Engine - 4.0l SOHC Ford Explorer Sport Trac I

GENERAL SPECIFICATIONS

GENERAL SPECIFICATION

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

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The 4.0L SOHC engine consists of the following

1. Single Overhead Camshafts
2. Sequential Multiport Fuel Injection (SFI)
3. Distributorless Ignition System
4. Aluminum Cylinder Heads
5. Cast Iron, 60-Degree V Cylinder Block
6. Balance Shaft (4x4 Vehicles)
7. Jackshaft
8. Unique Engine Timing Configuration

For quick identification, refer to the vehicle control information decal mounted under the hood.

An engine identification label is attached to the engine. The label

1. Identifies the symbol code for determining parts usage.

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Refer to DIAGNOSIS & TESTING .

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1. Disconnect the battery ground cable.
2. Remove the bolts and the shield.
3. Remove the air cleaner outlet pipe. Disconnect the tube. Detach the mass airflow (MAF) sensor wiring push-pin. Loosen the clamps and remove the pipe.
4. Disconnect the idle air control (IAC) valve and the throttle position sensor (TPS) electrical connectors. Disconnect the exhaust gas recirculation (EGR) valve vacuum hose.
5. Disconnect the accelerator and speed control cables. Detach the accelerator and speed control cables from the throttle body. Detach the accelerator and speed control cables from the bracket, and position the cables aside.
6. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube.
7. Disconnect the EGR valve vacuum regulator electrical connector and vacuum hoses.
8. Disconnect the hose.
9. Loosen the clamp and disconnect the brake booster vacuum hose.
10. Disconnect the RH spark plug wires from coil. Remove spark plug wire routing clip push-pin and position the wires aside.
11. Remove wiring harness bracket retainer, then position wiring harness aside.
12. Remove accelerator cable routing clip push-pin and wiring harness push-pin.
13. Remove the bolts.
14. Remove the bolt and position the coil and bracket aside.
15. Disconnect the vacuum hoses.
16. Remove the nut.
17. Disconnect the powertrain control module (PCM) electrical connector.
18. Disconnect the ground wires and position the wiring harness aside.
19. Detach the electrical connector retainer.
20. Remove the intake manifold bolts and lift up the intake manifold.
21. Remove the heated PCV hose retainers and remove the heated PCV fitting.
22. Remove the intake manifold.
23. To install, reverse the removal procedure.

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1. Drain the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
2. Remove the air cleaner outlet pipe. Disconnect the tube. Detach the mass airflow (MAF) sensor wiring push-pin. Loosen the clamps and remove the pipe.
3. Release hose clamps and remove hose.
4. Remove hose.
5. Disconnect the vacuum hose.
6. Loosen hose clamps and disconnect hoses.
7. Release hose clamps and disconnect hoses.
8. Release hose clamp and disconnect hose.
9. Release hose clamp and disconnect hose. Position hose aside.
10. Remove the bolts.
11. Detach the wiring harness retainer. Remove the heater tube and bracket assembly.
12. Disconnect MAF sensor connector and wiring push-pin. Position wiring aside.
13. Position the spark plug wires aside. Disconnect the spark plug wires. Disconnect the spark plug wire retainer and position the wires aside.
14. Disconnect fuel injector connectors. Position wiring aside.
15. Remove the bolts and the valve cover.
16. To install, reverse the removal procedure.

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1. Disconnect the battery negative cable.
2. Detach the accelerator and speed control cables. Detach the accelerator and speed control cables from the throttle body. Detach the accelerator and speed control cables from the bracket, and position the cables aside.
3. Detach the spark plug wire retainer.
4. Disconnect the spark plug wires.
5. Remove the bolts.
6. Remove the bolt.
7. Disconnect the coil electrical connector.
8. Disconnect the radio interference capacitor electrical connector and position the coil aside.
9. Loosen the bolt and disconnect the electrical connector.
10. Disconnect the following: Exhaust gas recirculation (EGR) valve vacuum hose. EGR valve vacuum regulator solenoid vacuum hoses. EGR valve vacuum regulator solenoid electrical connector. Camshaft position sensor electrical connector. Differential pressure feedback electrical connector.
11. Detach the spark plug wire retainer.
12. Disconnect the fuel vapor hose and the vacuum hose.
13. Remove the bolt and position the electrical connector and bracket aside.
14. Remove the screws and the EGR valve vacuum regulator solenoid.
15. Remove the differential pressure feedback with the hoses from the exhaust manifold-to-EGR valve tube.
16. Relieve the fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/ford/explorer-sport-trac/i-2000-2005/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-trucks-except-diesel__fuel-system-pressure-release) .
17. Detach the clip.
18. Using the special tool, disconnect the fuel supply line.
19. Remove the bolt and position the fuel supply line aside.
20. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube.
21. Disconnect the hose.
22. Unscrew fitting.
23. Remove the bolts and the valve cover.
24. To install, reverse removal procedure.

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1. Remove the fan shroud. For additional information, refer to COOLING FAN SHROUD .
2. Remove the accessory drive belt. For additional information, refer to «DRIVE BELT ROUTING»(/ford/explorer-sport-trac/i-2000-2005/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) .
3. Remove the damper bolt.
4. Using the special tool, remove the crankshaft pulley.

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1. Using the special tool, install the crankshaft pulley.
2. Install a NEW crankshaft pulley bolt. Tighten the bolt in two stages: Stage 1 Tighten the bolt to 50 Nm (37 lb-ft). Stage 2 Tighten the bolt an additional 90 degrees.
3. Install the accessory drive belt. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/explorer-sport-trac/i-2000-2005/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) article.
4. Install the fan shroud. For additional information, refer to COOLING FAN SHROUD .

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1. Remove the crankshaft pulley. See «CRANKSHAFT PULLEY»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
2. Using the special tool, remove the crankshaft front oil seal.

Installation

1. Using the special tools and install the crankshaft front oil seal.
2. Install the crankshaft pulley. See «CRANKSHAFT PULLEY»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .

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1. Remove the radiator. For additional information, refer to RADIATOR .
2. Remove the crankshaft pulley. See «CRANKSHAFT PULLEY»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
3. Remove the bolt and the wiring harness routing clip.
4. Remove the accessory bracket bolts and position the bracket aside.
5. Remove the drive belt tensioner. For additional information, refer to «DRIVE BELT ROUTING»(/ford/explorer-sport-trac/i-2000-2005/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) .
6. Disconnect the generator wiring and position the wiring aside.
7. Remove the generator mounting bracket.
8. Disconnect the crankshaft position (CKP) sensor electrical connector.
9. Remove the wiring anchors and position the wiring aside.
10. Remove the wiring harness retainer and position the wiring aside.
11. Remove the thermostat housing. Remove the bolts. Release the bypass hose clamp.
12. Release the hose clamp and remove the lower heater water hose.
13. Release the hose clamp and remove the lower radiator hose.
14. On A/C equipped vehicles, remove the A/C line bracket bolt and position the A/C line aside.
15. Remove the engine front cover.

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1. Clean and inspect the sealing surfaces.
2. Apply silicone gasket and sealant to the oil pan and the engine block mating surfaces.
3. Apply silicone gasket and sealant to the front cover in two places.
4. Install the engine front cover.
5. On A/C equipped vehicles, install the A/C line bracket and bolt.
6. Install the lower radiator hose and clamp.
7. Install the lower heater water hose and clamp.
8. Install the thermostat housing. Install the housing into the bypass hose. Install the bolts. Position the bypass hose clamp.
9. Position the wiring harness and install the bolt.
10. Secure the wiring anchors.
11. Connect the CKP sensor electrical connector.
12. Install the generator mounting bracket.
13. Connect the generator wiring.
14. Install the drive belt tensioner. For additional information, refer to «DRIVE BELT ROUTING»(/ford/explorer-sport-trac/i-2000-2005/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) .
15. Install the accessory bracket bolts.
16. Install the routing clip and bolt.
17. Install crankshaft pulley. See «CRANKSHAFT PULLEY»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
18. Install the radiator. For additional information, refer to RADIATOR .
19. Raise and support the vehicle.
20. Drain the engine oil.
21. Lower the vehicle.
22. Fill the engine oil with clean engine oil.
23. Fill the engine will coolant. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .

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1. Remove the valve covers. See «VALVE COVER - RH»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) and «VALVE COVER - LH»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
2. Remove the intake manifold. See «INTAKE MANIFOLD»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
3. Remove the fuel supply manifold. For additional information, refer to «FUEL RAILS & INJECTORS»(/ford/explorer-sport-trac/i-2000-2005/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal) .
4. Remove the accessory drive belt. For additional information, refer to «DRIVE BELT ROUTING»(/ford/explorer-sport-trac/i-2000-2005/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) .
5. Remove the thermostat housing. For additional information, refer to THERMOSTAT .
6. Remove the roller followers. See «ROLLER FOLLOWERS»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
7. Turn the crankshaft clockwise to position the number one cylinder at TDC.
8. Install the special tool.
9. Using the special tool, loosen the RH camshaft sprocket bolt.
10. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools and install the special tools on the front of the RH cylinder head.
11. Raise and support the vehicle.
12. Remove the RH wheel and tire.
13. Remove the RH lower splash shield.
14. Remove the RH camshaft tensioner.
15. Lower the vehicle.
16. Install the special tools on the rear of the RH cylinder head.
17. Install the special tool.
18. Tighten the bolts. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). Tighten the camshaft bolt.
19. Remove the special tool.
20. Install the RH camshaft tensioner.
21. Raise the vehicle.
22. Install the RH lower splash shield.
23. Install the RH wheel and tire.
24. Lower the vehicle.
25. Remove the special tools from the RH cylinder head.
26. Remove the LH camshaft tensioner.
27. Install the special tools on the front of the LH cylinder head and tighten the top two clamp bolts to 10 Nm (89 lb-in).
28. Loosen the LH camshaft sprocket bolt.
29. Loosen the top two clamp bolts on the special tool to allow the camshaft sprocket to rotate freely.
30. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools, and install the special tools on the rear of the LH cylinder head.
31. Install the special tool.
32. Tighten the bolts. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). Tighten the camshaft bolt.
33. Remove the special tool.
34. Install the LH camshaft tensioner.
35. Remove all of the special tools.
36. Install the roller followers. See «ROLLER FOLLOWERS»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
37. Install the thermostat housing. For additional information, refer to THERMOSTAT .
38. Install the accessory drive belt. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/explorer-sport-trac/i-2000-2005/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) .
39. Install the fuel supply manifold. For additional information, refer to «FUEL RAILS & INJECTORS»(/ford/explorer-sport-trac/i-2000-2005/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal) .
40. Install the lower intake manifold. See «INTAKE MANIFOLD»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
41. Install the valve covers. See «VALVE COVER - LH»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) and «VALVE COVER - RH»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .

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1. Remove the wheel and tire.
2. Remove the lower splash shield.
3. Remove the RH camshaft tensioner.
4. To install, reverse the removal procedure.

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1. Remove the upper intake manifold. See «INTAKE MANIFOLD»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
2. Remove the thermostat housing. For additional information, refer to THERMOSTAT .
3. Remove the LH camshaft tensioner.
4. To install, reverse the removal procedure.

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1. Remove the intake manifold. See «INTAKE MANIFOLD»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
2. Remove valve covers. See «VALVE COVER - RH»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) and «VALVE COVER - LH»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
3. Remove the fuel supply manifold. For additional information, refer to «FUEL RAILS & INJECTORS»(/ford/explorer-sport-trac/i-2000-2005/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal) .
4. Remove the engine front cover. See «ENGINE FRONT COVER»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
5. Remove the thermostat housing. For additional information, refer to THERMOSTAT .
6. Remove all of the roller followers. See «ROLLER FOLLOWERS»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
7. Turn the crankshaft clockwise to position number one cylinder at TDC.
8. Remove the LH camshaft chain tensioner.
9. Remove the LH camshaft sprocket bolt. Install the special tools to hold the camshaft sprocket. Loosen but do not remove the bolt.
10. Remove the tool and bolt.
11. Hold the crankshaft from turning and loosen the jackshaft sprocket bolt.
12. Remove the primary chain tensioner.
13. Remove the primary chain and sprocket.
14. Remove the camshaft drive cassette. Remove the chain guide bolts. Remove the sprockets. Lift the chain and guide up and out of the cylinder head.
15. Clean all surfaces. Clean all debris from engine.

