1991 1999 ford explorer chilton User Manual
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ChiltonDIY Maintaince and Repair Manual Ford Explorer 1991-1999
Table of Contents HOW TO USE THIS BOOK .............................................................................................................................1 Introduction ..............................................................................................................................................1 Where to Begin ........................................................................................................................................1 Avoiding Trouble.....................................................................................................................................1 Maintenance or Repair? ...........................................................................................................................1 Avoiding the Most Common Mistakes....................................................................................................2 TOOLS AND EQUIPMENT .............................................................................................................................3 Introduction ..............................................................................................................................................3 Special Tools..........................................................................................................................................11 SERVICING YOUR VEHICLE SAFELY.....................................................................................................13 Introduction ............................................................................................................................................13 Dos ........................................................................................................................................................14 Donts .....................................................................................................................................................15 FASTENERS, MEASUREMENTS AND CONVERSIONS .........................................................................17 Bolts, Nuts and Other Threaded Retainers............................................................................................17 Torque ....................................................................................................................................................18 TORQUE WRENCHES ..................................................................................................................19 TORQUE ANGLE METERS .........................................................................................................20 Standard and Metric Measurements .......................................................................................................21 SERIAL NUMBER IDENTIFICATION ........................................................................................................23 Vehicle Identification Number (VIN)....................................................................................................23 Vehicle Data...........................................................................................................................................25 Safety Compliance Certification Label..................................................................................................28 Emission Calibration Label...................................................................................................................29 Engine ....................................................................................................................................................30 Transmission ..........................................................................................................................................30 Transfer Case.........................................................................................................................................30 Front Drive Axle....................................................................................................................................30 Rear Axle ...............................................................................................................................................30 ROUTINE MAINTENANCE AND TUNE-UP .............................................................................................33 Introduction ............................................................................................................................................33 Air Cleaner (Element) ............................................................................................................................40 REMOVAL & INSTALLATION ...................................................................................................40 Fuel Filter ...............................................................................................................................................43 REMOVAL & INSTALLATION ...................................................................................................43 PCV Valve .............................................................................................................................................48 INSPECTION ..................................................................................................................................48 REMOVAL & INSTALLATION ...................................................................................................49 Evaporative Canister..............................................................................................................................49 SERVICING ....................................................................................................................................50 Battery ....................................................................................................................................................50 PRECAUTIONS .............................................................................................................................50 GENERAL MAINTENANCE ........................................................................................................51 BATTERY FLUID..........................................................................................................................51 CABLES ..........................................................................................................................................54 CHARGING ....................................................................................................................................57 REPLACEMENT ............................................................................................................................57HOW TO USE THIS BOOK i
Table of Contents ROUTINE MAINTENANCE AND TUNE-UP Belts .......................................................................................................................................................57 INSPECTION ..................................................................................................................................57 ADJUSTMENT ...............................................................................................................................59 REMOVAL & INSTALLATION ...................................................................................................63 Timing Belts..........................................................................................................................................68 INSPECTION ..................................................................................................................................68 CAMSHAFT TIMING INSPECTION ...........................................................................................72 Hoses ......................................................................................................................................................72 INSPECTION ..................................................................................................................................72 REMOVAL & INSTALLATION ...................................................................................................74 CV-Boots .............................................................................................................................................76 INSPECTION ..................................................................................................................................76 Spark Plugs ............................................................................................................................................77 SPARK PLUG HEAT RANGE ......................................................................................................78 REMOVAL & INSTALLATION ...................................................................................................80 INSPECTION & GAPPING ...........................................................................................................82 Spark Plug Wires ...................................................................................................................................85 REMOVAL & INSTALLATION ...................................................................................................85 TESTING ........................................................................................................................................86 Distributor Cap and Rotor ......................................................................................................................88 REMOVAL & INSTALLATION ...................................................................................................88 INSPECTION ..................................................................................................................................89 Ignition Timing......................................................................................................................................90 GENERAL INFORMATION .........................................................................................................90 INSPECTION & ADJUSTMENT ..................................................................................................90 Valve Lash.............................................................................................................................................92 Idle Speed and Mixture Adjustments .....................................................................................................92 Air Conditioning System.......................................................................................................................93 SYSTEM SERVICE & REPAIR ....................................................................................................93 PREVENTIVE MAINTENANCE ..................................................................................................93 SYSTEM INSPECTION .................................................................................................................94 Windshield Wipers................................................................................................................................94 ELEMENT (REFILL) CARE & REPLACEMENT .......................................................................95 Tires and Wheels ....................................................................................................................................96 TIRE ROTATION ...........................................................................................................................97 TIRE DESIGN ................................................................................................................................97 TIRE STORAGE .............................................................................................................................99 INFLATION & INSPECTION .......................................................................................................99 FLUIDS AND LUBRICANTS .......................................................................................................................103 Fluid Disposal ......................................................................................................................................103 Oil and Fuel Recommendations ...........................................................................................................103 ENGINE OIL................................................................................................................................103 FUEL .............................................................................................................................................105 OPERATION IN FOREIGN COUNTRIES .................................................................................105 Engine ..................................................................................................................................................105 OIL LEVEL CHECK ....................................................................................................................105 OIL & FILTER CHANGE ............................................................................................................107 Manual Transmission ...........................................................................................................................113 FLUID RECOMMENDATION ....................................................................................................113 LEVEL CHECK ............................................................................................................................113 HOW TO USE THIS BOOK ii
Table of Contents FLUIDS AND LUBRICANTS DRAIN & REFILL ........................................................................................................................113 Automatic Transmission ......................................................................................................................114 FLUID RECOMMENDATION ....................................................................................................114 LEVEL CHECK ............................................................................................................................114 DRAIN, PAN/FILTER SERVICE & REFILL .............................................................................116 Transfer Case.......................................................................................................................................123 FLUID RECOMMENDATION ....................................................................................................123 LEVEL CHECK ............................................................................................................................123 DRAIN & REFILL ........................................................................................................................125 Front and Rear Drive Axle...................................................................................................................125 FLUID RECOMMENDATION ....................................................................................................125 LEVEL CHECK ............................................................................................................................126 DRAIN & REFILL ........................................................................................................................128 Cooling System....................................................................................................................................131 FLUID RECOMMENDATIONS ..................................................................................................132 INSPECTION ................................................................................................................................132 DRAINING, FLUSHING & REFILLING ....................................................................................136 Brake Master Cylinder .........................................................................................................................140 FLUID RECOMMENDATIONS ..................................................................................................140 LEVEL CHECK ............................................................................................................................140 Clutch Master Cylinder ........................................................................................................................142 FLUID RECOMMENDATIONS ..................................................................................................142 LEVEL CHECK ............................................................................................................................142 Power Steering Pump Reservoir ..........................................................................................................142 FLUID RECOMMENDATIONS ..................................................................................................142 LEVEL CHECK ............................................................................................................................143 Manual Steering Gear..........................................................................................................................144 Chassis Greasing ..................................................................................................................................144 Body Lubrication .................................................................................................................................145 HOOD/DOOR LATCH & HINGES .............................................................................................145 LOCK CYLINDERS .....................................................................................................................145 DOOR WEATHERSTRIPPING ...................................................................................................145 THROTTLE VALVE (TV) & KICKDOWN LINKAGE.............................................................145 Wheel Bearings ....................................................................................................................................145 REPACKING ................................................................................................................................146 TOWING THE VEHICLE ............................................................................................................................151 General Recommendations .................................................................................................................151 Trailer Weight .....................................................................................................................................151 Hitch (Tongue) Weight.......................................................................................................................151 Oil Cooler ...........................................................................................................................................152 TRANSMISSION .........................................................................................................................152 Handling a Trailer ...............................................................................................................................152 Towing the Vehicle .............................................................................................................................152 JUMP STARTING A DEAD BATTERY .....................................................................................................155 Introduction ..........................................................................................................................................155 Jump Starting Precautions ...................................................................................................................155 Jump Starting Procedure ......................................................................................................................156HOW TO USE THIS BOOK iii
