Engine - 5.0L V8 - VIN [P]: Removal & Installation Ford Explorer II

REMOVAL & INSTALLATION

Removal

1. Drain cooling system and crankcase. Mark hood hinges, and remove hood. Disconnect negative battery cable. Remove air intake duct. Discharge A/C system using approved refrigerant recovery/recycling equipment, and remove condenser (if equipped). Plug A/C manifold lines and condenser openings.
2. Remove radiator and fan shroud. Remove positive battery cable and battery. Remove accessory drive belt. Disconnect power steering reservoir bolts, and position reservoir aside. Disconnect power steering pump, and position aside.
3. Disconnect A/C lines and electrical connectors at compressor. Plug A/C manifold lines and compressor openings. Remove A/C and power steering pump bracket with A/C compressor still attached. Disconnect plug wires at spark plugs. Remove ignition coil bracket with coil and plug wires attached. Remove alternator.
4. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-1341-S08966044592000031300000). Using Spring Lock Coupling Remover (D87L-9280-A) for 3/8" line or (D87L-9280-B) for 1/2" line, disconnect fuel supply and return lines. (Scheme 29) Disconnect lower steering shaft from steering rack. Disconnect necessary water and vacuum hose connections.
5. Disconnect control cables from throttle body. Disconnect control cable bracket, and position aside. Disconnect necessary wiring harness and ground connections. Raise and support vehicle. Remove power steering cooler retaining nuts, and position cooler aside. Remove transmission cooler line-to-engine clips. Remove motor mount-to-subframe bolts.
6. Remove starter. Remove transmission inspection plate. Remove torque converter nuts. Remove shift cable from transmission cable. Remove 6 bellhousing bolts. Remove oil filter. Remove exhaust manifolds. See «EXHAUST MANIFOLD»(ref-1341-S18557623912000031300000). Lower vehicle. Connect engine to engine hoist, and lift engine out of engine compartment.

Installation

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Check and top off all engine fluids. Fill and bleed air from cooling system. See COOLING SYSTEM BLEEDING .

Scheme 29

1. Disconnect negative battery cable. Drain cooling system. Remove air cleaner and intake tube assembly. Mark and disconnect electrical connectors at upper intake components. Disconnect control cable by prying with screwdriver. DO NOT pull off by hand. Disconnect control cables from throttle body. Remove control cable bracket, and position aside.
2. Mark and disconnect vacuum lines at upper intake. Disconnect PCV hose from rear of upper intake. Remove 2 canister purge lines from throttle body. Disconnect heater hoses attached to throttle body. Disconnect EGR tube from EGR valve.
3. Remove upper intake support bracket. Remove 6 upper intake manifold mounting bolts in reverse order of tightening sequence. (Scheme 30) Remove upper intake manifold and throttle body as an assembly. Remove intake manifold gasket.

1. Ensure gasket mating surfaces are clean and flat. Install NEW gasket on lower intake manifold. If available, install 2 guide pins in opposite corners. Install upper intake manifold, and finger tighten bolts.
2. Tighten bolts in sequence to specification. (Scheme 30) See «TORQUE SPECIFICATIONS»(ref-1341-S35044070512000031300000). To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(ref-1341-S21359212482000031300000).

Scheme 30

1. Set engine so cylinder No. 1 is at TDC on compression stroke. Disconnect negative battery cable. Disconnect CMP sensor electrical connector. Note position of electrical connector for reassembly reference. Remove 2 screws and CMP sensor.
2. Place reference marks on camshaft synchronizer housing and engine. Remove synchronizer hold-down bolt and clamp. Remove camshaft synchronizer.

1. Install Synchro Positioner (T96T-12200-A) on camshaft synchronizer. (Scheme 31) Ensure tabs and notches are properly engaged.
2. Ensure cylinder No. 1 is at TDC on compression stroke. Install camshaft synchronizer assembly into engine. Ensure synchro positioner is pointing directly forward (parallel to crankshaft centerline). (Scheme 32)
3. Install hold-down clamp and tighten bolt to specification. See TORQUE SPECIFICATIONS. Install CMP sensor on synchronizer. Ensure electrical connector is facing front of engine. Tighten hold-down screws to specification. Reconnect wiring to CMP sensor. Connect negative battery cable.

