Engine - 4.0L V6 - VIN E: Removal & Installation Ford Explorer II

REMOVAL & INSTALLATION

Note. For reassembly reference, label all harness connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood before removal.

Note. Special tools are required for this procedure. (Scheme 39)

1. Disconnect the battery ground cable. Remove the fan shroud. Remove the left motor mount nuts. Remove the bolt and install the Lifting Eye. (Scheme 40)
2. Remove the right motor mount nuts. Remove the bolt and install the Lifting Eye. (Scheme 41) Remove the radiator mounting bolts. (Scheme 42)
3. Install the three bar support equipment. (Scheme 43) The weight of the engine should be fully supported by the three bar support. Remove the front wheel and tire assemblies. If equipped, remove the pin-type retainers and the corresponding inner fender well splash shield(s). (Scheme 44)
4. On 4WD, disconnect the vent hose from the differential housing vent tube. Secure the axle housing to a suitable lift. (Scheme 45) Remove and discard the differential support bolts. (Scheme 46) Lower the axle housing approximately 1" (25 mm). It is not necessary to remove driveshaft.
5. On all models, remove the left lower motor mount nut and washer. (Scheme 47) If equipped, remove the wire harness bracket from the left upper motor mount bracket. Remove the three bolts and the left upper motor mount bracket and the motor mount. (Scheme 48)
6. Remove the right lower motor mount nut and washer. Remove the bolts and the right upper motor mount bracket and the motor mount. To install, reverse the removal procedure. Remove the jack after the front differential retainers have been installed to provide clearance for torque access. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000).

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Note. Engine removal procedure is for engine only, without transmission attached.

1. Disconnect negative battery cable. Mark position of hood for proper installation. Remove hood. On vehicles equipped with A/C, recover air conditioning system. Drain cooling system into proper container. Relieve fuel pressure. See «FUEL PRESSURE RELEASE»(ref-9556-S40396753072002020700000). Remove engine air cleaner outlet tube.
2. Remove radiator, fan blade and fan shroud. Remove upper intake manifold. See «INTAKE MANIFOLDS»(ref-9556-S28186673972000110300000). Disconnect engine harness connector. Disconnect Powertrain Control Module (PCM) ground wire. Disconnect powertrain control module (PCM) harness connector. Disconnect engine ground wire.
3. On A/C equipped vehicles, disconnect A/C high pressure switch harness connector. Remove A/C compressor manifold bolt and position A/C lines aside. Disconnect 2 heater hoses. Disconnect fuel lines. (Scheme 49)or (Scheme 50). Raise and support vehicle. Remove starter.
4. Remove oil drain plug and drain oil into proper container. Install oil drain plug. Remove 2 left side exhaust manifold to exhaust pipe bolts. Remove 2 right side exhaust manifold to exhaust pipe bolts. Disconnect transmission electrical harness connector. Disconnect right and left heated exhaust gas oxygen (HEGO) sensor harness connectors. Remove transmission cooling line bracket bolt and position it aside.
5. Remove A/C line bracket nut and position it aside. Remove power steering cooler return hose. (Scheme 51) Remove power steering pressure line. (Scheme 52) Disconnect Vapor Management Valve (VMV) hose connector. (Scheme 53)
6. Remove transmission-to-engine bolts. Lower vehicle. Remove 2 right side motor mount nuts. Remove 2 left side motor mount nuts. Use floor crane to raise and remove engine. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000). Check and top off all engine fluids.

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Removal & Installation (Upper Intake Manifold)

1. Disconnect negative battery cable. Remove 4 bolts and accelerator control splash shield. Remove accelerator and speed control cables. Pull up on speed control cable to remove. Rotate throttle body cam and remove accelerator cable end from cam. Remove screws and accelerator and speed control cable. Remove air cleaner outlet tube.
2. Disconnect right side upper intake manifold vacuum connection. Disconnect Idle Air Control (IAC) valve harness connector. Disconnect Throttle Position Sensor (TPS) harness connector. Disconnect Engine Vacuum Regulator (EVR) and Variable Induction System (VIS) solenoid harness connectors. Disconnect Positive Crankcase Ventilation (PCV) vacuum hose.
3. Disconnect Intake Manifold Tuning Valve (IMTV) vacuum hose. Disconnect power brake booster vacuum line. Remove 8 upper intake manifold bolts. (Scheme 54) Inspect "O" rings and replace as necessary. Disconnect left side fuel Vapor Management Valve (VMV) hose. (Scheme 55) Inspect "O" rings and replace as necessary. Disconnect right side VMV hose and remove upper intake manifold.
4. Ensure gasket mating surfaces are clean and flat. Install NEW gasket. Install upper intake manifold. Evenly tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000). To complete installation, reverse removal procedure.