Table of Contents JACKING ........................................................................................................................................................159 SPECIFICATION CHARTS.........................................................................................................................163 DISTRIBUTOR IGNITION SYSTEM.........................................................................................................169 General Information .............................................................................................................................169 SYSTEM OPERATION ................................................................................................................170 Diagnosis and Testing ..........................................................................................................................171 SERVICE PRECAUTIONS ..........................................................................................................171 PRELIMINARY CHECKS...........................................................................................................171 TEST PROCEDURES ..................................................................................................................171 Ignition Coil.........................................................................................................................................177 TESTING ......................................................................................................................................177 REMOVAL & INSTALLATION .................................................................................................180 Ignition Control Module (ICM)...........................................................................................................180 REMOVAL & INSTALLATION .................................................................................................180 Distributor ............................................................................................................................................182 REMOVAL & INSTALLATION .................................................................................................182 Camshaft Position (CMP) Sensor........................................................................................................184 DISTRIBUTORLESS IGNITION SYSTEM...............................................................................................185 General Information .............................................................................................................................185 SYSTEM OPERATION ................................................................................................................185 Diagnosis and Testing ..........................................................................................................................187 SERVICE PRECAUTIONS ..........................................................................................................187 PRELIMINARY CHECKS...........................................................................................................187 GENERAL SYSTEM TEST.........................................................................................................187 Ignition Coil Pack(s) ............................................................................................................................199 TESTING ......................................................................................................................................199 REMOVAL & INSTALLATION .................................................................................................201 Ignition Control Module (ICM)...........................................................................................................207 REMOVAL & INSTALLATION .................................................................................................207 Camshaft Position (CMP) and Crankshaft Position (CKP) Sensors ....................................................209 FIRING ORDERS ..........................................................................................................................................211 CHARGING SYSTEM...................................................................................................................................217 General Information .............................................................................................................................217 Alternator Precautions .........................................................................................................................218 Alternator .............................................................................................................................................219 TESTING ......................................................................................................................................219 REMOVAL & INSTALLATION .................................................................................................220 Voltage Regulator ................................................................................................................................223 REMOVAL & INSTALLATION .................................................................................................223 STARTING SYSTEM....................................................................................................................................227 General Information .............................................................................................................................227 Starter ...................................................................................................................................................229 TESTING ......................................................................................................................................229 REMOVAL & INSTALLATION .................................................................................................230 RELAY REPLACEMENT ............................................................................................................232HOW TO USE THIS BOOK iv
Table of Contents SENDING UNITS...........................................................................................................................................237 Introduction ..........................................................................................................................................237 Coolant Temperature Sender...............................................................................................................237 TESTING ......................................................................................................................................237 REMOVAL & INSTALLATION .................................................................................................239 Oil Pressure Sender and Switch ...........................................................................................................241 TESTING ......................................................................................................................................241 REMOVAL & INSTALLATION .................................................................................................243 Low Oil Level Sensor ..........................................................................................................................245 TESTING ......................................................................................................................................245 REMOVAL & INSTALLATION .................................................................................................246 SPECIFICATION CHARTS.........................................................................................................................249 ENGINE MECHANICAL ..............................................................................................................................251 Engine ..................................................................................................................................................251 REMOVAL & INSTALLATION .................................................................................................251 Valve Rocker Arm Cover ....................................................................................................................258 REMOVAL & INSTALLATION .................................................................................................258 Rocker Arms........................................................................................................................................269 REMOVAL & INSTALLATION .................................................................................................269 Rocker Arm Shaft Assembly ...............................................................................................................271 