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

VALVE CLEARANCE

Note. Information on valve clearance check is not available from manufacturer.

Engine uses nonadjustable hydraulic roller lifters and nonadjustable rocker arms. If lifters are excessively worn or noisy, repair or replace as necessary.

FUEL PRESSURE RELEASE

To release fuel pressure, disconnect negative battery cable. Remove fuel cap to release fuel tank pressure. Remove relief valve cap from fuel rail. Connect fuel pressure gauge to fuel rail, and release fuel into a suitable container.

COOLING SYSTEM BLEEDING

1. Fill cooling system with 50/50 mixture of coolant and water. Pause several minutes for circulation. Fill radiator to filler neck seat. Install radiator cap fully, then back off to first stop.
2. Set heater controls to maximum heat. Start engine and operate at 2000 RPM for approximately 3-4 minutes. Turn engine off. Use a protective rag, and carefully remove radiator cap. Add coolant to filler neck seat.
3. Install radiator cap fully, then back off to first stop. Start engine and allow to operate at 2000 RPM until upper radiator hose is warm. Check heater output. Turn engine off. Use protective rag, and carefully remove radiator cap. Add coolant to filler neck seat if necessary.
4. Tightly install radiator cap. Remove small cap (large cap is for windshield washer reservoir) on coolant recovery reservoir. Add 1.1 qt. (1L) of 50/50 mixture of coolant and water to reservoir. Install reservoir cap.

CYLINDER HEAD

Note. On Explorer and Mountaineer, discharge A/C system using approved refrigerant recovery/recycling equipment. Remove A/C manifold line from compressor, and plug openings.

TIMING CHAIN COVER

Note. It is necessary to remove oil pan to properly reseal timing chain cover. It is necessary to remove engine to remove oil pan.

TIMING CHAIN & SPROCKETS

Note. It is necessary to remove oil pan to properly reseal timing chain cover. It is necessary to remove engine to remove oil pan.

CMP SYNCHRONIZER

For camshaft position sensor synchronizer installation and alignment procedure, see

1. 1998 Explorer «REMOVE/INSTALL/OVERHAUL - 4.0L»(ref-131449) article in ENGINE PERFORMANCE
2. 1998 Ranger «REMOVE/INSTALL/OVERHAUL - 4.0L»(ref-131451) article in ENGINE PERFORMANCE
3. 1999 Explorer & Ranger «REMOVAL, OVERHAUL & INSTALLATION»(ref-2285) article in ENGINE PERFORMANCE

CAMSHAFT

Note. It is necessary to remove oil pan to properly reseal timing chain cover. It is necessary to remove engine to remove oil pan.

OIL PAN

Note. It is necessary to remove oil pan to properly reseal timing chain cover.

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1. On all vehicles, check vehicle ride height. For additional information refer to «RIDE HEIGHT»(ref-1320-S11017440782000031300000) .
2. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-1219-S15502358132000031300000) .
3. Drain the engine oil and reinstall the drain plug.
4. Remove both front torsion bars. For additional information, refer to «SUSPENSION - FRONT - 2WD»(ref-1303) article or «SUSPENSION - FRONT - 4WD TORSION BAR»(ref-1310) article.
5. For 4WD vehicles, disconnect the front driveshaft CV joint and position aside.
6. Disconnect the axle vent tube.
7. Support the axle with a suitable jack.
8. Remove the left front axle-to-frame bolt.
9. Remove the two axle-to-frame bolts. Lower the axle to just rest on the lower control arms.
10. On all vehicles, remove the starter motor. For additional information, refer to «STARTER MOTOR»(ref-58738-S03663894162001011700000) .
11. Remove the bolts.
12. Remove the bolts and the nuts.
13. Remove the oil pan and the gasket.

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1. On all vehicles, clean and inspect the sealing surfaces.
2. Apply a bead of silicone rubber in six places. Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.
3. Position the gasket and the oil pan.
4. Install the bolts and nuts and tighten in the sequence shown in illustration. (Scheme 24) See «TORQUE SPECIFICATIONS»(ref-1335-S30364515762000031300000).
5. Install the bolts.
6. Install the starter motor. For additional information, refer to «STARTER MOTOR»(ref-58738-S03663894162001011700000).
7. For 4WD vehicles, raise the axle and install the two axle-to-frame bolts and nuts.
8. Install the left front axle-to-frame bolt and nut.
9. Remove the jack from the axle.
10. Connect the axle vent tube.
11. Connect the front driveshaft CV joint.
12. Install the front torsion bars. For additional information, refer to «SUSPENSION - FRONT - 2WD»(ref-1303) article or «SUSPENSION - FRONT - 4WD TORSION BAR»(ref-1310) article.
13. Lower the vehicle.
14. Fill the engine with Super Premium SAE 5W-30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
15. Check vehicle ride height. For additional information, refer to «RIDE HEIGHT»(ref-94683-S29446956692001033100000).

