Ford repair professionals: Cylinder head removal on ford explorer?

Cylinder Head 1

Removal & Installation

4.0L Engine
OHV Engine
VIN X

NOTE

New cylinder head bolts must be used when installing the cylinder head on the 4.0L OHV engine.

Before servicing the vehicle, refer to the Precautions section.

Relieve the fuel system pressure.

Evacuate the A/C system.

Drain the cooling system.

Drain the engine oil.

Remove or disconnect the following:

Negative battery cable
Drive belt
Separate the A/C manifold tube from the A/C compressor
A/C compressor electrical connectors
A/C compressor mounting bracket and move it aside
Alternator electrical connectors
Heater hose and move it aside
Alternator mounting bracket
Lower intake manifold
Both exhaust manifolds

Gradually loosen the rocker arm shafts and remove them.

Matchmark the position of the push rods and remove them
Cylinder head and gasket

To install:

Clean the mating surface where the cylinder head attaches to the engine.

Install a new cylinder head gasket and the cylinder head to the engine.

Fig. Cylinder head bolt torque sequence 4.0L OHV engine

Torque the new cylinder head bolts in sequence, as follows:
1. Step 1: 25 ft. lbs. (34 Nm).
2. Step 2: 53 ft. lbs. (72 Nm).
3. Step 3: Plus an additional 90 degrees.

Install or connect the following:

Push rods
Rocker arm shafts gradually. Torque the bolts to 24 ft lbs. (33 Nm) plus an additional 90 degrees
Exhaust manifolds
Lower intake manifold
Alternator bracket. Torque the bolts to 35 ft. lbs. (47 Nm).
Heater hose retaining clip
Alternator electrical connectors
A/C compressor mounting bracket. Torque the bolts to 35 ft. lbs. (47 Nm).
A/C compressor electrical connectors
A/C manifold tube to the A/C compressor
Drive belt
Negative battery cable

Fill the cooling system.

Fill the engine with clean oil. A filter replacement is also recommended.

Recharge the A/C system.
NOTE
When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven about 10 miles (16 km) or more to relearn the strategy.

Start the engine and check for leaks.

VIN E SOHC Engine

NOTE

If only one cylinder head is to be removed, only follow the procedures that apply. The following tools, or their equivalents are absolutely necessary to properly perform this procedure:

Cam Chain Tensioner tool T97T-6K254-A

Cam Gear Removal tool T97T-6256-F

Cam Gear Torque adapter T97T-6256-G

Camshaft Gear Positioning/Holding tool T97T-6256-B

Camshaft Gear Positioning/Holding tool adapter T97T-6256-A

Camshaft holding tool T97T-6256-C

Crankshaft holding tool T97T-6303-A

Camshaft holding tool adapter T97T-6256-D

Before servicing the vehicle, please familiarize yourself with safety procedures.

Properly relieve the fuel system pressure.

Drain the cooling system.

Remove or disconnect the following:

Negative battery cable
Lower intake manifold
Fan blade and shroud
Valve cover
Roller followers, if equipped
Drive belt
Upper radiator hose and tube
Alternator electrical connectors
Alternator mounting bracket
Engine accessory bracket and move it aside
Camshaft Position (CMP) electrical connector
Crankshaft Position (CKP) sensor electrical connector
Engine Coolant Temperature (ECT) sensor electrical connector
Coil pack electrical connector
Exhaust Gas Recirculation (EGR) valve electrical connector
EGR valve bracket and move it aside
Heater hoses
Fuel injector electrical connectors
Water bypass hose
Thermostat housing
Spark plug wires
Fuel injection supply manifold
Fuel injectors
Crankcase vent separator spring
Oil dipstick housing
Exhaust manifold
Hydraulic chain tensioner
Cassette retaining bolt
Camshaft sprocket
Cylinder head and discard the gasket

To install:

Fig. The correct cylinder head bolt loosening sequence must be used to prevent warpage-2000-04 4.0L SOHC engine

Thoroughly clean all gasket mating surfaces. Remove all traces of old gasket material, oil, grease or dirt.

Insure that the rubber band is holding the right-hand chain to the cassette.

Install a new head gasket and the cylinder head.

