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

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on hood and other major assemblies before removal.

Removal

1. Disconnect negative battery cable. Mark hood hinges and remove hood. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove air cleaner tube and assembly. Drain cooling system and engine oil.
2. Remove upper and lower radiator hoses. Disconnect radiator fan shroud and position over fan. Remove radiator and fan shroud. Using Fan Clutch Nut Wrench (T96T-6312-A) and Fan Clutch Holder (T96T-6312-B) remove cooling fan. Remove accessory drive belt.
3. Disconnect A/C manifold tube from compressor (if equipped) and plug openings. Unbolt A/C bracket and position compressor, power steering pump and bracket assembly aside.
4. Remove generator and bracket assembly. Disconnect heater hoses from water pump and intake manifold. Disconnect control cables from throttle body. Disconnect necessary vacuum connections. Disconnect necessary wiring harness connections and ground cables.
5. On Ranger, disconnect A/C manifold tube from condenser and receiver-drier, and plug openings. On all models, disconnect and/or remove necessary A/C lines and components. Relieve fuel pressure. See «FUEL PRESSURE RELEASE»(ref-1335-S12569072462000031300000). Using Spring Lock Coupling Remover (T81P-19623-G1) for 3/8" line or (T81P-19623-G2) for 1/2" line, disconnect fuel supply and return lines. (Scheme 2) Disconnect Powertrain Control Module (PCM).
6. Raise and support vehicle. Remove A/C manifold bracket. Remove starter. On models with automatic transmission, disconnect flexplate from torque converter through starter opening. Remove transmission cooler line-to-engine bolts. On all models, disconnect transmission wiring harness connectors.
7. Remove transmission-to-engine bolts. Disconnect exhaust pipes from exhaust manifolds. Lower vehicle. Support transmission. Remove right and left top engine mount nuts. Attach engine hoist and remove engine from vehicle.

Installation

To install, reverse removal procedure. Evacuate and recharge A/C system (if equipped). Check and top off all fluid levels. Fill and bleed air from cooling system. See COOLING SYSTEM BLEEDING .

Scheme 2

Removal (Upper)

1. Disconnect negative battery cable. Remove air cleaner outlet tube. Remove splash shield to expose throttle linkage. Remove control cable(s) and bracket from throttle body.
2. Disconnect necessary vacuum hoses. Disconnect necessary wiring harness and ground connections. Disconnect heater hose locating bracket and transmission dipstick tube, position aside.
3. Disconnect spark plug wires and harness connectors from coil pack. Remove coil pack and EGR valve. Remove oil dipstick tube. Remove EGR manifold tube, EGR transducer and EGR solenoid (if equipped). Remove upper intake manifold retaining bolts. Remove upper intake manifold and gasket.

Clean and inspect mounting surfaces. Position NEW gasket on mounting studs. Install upper intake manifold, and tighten bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

Removal (Lower)

With upper intake manifold removed. Disconnect upper radiator hose from manifold. Relieve fuel pressure. See FUEL PRESSURE RELEASE. Using Spring Lock Coupling Remover (T81P-19623-G1) for 3/8" line or (T81P-19623-G2) for 1/2" line, disconnect fuel supply and return lines. (Scheme 2) Remove valve covers. See VALVE COVERS. Drain cooling system. Remove lower intake manifold retaining bolts. Remove lower intake manifold and gasket.

Clean gasket mating surfaces. Install intake manifold gaskets. Apply silicone sealer at 4 corners of cylinder block sealing surface. Install lower intake manifold within 15 minutes of silicone sealer application. Tighten bolts in sequence to specification. (Scheme 3) See TORQUE SPECIFICATIONS.

Scheme 3

Disconnect negative battery cable. On right manifold, remove heater hose support bracket. Disconnect heater hoses. On left manifold, remove oil dipstick tube. Remove EGR manifold tube and EGR valve. Remove EGR transducer vacuum hoses. Remove EGR-to-intake manifold tube. Remove power steering hoses from power steering pump (if necessary). On both manifolds, disconnect exhaust pipe at exhaust manifold. Remove exhaust manifold retaining nuts. Remove exhaust manifold and gasket.

Clean all mating surfaces. Lightly oil all bolt/stud threads before installation. Install exhaust manifold on cylinder head, and tighten bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure. Fill and bleed cooling system if necessary. See COOLING SYSTEM BLEEDING .

1. Disconnect negative battery cable. Remove intake air tube and throttle body splash shield. Remove spark plug wires. Disconnect necessary vacuum hoses. Remove wiring as necessary. Remove engine harness clips.
2. If removing right valve cover, drain cooling system. Remove upper radiator hose. Remove ignition coil and alternator. Disconnect heater water hose. Disconnect throttle cable.
3. If removing left valve cover, remove upper intake manifold. See «INTAKE MANIFOLDS»(ref-1335-S22729903762000031300000) . Remove A/C compressor with hoses attached. Position A/C compressor and harness aside.
4. Remove PCV hose and breather. Keeping in removal order, remove valve cover attaching bolts and load distribution washers. Remove valve covers.

