Engine System - General Information: Other Ford Explorer V

Material(s)

MATERIAL(S)

General Procedure

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 810

1. Measure each camshaft bearing in 2 directions. Subtract the camshaft journal diameter from the camshaft bearing diameter.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 811

1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play.
2. Position the camshaft to the rear of the cylinder head.
3. Zero the Dial Indicator Gauge.
4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. If camshaft end play exceeds specifications, install a new camshaft and recheck end play. If camshaft end play exceeds specification after camshaft installation, install a new cylinder head.

Scheme 812

1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside the contact area.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 813

1. Use the Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift. Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial Indicator Gauge reading to figure the camshaft lobe lift.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Note. Camshaft journals must be within specifications before checking runout.

Scheme 814

1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft runout. Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial Indicator Gauge reading.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 815

Scheme 816

1. Use a telescoping gauge to determine the ID of the connecting rod bushing, if equipped.
2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Note. The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearance.

Scheme 817

Scheme 818

1. Remove the connecting rod bearing cap.
2. Position a piece of Plastigage across the bearing surface.
3. NOTE: Do not turn the crankshaft during this step. Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be smooth and flat. A changing width indicates a tapered or damaged connecting rod or connecting rod bearing.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 819

1. Measure the crankshaft connecting rod journal diameters in 2 directions perpendicular to one another at each end of the connecting rod journal. The difference in the measurements from one end to the other is the taper. Verify measurement is within the wear limit.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 820

1. Using the Feeler Gauge Set, measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 821

1. NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed on the original connecting rod in the original position. Do not reverse the cap. Parts are not interchangeable. Mark and separate the parts and clean with solvent. Clean the oil passages.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 822

1. Tighten the bolts to specification, then measure the bore in 2 directions. The difference is the connecting rod bore out-of-round. Verify the out-of-round is within specification.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 823

1. Using the Feeler Gauge Set, measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the measurement is within specification.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 824

1. Using the Feeler Gauge Set, measure the clearance between the connecting rod and the crankshaft. Verify the measurement is within specification.

Scheme 825

Scheme 826

Scheme 827

1. NOTE: Cylinder block core plug shown, cylinder head core plug similar. Use the Slide Hammer and a freeze plug remover to remove the core plug.
2. NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug. Inspect the core plug bore for any damage that would interfere with the correct sealing of the plug. If the core plug bore is damaged, bore for the next oversize plug.
3. NOTE: Use care during this procedure so as not to disturb or distort the cup sealing surface. NOTE: When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore If installing a cup-type core plug, coat the plug and bore lightly with sealant and install the core plug using a freeze plug installer.
4. NOTE: Do not contact the crown when installing an expansion-type core plug. This could expand the plug before seating and result in leakage. If installing a expansion-type core plug, coat the plug and bore lightly with sealant and install the core plug using a freeze plug installer.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 828

1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each end of the main bearing journal.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 829

Scheme 830

1. NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance. Remove the crankshaft main bearing caps and crankshaft main bearing.
2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface.
3. NOTE: Do not turn the crankshaft while carrying out this procedure. Install and remove the crankshaft main bearing cap.
4. Verify the crankshaft journal clearance.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 831

1. Install the Dial Indicator Gauge with Holding Fixture.
2. Position the crankshaft to the rear of the cylinder block.
3. Zero the Dial Indicator Gauge.
4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 832

1. NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.01 mm (0.0004 in) from end-to-end. Use a straightedge and a Feeler Gauge Set to inspect the cylinder block for flatness.

1. NOTE: If these procedures are not followed, rusting of the cylinder bores may occur. Clean the cylinder bores with soap or detergent and water.
2. Thoroughly rinse with clean water and wipe dry with a clean, lint-free cloth.
3. Use a clean, lint-free cloth and lubricate the cylinder bores. Use clean engine oil meeting Ford specification.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 833

1. Measure the cylinder bore in 2 directions. The difference is the out-of-round.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 834

1. Measure the cylinder bore at the top, middle and bottom of piston ring travel in 2 directions as indicated. Verify the cylinder bore is within the wear limit. The difference indicates the cylinder bore taper. Bore the cylinder to the next oversize limit if the cylinder bore is not within specification.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 835

1. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, silicone sealant, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check. NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if the Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.01 mm (0.0004 in) from end-to-end. Using a straightedge and a Feeler Gauge Set, inspect the cylinder head for flatness in the sequence shown.

Note. Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can occur.

