Ford Explorer 4.0 L SOHC Intake Replacement

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Tools

Ratchets and Extensions, 1 1/16 wrench,Trim Panel Tool,Air Blower, Picks, Torx 20,30, 7,8mm sockets, WD40, 20mm deep socket

Instructions

Step 1
Use 7mm socket and ratchet, remove 4 cover retaining screws and throttle and cruise control retaining screws under cover, remove cables from throttle body and place out of way

Step 2
Remove air intake tube and place to side

Step 3
Disconnect TP Sensor and IAC connector

Step 4
Remove vacuum tube to brake booster and PCV tube to back of intake on both sides and vacuum supply on RH side

Step 5
Remove EVR solenoid bracket, 2 Torx 20 screws, use blow gun to blow all debris away form intake manifold

Step 6

Step 7

Loosen all Torx 30 screws holding upper intake down. you dont have to pull them all the way out

Step 8
Pull up intake carefully rocking to release from egr tube, necc to remove tubes attached under intakeon both sides

Step 9
Place upper intake to side, remove 12 8mm bolts holding down lower intake and remove

Step 10
If your only doing Intake Gaskets ,clean all mounting surfaces,replace lower gaskets and reinstall
If your doing the Tensioner follow the next steps. Be careful not to drop anything down any of the cylinders or you will be crying when you have to replace the engine.

Step 11
Remove ECT Sensor connector and use 20mm socket to remove ECT Sensor from Thermostat housing

Step 12
Use 1 1/16 Wrench to break loose tensioner see it in above photo, also be careful of th fuel line . once broken loose should spin out by hand

Step 13
Remove TORX 30 and install OIl restrictor that comes with FORD OEM KIT

Step 14
Reinstall new TORX 30 ,Reinstall new Camshaft Chain Tensioner, Make sure to hand start both this is one job you don't want to crossthread. Once you have spun in Tensioner all the way tighten with wrench.

Step 15
Reinstall all, Make sure you reinstall all your vacuum lines, I plug in LH PCV hose, lube EGR Tube O-Ring and route IAC wiring first when installing upper intake, I also don't install upper gaskets until i'm ready to install upper intake because they tend to swell and come loose.
Step 16
Disconnect Battery or PCM to clear fuel tables

Vehicle list applied to this article:-

Make Model Variant From To

Ford

Explorer

1997

2002

Ford

Explorer Sport

1997

2002

Ford

Explorer Sport Trac

1997

2002

Inserted Text

Removed Text

Changed Text

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Ford

Explorer

1997

2002

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Ford

Explorer Sport

1997

2002

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Ford

Explorer Sport Trac

1997

2002

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Article Title:	Ford Explorer 4.0 L SOHC Intake Replacement

<table cellspacing="5" cellpadding="0" width="100%" border="0"> <tbody> <tr> <td style="HEIGHT: 20px" colspan="2"> </td> </tr> <tr> <td style="WIDTH: 1%"> </td> <td> <table cellspacing="0" cellpadding="0" width="100%" align="left" border="0"> <tbody> <tr> <td valign="top"><strong><font face="Verdana" color="#e70000">Tools</font></strong></td> </tr> <tr> <td> <img class="Button" height="288" alt="" width="384" onclick="javascript:window.open('../Article/popup.aspx?Image=http://www.mechanixtrix.com/UserFiles/DSC00992(1).JPG','popup','location=no,directories=no,status=no,menubar=no,toolbar=no,resizable=no,scroll=no')" src="/UserFiles/DSC00992(1).JPG" /><br /> Ratchets and Extensions, 1 1/16 wrench,Trim Panel Tool,Air Blower, Picks, Torx 20,30, 7,8mm sockets, WD40, 20mm deep socket<br /> </td> </tr> </tbody> </table> </td> </tr> <tr> <td style="WIDTH: 1%"> </td> <td> <table cellspacing="0" cellpadding="0" width="100%" align="left" border="0"> <tbody> <tr> <td><strong><font face="Verdana" color="#e70000">Instructions</font></strong></td> </tr> <tr> <td>Step 1<br /> Use 7mm socket and ratchet, remove 4 cover retaining screws and throttle and cruise control retaining screws under cover, remove cables from throttle body and place out of way<br /> <img class="Button" height="288" alt="" width="384" onclick="javascript:window.open('../Article/popup.aspx?Image=http://www.mechanixtrix.com/UserFiles/DSC00967.JPG','popup','location=no,directories=no,status=no,menubar=no,toolbar=no,resizable=no,scroll=no')" src="/UserFiles/DSC00967.JPG" /><br /> <br /> Step 2<br /> Remove air intake tube and place to side<br /> <br /> Step 3<br /> Disconnect TP Sensor and IAC connector<br /> <img class="Button" height="288" alt="" width="384" onclick="javascript:window.open('../Article/popup.aspx?Image=http://www.mechanixtrix.com/UserFiles/DSC00969.JPG','popup','location=no,directories=no,status=no,menubar=no,toolbar=no,resizable=no,scroll=no')" src="/UserFiles/DSC00969.JPG" /><br /> <br /> Step 4<br /> Remove vacuum tube to brake booster and PCV tube to back of intake on both sides and vacuum supply on RH side<br /> <img class="Button" height="288" alt="" width="384" onclick="javascript:window.open('../Article/popup.aspx?Image=http://www.mechanixtrix.com/UserFiles/DSC00971.JPG','popup','location=no,directories=no,status=no,menubar=no,toolbar=no,resizable=no,scroll=no')" src="/UserFiles/DSC00971.JPG" /><br /> <br /> <img class="Button" height="288" alt="" width="384" onclick="javascript:window.open('../Article/popup.aspx?Image=http://www.mechanixtrix.com/UserFiles/DSC00972.JPG','popup','location=no,directories=no,status=no,menubar=no,toolbar=no,resizable=no,scroll=no')" src="/UserFiles/DSC00972.JPG" /><br /> <br /> Step 5<br /> Remove EVR solenoid bracket, 2 Torx 20 screws, use blow gun to blow all debris away form intake manifold<br /> <br /> Step 6<br /> <img class="Button" height="288" alt="" width="384" onclick="javascript:window.open('../Article/popup.aspx?Image=http://www.mechanixtrix.com/UserFiles/DSC00974.JPG','popup','location=no,directories=no,status=no,menubar=no,toolbar=no,resizable=no,scroll=no')" src="/UserFiles/DSC00974.JPG" /><br /> <br /> Step 7<br /> <br /> Loosen all Torx 30 screws holding upper intake down. you dont have to pull them all the way out<br /> <img class="Button" height="288" alt="" width="384" onclick="javascript:window.open('../Article/popup.aspx?Image=http://www.mechanixtrix.com/UserFiles/DSC00990.JPG','popup','location=no,directories=no,status=no,menubar=no,toolbar=no,resizable=no,scroll=no')" src="/UserFiles/DSC00990.JPG" /><br /> <br /> Step 8<br /> Pull up intake carefully rocking to release from egr tube, necc to remove tubes attached under intakeon both sides<br /> <img class="Button" height="288" alt="" width="384" onclick="javascript:window.open('../Article/popup.aspx?Image=http://www.mechanixtrix.com/UserFiles/DSC00975.JPG','popup','location=no,directories=no,status=no,menubar=no,toolbar=no,resizable=no,scroll=no')" src="/UserFiles/DSC00975.JPG" /><br /> <br /> Step 9 <br /> Place upper intake to side, remove 12 8mm bolts holding down lower intake and remove<br /> <img class="Button" height="288" alt="" width="384" onclick="javascript:window.open('../Article/popup.aspx?Image=http://www.mechanixtrix.com/UserFiles/DSC00977.JPG','popup','location=no,directories=no,status=no,menubar=no,toolbar=no,resizable=no,scroll=no')" src="/UserFiles/DSC00977.JPG" /><br /> <br /> Step 10<br /> If your only doing Intake Gaskets ,clean all mounting surfaces,replace lower gaskets and reinstall<br /> If your doing the Tensioner follow the next steps. Be careful not to drop anything down any of the cylinders or you will be crying when you have to replace the engine.<br /> <br /> Step 11<br /> Remove ECT Sensor connector and use 20mm socket to remove ECT Sensor from Thermostat housing<br /> <img class="Button" height="288" alt="" width="384" onclick="javascript:window.open('../Article/popup.aspx?Image=http://www.mechanixtrix.com/UserFiles/DSC00987.JPG','popup','location=no,directories=no,status=no,menubar=no,toolbar=no,resizable=no,scroll=no')" src="/UserFiles/DSC00987.JPG" /><br /> <br /> Step 12 <br /> Use 1 1/16 Wrench to break loose tensioner see it in above photo, also be careful of th fuel line . once broken loose should spin out by hand <br /> <br /> Step 13<br /> Remove TORX 30 and install OIl restrictor that comes with FORD OEM KIT<br /> <img class="Button" height="288" alt="" width="384" onclick="javascript:window.open('../Article/popup.aspx?Image=http://www.mechanixtrix.com/UserFiles/DSC00988.JPG','popup','location=no,directories=no,status=no,menubar=no,toolbar=no,resizable=no,scroll=no')" src="/UserFiles/DSC00988.JPG" /><br /> <br /> Step 14 <br /> Reinstall new TORX 30 ,Reinstall new Camshaft Chain Tensioner, Make sure to hand start both this is one job you don't want to crossthread. Once you have spun in Tensioner all the way tighten with wrench.<br /> <br /> Step 15<br /> Reinstall all, Make sure you reinstall all your vacuum lines,  I plug in LH PCV hose, lube EGR Tube O-Ring and route IAC wiring first when installing upper intake, I also don't install upper gaskets until i'm ready to install upper intake because they tend to swell and come loose.<br /> Step 16 <br /> Disconnect Battery or PCM to clear fuel tables <br /> </td> </tr> </tbody> </table> </td> </tr> </tbody> </table>
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