Scheme 54

Scheme 55

Removal & Installation (Lower Intake Manifold)

1. Remove upper intake manifold. See «REMOVAL & INSTALLATION (UPPER INTAKE) MANIFOLD»(ref-9556-S37508376702002020700000). Remove 12 bolts and remove lower intake manifold. (Scheme 56)
2. Ensure gasket mating surfaces are clean and flat. Install NEW gasket. Position lower intake manifold and install bolts. Evenly tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000). To complete installation, reverse removal procedure.

Scheme 56

Scheme 57

Removal & Installation (Left Side)

1. Disconnect negative battery cable. Raise and support vehicle. Remove 2 left side exhaust manifold-to-exhaust inlet pipe bolts. Lower vehicle. Disconnect hoses from Differential Pressure Feedback Exhaust Gas Recirculation (DPFEGR) system ports. Disconnect EGR tube from exhaust manifold.
2. Disconnect EGR tube from EGR valve and remove EGR tube. Remove 6 exhaust manifold nuts. Remove left side exhaust manifold and gasket. Ensure gasket mating surfaces are clean and flat. Use NEW exhaust manifold gaskets and nuts. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000) .

Removal & Installation (Right Side)

1. Disconnect negative battery cable. Raise and support vehicle. Remove 2 right side exhaust manifold-to-exhaust inlet pipe bolts. Lower vehicle. Remove bolt and oil level indicator tube. Remove 6 exhaust manifold nuts. Remove right side exhaust manifold and gasket.
2. Ensure gasket mating surfaces are clean and flat. Use NEW exhaust manifold gaskets and exhaust manifold nuts. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000) .

1. Remove upper intake manifold. See «REMOVAL & INSTALLATION (UPPER INTAKE MANIFOLD)»(ref-9556-S37508376702002020700000) «INTAKE MANIFOLDS»(ref-9556-S28186673972000110300000) . Disconnect Camshaft Position (CMP) sensor harness connector. Disconnect Differential Pressure Feedback (DPFE) transducer. Disconnect engine harness connector. Push clip and slide harness connector from valve cover.
2. Disconnect radio ignition interference capacitor harness connector. Disconnect coil pack harness connector. Mark placement and disconnect spark plug wires from coil pack. Remove bolts and valve cover. Discard gasket. To install, reverse removal procedure. Torque all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000) .

1. Remove upper intake manifold. See «REMOVAL & INSTALLATION (UPPER INTAKE MANIFOLD)»(ref-9556-S37508376702002020700000) . Drain cooling system into proper container. Remove upper radiator tube bolt. Remove upper radiator hose. Remove 2 heater hose bracket bolts and disconnect transmission dipstick tube.
2. Mark placement and disconnect spark plug wires. Remove bolts and valve cover. Discard gasket. To install, reverse removal procedure. Torque all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000) .