REMOVAL & INSTALLATION .................................................................................................271 DISASSEMBLY & REASSEMBLY ............................................................................................274 Thermostat ...........................................................................................................................................274 REMOVAL & INSTALLATION .................................................................................................274 Intake Manifold ....................................................................................................................................280 REMOVAL & INSTALLATION .................................................................................................280 Exhaust Manifold .................................................................................................................................305 REMOVAL & INSTALLATION .................................................................................................305 Radiator ................................................................................................................................................314 REMOVAL & INSTALLATION .................................................................................................314 Engine Fan...........................................................................................................................................318 REMOVAL & INSTALLATION .................................................................................................318 Water Pump .........................................................................................................................................323 REMOVAL & INSTALLATION .................................................................................................324 Cylinder Head......................................................................................................................................334 REMOVAL & INSTALLATION .................................................................................................334 Oil Pan .................................................................................................................................................356 REMOVAL & INSTALLATION .................................................................................................356 Oil Pump ..............................................................................................................................................364 REMOVAL & INSTALLATION .................................................................................................365 Crankshaft Damper..............................................................................................................................370 REMOVAL & INSTALLATION .................................................................................................370 Timing Belt and Cover ........................................................................................................................372 TROUBLESHOOTING ................................................................................................................372 REMOVAL & INSTALLATION .................................................................................................372 Timing Chain Cover & Oil Seal ..........................................................................................................375 REMOVAL & INSTALLATION .................................................................................................375 Timing Chain and Gears ......................................................................................................................387 REMOVAL & INSTALLATION .................................................................................................387 TIMING CHAIN DEFLECTION .................................................................................................407 HOW TO USE THIS BOOK v
Table of Contents ENGINE MECHANICAL Camshaft and Auxiliary Shaft Sprockets and Seals .............................................................................408 REMOVAL & INSTALLATION .................................................................................................408 Camshafts, Bearings and Lifters ..........................................................................................................408 REMOVAL & INSTALLATION .................................................................................................408 INSPECTION ................................................................................................................................421 BEARING REMOVAL & INSTALLATION ..............................................................................424 Auxiliary Shaft.....................................................................................................................................427 REMOVAL & INSTALLATION .................................................................................................427 Rear Main Oil Seal ...............................................................................................................................429 REMOVAL & INSTALLATION .................................................................................................429 Flywheel and Ring Gear......................................................................................................................431 REMOVAL & INSTALLATION .................................................................................................431 EXHAUST SYSTEM......................................................................................................................................437 REPLACEMENT ................................................................................................................................440 ENGINE RECONDITIONING .....................................................................................................................443 Determining Engine Condition ............................................................................................................443 COMPRESSION TEST................................................................................................................443 OIL PRESSURE TEST.................................................................................................................444 Buy or Rebuild? ...................................................................................................................................445 Engine Overhaul Tips..........................................................................................................................445 TOOLS ..........................................................................................................................................446 OVERHAUL TIPS........................................................................................................................446 CLEANING ...................................................................................................................................447 REPAIRING DAMAGED THREADS.........................................................................................449 Engine Preparation ...............................................................................................................................451 Cylinder Head......................................................................................................................................452 DISASSEMBLY ...........................................................................................................................453 INSPECTION ................................................................................................................................464 REFINISHING & REPAIRING ...................................................................................................468 ASSEMBLY ..................................................................................................................................471 Engine Block........................................................................................................................................471 GENERAL INFORMATION .......................................................................................................472 DISASSEMBLY ...........................................................................................................................472 INSPECTION ................................................................................................................................475 REFINISHING ..............................................................................................................................478 ASSEMBLY ..................................................................................................................................480 Engine Start-up and Break-in .............................................................................................................486 STARTING THE ENGINE ...........................................................................................................486 BREAKING IT IN ........................................................................................................................487 KEEP IT MAINTAINED ..............................................................................................................487 SPECIFICATION CHARTS.........................................................................................................................489 EMISSION CONTROLS ...............................................................................................................................511 Positive Crankcase Ventilation (PCV) System ....................................................................................511 OPERATION ................................................................................................................................511 TESTING ......................................................................................................................................511 REMOVAL & INSTALLATION .................................................................................................512 Evaporative Emission Control System................................................................................................515 HOW TO USE THIS BOOK vi
