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Friday, October 14, 2011

How to replace 4.0L engine on 2005 ford explorer?


Engine



Removal & Installation



4.0L (VIN E) SOHC Engine


Click image to see an enlarged view
Fig. Left side engine support-4.0L engine


Click image to see an enlarged view
Fig. Right side engine support-4.0L engine

CAUTION
If the fuel supply manifold is used as a leverage device, damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold.

  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2. Remove or disconnect:
    NOTE
    Heater hose will be removed with engine.


    NOTE
    The lifting eyes should be installed on the exhaust manifold studs for number three and number four cylinders.



    Accelerator cable from engine
    Speed control cable from engine
    Radiator, the fan blade, and the fan shroud
    Accessory bracket bolts and position bracket aside
    Alternator wiring
    Wiring harness retainer and position alternator wiring away from engine
    Engine electrical connector
    PCM connector
    PCM ground wire
    Engine ground wire
    Brake booster vacuum hose
    A/C high pressure switch electrical connector
    Bolt and position the A/C lines aside



    Heater hoses
    Fuel line
    Starter motor
    Engine oil
    Oil drain plug
    Transmission portion of wiring harness
    Right and left heated oxygen sensor connectors
    Transmission control connector
    Output shaft speed sensor connector
    Digital transmission range sensor connector
    Catalyst monitor sensor electrical connector
    Transmission/transfer case portion of the wiring harness from any routing clips or pushpins. Route transmission/transfer case portion of the wiring harness to top of engine.
    Bolt, and position the transmission cooling line bracket aside
    A/C line bracket nut and position it aside
    Power steering return hose
    Power steering pressure hose
    Vapor management valve hose connector
    Eight bolts and the left and the right engine support insulator nuts
  3. Install the lifting eyes.
  4. Install the spreader bar to the lifting eyes.
  5. Attach a floor crane to the spreader bar and remove the engine.
  6. Installation is the reverse of removal. Observe the following torques:

    Left and right engine insulator nuts: 81 ft. lbs. (110 Nm)
    Engine mount nuts: 59 ft. lbs. (80 Nm)
    Transmission-to-engine bolts: 35 ft. lbs. (47 Nm)
    Torque converter nuts: 35 ft. lbs. (47 Nm)
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Release the fuel system pressure as follows:
    1. Remove the fuel pump relay (located in the battery junction box).
    2. Start the engine and allow it to idle until it stalls.
    3. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released.
    4. Turn the ignition switch to the OFF position.
  3. Remove the fuel line spring-lock coupling.
  4. Remove or disconnect the following:

    Battery cables
    Engine ground wire from body
    Wiring harness connector and retainers along the fender

    Click image to see an enlarged view
    Fig. Identifying the wiring harness connector and retainers to remove
  5. Lift the engine compartment relay box cover and disconnect the battery cable from the stud.
  6. Drain the cooling system.
  7. Recover the A/C system refrigerant.
  8. Disconnect the windshield washer hoses from the hood. Mark the hood hinge locations and remove the hinge bolts and the hood.
  9. Remove the cooling fan and shroud.
  10. Remove or disconnect the following:
    NOTE
    Cover the accumulator opening to prevent contamination.



    Accessory drive belt
    Power steering pump pulley
    Air cleaner assembly and the outlet pipe
    Mass air flow (MAF) sensor electrical connector
    Powertrain control module (PCM) electrical connectors

    Click image to see an enlarged view
    Fig. Disconnect the PCM electrical connectors-4.0L engine (2005 models)
    Wiring harness clips from the bulkhead
    Transmission control wiring harness pin-type retainers from the engine wiring harness

    Click image to see an enlarged view
    Fig. Disconnect the transmission control wiring harness pin-type retainers from the engine wiring harness -4.0L engine
    Evaporative emissions (EVAP) tube from the engine connection and position it aside
    Vacuum hoses at the bulkhead connections (mark for reinstallation)
    Engine ground wire at the bulkhead
    Heater control valve vacuum hose and heater hoses from the bulkhead
    Upper radiator hose and heater hose from the block connections
    Lower radiator hose at the coolant pump
    Coolant hoses from the coolant reservoir bottle
    A/C tube from the accumulator; discard the O-ring seal