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1. Install the chain guide through the cylinder head.
2. Install the chain.
3. Install the new chain guide bolts.
4. Install the lower chain sprocket and the camshaft sprocket.
5. Install, but do not tighten the camshaft sprocket bolt.
6. Install the primary chain and gear.
7. Install the primary drive chain tensioner.
8. Hold the crankshaft from turning and tighten the jackshaft sprocket bolt in two stages. Stage 1 Tighten bolts to 45 Nm (33 lb-ft). Stage 2 Tighten bolts an additional 90 degrees.
9. Install the engine front cover. See «ENGINE FRONT COVER»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
10. Time the engine. See «TIMING DRIVE COMPONENTS - CAMSHAFT TIMING»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .

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Removal & Installation

1. Remove the camshaft roller followers. See «ROLLER FOLLOWERS»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
2. Position the piston at top dead center.
3. Hold the valve in the cylinder head. Remove the spark plugs. For additional information, refer to «SPARK PLUGS»(/ford/explorer-sport-trac/i-2000-2005/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal) . Use a suitable tool to apply air pressure to the cylinder.
4. Using the special tool, remove, the valve spring retainer keys, the valve spring and the retainer.
5. Inspect the components. See «GENERAL PROCEDURES»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-system-general-information) in ENGINE SYSTEM - GENERAL INFORMATION article.
6. To install, reverse the removal procedure.

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Removal

1. Remove the valve springs. See «VALVE - VALVE SPRING»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
2. Remove the valve stem seals.

1. Using the special tool, install the valve stem seals.
2. Install the valve springs. See «VALVE - VALVE SPRING»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .

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1. Remove the camshaft roller followers. See «ROLLER FOLLOWERS»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
2. Remove the hydraulic lash adjusters.
3. To install, reverse the removal procedure.

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1. Remove the valve covers. See «VALVE COVER - LH»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) or «VALVE COVER - RH»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
2. Remove the fuel supply manifold. For additional information, refer to «FUEL RAILS & INJECTORS»(/ford/explorer-sport-trac/i-2000-2005/remont/removal-installation/#how-to-overhaul-installation-the-engine-controls-removal) .
3. Using the special tool, remove the camshaft roller followers.
4. To install, reverse the removal procedure.

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1. Remove the camshaft roller followers. See «ROLLER FOLLOWERS»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
2. Remove the LH hydraulic camshaft tensioner. See «TIMING DRIVE COMPONENTS - LH HYDRAULIC CHAIN TENSIONER»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
3. Remove the bolt and the camshaft sprocket.
4. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube.
5. Remove the camshaft.

1. Install the camshaft.
2. Position the oil supply tube, the camshaft bearing caps, and the bolts. Tighten the bolts in the sequence shown in two stages. Stage 1 Tighten the bolts to 6 Nm (53 lb-in). Stage 2 Tighten the bolts to 16 Nm (12 lb-ft).
3. The camshaft must be re-timed. See «TIMING DRIVE COMPONENTS - CAMSHAFT TIMING»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
4. Install the camshaft roller followers. See «ROLLER FOLLOWERS»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .

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1. Remove the camshaft roller followers. See «ROLLER FOLLOWERS»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
2. Remove the RH hydraulic camshaft tensioner. See «TIMING DRIVE COMPONENTS - RH HYDRAULIC CHAIN TENSIONER»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
3. Using the special tool, remove the bolt and the camshaft sprocket.
4. Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply tube.
5. Remove the camshaft.

1. Install the camshaft.
2. Position the oil supply tube, the camshaft bearing caps, and the bolts. Tighten the bolts in the sequence shown in two stages: Stage 1 Tighten the bolts to 6 Nm (53 lb-in). Stage 2 Tighten the bolts to 16 Nm (12 lb-ft).
3. The camshaft must be re-timed. See «TIMING DRIVE COMPONENTS - CAMSHAFT TIMING»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
4. Install the camshaft roller followers. See «ROLLER FOLLOWERS»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .

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1. Raise and support the vehicle.
2. Remove the bolts.
3. Lower the vehicle.
4. Disconnect the hoses from the differential pressure feedback (EGR) transducer.
5. Disconnect the EGR valve to exhaust manifold tube from the exhaust manifold.
6. Disconnect the EGR valve to exhaust manifold tube from the EGR valve and remove the EGR valve to exhaust manifold tube.
7. Remove the LH exhaust manifold.
8. To install, reverse the removal procedure.

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1. Raise and support the vehicle.
2. Remove the bolts.
3. Lower the vehicle.
4. Remove the RH exhaust manifold.
5. To install, reverse the removal procedure.

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1. On All Vehicles Relieve the fuel system pressure. See «FUEL SYSTEMS»(/ford/explorer-sport-trac/i-2000-2005/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-trucks-except-diesel__fuel-systems) in BASIC DIAGNOSTIC PROCEDURES - TRUCKS article.
2. Drain the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
3. Remove the intake manifold. See «INTAKE MANIFOLD»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
4. Remove the cooling fan shroud. For additional information, refer to COOLING FAN SHROUD .
5. Remove the accessory drive belt. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/explorer-sport-trac/i-2000-2005/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) article.
6. Disconnect the generator electrical connectors.
7. Remove the accessory drive belt tensioner.
8. Remove the generator mounting bracket and the generator as an assembly.
9. Disconnect the crankshaft position (CKP) sensor electrical connector.
10. Remove the electrical harness retainers.
11. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
12. Using the special tool, disconnect the spark plug wires from the spark plugs.
13. Disconnect the radio interference capacitor electrical connector.
14. Disconnect the coil pack electrical connector.
15. Disconnect the vacuum hose.
16. Disconnect the fuel pressure regulator vacuum hose.
17. Disconnect the vacuum hose.
18. Disconnect the fuel injector electrical connectors.
19. Disconnect the electrical connectors. Camshaft angle sensor. Differential pressure feedback exhaust gas recirculation (EGR) system.
20. Disconnect the engine wiring harness main electrical connector.
21. Remove the engine wiring harness main electrical connector from the bracket.
22. Disconnect the heater water hoses.
23. On Vehicles With Automatic Transmissions Remove the nut and position the transmission fluid level indicator and tube assembly aside.
24. On All Vehicles Remove the bolts and position the heater hose bracket aside.
25. Move the lower bypass hose clamp off the water pump outlet.
26. Remove the thermostat housing and the water bypass hose.
27. Remove the LH valve cover.
28. Secure the wiring harness to the LH fuel rail.
29. Remove the RH valve cover.
30. Remove the ground strap.
31. Remove the bracket.
32. Use the special tool to remove the roller followers.
33. Remove the four bolts and position the fuel supply line aside.
34. Remove the RH fuel rail.
35. Remove the RH exhaust manifold. See «EXHAUST MANIFOLD - RH»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
36. Remove the lower radiator hose.
37. Remove the nut and position the A/C line bracket aside.
38. Lower the vehicle.
39. Set the camshaft timing. See «TIMING DRIVE COMPONENTS - CAMSHAFT TIMING»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
40. Remove the RH camshaft chain tensioner.
41. Remove the RH camshaft sprocket from the cassette.
42. Remove the two 8-mm (0.32 in) bolts and the eight 12-mm (0.48 in) bolts in the sequence shown, and remove the RH cylinder head. Discard the head gasket. Discard the cylinder head bolts.
43. Clean the gasket mating surfaces.

