1991 1999 ford explorer chilton User Manual

							Upper intake manifold torque sequence on the 2.3L and 2.5L engine
Engage the four electrical connectors to the injectors.
19. 
Install the engine oil dipstick, then connect the fuel return and supply lines to the fuel supply
manifold.
20. 
The following procedures are for installing the upper intake manifold. Make sure the gasket surfaces of the upper and lower intake manifolds are clean. Place a gasket on the
lower intake manifold assembly, then place the upper intake manifold in position.
2. 
Install the retaining bolts and tighten in sequence to 15-3 ft. lbs.
3. 
Connect the EGR tube to the EGR valve and tighten it to 18 ft. lbs.
4. 
Connect the coolant bypass line and tighten the clamp. Connect the PCV system hose to the fitting on
the underside of the upper intake manifold.
5. 
If removed, install the vacuum tee on the upper intake manifold. Use Teflon® tape on the threads and
tighten to 12-18 ft. lbs. Reconnect the vacuum lines to the tee, the EGR valve and the fuel pressure
regulator and canister purge line as necessary.
6. 
Hold the accelerator cable bracket in position on the upper intake manifold and install the retaining
bolt. Tighten the bolt to 10-15 ft. lbs.
7. 
Install the accelerator cable to the bracket.
8. 
Position a new gasket on the fuel charging assembly air throttle body mounting flange. Install the air
throttle body to the fuel charging assembly. Install two retaining nuts and two bolts and tighten to
15-6 ft. lbs.
9. 
Connect the accelerator and speed control cable (if equipped), then install the throttle linkage shield.
10. 
Reconnect any electrical harness plugs which were removed.
11. 
Connect the air intake hose, air bypass hose and crankcase ventilation hose.
12. 
Reconnect the negative battery cable. Refill the cooling system to specifications and pressurize the
fuel system by turning the ignition switch on and off (without starting the engine) at least six times.
Leaving the ignition on for at least five seconds each time.
13. 
Start the engine and let it idle while checking for fuel, coolant and vacuum leaks. Correct as
necessary. Road test the vehicle for proper operation.
14. 
2.9L Engine Disconnect battery negative cable.
1. 
Remove air cleaner air intake duct from throttle body.
2. 
Disconnect throttle cable and bracket assembly.
3. 
Disconnect EGR tube at EGR valve.
4. 
Label and disconnect all vacuum hoses from fittings on upper intake manifold.
5. 
Detach the electrical connections at throttle body, EGR pressure sensor, intake manifold upper and
lower and distributor. Also disconnect fuel injector subharness from main EEC harness.
6. 
Remove upper intake manifold (plenum) assembly.
7.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 285 
						

							
If you only need to remove the upper intake manifold, stop at this point. Otherwise, continue with the
procedure to also remove the lower intake manifold.
Drain coolant. Remove the upper radiator and heater supply hoses from intake manifold.
8. 
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.
Remove distributor cap and spark plug wires as an assembly.
9. 
Observe and mark the location of the distributor rotor and housing so ignition timing can be
maintained at reassembly. Remove distributor hold-down screw and clamp and lift out distributor.
10. 
Remove rocker arm covers.
11. 
Remove intake manifold attaching bolts and nuts. Note length of manifold attaching bolts during
removal so that they may be installed in their original positions. Tap manifold lightly with a plastic
mallet to break gasket seal. Lift off manifold.
12. 
Remove all old gasket material and sealing compound.
13. 
To install: Apply sealing compound to the joining surfaces. Place the intake manifold gasket in position. Ensure
the tab on the right hand bank cylinder head gasket fits into the cutout of the manifold gasket.
14. 
Intake manifold tightening sequence and procedure for the 2.9L engine Click to enlarge
Apply sealing compound to the attaching bolt bosses on the intake manifold and position the intake
manifold. Follow the tightening sequence and tighten the bolts to specifications.
15. 
Install distributor so that rotor and housing are in the same position marked at removal.
16. 
Install distributor clamp and attaching bolts.
17. 
Replace rocker arm cover gasket, and install rocker arm valve covers using the procedure under
Rocker Arm Cover and Rocker Arm.
18.  HOW TO USE THIS BOOK
286 REMOVAL & INSTALLATION 
						

							Install distributor cap. Coat the inside of each spark plug wire connector with silicone grease with a
small screwdriver, and install the wires. Connect distributor wiring harness.
19. 
The following procedures are for installing the upper intake manifold. Apply sealing compound to the joining surfaces of the upper and lower intake manifolds. Install the
upper intake manifold gaskets.
1. 
Install upper intake manifold (plenum) assembly. Tighten the bolts in two steps to specifications.
2. 
Connect all vacuum hoses to fittings on upper intake manifold.
3. 
Engage electrical connections at throttle body, EGR pressure sensor, intake manifolds sub harness to
EEC main harness.
4. 
Install and adjust throttle linkage bracket assembly and cover.
5. 
Connect hoses from water outlet to radiator, and bypass hose from thermostat housing rear cover to
intake manifold.
6. 
Connect battery negative cable.
7. 
Refill and bleed the cooling system.
8. 
Recheck ignition timing and reset engine idle speed to specification.
9. 
Run engine at fast idle and check for coolant and oil leaks.
10. 
3.0L Engine
The throttle body is cast integral to the upper intake manifold. To remove the upper intake manifold,
refer to Section 5 for throttle body removal.
Drain the cooling system (with the engine cold).
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.
Disconnect the battery ground cable.
2. 
Depressurize the fuel system and remove the air intake throttle body as outlined in Section 5.
3. 
Disconnect the fuel return and supply lines.
4. 
Remove the fuel injector wiring harness from the engine.
5. 
Disconnect the upper radiator hose.
6. 
Disconnect the water outlet heater hose.
7. 
If equipped with distributor ignition, disconnect the distributor cap with the spark plug wires attached.
Matchmark and remove the distributor assembly.
8. 
If equipped with distributorless ignition, Label and remove the spark plug wires from the coil pack,
then remove the coil pack.
9. 
Remove the valve covers. Loosen retaining nut from cylinder #3 intake valve and rotate rocker arm
fulcrum away from valve retainer. Remove the pushrod.
10. 
Remove the intake manifold attaching bolts and studs (Torx® socket required).
11. 
Lift the intake manifold off the engine. Use a plastic mallet to tap lightly around the intake manifold
to break it loose, if necessary. Do not pry between the manifold and cylinder head with any sharp
instrument. The manifold can be removed with the fuel rails and injectors in place.
12. 
Remove the manifold side gaskets and end seals and discard. If the manifold is being replaced,
transfer the fuel injector and fuel rail components to the new manifold on a clean workbench. Clean
all gasket mating surfaces.
13. 
To install: HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 287 
						

