303-01A-1 Engine — 4.

0L SOHC 303-01A-1

DISASSEMBLY
Special Tool(s)
Engine Adapter for 303-564
303-578 (T97T-6256-A)
Special Tool(s)
Reamer, Cylinder Ridge
303-016 (T64L-6011-EA)

Compressor, Valve Spring

303-581 (T97T-6565-A)

Remover, Crankshaft Vibration

Damper
303-101 (T74P-6316-A)

Holding Tool, Crankshaft

303-634

Remover, Spark Plug Wire

303-106 (T74P-6666-A)

Holding Tool, Camshaft

Sprocket
303-564 (T97T-6256-B)

(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-2 Engine — 4.0L SOHC 303-01A-2

DISASSEMBLY (Continued)
CAUTION: If the supply manifold is used
as a leverage device, damage can occur to the
supply manifold. Care must be taken when
working around the fuel supply manifold.

CAUTION: Do not use metal scrapers,

wire brushes, power abrasive discs or other
abrasive means to clean sealing surfaces. These
tools cause scratches and gouges which make
leak paths.

1. Illustration 1 of 14. Remove the components in

the order indicated in the following illustration
and table.

Item Part Number Description 2. Install the engine on a suitable engine stand and
1 6379 Flexplate bolts (8 req’d) remove the engine lifting eyes.
2 6375 Flexplate
3 7007 Rear cover

2003 Explorer/Mountaineer, 9/2002

303-01A-3 Engine — 4.0L SOHC 303-01A-3

DISASSEMBLY (Continued)
3. Illustration 2 of 14. Remove the components in
the order indicated in the following illustration
and table.

Item Part Number Description Item Part Number Description

4 — A/C tube nuts (2 req’d) 8 — Accessory drive belt tensioner
5 — A/C tube bolt
6 8620 Accessory drive belt 9 6B209 Accessory drive belt tensioner
7 — Accessory drive bracket bolts 10 E800511 Crankshaft pulley bolt and
(2 req’d) washer
(Continued)
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-4 Engine — 4.0L SOHC 303-01A-4

DISASSEMBLY (Continued)
Item Part Number Description Item Part Number Description
11 6B321 Crankshaft pulley 17 — Accessory drive bracket bolts
Disassembly Note (4 req’d)
12 — Generator electrical connector 18 — Accessory drive bracket
(part of 14300) 19 W702527 Thermostat housing bolts (3
13 — Generator B+ terminal nut req’d)
Disassembly Note 20 108884 Coolant temperature sensor
14 — Alternator bracket bolts (3 electrical connector
req’d) 21 W525966 Coolant bypass hose clamp
15 — Alternator bracket 22 8548 Thermostat housing
16 — A/C compressor electrical
connector (part of 14A280)
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-5 Engine — 4.0L SOHC 303-01A-5

DISASSEMBLY (Continued)
4. Illustration 3 of 14. Remove the components in
the order indicated in the following illustration
and table.

Item Part Number Description Item Part Number Description

23 — Electrical connectors (part of 26 12A310 Ignition coil bracket
12B637) Disassembly Note
Disassembly Note 27 — Coolant pump pulley bolts (4
24 12281/12280 Ignition wires (6 req’d) req’d)
Disassembly Note 28 — Coolant pump pulley
25 W500213 Ignition coil bracket bolts (2 (Continued)
req’d)
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-6 Engine — 4.0L SOHC 303-01A-6

DISASSEMBLY (Continued)
Item Part Number Description Item Part Number Description
29 W500014 Coolant pump bolts (12 35 E802185 Oil pan bolts (5 req’d)
req’d) 36 6019 Engine front cover
30 8501 Coolant pump 37 6020 Engine front cover gasket
31 8507 Coolant pump gasket 38 W701723 Oil level indicator and tube
32 — Crankshaft position sensor bolt
(CKP) electrical connector 39 6754 Oil level indicator and tube
(part of 12B637) assembly
33 — Wiring anchors (2 req’d) (part
of 12B637) 5. Illustration 4 of 14. Remove the components in
34 W500024 Engine front cover bolts (9 the order indicated in the following illustration
req’d) and table.
(Continued)

Item Part Number Description Item Part Number Description

40 6C342 Positive crankcase ventilation 44 9431 RH exhaust manifold
(PCV) hose Disassembly Note
41 W500235 Engine wiring harness 45 9448 RH exhaust manifold gasket
retainer bolts (2 req’d) 46 — Oil filter adapter bolt and
42 14A099 Engine wiring harness gasket (part of 6895A)
retainer 47 6895A Oil filter adapter
43 W701706 RH exhaust manifold nuts (6
req’d)
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-7 Engine — 4.0L SOHC 303-01A-7

DISASSEMBLY (Continued)
6. Illustration 5 of 14. Remove the components in
the order indicated in the following illustration
and table.

