Engine Mechanical - 3.5L-TI-VCT: Other Ford Explorer V

Material(s)

MATERIAL(S)

Exhaust Emission Control System

Operation and required maintenance of the exhaust emission control devices used on this engine is are in ENGINE EMISSION CONTROL SYSTEM and EVAPORATIVE EMISSIONS SYSTEM article.

Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 6 solenoid operated fuel injectors

1. are mounted between the fuel rail and the intake manifold.
2. meter fuel into the air intake stream in accordance with engine demand.
3. are positioned so that their tips direct fuel just ahead of the engine intake valves.

Valve Train

The valve train uses DAMB. The camshaft lobes are positioned directly above mechanical buckets which are positioned on top of the valves.

Twin Independent VCT System

The twin independent VCT system allows variable control of intake valve closing which optimizes combustion at full load providing improved power and low speed torque (broadening the torque curve) which enables variable valve overlap which provides better fuel economy and emissions and provides optimized cold start operation with improved exhaust emissions.

PCV System

All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the upper intake manifold.

Oil Pump

The lubrication system is designed to provide optimum oil flow to critical components of the engine through its entire operating range.

The heart of the system is a positive displacement internal gear oil pump.

Generically, this design is known as a gerotor pump, which operates as follows

1. The oil pump is mounted on the front face of the cylinder block.
2. The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
3. System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump.
4. Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure both at hot idle and maximum speed.
5. The relief valve calibration protects the system from excessive pressure during high-viscosity conditions.
6. The relief valve is designed to provide adequate connecting rod bearing lubrication under high temperature and high-speed conditions.

Scheme 530

Cooling System

The engine cooling system includes the following

1. Radiator
2. Timing chain driven coolant pump
3. Electric fan assembly
4. Degas bottle (aids in maintaining the correct volume of engine coolant)
5. Coolant thermostat
6. Coolant hoses

Scheme 531

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Scheme 533

Scheme 534

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Remove the RH splash shield. REFER to «FENDER SPLASH SHIELD»(ref-517609-S36660239832012121200000) .
3. Remove the accessory drive belt. REFER to «ACCESSORY DRIVE»(ref-517567) .
4. Using 303-D055 (D85L-6000-A), remove the crankshaft pulley bolt and washer. Discard the bolt.
5. Using 303-D121 , remove the crankshaft pulley.

Scheme 535

Scheme 536

1. Lubricate the crankshaft front seal inner lip with clean engine oil.
2. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil. Using 303-102 (T74P-6316-B) and 303-335 (T88T-6701-A), install the crankshaft pulley.
3. Using 303-D055 (D85L-6000-A), install the crankshaft pulley washer and new bolt and tighten in 4 stages. Stage 1: Tighten to 120 Nm (89 lb-ft). Stage 2: Loosen one full turn. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees.
4. Install the accessory drive belt. REFER to «ACCESSORY DRIVE»(ref-517567) .
5. Install the RH splash shield. REFER to «FENDER SPLASH SHIELD»(ref-517609-S36660239832012121200000) .

Scheme 537

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Remove the crankshaft pulley. REFER to «Crankshaft Pulley»(ref-517529-S41000692492012121200000) .
3. Using 303-409 (T92C-6700-CH), remove and discard the crankshaft front seal.
4. Inspect the crankshaft seal bore in the front cover for any damage or casting imperfections that may effect the crank seal outer diameter sealing. Repair/replace as necessary.

Scheme 538

1. Clean all sealing surfaces with Motorcraft® Metal Surface Prep.
2. NOTE: Apply clean Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada) to the crankshaft front seal bore in the engine front cover. Using 303-1251 and 303-102 (T74P-6316-B), install a new crankshaft front seal.
3. NOTE: Do not use grease on seal or pulley hub as this may result in premature seal failure. NOTE: Apply clean Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada) to the crankshaft front seal contact surface. Install the crankshaft pulley. REFER to «Crankshaft Pulley»(ref-517529-S41000692492012121200000) .

