How to: SOHC V6 Heads removal/installation

The following applies to my 2000 Explorer 4.0L SOHC V6. Other years should be similar.

Removal (Both heads)

1. Remove the lower intake manifold.

2. Remove the roller followers.
Note: It takes a special tool to compress the valve springs enough to remove the roller followers. If the crankshaft is positioned with piston 1 at TDC the heads may be removed without removing the roller followers. However, some of the valves will be extended so the heads should not be laid face down with their weight on the extended valves.

3. Remove the fan shroud.

4. Remove the belt tensioner.

5. Disconnect the alternator electrical connectors.


6. Remove the alternator mounting bracket.

7. Remove the power steering bracket bolts and position the accessory bracket aside.


8. Disconnect the crankshaft position (CKP) sensor electrical connector.

9. Remove the electrical harness retainer.


10. Disconnect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.


11. Disconnect the EGR tube nut.


12. Position the EGR valve bracket aside.

SOHC V6 heads removal (Continued)

13. Remove the upper heater water hose.
1. Squeeze the heater hose clamp.
2. Remove the heater water hose.


14. Remove the lower heater water hose and position aside.
1. Remove the bolt.
2. Squeeze the hose clamp.
3. Remove the heater water hose and position aside.


15. Disconnect the water bypass hose and position aside.


16. Remove the thermostat housing.


17. Remove the crankcase vent separator spring steel clip and remove the separator.

SOHC V6 heads removal (Continued)

18. Remove the oil level indicator tube.


19. Remove the exhaust manifolds.

20. Remove the engine wiring harness bolts and position the wiring harness aside.


21. Remove the engine compartment ground strap.


22. Remove the LH hydraulic chain tensioner.


23. Remove the left camshaft sprocket retaining bolt.

SOHC V6 heads removal (Continued)

24. Remove the left cassette positioning bolt.


25. CAUTION: To avoid breaking the left cassette, remove the camshaft sprocket from the chain and cassette to gain clearance to remove cylinder the head.
NOTE: Hold the chain and cassette with a rubber band to aid in removal and prevent the chain from falling into the cylinder block.
Remove the LH camshaft sprocket from the cassette.


26. Remove the eight 12 mm bolts and two 8 mm bolts in the sequence shown and remove the LH cylinder head.

Discard the head gasket.

27. Remove the RH hydraulic chain tensioner.


28. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
Using the special tool, remove the camshaft retaining bolt and the camshaft sprocket.

SOHC V6 heads removal (Continued)

29. Remove the right cassette positioning bolt.


30. CAUTION: To avoid breaking the cassette, remove the camshaft sprocket from the chain and cassette to gain clearance to remove cylinder the head.
NOTE: Hold the chain and cassette with a rubber band to aid in removal and prevent the chain from falling into the cylinder block.
Remove the RH camshaft sprocket from the cassette.


31. Remove the two 8 mm bolts and the eight 12 mm bolts (T55) in the sequence shown, and remove the RH cylinder head.

Discard the head gasket.

32. Inspect the cylinder head and block for flatness.

SOHC V6 Heads installation

1. NOTE: The LH is shown, the RH is similar.
Position the cylinder head gasket and the cylinder head.


2. NOTE: LH shown, RH similar.
Install the 12 mm bolts (T55) and tighten in the sequence shown.


3. NOTE: LH shown, RH similar.
Install the two 8 mm bolts.


4. NOTE: LH shown, RH similar.
Tighten the eight 12 mm bolts (T55) in the sequence shown in two stages.
 Stage 1: Tighten the bolts 90 degrees.
 Stage 2: Tighten the bolts an additional 90 degrees.


5. Install the RH rear camshaft sprocket in the cassette.

SOHC V6 Heads installation (Continued)

6. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
Install the RH rear camshaft bolt.


7. Install the RH cassette guide bolt.


8. CAUTION: The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
Install the LH front camshaft bolt.


9. Install the LH cassette guide bolt.


10. Perform SOHC V6 Camshaft Timing

SOHC V6 Heads installation (Continued)

11. Install the engine compartment ground strap.


12. Install the wiring harness.


13. Install the exhaust manifolds.

14. Install the oil level indicator tube.


15. Install the crankcase vent separator and the spring steel clip.


16. Install the thermostat housing.

SOHC V6 Heads installation (Continued)

17. Connect the water bypass hose.


18. Install the lower heater water hose.
1. Position the heater water hose.
2. Squeeze the heater hose clamp and position.
3. Install the bolt.


19. Install the upper heater water hose.
1. Position the heater water hose.
2. Squeeze the hose clamp and position.


20. Install the EGR bracket.


21. Connect the EGR tube nut.

SOHC V6 Heads installation (Continued)

22. Connect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.


23. Install the electrical harness retainer.


24. Connect the crankshaft position (CKP) sensor electrical connector.


25. Install the accessory bracket.


26. Install the alternator mounting bracket.

SOHC V6 Heads installation (Continued)

27. Connect the alternator electrical connectors.


28. Install the belt tensioner.

29. Install the fan shroud.

30. Install the camshaft roller followers if previously removed.

31. Install the lower intake manifold.