Scheme 58

Scheme 59

Scheme 60

1. Disconnect negative battery cable. Relieve fuel pressure. See «FUEL PRESSURE RELEASE»(ref-9556-S40396753072002020700000). Remove upper and lower intake manifolds. See «INTAKE MANIFOLDS»(ref-9556-S28186673972000110300000). Drain cooling system into proper container. Remove fan blade and fan shroud. Squeeze top radiator hose clamps and position aside. Remove top radiator tube bolt. Remove upper radiator top.
2. Remove accessory drive belt by rotating drive belt tensioner counterclockwise. Remove accessory drive belt from vehicle. Disconnect generator harness connectors. Remove 3 bolts and generator bracket. Remove bolts and position engine accessory bracket aside. Disconnect Camshaft Position (CMP) sensor harness connector. Disconnect coil pack harness connector. Disconnect radio ignition interference capacitor harness connector.
3. Disconnect engine harness connector. Disconnect harness connector and hoses from Differential Pressure Feedback Exhaust (DPFE) transducer. Disconnect Crankshaft Position (CKP) sensor harness connector. Remove bolt securing wiring harness. Disconnect coolant temperature sender and Engine Coolant Temperature (ECT) sensor harness connectors.
4. Disconnect fuel injector harness connectors. Position engine wiring harness aside. Remove EGR upper tube nut. Remove EGR valve bracket bolt and remove EGR valve. Remove 2 heater hoses bracket bolts and disconnect transmission dipstick tube. Squeeze upper heater hose clamp and remove upper heater hose. Remove heater control valve bracket bolt. Squeeze lower heater hose clamp and remove lower heater hose.
5. Compress thermostat housing bypass hose clamp and position aside. Remove 3 thermostat housing bolts and remove thermostat housing. Mark placement and disconnect all spark plug wires. Remove 2 fuel line upper bracket bolts. (Scheme 58) Remove 4 bolts and fuel injection supply manifold. (Scheme 59) Remove the roller followers. See «CAMSHAFT ROLLER FOLLOWERS»(ref-9556-S14976595622002020600000).
6. Remove fuel injectors. Remove crankcase vent separator spring steel clip and remove separator. (Scheme 60) Remove bolt and engine oil dipstick housing. Remove exhaust manifolds. See «EXHAUST MANIFOLD»(ref-9556-S40055735492000110300000).
7. Remove the engine wiring harness bolts and position the wiring harness aside. Remove the engine compartment ground strap. Remove left hydraulic chain tensioner. see scheme 3 Remove left camshaft sprocket bolt. Remove the left cassette bolt. (Scheme 62)
8. Remove the LH camshaft sprocket from the cassette. Remove 8 (12 mm) and 2 (8 mm) bolts in sequence and remove left cylinder head. (Scheme 62) Discard gasket.
9. Remove right hydraulic chain tensioner by gaining access through right fender well. see scheme 3 Use Cam Gear Torque Adapter Tool (T97T-6256-G) to remove right camshaft sprocket bolt. Remove RH camshaft sprocket. Remove the right cassette bolt.
10. Remove 8 (12 mm) and 2 (8 mm) bolts in sequence and remove right cylinder head. Discard gasket.

Installation

Scheme 61

1. Install a rubber band on right cassette to hold chain to cassette. Position NEW cylinder head gaskets and cylinder heads. Install 8 (12 mm) bolts and 2 (8 mm) bolts in cylinder heads. Tighten bolts in sequence. (Scheme 65) Use the following procedure to tighten bolts: Step 1) 12 mm Bolts - Tighten to 26 ft. lbs (35 N.m). Step 2) 8 mm Bolts - Tighten to 23-25 ft. lbs. (30-34 N.m). Step 3) 12 mm Bolts - Tighten an additional 90 degrees. Step 4) 12 mm Bolts - Tighten an additional 90 degrees. CAUTION: DO NOT tighten 8mm bolts tighter than 23-25 ft. lbs. (30-34 N.m).
2. Install right camshaft sprocket in cassette. Camshaft sprocket must turn freely on camshaft, DO NOT tighten bolt. Install right camshaft sprocket bolt. Install right cassette retaining bolt and tighten to 97 INCH lbs (11 N.m). (Scheme 63) Camshaft sprocket must turn freely on camshaft. DO NOT tighten bolt.
3. Install left camshaft sprocket in cassette. Install left camshaft sprocket bolt. Install left cassette retaining bolt and tighten to 97 INCH lbs (11 N.m). (Scheme 61) Install Camshaft Chain Tensioner Tool (T97T-6K254-A) on left cylinder head. see scheme 3 Turn crankshaft clockwise one revolution.
4. Position crankshaft at Top Dead Center (TDC) of No. 1 cylinder and install Crankshaft Holding Tool (T97T-6303-A). (Scheme 66) Position camshaft timing slots to properly fit Camshaft Holding Tool (T97T-6256-C) and position tool on left cylinder head. (Scheme 67) Install Camshaft Gear Positioning/Holding Tool (T97T-6256-B) on left cylinder head. (Scheme 68)
5. Tighten bolts on Camshaft Gear Positioning/Holding Tool (T97T-6256-B). 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).
6. 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 Top Dead Center (TDC) of No. 1 cylinder and install Crankshaft Holding Tool (T97T-6303-A). (Scheme 66) Position camshaft timing slots to properly fit Camshaft Holding Tool (T97T-6256-C) and position tool on right cylinder head. (Scheme 67)
7. 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).
8. Remove Camshaft Gear Positioning/Holding Tool (T97T-6256-B). Remove Camshaft Holding Tool (T97T-6256-C). Remove Crankshaft Holding Tool (T97T-6303-A). Install the engine compartment ground strap. Install the wiring harness. Install the exhaust manifolds. See «EXHAUST MANIFOLD»(ref-9556-S40055735492000110300000). Position dipstick housing, install retainer bolt and tighten to 22 ft. lbs. (30 N.m).
9. Install crankcase vent separator and spring steel clip. Lubricate fuel injector seals with engine oil and install fuel injectors. Install the roller followers. See «CAMSHAFT ROLLER FOLLOWERS»(ref-9556-S14976595622002020600000). Position fuel injection supply manifold, install 4 bolts and tighten to 19 ft. lbs (26 N.m). (Scheme 59) Tighten fuel line bracket bolts to 97 INCH lbs. (11 N.m). (Scheme 58)
10. Install spark plug wires. Position thermostat housing, install bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000). Compress and move thermostat housing bypass hose clamp into position. Install lower heater hose and hose clamp. Install heater valve bracket bolt. Install upper heater hose and hose clamp. Install heater hose bracket bolts and tighten to 29 ft. lbs. (40 N.m). Connect transmission dipstick tube. Position EGR bracket and tighten bolt to 92 INCH lbs. (10 N.m).
11. Connect upper EGR tube and tighten to 34 ft. lbs. (47 N.m). Position engine wiring harness clips onto 2 fuel rail studs. Connect fuel injector harness connectors. Connect water temperature indicator sender and engine coolant temperature (ECT) sensor harness connectors. Connect PCM harness and tighten bolt to 61 INCH lbs. (7 N.m). Connect CKP harness connector. Connect harness connector and hoses to DPFE backpressure transducer.
12. Connect radio ignition interference capacitor harness connector. Connect coil pack harness connector. Connect camshaft indicator (CID) sensor harness connector. Position engine accessory bracket and tighten 4 bolts to 40 ft. lbs. (54 N.m). Position generator bracket and tighten bolts to 40 ft. lbs. (54 N.m). Connect generator harness connectors. Install accessory drive belt.
13. Install upper radiator hose and tube. Install top radiator tube bolt. Install fan blade and shroud. Install lower intake manifold. See «INTAKE MANIFOLDS»(ref-9556-S28186673972000110300000). Fill cooling system. Fill crankcase with engine oil. Test drive vehicle.

