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2002 Explorer Sport/Sport Trac Workshop Manual
SECTION 303-01: Engine — 4.0L Single Overhead Camshaft (SOHC)
IN-VEHICLE REPAIR
Cylinder Head
Special Tool(s)
Spark Plug Wire Remover
303-106 (T74P-6666-A)
Valve Spring Compressor
303-581 (T97T-6565-A)
Timing Chain Tensioner
303-571 (T97T-6K254-A)
Camshaft Gear Removal Tool
303-575 (T97T-6256-F)
Camshaft Gear Torque Adapter
303-565 (T97T-6256-G)
Camshaft Gear Holding Tool
303-564 (T97T-6256-B)
Camshaft Gear Holding Tool Adapter
303-578 (T97T-6256-A)
Camshaft Holding Tool
303-577 (T97T-6256-C)
Crankshaft Holding Tool
303-573 (T97T-6303-A)
Camshaft Holding Tool Adapter
303-576 (T97T-6256-D)
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information , refer to
2. Relieve the fuel system pressure. For additional information, refer to
3. Drain the cooling system. For additional information, refer to
4. Remove the intake manifold. For additional information, refer to
5. Remove the cooling fan shroud. For additional information, refer to
6. Remove the accessory drive belt. For additional information, refer to
http://www.fordtechservice.dealerconnection.com/pubs/content/~...
Section
100-02.
Section
310-00.
Section
303-03.
Intake Manifold
in this section.
Section
303-03.
Section
303-05.
Page 1 of 17
2002 Explorer Sport/Sport Trac Workshop Manual
Procedure revision date: 07/13/2005
1/22/2010
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Table of Contents
Related Manuals for Ford Explorer Sport 2002
Summary of Contents for Ford Explorer Sport 2002
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Page 1: Removal Both Cylinder Heads
2002 Explorer Sport/Sport Trac Workshop Manual Page 1 of 17 SECTION 303-01: Engine — 4.0L Single Overhead Camshaft (SOHC) 2002 Explorer Sport/Sport Trac Workshop Manual IN-VEHICLE REPAIR Procedure revision date: 07/13/2005 Cylinder Head Special Tool(s) Spark Plug Wire Remover 303-106 (T74P-6666-A) Valve Spring Compressor 303-581 (T97T-6565-A) Timing Chain Tensioner... - Page 2 2002 Explorer Sport/Sport Trac Workshop Manual Page 2 of 17 7. Remove the LH valve cover. For additional information, refer to Valve Cover — LH in this section. 8. Remove the RH valve cover. For additional information, refer to Valve Cover — RH in this section.
- Page 3 2002 Explorer Sport/Sport Trac Workshop Manual Page 3 of 17 16. Remove the upper heater coolant hose. 1. Squeeze the heater hose clamp. 2. Remove the heater coolant hose. 17. Remove the lower heater coolant hose and position aside. 1. Remove the bolt. 2.
- Page 4 2002 Explorer Sport/Sport Trac Workshop Manual Page 4 of 17 22. Detach the wiring harness retainer. 23. Remove the bolt and the oil level indicator tube. 24. Using the special tool, disconnect the LH spark plug wires from the spark plugs. 25.
- Page 5 2002 Explorer Sport/Sport Trac Workshop Manual Page 5 of 17 28. NOTE: Mark each of the roller followers to make sure it is installed in its original position during reassembly. Use the special tool to remove the roller followers. 29. Remove the lower radiator hose. 30.
- Page 6 2002 Explorer Sport/Sport Trac Workshop Manual Page 6 of 17 34. Remove the RH exhaust manifold. For additional information, refer to Exhaust Manifold — RH in this section. 35. Remove the bolt and detach the ground strap. 36. Remove the bolt and detach the bracket. CAUTION: The RH camshaft sprocket bolt is a left-hand threaded bolt.
- Page 7 2002 Explorer Sport/Sport Trac Workshop Manual Page 7 of 17 40. Remove the eight 12 mm (0.47 in) bolts and the two 8 mm (0.31 in) bolts in the sequence shown, and remove the RH cylinder head. Discard the head gasket. Discard the cylinder head bolts.
- Page 8 2002 Explorer Sport/Sport Trac Workshop Manual Page 8 of 17 48. Clean the gasket mating surfaces. Installation LH cylinder head 1. Position the cylinder head gasket and the cylinder head. 2. NOTE: Cylinder head bolts are a torque-to-yield design. New bolts must be installed. Install the 12 mm (0.47 in) bolts and tighten in the sequence shown in two stages.
- Page 9 2002 Explorer Sport/Sport Trac Workshop Manual Page 9 of 17 CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt. Install the camshaft sprocket bolt. 7. Install the chain guide bolt. 8. Install the LH exhaust manifold. For additional information, refer to Exhaust Manifold LH in this section.
- Page 10 2002 Explorer Sport/Sport Trac Workshop Manual Page 10 of 17 12. Tighten the eight 12 mm (0.47 in) bolts in two stages in the sequence shown. Stage 1: Tighten the bolts 90 degrees. Stage 2: Tighten the bolts an additional 90 degrees. 13.
- Page 11 2002 Explorer Sport/Sport Trac Workshop Manual Page 11 of 17 19. NOTE: The camshaft timing slots are off-center. Position the camshaft timing slots below the centerline of the camshaft and install the special tools on the front of the RH cylinder head. 20.
- Page 12 2002 Explorer Sport/Sport Trac Workshop Manual Page 12 of 17 25. Install the RH camshaft chain tensioner. 26. Install the RH fenderwell splash shield. 27. If necessary, remove the LH camshaft chain tensioner. 28. If necessary, loosen the LH camshaft sprocket bolt. 29.
- Page 13 2002 Explorer Sport/Sport Trac Workshop Manual Page 13 of 17 31. Install the special tool. 32. Tighten the bolts. 1. Tighten the special tool top two clamp bolts to 10 Nm (89 lb-in). 2. Tighten the camshaft bolt. 33. Install the LH camshaft chain tensioner. 34.
- Page 14 2002 Explorer Sport/Sport Trac Workshop Manual Page 14 of 17 37. Install the fuel rail 1. Install the fuel rail and fuel injectors as an assembly. 2. Install the fuel supply tube to the fuel rail. 38. Connect the fuel pulse damper vacuum connector. 39.
- Page 15 2002 Explorer Sport/Sport Trac Workshop Manual Page 15 of 17 44. Position the thermostat housing and bypass hose and install the bolts. 45. Position the bypass hose clamp. 46. Install the lower heater coolant hose. 1. Position the heater coolant hose. 2.
- Page 16 2002 Explorer Sport/Sport Trac Workshop Manual Page 16 of 17 50. Connect the crankshaft position sensor electrical connector. 51. Position the generator and generator mounting bracket as an assembly and install the bolts. 52. Position the accessory drive belt tensioner and install the bolt. 53.
- Page 17 2002 Explorer Sport/Sport Trac Workshop Manual Page 17 of 17 http://www.fordtechservice.dealerconnection.com/pubs/content/~... 1/22/2010...