Table of Contents EMISSION CONTROLS OPERATION ................................................................................................................................515 COMPONENT TESTING............................................................................................................516 REMOVAL & INSTALLATION .................................................................................................523 Exhaust Gas Recirculation (EGR) System ..........................................................................................524 OPERATION ................................................................................................................................524 COMPONENT TESTING............................................................................................................525 REMOVAL & INSTALLATION .................................................................................................529 ELECTRONIC ENGINE CONTROLS .......................................................................................................533 Electronic Engine Control (EEC)........................................................................................................533 Powertrain Control Module (PCM).....................................................................................................533 OPERATION ................................................................................................................................533 REMOVAL & INSTALLATION .................................................................................................534 Heated Oxygen Sensors (HO2S) .........................................................................................................537 OPERATION ................................................................................................................................537 TESTING ......................................................................................................................................538 REMOVAL & INSTALLATION .................................................................................................539 Idle Air Control (IAC) Valve...............................................................................................................540 OPERATION ................................................................................................................................540 TESTING ......................................................................................................................................540 REMOVAL & INSTALLATION .................................................................................................541 Engine Coolant Temperature (ECT) Sensor ........................................................................................542 OPERATION ................................................................................................................................542 TESTING ......................................................................................................................................543 REMOVAL & INSTALLATION .................................................................................................544 Intake Air Temperature (IAT) Sensor ..................................................................................................545 OPERATION ................................................................................................................................545 TESTING ......................................................................................................................................545 REMOVAL & INSTALLATION .................................................................................................545 Mass Air Flow (MAF) Sensor.............................................................................................................546 OPERATION ................................................................................................................................546 TESTING ......................................................................................................................................547 REMOVAL & INSTALLATION .................................................................................................548 Throttle Position (TP) Sensor ..............................................................................................................550 OPERATION ................................................................................................................................550 TESTING ......................................................................................................................................551 REMOVAL & INSTALLATION .................................................................................................552 Camshaft Position (CMP) Sensor........................................................................................................553 OPERATION ................................................................................................................................553 TESTING ......................................................................................................................................555 REMOVAL & INSTALLATION .................................................................................................556 Crankshaft Position (CKP) Sensor ......................................................................................................561 OPERATION ................................................................................................................................561 TESTING ......................................................................................................................................561 REMOVAL & INSTALLATION .................................................................................................562 Vehicle Speed Sensor(VSS) ................................................................................................................565 OPERATION ................................................................................................................................566 TESTING ......................................................................................................................................566 REMOVAL & INSTALLATION .................................................................................................566 HOW TO USE THIS BOOK vii
Table of Contents COMPONENT LOCATIONS.......................................................................................................................567 TROUBLE CODES........................................................................................................................................581 General Description .............................................................................................................................581 FAILURE MODE EFFECTS MANAGEMENT (FMEM)..........................................................582 HARDWARE LIMITED OPERATION STRATEGY (HLOS)...................................................582 MALFUNCTION INDICATOR LAMP (MIL)............................................................................582 Diagnostic Connector...........................................................................................................................582 Reading Codes.....................................................................................................................................583 EEC-V EQUIPPED ENGINES....................................................................................................584 EEC-IV EQUIPPED ENGINES..................................................................................................584 Clearing Codes.....................................................................................................................................586 CONTINUOUS MEMORY CODES............................................................................................586 KEEP ALIVE MEMORY .............................................................................................................586 Diagnostic Trouble Code Charts ..........................................................................................................586 VACUUM DIAGRAMS .................................................................................................................................597 SPECIFICATION CHARTS.........................................................................................................................599 BASIC FUEL SYSTEM DIAGNOSIS ..........................................................................................................601 FUEL LINES AND FITTINGS .....................................................................................................................603 General Information .............................................................................................................................603 