Contents Wiring diagrams Section: Mechanical All sections

Engine - 4.0L (SOHC): Other Ford Explorer IV

Mechanical 43 illustrations ~1055 words

Material

ItemSpecificationFill Capacity
Motorcraft Metal Surface Prep ZC-31
Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)WSS-M97B51-A1
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A4.73L (5 qt) with filter
Silicone Brake Caliper Grease and Dielectric Compound XG-3-AESE-M1C171-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4
Silicone Gasket Remover ZC-30
Threadlock and Sealer TA-25WSK-M2G351-A5

Material

Camshaft Timing

Special Tools Illustration Tool Name Tool Number Adapter for 303-564 303-578 (T97T-6256-C) Adapter for 303-577 303-576 (T97T-6256-D) Extension, Torque Wrench 303-575 (T97T-6256-F) Holding Tool, Camshaft 303-577 (T97T-6303-C) Holding Tool, Camshaft Sprocket 303-564 (T97T-6256-B) Socket, Camshaft Sprocket Nut 303-565 (T97T-6256-G) or equivalent Tensioner, Timing Chain 303-571 (T97T-6K254-A) Timing Tool, Crankshaft TDC 303-573 (T97T-6303-A)

Scheme 15

Scheme 15: Camshaft Timing

Scheme 16

Scheme 16

Scheme 17

Scheme 17
ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

  1. Remove the camshaft roller followers. For additional information, refer to «Camshaft Roller Follower»(ref-270889-S26845398732007110700000) .
  2. If necessary, rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
  3. If necessary, remove the bolts and position the generator aside.
  4. If necessary, remove the bolts and position the A/C compressor and power steering pump bracket aside.
  5. Turn the crankshaft clockwise to position the No. 1 cylinder at top dead center (TDC).
  6. Remove the nut and position the wiring harness aside.
  7. Install the special tool.
  8. Install the special tools to the RH cylinder head and tighten the 2 top clamp bolts to 10 Nm (89 lb-in).
  9. Using the special tool with the Camshaft Sprocket Nut Socket 303-565, loosen the RH camshaft sprocket bolt.
  10. Loosen the top 2 special tool clamp bolts.
  11. 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.
  12. Remove the RH hydraulic camshaft tensioner.
  13. Install the special tool.
  14. Tighten the bolts. Tighten the special tool top 2 clamp bolts to 10 Nm (89 lb-in). Using the special tool with the Camshaft Sprocket Nut Socket 303-565, tighten the camshaft bolt to 61 Nm (45 lb-ft).
  15. Remove the special tool.
  16. Install the RH hydraulic camshaft tensioner. Tighten to 44 Nm (32 lb-ft).
  17. Remove the special tools from the RH cylinder head.
  18. Install the special tools on the front of the LH cylinder head and tighten the top 2 clamp bolts to 10 Nm (89 lb-in).
  19. Loosen the LH camshaft sprocket bolt.
  20. Loosen the top 2 clamp bolts on the special tool to allow the camshaft sprocket to rotate freely.
  21. 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.
  22. Remove the LH hydraulic camshaft tensioner.
  23. Install the special tool.
  24. Tighten the bolts. Tighten the special tool top 2 clamp bolts to 10 Nm (89 lb-in). Tighten the LH camshaft bolt to 85 Nm (63 lb-ft).
  25. Remove the special tool.
  26. Install the LH hydraulic camshaft tensioner. Tighten to 44 Nm (32 lb-ft).
  27. Remove the special tools from the LH cylinder head.
  28. Remove the special tool.
  29. Position the battery cable bracket and install the nut. Tighten to 20 Nm (15 lb-ft).
  30. If necessary, position the A/C compressor and power steering pump bracket and install the bolts. Tighten to 42 Nm (31 lb-ft).
  31. If necessary, position the generator and install the bolts. Tighten to 47 Nm (35 lb-ft).
  32. If necessary, rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
  33. Install the camshaft roller followers. For additional information, refer to «Camshaft Roller Follower»(ref-270889-S26845398732007110700000) .

Scheme 18

Scheme 18: Intake Manifold
ItemPart NumberDescription
1Knock sensor (KS) electrical connector
26K817PCV tube
39C482Brake booster vacuum supply hose
49E499Engine main vacuum harness-to-intake manifold fitting (part of 9E498)
59D289Evaporative emissions (EVAP) tube
614A464EGR system module electrical connector (part of 12B637)
7Wiring harness pin-type retainer (part of 12B637)
89E499EGR system module vacuum fitting (part of 9E498)
99J471EGR tube fitting (part of 9E469)
1014A464Throttle position (TP) sensor electrical connector (part of 12B637)
1114A464Electronic throttle body (TB) electrical connector (part of 12B637)
12Wiring harness nut
13Wiring harness bracket

