ENGINE-4.0L SOHC: Other Ford Explorer III

ENGINE EMISSION CONTROL

The engine emission control system consists of the

1. exhaust gas recirculation (EGR) valve (9D475)
2. differential pressure feedback EGR
3. EGR vacuum regulator solenoid (9J459)
4. EGR valve tube
5. positive crankcase ventilation (PCV) system

The engine emissions control system

1. cycles crankcase gases back through the engine intake system.
2. regulates ventilating air and blow-by fuel vapors.
3. reintroduces exhaust gases into the combustion cycle.
4. assists in the reduction of nitrogen oxides.

The PCV system uses intake manifold vacuum to ventilate the crankcase and return the fumes to the intake manifold for combustion. If equipped, a crankcase vent oil separator is used to prevent oil from entering the PCV system.

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Refer to ENGINE SYSTEM-GENERAL INFORMATION .

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1. Verify the customer's concern by operating the engine to duplicate the condition.
2. Inspect to determine if any of the following mechanical concerns apply
3. Inspect for drive belt cracking/chunking/wear.
4. If the concerns remain after inspection, determine the symptoms. GO to «Symptom Chart»(ref-194043-S06732136512005092600000) . Under severe operating conditions (high temperature, low humidity), drive belt rib cracking can occur at less than 96,000 km (60,000 miles). Drive belt rib cracking (cracks across grooves): is not a reason for concern. has no detrimental effect on drive belt performance. Cracks parallel to grooves are acceptable. The drive belt is still perfectly functional until rib chunking occurs. Drive belt chunking is where the rubber material actually chunks out between the cracks. A new drive belt should be installed if chunking occurs.
5. If the concern(s) remains after inspection, determine the symptoms. GO to «Symptom Chart»(ref-194043-S06732136512005092600000) .

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Drive Belt - Misalignment

Note. Original equipment drive belts are made of a special cord construction and are subjected to special testing before they are approved for use.

Non-standard new drive belts may track differently or incorrectly. If a new drive belt tracks incorrectly, install a new original equipment drive belt to avoid performance failure or loss of drive belt.

With the engine running, check drive belt tracking (the position of the drive belt on one of the grooveless pulleys, idlers or drive belt tensioner. If the edge of the drive belt rides beyond the edge of the pulley, noise and premature wear may result). If a drive belt tracking condition exists, visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly with the locating pins in the locating holes, the mounting surface pad will be out of position. This will result in abnormal drive belt tension and chirp and squeal noises.

If the above procedures do not correct the drive belt noise, install a new drive belt. However, the drive belt noise may return (with mileage) if one of the above conditions still exists uncorrected.

1. With engine running, visually observe the grooves in the pulleys (not the pulley flanges) for excessive wobble. Install new components as necessary.
2. Check all accessories, mounting brackets and drive belt tensioner, for any interference that would prevent the component from mounting correctly. Correct any interference condition and recheck belt tracking.
3. Tighten all accessories, mounting brackets and drive belt tensioner retaining hardware to specification. Recheck drive belt tracking.

Belt Tensioner

The automatic drive belt tensioner can be checked as follows

1. With the engine running, observe the drive belt tensioner movement. The drive belt tensioner should move (respond) when the A/C clutch cycles or when the engine is accelerated rapidly. If the drive belt tensioner movement is constant without A/C clutch cycling or acceleration, a pulley or shaft is probably bent or a pulley is out of round. In rare cases, excessive drive belt rideout (uneven depth of grooves in drive belt) can cause excessive drive belt tensioner movement. This condition can be checked by installing the suspect drive belt with a known good original equipment drive belt and repeating the observation.

Refer to SELF-DIAGNOSTICS - CNG, FLEX-FUEL & GASOLINE .

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1. In order to carry out camshaft timing, the following components must be removed. Remove the roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER AND HYDRAULIC LASH ADJUSTER»(ref-194043-S40561732132005092600000) .
2. Turn the crankshaft clockwise to position the number one cylinder at top dead center (TDC).
3. Remove the retainer and position the A/C manifold tube aside.
4. Install the special tool.
5. Install the special tools to the RH cylinder head and tighten the two top clamp bolts.
6. Using the special tool, loosen the RH camshaft sprocket bolt.
7. Loosen the top two special tool clamp bolts.
8. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools and install the special tools on the front of the RH cylinder head.
9. Remove the RH camshaft tensioner.
10. Install the special tool.
11. Tighten the bolts. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). Using the special tool, tighten the camshaft bolt.
12. Remove the special tool.
13. Install the RH camshaft tensioner.
14. Remove the special tools from the RH cylinder head.
15. Install the special tools on the front of the LH cylinder head and tighten the top two clamp bolts.
16. Loosen the LH camshaft sprocket bolt.
17. Loosen the top two clamp bolts on the special tool to allow the camshaft sprocket to rotate freely.
18. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools, and install the special tools on the rear of the LH cylinder head.
19. Remove the LH camshaft tensioner.
20. Install the special tool.
21. Tighten the bolts. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). Tighten the LH camshaft bolt.
22. Remove the special tool.
23. Install the LH camshaft tensioner.
24. Remove the special tools from the LH cylinder head.
25. Install the following components. Install the roller followers. For additional information, refer to «CAMSHAFT ROLLER FOLLOWER AND HYDRAULIC LASH ADJUSTER»(ref-194043-S40561732132005092600000) .

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1. Remove the components in the order indicated in the following illustration and table. To remove individual components, carry out only the listed steps.
2. To install, reverse the removal procedure.

TIMING DRIVE COMPONENTS - CAMSHAFT DRIVE CASSETTE, RH

Note. For Timing Drive Components - Camshaft Drive Cassette, RH service information, see ENGINE under DISASSEMBLY.

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1. Remove the LH and RH valve covers. For additional information, refer to «VALVE COVER LH»(ref-194043-S18704149072005092600000) and «VALVE COVER RH»(ref-194043-S41257120272005092600000) .
2. Remove the cooling fan. For additional information, refer to «ENGINE COOLING»(ref-194047) .
3. Remove the components in the order indicated in the following illustration and table. To remove individual components, carry out only the listed steps.
4. To install, reverse the removal procedure.
5. Install the cooling fan. For additional information, refer to «ENGINE COOLING»(ref-194047) .
6. Install the LH and RH valve covers. For additional information, refer to «VALVE COVER RH»(ref-194043-S41257120272005092600000) and «VALVE COVER LH»(ref-194043-S18704149072005092600000) .

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1. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
2. Using the special tool, remove the camshaft roller followers.

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1. Position the piston of the cylinder being serviced at top dead center (TDC).
2. Hold the valves in the cylinder head. Remove the spark plug of the cylinder being serviced. Use a suitable tool to apply air pressure to the cylinder.
3. Using the special tool, remove the valve spring retainer keys, valve spring retainers and the valve springs.

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1. Rotate the crankshaft clockwise to position the number one cylinder at TDC.
2. Remove the retainer and position the A/C manifold tube bracket aside.
3. Install the special tools.
4. Install the special tools on the rear of the RH cylinder head and tighten the top two clamp bolts to 10 Nm (89 lb-in)
5. Using the special tool, loosen the camshaft sprocket bolt.
6. Remove the special tools.
7. Remove the bolt and position the camshaft sprocket aside.
8. Remove the bolts in the sequence shown in illustration and remove the camshaft bearing caps and the oil supply tube.