1991 1999 ford explorer chilton User Manual

							Disconnect the fuel supply and return lines from the injector fuel rail
Label all of the electrical connections on the lower intake manifold ... ... then disconnect them. Next, remove the valve covers
Disconnect the fuel supply and return lines from the injector fuel rail.
11. 
Label and disconnect all of the electrical connections on the lower manifold assembly.
12. 
Remove the valve covers.
13.  HOW TO USE THIS BOOK
294 REMOVAL & INSTALLATION 
						

							Remove the lower intake manifold attaching bolts ...
... then lift the manifold from the engine
Remove the lower intake manifold bolts. Tap the manifold lightly with a plastic mallet and remove it.
14. 
Remove the old intake gasket from the cylinder heads and engine block
Clean all surfaces of old gasket material.
15.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 295 
						

							
To install:
Apply RTV silicone gasket material at the junction points of the heads and manifold.
16. 
This material will set within 15 minutes, so work quickly! Install new manifold gaskets and again apply the RTV material.
17. 
Intake manifold and gasket installation for the 4.0LClick to enlarge
HOW TO USE THIS BOOK
296 REMOVAL & INSTALLATION 
						

							Intake manifold torque sequence for the 4.0L
Position the manifold and install the nuts hand-tight. Tighten the nuts in 4 stages, using the sequence
shown, to 18 ft. lbs.
18. 
Once again, apply RTV material to the manifold/head joints.
19. 
Install the valve covers using new gaskets.
20. 
The following procedures are for installing the upper intake manifold. Position a new gasket and install the upper manifold. Tighten the nuts to 18 ft. lbs.
2. 
Install the EDIS coil.
3. 
Connect the fuel and return lines.
4. 
Install the throttle body.
5. 
Connect all wires.
6. 
Connect all vacuum lines.
7. 
Connect the throttle linkage.
8. 
Install the weather shield.
9. 
Install the air cleaner and duct.
10. 
Fill and bleed the cooling system.
11. 
Connect the battery ground.
12. 
Run the engine and check for leaks.
13. 
4.0L SOHC Engine (VIN E) Disconnect the negative battery cable.
1. 
Remove the air cleaner-to-intake tube.
2. 
Remove the accelerator splash shield.
3. 
Disconnect the accelerator and, if equipped with cruise control, speed control cables from the throttle
control cam.
4. 
Remove the accelerator cable retaining bracket from the upper intake manifold.
5. 
Label and disconnect all vacuum and electrical connections on the intake manifold.
6. 
Remove the eight upper intake manifold attaching bolts.
7. 
Lift up on the manifold and remove both fuel Vapor Management Valve (VMV) hoses.
8. 
Remove the upper intake manifold.
9. 
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.
Remove the 12 lower manifold attaching bolts.
10. 
Remove the lower intake manifold from the engine.
11. 
To install: Install the lower intake manifold to the engine.
12. 
Install the attaching bolts. Tighten to specification in several steps.
13.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 297 
						

							
Ford does not specify a sequence, but it is recommended that you start tightening in the middle and
work you way out to the ends. Repeat the tightening sequence several times until the bolts will no longer
turn at the specified torque.
The following procedures are for installing the upper intake manifold. Install the upper manifold.
14. 
Attach both VMV hoses to the manifold.
15. 
Install the attaching bolts and tighten to specification. See the note above.
16. 
Attach any vacuum and electrical connections that were removed.
17. 
Connect the accelerator cable bracket to the intake and the cable (or cables if equipped with cruise
control) to the throttle cam.
18. 
Install the accelerator splash shield.
19. 
Install the air cleaner-to-intake supply tube.
20. 
Connect the negative battery cable. Run the engine until normal operating temperature is reached and
check for vacuum leaks.
21. 
5.0L Engine
To remove the lower intake manifold on the 5.0L engine, the camshaft synchronizer, which houses the
Camshaft Position (CMP) sensor, must be removed. Refer to Section 4 before starting this procedure as
there are special tools necessary. If the tools are not available and you remove the CMP, the fuel
injectors will not remain timed to the engine and the vehicle will not run.
Disconnect the negative battery cable.
1. 
Drain the cooling system.
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.
Remove the air cleaner outlet tube.
3. 
Disconnect the crankcase ventilation hose from the throttle body.
4. 
Remove the throttle body shield then disengage the cables from the throttle shaft.
5. 
Label and disconnect any electrical components or vacuum lines attached to the upper intake
manifold.
6. 
Remove the accelerator cable brackets from the manifold and position aside.
7. 
If equipped, disconnect the EGR spacer (or throttle body) coolant hoses.
8. 
Label and remove the spark plug wires from the coil packs.
9. 
Disconnect the ignition coil wiring harness plug.
10. 
Unbolt and remove the coil packs from the engine.
11. 
Remove the intake cover plate to gain access to the two long upper intake manifold attaching bolts.
12. 
Remove any wires or loom holders from the upper manifold.
13.  HOW TO USE THIS BOOK
298 REMOVAL & INSTALLATION 
						