Removal

1. Disconnect the battery ground cable. Remove the accessory drive belt. Remove the fan blade assembly and the radiator shroud. Remove the crankshaft pulley bolts.
2. Remove the damper bolt. Using Crankshaft Damper Remover (303-101, T74P-6316-A), remove the crankshaft pulley. (Scheme 69)

1. Using Crankshaft Damper Replacer (303-102, T74P-6316-B), install the crankshaft pulley. see scheme 38
2. Install a new crankshaft pulley bolt. Tighten the bolt in two stages: Stage1: Tighten the bolt to 44 lb-ft (60 Nm). Stage 2: Tighten the bolt an additional 90 degrees.
3. Install the crankshaft pulley bolts. Install the fan blade and the fan shroud. Connect the battery ground cable. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000)

Scheme 62

Scheme 63

1. Remove crankshaft pulley. See «CRANKSHAFT PULLEY»(ref-9556-S10066644942005051100000) . Use seal remover to remove front cover seal.
2. Install front crankshaft seal using Crankshaft Seal Replacer/Cover Aligner (T74P-6316-B and T74P-6019-A). Install crankshaft pulley. See «CRANKSHAFT PULLEY»(ref-9556-S10066644942005051100000) .

1. Disconnect the negative battery cable. Drain the engine coolant. Remove the crankshaft pulley. See «CRANKSHAFT PULLEY»(ref-9556-S10066644942005051100000). Remove the accessory bracket and position aside. see scheme 39
2. Disconnect the generator electrical connectors. Remove the accessory drive belt tensioner. Remove generator mounting bracket and position aside. (Scheme 70)
3. Disconnect the crankshaft position (CKP) sensor electrical connector. Remove the fuel vapor tube retaining nut and position aside. (Scheme 71)
4. Remove the water bypass hose. Remove the lower heater water hose. Disconnect the lower radiator hose. On A/C-equipped vehicles, remove the A/C line bracket and position aside. (Scheme 72)
5. Remove the wiring harness retainer and position aside. (Scheme 73) Remove the crankshaft front oil seal. See «CRANKSHAFT FRONT SEAL»(ref-9556-S41538162162000110300000).
6. Remove the engine front cover. see scheme 44