    Low-pressure A/C tube from the condenser; discard the O-ring seal
    Brake booster vacuum hoses and tubes from the cylinder head cover
    A/C high-pressure cut-off switch electrical connector
    High-pressure A/C tube from the condenser
    A/C tube from the retainer
  11. Remove the exhaust manifold-to-exhaust gas recirculation (EGR) valve tube on the side of the engine as follows:
    1. Disconnect the exhaust manifold-to-EGR valve tube fittings.
    2. Remove the exhaust manifold-to-EGR valve tube.
  12. Remove or disconnect the following:

    Starter motor
    Lower air shroud panel (retained with pushpins)
    Battery cable retainer bracket
  13. Position a jack stand under the transfer case (4WD) or a transmission jack under the transmission (2WD).
  14. Remove or disconnect the following:

    LH and RH catalytic converter heat shields
    2 heated oxygen sensor (HO2S) electrical connectors
    2 catalyst monitor sensor electrical connectors
    RH and LH heat shields at the exhaust manifold
    Plastic shield on the right side of the crossmember
    4 upper and 4 lower crossmember bolts
    Cable bracket from the transmission (2WD only)
    Transmission support insulator nuts and remove the crossmember
    Bolts, springs, flag nuts and separate the muffler from the converter
    4 converter-to-manifold nuts
  15. Remove the transmission-mounted exhaust hanger, the 3-way converter system and the RH heat shield as follows:
    1. Remove the bolt and the converter assembly.
    2. If required, remove the second bolt and mount.
  16. Disconnect the shift cable and remove the bracket.

    Click image to see an enlarged view
    Fig. Disconnect the shift cable and remove the bracket-4.0L engine (2005 models)
  17. On 4WD models, perform the following to remove the front driveshaft:
    1. Index-mark the front axle pinion flange and the front driveshaft.
    2. Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.
    3. Remove and discard all of the bolts, washers and U-joint nuts from both flanges.
    4. Remove the front driveshaft.
      CAUTION
      Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot and cause the boot to tear. Tape the bearing cups to the driveshaft to prevent them from falling off the spider.
  18. On all models, perform the following to remove the rear driveshaft:
    1. Mark the driveshaft flange to the rear axle pinion flange, and if equipped, the transfer case rear output flange for assembly reference.
    2. Remove the 4 rear axle flange bolts.
    3. Index-mark the driveshaft at the 6 o'clock position (2WD).
    4. Remove the 4 transfer case flange bolts (4WD).
    5. Using a suitable tool as shown, disconnect the driveshaft flange and remove the driveshaft.
      CAUTION
      Do not rotate the driveshaft. The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange.



      Click image to see an enlarged view
      Fig. Using a suitable tool as shown, disconnect the driveshaft flange and remove the driveshaft-4.0L engine
  19. For 2WD models, Pull the seal away from the transmission output shaft, and mark the transmission output shaft at the 6 o-clock position.
  20. For all models, remove or disconnect the following:
    NOTE
    Make an identifying mark on the nut, stud and flexplate to allow for correct installation.



    RH catalyst monitor connector and the fuel tubes from the bracket
    RH HO2S electrical connector from the transmission
    Shift motor electrical connector, if equipped
    LH HO2S electrical connector retainer and the harness clip from the transmission
    LH catalyst monitor connector from the transmission
    4 torque converter nuts (Rotate the crankshaft to access all the nuts)



    Digital transmission range sensor

    Click image to see an enlarged view
    Fig. Pull the boot back and disconnect the digital transmission range sensor-4.0L engine
    Electrical connectors from the side of the transmission housing
    Solenoid body electrical connector (clean the area before disconnecting)
    Harness retainers from the side of the transmission
    Transmission cooler tubes and clips (both ends of the tubes)
  21. On 4WD models, support the transmission with a transmission jack and remove the jack stand from under the transfer case.
  22. On all models, remove the 8 engine-to-transmission retaining bolts and remove the transmission.
  23. Install the special holding tool (307-346) to the flexplate.
  24. Remove the power steering return hose
  25. Remove the drain plug and drain the engine oil. Remove the oil filter.
  26. Remove or disconnect the following:

    LH engine support insulator bolt
    Power steering fluid reservoir-to-fluid cooler hose and detach the clip
    Power steering tube support bracket
    Power steering pressure (PSP) tube (discard the O-ring seal)
    RH engine support insulator nuts
    LH and RH radiator support brackets
    RH radiator support bracket
    Radiator and A/C condenser as an assembly
  27. Install the lifting hangars on the LH and RH sides of the engine, using bolts on the exhaust manifolds to retain the hangars.
  28. Attach the lifting sling, and with a floor crane, remove the engine.
To install:
  1. Using the floor crane, carefully lower the engine into the vehicle.
  2. Install the RH engine support insulator nuts, and tighten the nuts to 59 ft. lbs. (80 Nm).
  3. Install the radiator and A/C condenser as an assembly.
  4. Position the RH and LH radiator support brackets and the bolts and tighten to 9 ft. lbs. (12 Nm).
  5. Remove the lifting hangars from both sides of the engine.
  6. Using the special tool (211-D027) , install a new seal on the power steering pressure (PSP) hose fitting.

    Click image to see an enlarged view
    Fig. Using the special tool (211-D027) , install a new seal on the power steering pressure (PSP) hose fitting-4.0L engine
  7. Connect the PSP hose to the power steering pump. Tighten the fitting to 48 ft. lbs. (65 Nm).
  8. Install the PSP hose support bracket and the bolt. Tighten the bolt to 8 ft. lbs. (11 Nm).
  9. Install the LH support insulator through bolt. Tighten the bolt to 81 ft. lbs. (110 Nm).
  10. Connect the power steering return hose to the power steering cooler.
  11. Remove the holding tool from the flexplate. Make sure the stud and flexplate marks made during removal line up.
  12. Position the transmission in the vehicle. Install the 8 engine-to-transmission bolts and tighten to 35 ft. lbs. (48 Nm).

    Click image to see an enlarged view
    Fig. Position the transmission in the vehicle. Install the 8 engine-to-transmission bolts and tighten to 35 ft. lbs. (48 Nm)-4.0L engine
  13. Position the transmission cooler tubes, and the bracket and install the nut. Tighten the nut to 14 ft. lbs. (19 Nm).
  14. Connect the transmission cooler tubes to the cooler, and install the tube clips.
  15. Connect the cooler tubes to the transmission. Tighten the fittings to 26 ft. lbs. (35 Nm).
  16. Install the wiring harness retaining clips onto the side of the transmission housing.
  17. Lubricate new O-rings with petroleum jelly. Install new O-ring seals on the transmission body electrical connector, connect the electrical connector and tighten the screw. Tighten the screw to not more than 44 inch lbs. (5 Nm).
    CAUTION
    Damage will occur to the solenoid body assembly if the screw is tightened above the specification.
  18. Connect the electrical connectors to the side of the transmission housing.

    Click image to see an enlarged view
    Fig. Connect the electrical connectors to the side of the transmission housing-4.0L engine
  19. Connect the digital Transmission Range (TR) sensor and move the cover boot back into place.
  20. Match the identifying mark on the nut, stud and flexplate to allow for correct installation.
  21. Install the 4 torque converter nuts and tighten them to 28 ft. lbs. (38 Nm).
  22. Install or connect the following:

    LH catalyst monitor connector to the transmission
    LH heated oxygen sensor (HO2S) electrical connector retainer and the harness clip to the transmission
    shift motor electrical connector (if equipped)
    RH HO2S electrical connector to the transmission
    RH catalyst monitor connector and the fuel tubes to the bracket
  23. Align the marks on the transmission output shaft. Position the driveshaft and install the driveshaft-to-pinion flange bolts in the sequence shown. Torque to 83 ft. lbs. (112 Nm).
    NOTE
    Use new bolts and washers.



    Click image to see an enlarged view
    Fig. Align the marks on the transmission output shaft, then position the driveshaft and install the driveshaft-to-pinion flange bolts in the sequence shown (2WD and 4WD models)-4.0L engine
  24. On 4WD models, perform the following to install the rear driveshaft:
    1. Align the marks made on the flange and driveshaft during removal.
    2. Install the rear driveshaft-to-transfer case, with new flange bolts and washers, in the sequence shown. Tighten the bolts to 83 ft. lbs. (112 Nm).
    3. Position the front driveshaft flange with the location marks aligned and install the retaining bolts finger-tight.
    4. Connect the front driveshaft to the front differential and install new bolts (and new straps). Tighten the bolts to 13 ft. lbs. (18 Nm).
    5. Tighten the front driveshaft flange bolts, in the sequence shown, to 22 ft. lbs. (30 Nm).

