99 Ford Explorer Timing/Heads Gasket Replacement

Resources

• Excellent 4 part FordTechMakuloco series + Bonus Video
  1. Engine Removal
  2. Mounting and Teardown
  3. Timing
  4. Assembly & Installation
  5. Cleaning Mating Surfaces
• Cloyes Timing Tutorial (Cloyes kit# 9-0398SB)
• Torque Head Bolts
• Platinum Garage
  1. Good Rebuild Video w/ Purchasing Recommendations
  2. Very Good Engine Installation Video
• Torque Specifications

Tips for Pulling Engine

General

1. Take lots of pictures
2. Keep bolts with what they belong too (if possible)

Prep

1. Spray Rust Pentrant
   1. Exhaust Manifold
   2. Engine Mounts
2. Drain Coolant
3. Drain Oil
4. Mark Plug Wires

Underneath

1. Disconnect Exhaust Manifold
2. Mark One Bolt on Torque Converter w/ White Paint

Front

1. Alternator
2. Power Steering
3. Compressor
4. Intake (Upper and Lower)
5. Fan, Radiator, Condensor

Engine Mount

1. Remove Engine Mount to Frame Nuts
2. Loosen Engine Mount to Engine Bolts

Initial Lift

1. Connect chains to front of left head and back of right head
2. Support transmissision w/ jack and block of wood
3. Lift Engine Slightly
4. Once engine weight is on hoist, remove engine mount entirely to make it easier to dismount/mount transmission
5. Remove last 2 bellhousing bolts
6. Disconnect fuel line (do it last so you don't smell fuel)

Remove

1. Raise a few Inches
2. Shake free from transmission
3. Verify that everything is free
4. Gently raise a few inches at a time verifying clearances
5. Raise to clear front radiator area, drag engine free, but move very slowly to prevent a tip
6. Once clear of truck, lower to reduce center of gravity

Post Removal Cleanup

1. Make sure torque converter is fully seated
2. Put transmission on jack stand
3. Put rags in exhaust pipes
4. Use equalizer to lift back of engine and finish draining coolant
5. Plug intake holes with rags

Flex Plate Removal and Engine Mounting

1. Remove 1 bolt
2. With white paint marker, mark threads and hole
3. Remove flex plate
4. Remove bracket covering jack shaft
5. For bottom engine mount holes, tap dowels with M12 tap, thread bolt, and then use slide hammer to pull dowels

Engine Teardown (Top)

1. Blow everything off well with compressed air
2. Ensure fuel line isn't leaking
3. May require heating EGR bolt well to remove
4. Take pictures of front of engine
5. Remove Parts
   1. Waterpump
   2. Thermostat Housing
   3. Dampener
      1. Remove 19mm bolt in center
      2. Insert M8 1.25 thread 100mm long bolt into dampener holes
      3. There's nothing to press against, so insert metal rod of some kind inside hole
      4. Install dampener removal tool and press dampener off
6. Front Cover (Waterpump Area) (leave top bolt in loose and pry part is top right)
7. Valve Covers
8. Roller followers (need rocker removal tool OTC 303-567)
   1. May not be able to do 1 end rocker so move cam neutral)
   2. See 22:52
9. Remove tensioners (1 1/16")
10. Camshaft Sprocket Bolts
    1. Driver side (normal right hand thread)
    2. Passenger side (left hand thread) !!
11. Remove Camshaft caps and pull camshaft and caps together (maintain order)
12. Remove last rocker roller

Engine Teardown (bottom)

1. Pull lower pan (10mm)
2. Remove intake tube (lift while unscrewing)
3. Remove t-30 torque bolts in back of block (1 long, 1 short)
4. Remove 8 inner bolts (13mm)
5. Remove outside bolts and nuts (10mm)
6. Gently tap front to break seal
7. Remove gasket (ideally in 1 piece to reduce cleanup)
8. Look for any plastic debris

Engine Teardown (timing)

1. Take lots of pictures and note sprocket orientation
2. Remove main tensioner
3. Remove Jackshaft Bolt (E18)
4. Pull Jackshaft sprocket, chain, and Crank sprocket together (keep them in the correct orientation to make assembly more obvious)
5. Front cover gasket
6. Cassette bolts near jackshaft (10mm) and on head (torx)
7. Remove Front (Driver )Cassette
   1. Very annoying
   2. Use prybar from top to distort pin
   3. Then use another prybar to push cassette hinge from bottom up through head
8. Remove Rear (Passenger) Cassette
   1. Less annoying
   2. Torx on block
   3. 10mm bolt on head
9. Remove rear Jackshaft Bolt
   1. Remove plug by tapping on it to deform it to access Jackshaft bolt (T55)
   2. Put Sprocket back on Front and Hold with Rag
   3. Use impact to Remove rear jackshaft bolt (T55)
10. Use pick to separate rear jackshaft sprocket and work chain and sprocket out of head

Needed Tools

1. 5lb slide hammer ($85)
2. Ford Timing Kit ($65)
3. M12 bolt for Pulling Engine Dowels
4. Engine Hoist Leveler ($32)
5. Dampener Removal Tool ($22)
6. Rocker Removal Tool (OTC 303-567) ($21)
7. External Torx Set ($25)
8. 3m Broloc Cleaning Discs ($32)
9. Red Scotch Brite ($9)
10. Permatex Engine Assembly Lube ($8)
11. 100mm M10 1.25 Bolt for Engine Stand Mounting x4

Parts to Replace

1. Jackshaft Bolts (TTY, but I can't seem to find anywhere)
2. Timing Components
   • Timing Components ($129)
   • Cloyes Timing Chain Kit (appear to be much higher quality) ($250)
3. Heads
   • Remanufactured Heads @alliedautoparts ($550) (reviews are all over the place)
   • Servicing of Heads @ Southern Performance in Atoka TN ($450)
4. 6 DESNO Platinum Spark Plugs ($20)
5. Head Gasket Kits
   • Gasket kit ($103)
6. Oil Pump ($70)

Reinstallation

Crankshaft Installation

1. Ensure everything is as clean as possible and blow out oil galleys on block and crankshaft
2. Install the main bearings to block dry. Ensure oil galley markings line up
3. Very gently install the crankshaft
4. Apply small bead of high temp sealant to the rear main bearing cap
5. Install the main bearing caps taking note of the arrows and numbers (relative to front of engine)
6. Clearances should be:
   • Desired 0.0008-0.0015
   • Allowable 0.0005-0.0019
7. Torque bolts to 72 ft lbs in the following order, 3, 2, 4, 1
8. Ensure crank turns freely

Piston Installation

1. Check ring clearance is no greater than .015
2. Lubricate piston rings and install. Ensure that gaps are correctly spaced around the circumference of the piston
3. Install new rod bolts
4. Install rod bearings
5. Add rubber hose to rod bolts and feed
6. Using piston installation tool, install piston ensuring correct piston numbering and arrow alignment