Scheme 19

Scheme 19
ItemPart NumberDescription
19K479Intake manifold bolt (8 required)
29424Intake manifold
39461Intake manifold gasket (6 required)

Valve Cover - RH

ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Scheme 20

Scheme 20
ItemPart NumberDescription
1W500023Heater hose tube bracket rear bolt
2W500041Heater hose tube bracket front bolt
39E469EGR system module tube fitting
4W500204Fuel supply tube-to-valve cover bracket bolt
5W708086Fuel supply tube bolts (4 required)
69E964Fuel supply tube
712297Spark plug wire retainers
86758Crankcase ventilation tube

Scheme 21

Scheme 21
ItemPart NumberDescription
16C519RH valve cover fastener (6 required)
26582RH valve cover
36584RH valve cover gasket

Crankshaft Front Seal

Special Tools Illustration Tool Name Tool Number Aligner, Front Cover 303-093 (T74P-6019-A) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)

Scheme 22

Scheme 22: Crankshaft Front Seal

Scheme 23

Scheme 23
ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Scheme 24

Scheme 24
ItemPart NumberDescription
16700Front crankshaft seal

Crankshaft Pulley

Special Tools Illustration Tool Name Tool Number Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Remover, Crankshaft Vibration Damper 303-101 (T74P-3616-A) Remover, Crankshaft Vibration Damper 303-773 Strap Wrench 303-D055 (D85L-6000-A) or equivalent

Scheme 25

Scheme 25
8-mm x 1.25 x 100-mm bolts (2 required)

General Equipment

Scheme 26

Scheme 26
ItemPart NumberDescription
1E800511Crankshaft pulley bolt
26B321Crankshaft pulley

Cylinder Head

Special Tools Illustration Tool Name Tool Number Adapter for 303-564 303-578 (T97T-6256-A) or equivalent Holding Tool, Camshaft Sprocket 303-564 (T97T-6256-B) or equivalent Remover, Spark Plug Wire 303-106 (T74P-6666-A) Socket, Camshaft Sprocket Nut 303-565 (T97T-6256-G) or equivalent Torque Wrench Extension 303-575 (T97T-6256-F) or equivalent

ItemSpecification
Silicone Brake Caliper Grease and Dielectric Compound XG-3-AESE-M1C171-A

Material

Scheme 27

Scheme 27
ItemPart NumberDescription
18620Accessory drive belt
2W500325Accessory drive belt tensioner bolt
36B209Accessory drive belt tensioner
4N807938Generator bracket bolt (3 required)
510239Generator bracket
614A240Generator B+ terminal cover (part of 12A280)
7Generator B+ terminal nut
8Generator B+ terminal
914489Generator electrical connector (part of 14A280)
1014489Generator electrical connector (part of 14A280)

Scheme 28

Scheme 28
ItemPart NumberDescription
18B274Upper radiator hose
218472Heater hose
314A464Engine coolant temperature (ECT) sensor electrical connector (part of 12B637)
48548Bypass hose
5W702527Thermostat housing bolt (3 required)
69K478Thermostat housing
78255O-ring seal

Scheme 29

Scheme 29
ItemPart NumberDescription
1W500041Heater tube assembly front bolt
2W500022Heater tube assembly rear bolt
318696Heater tube assembly
4W505421Engine ground strap bolt
519A095Engine ground strap
66K254RH hydraulic timing chain tensioner
7RH hydraulic timing chain tensioner O-ring seal
86M276RH camshaft sprocket bolt
96U000RH timing cassette-to-cylinder head bolt
10W505430Wiring harness retainer bolt
1114C508Wiring harness retainer (part of 12B637)

Scheme 30

Scheme 30
ItemPart NumberDescription
112280RH spark plug wire (3 required)
212281LH spark plug wire (3 required)

Scheme 31

Scheme 31
ItemPart NumberDescription
1N807938A/C compressor and power steering pump bracket bolt (4 required)
219E708A/C compressor and power steering pump bracket
3Ignition coil and bracket assembly bolt (4 required)
412A310Ignition coil and bracket assembly
514A464Radio ignition interference capacitor electrical connector (part of 12B637)

Scheme 32

Scheme 32
ItemPart NumberDescription
1Oil level indicator tube assembly bolt
26754Oil level indicator tube assembly
36M276LH camshaft sprocket bolt
46K254LH hydraulic timing chain tensioner
5LH hydraulic timing chain tensioner O-ring seal
66U001LH timing cassette-to-cylinder head bolt

Scheme 33

Scheme 33
ItemPart NumberDescription
16065LH cylinder head bolt (M8) (2 required)
26065LH cylinder head bolt (M12) (8 required)
36M099LH cylinder head
46083LH cylinder head gasket
56065RH cylinder head bolt (M8) (2 required)
66065RH cylinder head bolt (M12) (8 required)
76049RH cylinder head
86051RH cylinder head gasket