1. Clean and inspect the sealing surfaces. Install the front cover gasket. Install the engine front cover. see scheme 44
2. Install the crankshaft front oil seal. See «CRANKSHAFT FRONT SEAL»(ref-9556-S41538162162000110300000). Install the wiring harness retainer. (Scheme 73)
3. On A/C equipped vehicles, install the A/C line bracket nut. (Scheme 72)
4. Connect the lower radiator hose. Connect the lower heater water hose. Install the water bypass hose.
5. Position the fuel vapor tube and bracket, and install the nut. (Scheme 71) Connect the crankshaft position (CKP) sensor electrical connector.
6. Install the generator mounting bracket. (Scheme 70) Connect the generator electrical connectors. Install the accessory bracket. see scheme 39 Install the crankshaft pulley. See «CRANKSHAFT PULLEY»(ref-9556-S10066644942005051100000).
7. Raise and support the vehicle. Drain the engine oil. Fill the engine with Super Premium SAE 5W-30 Motor Oil (XO-5W30-QSP), or equivalent meeting Ford specification
8. Fill the engine with coolant. Connect the negative battery cable. Bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-40676-S25755587792001080300000).

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Note. New camshaft cassettes come assembled, but must be disassembled and individual components installed separately.

Scheme 70

1. Install the NEW chain guide through cylinder head. see scheme 49 Install new chain. Install NEW chain guide bolts. Tighten upper bolt to 106 INCH lbs. (12 N.m) and lower bolt to 14 ft. lbs. (19 N.m).
2. Install the NEW lower chain sprocket on jackshaft and new upper chain sprocket on camshaft. Install, but DO NOT tighten, camshaft sprocket bolt. Install primary chain, crankshaft sprocket, jackshaft sprocket and NEW jackshaft sprocket bolt. Install primary drive chain tensioner. Tighten bolts to 80 INCH lbs. (9 N.m).
3. Hold crankshaft from turning using Special Tool (303-674) and tighten NEW jackshaft sprocket bolt in 2 stages. Stage 1: tighten bolt to 33 ft lbs. (45 N.m). Stage 2: tighten bolt an additional 90 degrees.
4. Install the engine front cover. See «ENGINE FRONT COVER»(ref-9556-S08093035002005051100000).
5. If the cassette was broken into several small pieces, go to «OIL PUMP PICKUP TUBE REPLACEMENT»(ref-9556-S37961272462003110500000). If cassette was not broken into several small pieces, and if engine oil was not previously drained during engine front cover installation, drain engine oil at this time and remove oil filter. Install a NEW oil filter and fill engine with NEW oil. Camshaft timing must be set. Go to «CAMSHAFT TIMING»(ref-9556-S20270659162005051200000).

Remove upper intake manifold. See INTAKE MANIFOLDS . Remove thermostat housing. See THERMOSTAT HOUSING . Remove left 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). To install, reverse removal procedure.

Remove wheel and tire. Remove lower splash shield. Remove right camshaft tensioner. see scheme 3 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). To install, reverse removal procedure.

Remove the camshaft roller followers. See CAMSHAFT ROLLER FOLLOWERS. Remove the hydraulic lash adjusters. see scheme 50 To install, reverse the removal procedure.

Scheme 71

OIL PUMP PICKUP TUBE REPLACEMENT

Note. The purpose of this procedure is to remove as much of the broken guide material from the crankcase as possible. This procedure is to be followed only if the camshaft cassette was found to be broken-up into small pieces.

1. Raise and support vehicle. Drain oil and remove oil filter. Remove lower section of oil pan. See «OIL PAN»(ref-9556-S38742653082000110300000) .
2. Remove oil pump screen and pickup tube. Inspect and clean all debris from crankcase area.
3. Clean pickup tube mating surfaces and install the new oil pump screen and pickup tube with a new gasket. Tighten the bolts to 97 INCH lbs. (11 N.m). Clean oil pan, oil pump pickup tube area and all mating surfaces of any debris.
4. Install oil pan and install a new gasket as needed. Install a new oil filter and fill the engine with new oil. Remove vehicle supports and lower vehicle. Ensure camshaft timing is set properly. See «CAMSHAFT TIMING»(ref-9556-S20270659162005051200000) .

Removal (Left Side)

Remove camshaft roller followers. See CAMSHAFT ROLLER FOLLOWERS. Remove left hydraulic camshaft tensioner. see scheme 3 Remove bolt and camshaft sprocket. Remove bolts in sequence shown. (Scheme 74) Remove camshaft bearing caps and oil supply tube. Remove camshaft.

Scheme 72

Installation (Left Side)

Note. After installing bolts, check camshaft for free rotation.

