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

Mechanical 7 illustrations ~1914 words

ENGINE DISASSEMBLY

Note. For component reference, refer to illustrations. see scheme 57and see scheme 58.

Scheme 77

Scheme 77: ENGINE DISASSEMBLY
Scheme 77: ENGINE DISASSEMBLY

Scheme 78

Scheme 78
Scheme 78

Scheme 79

Scheme 79
Scheme 79
  1. Remove accessory drive belt. Remove bolts and engine accessory bracket. Remove bolts and generator bracket. Disconnect Throttle Position (TP) sensor harness connector. Disconnect Idle Air Control (IAC) valve harness connector. Disconnect Intake Manifold Tuning Valve (IMTV) vacuum hose. Disconnect Exhaust Gas Recirculation (EGR) valve vacuum hose. Disconnect Camshaft Position (CMP) sensor harness connector.
  2. Disconnect coil pack harness connector. Disconnect radio ignition interference capacitor harness connector. Disconnect Engine Vacuum Regulator (EVR) and IMTV harness connectors. Disconnect Differential Pressure Feedback EGR (DPFE) transducer. Disconnect Crankshaft Position (CKP) sensor harness connector. Mark placement and remove all spark plug wires. Disconnect vacuum hose on right upper intake manifold. Disconnect Positive Crankcase Ventilation (PCV) hose.
  3. Remove 8 bolts for upper intake manifold. Disconnect left and right Vapor Management Valve (VMV) hoses. Remove bolts and lower intake manifold. Remove vacuum reservoir and vacuum lines. Disconnect water temperature indicator sender and Engine Coolant Temperature (ECT) sensor harness connectors. Disconnect fuel injector harness connectors. Remove engine wiring harness.
  4. Disconnect EGR tube from EGR valve. Disconnect EGR tube from exhaust manifold. Remove bolt and position lower fuel line bracket aside. Remove bolts and position upper fuel line bracket aside. Remove bolts and fuel injection supply manifold. Remove bolts and both valve covers. Remove fuel injectors. Remove nut and position VMV hose bracket aside. Compress hose clamp and disconnect bypass hose. Remove bolts and thermostat housing. Remove crankcase vent separator spring steel clip and remove separator.
  5. Remove bolt and knock sensor. Remove nuts and right exhaust manifold. Remove dipstick housing bolt and remove dipstick. Remove nuts and left exhaust manifold. Remove 12 bolts and water pump. Remove crankshaft pulley bolt. Install Crankshaft Damper Remover Tool (T74P-6316-A) and remove crankshaft pulley. Remove right hydraulic chain tensioner. see scheme 3
  6. Remove camshaft cassette. See «CAMSHAFT CASSETTES»(ref-9556-S04221884862003110400000).
  7. Remove left hydraulic chain tensioner. see scheme 3 Remove camshafts. See «CAMSHAFTS»(ref-9556-S41388655672000110300000).
  8. Remove 8 (12 mm) and 2 (8 mm) bolts in sequence shown and remove left cylinder head. see scheme 30 Remove 12 mm bolts and 8 mm bolts in sequence and remove right cylinder head. Remove 16 bolts and engine front cover. Remove bolts and oil pan. Remove 2 bolts and oil pickup tube. Remove 8 center ladder frame bolts. Remove 2 rear ladder frame bolts. Remove 15 side ladder frame bolts and 2 nuts. Remove ladder frame. Remove bolts and oil pump.
  9. Remove chain tensioner. see scheme 53 Remove chain guide. Remove jackshaft sprocket bolt. Remove jackshaft sprocket and chain. Remove front cassette retaining bolt and remove front cassette. see scheme 54 Remove rear jackshaft plug from rear of engine block. Remove rear cassette retaining bolt and spacer. Remove rear jackshaft sprocket bolt and remove cassette. Remove bolt and oil pump drive. Remove 2 jackshaft thrust plate bolts. see scheme 55 Remove jackshaft.
  10. Install a pin in balance shaft tensioner. see scheme 56 Remove 2 balance shaft tensioner bolts and remove balance shaft tensioner. Remove 2 balance shaft front bolts. Remove balance shaft tensioner. Remove balance shaft chain and crankshaft sprocket. Remove balance shaft. Remove 2 rear balance shaft bolts. Remove balance shaft. Use Cylinder Ridge Reamer (T64L-6011-EA) to remove ridge from top of 6 cylinder bores.
  11. Remove connecting rods. Install rubber hose on connecting rod bolts to protect crankshaft. Remove pistons. Remove crankshaft main bearing cap bolts. Remove crankshaft main bearing caps. Remove crankshaft rear oil seal from crankshaft. Remove crankshaft from engine. Remove engine main bearings.