1. Clean head gasket mating surface. Clean carbon from combustion chambers. Use care not to damage surfaces. Check cylinder head for cracks, burrs, nicks and warpage.
2. Check cylinder head warpage. Resurface cylinder head if warpage exceeds specification. See «CYLINDER HEAD»(ref-1335-S18002615482000031300000) table under ENGINE SPECIFICATIONS. DO NOT machine more than .010" (.25 mm) from original cylinder head surface.

Valve Springs

1. Measure valve spring installed height from surface of cylinder head spring pad to underside of spring retainer. If installed height is greater than specification, a shim can be installed between cylinder head and valve spring to obtain correct height. See «VALVES & VALVE SPRINGS»(ref-1335-S09645636242000031300000) table under ENGINE SPECIFICATIONS.
2. Inspect valve spring free length and pressure. Replace valve spring if free length and pressure are not within specification. See «VALVES & VALVE SPRINGS»(ref-1335-S09645636242000031300000) table.

Valve Stem Oil Seals

Different types of valve stem oil seals are used on intake and exhaust valves. Use Valve Stem Seal Installer (T90T-6571-A) to install NEW valve stem seals. Ensure seal bottoms on valve guide. Oversized seals must be installed when using oversized valves.

Valve Guides

1. Valve guides must be reamed for an oversize valve if valve stem oil clearance exceeds specification. See «CYLINDER HEAD»(ref-1335-S18002615482000031300000) table under ENGINE SPECIFICATIONS. Valves are available in .008" (.20 mm) and .016" (.41 mm) oversizes.
2. If oversize valves or oversize valve stem seals are not available, valve guide may be reamed to use a service bushing. Always use reamers in proper sequence (smallest first).

Valve Seat

Ensure valve seat angle, seat width and seat runout are within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valve seats must be ground when valve guide is reamed or replaced. Replacement information is not available from manufacturer.

Valves

1. Grind valve face to 44-degree angle. Ensure head diameter, valve face runout, stem diameter and valve margin are within specification. See «VALVES & VALVE SPRINGS»(ref-1335-S09645636242000031300000) table under ENGINE SPECIFICATIONS.
2. Oversize valves are available in .008" (.20 mm) and .016" (.41 mm). When servicing valve stem tip, DO NOT remove more than .010" (.25) from end of valve stem.

Valve Seat Correction Angles

Grind valve seat to 45-degree angle. If seat is too wide after grinding, use a 30-degree stone to lower seat, or a 60-degree stone to raise seat. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Fitting Pistons

Measure cylinder bore out-of-round, taper and piston-to-cylinder bore clearance. Measure with components at about 70°F (21°C). If measurements are not within specification, hone or bore cylinders and fit suitable pistons. See CYLINDER BLOCK and PISTONS, PINS & RINGS tables under ENGINE SPECIFICATIONS.

Piston Rings

1. Select rings for bore diameter. Place ring in cylinder bore in which it will be installed. Using piston to square ring in bore, place ring below normal ring wear area. Measure ring end gap. If gap is too small, file material from end of ring. If ring gap exceeds specification, try another ring set. See «PISTONS, PINS & RINGS»(ref-1335-S03267267232000031300000) 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-1335-S03267267232000031300000) table. Ensure rings are properly spaced on piston before installing pistons into cylinder. see scheme 30

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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-1335-S12177087352000031300000) 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-1335-S10087803662000031300000) 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-1335-S12177087352000031300000) 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-1335-S10087803662000031300000) table under ENGINE SPECIFICATIONS.
4. To install thrust bearing, tighten main bearing cap bolts finger tight. Pry crankshaft forward while prying thrust bearing cap rearward. Tighten bearing caps to specification. See «TORQUE SPECIFICATIONS»(ref-1335-S30364515762000031300000) .
5. Mount dial indicator, and pry on crankshaft to check crankshaft end play. Replace thrust bearing, and inspect crankshaft thrust faces if end play is not within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-1335-S10087803662000031300000) 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-1335-S14978905682000031300000) table under ENGINE SPECIFICATIONS.
2. Install all main bearing caps and tighten to specification before honing cylinder bore. See «TORQUE SPECIFICATIONS»(ref-1335-S30364515762000031300000) . Ensure bearing caps are installed in their original location, with arrow on cap pointing toward 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

Oil pressure with engine at normal operating temperature is 40-60 psi (2.8-4.2 kg/cm 2 ) at 2000 RPM.

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