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

DISASSEMBLY

1. Remove the spark plugs.
2. Remove the hydraulic lash adjusters.
3. Using the special tool, remove the valve spring retainer keys, the valve spring and the retainer. Remove the valve. Repeat the procedure until all of the valves are removed.
4. Remove and discard the valve seals.
5. Remove the bolts in the sequence shown and remove the camshaft bearing caps.
6. Remove the camshaft.

ASSEMBLY

Note. Lubricate all parts with clean engine oil prior to assembly.

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

1. Inspect the cylinder head. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-270909) .
2. Position the camshaft.
3. Position the camshaft bearing caps and the bolts. Tighten the bolts in the sequence shown in 2 stages. Stage 1: Tighten to 6 Nm (53 lb-in). Stage 2: Tighten to 16 Nm (12 lb-ft).
4. Install the valve.
5. Using the special tool, install new valve stem seals.
6. Using the special tool, install the valve spring, the retainer and the retainer keys.
7. Install the hydraulic lash adjusters.

Note. The connecting rod bolts and nuts cannot be reused.

Note. Mark the position of the parts, so they can be installed in their original positions.

1. Remove the connecting rod bearings from the connecting rod and cap.
2. Remove the piston rings from the piston.
3. Using the special tool, press the piston pin out of the connecting rod and piston assembly.

Note. Lubricate all parts with clean engine oil.

Note. Install the piston in the connecting rod with the cylinder number side of the rod and the indentation notch in the piston on the same side.

Note. The oil hole in the connecting rod must face the RH side of the cylinder block and the arrow on the piston must face the front of the engine block.

1. 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.
2. Using the special tool, press the piston pin into the piston and connecting rod assembly.
3. Install the piston rings.
4. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.
5. Install the connecting rod bearings in the connecting rod and cap.

Special Tools Illustration Tool Name Tool Number Adapter for 303-564 303-578 (T97T-6256-A) Adapter for 303-577 303-576 (T97T-6256-D) Aligner, Front Cover 303-093 (T74P-6019-A) Compressor, Piston Ring 303-D032 (D81L-6002-C) Compressor, Valve Spring 303-581 (T97T-6565-A) Crankshaft Socket 303-674 Holding Tool, Camshaft 303-577 (T97T-6256-C) Holding Tool, Camshaft Sprocket 303-564 (T97T-6256-B) Installer, Crankshaft Rear Oil Seal 303-579 (T97T-6701-A) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Lifting Eyes 303-050 Service Set, Crankshaft Rear Oil Seal 303-S524 (T95T-6701-AR) Strap Wrench 303-D055 (85L-6000-A) or equivalent Tensioner, Timing Chain 303-571 (T97T-6K254-A) Timing Tool, Crankshaft TDC 303-573 (T97T-6303-A)

Scheme 12

Material

Scheme 13

Scheme 14

Note. During engine assembly it may be necessary to check the bearing clearances and crankshaft end play. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

Note. Before engine assembly, use silicone gasket remover and metal surface prep and a suitable plastic or wooden scraper to clean the sealing surfaces. Follow the directions on the packaging. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.

