How to replace 4.0L engine on 2005 ford explorer?

Engine

Removal & Installation

4.0L (VIN E) SOHC Engine

Fig. Left side engine support-4.0L engine

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
   
   

   

   

   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
    
    

    

    

    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
    
    

    

    

    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.
    
    
    

    

    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.
       
       
       
       
       

       

       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
    
    

    

    

    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.
   
   
   

   

   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).
    
    
    

    

    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.
    
    
    

    

    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.
    
    
    
    
    

    

    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).
       
       
       

       

       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).
    
    
    

    

    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.