Engine - 4.0L V6 - VIN E: Other Ford Explorer II

VALVE CLEARANCE CHECK

Note. Hydraulic valve adjusters are used. No adjustment is necessary.

CAMSHAFT TIMING

Note. Procedures in Step 1) may already have been completed if sent here from a another procedure.

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

1. Remove valve covers. See «VALVE COVERS»(ref-9556-S34942275442001040900000). Remove lower intake manifold. See «REMOVAL & INSTALLATION (LOWER INTAKE MANIFOLD)»(ref-9556-S12737687522002020700000) under INTAKE MANIFOLDS. Remove fuel supply manifold. see scheme 27 Remove accessory drive belt. Remove thermostat housing. See «THERMOSTAT HOUSING»(ref-9556-S34798726622004020900000). Remove camshaft roller followers. See «CAMSHAFT ROLLER FOLLOWERS»(ref-9556-S14976595622002020600000).
2. While observing timing mark on damper, turn crankshaft clockwise to position number one cylinder at TDC and install Crankshaft Holding Tool (T97T-6303-A) to hold crankshaft in position. This will prepare the engine for cam timing. see scheme 34 Install Camshaft Gear Holding Tool (T97T-6256-B) and Adapter (T97T-6256-A) onto right camshaft sprocket and tighten top 2 clamp bolts of Camshaft Gear Holding Tool (T97T-6256-B) to 89 INCH lbs. (10 N.m). see scheme 36 CAUTION: Right camshaft sprocket bolt is a LEFT-HAND threaded bolt.
3. Using Camshaft Gear Removal Tool (T97T-6256-F), loosen right camshaft sprocket bolt. Loosen top bolts of Camshaft Gear Holding Tool (T97T-6256-B). (Scheme 84)
4. Position the camshaft timing slots below centerline of camshaft to allow proper installation of Camshaft Holding Tool (T97T-6256-C) and Adapter (T97T-6256-0) onto the cylinder head. Then, install both tools onto cylinder head. (Scheme 85)
5. Raise and support vehicle. Remove right wheel and tire. Remove lower splash shield. Remove right camshaft tensioner and install Timing Chain Tensioner Tool (T97T-6K254-A). (Scheme 86) Remove vehicle supports and lower vehicle. CAUTION: Right camshaft sprocket bolt is a LEFT-HAND threaded bolt. NOTE: If Camshaft Gear Removal Tool (T97T-6256-F) is being used with torque wrench, keep torque wrench IN-LINE with tool and tighten camshaft sprocket to 45 ft. lbs. (61 N.m). This tool will amplify the torque. Otherwise, tighten camshaft sprocket to 63 ft. lbs. (85 N.m).
6. Tighten top 2 clamp bolts on Camshaft Gear Holding Tool (T97T-6256-B) to 89 INCH lbs. (10 N.m). Then, tighten camshaft sprocket bolt to 63 ft. lbs. (85 N.m). (Scheme 84)
7. Raise and support the vehicle. Remove Timing Chain Tensioner Tool (T97T-6K254-A) and install right camshaft tensioner with a NEW washer. Tighten to 32 ft. lbs. (44 N.m). Install lower splash shield, wheel and tire and tighten lug nuts to 100 ft. lbs. (135 N.m) in a star pattern. Remove vehicle supports and lower vehicle. Remove all special tools from the cylinder head. NOTE: Leave top 2 clamp bolts loose on Camshaft Gear Holding Tool (T97T-6256-B).
8. Install Camshaft Gear Holding Tool (T97T-6256-B) and Adapter (T97T-6256-A) onto left camshaft sprocket. see scheme 36 CAUTION: It is important that tool be installed correctly. If not, engine may run badly, with one cam being off by 180 degrees. NOTE: Camshaft timing slots are off center.
9. Position camshaft timing slots below centerline of camshaft to allow proper installation of Camshaft Holding Tool (T97T-6256-C) and Adapter (T97T-6256-D) onto rear of left cylinder head. Then, install both tools onto cylinder head. (Scheme 85)
10. Remove left camshaft tensioner and install Timing Chain Tensioner Tool (T97T-6K254-A). (Scheme 87) Tighten top 2 clamp bolts on Camshaft Gear Holding Tool (T97T-6256-B) to 89 INCH lbs. (10 N.m). Then, tighten camshaft sprocket bolt to 63 ft. lbs. (85 N.m). (Scheme 88)
11. Remove Timing Chain Tensioner Tool (T97T-6K254-A) and install left camshaft tensioner with a NEW washer and tighten to 32 ft. lbs. (44 N.m). Remove all special tools from cylinder head. Remove Crankshaft Holding Tool (T97T-6303-A) from crankshaft. Install accessory bracket. Tighten 4 bolts to 31 ft. lbs. (42 N.m).
12. Install radiator. Install the engine coolant temperature sensor and tighten to 11 ft. lbs. (15 N.m). Connect engine coolant temperature connector. Install camshaft roller followers. See «CAMSHAFT ROLLER FOLLOWERS»(ref-9556-S14976595622002020600000). To complete installation, reverse removal procedure.

