ENGINE-4.0L SOHC: Overhaul Ford Explorer III

Item 24: Ignition Wires Disassembly Note

1. Remove the spark plug wires.

Item 44: RH Exhaust Manifold Disassembly Note

1. Remove the three bolts and the RH engine insulator bracket.

Item 70: LH Exhaust Manifold Disassembly Note

1. Remove the three bolts and the LH engine insulator bracket.

Scheme 291

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.

Item 76: Hydraulic Lash Adjuster Disassembly Note

1. Remove the hydraulic lash adjusters.

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1. Using the special tool, hold the crankshaft.
2. Remove the rear jackshaft sprocket bolt.
3. Remove the rear bolt and spacer.

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1. Install the special tools on the RH cylinder head.
2. Loosen the camshaft sprocket bolt.
3. Remove the camshaft sprocket bolt. Remove the special tools. Remove the camshaft sprocket bolt.
4. Separate the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.

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1. Install the special tools on the LH cylinder head.
2. Loosen the camshaft sprocket bolt.
3. Remove the camshaft sprocket bolt. Remove the special tools. Remove the camshaft sprocket bolt.
4. Separate the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.

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1. Using the special tool, keep the crankshaft from turning while loosening the jackshaft sprocket bolt.
2. Remove the jackshaft thrustplate bolts and the jackshaft thrustplate.

Scheme 304

1. Remove the primary chain guide bolts and the primary chain guide.

Items 96 and 99: LH and RH Cylinder Head Bolts Disassembly Note

1. Remove the bolts in the sequence shown in illustration and remove the cylinder head.

Items 97 and 100: LH and RH Cylinder Head Disassembly Note

1. Clean and inspect the sealing surfaces. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-194039) .

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1. Remove the oil pump pick-up tube, the oil pump, and the oil pump intermediate shaft.
2. Remove the bolt, the clamp, and the oil pump drive assembly.

Scheme 307

1. Install a pin in the balance shaft tensioner.

Item 117: Balance Shaft Drive Chain Disassembly Note

1. Remove the balance shaft chain and crankshaft sprocket.

Scheme 308

1. Using the cylinder ridge reamer, remove the ridge and carbon deposits from the top of each cylinder to allow removal of the piston(s).

Scheme 309

1. Install rubber hose pieces on the bolts to protect the crankshaft and remove the pistons.

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1. Disassemble the components in the order listed in the following illustrations and table.
2. To assemble, reverse the disassembly procedure.

Items 2: Camshaft Roller Follower Disassembly Note

1. Using the special tool, remove the camshaft roller followers.

Item 3: Hydraulic Lash Adjuster Disassembly Note

1. Remove the hydraulic lash adjusters.

Scheme 312

1. Using the special tool, remove the valve spring retainer keys, the valve spring and the retainer.
2. Repeat the procedure until all of the valves are removed.

Items 9, 10 and 11: Camshaft Bearing Cap Mounting Bolts, Oil Supply Tube and Camshaft Bearing Caps Disassembly Note

1. Remove the bolts in the sequence shown in illustration and remove the camshaft bearing caps.

Item 13: Cylinder Head Disassembly Note

1. Inspect the cylinder head. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-194039) .

Items 11, 10 and 9: Camshaft Bearing Caps, Oil Supply Tube and Camshaft Bearing Cap Mounting Bolts Assembly Note

1. Position the oil supply tube, the camshaft bearing caps and the bolts. Tighten in the sequence shown in illustration in two stages: Stage 1: Tighten to 6 Nm (53 lb-in). Stage 2: Tighten to 16 Nm (12 lb-ft).

Scheme 313

1. Install the valve.
2. Using the special tool, install the valve stem seals.

Scheme 314

1. Using the special tool, install the valve spring, the retainer and the retainer keys.

Scheme 315

1. Install the hydraulic lash adjusters.

Item 2: Camshaft Roller Follower Assembly Note

1. Install the camshaft roller followers only after the cylinder head is installed in the vehicle and the timing procedure has been carried out.

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1. Remove the connecting rod bearings from the connecting rod and caps.
2. Disassemble the components in the order listed in the following illustrations and table.
3. To assemble, reverse the disassembly procedure.

Scheme 319

1. Using the special tool, press the piston pin out of the connecting rod and piston assembly.

Scheme 320

1. Position the piston pin in the bore, aligned with the connecting rod bore.
2. Gradually heat the pin bore side of the connecting rod to approximately 232°C- 316°C (467°F-626°F) and immediately install the piston pin.
3. Using the special tool, press the piston pin into the piston and connecting rod assembly.