Engine Front Cover

ItemSpecification
Motorcraft Metal Surface Prep ZC-31
Silicone Gasket and Sealant TA-30WSE-M4G323-A4
Silicone Gasket Remover ZC-30

Material

Scheme 34

Scheme 34
ItemPart NumberDescription
1W520102Wiring harness bracket nut
210A779Wiring harness bracket (part of 14A280)
3W503275Cylinder block cradle-to-front cover bolt (5 required)
48260Lower radiator hose
5Accessory drive belt tensioner bolt
66B209Accessory drive belt tensioner
7Heater hose
814A464Crankshaft position (CKP) sensor electrical connector

Scheme 35

Scheme 35
ItemPart NumberDescription
1Generator wiring connections
2Generator bracket bolt (3 required)
3Generator bracket
4Ignition coil bracket-to-LH accessory drive bracket bolt
5LH accessory drive bracket bolt (4 required)
6LH accessory drive bracket
7Wiring harness routing clips
8Engine coolant temperature (ECT) sensor electrical connector
918472Heater hose
108260Upper radiator hose
11Bypass hose clamp
12Thermostat housing bolt (3 required)
13Thermostat housing

Scheme 36

Scheme 36
ItemPart NumberDescription
1Engine front cover bolt (10 required)
2Engine front cover
3Gasket

Camshaft Drive Cassette - LH

Special Tools Illustration Tool Name Tool Number Adapter for 303-564 303-578 (T97T-6256-A) Holding Tool, Camshaft Sprocket 303-564 (T97T-6256) Holding Tool, Crankshaft 303-674

Scheme 37

Scheme 37
ItemPart NumberDescription
16K254Hydraulic chain tensioner
26M276Camshaft sprocket bolt
36M276Jackshaft sprocket bolt
4W500011Primary chain tensioner bolts (2 required)
56M271Primary chain tensioner
6Primary chain and sprocket assembly
76U001LH cassette upper bolt
8W500110LH cassette lower bolt
96M289LH cassette

Timing Drive Components - Camshaft Drive Cassette, RH

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

Hydraulic Timing Chain Tensioner - LH

ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Scheme 38

Scheme 38
ItemPart NumberDescription
16K524LH hydraulic chain tensioner
2LH hydraulic chain tensioner O-ring seal

Hydraulic Timing Chain Tensioner - RH

ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Scheme 39

Scheme 39
ItemPart NumberDescription
16K254RH hydraulic chain tensioner
2RH hydraulic chain tensioner O-ring seal

Camshafts

Special Tools Illustration Tool Name Tool Number Adapter for 303-564 303-578 (T97T-6256-A) or equivalent Extension, Torque Wrench 303-575 (T97T-6256-F) or equivalent Holding Tool, Camshaft Sprocket 303-564 (T97T-6256-B) or equivalent Socket, Camshaft Sprocket Nut 303-565 (T97T-6256-G) Timing Tool, Crankshaft TDC 303-573 (T97T-6303-A) or equivalent

ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Camshaft Roller Follower

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-581 (T97T-6565-A)

ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Valve Springs

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-581 (T97T-6565-A)

ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Valve Seals

Special Tools Illustration Tool Name Tool Number Installer, Valve Stem Seal 303-370 (T90T-6571-A)

ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Hydraulic Lash Adjuster

ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Oil Pan

ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Cylinder Block Cradle

Special Tools Illustration Tool Name Tool Number Adapter for 303-290A 303-290-01 Adapter for 303-290A 303-290A-03A Lifting Bracket 303-050 (T70P-6000) Support Bar, Engine 303-290A

Scheme 40

Scheme 40: Cylinder Block Cradle

Scheme 41

Scheme 41
ItemSpecification
Motorcraft Metal Surface Prep ZC-31
Silicone Gasket and Sealant TA-30WSE-M4G323-A4
Silicone Gasket Remover ZC-30

Material

Scheme 42

Scheme 42
ItemPart NumberDescription
116C824Weatherstrip
2W503924Power steering fluid reservoir bolt
33R700Power steering fluid reservoir
4W709027Coolant expansion tank bolt (2 required)
58C045Coolant expansion tank
619972A/C tube

Scheme 43

Scheme 43
ItemPart NumberDescription
1W713417Upper cooling fan shroud bolt (2 required)
28K618Upper cooling fan shroud

Scheme 44

Scheme 44
ItemPart NumberDescription
1W500041Heater tube bracket front bolt
2N802330RH engine support insulator nut
3W708103LH engine support insulator through bolt

Scheme 45

Scheme 45
ItemPart NumberDescription
1W707472Stabilizer bar bracket bolt (4 required)
23B353Stabilizer bar bracket (2 required)
35D120Crossmember bolt (4 required)
45E138Crossmember

Scheme 46

Scheme 46
ItemPart NumberDescription
13B476Differential housing vent hose
2W506549Differential housing bolt (3 required)
3W706348Differential housing flag nuts (2 required)
4W708348Differential housing flag nut
53002Differential housing

Oil Pump

ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

  1. Remove the cylinder block cradle. For additional information, refer to «Cylinder Block Cradle»(ref-270889-S29023607702007110700000) .
  2. Remove the bolts and the oil pump. To install, tighten to 19 Nm (14 lb-ft).
  3. To install, reverse the removal procedure. Lubricate the oil pump with clean engine oil.