Item Part Number Description Item Part Number Description

48 — Throttle position (TP) sensor 50 — Knock sensor (KS) wiring
electrical connector (part of harness electrical connector
12B637) (part of 12B637)
49 — Exhaust gas recirculation 51 — Idle air control (IAC) valve
(EGR) solenoid control valve electrical connector (part of
electrical connector (part of 12B637)
12B637) (Continued)
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-8 Engine — 4.0L SOHC 303-01A-8

DISASSEMBLY (Continued)
Item Part Number Description Item Part Number Description
52 — EGR solenoid valve vacuum 55 9424 Intake manifold
fitting (part of 9E498) 56 9461 Intake manifold gaskets (6
53 — EGR valve vacuum fitting req’d)
(part of 9E498)
54 — Intake manifold bolts (8
req’d) (part of 9K479)
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-9 Engine — 4.0L SOHC 303-01A-9

DISASSEMBLY (Continued)
7. Illustration 6 of 14. Remove the components in
the order indicated in the following illustration
and table.

Item Part Number Description Item Part Number Description

57 — Wiring harness anchor (part 60 12B637 Engine wiring harness
of 12B637) 61 — Fuel pulse dampener vacuum
58 — Wiring harness anchors (2 connector (part of 9E498)
req’d) (part of 12B637) 62 W700902 RH fuel supply manifold
59 — Fuel injector electrical bolts (2 req’d)
connectors (6 req’d) (Continued)
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-10 Engine — 4.0L SOHC 303-01A-10

DISASSEMBLY (Continued)
Item Part Number Description Item Part Number Description
63 W700902 LH fuel supply manifold bolts 71 9448 LH exhaust manifold gasket
(2 req’d) 72 6C519 LH valve cover bolts (6
64 9D280 Fuel supply manifold req’d)
65 9F593 Fuel injectors (6 req’d) 73 6C513 LH valve cover assembly
66 6C519 RH valve cover bolts (6 74 6584 LH valve cover gasket
req’d)
67 6C513 RH valve cover assembly 9. Illustration 8 of 14. Remove the components in
68 6584 RH valve cover gasket the order indicated in the following illustration
and table.
8. Illustration 7 of 14. Remove the components in
the order indicated in the following illustration
and table.

Item Part Number Description

75 6564 Camshaft roller followers (12
req’d)
Item Part Number Description Disassembly Note
69 W701706 LH exhaust manifold nuts (6 76 6500 Hydraulic lash adjusters (12
req’d) req’d)
Disassembly Note
70 9431 LH exhaust manifold
Disassembly Note
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-11 Engine — 4.0L SOHC 303-01A-11

DISASSEMBLY (Continued)
10. Illustration 9 of 14. Remove the components in
the order indicated in the following illustration
and table.

Item Part Number Description Item Part Number Description

77 6K254 RH hydraulic timing chain 81 6M276 RH camshaft sprocket bolt
tensioner Disassembly Note
78 6M052 Jackshaft plug 82 6U001 RH camshaft guide bolt
79 6M276 Jackshaft sprocket bolt 83 6M289 RH camshaft drive cassette
Disassembly Note assembly
80 6U001 RH camshaft guide bolt
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-12 Engine — 4.0L SOHC 303-01A-12

DISASSEMBLY (Continued)
11. Illustration 10 of 14. Remove the components
in the order indicated in the following
illustration and table.

Item Part Number Description Item Part Number Description

84 6K254 LH hydraulic timing chain 88 6M271 Primary chain tensioner
tensioner 89 6M272 Primary chain guide
85 6M276 LH camshaft sprocket bolt Disassembly Note
Disassembly Note 90 6M720 Primary chain and sprocket
86 6M276 Jackshaft sprocket bolt assembly
Disassembly Note 91 6U001 Guide bolt
87 W500011 Primary tensioner bolts (2 92 W500110 Guide bolt
req’d)
93 6M289 LH camshaft drive cassette
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-13 Engine — 4.0L SOHC 303-01A-13

DISASSEMBLY (Continued)
12. Illustration 11 of 14. Remove the components
in the order indicated in the following
illustration and table.

Item Part Number Description Item Part Number Description

94 W500255 Knock sensor bolt 97 6050 LH cylinder head
95 12A699 Knock sensor Disassembly Note
96 6065 LH cylinder head bolts (8 98 6051 LH cylinder head gasket
req’d) 99 6065 RH cylinder head bolts (8
Disassembly Note req’d)
(Continued) Disassembly Note
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-14 Engine — 4.0L SOHC 303-01A-14

DISASSEMBLY (Continued)
Item Part Number Description 13. Illustration 12 of 14. Remove the components
100 6049 RH cylinder head in the order indicated in the following
Disassembly Note illustration and table.
101 6051 RH cylinder head gasket

Item Part Number Description Item Part Number Description

102 E802185 Oil pan bolts (12 req’d) 109 E802185 Lower block cradle bolts (18
103 6675 Oil pan req’d)
104 6710 Oil pan gasket 110 — Lower block cradle bolts (8
req’d)
105 W500214 Oil pump pickup tube bolt
111 6F092 Lower block cradle
106 6617 Oil pump pickup tube
112 6710 Lower block cradle gasket
107 E804588 Lower block cradle bolts (2
req’d) 113 E804387 Oil pump bolts
108 E804587 Lower block cradle bolt 114 6600 Oil pump
Disassembly Note
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-15 Engine — 4.0L SOHC 303-01A-15

DISASSEMBLY (Continued)
14. Illustration 13 of 14. On 4x4 vehicles only,
remove the components in the order indicated
in the following illustration and table.

Item Part Number Description Item Part Number Description

115 W702523 Balance shaft tensioner bolts 118 W500014 Balance shaft drive chain
(2 req’d) guide bolts (2 req’d)
Disassembly Note 119 6K357 Balance shaft drive chain
116 6K355 Balance shaft tensioner guide
117 6A364 Balance shaft drive chain 120 W702523 Balance shaft bolts (2 req’d)
Disassembly Note 121 6A311 Balance shaft
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-16 Engine — 4.0L SOHC 303-01A-16

DISASSEMBLY (Continued)
15. Illustration 14 of 14. Remove the components Item Part Number Description
in the order indicated in the following 132 6329 Crankshaft main bearing cap
illustration and table.
133 6833 Crankshaft main bearing
134 6303 Crankshaft
135 6701 Crankshaft rear oil seal

Item 11: Crankshaft Pulley Disassembly Note

1. Using the special tool, remove the crankshaft
dampener.

Item 13: Generator B+ Terminal Disassembly

Note
1. Disconnect the oil pressure switch electrical
connector and remove the battery cable and
harness.

Item Part Number Description

122 6M263 Jackshaft bolt
123 6M264 Jackshaft sprocket
124 6M278 Jackshaft thrust plate
125 6M263 Jackshaft assembly
126 W701473 Piston connecting rod bearing
cap nuts (12 req’d)
Disassembly Note
127 6210 Connecting rod bearing cap
128 6211 Connecting rod bearing
129 6100 Piston assembly
Disassembly Note
130 6211 Connecting rod bearing 2. Remove the oil pressure switch.
131 6345 Crankshaft main bearing cap
bolts (8 req’d)
(Continued)

2003 Explorer/Mountaineer, 9/2002

303-01A-17 Engine — 4.0L SOHC
DISASSEMBLY (Continued)
Item 23: Electrical Connectors Disassembly Note
1. Disconnect the following:
• Camshaft position (CMP) sensor electrical
connector.
• Ignition coil electrical connector.
• Pin-type retainer.
Item 24: Ignition Wires Disassembly Note
1. CAUTION: It is important to twist
the spark plug wire boots while pulling
upward to avoid possible damage to the
spark plug wires.
NOTE: Spark plug wires must be connected to
the correct ignition coil terminal. Mark spark
plug wire locations before removing them.
Remove the spark plug wires.
303-01A-17
Item 26: Ignition Coil Bracket Disassembly Note
1. Disconnect the radio ignition interference
capacitor electrical connector.
Item 44: RH Exhaust Manifold Disassembly Note
1. Remove the three bolts and the RH engine
insulator bracket.
Item 70: LH Exhaust Manifold Disassembly Note
1. Remove the three bolts and the LH engine
insulator bracket.
Item 75: Camshaft Roller Followers Disassembly
Note
1. Rotate the crankshaft until the camshaft for the
cylinder being serviced is at base circle.
2003 Explorer/Mountaineer, 9/2002
303-01A-18 Engine — 4.0L SOHC 303-01A-18

DISASSEMBLY (Continued)
2. NOTE: Mark each camshaft roller follower to
make sure it is returned to its original position.
Using the special tool, remove the camshaft
roller followers.