Scheme 31

Scheme 32

1. Disconnect negative battery cable. Remove upper intake manifold. See «UPPER INTAKE MANIFOLD»(ref-1341-S07551859452000031300000). Drain cooling system. Disconnect necessary hoses from hot water tube. Disconnect necessary wiring connections. Remove vacuum line assembly. Remove upper radiator hose from thermostat housing. Remove thermostat by-pass hose.
2. Remove camshaft positions sensor synchronizer. See «CMP SYNCHRONIZER»(ref-1341-S15544374242002030400000). Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-1341-S08966044592000031300000). Using Spring Lock Coupling Remover (D87L-9280-A) for 3/8" line, or (D87L-9280-B) for 1/2" line, disconnect fuel supply and return lines. (Scheme 29) Remove lower intake manifold bolts evenly. Remove lower intake manifold and gaskets.

1. Clean gasket mating surfaces. Apply a 1/16" (1.6 mm) bead of silicone rubber sealer on full width of each intake manifold seal (4 places). Install NEW lower intake manifold gaskets on cylinder block and heads.
2. Ensure gaskets are interlocked with end rubber gaskets. Install 2 guide pins in opposite corners. Install lower intake manifold and tighten bolts finger tight. Tighten bolts evenly, in sequence to specification. (Scheme 33) See «TORQUE SPECIFICATIONS»(ref-1341-S35044070512000031300000). To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(ref-1341-S21359212482000031300000).

Scheme 33

Removal (Right)

1. Disconnect negative battery cable. Drain cooling system. Remove accessory drive belt and tensioner. Disconnect generator wiring and bracket. Disconnect heater hose from hot water tube. Disconnect plug wires from spark plugs.
2. Raise and support vehicle. Remove exhaust pipe-to-exhaust manifold nuts. Lower vehicle to suitable height, and remove exhaust manifold retaining bolts through wheelwell opening. Lower vehicle and, remove exhaust manifold.

Removal (Left)

1. Remove accessory drive belt. Remove A/C compressor bolts, and position compressor aside. Remove oil level indicator tube. Disconnect plug wires from spark plugs.
2. Raise and support vehicle. Remove exhaust pipe-to-exhaust manifold nuts. Lower vehicle to suitable height, and remove exhaust manifold retaining bolts through wheelwell opening. Lower vehicle, and remove exhaust manifold.

Ensure gasket mating surfaces are clean and flat. Install exhaust manifold and bolts. Tighten bolts, starting from center and moving outward, to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure. Tighten bolts and nuts to specification.

1. Remove lower intake manifold. See «LOWER INTAKE MANIFOLD»(ref-1341-S04638064182000031300000). Remove valve cover(s). Remove drive belt. Remove exhaust manifolds. See «EXHAUST MANIFOLD»(ref-1341-S18557623912000031300000). On all models, remove air cleaner duct. Disconnect exhaust pipe(s) from manifold(s).
2. To remove left cylinder head, remove A/C compressor (if equipped) and power steering bracket as an assembly. Remove oil dipstick tube and speed control bracket (if equipped).
3. To remove right cylinder head, remove generator and air pump mounting bracket complete with accessories. Swing alternator down, and position aside. Remove transmission oil fill tube.
4. To remove either cylinder head, loosen rocker arm bolts. Mark push rods for installation reference and remove. Disconnect air injection supply hoses at check valves, and plug check valve.
5. Remove cylinder head bolts in reverse order of tightening sequence. (Scheme 34) Remove cylinder head and gasket.

Scheme 34

1. Ensure gasket mating surfaces are clean and flat. Properly install NEW cylinder head gasket as marked on gasket. DO NOT use sealer on head gasket. Install cylinder head and bolts. Tighten bolts in sequence to specification. (Scheme 34) See «TORQUE SPECIFICATIONS»(ref-1341-S35044070512000031300000).
2. Lubricate push rod ends, valve stem tips, rocker arms and fulcrum seats with Multipurpose Grease (DOAZ-19584-AA). To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-1341-S35044070512000031300000). Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(ref-1341-S21359212482000031300000).

Note. Front seal can be replaced without removing front cover. Use Seal Remover (T70P-6B070-B) and Crankshaft Seal Installer/Cover Aligner (T88T-6701-A) to remove and install cover seal.

