Non-Turbo Engine Complete Assembly for 2020-2024 Ford Explorer

A quick look at your own vehicle makes sure the right engine shows up:

• Verify the 8th digit of your 17-digit VIN is 'H'.
• Confirm your Explorer is a 4x4 (AWD) model.
• Verify your existing turbocharger, wastegate actuator, and exhaust manifold are in good, reusable condition to transfer to this engine.

What the install really takes — plan and budget with confidence:

Special tools this job needs:

• Ford Camshaft/Crankshaft Timing Lock Tool Set (OEM 303-1565, 303-1600, 303-748, 303-1594, 303-1595, 303-1521, 303-1504)
• Torque Angle Gauge
• High-pressure fuel line disconnect tools
• Engine hoist with a load leveler
• Engine stand
• Ford-specific diagnostic scan tool (FORScan or dealer-level IDS)
• Reverse Torx sockets

Budget for these consumables at install:

• 5.7 quarts of SAE 5W-30 full synthetic motor oil meeting Ford specification WSS-M2C961-A1
• New Motorcraft FL-910S oil filter (or equivalent)
• Motorcraft Yellow Prediluted Antifreeze/Coolant meeting Ford specification WSS-M97B57-A2
• New Motorcraft SP-594 spark plugs, gapped to 0.028–0.031 inches
• New intake manifold gasket
• New exhaust manifold gasket
• New turbocharger mounting gaskets and oil/coolant line copper washers
• New high-pressure fuel pump O-ring
• New crankshaft pulley bolt (one-time use)
• New flywheel/flexplate bolts (one-time use)
• New high-pressure fuel pump mounting bolts (one-time use)
• New rear main seal (highly recommended)
• New thermostat (recommended)

What your vehicle’s computers will need after the swap:

What’s involved: VIN Programming, PATS Security Relearn, and Misfire Monitor Neutral Profile Correction

Sources differ on programming requirements. To be safe, assume programming is required. The Powertrain Control Module (PCM) must be programmed to your vehicle's specific VIN and a PATS security relearn performed. Additionally, a Misfire Monitor Neutral Profile Correction (Crankshaft Position Sensor Relearn) is mandatory. If not completed, the PCM will trigger false misfire codes (P0300, P0301, etc.) and potentially put the vehicle into a degraded performance mode.

Pro tips for a smooth first start-up — hand them to whoever does the install:

• CRITICAL: Keyless / Friction-Fit Crankshaft Snout. The crankshaft pulley and timing sprocket are NOT keyed. If you loosen the crankshaft pulley bolt without locking the camshafts and crankshaft with special timing tools, the timing sprocket will spin freely, causing the valves to strike the pistons and destroy the engine. Never rotate the engine with the harmonic balancer removed.
• High-Pressure Fuel System operates over 2,000 PSI. Relieve pressure before disconnecting. High-pressure fuel line and fuel pump bolts are one-time-use and must be replaced.
• AWD Transfer Case (PTU) must be unbolted and supported during the swap. Ensure splines are clean, lubricated, and seals are replaced.
• Rear Vacuum Pump at the rear of the cylinder head must be removed to install the camshaft alignment tool. Be careful not to crack fragile plastic vacuum lines.
• Fragile plastic connectors on modern engine harnesses can become brittle with heat and age. Use proper trim tools to avoid breaking clips.
• Turbocharger Transfer: Ensure all oil and coolant lines are clean, free of debris, and not kinked. Use new gaskets and O-rings to prevent premature turbo failure.

Easy to get right once you know them:

• Reusing the Crankshaft Pulley Bolt: This torque-to-yield bolt will stretch or back out if reused, causing the keyless timing gear to slip and instantly bend the valves.
• Rotating the Crankshaft with the Balancer Off: Causes the timing gear to slip and throws the engine out of time, destroying the valves.
• Blaming the Engine for False Misfire Codes: Requesting returns for random misfire codes (P0300) when they simply failed to perform the mandatory Misfire Monitor Neutral Profile Correction.
• Failing to Side-by-Side Compare Accessories: Not transferring original brackets, sensors, or oil pan if minor differences exist due to vehicle options.
• Ignoring the VIN Code: Ordering without verifying that the 8th digit of the VIN is 'H'.
• Buying for a RWD Model: Ordering this 4x4 engine for a RWD vehicle, which uses a different oil pan and will not fit.
• Not Planning for Programming: Expecting the engine to start without arranging for the required PCM programming and PATS security relearn.
• Reusing Old Turbo Lines: Reusing contaminated or restricted oil feed lines, which is a primary cause of turbo failure.

Not issues with the units on this page — the manufacturer documented these for every engine of this family, wherever you buy one. Handy for your installer: