Engine Mechanical - 2.0L-GTDI: Overhaul Ford Explorer V

Disassembly

1. NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

Assembly

1. NOTE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure. NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement.

Scheme 660

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

Note. Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

Note. If the components are to be reinstalled, mark the location of the components removed, they must be installed in the same location.

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1. NOTE: RH shown in illustration, LH similar. Remove the 2 bolts and the LH and RH engine lift eyes.
2. Remove the 3 bolts and the coolant outlet and gasket.
3. Remove and discard the CHT sensor.
4. Using the 303-300 (T87C-6565-A), the 303-350 (T89P-6565-A), the 303-472 (T94P-6565-AH) and the 303-1249 compress the valve spring and remove the valve collet, using some multi-purpose grease and a small screwdriver. Remove the valve spring retainer and the valve spring. Inspect the valve springs.
5. Remove and discard the valve seal. Position the 303-468 (T94P-6510-AH) and 307-005 (T59L-100-B) over the seal. Pull up on the 307-005 (T59L-100-B) and 303-468 (T94P-6510-AH) and remove the seal.
6. NOTE: Mark each valve location if the original valves are to be used. Remove the valves. Inspect the valves. REFER to «VALVE INSPECTION»(ref-517560-S10776731472012121200000) .

Scheme 666

1. NOTE: If installing the original valves, make sure the valves are installed in the same position from which they were removed. Coat the valve stems with clean engine oil and install the valves.
2. NOTE: Lubricate the valve seal with clean engine oil prior to installing. Using the 303-470 (T94P-6510-CH), install the valve seal.
3. NOTE: Check the seating of the valve collet. Install the valve spring and the valve spring retainer. Using the 303-300 (T87C-6565-A), the 303-350 (T89P-6565-A), the 303-472 (T94P-6565-AH) and the 303-1249 compress the valve spring and install the valve collet using some grease and a small screwdriver.
4. Install a new CHT sensor. Tighten to 11 Nm (97 lb-in).
5. Inspect the gasket and replace if necessary.
6. Install the gasket, coolant outlet and the 3 bolts. Tighten to 10 Nm (89 lb-in).
7. NOTE: RH shown in illustration, LH similar. Install the LH and RH engine lift eyes and the 2 bolts. Tighten to 47 Nm (35 lb-ft).

Note. If the piston and connecting rod are to be reinstalled, they must be assembled in the same orientation. Mark the piston orientation to the connecting rod reassembly.

Scheme 667

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1. Remove and discard the piston rings.
2. Remove and discard the 2 piston pin retainers.
3. Separate the piston from the connecting rod. Clean and inspect the piston and connecting rod. REFER to «CONNECTING ROD CLEANING»(ref-517560-S38645828962012121200000) .

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1. Align the piston-to-connecting rod orientation marks and position the piston on the connecting rod.
2. NOTE: Lubricate the piston pin and pin bore with clean engine oil. Install the piston pin in the piston and connecting rod assembly.
3. Install the 2 new piston pin retainers in the piston.
4. NOTE: Lubricate the piston and the new piston rings with clean engine oil. Install the piston rings on the piston.
5. Align the piston rings on the piston. Upper oil control segment ring gap location Oil control spacer gap location Lower oil control segment ring gap location