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Performance Upgrades - Maintenance - Modifications - Problem Solving - Off-Road - Street Trucks. Covering the Explorer, ST, Sport, Lincoln Aviator, Sport Trac, Mercury Mountaineer, Mazda Navajo, Ford Ranger, Mazda Pickups, and the Aerostar. Featuring H.I. - Human Intelligence.
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.
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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.
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.
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.