Hairpin Clip Fitting ..............................................................................................................................603 REMOVAL & INSTALLATION .................................................................................................603 Duckbill Clip Fitting ............................................................................................................................605 REMOVAL & INSTALLATION .................................................................................................605 REMOVAL & INSTALLATION .................................................................................................607 SEQUENTIAL FUEL INJECTION (SFI) SYSTEM ..................................................................................609 General Information .............................................................................................................................609 FUEL SYSTEM SERVICE PRECAUTIONS ..............................................................................610 Relieving Fuel System Pressure ..........................................................................................................610 Inertia Switch .......................................................................................................................................611 GENERAL INFORMATION .......................................................................................................611 RESETTING THE SWITCH ........................................................................................................611 Fuel Pump ............................................................................................................................................613 REMOVAL & INSTALLATION .................................................................................................613 TESTING ......................................................................................................................................617 Throttle Body Assembly ......................................................................................................................620 REMOVAL & INSTALLATION .................................................................................................620 Fuel Supply Manifold and Injectors ....................................................................................................625 REMOVAL & INSTALLATION .................................................................................................626 TESTING ......................................................................................................................................632 Fuel Pressure Regulator .......................................................................................................................633 REMOVAL & INSTALLATION .................................................................................................633 Pressure Relief Valve...........................................................................................................................640 REMOVAL & INSTALLATION .................................................................................................640 HOW TO USE THIS BOOK viii
Table of Contents FUEL TANK ...................................................................................................................................................641 Tank Assembly ....................................................................................................................................641 REMOVAL & INSTALLATION .................................................................................................641 Sending Unit........................................................................................................................................647 REMOVAL & INSTALLATION .................................................................................................647 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS....................................649 Basic Electrical Theory........................................................................................................................649 HOW DOES ELECTRICITY WORK: THE WATER ANALOGY ............................................649 OHMS LAW.................................................................................................................................650 Electrical Components .........................................................................................................................651 POWER SOURCE ........................................................................................................................651 GROUND ......................................................................................................................................651 PROTECTIVE DEVICES.............................................................................................................651 SWITCHES & RELAYS ..............................................................................................................653 LOAD ............................................................................................................................................654 WIRING & HARNESSES ............................................................................................................654 CONNECTORS ............................................................................................................................655 Test Equipment ....................................................................................................................................656 JUMPER WIRES..........................................................................................................................656 TEST LIGHTS ..............................................................................................................................657 MULTIMETERS ...........................................................................................................................658 Troubleshooting Electrical Systems....................................................................................................659 Testing .................................................................................................................................................659 OPEN CIRCUITS .........................................................................................................................659 SHORT CIRCUITS .......................................................................................................................660 VOLTAGE ....................................................................................................................................660 VOLTAGE DROP........................................................................................................................661 RESISTANCE ...............................................................................................................................661 Wire and Connector Repair.................................................................................................................663 BATTERY CABLES......................................................................................................................................665 AIR BAG (SUPPLEMENTAL RESTRAINT) SYSTEM...........................................................................667 SERVICE PRECAUTIONS ................................................................................................................668 DISARMING THE SYSTEM .......................................................................................................668 ARMING THE SYSTEM .............................................................................................................668 HEATING AND AIR CONDITIONING ......................................................................................................669 Blower Motor.......................................................................................................................................669 REMOVAL & INSTALLATION .................................................................................................669 Blower Motor Resistor .........................................................................................................................672 REMOVAL & INSTALLATION .................................................................................................672 Heater Core..........................................................................................................................................672 REMOVAL & INSTALLATION .................................................................................................672 Control Head........................................................................................................................................677 REMOVAL & INSTALLATION .................................................................................................678 Control Cables.....................................................................................................................................681 ADJUSTMENT .............................................................................................................................681 REMOVAL & INSTALLATION .................................................................................................681 Air Conditioning Components.............................................................................................................683 REMOVAL & INSTALLATION .................................................................................................683 HOW TO USE THIS BOOK ix