2. Remove the rear jackshaft sprocket bolt.

Item 76: Hydraulic Lash Adjuster Disassembly

Note
1. NOTE: Mark each hydraulic lash adjuster to
make sure it is returned to its original position.
Remove the hydraulic lash adjusters.

3. Remove the rear bolt and spacer.

Item 79: Jackshaft Sprocket Bolt Disassembly

Note
1. Using the special tool, hold the crankshaft.

2003 Explorer/Mountaineer, 9/2002

303-01A-19 Engine — 4.0L SOHC 303-01A-19

DISASSEMBLY (Continued)
Item 81: RH Camshaft Sprocket Bolt 4. Separate the camshaft sprocket from the
Disassembly Note camshaft and install a rubber band on the
1. Install the special tools on the RH cylinder cassette to hold the chain and camshaft sprocket
head. in place.

Item 85: LH Camshaft Sprocket Bolt

2. CAUTION: The RH camshaft sprocket Disassembly Note
bolt is a LH threaded bolt.
1. Install the special tools on the LH cylinder
Loosen the camshaft sprocket bolt.
head.

3. Remove the camshaft sprocket bolt.

2. Loosen the camshaft sprocket bolt.
1 Remove the special tools.
2 Remove the camshaft sprocket bolt.

2003 Explorer/Mountaineer, 9/2002

303-01A-20 Engine — 4.0L SOHC 303-01A-20

DISASSEMBLY (Continued)
3. Remove the camshaft sprocket bolt.
1 Remove the special tools.
2 Remove the camshaft sprocket bolt.

2. Remove the jackshaft thrustplate bolts and the

jackshaft thrustplate.

4. Separate the camshaft sprocket from the

camshaft and install a rubber band on the
cassette to hold the chain and camshaft sprocket
in place.

Item 89: Primary Chain Guide Disassembly Note

1. Remove the primary chain guide bolts and the
primary chain guide.

Item 86: Jackshaft Sprocket Bolt Disassembly

Note
1. Using the special tool, keep the crankshaft from
turning while loosening the jackshaft sprocket
bolt.

2003 Explorer/Mountaineer, 9/2002

303-01A-21 Engine — 4.0L SOHC 303-01A-21

DISASSEMBLY (Continued)
Items 96 and 99: LH and RH Cylinder Head
Bolts Disassembly Note
1. NOTE: New cylinder head bolts must be
installed. They are a torque-to-yield design and
cannot be reused.
Remove the bolts in the sequence shown and
remove the cylinder head.

Items 97 and 100: LH and RH Cylinder Head

Disassembly Note
1. CAUTION: Do not use metal scrapers,
wire brushes, power abrasive discs or other
abrasive means to clean sealing surfaces.
These tools cause scratches and gouges which 2. Remove the bolt, the clamp, and the oil pump
make leak paths. drive assembly.
Clean and inspect the sealing surfaces. For
additional information, refer to Section 303-00.

Item 114: Oil Pump Disassembly Note

1. Remove the oil pump pick-up tube, the oil
pump, and the oil pump intermediate shaft.

2003 Explorer/Mountaineer, 9/2002

303-01A-22 Engine — 4.0L SOHC 303-01A-22

DISASSEMBLY (Continued)
Item 115: Balance Shaft Tensioner Bolts Item 126: Piston Connecting Rod Bearing Cap
Disassembly Note Nuts Disassembly Note
1. Install a pin in the balance shaft tensioner. 1. Using the cylinder ridge reamer, remove the
ridge and carbon deposits from the top of each
cylinder to allow removal of the piston(s).

Item 117: Balance Shaft Drive Chain

Disassembly Note
1. NOTE: DO NOT remove the balance shaft Item 129: Piston Assembly Disassembly Note
sprocket bolt. 1. Install rubber hose pieces on the bolts to protect
Remove the balance shaft chain and crankshaft the crankshaft and remove the pistons.
sprocket.

2003 Explorer/Mountaineer, 9/2002