FUEL PRESSURE RELEASE

Disconnect negative battery cable. Remove Schrader valve cap and attach EFI/CFI fuel pressure gauge. (Scheme 89) This may drain fuel from system, if so, place fuel in a suitable container. Open manual valve on EFI/CFI fuel pressure gauge and relieve fuel pressure.

Scheme 89

CRANKSHAFT FRONT SEAL

TIMING CHAIN

To diagnose timing chain noise, see OWNER NOTIFICATION PROGRAM 01M01 - CAM CHAIN TSB. For timing chain removal and installation procedures, see CAMSHAFT CASSETTES .

CAMSHAFT CASSETTES

Note. To diagnose camshaft timing chain noise, see OWNER NOTIFICATION PROGRAM 01M01 - CAM CHAIN TSB.

Scheme 90

Scheme 91

1. Remove left and right camshaft roller followers. See «CAMSHAFT ROLLER FOLLOWERS»(ref-9556-S14976595622002020600000). Disconnect and remove engine coolant temperature sensor. Remove radiator. Remove engine front cover. See «ENGINE FRONT COVER»(ref-9556-S08093035002005051100000). CAUTION: Camshaft timing must be performed if either camshaft is disturbed. See «CAMSHAFT TIMING»(ref-9556-S20270659162005051200000).
2. Inspect left camshaft cassette for damage to plastic inserts of chain guide. Look for any cracks, broken or small pieces that may enter engine lubrication system. see scheme 45 If cracks, broken or small pieces are present, this problem is addressed in step 5 under INSTALLATION. Remove left camshaft chain tensioner. see scheme 46
3. Install Camshaft Gear Holding Tool (T97T-6256-8) and Adapter (T97T-6256-A) onto camshaft sprocket. Loosen, but DO NOT remove, camshaft sprocket bolt. see scheme 46 Remove special tools and sprocket bolt. Hold crankshaft from turning with Special Tool (303-674), and loosen jackshaft sprocket bolt. see scheme 46
4. Remove primary chain tensioner. see scheme 47 Remove primary chain, jackshaft sprocket and crankshaft sprocket. see scheme 47
5. Remove camshaft drive cassette. Remove upper and lower chain guide bolts. Remove sprockets and chain. Lift chain guide up and out of cylinder head. see scheme 48 CAUTION: When cleaning sealing surfaces, be sure to cover the opening to oil pan area with clean shop cloths to ensure no gasket material falls into oil pan area.
6. Using clean shop cloths, clock all openings that may allow dirt to enter the oil pan. Clean all surfaces. Clean all debris from engine. Remove all shop cloths placed in the engine.

JACKSHAFT

Manufacturer does not supply separate removal and installation procedure. See ENGINE DISASSEMBLY .

BALANCE SHAFT(4WD)

Manufacturer does not supply separate removal and installation procedure. See ENGINE DISASSEMBLY .

CYLINDER HEAD

1. Clean head gasket mating surface. Clean carbon from combustion chambers. DO NOT damage surfaces. Check cylinder head for cracks, burrs, nicks and warpage.
2. DO NOT machine more than .010" (.25 mm) from original cylinder head surface to correct warpage. Replace cylinder head as necessary. See «CYLINDER HEAD»(ref-9556-S23429798192000110300000) table under ENGINE SPECIFICATIONS.

VALVE SPRINGS

1. Measure valve spring installed height from top of spring seat to underside of spring retainer. Ensure installed height is within specification. See «VALVES & VALVE SPRINGS»(ref-9556-S10392585992000110300000) table under ENGINE SPECIFICATIONS.
2. If installed height is not within specification, a spacer can be installed between cylinder head and valve spring to obtain correct height. Inspect valve spring free length and pressure. Replace valve spring if free length and pressure are not within specification. See «VALVES & VALVE SPRINGS»(ref-9556-S10392585992000110300000) table under ENGINE SPECIFICATIONS.

VALVE STEM OIL SEALS

When installing NEW valve stem seals, ensure oil seal bottoms on valve guide. Oversize valve stem seals must be installed when oversize valves are used.

VALVE GUIDES

1. Valve guides must be reamed for an oversize valve if valve stem oil clearance exceeds specification. See «CYLINDER HEAD»(ref-9556-S23429798192000110300000) table under ENGINE SPECIFICATIONS. Valves are available in .015" (.38 mm) and .030" (.76 mm) oversize.
2. If oversize valves or oversize valve stem oil seals are not available, valve guide may be bored out to use a service bushing. Always use reamers in proper sequence (smallest first).

