How to: 2002 Explorer SOHC V6 Front Cover Removal & Install

Removal

1. Disconnect the battery ground cable
2. Remove the radiator. See 2002 Explorer Radiator Removal/Installation
3. Remove the power steering cooler bolts (if so equipped) and position the cooler aside.

4. Remove the crankshaft pulley.
CAUTION: The pulley retaining bolt is torque-to-yield and cannot be reused.
a. Remove and discard the damper bolt.
b. Using the special tool, remove the crankshaft pulley.

Removal (cont)

5. Remove the brackets.


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.
6. Remove all spark plug wires from the ignition coil.

7. Remove the bolts.

8. Remove the accessory bracket and position aside.

Removal (cont)

9. Disconnect the alternator wiring and position the wiring aside.

10. Remove the accessory drive belt tensioner.
11. Remove alternator mounting bracket and position aside.

Removal (cont)

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

13. Remove the wiring anchors and position the wiring aside.

14. Remove the wiring harness anchor and position the wiring aside.

15. Remove the thermostat housing.
a. Remove the bolts.

b. Release the bypass hose clamp.

Removal (cont)

16. Release the hose clamp and remove the lower heater water hose.

17. Remove the bracket bolt.

18. Release the hose clamp and remove the lower radiator hose.
NOTE: It is not necessary to remove the water pump. The front cover can be removed with the water pump attached.
19. Remove the engine front cover.
a. Remove the front cover to block bolts.

b. Remove the block cradle to front cover bolts.

Install

1. Clean and inspect the sealing surfaces.
2. Apply silicone gasket and sealant to the oil pan and the engine block mating surfaces.

3. Apply silicone gasket and sealant to the front cover in two places.

4. Install the engine front cover.
Front cover to block bolts (14 lb-ft)

Block cradle to front cover bolts (80 lb-in)
5. Install the lower radiator hose and clamp.

6. Install the bracket bolt (27 lb-ft).

Install (cont)

7. Install the lower heater water hose and clamp.

8. Install the thermostat housing.
a. Install the bypass hose onto the water pump.

b. Install the bolts (8 lb-ft).
c. Position the bypass hose clamp.
9. Install the wiring anchor.

10. Secure the wiring anchors.

11. Connect the CKP sensor electrical connector.

Install (cont)

12. Install the alternator mounting bracket (31 lb-ft).

13. Connect the alternator wiring.

14. Install the accessory drive belt tensioner.
15. Install the accessory bracket (31 lb-ft).

16. Install the bolts (89 lb-in.

NOTE: Apply silicone dielectric compound to the inside of the spark plug wire boots.
17. Install the spark plug wires onto the ignition coil.

Install (cont)

18. Raise and support the vehicle.
19. Install the brackets (14 lb-ft).

20. Install the crankshaft pulley.
21. Install the power steering cooler (if so equipped).

22. Install the radiator. See 2002 Explorer Radiator Removal/Installation
23. Drain the engine oil.
24. Lower the vehicle.
25. Fill the engine with clean engine oil.
26. Fill the engine with coolant.
27. Connect the negative battery cable.