1991 1999 ford explorer chilton User Manual

							Engine mounting points for 3.0L engines
Click to enlarge
HOW TO USE THIS BOOK
254 REMOVAL & INSTALLATION 
						

							Engine mounting points 4.0L engines
Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 255 
						

							Engine mounting points 5.0L engines
Click to enlarge
HOW TO USE THIS BOOK
256 REMOVAL & INSTALLATION 
						

							Engine damper mounting for 4.0L engines
Click to enlarge
Remove the front engine support insulator-to-crossmember retaining fasteners.
22. 
If equipped, remove the engine damper mounting bracket from the engine. The bracket may use two
TORX® bolts for the lower mounting points.
23. 
Partially lower the vehicle and support it with jackstands in the new position.
24. 
Support the transmission with a floor jack.
25. 
Using a engine crane or hoist, lift the engine out of the vehicle. Be sure to lift the engine slowly and
check often that nothing (such as wires, hoses, etc.) will cause the engine to hang up on the vehicle.
26. 
At this point, the engine can be installed on an engine stand.
27. 
To install:
Lightly oil all bolts and stud threads, except those specifying special sealant, prior to installation. Using the hoist or engine crane, slowly and carefully position the engine in the vehicle. Make sure the
exhaust manifolds are properly aligned with the exhaust pipes.
28. 
Align the engine to the transmission and install two engine-to-transmission bolts.
29.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 257 
						

							
Seat the left-hand side, front engine support insulator locating pin prior to the right-hand side, front
engine support insulator.
Lower the engine onto the front engine support insulators.
30. 
Detach the engine crane or hoist from the engine.
31. 
Remove the floor jack from beneath the transmission fluid pan.
32. 
Tighten the two installed engine-to-transmission bolts, then raise and securely support the vehicle on
jackstands.
33. 
Install and tighten the remaining engine-to-transmission bolts.
34. 
The remainder of installation is the reverse of the removal procedure. Be sure to tighten the fasteners
to the values presented in the torque specification chart.
35. 
WARNING
Do NOT start the engine without first filling it with the proper type and amount of clean engine oil, and
installing a new oil filter. Otherwise, severe engine damage will result.
Fill the crankcase with the proper type and quantity of engine oil. If necessary, adjust the transmission
and/or throttle linkage.
36. 
Install the air intake duct assembly.
37. 
Connect the negative battery cable, then fill and bleed the cooling system.
38. 
Bring the engine to normal operating temperature, then check for leaks.
39. 
Stop the engine and check all fluid levels.
40. 
Install the hood, aligning the marks that were made during removal.
41. 
If equipped, have the A/C system properly leak-tested, evacuated and charged by a MVAC-trained,
EPA-certified, automotive technician.
42. 
Valve Rocker Arm Cover
REMOVAL & INSTALLATION
2.3L and 2.5L Engines
To service the valve cover on the 2.3L and 2.5L engine, the throttle body assembly and EGR supply
tube must first be removed. Refer to the necessary service procedures.
Disconnect the negative battery cable.
1. 
Unplug any electrical connections on the air intake hose, then remove the hose.
2. 
Remove any splash shielding from around the throttle body.
3. 
Remove the throttle body assembly from the intake manifold.
4. 
Label and disconnect any electrical connections, including spark plug cables, that will interfere with
the removal of the valve cover.
5. 
If necessary, remove the EGR supply tube.
6. 
Remove the valve cover retaining bolts and remove the valve cover.
7. 
A gentle tap with a soft hammer may help to break the seal on the gasket. WARNING
Never pry between the valve cover and the cylinder head. Damage to the machined sealing surface, or
distortion to the valve cover could occur, resulting in an oil leak. HOW TO USE THIS BOOK
258 Valve Rocker Arm Cover 
						

							Exploded view of the 2.3L and 2.5L engine rocker arm cover
Click to enlarge
Remove the valve cover gasket from the cover.
3. 
To install: Thoroughly clean the gasket mating surfaces on the cover and the cylinder head.
4. 
Install a new gasket to the valve cover.
5. 
Place the valve cover onto the cylinder head and install all of the retaining bolts finger-tight.
6. 
Alternately tighten the bolts to the proper specification.
7. 
If removed, install the EGR supply tube.
8. 
Install any electrical connections which were removed.
9.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 259 
						