Scheme 836

Scheme 837

1. Clean and inspect the (1) ring lands, (2) skirts, (3) pin bosses and the (4) tops of the pistons. If wear marks, scores or glazing is found on the piston skirt, check for a bent or twisted connecting rod.
2. Use the Piston Ring Groove Scraper to clean the piston ring grooves. Make sure the oil ring holes are clean.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 838

1. NOTE: Piston and piston pins are a matched set and should not be interchanged. Measure the piston pin bore diameter in 2 directions in the middle of each side as shown. Verify the diameter is within specification.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 839

1. Measure the piston diameter 90 degrees from the piston pin at the point indicated.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore clearance.

Note. The cylinder bore must be within the specifications for taper and out-of-round before fitting a piston.

1. For precision fit, new pistons come in single grade size only.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Note. Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore.

Note. Piston rings should not be transferred from one piston to another.

Note. The cylinder bore must be within specification for taper and out-of-round.

Scheme 840

Scheme 841

1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel.
2. Use the Feeler Gauge Set to measure the top piston ring end gap and the second piston ring end gap.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 842

Scheme 843

1. Inspect the piston for ring land damage or accelerated wear.
2. Using the Feeler Gauge Set, measure the piston ring-to-groove clearance.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 844

1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within specification.

Note. Refer to the appropriate engine mechanical service information and procedure for special instructions on loosening and tightening mount fasteners.

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. NOTE: Do not twist or strain the powertrain/drivetrain mounts or damage to the mounts may occur. Start the vehicle and move it in forward 0.6 m (1.97 ft) - 1.2 m (3.94 ft). Then move the vehicle in reverse the same distance.
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.

Scheme 845

Scheme 846

Scheme 847

Scheme 848

Scheme 849

Scheme 850

Scheme 851

1. Inspect the spark plug for a bridged gap. Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. Install a new spark plug.
2. Check for oil fouling. Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil entering the combustion chamber through worn rings and pistons, excessive valve-to-guide clearance or worn or loose bearings. Correct the oil leak concern. Install a new spark plug.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner, too rich a fuel mixture or excessive idling. Install new spark plugs.
4. Inspect for normal burning. Check for light tan or gray deposits on the firing tip.
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads. Install a new spark plug.
6. Inspect for overheating, identified by white or light gray spots and a bluish-burnt appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition timing. Install a new spark plug.
7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters. These are caused by sudden acceleration. Install a new spark plug.

Scheme 852

1. Inspect the sprockets for cracks and worn or chipped teeth.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 853

1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification.

Scheme 854

1. Inspect the following valve areas: The end of the stem for grooves or scoring. The valve face and the edge for pits, grooves or scores. The valve head for signs of burning, erosion, warpage and cracking. The valve margin for wear.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 855

Scheme 856

1. NOTE: Valve guides tend to wear in an hourglass pattern. The ball gauge can be inserted into the combustion chamber side of the valve guide, if necessary. Use a ball gauge to determine the inside diameter of the valve guides in 2 directions at the top, middle and bottom of the valve guide.
2. Measure the ball gauge with a micrometer.
3. If the valve guide is not within specifications, install a new cylinder head assembly.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Note. The valve stem diameter must be within specifications before checking valve stem-to-valve guide clearance. REFER to Valve Stem Diameter .

Scheme 857

1. NOTE: If necessary, use a magnetic base. Install a Valve Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve guide.
2. Move the Valve Guide Clearance Gauge toward the Dial Indicator Gauge with Holding Fixture and zero the Dial Indicator Gauge. Move the Valve Guide Clearance Gauge away from the Dial Indicator Gauge with Holding Fixture and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 858

1. Measure the installed length of each valve spring.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 859

1. Measure the free length of each valve spring.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 860

1. Measure the out-of-square on each valve spring. Turn the valve spring and observe the space between the top of the valve spring and the square. Install a new valve spring if out of square.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 861

1. Use the Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the specified valve spring length.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Note. After grinding valves or valve seats, always check valve clearance.

Scheme 862

1. Check the valve head and seat. Check valve angles. Check margin width. Be sure margin width is within specification.
2. Inspect for abnormalities on the valve face and seat. Install a new cylinder head assembly if abnormalities are found.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 863

1. Measure the valve seat width. If necessary, grind the valve seat to specification. Measure the intake valve seat width. Measure the exhaust valve seat width. Recheck the valve spring installed length after the seats have been ground, and shim the valve springs as necessary to achieve the correct installed spring length.

Note. For specifications refer to the appropriate engine mechanical article. For 2.0L GTDI, refer to the GENERAL SPECIFICATIONS , or for 3.5L Ti-VCT, refer to the GENERAL SPECIFICATIONS tables.

Scheme 864

1. Use a valve seat runout gauge to check valve seat runout.

Scheme 865

1. Inspect the valve tappet for damage, especially in the indicated areas. If any damage is evident, inspect the camshaft lobes and valves for damage. Install new components as necessary.