303-01A-1 Engine — 4.

0L SOHC 303-01A-1

IN-VEHICLE REPAIR
Oil Pan, Oil Pump, Oil Pump Screen
and Pickup Tube

Special Tool(s)
Lifting Eyes
303-D050 (D81L-6000-D) or
equivalent

3 Bar Engine Support Kit 5. NOTE: Not all vehicles will have screws
303-290A installed in the radiator fan shroud.
Remove and discard the screws. Remove the
bolts and the fan shroud.

Material
Item Specification
Metal Surface Cleaner WSE-M5B392-A
F4AZ-19A536-RA
Super Premium SAE WSS-M2C153-G
5W-30 Motor Oil
XO-5W30-QSP or
equivalent

1. With the vehicle in neutral, position it on a

hoist. For additional information, refer to 6. Remove the air cleaner outlet tube. For
Section 100-00. additional information, refer to Section
303-04A.
2. Disconnect the negative battery cable. For
additional information, refer to Section 414-00. 7. Remove the bolt.
3. Remove the upper air deflector.

4. Remove the weatherstrip.

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

IN-VEHICLE REPAIR (Continued)

8. Install the RH lifting eye using the previously 11. NOTE: RH side shown, LH side similar.
removed bolt. On 4x2 vehicles, remove the motor mount nuts.

9. NOTE: This is not a typical setup. Only the 12. On 4x4 vehicles, remove the four bolts and the
right side of the motor will be raised. crossmember bolts.
Install the special tools.

13. On 4x4 vehicles, remove the RH motor mount

10. Drain the engine oil. nut.

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

IN-VEHICLE REPAIR (Continued)

14. On 4x4 vehicles, remove the LH side through 16. Remove the components in the order indicated
bolt and nut. in the following illustration and table. To
remove individual components, carry out only
the listed steps.

Component Steps
Oil pan 4x4 1-9
Oil pan 4x2 7-9
Oil pump pickup tube 4x4 1-11
Oil pump pickup tube 4x2 7-11
Lower block cradle 4x4 1-18
Lower block cradle 4x2 7-18
Oil pump 4x4 1-20
Oil pump 4x2 7-20
15. Raise the engine.

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

IN-VEHICLE REPAIR (Continued)

17. NOTE: The following illustration and related
steps are only intended for 4x4 vehicles only.
Illustration 1 of 2. Remove the components in
the order indicated in the following illustration.

Item Part Number Description Item Part Number Description

1 W707472-S Stabilizer bar bracket bolts (4 4 N808403 Axle housing bolt
required) 5 N808403 Axle housing bolt
2 — Stabilizer bar (position aside) 6 — Axle housing
3 N808403 Axle housing bolt Removal Note
(Continued)

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

IN-VEHICLE REPAIR (Continued)

18. Illustration 2 of 2. Remove the components in
the order indicated in the following illustration.

Item Part Number Description Item Part Number Description

7 E802185 Oil pan bolt (12 required) 18 6710 Lower block cradle gasket
8 6675 Oil pan Removal Note
9 6710-A Oil pan gasket 18 6710 Lower block cradle gasket
Installation Note
10 W500214 Pickup tube bolt
19 E804387 Oil pump bolt
11 6617 Oil pump pickup tube
20 6600 Oil pump
12 E804588 Lower block cradle bolt
Installation Note 19. To install, reverse the removal procedure.
13 E804587 Lower block cradle bolt
Installation Note 20. Fill the engine with clean engine oil.
14 E802185 Lower block cradle bolt
Installation Note Item 6: Axle Housing Removal Note
15 — Lower block cradle bolt
Installation Note 1. CAUTION: Do not let the axle housing
16 — Lower block cradle bolt
hang freely. Failure to follow this instruction
Installation Note can result in damage to the vehicle.
17 6F092 Lower block cradle Using a transmission jack, lower the axle
Removal Note housing to gain clearance for the removal of the
17 6F092 Lower block cradle oil pan.
Installation Note
(Continued)

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

IN-VEHICLE REPAIR (Continued)

Item 17: Lower Block Cradle Removal Note
1. Remove the starter motor. For additional
information, refer to Section 303-04A.

2. CAUTION: Failure to back off the set

screws can result in damage to the lower
block cradle.
Back the set screws off until they are below the
lower block cradle boss.

Item 18: Lower Block Cradle Gasket Installation

Note
1. NOTE: If the block cradle gasket is not
secured within four minutes of the sealant
application, the sealant must be removed and
the sealing area cleaned with metal surface
cleaner. Allow the silicone to dry until there is
no sign of wetness, or four minutes, whichever
is longer. Failure to follow this procedure can
cause future oil leakage.
Item 18: Lower Block Cradle Gasket Removal Apply silicone in the six places shown.
Note
1. NOTE: Gasket material as well as silicone
sealant may be present in the cavities in the
main bearing cap. This material must be
removed completely prior to assembly.
Clean the sealant from the cavities on the rear
main bearing cap.

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

IN-VEHICLE REPAIR (Continued)

Item Number 12, 13, 14, 15, 16 and 17: Lower
Block Cradle and Bolts Installation Note
1. Position the lower block cradle and gasket
assembly.

5. NOTE: The lower block cradle to the cylinder

block alignment must be within a maximum
mismatch of 0.25 mm (0.01 in) lower block
cradle underflush or 0.05 mm (0.00196 in)
lower block cradle protrusion.
2. Install and hand-tighten the outer bolts and Using a straightedge, align the transmission face
nuts. of the lower block cradle with the rear face of
the cylinder block.

3. Install and hand-tighten the rear lower block

cradle bolts. 6. Tighten the outer bolts.

4. Install the two rear lower block cradle-to-bell

housing bolts.

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

IN-VEHICLE REPAIR (Continued)

7. Tighten the rear lower block cradle bolts. 10. Install and hand-tighten the six remaining bolts.

8. Tighten the eight inserts. 11. Tighten the lower block cradle bolts in two
stages:
• Stage 1: Tighten to 15 Nm (11 lb-ft).
• Stage 2: Tighten to 34 Nm (25 lb-ft).

9. Install the two silver covered bolts and new

washer seals. Hand-tighten them at this time.

2003 Explorer/Mountaineer, 9/2002