Fig. Cylinder head bolt torque sequence-2000-04 4.0L SOHC engine

Torque the new cylinder head bolts in sequence as follows:

2002

Step 1: 24 ft. lbs. (32 Nm).

Step 2: Plus 90 degrees.

Install or connect the following:

Camshaft sprocket in the cassette and make certain that the camshaft sprocket turns freely on the camshaft
Cassette retaining bolt. Torque the bolt to 89 inch lbs. (10 Nm).
Exhaust manifold
Oil level indicator tube. Torque the bolt to 18 ft. lbs. (25 Nm).
Crankcase vent separator and spring
Thermostat housing. Torque the bolts to 8 ft. lbs. (11 Nm).
Water bypass hose
Heater hoses
EGR bracket. Torque the bolt to 89 inch lbs. (10 Nm).
EGR tube. Torque the nut to 30 ft. lbs. (40 Nm).
ECT sensor electrical connector
Electrical harness retainer. Torque the bolt to 89 inch lbs. (10 Nm).
CKP and CMP electrical connectors
Accessory bracket. Torque the bolts to 31 ft. lbs. (42 Nm).
Alternator mounting bracket. Torque the bolts to 31 ft. lbs. (42 Nm).
Alternator and electrical connectors
Drive belt
Fan shroud
Roller followers
Valve cover
Lower intake manifold
Negative battery cable

Change the engine oil and filter.

Refill the cooling system.

Start the engine and check for leaks, repair if necessary.

NOTE

If only one cylinder head is to be removed, only follow the procedures that apply. The following tools, or their equivalents are absolutely necessary to properly perform this procedure:

Cam Chain Tensioner tool T97T-6K254-A

Cam Gear Removal tool T97T-6256-F

Cam Gear Torque adapter T97T-6256-G

Camshaft Gear Positioning/Holding tool T97T-6256-B

Camshaft Gear Positioning/Holding tool adapter T97T-6256-A

Camshaft holding tool T97T-6256-C

Crankshaft holding tool T97T-6303-A

Camshaft holding tool adapter T97T-6256-D

Before servicing the vehicle, refer to the precautions in the beginning of this section.

Properly relieve the fuel system pressure.

Drain the cooling system.

Remove or disconnect the following:

Negative battery cable
Lower intake manifold
Fan blade and shroud
Valve cover
Roller followers, if equipped
Drive belt
Upper radiator hose and tube
Alternator electrical connectors
Alternator mounting bracket
Engine accessory bracket and move it aside
Camshaft Position (CMP) electrical connector
Crankshaft Position (CKP) sensor electrical connector
Engine Coolant Temperature (ECT) sensor electrical connector
Coil pack electrical connector
Exhaust Gas Recirculation (EGR) valve electrical connector
EGR valve bracket and move it aside
Heater hoses
Fuel injector electrical connectors
Water bypass hose
Thermostat housing
Spark plug wires
Fuel injection supply manifold
Fuel injectors
Crankcase vent separator spring
Oil dipstick housing
Exhaust manifold
Hydraulic chain tensioner
Cassette retaining bolt
Camshaft sprocket
Cylinder head and discard the gasket

To install:

Fig. The correct cylinder head bolt loosening sequence must be used to prevent warpage-4.0L SOHC engine

Thoroughly clean all gasket mating surfaces. Remove all traces of old gasket material, oil, grease or dirt.

Insure that the rubber band is holding the right-hand chain to the cassette.

Install a new head gasket and the cylinder head.

Fig. Cylinder head bolt torque sequence 4.0L SOHC engine

Torque the new cylinder head bolts in sequence as follows:

1998-99

Step 1: 26 ft. lbs. (34 Nm).

Step 2: Plus 90 degrees.

Step 3: Plus an additional 90 degrees.

2000-01

Step 1: 28 ft. lbs. (38 Nm).

Step 2: Plus 90 degrees.

Step 3: Plus an additional 90 degrees.

2002

Step 1: 24 ft. lbs. (32 Nm).

Step 2: Plus 90 degrees.

