Arnott Air Suspension Products, a leader in aftermarket air suspension products and accessories, recently announced a significant enhancement to its BMW aftermarket air suspension product line with the...More

Nissan Group sees 11 percent increase in July

Nissan Group announced total U.S. sales for July 2014 of 121,452 units, an increase of 11.4 percent over the prior-year and a July record. Nissan highlights: Nissan Division set a July record with...More

Fiat 500 six-speed automatic transmission available to try at Abarth Track Experience

With the addition of three new stops on the 2014 schedule, Fiat 500 Abarth owners will now have more opportunities to develop their driving skills in the one-day Abarth Track Experience. The Fiat...More

Clutch Repairs Made Easy: Making Use of Something We Normally Throw Away

Clutch replacement is a job that normally takes a good bit of time, and we want the job to go right the first time. Whether it’s a 4-wheel drive Ford F-450 or a Chevrolet Cobalt, we don’t want...More

Custom Wheels and TPMS: What Are Your Options?

Selling, mounting and balancing custom wheels can be a profitable business, but what about tire pressure monitoring system (TPMS) sensors? According to the National Highway Traffic Safety Administration...More

Snap-on Offers Top 14.2 Reasons To Upgrade To Latest Diagnostic Software Release

Keeping the diagnostic tools up-to-date is critical, because without the latest vehicle coverage, professional technicians simply cannot service as many vehicles in a day. Snap-on Software Upgrade 14.2...More

Tell Us Your Top 5 Tools and Win!

Send in your list of your five favorite tools and equipment that help you most in the shop, and you could be chosen to win a $25 gift card for Bass Pro Shops. From scan tools to flashlights, impact...More