1. Install the crankshaft main bearings and the thrust bearing. Lubricate the crankshaft main bearings with clean engine oil.
2. Install the lower main bearings in the bearing caps.
3. Install the crankshaft.
4. Apply silicone gasket and sealant to the rear main bearing cap to cylinder block parting line.
5. Install the main bearing caps in the same position from which they were removed.
6. Tighten the bolts. Tighten to 97 Nm (72 lb-ft).
7. Check the piston to cylinder bore and ring clearance. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-270909) .
8. Install the piston rings.
9. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.
10. Install the connecting rod bearings.
11. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.
12. Using the special tool, install the pistons. Rotate the crankshaft as necessary.
13. Check the clearance of each connecting rod bearing. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-270909) .
14. Rotate the crankshaft until the piston is at the bottom of its stroke.
15. Loosen the first nut until the face is approximately 2 mm (0.08 in) over the end of the bolt.
16. Tap on the nut until the bolt can be removed by hand.
17. Repeat the previous 2 steps for the opposite bolt.
18. Install the new bolts, making certain that the bolt head is parallel to the sideward face of the connecting rod.
19. Install the connecting rod cap in the original position.
20. Install and tighten the connecting rod nuts finger-tight.
21. Tighten the connecting rod nuts in 2 stages: Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
22. Repeat the previous 4 steps for the remaining connecting rods.
23. Rotate the crankshaft until the No. 1 piston is at top dead center (TDC).
24. Install the balance shaft. Install the balance shaft assembly. Install the bolts. Tighten to 29 Nm (21 lb-ft).
25. Align the timing marks. Install a 4 mm (0.16 in) pin to hold the shaft in place.
26. Install the balance shaft chain and crankshaft sprocket.
27. Install the balance shaft tensioner and chain guide. Install the balance shaft tensioner. Install the bolts and tighten to 29 Nm (21 lb-ft). Position the balance shaft chain guide, install the 2 bolts and tighten to 10 Nm (89 lb-in). Remove the pins from the tensioner and the sprocket. Install the crankshaft key.
28. Install the oil pump intermediate shaft, the oil pump and the bolt. Tighten to 19 Nm (14 lb-ft).
29. Install the jackshaft.
30. Install the jackshaft thrust plate and bolts. Tighten to 11 Nm (8 lb-ft).
31. Install the front cassette and bolt. Tighten to 19 Nm (14 lb-ft).
32. Position the jackshaft, the crankshaft sprockets and the chain.
33. Install the chain guide and the bolts. Tighten to 19 Nm (14 lb-ft).
34. Install the jackshaft chain tensioner and the bolts. Tighten to 9 Nm (80 lb-in).
35. Using the special tool, hold the crankshaft.
36. Install the jackshaft front bolt and tighten in 2 stages. Stage 1: Tighten to 45 Nm (33 lb-ft). Stage 2: Tighten an additional 90 degrees.
37. Install the oil pump drive and the bolt. Tighten to 19 Nm (14 lb-in).
38. Install the RH cassette and sprocket to the jackshaft. Install, but do not tighten the bolt at this time.
39. Install the RH cassette bolt. Tighten to 19 Nm (14 lb-ft).
40. Using the special tool, hold the crankshaft.
41. Tighten the rear jackshaft bolt in 2 stages. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees.
42. Install the rear jackshaft plug.
43. Position the front cover gasket, the front cover and loosely install the bolts.
44. Install the special tool and tighten the front cover bolts. Tighten to 19 Nm (14 lb-ft).
45. Using the special tools, install the crankshaft front oil seal.
46. Loosen the cylinder block cradle inserts.
47. Apply silicone gasket and sealant to the front cover in 4 places.
48. Apply silicone gasket and sealant to the rear main bearing cap as shown. Position the cylinder block cradle gasket.
49. Position the cylinder block cradle and gasket assembly.
50. Install and finger-tighten the 20 bolts and 2 nuts.
51. Install and finger-tighten the Torx bolts.
52. Using a straightedge, align the transmission face of the cylinder block cradle with the rear face of the cylinder block.