Install or connect the following:

Camshaft sprocket in the cassette and make certain that the camshaft sprocket turns freely on the camshaft
Cassette retaining bolt. Torque the bolt to 89 inch lbs. (10 Nm).
Exhaust manifold
Oil level indicator tube. Torque the bolt to 18 ft. lbs. (25 Nm).
Crankcase vent separator and spring
Thermostat housing. Torque the bolts to 8 ft. lbs. (11 Nm).
Water bypass hose
Heater hoses
EGR bracket. Torque the bolt to 89 inch lbs. (10 Nm).
EGR tube. Torque the nut to 30 ft. lbs. (40 Nm).
ECT sensor electrical connector
Electrical harness retainer. Torque the bolt to 89 inch lbs. (10 Nm).
CKP and CMP electrical connectors
Accessory bracket. Torque the bolts to 31 ft. lbs. (42 Nm).
Alternator mounting bracket. Torque the bolts to 31 ft. lbs. (42 Nm).
Alternator and electrical connectors
Drive belt
Fan shroud
Roller followers
Valve cover
Lower intake manifold
Negative battery cable

Change the engine oil and filter.

Refill the cooling system.

Start the engine and check for leaks, repair if necessary.

Before servicing the vehicle, refer to the -Precautions- section.

Disconnect the battery ground cable.

With the vehicle in NEUTRAL, position it on a hoist.

Drain the engine cooling system.

Remove the camshaft roller followers.

Remove the accessory drive belt tensioner.

On the right side:
1. Disconnect the alternator electrical connections and disconnect the pushpin.
2. Remove the alternator mounting bracket assembly.
3. Remove the heater hose from the thermostat housing.
4. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
5. Disconnect the upper radiator hose.
6. Position the coolant bypass hose clamp aside.
7. Remove the bolts and the thermostat housing.
8. Remove the engine wiring harness bolts and position the engine wiring harness aside.
9. Remove the engine ground strap.

On the left side:
1. Disconnect the radio ignition interference capacitor electrical connector.
2. Remove the bolts.
3. Remove the bolts and position the accessory bracket aside.
4. Remove the bolts and the coil bracket.
5. Remove the oil level indicator tube.
  WARNING
  It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.

Disconnect all of the spark plug wires from the spark plugs.

Fig. These special tools are necessary for cylinder head removal and installation-2005 4.0L engine

Remove the engine noise shield.

Remove the 4 catalytic converter-to-manifold nuts.

Remove both of the exhaust manifolds and gaskets.

Discard the gaskets and the retaining nuts.

On the right side:
1. Remove the right side hydraulic chain tensioner.
2. Install the special tools. Tighten to 89 inch lbs. (10 Nm).
3. Using the special tool with the Camshaft Sprocket Nut Socket 303-565, remove the right camshaft bolt.
4. Remove the right side cassette bolt.
  WARNING
  Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.
  
  NOTE
  Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.
5. Remove the right camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.

On the left side:
1. Remove the left side hydraulic chain tensioner.
2. Install the special tools. Tighten the top clamp bolts to 89 inch lbs. (10 Nm).
3. Remove the left side camshaft sprocket bolt.
4. Remove the left side cassette bolt.
  WARNING
  Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.
  
  NOTE
  Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.
5. Remove the left camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.
  WARNING
  To avoid damage to the timing chain cassette an assistant will be required to help lift the cylinder head from the vehicle.
  
  WARNING
  On the left side, when lifting the cylinder head be careful to avoid contacting the A/C tube.
  
  NOTE
  New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

Remove the cylinder heads.

Remove the cylinder head bolts in the sequence shown. Discard all bolts.

Fig. Cylinder head bolt loosening sequence-2005 4.0L (VIN E) engine

Remove and discard the head gasket.
WARNING
Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

Clean and inspect the mating surfaces.

Inspect the cylinder head and the cylinder block for flatness

To install:

Position the cylinder head gasket on the block.

Fig. Right side cylinder head bolt torque sequence-2005 4.0L (VIN E) engine

On the right side:
WARNING
To avoid damage to the timing chain cassette an assistant will be required to help position the cylinder head in the vehicle.

WARNING
On the right side, when lifting the cylinder head be careful to avoid contacting the A/C tube.

NOTE
New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
1. Install the cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages.
  