Clean all gasket surfaces. Position NEW gasket in place. Install valve cover. Install valve cover load distribution washers in their original location. Install valve cover bolts and tighten in crisscross pattern to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Drain cooling system. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-1335-S12569072462000031300000) . Remove upper and lower intake manifolds. See «INTAKE MANIFOLDS»(ref-1335-S22729903762000031300000) . Remove exhaust manifold. See «EXHAUST MANIFOLDS»(ref-1335-S24824381372000031300000) .
2. Remove valve covers. See «VALVE COVERS»(ref-1335-S19860831922000031300000) . Remove spark plugs. Remove accessory drive belt. If removing left cylinder head, remove A/C compressor with hoses attached, and position aside (if equipped). Remove power steering pump bracket with power steering pump attached, and position aside.
3. If removing right cylinder head, remove generator and bracket. Remove Ignition coil and bracket as an assembly. Remove Spark plugs. On all cylinder heads, disconnect exhaust pipe at exhaust manifold. Remove rocker arm shaft bolts evenly by loosening bolts 2 turns at a time. Remove rocker arm shaft assembly.
4. Mark push rod location for installation reference, and remove push rods. Remove and discard cylinder head bolts. Remove cylinder head(s) and gaskets.

1. Ensure all bolt holes in cylinder block are clean. Install gaskets and cylinder heads. Install NEW cylinder head bolts. Tighten cylinder head bolts in sequence to specification. (Scheme 4) See «TORQUE SPECIFICATIONS»(ref-1335-S30364515762000031300000).
2. Install lower intake manifold. See «INTAKE MANIFOLDS»(ref-1335-S22729903762000031300000). Tighten lower intake manifold bolts in sequence to specification. (Scheme 3) See «TORQUE SPECIFICATIONS»(ref-1335-S30364515762000031300000).
3. Coat push rods with Oil Conditioner (D9AZ-19579-D) and install in original position. Install rocker arm shaft assembly to cylinder head. Guide rocker arms onto push rods.
4. Tighten rocker arm bolts evenly to specification. To complete installation, reverse removal installation. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-1335-S26345722142000031300000).

Scheme 4

1. Disconnect negative battery cable. Remove fan blade and fan shroud. Remove accessory drive belts. Remove crankshaft damper retaining bolt. Using Crankshaft Damper Remover (T74P-6316-A), remove crankshaft damper. Carefully pry seal from timing chain cover. DO NOT damage timing chain cover or crankshaft.
2. To install, lubricate seal lip with engine oil. Using Timing Chain Cover Aligner (T74P-6019-A) and Crankshaft Front Seal Installer (T90T-6701-A), install front crankshaft seal. Apply silicone sealer to crankshaft keyway.
3. Coat crankshaft damper sealing surface with engine oil. Install crankshaft damper. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-1335-S30364515762000031300000) . Install accessory drive belts.

1. Remove oil pan. See «OIL PAN»(ref-1335-S27735391222000031300000). Remove air intake tube. Drain cooling system. Remove accessory drive belt. Using Fan Clutch Pulley Holder (T84T-6312-C) and Fan Clutch Nut Wrench (T84T-6312-D), remove fan and clutch assembly. (Scheme 8)
2. Remove fan shroud. Remove accessory drive belt tensioner. Remove lower radiator hose. Remove power steering pump with bracket and A/C compressor attached (if equipped), and position aside.
3. Remove generator with bracket, and position aside. Remove water pump pulley. Remove water pump attaching bolts, and remove pump. Remove gasket. Using Crankshaft Damper Remover (T74P-6316-A), remove crankshaft damper.
4. Remove crankshaft position sensor. Remove timing chain cover bolts (note bolt location for installation reference). Remove cover and gasket.

1. Clean timing chain cover mating surfaces. Apply sealing compound to gasket surfaces. Place NEW timing chain cover gasket into position. Replace crankshaft seal. Position timing chain cover on engine. Insert bolts in their original location.
2. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1335-S30364515762000031300000) . Apply silicone sealer to crankshaft keyway. To complete installation, reverse removal procedure. Install oil pan. See «OIL PAN»(ref-1335-S27735391222000031300000) . Fill or top off all fluids. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(ref-1335-S26345722142000031300000) .