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1. On All Vehicles Position the cylinder head gasket and the cylinder head.
2. Install the 12-mm (0.48 in) bolts and tighten in the sequence shown.
3. Install the two 8-mm (0.32 in) bolts.
4. Tighten the 12-mm (0.48 in) bolts in the sequence shown.
5. Tighten the eight 12-mm (0.48 in) bolts in the sequence shown in two stages: Stage 1 Tighten the bolts 90 degrees. Stage 2 Tighten the bolts an additional 90 degrees.
6. Install the RH rear camshaft sprocket in the cassette.
7. Install the RH rear camshaft bolt.
8. Install the bolt.
9. Carry out camshaft timing. See «TIMING DRIVE COMPONENTS - CAMSHAFT TIMING»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
10. Install the RH exhaust manifold. See «EXHAUST MANIFOLD - RH»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
11. Install the lower radiator hose.
12. Install the A/C bracket.
13. Lower the vehicle.
14. Using the special tool, install the camshaft roller followers.
15. Install the valve covers.
16. Install the RH fuel rail.
17. Reposition the engine wiring harness. Do not connect the electrical connectors at this time.
18. Install the fuel supply line.
19. Install the ground strap.
20. Install the bracket.
21. Install the thermostat housing.
22. Connect the water bypass hose clamp.
23. Connect the fuel injector electrical connectors.
24. Connect the electrical connectors. Camshaft angle sensor. Differential pressure feedback exhaust gas recirculation (EGR) system.
25. Position the engine wiring harness main electrical connector on the bracket
26. Connect the engine wiring harness main electrical connector.
27. Connect the vacuum hose.
28. Connect the fuel pressure regulator vacuum hose.
29. Connect the vacuum hose.
30. Install the heater hose bracket.
31. On Vehicles With Automatic Transmission Install the transmission fluid indicator tube.
32. On All Vehicles Connect the coil pack electrical connections.
33. Connect the radio interference capacitor electrical connector.
34. Connect the spark plug wires.
35. Install the water heater hoses.
36. Connect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
37. Install the electrical harness retainers.
38. Connect the crankshaft position (CKP) sensor electrical connector.
39. Install the generator mounting bracket and generator as an assembly.
40. Connect the generator electrical connectors.
41. Install the accessory drive belt tensioner.
42. Install the accessory drive belt. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/explorer-sport-trac/i-2000-2005/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) article.
43. Install the fan shroud. For additional information, refer to COOLING FAN SHROUD .
44. Install the intake manifold. See «INTAKE MANIFOLD»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
45. Fill and bleed the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .

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1. Remove the intake manifold. See «INTAKE MANIFOLD»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
2. Remove the roller followers. See «ROLLER FOLLOWERS»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
3. Remove the fan shroud. For additional information, refer to COOLING FAN SHROUD .
4. Remove the accessory drive belt. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/explorer-sport-trac/i-2000-2005/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) article.
5. Disconnect the generator wiring.
6. Remove drive belt tensioner. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/explorer-sport-trac/i-2000-2005/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) article.
7. Remove the generator mounting bracket.
8. Remove the bolt and the wiring harness routing clip.
9. Remove the bolts and position the accessory bracket aside.
10. Disconnect the crankshaft position (CKP) sensor electrical connector.
11. Remove the electrical harness retainer.
12. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
13. Disconnect the EGR tube nut.
14. Remove the upper heater water hose. Squeeze the heater hose clamp. Remove the heater water hose.
15. Remove the lower heater water hose and position aside. Remove the bolt. Squeeze the hose clamp. Remove the heater water hose and position aside.
16. Remove the thermostat housing. Remove the bolts. Release the bypass hose clamp.
17. Remove the oil level indicator tube.
18. Remove the exhaust manifolds. See «EXHAUST MANIFOLD - RH»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) and «EXHAUST MANIFOLD - LH»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
19. Remove the LH hydraulic chain tensioner.
20. Remove the bolt.
21. Remove the bolt.
22. Remove the LH camshaft sprocket from the cassette.
23. Remove the eight 12-mm bolts and two 8-mm bolts in the sequence shown and remove the LH cylinder head. Discard the head gasket. Discard the cylinder head bolts.

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1. Position the cylinder head gasket and the cylinder head.
2. Install the 12-mm bolts and tighten in the sequence shown.
3. Install the two 8-mm bolts.
4. Tighten the eight 12-mm bolts in the sequence shown in two stages: Stage 1 Tighten the bolts 80 degrees. Stage 2 Tighten the bolts an additional 80 degrees.
5. Install the LH front camshaft bolt.
6. Install the LH bolt.
7. Carry out camshaft timing. See «TIMING DRIVE COMPONENTS - CAMSHAFT TIMING»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
8. Install the exhaust manifolds. See «EXHAUST MANIFOLD - RH»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
9. Install the oil level indicator tube.
10. Install the thermostat housing. Install thermostat housing into bypass hose. Install the bolts. Position the bypass hose clamp.
11. Install the lower heater water hose. Position the heater water hose. Squeeze the heater hose clamp and position. Install the bolt.
12. Install the upper heater water hose. Position the heater water hose. Squeeze the hose clamp and position.
13. Connect the EGR tube nut.
14. Connect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
15. Install the electrical harness retainer.
16. Connect the crankshaft position (CKP) sensor electrical connector.
17. Install the accessory bracket.
18. Install the routing clip and bolt.
19. Install the generator mounting bracket.
20. Connect the generator wiring.
21. Install drive belt tensioner. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/explorer-sport-trac/i-2000-2005/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) article.
22. Install the accessory drive belt. See «SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/explorer-sport-trac/i-2000-2005/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) article.
23. Install the fan shroud. For additional information, refer to COOLING FAN SHROUD .
24. Install the roller followers. See «ROLLER FOLLOWERS»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
25. Install the intake manifold. See «INTAKE MANIFOLD»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .

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Scheme 326

1. Raise and support the vehicle.
2. Drain the engine oil.
3. Remove the bolts and the oil pan.
4. To install, reverse the removal procedure.

Scheme 327

1. Remove the oil pan. See «OIL PAN»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
2. Remove the oil pump screen cover and tube.
3. To install, reverse the removal procedure.

Scheme 328

1. Remove the clutch. See «CLUTCH ASSEMBLY»(/ford/explorer-sport-trac/i-2000-2005/remont/clutches-manual-hydraulic/#clutch-system__clutch-assembly) in CLUTCH article.
2. Remove the flywheel.
3. Clean and inspect the flywheel.

1. Install the flywheel. Tighten the bolts in the sequence shown in two stages: Stage 1 Tighten the bolts to 13 Nm (10 lb-ft). Stage 2 Tighten the bolts to 71 Nm (52 lb-ft).
2. Install the transmission. See «TRANSMISSION»(/ford/explorer-sport-trac/i-2000-2005/remont/clutches-manual-hydraulic/#clutch-system) in CLUTCH article.

Scheme 329

1. Remove the transmission. See «TRANSMISSION»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) in AUTOMATIC TRANSMISSION article.
2. Remove the flexplate.

1. Install the flywheel. Tighten the bolts in the sequence shown in two stages. Stage 1: Tighten the bolts to 13 Nm (10 lb-ft). Stage 2: Tighten the bolts to 71 Nm (52 lb-ft).
2. Install the transmission. See «TRANSMISSION»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission) in AUTOMATIC TRANSMISSION article.

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1. Remove the flexplate. See «FLEXPLATE»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
2. Using the special tool, remove the crankshaft rear oil seal.

Scheme 332

1. Lubricate the crankshaft rear oil seal with clean engine oil and install on the special tool.
2. Using the special tool, install the crankshaft rear oil seal.
3. Install the flexplate. See «FLEXPLATE»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .

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1. On All Vehicles Remove the fan shroud. For additional information, refer to COOLING FAN SHROUD .
2. Remove the LH engine insulator nuts.
3. Remove the RH engine insulator nuts.
4. Raise and support the vehicle.
5. On 4x4 Vehicles Secure the axle housing to a suitable lift.
6. Loosen, but do not remove, the front axle bolts. Position the lift to access the left motor mount nut.
7. On All Vehicles Remove the LH and RH engine support insulator nuts.
8. Raise and support the engine.
9. Remove the engine support insulators.
10. To install, reverse the removal procedure.

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1. Disconnect the battery ground cable.
2. Remove the hood.
3. Discharge and recover the A/C system. See «RECOVERY/EVACUATION & RECHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing) in GENERAL SERVICING PROCEDURES article.
4. Relieve the fuel pressure. See «FUEL SYSTEMS»(/ford/explorer-sport-trac/i-2000-2005/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-trucks-except-diesel__fuel-systems) in BASIC DIAGNOSTIC PROCEDURES - TRUCKS article.
5. Remove the air cleaner outlet tube.
6. Disconnect accelerator cable from engine.
7. Disconnect speed control cable from engine, if equipped.
8. Remove the radiator, the fan blade, and the fan shroud. For additional information, refer to RADIATOR and COOLING FAN SHROUD .
9. Remove the accessory bracket bolts and position bracket aside.
10. Disconnect the generator wiring.
11. Remove the wiring harness retainer and position generator wiring away from engine.
12. Install the accessory bracket bolts.
13. Disconnect the engine electrical connector.
14. Disconnect the powertrain control module (PCM) electrical connector.
15. Disconnect the PCM electrical ground wire.
16. Disconnect the engine ground wire.
17. Release hose clamp and disconnect the brake booster vacuum hose.
18. Disconnect the A/C high pressure switch electrical connector.
19. Remove the bolt and position the A/C lines aside.
20. Release hose clamp and disconnect hose.
21. Disconnect the two heater water hoses.
22. Disconnect the fuel line. See «FUEL SYSTEMS»(/ford/explorer-sport-trac/i-2000-2005/remont/testing-diagnostics/#engine-controls-basic-diagnostic-procedures-trucks-except-diesel__fuel-systems) in BASIC DIAGNOSTIC PROCEDURES - TRUCKS article.
23. Raise and support the vehicle.
24. Remove the starter motor. See «STARTER MOTOR»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters) in STARTERS article.
25. Remove the four nuts.
26. Drain the engine oil.
27. Install the oil drain plug.
28. Remove the bolts.
29. Remove the bolts.
30. On all models, disconnect transmission portion of wiring harness. Disconnect the RH and LH heated oxygen sensor (HO2S) connectors. Disconnect the transmission control connector. Disconnect the output shaft speed (OSS) sensor connector. Disconnect the digital transmission range (TR) sensor connector.
31. Disconnect the catalyst monitor sensor electrical connector.
32. Release transmission/transfer case portion of the wiring harness from any routing clips or push-pins.
33. Route transmission/transfer case portion of the wiring harness to top of engine.
34. Remove the bolt and position the transmission cooling line bracket aside.
35. Remove the A/C line bracket nut and position it aside.
36. Disconnect the power steering return hose.
37. Disconnect the power steering pressure hose.
38. Disconnect the vapor management valve (VMV) hose connector.
39. Remove the eight bolts.
40. Remove the LH and the RH engine support insulator nuts.
41. Lower the vehicle.
42. Remove the RH engine insulator nuts.
43. Remove the LH engine insulator nuts.
44. Install the lifting eyes.
45. Install the spreader bar to the lifting eyes.
46. Attach a floor crane to the spreader bar and remove the engine.
47. Remove the flywheel.
48. Remove the spacer plate.
49. Install the engine on a suitable engine stand.