							Upper intake manifold bolt loosening sequence
Click to enlarge
Loosen and remove the upper intake manifold attaching bolts in the sequence given.
14. 
Remove the upper manifold and its gasket.
15. 
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.
CAUTION
Fuel lines on fuel injected vehicles will remain pressurized after the engine is shut off. Fuel pressure must be
relieved before servicing the fuel system.
Properly relieve the fuel system pressure then disconnect the fuel supply and return lines from the fuel
supply manifold.
16.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 299 
						

							Hot water tube assembly and its mounting points
Click to enlarge
Disconnect the heater hoses from the hot water tube. Also remove the tube from the lower manifold.
17. 
Label and disconnect any electrical components, sensors or vacuum lines connected to the lower
manifold.
18. 
Disconnect the upper radiator hose from the water outlet.
19. 
Loosen the water pump bypass hose clamp at the pump.
20. 
Remove the rear engine ground strap.
21. 
Remove the camshaft synchronizer with the Camshaft Position (CMP) sensor installed. Refer to
Section 4.
22.  HOW TO USE THIS BOOK
300 REMOVAL & INSTALLATION 
						

							Lower intake manifold loosening sequence
Click to enlarge
Loosen and remove the lower manifold attaching bolts in the sequence given.
4. 
Remove the lower manifold and its gasket from the engine.
5. 
To install: Ensure that all of the gasket mating surfaces are clean and free or grease, oil or dirt. Also ensure that
the EGR passages in the manifolds and heads are clear.
6.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 301 
						

							Intake manifold gasket and sealant points. Note that points (1) and (5) are sealed with RTV
silicone
Apply a  1
/16  in. (1.6mm) bead of silicone sealer to the points where the cylinder block rails meet the
cylinder heads.
7. 
Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets
interlocked with the seal tabs. Make sure the holes in the gaskets are aligned with the holes in the
cylinder heads.
8. 
Apply a  1
/16  in. (1.6mm) bead of sealer to the outer end of each intake manifold seal for the full width
of the seal. Make sure the silicone sealer will not fall into the engine and possibly block oil passages.
9. 
Using guide pins to ease installation, carefully lower the intake manifold into position on the cylinder
block and cylinder heads. Also, ensure that the water pump bypass hose is installed at the same time.
10.  HOW TO USE THIS BOOK
302 REMOVAL & INSTALLATION 
						

							Lower intake manifold bolt tightening sequence
Click to enlarge
Install the lower manifold attaching bolts and tighten, in sequence shown, to specification in two steps
as follows: Tighten all bolts to 5-10 ft. lbs. (6-14 Nm).
1. 
Tighten all bolts to 4-6 ft. lbs. (12-17 Nm).
2. 
11. 
Install the camshaft synchronizer. Refer to Section 4.
12. 
Install the rear engine ground strap.
13. 
Tighten the water pump bypass hose clamp at the water pump.
14. 
Install the upper radiator hose to the water outlet.
15. 
Connect any electrical components or vacuum lines which were removed from the lower manifold.
16. 
Install the hot water tube to the engine, and connect the heater hose to the tube.
17. 
Connect the fuel lines, then temporarily connect the negative battery cable. Cycle the ignition to
pressurize the fuel system and check for leaks. Turn the ignition key back and forth (from ONto OFF)
at least 6 times, leaving the key ONfor 5 seconds each time. If no leaks are found, disconnect the
negative battery cable and continue the installation.
18.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 303