1. Position No. 1 piston at TDC of compression stroke. Remove timing chain cover. See «TIMING CHAIN COVER»(ref-1335-S05109513372000031300000). Remove oil pan. See «OIL PAN»(ref-1335-S27735391222000031300000).
2. Ensure all timing marks are aligned. (Scheme 5) Check camshaft end play. If end play is not within specification, replace camshaft thrust plate. See «CAMSHAFT»(ref-1335-S08799583382000031300000) table under ENGINE SPECIFICATIONS.
3. Retract timing chain tensioner and install packaging clip from new tensioner or one that you have fabricated. Remove camshaft sprocket retaining bolt and crankshaft sprocket Woodruff key. Remove tensioner and guide rail. Replace worn parts as necessary. Remove crankshaft, camshaft sprockets and timing chain as an assembly.
4. If crankshaft sprocket is difficult to remove, carefully pry off with a pair of screwdrivers positioned evenly on sprocket.

1. Install guide rail to cylinder block, with pin inserted into oil hole of block. Install 2 tensioner retaining bolts. Ensure timing marks are aligned. (Scheme 5) If camshaft thrust plate was removed, install thrust plate so that it covers main oil gallery. (Scheme 6)
2. Install crankshaft, camshaft sprocket and timing chain as an assembly. Install tensioner with clip in place to lock tensioner in retracted position. (Scheme 5) Install camshaft sprocket bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-1335-S30364515762000031300000).
3. Remove clip from tensioner. Rotate crankshaft 2 revolutions clockwise, and recheck timing marks. To complete installation, reverse removal procedure. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-1335-S26345722142000031300000).

Scheme 5

Scheme 6

Remove lower intake manifold. See INTAKE MANIFOLDS . Note original location of push rods and lifters during removal for installation reference. Gradually loosen rocker shaft and remove rocker shaft. Remove push rods and lifters.

Lubricate lifter and cylinder block bore with Oil Conditioner (D9AZ-19579-D) or heavy engine oil. Install lifter in original location, with alignment tab in locating groove of bore. (Scheme 7) Ensure lifters slide freely in bore. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 7

Remove radiator. Remove oil pump. See OIL PUMP . Remove camshaft position sensor and camshaft synchronizer. See CMP SYNCHRONIZER . Remove lifters. See VALVE LIFTERS . Remove timing chain. See TIMING CHAIN . Remove camshaft thrust plate. Remove camshaft.

1. Lubricate camshaft lobes and bearing surfaces with Oil Conditioner (D9AZ-19579-D). Install camshaft carefully to prevent damaging bearings and journal surfaces. Install thrust plate so it covers main oil gallery. (Scheme 6)
2. Ensure camshaft end play is within specification. See «CAMSHAFT»(ref-1335-S08799583382000031300000) table under ENGINE SPECIFICATIONS. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1335-S30364515762000031300000). Ensure CMP synchronizer is installed and adjusted properly. See «CMP SYNCHRONIZER»(ref-1335-S05226129762001041900000). Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-1335-S26345722142000031300000).

1. Rear main bearing oil seal is a one-piece seal. Remove transmission. See appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Punch hole in metal portion of seal with an awl. Remove seal using a slide hammer.
2. To install, lubricate seal and mating surfaces with engine oil. Install seal on crankshaft, with spring side toward crankshaft. Using Crankshaft Rear Oil Seal Replacer (T95T-6701-A), install seal into position until seal is firmly seated. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1335-S30364515762000031300000) .

1. Remove negative battery cable. Drain cooling system. Disconnect lower radiator hose and heater return hose from water pump. Using Fan Clutch Pulley Holder (T96T-6312-B) and Fan Clutch Nut Wrench (T96T-6312-A), remove radiator fan and clutch assembly. (Scheme 8)
2. Remove accessory drive belt. Remove power steering pump with bracket and A/C compressor (if equipped), and position aside. Remove generator bracket with generator, and position aside. Remove accessory drive belt tensioner. Remove water pump pulley. Remove water pump retaining bolts. Remove water pump and gasket.

Clean all gasket surfaces. Apply sealer to both sides of NEW gasket, and position gasket on water pump. Install water pump. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM BLEEDING .

Scheme 8

1. Disconnect the battery ground cable.
2. Remove the ground strap bolt. see scheme 25
3. Remove the nuts and lower the starter motor. see scheme 26
4. Remove the cap. (Scheme 13)
5. Remove the terminal nuts and remove the starter motor. see scheme 28
6. To install, follow the removal procedure in reverse order.

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Removal & Disassembly

Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove oil pump attaching bolts. Remove oil pump and oil pump drive shaft. Disassemble oil pump. Note direction of component installation for reassembly reference.

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure components are installed in original location. To install, prime oil pump with engine oil. Rotate oil pump drive shaft to distribute oil within pump body.
2. Insert oil pump drive shaft into engine block, with pointed end of oil pump drive shaft inward. Pointed end is closest to pressed-on retainer ring. see scheme 32
3. Position NEW gasket in place and install oil pump. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-1335-S00475298652000031300000) table.

Scheme 13