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Engine Disassembly

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1. Rotate the drive belt tensioner counterclockwise and remove the drive belt.
2. Remove the bolts and position the accessory bracket aside.
3. Disconnect the generator wiring.
4. Remove the generator mounting bracket. Remove drive belt tensioner bolt. Remove generator mounting bracket bolts.
5. Disconnect the throttle position (TP) sensor electrical connector.
6. Disconnect the idle air control (IAC) valve electrical connector and disconnect the EGR valve vacuum hose.
7. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube.
8. Disconnect the ignition coil electrical connector.
9. Disconnect the radio ignition interference capacitor electrical connector.
10. Disconnect the exhaust gas regulator (EGR) vacuum regulator.
11. Using the special tool, remove the spark plug wires from the spark plugs and all routing clips.
12. Remove the bolts.
13. Remove the bolt and the coil and ignition wires.
14. Disconnect the vacuum hoses.
15. Detach and disconnect the electrical connector.
16. Remove the intake manifold bolts and lift up the intake manifold.
17. Remove the heated PCV hose retainers and remove the heated PCV fitting.
18. Remove the intake manifold.
19. Remove the bolts.
20. Detach the wiring harness retainer and remove the heater tube and bracket assembly.
21. Disconnect the camshaft position (CMP) sensor electrical connector.
22. Disconnect the differential pressure feedback EGR transducer.
23. Disconnect the crankshaft position (CKP) sensor electrical connector.
24. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
25. Disconnect the six fuel injector electrical connectors.
26. Remove the engine control/fuel charging wiring.
27. Disconnect the EGR valve to exhaust manifold tube from the exhaust manifold.
28. Remove the bolt and position the lower fuel line bracket aside.
29. Remove the fuel injection supply manifold.
30. Remove the LH valve cover and the gasket.
31. Remove the RH valve cover and the gasket.
32. Remove the fuel injectors.
33. Remove the thermostat housing. Remove the bolts. Release the bypass hose clamp.
34. Remove the oil level indicator tube.
35. Remove the knock sensor.
36. Remove the RH exhaust manifold and the gasket.
37. Remove the LH exhaust manifold and the gasket.
38. Remove the water pump.
39. Remove the bolt.
40. Using the special tool, remove the crankshaft pulley.
41. Remove the RH hydraulic chain tensioner.
42. Using the special tool, remove the camshaft roller followers.
43. Remove the RH camshaft sprocket bolt.
44. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.
45. Remove the bolt.
46. Remove the LH hydraulic chain tensioner.
47. Remove the LH camshaft sprocket bolt.
48. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.
49. Remove the bolt.
50. Remove the bolts in the sequence shown and remove the LH cylinder head.
51. Remove the bolts in the sequence shown and remove the RH cylinder head.
52. Remove the engine front cover.
53. Remove the oil pan.
54. Remove the oil pump screen cover and tube.
55. Remove the bolts.
56. Remove the ladder frame bolts.
57. Remove the 15 bolts and the two nuts. Remove the ladder frame.
58. Remove the oil pump.
59. Remove the oil filter.
60. Remove the oil filter adapter.
61. Inspect and install new O-ring seals if necessary.
62. Remove the chain tensioner.
63. Remove the chain guide.
64. Remove the rear jackshaft plug.
65. Install the special tool at the rear of the jackshaft.
66. Loosen the front sprocket retaining bolt.
67. With special tool still in place, loosen the rear sprocket retaining bolt.
68. Remove the special tool.
69. Remove the bolt.
70. Remove the jackshaft sprocket and chain.
71. Remove the bolt and the front cassette.
72. Remove the bolt and spacer.
73. Remove the bolt and remove the cassette.
74. Remove the oil pump drive.
75. Remove the jackshaft thrust plate.
76. Remove the jackshaft.
77. On 4x4 vehicles, remove the balance shaft tensioner. Install a pin in the balance shaft tensioner. Remove the bolts. Remove the balance shaft tensioner.
78. On 4x4 vehicles, remove the balance shaft chain and crankshaft sprocket.
79. On 4x4 vehicles, remove the balance shaft. Remove the bolts. Remove the balance shaft.
80. Using the cylinder ridge reamer, remove the ridge and carbon deposits from the top of each cylinder.
81. Remove the piston and connecting rod assemblies. Remove the connecting rod nuts. Remove the connecting rod cap.
82. Install rubber hose pieces on the bolts to protect the crankshaft and remove the pistons.
83. Remove the bolts.
84. Remove the crankshaft main bearing caps.
85. Remove the crankshaft rear oil seal from the crankshaft.
86. Remove the crankshaft.
87. Remove the crankshaft main bearings and the thrust bearing.

Scheme 444

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Scheme 448

1. Remove the spark plugs.
2. Using the special tool, remove the camshaft roller followers.
3. Using the special tool, remove the valve spring retainer keys, the valve spring and the retainer.
4. Remove the valve.
5. Repeat the procedure until all of the valves are removed.
6. Remove the valve stem seals.
7. Remove the bolts in the sequence shown and remove the camshaft bearing caps.
8. Remove the camshaft.
9. Inspect the cylinder head. See «GENERAL PROCEDURES»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-system-general-information) in ENGINE SYSTEM - GENERAL INFORMATION article.

Assembly

Note. Prior to assembly, coat all of the valve train components with clean engine oil.

Scheme 449

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Scheme 452

1. Install the camshaft.
2. Position the oil supply tube, the camshaft bearing caps, and bolts. Tighten in the sequence shown in two stages: Stage 1 Tighten to 6 Nm (53 lb-in). Stage 2 Tighten to 16 Nm (12 lb-ft).
3. Install the valve.
4. Using the special tool, install the valve stem seals.
5. Using the special tool, install the valve spring, the retainer and the retainer keys.
6. Repeat the procedure until all of the valves are installed.
7. Install the spark plugs.
8. Install the camshaft roller followers only when the cylinder head is installed in the vehicle and the timing procedure has been carried out.

Scheme 453

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Scheme 456

1. Remove the connecting rod bearings from the connecting rod and caps.
2. Remove the piston rings. See «GENERAL PROCEDURES»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-system-general-information) in ENGINE SYSTEM - GENERAL INFORMATION article.
3. Using the special tool, press the piston pin out of the connecting rod and piston assembly.
4. Remove the connecting rod from the piston.
5. Clean and inspect the connecting rod and piston. See «GENERAL PROCEDURES»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-system-general-information) in ENGINE SYSTEM - GENERAL INFORMATION article.