Scheme 539

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Scheme 541

1. 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, may cause engine failure. Depending on the valve tappets being serviced, remove the LH and/or the RH camshafts. REFER to «Camshaft»(ref-517529-S40155488572012121200000) .
2. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Remove the valve tappets from the cylinder head.

Scheme 542

Scheme 543

1. Remove the RH catalytic converter. REFER to «CATALYTIC CONVERTER - RH, FWD»(ref-517548-S23530022892012121200000) , or REFER to «CATALYTIC CONVERTER - RH, AWD»(ref-517548-S18883039122012121200000) .
2. Disconnect the RH HO2S electrical connector.
3. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and gasket.
4. Clean and inspect the RH exhaust manifold. REFER to «EXHAUST MANIFOLD CLEANING AND INSPECTION»(ref-517560-S28842392022012121200000) .
5. Remove and discard the 6 RH exhaust manifold studs.
6. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. Clean the exhaust manifold mating surface of the cylinder head with Motorcraft® Metal Surface Prep. Follow the directions on the packaging.

Scheme 544

Exploded View

Note. Oil filter adapter with oil cooler shown in illustration, Oil filter adapter without oil cooler similar.

Scheme 545

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Scheme 547

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Remove and discard the engine oil filter.
3. If equipped, remove the oil cooler. REFER to «Oil Cooler»(ref-517529-S10212333682012121200000) .
4. NOTE: Oil filter adapter with oil cooler shown in illustration, oil filter adapter without oil cooler similar. Remove the 3 oil filter adapter bolts and the oil filter adapter. Discard the gasket.

Scheme 548

1. NOTE: Clean and inspect all sealing surfaces. NOTE: Oil filter adapter with oil cooler shown in illustration, oil filter adapter without oil cooler similar. Using a new gasket, install the oil filter adapter and the 3 oil filter adapter bolts. Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.
2. If equipped, install the oil cooler. REFER to «Oil Cooler»(ref-517529-S10212333682012121200000) .
3. NOTE: Do not lubricate the engine oil filter gasket. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.

Oil Cooler

Scheme 549

Scheme 550

Scheme 551

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Using hose clamp pliers, clamp the 2 oil cooler coolant hoses and remove the 2 coolant hoses from the oil cooler.
3. Remove the oil filter and discard.
4. NOTE: If metal or aluminum is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may result in engine failure. To diagnose mechanical concerns, REFER to «SYMPTOM CHART(S)»(ref-517560-S28288183012012121200000) . Remove the 6 bolts and the oil cooler.
5. Discard the oil cooler gasket and inspect the oil cooler. Clean and inspect all sealing surfaces.

Scheme 552

Scheme 553

1. Using new gaskets, install the oil cooler and the 6 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
2. Install the 2 coolant hoses to the oil cooler. Remove the 2 hose clamp pliers.
3. NOTE: Do not lubricate the engine oil filter gasket. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in), then turn an additional 180 degrees.

Scheme 554

Scheme 555

Scheme 556

1. If equipped, remove the engine oil cooler. REFER to «Oil Cooler»(ref-517529-S10212333682012121200000) .
2. Disconnect the EOP switch electrical connector.
3. Remove the EOP switch.

Scheme 557

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Scheme 561

1. Remove the piston rings from the piston. Discard the piston rings.
2. Remove the 2 piston pin retainers and the piston pin. Discard the 2 piston pin retainer clips.
3. 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 for reassembly. Separate the piston from the connecting rod. Clean and inspect the piston and connecting rod. REFER to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-517560) .

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Scheme 566

1. NOTE: If the piston and/or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block. Align the piston-to-connecting rod orientation marks and position the connecting rod in the piston.
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 new piston pin retaining clips in the piston. The piston pin retaining clip gap orientation must be toward the top or dome of piston.
4. NOTE: Lubricate the piston and the new piston rings with clean engine oil. Install the piston rings on the piston.
5. NOTE: The piston compression upper and lower ring should be installed with the "O" mark on the ring face pointing up toward the top of the piston. Install the piston rings onto the piston as shown in illustration. Center line of the piston parallel to the wrist pin bore Upper compression ring gap location Upper oil control segment ring gap location Lower oil control segment ring gap location Expander ring and lower compression ring gap location