1991 1999 ford explorer chilton User Manual

							Remove the coil pack mounting bracket attaching bolts ...
... then remove the coil pack and bracket from the engine
Remove the valve cover bolts and load distribution pieces. The washers must be installed in their
original positions, so keep track of them.
5. 
Remove the valve cover. It will probably be necessary to tap the cover loose with a plastic or rubber
mallet.
6. 
Remove the valve cover gaskets.
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264 REMOVAL & INSTALLATION 
						

							Remove the valve cover hold-down bolts ...
... then remove the cover from the engine. A slight tap with a soft-faced hammer helps to break the seal
Remove the old valve cover gasket and discard
To install:
Clean all gasket material from the cover and head.
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REMOVAL & INSTALLATION 265 
						

							Rocker arm cover installation on 4.0L engines
Click to enlarge
Installation is the reverse of removal. Always use a new gasket coated with sealer. If any of the RTV
silicone gasket material was removed from the mating area of the head(s) and intake manifold, replace
it. Torque the bolts to 3-5 ft. lbs.
4. 
Reconnect the negative battery cable. Start the engine and run to normal operating temperature and
check for oil and fuel leaks.
5. 
4.0L SOHC Engine (VIN E)
Always use new gaskets when installing the valve covers.
RIGHT HAND COVER
Disconnect the negative battery cable.
1. 
Remove the upper intake manifold.
2. 
CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are
quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove
fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless
it is contaminated or several years old.
Drain the cooling system until the coolant is below the upper radiator hose.
3. 
Remove the upper radiator hose and the connector tube behind the alternator.
4. 
Remove the bolts securing the heater hose bracket and the transmission dipstick tube.
5. 
Label and disconnect the spark plug cables from their plugs and wire looms.
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266 REMOVAL & INSTALLATION 
						

							Remove the valve cover hold-down bolts and remove the cover from the engine. Discard the old
valve cover gasket.
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.
To install:
Thoroughly clean the mating surfaces of the engine and cover.
3. 
Install a new gasket to the cover and place the cover in position on the engine.
4. 
Install all of the hold-down bolts and tighten to specifications.
5. 
Attach the spark plug cables to their wire looms and plugs.
6. 
Install the upper radiator hose assembly and the tube securing bolt.
7. 
Install the upper intake manifold.
8. 
Refill the cooling system and run the engine.
9. 
Connect the negative battery cable.
10. 
Allow the engine to reach normal operating temperature (upper radiator hose hot) and check for leaks.
11. 
LEFT HAND COVER
Disconnect the negative battery cable.
1. 
Remove the upper intake manifold.
2. 
Remove the two fuel line upper bracket bolts.
3. 
Detach the Camshaft Position (CMP) sensor electrical connection.
4. 
Disconnect the wire harness from the Differential Pressure Feedback (DPFE) transducer, which is
mounted to the valve cover.
5. 
Label and detach the two vacuum lines connected to the DPFE transducer.
6. 
Disconnect the engine electrical multi-plug and remove it from the valve cover.
7. 
Detach the wire harness connections on the coil pack.
8. 
Label and remove the spark plug cables from the coil pack.
9. 
Remove the valve cover hold-down bolts and remove the valve cover. Discard the old valve cover
gasket.
10. 
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.
To install:
Thoroughly clean the mating surfaces of the engine and cover.
11. 
Install a new gasket to the cover and place the cover in position on the engine.
12. 
Install all of the hold-down bolts and tighten to specifications.
13. 
Attach the spark plug cables to the coil pack.
14. 
Attach the wire harness connections to the coil pack.
15. 
Install and connect the engine electrical multi-plug to the valve cover.
16. 
Attach the vacuum lines and electrical connections to the DPFE transducer.
17. 
Connect the CMP sensor harness.
18. 
Install the two fuel line upper bracket bolts.
19. 
Install the upper intake manifold.
20. 
Connect the negative battery cable.
21. 
Allow the engine to reach normal operating temperature (upper radiator hose hot) and check for leaks.
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REMOVAL & INSTALLATION 267 
						

