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Engine - 5.0L V8 - VIN [P]: Other Ford Explorer II

Mechanical 1 illustration ~1144 words

FUEL PRESSURE RELEASE

Remove fuel cap to release fuel tank pressure. Remove relief valve cap. Relief valve is located on fuel rail. Connect fuel pressure gauge to relief valve. Release fuel into a suitable container.

COOLING SYSTEM BLEEDING

WARNINGWhen engine is operating, DO NOT remove radiator cap under any conditions. Failure to follow instruction could damage cooling system or engine, or cause personal injury. Always wrap protective material around radiator cap to avoid injury from hot steam or hot coolant.
  1. Fill cooling system with 50/50 mixture of water and coolant. Pause several minutes for circulation. Fill radiator to filler neck seat. Disconnect heater outlet hose at water pump to bleed trapped air. Fill radiator until coolant begins to escape.
  2. Connect heater outlet hose. Fill radiator until coolant is between cap seal in filler neck to 1.5" (38 mm) below cap seal. Install radiator cap. Start engine and allow to warm. Shut engine off. Allow engine to cool. Remove radiator cap and check coolant level. Top off radiator coolant as necessary.

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

WARNINGDisable air bag system before removing or disconnecting components. To disable air bag system, see AIR BAG RESTRAINT SYSTEMS article in ACCESSORIES & EQUIPMENT.

CMP SYNCHRONIZER

CAUTIONSynchro Positioner (T96T-12200-A) is required to properly install synchronizer. Failure to use synchro positioner during installation will cause fuel injection to be out of time and may cause engine damage.

EXHAUST MANIFOLD

Note. Exhaust manifold bolts vary in length and type. Mark location for installation reference.

CAMSHAFT

Note. Manufacturer recommends engine be removed for camshaft removal. No in-vehicle procedure is available from manufacturer.

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-1341-S33738776122000031300000) 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-1341-S33406910642000031300000) 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-1341-S33406910642000031300000) table.

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 oversized 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-1341-S33738776122000031300000) 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-1341-S33738776122000031300000) table under ENGINE SPECIFICATIONS.
  2. Ensure valve seat angle, seat width and seat runout are within specification. See «CYLINDER HEAD»(ref-1341-S33738776122000031300000) table under ENGINE SPECIFICATIONS. Valve seats must be ground when valve guide is reamed or replaced. Replacement information is not available from manufacturer.

Valves

CAUTIONDO NOT remove more than .010" (.25 mm) from end of valve stem when resurfacing tip of valve.

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

Fitting Pistons

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

  1. Check piston-to-bore clearance. See «PISTONS, PINS & RINGS»(ref-1341-S20841924832000031300000) 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-1341-S20841924832000031300000) table.

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-1341-S20841924832000031300000) 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-1341-S20841924832000031300000) table. Ensure rings are properly spaced on piston before installing pistons into cylinder. (Scheme 38)

Scheme 38

Scheme 38
Scheme 38

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-1341-S12067870072000031300000) 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-1341-S35496297372000031300000) table under ENGINE SPECIFICATIONS.
Excess Bearing Clearance - In. (mm)Use Upper Bearing - In. (mm)Use Lower Bearing - In. (mm)
0-.0005 (0-.013).001 (.025)(2)
.0005-.0010 (.013-.025).001 (.025).001 (.025)
.0010-.0015 (.025-.039).002 (.050).001 (.025)
.0015-.0020 (.039-.050).002 (.050).002 (.050)
(1) DO NOT use any bearing combination other than listed. If bearing combinations does not bring clearance within specification, machine or replace crankshaft as necessary. (2) Use standard bearing.
(1)DO NOT use any bearing combination other than listed. If bearing combinations does not bring clearance within specification, machine or replace crankshaft as necessary.
(2)Use standard bearing.

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-1341-S12067870072000031300000) 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-1341-S35496297372000031300000) 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-1341-S35044070512000031300000) . Install No. 3 bearing cap, and finger tighten bolts.
  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-1341-S35044070512000031300000) .
  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-1341-S35496297372000031300000) table.

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-1341-S15782086332000031300000) table under ENGINE SPECIFICATIONS.
  2. Install all main bearing caps and tighten to specification before honing cylinder bore. See «TORQUE SPECIFICATIONS»(ref-1341-S35044070512000031300000) . 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.

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