1. Remove fan, fan clutch and fan shroud. Remove accessory drive belt. Remove crankshaft pulley and damper. Place Seal Remover (T70P-6B070-B) onto timing chain cover plate over front seal.
2. Tighten 2 through-bolts, forcing seal remover under seal flange. Alternately tighten puller bolts one-half turn at a time until seal is removed from engine.

Coat seal with grease. Using Seal Installer (T88T-6701-A), install crankshaft front seal. Ensure seal is fully seated and spring is properly positioned in seal. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

1. Disconnect battery ground cable. Raise and support vehicle. Remove transmission mount nuts. Position the High-Lift Transmission Jack under the transmission. Lift transmission. Remove crossmember bolts and remove crossmember. Remove support Insulator bracket. Remove transfer case skid plate, if equipped.
2. Disconnect heated oxygen sensors (HO2S). Remove three-way catalytic converters (TWC). Install crossmember. Lower transmission onto crossmember and position High-Lift Transmission Jack aside. Remove radiator air deflector. Remove radiator. Remove accessory drive belt.
3. Remove water bypass hose. Disconnect heater water hose. Position control sensor wiring harness aside. Remove bolts and remove water pump pulley. Remove lower rediator hose. Remove 9 bolts and remove water pump. Remove Crankshaft Position (CKP) sensor. Remove crankshaft pulley bolt. Using special tool, remove crankshaft pulley. Drain engine oil.
4. Remove steering gear. See appropriate POWER RACK & PINION article in STEERING.
5. Remove front axle assembly. See «REMOVAL & INSTALLATION»(ref-1137-S38557386872000031300000) .
6. Remove bolts and lower oil pan. Remove bolts and lower oil pump into oil pan and remove oil pan. Using special tool, remove crankshaft front seal. Remove bolts and studs and remove engine front cover. Inspect and clean all components and gasket surfaces.

1. Position engine front cover and engine front cover gasket and install bolts and stud bolts. Oil pan gasket must be installed within 4 minutes of applying silicone. Apply sealant to oil pan surface corners on block and at gap between block and engine front cover. Install pan gasket. Apply sealant to 4 corners of pan gasket. Oil pump and pan must be installed as an assembly. Install oil pump. Install oil pan and reinforcement rails. Tighten 4 end bolts. Tighten remaining 18 bolts. See «TORQUE SPECIFICATIONS»(ref-1341-S35044070512000031300000) .
2. Install front axle assembly. See «REMOVAL & INSTALLATION»(ref-1137-S38557386872000031300000) .
3. Install steering gear. See appropriate POWER RACK & PINION article in STEERING.
4. Using special tool, install crankshaft front seal. Apply silicone to woodruff key slot on crankshaft pulley. Position crankshaft pulley and install bolt. Install Crankshaft Position (CKP) sensor. Install water pump gasket and water pump using 9 bolts. See «TORQUE SPECIFICATIONS»(ref-1341-S35044070512000031300000) . Install lower radiator hose. Install water pump pulley. Position engine control sensor wiring harness. Install heateer water hose. Install water by-pass tube.
5. Install accessory drive belt. Install radiator assembly. Install radiator air deflector. Position High-Lift Transmission Jack under transmission and lift transmission. Remove transmission crossmember. Install TWC. Install support insulator bracket. Connect Heated Oxygen Sensors (HO2S). Install transmission crossmember. Lower transmission onto crossmember and install nuts.
6. Position High-Lift Transmission Jack aside. Lower vehicle. Fill crankcase with clean oil. Fill and bleed air from cooling system. See «COOLING SYSTEM BLEEDING»(ref-1341-S21359212482000031300000) Fill and leak check power steering system. Connect battery ground cable.

1. Position No. 1 piston on TDC of compression stroke. Remove timing chain cover. See «TIMING CHAIN COVER»(ref-1341-S03827793642000031300000). Check alignment of camshaft and crankshaft sprocket timing marks. (Scheme 35) Check timing chain deflection.
2. If chain deflection is not within specification, replace timing chain and sprockets. See «CAMSHAFT»(ref-1341-S36775139232003051400000) table under ENGINE SPECIFICATIONS. Remove camshaft sprocket bolt and washer. Slide sprockets and timing chain forward, and remove as an assembly.

Install crankshaft sprocket, camshaft sprocket and timing chain as an assembly. Ensure timing marks are properly aligned. (Scheme 35) Apply oil to timing chain and sprockets. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS.