							
5.0L Engines
To remove the valve covers, the upper intake manifold must be removed. Obtain a new gasket for the
intake assembly before removing it. If only the right-hand valve cover is to be removed, the intake
manifold can remain on the engine, however, you will need to remove the throttle body assembly from
the upper intake manifold.
Disconnect the negative battery cable.
1. 
CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are
quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove
fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless
it is contaminated or several years old.
Drain the cooling system until the coolant level is below the intake manifold.
2. 
Remove the upper intake manifold.
3. 
Label and remove the spark plug wires from the coil packs.
4. 
Detach the coil pack electrical connections and remove them from the engine.
5. 
Remove any remaining wires or lines which will interfere with valve cover removal.
6. 
Remove the valve cover hold-down bolts and remove the covers.
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.
To install:
Clean all gasket mating surfaces. Install a new gasket to the cylinder head and position the cover on
the engine.
3. 
Ensure that the stamping and chamfered edge of the steel carrier of the gasket are facing up when
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268 REMOVAL & INSTALLATION 
						

							Tighten the 5.0L engine valve cover hold-down bolts in the sequence shown
Click to enlarge
Install all of the hold-down bolts and tighten to specifications in the sequence given.
4. 
Connect all wires and lines disconnected from the engine.
5. 
Install the coil packs and the spark plug wires to the coils.
6. 
Install the upper intake manifold.
7. 
Refill the cooling system.
8. 
Connect the negative battery cable.
9. 
Allow the engine to reach normal operating temperature (upper radiator hose hot) and check for leaks.
10. 
Rocker Arms
REMOVAL & INSTALLATION
2.3L, 2.5L and 4.0L SOHC (VIN E) Engines
A special tool is required to compress the valve spring. Remove the valve cover and associated parts as required.
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Rocker Arms 269 
						

							Rotate the camshaft so that the base circle of the cam is against the cam follower you intend to
remove.
2. 
Use a special valve spring compressing tool to remove the follower
If removing more than one cam follower, label them so they can be returned to their original position.
Using special tool T88T-6565-BH (for 2.3L and 2.5L engines), T97T-6565-A (for 4.0L engines) or
equivalent, depress the valve spring, as necessary, a000nd slide the cam follower over the lash
adjuster and out from under the camshaft.
3. 
Install the cam follower in the reverse order of removal. Lubricate the followers with SAE 50W
engine oil meeting Ford specification WSE-M2C908-A1 and API SG prior to installing.
4. 
3.0L and 5.0L Engines Remove the rocker arm covers.
1. 
Remove the single retaining bolt at each rocker arm.
2. 
Exploded view of the valve rocker arms used on the 3.0L engines HOW TO USE THIS BOOK
270 REMOVAL & INSTALLATION 
						

							Exploded view of the 5.0L engine rocker arm assembly
The rocker arm and pushrod may then be removed from the engine. Keep all rocker arms and
pushrods in order so they may be installed in their original locations.
3. 
Installation is the reverse of removal. Lubricate the rocker arm assemblies with SAE 50W engine oil.
Insure that the fulcrums are properly seated into the cylinder head (3.0L engines) or the fulcrum guide
(5.0L engines). Tighten the rocker arm fulcrum bolts to specifications.
4. 
Rocker Arm Shaft Assembly
REMOVAL & INSTALLATION
This procedure applies only to 2.9L and 4.0L (VIN X) engines. Remove the valve rocker arm covers.
1. 
Remove the rocker arm shaft stand attaching bolts by loosening the bolts two turns at a time, in
sequence (from the end of shaft to middle shaft).
2. 
Lift off the rocker arm and shaft assembly. If equipped, remove the oil baffle.
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Rocker Arm Shaft Assembly 271 
						

							To remove the rocker shaft, first remove the valve cover, then loosen the shaft retaining bolts ...
... and remove the assembly from the cylinder head
To install:
If equipped, loosen the valve lash adjusting screws a few turns. Apply engine oil to the assembly to
provide the initial lubrication.
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							Rocker arm shaft assembly installation on the 2.9L engine
Rocker arm shaft installation on the 4.0L engine HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 273