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Note. Before engine assembly, use metal surface cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

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1. Illustration 1 of 14. Install the components in the order indicated in the following illustration and table.
2. Illustration 2 of 14. On 4x4 vehicles only, install the components in the order indicated in the following illustration and table.
3. Illustration 3 of 14. Install the components in the order indicated in the following illustration and table.
4. Illustration 4 of 14. Install the components in the order indicated in the following illustration and table.
5. Illustration 5 of 14. Install the components in the order indicated in the following illustration and table.
6. Illustration 6 of 14. Install the components in the order indicated in the following illustration and table.
7. Illustration 7 of 14. Install the components in the order indicated in the following illustration and table.
8. Illustration 8 of 14. Install the components in the order indicated in the following illustration and table.
9. Illustration 9 of 14. Install the components in the order indicated in the following illustration and table.
10. Illustration 10 of 14. Install the components in the order indicated in the following illustration and table.
11. Illustration 11 of 14. Install the components in the order indicated in the following illustration and table.
12. Illustration 12 of 14. Install the components in the order indicated in the following illustration and table.
13. Illustration 13 of 14. Install the components in the order indicated in the following illustration and table.
14. Install the engine lifting eyes and remove the engine from the engine stand.
15. Illustration 14 of 14. Install the components in the order indicated in the following illustration and table.

Item 2: Crankshaft Assembly Note

1. Install the crankshaft.

Item 3: Crankshaft Main Bearing Cap Assembly Note

1. Apply silicone gasket and sealant to the rear main bearing cap-to-cylinder block parting line.

Scheme 348

1. Tighten the bolts in the sequence shown in illustration to 97 Nm (72 lb-ft).

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1. Check the piston-to-cylinder bore and ring clearances. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-194039) .
2. Using a suitable tool, install the piston rings.
3. Make sure the piston ring gaps (oil spacer-A, oil ring-B, and compression ring-C) are correctly spaced around the circumference of the piston.
4. Install the connecting rod bearings.
5. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.
6. Using the special tool, install the pistons. Rotate the crankshaft as necessary.
7. Check the clearance of each connecting rod bearing. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-194039) .
8. Rotate the crankshaft until the piston is at the bottom of its stroke.
9. Loosen the first nut until the face is approximately 2 mm (0.08 in) over the end of the bolt.
10. Tap the nut until the bolt can be removed by hand.
11. Repeat the previous two steps for the opposite bolt.
12. Install the new bolts, making certain that the new bolt head is parallel to the sideward face of the connecting rod.
13. Install and tighten the connecting rod nuts in the sequence shown in illustration in two stages: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten 90 degrees.
14. Repeat these steps for the remaining connecting rods.

Scheme 354

1. Install the jackshaft thrust plate and bolts.

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1. Rotate the crankshaft until No. 1 piston is at top dead center (TDC).
2. Align the timing marks. Install a 4 mm (0.16 in) pin to hold the shaft in place.
3. Install the balance shaft chain and crankshaft sprocket.
4. Install the balance shaft tensioner and chain guide. Install the balance shaft tensioner. Install the balance shaft tensioner bolts. Position the balance shaft chain guide and install the two bolts. Remove the pin from the balance shaft tensioner.

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Scheme 358

1. Install the oil pump intermediate shaft, the oil pump, and the oil pump pick- up tube.
2. Install the oil pump drive assembly, the clamp, and the bolt.

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1. Clean and inspect the sealing surfaces. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-194039) .
2. Apply silicone in the six places shown in illustration.
3. Back the set screws off until they are below the lower block cradle boss.
4. Position the lower block cradle and gasket assembly.
5. Install and hand-tighten the outer bolts and nuts.
6. Install and hand-tighten the rear lower block cradle bolts.
7. Using a straightedge, align the transmission face of the lower block cradle with the rear face of the cylinder block.
8. Tighten the outer bolts and nuts.
9. Tighten the rear lower block cradle bolts.
10. Tighten the eight inserts.
11. Install the two silver covered bolts and new washer seals. Hand-tighten them at this time.
12. Install and hand-tighten the six remaining bolts.
13. Tighten the lower block cradle bolts in two stages: Stage 1: Tighten to 15 Nm (11 lb-ft). Stage 2: Tighten to 34 Nm (25 lb-ft).
14. Measure the step between the rear face of the cylinder block and the transmission face of the lower block cradle.
15. Repair all assemblies that exceed underflush specification by installing shims on one of both sides of the lower block cradle.