Scheme 80

Scheme 80
Scheme 80

Scheme 81

Scheme 81
Scheme 81

ENGINE REASSEMBLY

CAUTIONCamshafts must be re-timed when either camshaft is disturbed. See CAMSHAFT TIMING under ADJUSTMENTS.

Note. For component reference, refer to illustrations. see scheme 57and see scheme 58.

Scheme 82

Scheme 82
Scheme 82

Scheme 83

Scheme 83
Scheme 83
  1. Lubricate crankshaft main bearings with engine oil. Install crankshaft main bearings. Inspect bearing clearance. See «CRANKSHAFT & MAIN BEARINGS»(ref-9556-S34457245142000110300000) in CYLINDER BLOCK ASSEMBLY under OVERHAUL. Install crankshaft. Apply sealant to rear main bearing cap to cylinder block parting line. Install main bearings in main bearing caps. Install main bearing cap. Tighten main bearing cap bolts to 74 ft. lbs. (104 N.m).
  2. Inspect piston rings. If replacing piston rings, see «PISTON RINGS»(ref-9556-S24067709372000110300000) in CYLINDER BLOCK ASSEMBLY under OVERHAUL. Lubricate piston rings with engine oil. Ensure that piston rings are properly spaced. Install rubber hoses on connecting rod bolts to protect crankshaft. Position piston with indentation arrow on piston toward front of engine block. Use piston ring compressor to install pistons.
  3. Inspect clearance of each connecting rod bearing. See «ROD BEARINGS»(ref-9556-S42236922962000110300000) in CYLINDER BLOCK ASSEMBLY under OVERHAUL. Rotate crankshaft until piston is at bottom of its stroke. For cylinders No. 1, 2 and 3, remove connecting rod nut at oil split hole side first. For cylinders No. 4, 5 and 6, remove opposite connecting rod nut first.
  4. Loosen first connecting rod nut until face is approximately 2 mm over end of bolt. Tap connecting rod bolt on nut until bolt can be removed by hand. Repeat this step for opposite connecting rod bolt. Install NEW connecting rod bolts making certain that bolt head is parallel to sideward face of connecting rod. Install connecting rod cap in original position.
  5. Install and tighten connecting rod nuts until they touch connecting surface of connecting rod cap. Tighten connecting rod nuts simultaneously in 2 stages: 14 ft. lbs. (20 N.m). Turn an additional 90 degrees. Repeat step 4 and this step for remaining connecting rods.
  6. Lubricate rear main seal with engine oil. Using Crankshaft Rear Main Oil Seal Adapter Tool (T95T-6701-AR), install rear main seal until flush with block. Rotate crankshaft until No. 1 piston is at TDC. Install balance shaft. Install balance shaft chain and crankshaft sprocket. Align balance shaft timing marks. see scheme 59 Install a 4 mm pin to hold shaft in place. Install balance shaft tensioner bolts and tighten bolts to 22 ft. lbs. (30 N.m). Position balance shaft chain guide and install 2 bolts to 97 INCH lbs. (11 N.m). Remove pin from tensioner.
  7. Install a NEW gasket and oil pump and tighten to 15 ft. lbs. (21 N.m). Install jackshaft. Install jackshaft thrust plate and bolts and tighten to 115 INCH lbs. (13 N.m). Install oil pump drive and tighten to 15 ft. lbs. (21 N.m). Attach cassette and sprocket to jackshaft bolt in 2 stages: 14.7 ft. lbs. (20 N.m). Turn an additional 37 degrees. Install rear cassette and retaining bolt and tighten to 10 ft. lbs (14 N.m). Install rear jackshaft plug. Install front cassette and retaining bolt and tighten to 15 ft. lbs. (21 N.m).
  8. Position jackshaft sprocket and chain. Hold jackshaft sprocket stationary and install jackshaft sprocket bolt in 2 stages: 35 ft. lbs. (47 N.m). Turn an additional 75 degrees. Install chain guide and bolts. Install chain tensioner and bolts. Install front cover and tighten bolts to 15 ft. lbs. (21 N.m). Apply RTV sealant to front cover in 4 positions as shown. see scheme 60 Apply RTV sealant to rear main bearing cap.
  9. Position ladder frame gasket and install ladder frame. Reset ladder frame inserts to index position. see scheme 61 Tighten ladder frame inserts to 35 INCH lbs. (4 N.m).
  10. Position ladder frame and gasket assembly. Position 15 side ladder frame bolts and 2 nuts. Position 2 rear ladder frame bolts. Ladder frame to block alignment must be within a maximum mismatch of.254 mm ladder frame underflush, or.05 mm ladder frame protrusion. Using a straightedge, align transmission face of ladder frame with rear face of block. see scheme 62