  Stage 1: Tighten to 106 inch lbs. (12 Nm).
  Stage 2: Tighten to 18 ft. lbs. (25 Nm).
2. Install 2 new 8-mm bolts. Tighten to 24 ft. lbs. (32 Nm).
3. Tighten the 8 12-mm bolts in the sequence shown in 2 stages.
  WARNING
  The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time
  
  Stage 1: Tighten the bolts 90 degrees.
  Stage 2: Tighten the bolts an additional 90 degrees.
4. Remove the rubber band. Install the camshaft sprocket and bolt.
5. Install the right side cassette bolt. Tighten to 106 inch lbs. (12 Nm).
  
  Fig. Left side cylinder head bolt torque sequence-2005 4.0L (VIN E) engine

On the left side:
WARNING
To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.

NOTE
New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
1. Install the cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages.
  
  Stage 1: Tighten to 106 inch lbs. (12 Nm).
  Stage 2: Tighten to 18 ft. lbs. (25 Nm).
2. Install 2 new 8-mm bolts. Tighten to 24 ft. lbs. (32 Nm).
3. Tighten the 8 12-mm bolts in the sequence shown in 2 stages.
  WARNING
  The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time.
  
  Stage 1: Tighten the bolts 90 degrees.
  Stage 2: Tighten the bolts an additional 90 degrees.
4. Remove the rubber band. Install the camshaft sprocket and bolt.
5. Install the left side cassette bolt. Tighten to 14 ft. lbs. (19 Nm).

Install both of the exhaust manifolds gaskets, the exhaust manifolds and the nuts. Tighten to 16 ft. lbs. (22 Nm).
NOTE
Apply dielectric compound to the inside of the spark plug wire boots.

Connect all of the spark plug wires to the spark plugs.

Install the 4 catalytic converter-to-exhaust manifold nuts. Tighten to 30 ft. lbs. (40 Nm).

Install the engine noise shield.

On the right side:
1. Install the engine ground strap and the bolt. Tighten to 89 inch lbs. (10 Nm).
2. Position the engine wiring harness and install the bolts. Tighten to 35 ft. lbs. (47 Nm).
  NOTE
  Inspect the O-ring seal. Install a new O-ring seal if necessary.
3. Install the thermostat housing and the bolts. Tighten to 71 inch lbs. (11 Nm).
4. Position the coolant bypass hose clamp.
5. Install the upper radiator hose.
6. Connect the engine coolant temperature (ECT) sensor electrical connector.
7. Install the heater hose to the thermostat housing.
8. Install the alternator mounting bracket assembly and the bolts. Tighten to 31 ft. lbs. (42 Nm).
9. Connect the alternator electrical connections and install the pushpin. Tighten to 71 inch lbs. (8 Nm).

On the left side:
1. Install the oil level indicator tube and bolt. Tighten to 89 inch lbs. (10 Nm).
2. Install the coil bracket and the bolts. Tighten to 89 inch lbs (10 Nm).
3. Install the accessory bracket and the bolts. Tighten to 31 ft. lbs. (42 Nm).
4. Install the vertical bolts. Tighten to 89 inch lbs. (10 Nm).
5. Connect the radio ignition interference capacitor electrical connector.

Install the accessory drive belt tensioner.
NOTE
You must retime the left and right camshafts when either camshaft is disturbed.

Fig. Tool 303-573 installed-2005 4.0L (VIN E) engine

Fig. Tool 303-578 and 303 564 installed-2005 4.0L (VIN E) engine

Fig. Tools 303 576 and 303 577 installed-2005 4.0L (VIN E) engine

Fig. Tool 303-571 installed-2005 4.0L (VIN E) engine

Fig. Tool 303-575 installed-2005 4.0L (VIN E) engine

Fig. Tool 303-573 installed-2005 4.0L (VIN E) engine

Turn the crankshaft clockwise to position the number one cylinder at top dead center (TDC).

Remove the retainer and position the A/C manifold tube bracket aside.
WARNING
Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine.

NOTE
The special tool must be installed on the damper and should contact the engine block, this positions the engine at TDC.

Install special tool 303 573 as shown.
NOTE
Leave the top 2 special tool clamp bolts loose.

Install special tools 303 578 and 303 564 on the rear of the right cylinder head.
NOTE
The camshaft timing slots are off-center.

Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools 303 576 and 303 577, and install the special tools on the front of the right cylinder head. Install special tool 303 571.
WARNING
The right camshaft sprocket bolt is a left threaded bolt.