Scheme 457

1. Install the large chamfered side of the connecting rod bearing bore facing toward the engine front on the RH bank connecting rod and facing toward the rear of the engine on LH bank connecting rod.
2. Position the piston pin in the bore aligned with the connecting rod bore.
3. Gradually heat the pin bore side of the connecting rod to approximately 232-316°C (467-626°F) and immediately install the piston pin.
4. Using the special tool, press the piston pin into the piston and connecting rod assembly.
5. Install the piston rings. See «GENERAL PROCEDURES»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-system-general-information) in ENGINE SYSTEM - GENERAL INFORMATION article.

Scheme 458

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Scheme 460

Engine Assembly

Note. Before engine assembly, use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

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1. Install the upper crankshaft main bearings and the thrust bearing. Lubricate the crankshaft main bearings with clean engine oil.
2. Install the crankshaft.
3. Apply silicone gasket and sealant to the rear main bearing cap to cylinder block parting line.
4. Install the crankshaft lower main bearings in the main bearing caps.
5. Install the main bearing caps.
6. Tighten the bolts.
7. Lubricate the piston rings with clean engine oil.
8. Make sure that the piston rings are correctly spaced. See «GENERAL PROCEDURES»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-system-general-information) in ENGINE SYSTEM - GENERAL INFORMATION article.
9. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.
10. Using the special tool, install the pistons.
11. Check the clearance of each connecting rod bearing. See «GENERAL PROCEDURES»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-system-general-information) in ENGINE SYSTEM - GENERAL INFORMATION article.
12. Rotate the crankshaft until the piston is at the bottom of its stroke.
13. Loosen the first nut until the face is approximately 2 mm (0.08 in) over the end of the bolt.
14. Tap the bolt on the nut until it can be removed by hand.
15. Repeat previous two steps for the opposite bolt.
16. Install the new bolts making certain that the bolt head is parallel to the sideward face of the connecting rod.
17. Install the connecting rod cap in the original position.
18. Install and tighten the connecting rod nuts finger tight.
19. Tighten the connecting rod nuts simultaneously in two stages: Stage 1 Tighten 20 Nm (15 lb-ft). Stage 2 Tighten 90 degrees.
20. Repeat previous four steps for the remaining connecting rods.
21. Rotate crankshaft until No. 1 piston is at top dead center.
22. On 4x4 vehicles, install the balance shaft. Install the balance shaft assembly. Install the bolts.
23. On 4x4 vehicles, install the balance shaft chain and crankshaft sprocket.
24. On 4x4 vehicles, align the timing marks. Install a 4 mm pin to hold the shaft in place.
25. On 4x4 vehicles, install the balance shaft tensioner. Install the balance shaft tensioner. Install the bolts. Position the balance shaft chain guide and install the two bolts. Remove the pin from the tensioner.
26. Install the oil pump.
27. Install the jackshaft.
28. Install the jackshaft thrust plate and bolts.
29. Install the oil pump drive.
30. Attach the rear cassette and sprocket to the bolt. Do not tighten at this time.
31. Install the rear cassette and bolt.
32. Install the front cassette and bolt.
33. Position the jackshaft sprocket and chain.
34. Install the chain guide.
35. Install the chain tensioner.
36. Install the bolt. Do not tighten at this time.
37. While holding the front jackshaft sprocket bolt secure, tighten the rear bolt to 20 Nm (15 lb-ft).
38. Install the special tool on the rear of the jackshaft.
39. Tighten the rear bolt an additional 90 degrees.
40. Tighten the front bolt in two stages. Stage 1 Tighten to 45 Nm (33 lb-ft). Stage 2 Tighten 90 degrees.
41. Remove the special tool and install the rear jackshaft plug.
42. Position the front cover gasket and install the front cover.
43. Apply silicone gasket and sealant to the front cover in four places.
44. Apply silicone gasket and sealant to the rear main bearing cap as shown. Position the ladder frame gasket.
45. Loosen the ladder frame inserts.
46. Position the ladder frame and gasket assembly.
47. Install and hand tighten the fifteen bolts and two nuts.
48. Install and hand tighten the bolts.
49. Using a straightedge, align the transmission face of the ladder frame with the rear face of the cylinder block.
50. Tighten the fifteen bolts and two nuts.
51. Tighten the bolts.
52. Tighten the inserts.
53. Install new seals on the two silver bolts and position them in the ladder frame.
54. Position the six remaining bolts.
55. Tighten the ladder frame bolts in two stages. Stage 1 Tighten to 15 Nm (11 lb-ft). Stage 2 Tighten to 33 Nm (24 lb-ft).
56. Measure the step between the rear face of the cylinder block and the transmission face of the ladder frame.
57. Repair all assemblies that exceed underflush specification by installing shims on one or both sides of the ladder frame.
58. Install the oil pump screen cover and tube.
59. Install the gasket, and the oil pan.
60. Install the oil filter adapter.
61. Install the oil filter.
62. Install the water pump.
63. Install the cylinder head gasket.
64. Install the cylinder head and tighten the bolts in the sequence shown. (Scheme 567) Bolts are tightened in multiple stages. Stage 1: Tighten bolts to 12 Nm (9 lb-ft). Stage 2: Tighten bolts to 25 Nm (18 lb-ft).
65. Install the two 8 mm bolts and tighten to 32 Nm (24 lb-ft). (Scheme 568)
66. Using the torque-turn method, tighten the 12-mm bolts in the sequence shown in 2 stages. (Scheme 569) Stage 1: Tighten the bolts 90°. Stage 2: Tighten the bolts an additional 90°.
67. Using the special tool, install the crankshaft pulley.
68. Tighten the bolt in two stages. Stage 1 Tighten to 50 Nm (37 lb-ft). Stage 2 Rotate an additional 90 degrees.
69. Install the RH rear camshaft bolt.
70. Install the bolt.
71. Install the LH front camshaft bolt.
72. Install the bolt.
73. Turn the crankshaft one revolution clockwise.
74. Install the special tool.
75. Install the special tools on the front of the RH cylinder head.
76. Install the special tools on the rear of the RH cylinder head.
77. Install the special tool.
78. Tighten the bolts. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). Tighten the camshaft bolt.
79. Remove the special tool and install the RH camshaft tensioner.
80. Remove the special tools from the RH cylinder head.
81. Install the special tools on the front of the LH cylinder head.
82. Install the special tools on the rear of the LH cylinder head.
83. Install the special tool.
84. Tighten the bolts. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). Tighten the camshaft bolt.
85. Remove the special tool and install the LH camshaft tensioner.
86. Remove the special tools from the LH cylinder head.
87. Remove the special tool.
88. Using the special tool, install the roller followers in their original position.
89. Install the gasket and the LH exhaust manifold.
90. Install the gasket and the RH exhaust manifold.
91. Install the knock sensor.
92. Install the oil level indicator tube.
93. Install the thermostat housing. Install the housing into the bypass hose. Install the bolts. Position the bypass hose clamp.
94. Install the fuel injectors. Lubricate the fuel injector O-ring seals with engine oil.
95. Install the gasket and the RH valve cover.
96. Install the gasket and the LH valve cover.
97. Install the fuel injection supply manifold.
98. Install the lower fuel line bracket.
99. Connect the EGR valve to exhaust manifold tube to the exhaust manifold.
100. Install the fuel charging wiring.
101. Connect the six fuel injector electrical connectors.
102. Connect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
103. Connect the crankshaft position (CKP) sensor electrical connector.
104. Connect the differential pressure feedback EGR transducer.
105. Connect the camshaft position (CMP) sensor electrical connector.
106. Attach the wiring harness retainer and install the heater tube bracket assembly.
107. Install the bolts.
108. Position the intake manifold close to the installed position.
109. Install the heated PCV fitting.
110. Install the intake manifold.
111. Connect and attach the electrical connector.
112. Connect the vacuum hoses.
113. Install the coil and ignition wire. Install the bolt.
114. Install the bolts.
115. Connect the spark plug wires to the spark plugs.
116. Connect the exhaust gas recirculation (EGR) vacuum regulator.
117. Connect the radio ignition interference capacitor electrical connector.
118. Connect the ignition coil electrical connector.
119. Connect the EGR valve-to-exhaust manifold tube to the EGR valve.
120. Connect the idle air control (IAC) valve electrical connector and connect the EGR valve vacuum hose.
121. Connect the throttle position (TP) sensor electrical connector.
122. Install the generator mounting bracket. Install the generator mounting bracket bolts. Install the drive belt tensioner bolt.
123. Connect the generator wiring.
124. Install the accessory bracket and tighten the bolts.
125. Rotate the drive belt tensioner counterclockwise and install the drive belt.