  11. Tighten left, then right side ladder frame bolts and nuts to 89 INCH lbs. (10 N.m). Tighten frame inserts in sequence shown. see scheme 63 Install NEW seals on 2 Silver "M8" bolts and position them in No. 5 and 6 positions and remaining 6 ladder frame bolts in remaining bolt positions. see scheme 63 Tighten ladder frame bolts in sequence in 2 stages: 13 ft. lbs. (17 N.m). 27 ft. lbs. (36 N.m). Measure step between rear face of block and transmission face of ladder frame. see scheme 62 Repair all assemblies that exceed underflush specification by installing shims on one or both sides of ladder frame.
  12. Install NEW gasket and oil pump screen cover and tube. Tighten oil pump tube to 115 INCH lbs. (13 N.m). Position oil pan and gasket and install bolts. Tighten oil pan bolts to 89 INCH lbs. (10 N.m). Position NEW cylinder head gaskets and cylinder heads. Install 12 mm bolts and tighten to 25 ft. lbs. (35 N.m) in sequence shown for both cylinder heads. see scheme 33 Tighten 12 mm cylinder head bolts an additional 90° in same sequence. Tighten 12 mm cylinder head bolts another additional 90° in same sequence. Install 8 mm bolts in both cylinder heads and tighten to 22 ft. lbs. (30 N.m)
  13. Position water pump and gasket and tighten bolts to 97 INCH lbs. (11 N.m). Install crankshaft pulley and bolt in 2 stages: 37 ft. lbs. (50 N.m). Turn an additional 90 degrees.
  14. Install right camshaft sprocket bolt. Install right cassette retaining bolt. Tighten right cassette retaining bolt to 97 INCH lbs. (11 N.m). Install left camshaft sprocket bolt. Install left cassette retaining bolt. Tighten left cassette retaining bolt to 10 ft. lbs. (14 N.m). Install Camshaft Chain Tensioner Tool (T97T-6K254-A) on left cylinder head. Turn crankshaft clockwise one revolution.
  15. Position crankshaft at Top Dead Center (TDC) of No. 1 cylinder and install Crankshaft Holding Tool (T97T-6303-A). see scheme 34 Position camshaft timing slots to properly fit Camshaft Holding Tool (T97T-6256-C) and position tool on left cylinder head. see scheme 35 Install Camshaft Gear Positioning/Holding Tool (T97T-6256-B) on left cylinder head. see scheme 36
  16. Tighten bolts on Camshaft Positioning/Holding Tool. Tighten left camshaft sprocket bolt to 63 ft. lbs. (85 N.m). Remove Camshaft Chain Tensioner Tool (T97T-6K254-A). Install left hydraulic camshaft tensioner. If using a new washer, tighten to 32 ft. lbs. (44 N.m). If using old washer, tighten to 49 ft. lbs. (67 N.m). Remove Camshaft Gear Positioning/Holding Tool (T97T-6256-B). Remove Camshaft Holding Tool (T97T-6256-C). Remove Crankshaft Holding Tool (T97T-6303-A).
  17. Install Camshaft Chain Tensioner Tool (T97T-6K254-A) on right cylinder head. Gain access to chain tensioner through fender well. Turn crankshaft one revolution. Position crankshaft at TDC of No. 1 cylinder and install Crankshaft Holding Tool (T97T-6303-A). see scheme 34 Position camshaft timing slots to properly fit Camshaft Holding Tool (T97T-6256-C) and position tool on right cylinder head. see scheme 35
  18. Tighten bolts on Camshaft Positioning/Holding Tool. Using Camshaft Gear Torque Adapter (T97T-6256-G), tighten camshaft sprocket bolt to 63 ft. lbs. (85 N.m). Remove Camshaft Chain Tensioner Tool (T97T-6K254-A). Install right hydraulic camshaft tensioner. If using a new washer, tighten to 32 ft. lbs (44 N.m). If using old washer, tighten to 49 ft. lbs. (67 N.m).
  19. Remove Camshaft Gear Positioning/Holding Tool (T97T-6256-B). Remove Camshaft Holding Tool (T97T-6256-C). Remove Crankshaft Holding Tool (T97T-6303-A). Install exhaust manifolds and tighten exhaust manifold nuts to 18 ft. lbs (25 N.m). To complete assembly, reverse disassembly procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000).

Piston & Rod Assembly

Note. Take measurements with components at a stabilized room temperature of about 70° F (21° C).

Ensure pistons and rods are installed in cylinder from which they were removed. Ensure arrow on piston top is pointing toward front of engine. Ensure oil hole in rod faces right side of engine block. When installing replacement rods, ensure large-chamfered side of connecting rod bearing bore is toward crankshaft cheek, facing front of engine for right rods, and rear of engine for left rods.

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