							Install the throttle body to the intake manifold.
10. 
Install any splash shielding removed from around the throttle body.
11. 
Install the air intake hose and attach the wire harness connections which were removed.
12. 
Reconnect the negative battery cable.
13. 
Start the engine and check for leaks.
14. 
2.4L Engines Disconnect the negative battery cable. Remove the air cleaner and attaching parts. Label each spark
plug wire prior to its removal in order to ease the installation of the wires on the correct spark plugs.
1. 
Remove the spark plug wires.
2. 
Remove the PCV valve and hose.
3. 
Remove the rocker arm cover attaching screws and the load distribution washers (patch pieces). Be
sure the washers are installed in their original position.
4. 
Detach the transmission fluid level indicator tube and bracket from the valve cover.
5. 
Disconnect the vacuum line at the canister purge solenoid and disconnect the line routed from the
canister to the purge solenoid (disconnect the power brake booster hose, if so equipped).
6. 
With a light plastic hammer, tap the rocker arm covers to break the seal.
7. 
Remove the rocker arm covers.
8. 
To install: Clean all gasket material from the cylinder heads and rocker arm cover gasket surfaces.
4. 
Install the rocker arm covers, using new gaskets and install the attaching screw and rocker arm cover
reinforcement pieces.
5. 
Rocker arm cover reinforcement washer locations on 2.4L engines HOW TO USE THIS BOOK
260 REMOVAL & INSTALLATION 
						

							Click to enlarge
Attach the transmission fluid level indicator tube and the bracket to the rocker arm cover.
11. 
After ensuring all rocker arm cover reinforcement washers are installed in their original position,
tighten the rocker arm cover screws to the proper specification.
12. 
Install the spark plug wires.
13. 
Install the PCV valve and hose.
14. 
Install the engine oil fill cap.
15. 
Connect the vacuum line at the canister purge (connect the power brake hose, if so equipped) solenoid
and connect the line routed from canister to the purge solenoid.
16. 
Install the air cleaner and the attaching parts.
17. 
Reconnect the negative battery cable. Start the engine and check for oil leaks.
18. 
3.0L Engine
The valve covers installed on the 3.0L engine incorporate integral (built in) gaskets which should last
the life of the vehicle. Replacement gaskets are available if required.
Disconnect the negative battery cable. Disconnect the ignition wires from the spark plugs, but leave
them attached to their wire looms.
1. 
Remove the ignition wire separators from the rocker arm cover attaching bolt studs with the wires
attached, then lay the wires out of the way.
2. 
If the left hand cover is being removed, remove the throttle body assembly, the PCV valve and fuel
injector harness stand-offs. If the right hand cover is being removed, remove the engine harness
connectors, fuel injector harness stand-offs and air cleaner closure hose from the oil fill adapter.
3. 
Using caution, slide a sharp thin blade knife between the cylinder head gasket surface and the valve
cover gasket at the four RTV junctions. CUT ONLY THE RTV SEALER AND AVOID CUTTING
THE INTEGRAL GASKET.
4. 
Remove the integral gasket from the valve cover gasket channel. Note bolt/stud fasteners locations
before removing gasket for correct installation. Clean gasket channel and remove any traces of RTV
sealant.
5. 
To install: Align fastener holes, lay new gasket onto channel and install by hand. Install gasket to each fastener,
seat fastener against cover and at the same time roll gasket around fastener collar. If installed
correctly all fasteners will be secured by gasket and not fall out.
1. 
Install valve cover to the engine, lightly oil all bolts and stud threads. Apply a bead of RTV sealant at
the cylinder head to intake manifold rail step (two places per rail).
2. 
Place the valve cover on the cylinder head and install attaching bolts and studs. Tighten the attaching
bolts to specifications.
3.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 261 
						

							Rocker arm cover installation on 3.0L engines
Click to enlarge
Install all remaining components in reverse order of removal procedure. Connect the ignition wires to
the spark plugs and reconnect the negative battery cable. Start the engine and run to normal operating
temperature, then check for oil and vacuum leaks.
4. 
4.0L Engine (VIN X)
Failure to install new valve cover gaskets and valve cover reinforcement pieces will result in oil leaks. Disconnect the negative battery cable. Tag and remove the spark plug wires.
1. 
Disconnect and remove the fuel supply and return lines. See Section 5.
2. 
For left valve cover removal, remove the upper intake manifold.
3. 
For right valve cover removal, remove the air inlet duct and hose to oil fill tube and the alternator.
Drain the cooling system and remove the upper radiator hose from the engine. Remove the EDIS
ignition coil and bracket assembly. Remove the A/C low pressure hose bracket if so equipped.
Remove the PCV valve hose and breather.
4.  HOW TO USE THIS BOOK
262 REMOVAL & INSTALLATION 
						

							To remove the valve cover, first disconnect the crankcase breather vent tube
Label and unplug any electrical connections ...
... as well as vacuum fittings which will inhibit valve cover removal HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 263