							First lightly oil all attaching bolts and stud threads. The intake manifold, cylinder head and cylinder
block mating surfaces should be clean and free of old silicone rubber sealer. Use a suitable solvent to
clean these areas.
14. 
Silicone sealer and intake end seal application for the 3.0L engine Click to enlarge
Intake manifold gasket positioning for the 3.0L Click to enlarge
HOW TO USE THIS BOOK
288 REMOVAL & INSTALLATION 
						

							Intake manifold torque sequence for the 3.0L
Click to enlarge
Apply silicone rubber sealer (D6AZ-19562-A or equivalent) to the intersection of the cylinder block
assembly and head assembly at four corners as illustrated.
15. 
When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application.
After this time, the sealer may start to set-up and its sealing effectiveness may be reduced. In high
temperature/humidity conditions, the RTV will start to skin over in about 5 minutes.
Install the front intake manifold seal and rear intake manifold seal, then secure them with retaining
features.
16. 
Position the intake manifold gaskets in place and insert the locking tabs over the tabs on the cylinder
head gaskets.
17. 
Apply silicone rubber sealer over the gasket in the same places as in Step 14.
18. 
Carefully lower the intake manifold into position on the cylinder block and cylinder heads to prevent
smearing the silicone sealer and causing gasketing voids.
19. 
Install the retaining bolts. Tighten in two stages, using the sequence illustrated, first to 11 ft. lbs., then
to 18 ft. lbs.
20. 
If installing a new manifold, install fuel supply rail and injectors. Refer to the necessary service
procedures.
21. 
Install #3 cylinder intake valve pushrod. Apply oil to pushrod and fulcrum prior to installation. Rotate
the crankshaft to place the lifter on the heel position or base circle of camshaft. Tighten to 8 ft. lbs. to
seat fulcrum in cylinder head. Final bolt torque is 5 ft. lbs.
22. 
Install valve covers, fuel injector harness, throttle body assembly, hose and electrical connections.
23. 
If equipped with distributor ignition, install the distributor assembly, using the matchmarks made
earlier to insure correct alignment. Install the distributor cap and spark plug wires.
24. 
If equipped with distributorless ignition, install the coil pack then install the spark plug wires to their
original locations.
25. 
Install coolant hoses. Connect all vacuum lines. Reconnect fuel lines. Install fuel line safety clips.
26. 
Fill and bleed cooling system. If any engine coolant accidentally spilled into the engine while the
intake was off, change engine oil and filter.
27. 
Install air cleaner hose. Connect battery ground cable. Start engine and check for coolant, oil, fuel and
vacuum leaks.
28.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 289 
						

							If equipped with distributor ignition, verify base initial timing as outlined. Check and adjust engine
idle as necessary.
29. 
4.0L Engine (VIN X)
The intake manifold is a 4-piece assembly, consisting of the upper intake manifold, the throttle body, the fuel
supply manifold, and the lower intake manifold.
Disconnect the battery ground cable.
1. 
Begin the intake removal by unbolting the throttle linkage weather shield ...... then remove the air intake duct from the throttle body HOW TO USE THIS BOOK
290 REMOVAL & INSTALLATION 
						

							Disconnect the throttle linkage, then unbolt and remove the cable bracket
Remove the weather shield.
2. 
Remove the air cleaner intake duct.
3. 
Disconnect the throttle cable and bracket.
4. 
Label all of the electrical and vacuum connections on the intake manifold ... ... then disconnect the vacuum lines ...HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 291 
						

							... and the electrical harness plugs
Tag and unplug all vacuum lines connected to the manifold.
5. 
Tag and disconnect all electrical wires attached to the upper manifold assembly.
6. 
Relieve the fuel system pressure.
7. 
Also, ensure that any brackets which are bolted to the manifold are unfastened
Tag and remove the spark plug wires.
8. 
Remove the EDIS ignition coil and bracket.
9.  HOW TO USE THIS BOOK
292 REMOVAL & INSTALLATION 
						

							Remove the upper intake manifold attaching bolts ...
... then lift the manifold from the engine
Stuff rags into the intake runners, then remove the old upper intake gasket; use care when scraping
Remove the 6 attaching nuts and lift off the upper manifold.
10. 
If you only need to remove the upper intake manifold, stop at this point. Otherwise, continue with the
procedure to also remove the lower intake manifold. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 293