1. Position oil supply tube, camshaft bearing caps, and bolts. Tighten bolts in sequence shown in 2 stages as follows: Tighten cam bolts to 53 INCH lbs. (6 N.m). Tighten cam bolts to 12 ft. lbs. (16 N.m). (Scheme 74)
2. Install camshaft sprocket and bolt. DO NOT tighten bolt. Camshaft must be re-timed. See «CAMSHAFT TIMING»(ref-9556-S20270659162005051200000) under ADJUSTMENTS. Install camshaft roller followers. To complete installation, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000).

Removal (Right Side)

Remove camshaft roller followers. See CAMSHAFT ROLLER FOLLOWERS. Remove right hydraulic camshaft tensioner. see scheme 3 Using special tool, remove bolt and camshaft sprocket. Remove bolts in sequence shown. (Scheme 74) Remove camshaft bearing caps and oil supply tube. Remove camshaft.

Installation (Right Side)

Note. After installing bolts, check camshaft for free rotation.

1. Position oil supply tube, camshaft bearing caps, and bolts. Tighten bolts in sequence shown in 2 stages as follows: Tighten cam bolts to 53 INCH lbs. (6 N.m). Tighten cam bolts to 12 ft. lbs. (16 N.m). (Scheme 74)
2. Install camshaft sprocket and bolt. DO NOT tighten bolt. Camshaft must be re-timed. See «CAMSHAFT TIMING»(ref-9556-S20270659162005051200000) under ADJUSTMENTS. Install camshaft roller followers. To complete installation, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000).

Remove valve covers. See VALVE COVERS. Remove fuel supply manifold. (Scheme 59) Using Special Tool (T97T-6565-A), remove camshaft roller followers. (Scheme 75) To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS.

Scheme 73

Disconnect negative battery cable. Remove starter. Remove transmission. See appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Remove flywheel/flexplate and engine rear cover plate. Using Rear Crankshaft Seal Remover (T95C-6700-CH), remove rear oil seal.

To install, coat seal surfaces with light engine oil. DO NOT use grease for seal lubrication. Using Seal Installer (T95T-6701-A), install seal until firmly seated. To install remaining components, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .

Note. Make sure the air cleaner outlet tube screw clamps do not interfere with the throttle body cam.

1. Partially drain the cooling system. Remove the bolts and the accelerator control splash shield. Remove the air cleaner outlet tube. Remove the upper radiator pipe retaining bolt. see scheme 64
2. Disconnect the hose clamp from the pipe-to-thermostat hose at the pipe end. Remove and position hose aside. Remove the thermostat housing bolts, housing and thermostat. see scheme 65 Inspect the "O" ring seal. Install a new "O" ring seal if necessary.
3. To install, reverse the removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-9556-S21456605402000110300000).

Scheme 74

Scheme 75

Partially drain the engine cooling system. Remove the engine appearance cover bolts and cover. Remove the generator wiring harness bracket nut and position the wiring harness aside. see scheme 66 Remove the air cleaner outlet tube. Disconnect the upper radiator hose at thermostat housing. Remove the three thermostat housing bolts and remove housing. Remove thermostat. Inspect the "O" ring seal, install a new "O" ring seal if necessary. To install, reverse the removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS.

Scheme 76

Drain cooling system. Remove radiator. Remove accessory drive belt. Remove belt idler pulley. Slide water bypass hose clamp back. Disconnect heater hose at water pump. Remove hose. Disconnect lower radiator hose at water pump. Remove 4 water pump pulley bolts and water pump pulley. Remove 2 water pump stud bolts. Remove 10 water pump bolts and remove water pump.

Clean sealing surfaces. Position water pump and install 2 stud bolts. Connect water bypass hose and position clamp. Install 10 water pump bolts. Tighten all water pump bolts to 106 INCH lbs. (12 N.m). Position water pump pulley and install 4 water pump pulley bolts. Tighten water pump pulley bolts to 20 ft. lbs. (28 N.m). Connect lower radiator hose to water pump. Install clamp. Connect heater hose to water pump. Install clamp. Install belt idler pulley. Install accessory drive belt. Install radiator. Fill cooling system.

Disconnect negative battery cable. Raise and support vehicle. Remove oil pan plug and drain engine oil. Remove 10 oil pan bolts and remove oil pan. Discard gasket. All sealing surfaces must be cleaned prior to assembly. Tighten oil pan bolts to 89 INCH lbs. (10 N.m). To complete installation, reverse removal procedure. Fill crankcase with oil.