Scheme 544

Scheme 545

Scheme 546

Scheme 547

Scheme 548

Scheme 549

Scheme 550

Scheme 551

Scheme 552

Scheme 553

Scheme 554

Scheme 555

Scheme 556

Scheme 557

Scheme 558

Scheme 559

Scheme 560

Scheme 561

Scheme 562

Scheme 563

Scheme 564

Scheme 565

Scheme 566

Scheme 567

Scheme 568

Scheme 569

Scheme 570

1. Install the lifting eyes.
2. Install the spreader bar on the lifting eyes.
3. Attach the floor crane to the spreader bar and remove the engine from the engine stand.
4. Install the rear crankshaft oil seal. See «CRANKSHAFT REAR OIL SEAL»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
5. Install the spacer plate.
6. Install the flywheel. See «FLYWHEEL»(/ford/explorer-sport-trac/i-2000-2005/remont/mechanical/#engine-40l-sohc) .
7. Install the engine, remove the floor crane and the spreader bar.
8. Remove the lifting eyes.
9. Install the LH engine insulator nuts.
10. Install the RH engine insulator nuts.
11. Raise and support the vehicle.
12. Install the LH and the RH engine support insulator nuts.
13. Install the eight bolts.
14. Connect the vapor management valve (VMV) hose connector.
15. Connect the power steering pressure hose.
16. Connect the power steering return hose.
17. Position the A/C line bracket and install the nut.
18. Position the transmission cooling line bracket and install the bolt.
19. Route the transmission/transfer case portion of the wiring harness down to the transmission.
20. Attach the transmission/transfer case portion of the wiring harness to any routing clips or push-pins.
21. Connect the catalyst monitor sensor electrical connector.
22. Connect transmission portion of the wiring harness. Connect the RH and the LH heated oxygen sensor (HO2S) connector. Connect the transmission control connector. Connect the output shaft speed (OSS) sensor connector. Connect the digital transmission range (TR) sensor connector.
23. Install the bolts.
24. Install the bolts.
25. Install the four bolts.
26. Install the starter. See «STARTER MOTOR»(/ford/explorer-sport-trac/i-2000-2005/remont/starter/#starters) in STARTERS article.
27. Connect the fuel line.
28. Connect the two heater water hoses.
29. Attach heater hose and position clamp.
30. Position the A/C compressor manifold tube and install the bolt.
31. Connect the A/C high pressure switch electrical connector.
32. Connect the engine ground wire.
33. Connect the PCM electrical ground wire.
34. Connect the PCM electrical connector.
35. Connect the engine bulkhead electrical connector.
36. Remove the accessory bracket bolts and position bracket aside.
37. Position wiring harness and install bolt.
38. Connect generator wiring.
39. Install the accessory bracket bolts.
40. Install the radiator, the fan blade, and the fan shroud. For additional information, refer to RADIATOR and COOLING FAN SHROUD .
41. Connect the speed control cable, if equipped.
42. Connect accelerator cable.
43. Install the air cleaner outlet tube.
44. Install the hood.
45. Connect the battery ground cable.
46. Fill the engine to the correct oil level with clean engine oil.
47. Fill and bleed engine cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
48. Recharge A/C system. See «RECOVERY/EVACUATION & RECHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing) in GENERAL SERVICING PROCEDURES article.

See also:
• DIAGNOSIS & TESTING
• FUEL SYSTEM PRESSURE RELEASE
• DRIVE BELT ROUTING
• FUEL RAILS & INJECTORS
• FUEL SYSTEMS
• CLUTCH ASSEMBLY
• TRANSMISSION
• TRANSMISSION
• RECOVERY/EVACUATION & RECHARGING
• STARTER MOTOR
• CRANKSHAFT PULLEY