Scheme 35

1. Disconnect negative battery cable and remove starter. Remove transmission. See appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING.
2. Remove flywheel/flexplate and engine rear cover plate. Using a sharp awl, punch a hole in seal metal surface, between lip and block. Using Rear Crank Seal Remover (T95P-6701-EH) and slide hammer, remove rear oil seal.

Coat seal surfaces with light engine oil. DO NOT use grease for seal lubrication. Using Seal Installer (T95P-6701-BH), install seal until firmly seated. To install remaining components, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

Drain cooling system. Remove accessory drive belt. Remove upper radiator hose. Remove fan blade, fan clutch and fan shroud. Disconnect lower radiator hose, heater hose and water by-pass tube from water pump. Remove A/C and power steering bracket bolts, and position aside. Remove water pump retaining bolts. Remove water pump and gasket.

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

1. Disconnect battery ground cable. Raise and support vehicle. Remove transmission mount nuts. Position the High-Lift Transmission Jack under the transmission. Lift transmission. Remove crossmember bolts and remove crossmember. Remove support Insulator bracket. Remove transfer case skid plate, if equipped.
2. Disconnect heated oxygen sensors (HO2S). Remove three-way catalytic converters (TWC). Install crossmember. Lower transmission onto crossmember and position High-Lift Transmission Jack aside. Drain engine oil and reinstall drain plug.
3. Lower vehicle Place front wheels in straight-ahead position. Leave steering column in unlocked position. Raise and support vehicle. Disconnect power steering return hose at the power steering fluid cooler. Allow system to drain. Remove power steering fluid cooler-to-crossmember nuts. Disconnect power steering return hose. Remove power steering fluid cooler.
4. Remove front wheel and tire assemblies. Remove inner fender splash shields. Remove top motor mount nuts. Remove radiator air deflector. Loosen tie-rod end jam nuts. Disconnect tie-rod ends from steering knuckles. Do not damage tie-rod end seals. Remove LH tie-rod end. Count and record number of turns required to remove LH tie-rod end. Remove front stabilizer bar. See appropriate SUSPENSION-FRONT article.
5. Disconnect power steering pressure hose and power steering return hose from steering gear. Plug ends of all fluid hoses removed and ports in steering gear to prevent damage and entry of dirt. Rotate steering column shaft to access the intermediate shaft pinch bolt. Remove pinch bolt. Lower vehicle. Turn steering wheel back to straight-ahead position. Turn ignition key to locked position. Raise and support vehicle.
6. Disconnect intermediate shaft from steering gear input shaft. Position a block of wood between a screw jack and the bottom of the oil pan and raise the engine.
7. Remove nuts from steering gear-to-crossmember stud bolts. Remove stud bolts and washers. Remove steering gear-to-crossmember insulator bushings. Turn the steering gear input shaft to the right until the stop is reached. Move the steering gear as far to the right side of vehicle as possible. Move left front wheel spindle tie-rod forward to clear the crossmember. Turn the steering gear input shaft to the left until the stop is reached. Remove steering gear from vehicle.
8. For 4x4 vehicles, Remove bolts and position both calipers aside. Do not allow calipers to hang by the brake hoses. Install a wheel not to secure each brake disc in place. Unclip the left and right wheel anti-lock sensor wiring harness from the locators on the vehicle chassis, located above the stabilizer bar brackets.
9. Remove both pinch bolts and disconnect the upper ball joints. Pull the right halfshaft, with the wheel knuckle, away from the front axle until the halfshaft is out of the front axle. Pull the left halfshaft, with the wheel knuckle, away from the front axle. The left halfshaft cannot be removed from the front axle at this time.
10. Remove and discard the bolts and straps for front drive shaft. Secure driveshaft out of the way. Secure the axle housing to a suitable lift. Remove and discard axle housing bolts. Remove the top front axle housing bolt, then lower the axle 1 in. (25 mm) and move to the right .75 in. (19 mm), guiding the left axle halfshaft out of the axle. Disconnect the vent hose from the front axle housing. Lower the axle from the vehicle.
11. For all vehicles, Remove oil filter assembly. Remove bolt and O-ring and position aside the oil bypass assembly. Remove the oil pump and the oil pan as an assembly. Remove the bolts and lower the oil pan. Remove the bolts, lower the oil pump into the oil pan, and remove oil pan.