53. Tighten the 20 bolts and the 2 nuts. Tighten the nuts to 10 Nm (89 lb-in). Tighten the bolts to 14 Nm (10 lb-ft).
54. Tighten the Torx bolts. Tighten to 8 Nm (71 lb-in).
55. Tighten the inserts. Tighten to 3 Nm (27 lb-in).
56. Install new seals on the 2 silver bolts and position them in the cylinder block cradle.
57. Position the 6 remaining bolts.
58. Tighten the cylinder block cradle inner bolts in the sequence shown in 2 stages. Stage 1: Tighten to 15 Nm (11 lb-ft). Stage 2: Tighten to 34 Nm (25 lb-ft).
59. Measure the step between the rear face of the cylinder block and the transmission face of the cylinder block cradle. Cradles that exceed protrusion specification must be removed and the appropriate assembly steps repeated. Cradles that exceed the under flush specification may be repaired by installing shims (next step).
60. Repair all assemblies that exceed under flush specification by installing shims on one or both sides of the cylinder block cradle.
61. Install the oil pump screen cover and tube and the bolt. Tighten to 10 Nm (89 lb-in).
62. Install the gasket, the oil pan and the bolts. Tighten to 11 Nm (8 lb-ft).
63. Install the oil filter adapter and the bolt. Tighten to 57 Nm (42 lb-ft).
64. Install the coolant pump and the bolts. Tighten to 10 Nm (89 lb-in).
65. Install the cylinder head gaskets.
66. Install the LH cylinder head and tighten the new bolts in the sequence shown in 2 stages. Stage 1: Tighten to 12 Nm (9 lb-ft). Stage 2: Tighten to 25 Nm (18 lb-ft).
67. Install the two 8-mm bolts. Tighten to 32 Nm (24 lb-ft).
68. Tighten the bolts in the sequence shown in 2 stages. Stage 1: Rotate 90 degrees. Stage 2: Rotate an additional 90 degrees.
69. Install the RH cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages. Stage 1: Tighten to 12 Nm (9 lb-ft). Stage 2: Tighten to 25 Nm (18 lb-ft).
70. Install 2 new 8-mm bolts. Tighten to 32 Nm (24 lb-ft).
71. Tighten the eight 12-mm bolts in the sequence shown in 2 stages. Stage 1: Rotate 90 degrees. Stage 2: Rotate an additional 90 degrees.
72. Using the special tool, install the crankshaft pulley.
73. Using the special tool, tighten the bolt in 2 stages. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Rotate an additional 90 degrees.
74. Install the coolant pump pulley and the bolts. Tighten to 25 Nm (18 lb-ft).
75. Loosely install the RH camshaft sprocket bolt.
76. Install the bolt. Tighten to 10 Nm (89 lb-in).
77. Loosely install the LH camshaft sprocket bolt.
78. Install the bolt. Tighten to 12 Nm (9 lb-ft).
79. Turn the crankshaft one revolution clockwise.
80. Install the special tool.
81. Install the special tools on the front of the RH cylinder head.
82. Install the special tools on the rear of the RH cylinder head.
83. Install the special tool.
84. Tighten the bolts. Tighten the special tool top 2 clamp bolts to 10 Nm (89 lb-in). Tighten the camshaft bolt to 85 Nm (63 lb-ft).
85. Remove the special tool and install the RH camshaft tensioner. Tighten to 44 Nm (32 lb-ft).
86. Install the special tools on the front of the LH cylinder head.
87. Install the special tools on the front of the LH cylinder head.
88. Install the special tool.
89. Tighten the bolts. Tighten the special tool top 2 clamp bolts to 10 Nm (89 lb-in). Tighten the camshaft bolt to 85 Nm (63 lb-ft).
90. Install the LH camshaft tensioner. Tighten to 44 Nm (32 lb-ft).
91. Rotate the crankshaft until the cam lobe is in the up position.
92. Using the special tool, install the roller followers in their original positions.
93. Inspect the RH and LH exhaust manifold gasket mating surfaces for flatness. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-270909) .
94. Install 6 new RH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
95. Install a new gasket, the RH exhaust manifold and the new nuts. Tighten to 22 Nm (16 lb-ft).
96. Install 6 new LH exhaust manifold studs. Tighten to 12 Nm (9 lb-ft).
97. Install a new gasket, the LH exhaust manifold and the new nuts. Tighten to 22 Nm (16 lb-ft).
98. Install the knock sensor (KS) and the bolt. Tighten to 20 Nm (15 lb-ft).
99. Install the oil level indicator tube and bolt.
100. Position the thermostat housing and bypass hose on the coolant pump. Install the bolts. Tighten to 11 Nm (8 lb-ft). Position the bypass hose clamp.