Oil Cooler

ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Scheme 47

Scheme 47
ItemPart NumberDescription
16714Oil filter
26N867Oil cooler inlet hose
384947Heater hose
4Oil cooler threaded insert (part of 6A642)
56A642Oil cooler

Oil Filter Adapter

ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Scheme 48

Scheme 48
ItemPart NumberDescription
16714Oil filter
26890Oil filter adapter threaded insert (vehicles without an oil cooler)
3Oil cooler threaded insert (part of 6A642) (oil cooler equipped vehicles only)
46A642Oil cooler (oil cooler equipped vehicles only)
56895Oil filter adapter bolt
6E853188Oil filter adapter bolt O-ring seal
76884Oil filter adapter
86L621Oil filter adapter gasket

Crankshaft Rear Seal

Special Tools Illustration Tool Name Tool Number Installer, Crankshaft Rear Oil Seal 303-579 (T97T-6701-A) Remover, Oil Seal 303-409 (T92C-6700-CH) Service Set, Crankshaft Rear Oil Seal 303-S524 (T95T-6701-AR)

Scheme 49

Scheme 49: Crankshaft Rear Seal

Scheme 50

Scheme 50
ItemSpecification
Motorcraft Metal Surface Prep ZC-31
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Scheme 51

Scheme 51
ItemPart NumberDescription
16A373Spacer plate
26434Flexplate-to-crankshaft spacer
36701Crankshaft rear seal

Engine Support Insulators

Special Tools Illustration Tool Name Tool Number Adapter for 303-290A 303-290-01 Adapter for 303-290A 303-290A-03A Lifting Bracket 303-050 (T70P-6000) Support Bar, Engine 303-290A

ItemPart NumberDescription
116C824Weatherstrip
2W503924Power steering fluid reservoir bolt
33R700Power steering fluid reservoir
4W709027Coolant expansion tank bolt (2 required)
58C045Coolant expansion tank
619972A/C tube
ItemPart NumberDescription
1W713417Upper cooling fan shroud bolt (2 required)
28K618Upper cooling fan shroud

Scheme 52

Scheme 52
ItemPart NumberDescription
13B476Differential housing vent hose
2W707472Stabilizer bar bracket bolt (4 required)
33B353Stabilizer bar bracket (2 required)
4W506549Differential housing bolt (3 required)
5W706348Differential housing flag nuts (2 required)
6W708348Differential housing flag nut
73010Differential housing

Scheme 53

Scheme 53
ItemPart NumberDescription
1388577Inner fender splash shield push pin (5 required)
216034Inner fender splash shield

Scheme 54

Scheme 54
ItemPart NumberDescription
1N802330LH engine support insulator nut
2W705694LH engine support insulator through bolt
36038BLH engine support insulator

Scheme 55

Scheme 55
ItemPart NumberDescription
1N802330RH engine support insulator lower nut
2N802653RH engine support insulator upper nuts (2 required)
36038ARH engine support insulator

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-581 (T97T-6565-A) Installer, Valve Stem Oil Seal 303-370 (T90T-6571-A)

ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Scheme 56

Scheme 56
ItemPart NumberDescription
112405Spark plugs
26529Camshaft roller follower
36C501Hydraulic lash adjuster
46518Valve spring retainer key (12 required)
56A536Valve spring retainer
66513Valve spring (6 required)
76571Valve seal (6 required)
86505Exhaust valve
96507Intake valve
10W702341Camshaft bearing cap mounting bolt (8 required)
116A258Camshaft bearing cap (4 required)
126A274LH camshaft
136050Cylinder head

Piston

Special Tools Illustration Tool Name Tool Number Service Set, Piston Pin 303-S024 (T68P-6135-A)

ItemSpecification
Motorcraft SAE 5W-30 Premium Synthetic Blend Motor Oil XO-5W30-QSP (US); Motorcraft SAE 5W-30 Super Premium Motor Oil CXO-5W30-LSP12 (Canada); or equivalentWSS-M2C929-A

Material

Scheme 57

Scheme 57
ItemPart NumberDescription
16150Piston compression upper ring
26152Piston compression lower ring
36159Piston oil control upper segment ring
46161Piston oil control spacer
56159Piston oil control lower segment ring
66135Piston pin
76200Connecting rod
86110Piston