1. Apply sealant to the 4 corners of the pan surface on the block and the seam between the block and the timing cover. Install oil pan gasket. Apply sealant to the 4 corners of the oil pan gasket. Install oil pump. Install oil pan and reinforcement rails. Tighten 4 end bolts, then tighten remaining 18 bolts. Coat the oil bypass assembly O-ring with petroleum jelly and install into groove on adapter. Install oil bypass assembly and bolt. Install oil filter. See «TORQUE SPECIFICATIONS»(ref-1341-S35044070512000031300000) .
2. On 4x4 vehicles, secure front axle housing to a suitable lift. Position front axle close to the installed position. Connect the vent hose to the front axle. Install a new circlip on the end of the left halfshaft. Left halfshaft will not fully seat into front axle at this time. Guide left halfshaft into front axle. Raise the front axle to the fully installed position. Completely instal the left halfshaft.
3. Install front axle housing top bolt. Using new bolts, install remaining front axle housing bolts. Install a new circlip on the end of the right halfshaft and install the right halfshaft. Using new bolts, Install the front driveshaft. Connect the upper ball joints and install the pinch bolts. Install both front calipers.
4. On all vehicles, using special tool, install new seals on the power steering return hose and the power steering pressure hose. Ensure steering gear input shaft is turned to the left until the stop is reached. Handle steering gear with caution to avoid damage to fluid transfer tubes and to avoid dimples in the tie-rod boots. Turn steering gear input shaft to right until the stop is reached. Note the number of turns required.
5. Install steering gear into right opening of crossmember. Move steering gear as far to the right side of the vehicle as possible. Move left front wheel spindle tie-rod into opening in crossmember and move steering gear into position. To place the steering gear in the straight ahead position, turn steering gear input shaft to left by half the number of turns recorded previously.
6. Install steering gear-to-crossmember insulator bushings. The large end of the metal sleeve must be positioned downward. Check that the mounting surfaces on the crossmember are clean and free of debris. Install steering gear-to-crossmember washers and stud bolts. Hold tops of steering gear-to-crossmember stud bolts to avoid damaging steering fluid transfer tubes. Install nuts. Lower engine.
7. Connect intermediate shaft to steering gear input shaft. Install pinch bolt.
8. Connect power steering return hose. Connect power steering pressure hose. Install front stabilizer bar. See appropriate SUSPENSION-FRONT article. Rotate tie-rod end the number of turns recorded during removal. Connect tie-rod ends to steering knuckles. Check that brake dust shields are not bent and are not in contact with outer tie-rod boot seals. Tighten left tie-rod end jam nut.
9. Install radiator air deflector. Install top engine mount nuts. Install inner fender splash shields. Install front wheel and tire assemblies. Install power steering fluid cooler and connect power steering return hose. Install power steering fluid cooler crossmember nuts. Connect power steering return hose.
10. Position High-Lift Transmission Jack under transmission. Lift transmission. Remove crossmember. Install Three-Way Catalytic converter (TWC). Connect Heated Oxygen Sensors (HO2S). Install support insulator bracket. Install transfer case skid plate, if equipped. Install crossmember. Lower transmission onto crossmember and install nuts. See «TORQUE SPECIFICATIONS»(ref-1341-S35044070512000031300000) . Position High-Lift Transmission Jack aside.
11. Lower vehicle. Fill crankcase with clean oil. Fill and leak check power steering system. Connect battery ground cable.

Removal & Disassembly

1. Remove oil pan. See «OIL PAN»(ref-1341-S01176704832000031300000) under REMOVAL & INSTALLATION. Remove oil pump from oil pan. Remove oil pump drive shaft. Disassemble oil pump.
2. Note direction of component installation for reassembly reference. Drill a small hole in oil pressure relief valve cap. Install self-threading screw in drilled hole and pull on screw to remove cap.

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure components are installed in original location. Install NEW oil pressure relief valve cap. To install, prime oil pump by filling inlet opening with oil, and rotating pump shaft until oil emerges from outlet opening.
2. Install and tighten oil pump-to-cylinder block bolt to specification. See «TORQUE SPECIFICATIONS»(ref-1341-S35044070512000031300000) . To complete installation, reverse removal procedure.