Scheme 369

Scheme 370

1. Clean and inspect the sealing surfaces. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-194039).
2. Install the cylinder head and tighten the new 12-mm bolts in sequence. see scheme 403 Bolts are tightened in multiple stages. Stage 1: Tighten bolts to 12 Nm (9 lb-ft). Stage 2: Tighten bolts to 25 Nm (18 lb-ft).
3. Install the two 8 mm bolts and tighten to 32 Nm (24 lb-ft). see scheme 404
4. Using the torque-turn method, tighten the 12-mm bolts in the sequence shown in illustration in 2 stages. see scheme 405 Stage 1: Tighten the bolts 90°. Stage 2: Tighten the bolts an additional 90°.

Items 41 and 42: Knock Sensor Assembly Note

1. Install the knock sensor and bolt.

Item 43-56: RH Camshaft Drive Cassette Assembly Note

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1. Using the special tool, install the crankshaft pulley.
2. Position the crankshaft at top dead center (TDC) and install the special tool to the crankshaft pulley.
3. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools. Install the special tools on the front of the RH cylinder head.
4. Install the special tools on the rear of the RH cylinder head.
5. Install the special tool in place of the RH hydraulic timing chain tensioner.
6. Tighten the bolts. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). Tighten the RH camshaft bolt. Remove the special tool. Install the RH hydraulic timing chain tensioner. Remove the special tools from the RH cylinder head. NOTE: Leave the top two special tool clamp bolts loose. Install the special tools on the front of the LH cylinder head. NOTE: The camshaft timing slots are off-center. 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. Install the special tool in place of the LH hydraulic timing chain tensioner. Tighten the bolts. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). Tighten the LH camshaft bolt. Remove the special tool. Install the LH hydraulic timing chain tensioner. Remove all of the timing special tools. Using the special tool, remove the crankshaft dampener.

Item 47: RH Camshaft Sprocket Bolt Assembly Note

1. Hand-tighten the RH camshaft sprocket bolt at this time.

Scheme 383

1. Hand-tighten the jackshaft sprocket bolt at this time.

Scheme 384

1. Install the primary chain guide and bolts.

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Scheme 388

1. Using the special tool, hold the crankshaft.
2. Tighten the jackshaft sprocket bolt in two stages. Stage 1: Tighten to 45 Nm (33 lb-ft). Stage 2: Rotate the bolt an additional 90 degrees.
3. Tighten the rear jackshaft bolt in two stages. Tighten the rear jackshaft bolt to 20 Nm (15 lb-ft). Tighten the rear jackshaft bolt an additional 90 degrees.
4. Install the rear jackshaft plug.

Item 57: Hydraulic Lash Adjuster Assembly Note

1. Install the hydraulic lash adjusters in their original position.

Scheme 389

1. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
2. Using the special tool, install the camshaft roller followers in their original position.

Item 65: Fuel Injector Assembly Note

1. Install new O-ring seals on each of the fuel injectors.
2. Lubricate the fuel injector O-rings and install the fuel injectors.

Scheme 390

1. Inspect and install new O-rings as necessary.

Item 109: Ignition Wires Assembly Note

1. Connect the spark plug wires.

Scheme 391

1. Install the oil pressure switch.
2. Install the battery cable and harness and connect the oil pressure switch electrical connector.

Scheme 392

1. Using the special tool, install the crankshaft pulley.
2. Tighten the bolt in two stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Rotate an additional 90 degrees.

Item 134: Flexplate Bolts Assembly Note

1. Tighten the flexplate bolts in the sequence shown in illustration in two stages. Stage 1: Tighten the bolts to 13 Nm (10 lb-ft). Stage 2: Tighten the bolts to 71 Nm (52 lb-ft).

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1. Illustration 1 of 5. Install the components in the order indicated in the following illustration and table.
2. Illustration 2 of 5. Install the components in the order indicated in the following illustration and table.
3. Illustration 3 of 5. Install the components in the order indicated in the following illustration and table.
4. Illustration 4 of 5. Install the components in the order indicated in the following illustration and table.
5. Illustration 5 of 5. Install the components in the order indicated in the following illustration and table.
6. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-194049) .
7. Install the cooling fan. For additional information, refer to «ENGINE COOLING»(ref-194047) .
8. Install the power steering pump pulley. For additional information, refer to «STEERING SYSTEM»(ref-194037) .
9. Install the air cleaner outlet pipe. For additional information, refer to «REMOVAL & INSTALLATION»(ref-156578) .
10. Connect the fuel tube. For additional information, refer to «FUEL SYSTEM»(ref-194052) .
11. Fill the engine with clean engine oil.
12. Connect the battery ground cable. For additional information, refer to «BATTERY AND CHARGING SYSTEM»(ref-194056) .
13. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-194047) .
14. Charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM»(ref-194054) .
15. Install the hood.

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1. Using the special tool, install the engine.
2. Install the special tools.
3. Install the engine lifting hook.