Tighten the bolts.

Tighten the special tool top clamp bolts to 89 inch lbs. (10 Nm).

Using the special tool with the Camshaft Sprocket Nut Socket 303-565, tighten the camshaft bolt. Tighten to 45 ft. lbs. (61 Nm).

Install the right camshaft tensioner. Tighten to 32 ft. lbs. (44 Nm).
NOTE
Leave the top 2 special tool clamp bolts loose.

Install special tools 303 564 and 303 578 on the front of the left cylinder head.
NOTE
The camshaft timing slots are off-center.

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 left cylinder head.

Install special tools 303 576 and 303 577. Tighten the bolts.

Tighten the special tool top 2 clamp bolts to 89 inch lbs. (10 Nm).

Tighten the camshaft bolt. Tighten to 63 ft. lbs. (85 Nm).

Install the left camshaft tensioner. Tighten to 32 ft. lbs. (44 Nm).

Install the A/C manifold tube assembly bracket and the nut. Tighten to 15 ft. lbs. (20 Nm).

Install the roller followers.

Fill and bleed the engine cooling system.

Before servicing the vehicle, refer to the -Precautions- section.

Drain the cooling system.

Remove or disconnect the following:

Negative battery cable
Intake manifold; see -Intake Manifold- in this section
Cooling fan shroud
Accessory drive belt
Both valve covers
Alternator electrical connections
Alternator and bracket
CKP sensor electrical connector
Wiring harness from retainers across front of engine (discard retainers)
ECT sensor electrical connector
Thermostat housing
Wiring harness clip on side of engine
Accessory bracket (position aside)

Fig. Removing the accessory bracket to position aside-2005 4.0L Explorer Sport-Trac
Wiring harness casing from LH cylinder head
Oil level indicator tube
LH bank spark plug wires
Fuel rail and temperature sensor electrical and vacuum connectors

Remove the fuel injection supply manifold as follows:
1. Remove the fuel supply tube from the fuel manifold. Position the fuel supply tube aside.
2. Remove the fuel rail bolts. Remove the fuel rail and the fuel injectors as an assembly.
  
  Fig. Removing the fuel injection supply manifold-2005 4.0L Explorer Sport-Trac

Remove the camshaft roller followers.

Using the special tool 303-573, set the No. 1 piston to TDC.

Fig. Using the special tool 303-573, set the No. 1 piston to TDC-2005 4.0L Explorer Sport-Trac

On the RH cylinder head, remove or disconnect the following:
NOTE
The using of a special holding tool, 303-575, may be necessary.

RH fenderwell splash shield
RH camshaft chain tensioner

Fig. Remove the RH camshaft chain tensioner-2005 4.0L Explorer Sport-Trac
RH exhaust manifold
Bolt and bracket as shown

Fig. Remove the bolt and bracket as shown-2005 4.0L Explorer Sport-Trac
RH camshaft sprocket bolt

Fig. Using the holding tool while removing the RH camshaft sprocket bolt-2005 4.0L Explorer Sport-Trac

Chain guide bolt
RH camshaft sprocket (use a heavy rubber band to hold timing chain on cassette)

Remove the 8 12mm bolts and the 2 8mm bolts, in the sequence shown, and remove the RH cylinder head.

Fig. Cylinder head bolt removal sequence-2005 4.0L Explorer Sport-Trac

On the LH cylinder head, remove or disconnect the following:

LH exhaust manifold
Ground strap from rear of engine block
LH hydraulic chain tensioner

Fig. Showing the location of the LH hydraulic chain tensioner-2005 4.0L Explorer Sport-Trac
LH camshaft sprocket
LH camshaft chain guide bolt in front of the block

Hold the camshaft chain and cassette with a rubber band, as shown, to aid removal and to prevent chain from falling into the cylinder block.

Remove the LH camshaft sprocket from the cassette.

Fig. Holding the chain and cassette with a rubber band during removal-2005 4.0L Explorer Sport-Trac

Remove the 8 12mm bolts and the 2 8mm bolts, in the sequence shown, and remove the LH cylinder head.

Fig. Cylinder head bolt removal sequence-2005 4.0L Explorer Sport-Trac