      Click image to see an enlarged view
      Fig. Tighten the front driveshaft flange bolts, in the sequence shown, to 22 ft. lbs. (30 Nm)-4.0L engine with 4WD
  25. On all models, position the shift cable bracket and install the bolts, Connect the shift cable. Tighten the bolts to 30 ft. lbs. (40 Nm).
  26. Install a jack stand under the transfer case, and remove the transmission jack (4WD).
  27. Position the transmission-mounted exhaust hanger, the 3-way converter system and RH heat shield, as follows:
    1. If removed, position the mount and install the bolt. Tighten the bolt to 66 ft. lbs. (90 Nm).
    2. Position the exhaust hanger and the converter assembly and install the bolt. Tighten the bolt to 66 ft. lbs. (90 Nm).
  28. Install the 4 converter-to-manifold nuts. Tighten the nuts to 30 ft. lbs. (40 Nm).
  29. Connect the LH and RH mufflers to the converters and install the 2 new bolts, 2 springs and 2 new flag nuts. Tighten the bolts and nuts to 30 ft. lbs. (40 Nm).
  30. Install the crossmember and the 4 lower and 4 upper bolts. Torque the bolts to 52 ft. lbs. (70 Nm).
  31. Remove the jack from under the transfer case (4WD) or from under the transmission (2WD).
  32. Install the cable bracket and the bolts to the transmission (2WD). Tighten the bolts to 30 ft. lbs. (40 Nm).

    Click image to see an enlarged view
    Fig. Install the cable bracket and the bolts to the transmission (2WD)-4.0L engine
  33. Install or connect the following:

    Plastic shield and the 2 nuts on the right side of the crossmember; torque to 80 inch lbs. (9 Nm)
    Crossmember-to-transmission support insulator nuts; torque to 66 ft. lbs. (90 Nm)
    LH and RH heat shield bolts; torque to 15 ft. lbs. (20 Nm)
    LH and RH catalyst monitor sensor electrical connectors
    LH and RH heated oxygen sensor electrical connectors
    2 bolts and the RH heat shield; torque to 15 ft. lbs. (20 Nm)
    Battery retainer bracket and install the nut; torque to 15 ft. lbs. (20 Nm)
    Lower air shroud and install the pushpins
    Starter
    Exhaust manifold-to-exhaust gas recirculation (EGR) valve tube and tighten the fittings; torque the fitting to 30 ft. lbs. (40 Nm)
    A/C tube to the condenser and install the nut; torque to 71 inch lbs. (8 Nm)
    A/C tube to the retainer on the side of the condenser
    A/C high pressure cut-off switch electrical connector
    Vacuum hoses to the cylinder head cover
    New O-ring seal, connect the A/C tube to the condenser and install the nut; torque to 71 inch lbs. (8 Nm)
    New O-ring seal, connect the A/C tube to the accumulator and install the nut; torque to 71 inch lbs. (8 Nm)
    Coolant hoses to the coolant reservoir bottle
    Lower radiator hose at the coolant pump
    Upper radiator hose and heater hose to the block connections
    Heater hose bracket and install the bolts; torque to 17 ft. lbs. (23 Nm)
    Vacuum and heater hoses at the bulkhead
    Ground wire and the bolt to the engine; torque to 89 inch lbs. (10 Nm)
    Vacuum hose near the wiring harnesses on the bulkhead
    Evaporative emissions (EVAP) tube
    Fuel line spring lock coupling
    Transmission control wiring harness pin-type retainers to the engine wiring harness
    Engine wiring harness in the clips on the bulkhead
    Powertrain control module (PCM) electrical connectors
    Air cleaner
    Mass air flow (MAF) sensor electrical connector
    Hood, the 4 bolts and the hood supports; torque to 9 ft. lbs. (11 Nm)
    Windshield washer hose to the underside of the hood
    Battery cable to the power distribution box and install the nut
    Electrical connector and attach the wiring harness retainer on the fender rail
    Ground wire and the nut on the bulkhead; torque to 80 inch lbs. (9 Nm)
    Cooling fan and shroud
    Air cleaner outlet pipe
  34. Fill the engine with clean engine oil.
  35. Connect both battery cables.
  36. Fill and bleed the cooling system.
  37. Fill and purge the power steering system.
  38. Evacuate and recharge the A/C system.
  39. Start the engine and check for leaks
  40. Stop the engine and check all fluid levels.
4.0L OHV Engine (VIN X)
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Relieve the fuel system pressure.
  3. Drain the cooling system.
  4. Drain the engine oil.
  5. Properly discharge the A/C system.
  6. Remove or disconnect the following:

    Both battery cables
    Mass Air Flow (MAF) sensor
    Air cleaner outlet tube
    Drive belt
    Accelerator control splash shield
    Upper and lower radiator hoses
    Fan guard/shroud
    Radiator overflow tube
    Radiator
    Transmission cooler lines, if equipped
    Heater hoses
    Alternator electrical connectors
    Vacuum reservoir connection
    Throttle body heater hose
    A/C cycling switch
    Powertrain Control Module (PCM) connector
    Ground wire from the PCM
    Power steering cut-out switch
    Peanut fitting from the A/C condenser core
    A/C high pressure cut-out switch
    A/C manifold hose
    Accelerator and speed control cables
    Brake booster vacuum hose and tube from the intake manifold
    Vacuum reservoir line
    Fuel lines
    Power steering pressure and return hoses
    Block heater, if equipped
    Engine ground cable
    Automatic transmission harness connectors, if equipped
    Heated Oxygen (HO 2 S) sensor, if equipped
    Starter
    Catalytic converter
    Torque converter bolts, if equipped and properly support the transmission
    Differential pressure feedback sensor and support the engine with a floor crane
    Exhaust Gas Recirculation (EGR) transducer
    Upper transmission-to-engine bolts
    Engine from the vehicle
    Clutch/ flywheel, if equipped
To install:
  1. Install or connect the following:

    Flywheel. Torque the bolts to 64 ft. lbs. (87 Nm).
    Engine. Torque the mounting bolts to 85 ft. lbs. (115 Nm).
    HO 2 S sensor
    Upper transmission-to-engine bolts. Torque the bolts to 38 ft. lbs. (51 Nm).
    EGR transducer and remove the floor jack from the transmission
    Torque converter-to-engine bolts. Torque the bolts to 38 ft. lbs. (51 Nm).
    Catalytic converter
    Transmission wiring harness connectors
    Engine ground cable. Torque the bolt to 106 inch lbs. (12 Nm).
    Block heater, if equipped
    A/C high pressure cut out switch
    A/C manifold to the evaporator core
    Power steering cut-out switch
    Power steering pressure and return lines
    Engine sensor control wiring harness to the A/C compressor
    Fuel lines
    42 pin connector
    Vacuum reservoir vacuum line
    Brake booster vacuum hose and tube
    Accelerator cable
    Ground strap. Torque the bolt to 106 inch lbs. (12 Nm).
    A/C manifold hose
    PCM ground strap. Torque the bolt to 106 inch lbs. (12 Nm).
    PCM wire harness bracket bolt. Torque the bolt to 61 inch lbs. (7 Nm).
    A/C low pressure cut-out switch
    Throttle body heater hose
    Fan clutch and water pump pulley. Torque the bolt 17 ft. lbs. (23 Nm).
    Drive belt
    Alternator electrical connectors
    Inlet and outlet heater hoses
    Fuel charging wiring
    Radiator and fan shroud
    Transmission cooler lines, if equipped
    Upper, lower and overflow hoses to the radiator
    Accelerator control splash shield. Torque the bolts to 89 inch lbs. 10 Nm).
    Drive belt
    Air cleaner outlet tube
    MAF sensor
    Both battery cables
  2. Recharge the A/C system.
  3. Fill the cooling system.
  4. Fill the engine with clean oil.
  5. Run the engine and check for leaks and proper operation.
  6. Check and adjust the front end alignment.



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