VALVE SEAT

1. Grind valve seat to 45 degrees. If seat width is too wide after grinding, use a 30 degree stone to lower seat or a 60 degree stone to raise seat. See «CYLINDER HEAD»(ref-9556-S23429798192000110300000) table under ENGINE SPECIFICATIONS.
2. Ensure valve seat angle, seat width and seat runout are within specification. See «CYLINDER HEAD»(ref-9556-S23429798192000110300000) table under ENGINE SPECIFICATIONS. Valve seats must be ground when valve guide is reamed or replaced. Replacement information is not available from manufacturer.

VALVES

Ensure head diameter, valve face runout, stem diameter and valve margin are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Fitting Pistons

1. Check piston-to-bore clearance. See «PISTONS, PINS & RINGS»(ref-9556-S33100195062000110300000) table under ENGINE SPECIFICATIONS. Standard size pistons are color-coded Red, Blue or Yellow on piston dome. Oversize pistons are also available.
2. If bore diameter is in lower one-third of specification, use a Red coded piston. If bore diameter is in middle one-third of specification, use a Blue coded piston. If bore diameter is in upper one-third of specification, use Yellow coded piston. Use proper size piston to obtain specified clearance. See «PISTONS, PINS & RINGS»(ref-9556-S33100195062000110300000) table under ENGINE SPECIFICATIONS.

Piston Rings

1. Select rings for bore diameter. Place ring in cylinder bore in which it will be installed. Use piston to square ring in bore and place ring below normal ring wear area. Measure ring end gap. If ring gap is too small, file end of ring until within specification. If ring gap exceeds specification, try another ring set. See «PISTONS, PINS & RINGS»(ref-9556-S33100195062000110300000) table under ENGINE SPECIFICATIONS.
2. Check side clearance of rings after installing on piston. Ensure clearance is within specification around entire circumference. Replace piston and/or rings if clearance is not within specification. See «PISTONS, PINS & RINGS»(ref-9556-S33100195062000110300000) table under ENGINE SPECIFICATIONS. Ensure rings are properly spaced on piston before installing pistons into cylinder. see scheme 67

Scheme 92

Rod Bearings

1. Use Plastigage to check rod bearing clearance. If proper oil clearance cannot be obtained with standard bearings, try a combination of undersize bearings. DO NOT use any bearing combination other than listed. See «UNDERSIZE MAIN & ROD BEARING COMBINATIONS»(ref-9556-S07404867362000110300000) table.
2. If use of bearing combinations does not bring clearance within specification, machine or replace crankshaft as necessary. Always replace bearings in pairs. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-9556-S18746881582000110300000) table under ENGINE SPECIFICATIONS.

UNDERSIZE MAIN & ROD BEARING COMBINATIONS (1)

Crankshaft & Main Bearings

1. When checking main bearing clearance in vehicle, position a jack under adjoining bearing counterweight being checked. Remove only one main bearing cap at a time.
2. Use Plastigage to check main bearing clearance. If proper oil clearance cannot be obtained with standard bearings, try a combination of undersize bearings. DO NOT use any bearing combination other than listed. See «UNDERSIZE MAIN & ROD BEARING COMBINATIONS»(ref-9556-S07404867362000110300000) table.
3. If use of bearing combinations does not bring clearance within specification, machine or replace crankshaft as necessary. Always replace bearings in pairs. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-9556-S18746881582000110300000) table under ENGINE SPECIFICATIONS.
4. Install all bearing caps except thrust bearing cap (No. 3 from front of engine). Tighten main bearing cap bolts to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000) . Install No. 3 bearing cap and tighten bolts finger tight.
5. Pry crankshaft forward and pry No. 3 bearing cap to rear of engine to align thrust bearing. While retaining forward pressure on crankshaft, tighten bearing cap to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000) .
6. Ensure crankshaft end play is within specification. Replace thrust bearing if end play is not within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-9556-S18746881582000110300000) table under ENGINE SPECIFICATIONS.

Cylinder Block

1. Using a feeler gauge and straightedge, check cylinder block head gasket surface for warpage. Check cylinder bore for wear, taper, out-of-round and piston fit. See «CYLINDER BLOCK»(ref-9556-S31177819072000110300000) table under ENGINE SPECIFICATIONS.
2. Install all main bearing caps and tighten to specification before honing cylinder bore. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000) . Ensure bearing caps are installed in their original location, with arrow on cap pointing towards front of engine.
3. Use ONLY a spring-loaded type cylinder hone. After honing, thoroughly clean bore with detergent and water solution. Rinse solution from bore thoroughly with clean water. Wipe bore clean with lint-free cloth. Lubricate cylinder bores with engine oil.

Oil Pressure

Normal oil pressure at 2000 RPM should be 40-60 psi (2.8-4.2 kg/cm 2 ) with engine at normal operating temperature.

Pressure Relief Valve

Pressure relief valve is located in oil pump, and is not adjustable.

OIL PUMP

Note. Oil pump removal and installation information is not available from manufacturer.