101. Install the valve covers and tighten the bolts. Tighten to 10 Nm (89 lb-in).
102. Install new O-ring seals on each of the fuel injectors.
103. Install the fuel injectors.
104. Install the fuel rail and the bolts. Tighten to 24 Nm (18 lb-ft).
105. Position the fuel supply tube and install the bolt. Tighten to 6 Nm (53 lb-in).
106. Install the LH and RH insulator brackets and the bolts. Tighten to 80 Nm (59 lb-ft).
107. Install the oil pressure switch. Tighten to 13 Nm (10 lb-ft).
108. Position the battery cable and harness and attach the retainers.
109. Connect the oil pressure switch electrical connector. Position the battery cable and harness bracket and install the nut. Tighten to 20 Nm (15 lb-ft).
110. Position the vacuum harness on the engine and connect the fuel pressure and temperature sensor vacuum hose fittings.
111. Position the engine wiring harness on the engine.
112. Position the engine wiring harness retainer and install the bolt. Tighten to 47 Nm (35 lb-ft).
113. Connect the engine coolant temperature (ECT) sensor electrical connector.
114. Connect the fuel rail pressure and temperature sensor and the camshaft position (CMP) sensor electrical connector.
115. Connect the crankshaft position (CKP) sensor electrical connectors and new wiring anchors.
116. Connect the 6 fuel injector electrical connectors and attach the wiring harness retainers.
117. Install the gaskets, the intake manifold and the bolts. Tighten to 11 Nm (8 lb-ft).
118. Install the exhaust manifold-to-EGR system module tube. Tighten to 34 Nm (25 lb-ft).
119. Connect the electronic throttle body (TB) and throttle position (TP) sensor electrical connectors. Attach the wiring harness bracket and install the nut. Tighten to 9 Nm (80 lb-in).
120. Connect the EGR system module vacuum hose and electrical connector. Attach the wiring harness pin-type retainer.
121. Attach the wiring harness pin-type retainer and connect the KS electrical connector.
122. Connect the vacuum and PCV hoses to the intake manifold.
123. Install the oil cooler and hose. Tighten to 57 Nm (42 lb-ft).
124. Connect the oil cooler hose. Position the oil cooler hose bracket and install the bolt. Tighten to 25 Nm (18 lb-ft).
125. Position the ignition coil, bracket and spark plug wires as an assembly and install the bolts. Tighten to 10 Nm (89 lb-in).
126. Attach the wiring harness retainer and connect the coil and radio interference capacitor electrical connectors.
127. Attach the LH spark plug wire retainers and connect the LH spark plug wires to the spark plugs.
128. Attach the RH spark plug wire retainers and connect the RH spark plug wires to the spark plugs.
129. Position the heater hose tube bracket and the hoses as an assembly and install the bolt. Tighten to 23 Nm (17 lb-ft).
130. Connect the hose to the oil cooler.
131. Connect the heater hose to the thermostat housing.
132. Install the generator mounting bracket. Install the generator mounting bracket bolts. Tighten to 42 Nm (31 lb-ft). Install the drive belt tensioner and bolt. Tighten to 47 Nm (35 lb-ft).
133. Connect the generator electrical connections and the wire harness retainer. Tighten to 9 Nm (80 lb-in).
134. Install the accessory bracket and the bolts. Tighten to 42 Nm (31 lb-ft).
135. Connect the A/C compressor electrical connector and wire harness retainer.
136. Install the bolt. Tighten to 10 Nm (89 lb-in).
137. Install the right side lifting bracket. Tighten to 37 Nm (27 lb-ft).
138. Install the left side lifting bracket.
139. Using the special tool and a floor crane, remove the engine from the engine stand.
140. Lubricate the crankshaft rear oil seal with engine oil.
141. Install the special tools.
142. Position the crankshaft rear seal.
143. Using the special tool, install the crankshaft rear oil seal.
144. Install the spacer plate.
145. Install the flexplate-to-crankshaft spacer.
146. Install the flexplate. Tighten the bolts in the sequence shown in 3 stages. Stage 1: Tighten to 13 Nm (10 lb-ft). Stage 2: Tighten to 50 Nm (37 lb-ft). Stage 3: Tighten an additional 90 degrees.

Special Tools Illustration Tool Name Tool Number Lifting Brackets 303-050 (T70P-6000) or equivalent Spreader Bar 303-D701 or equivalent

Material