1991 1999 ford explorer chilton User Manual

							
The following procedures are for installing the upper intake manifold.
Upper intake manifold bolt tightening sequenceClick to enlarge
Install the upper intake manifold using a new gasket. Tighten the attaching bolts in the sequence given
to the proper specification.
38. 
Install the intake cover plate.
39. 
Install the ignition coils to the engine and connect the harness plug and spark plug wires to them.
40. 
If equipped, install the EGR spacer (throttle body) coolant hoses.
41. 
Install the accelerator cable brackets and cables to the intake and throttle shaft.
42. 
Connect any electrical components or vacuum lines removed from the upper manifold.
43. 
Install the throttle body shield.
44. 
Install the air cleaner outlet tube to the throttle body.
45. 
Refill and bleed the cooling system.
46. 
Connect the negative battery cable then start and run the engine until it reaches normal operating
temperatures. Check for leaks.
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304 REMOVAL & INSTALLATION 
						

							
Exhaust Manifold
REMOVAL & INSTALLATION CAUTION
Allow the engine to cool before attempting to remove the manifolds. Serious injury can result from contact
with hot exhaust manifolds.
2.3L and 2.5L Engines
Disconnect the negative battery cable.
1. 
Remove the air cleaner outlet tube.
2. 
Remove the EGR transducer lines at the tube. Loosen and remove the EGR valve-to-exhaust
manifold tube.
3. 
Exploded view of the 2.3L and 2.5L engine exhaust manifold Click to enlarge
Disconnect the exhaust pipe from the exhaust manifold.
4. 
Remove the two nuts securing the lifting bracket/transducer mount, and remove the bracket.
5. 
Remove the exhaust manifold mounting bolts/nuts and remove the manifold.
6. 
Install the exhaust manifold in the reverse order. Torque the manifold in sequence in two steps, first
5-7 ft. lbs. and then 16-23 ft. lbs.
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Exhaust Manifold 305 
						

							
2.9L Engines
Disconnect the attaching nuts from the muffler inlet pipe.
1. 
Remove the manifold attaching bolts.
2. 
Exploded view of both left and right-hand exhaust manifolds on the 2.9L engine Click to enlarge
Lift the manifold from the cylinder head.
3. 
To install: Position the manifold on the heads and install and tighten the attaching bolts to specification.
4. 
Install and tighten the inlet pipe attaching nuts.
5. 
3.0L Engine Disconnect the negative battery cable. Raise and safely support the vehicle as necessary.
1. 
Remove the spark plugs.
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							If removing the left side exhaust manifold remove the oil level indicator tube retaining nut, rotate the
dipstick assembly out of the way. Also, if equipped, loosen the EGR tube flare nut at the valve and
remove the tube bolt at the manifold.
3. 
Exploded view of both left and right-hand exhaust manifolds on the 3.0L engine Click to enlarge
Remove the manifold to exhaust pipe attaching nuts, then separate the exhaust pipe from the
manifold.
4. 
Remove the exhaust manifold attaching bolts and the manifold.
5. 
To install: Clean all gasket mating surfaces.
6. 
Lightly oil all bolt and stud threads before installation. If a new manifold is being installed, the
oxygen sensor will have to be transferred to the new part.
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REMOVAL & INSTALLATION 307 
						

							Position the exhaust manifold on the cylinder head and install the manifold attaching bolts. Tighten
them to 18 ft. lbs.
8. 
Connect (replace gasket if so equipped) the exhaust pipe to the manifold, then tighten the attaching
nuts to 30 ft. lbs. TIGHTEN BOTH NUTS IN EQUAL AMOUNTS TO CORRECTLY SEAT INLET
PIPE FLANGE.
9. 
If installing the left side manifold, install the oil tube dipstick assembly (apply sealer to the tube) as
necessary. Also reattach the EGR tube and components if removed.
10. 
Install the spark plugs.
11. 
Connect the negative battery cable. Start the engine and check for leaks.
12. 
4.0L Engine (VIN X) Disconnect the negative battery cable. Remove the oil level indicator tube bracket.
1. 
Exploded view of the left-hand exhaust manifold on the 4.0L engine Click to enlarge
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308 REMOVAL & INSTALLATION 
						

							Exploded view of the right-hand exhaust manifold on the 4.0L engine
Click to enlarge
Raise and safely support the vehicle.
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REMOVAL & INSTALLATION 309 
						

							To remove the exhaust manifold, first remove the exhaust pipe-to-manifold bolts from
underneath
Remove the exhaust pipe-to-manifold bolts.
3. 
Lower the vehicle.
4. 
Unbolt the hot air intake shroud, which wraps around the manifold and covers some of the attaching bolts
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310 REMOVAL & INSTALLATION 
						

							Remove the shroud ...
If removing the left-hand manifold, disconnect the power steering pump hoses.
5. 
If removing the right-hand manifold, remove the hot air intake shroud which is bolted around the
manifold.
6. 
... then unbolt the manifold ...... and lift it from the engine
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REMOVAL & INSTALLATION 311 
						

							Unbolt and remove the manifold.
7. 
Clean and lightly oil all fastener threads.
8. 
Installation is the reverse of removal. Replace all gaskets if so equipped. Torque the manifold bolts to
19 ft. lbs.; the exhaust pipe nuts to 20 ft. lbs. TIGHTEN BOTH EXHAUST PIPE RETAINING
NUTS IN EQUAL AMOUNTS TO CORRECTLY SEAT INLET PIPE FLANGE.
9. 
If installing the left-hand manifold, reconnect the power steering pump hoses, then fill and bleed the
system.
10. 
Connect the negative battery cable and run the engine to check for leaks.
11. 
4.0L SOHC Engine (VIN E)
When installing the exhaust manifold, always use a new gasket and attaching nuts. Disconnect the negative battery cable.
1. 
Raise and safely support the vehicle.
2. 
Remove the exhaust inlet pipe-to-manifold attaching bolts.
3. 
Lower the vehicle.
4. 
For removing the left-hand manifold, proceed as follows: Disconnect the hoses from the Differential Pressure Feedback EGR (DPFE) transducer, which
is mounted to the valve cover.
1. 
Disconnect the EGR tube from the manifold and the valve and remove the tube.
The 4.0L SOHC engine exhaust manifold is retained by six nuts. Always use new nuts when installing the manifold
2. 
5. 
Remove the six manifold-to-engine attaching nuts.
6. 
Remove the manifold and the gasket. Discard the old gasket.
7. 
To install: Clean the gasket mating surfaces.
8. 
Position the exhaust manifold and new gasket to the cylinder head and install new attaching nuts.
Tighten the nuts to 15-18 ft. lbs. (20-25 Nm).
9. 
For installing the left-hand manifold, proceed as follows: Position and install the EGR tube to the manifold and the valve.
1. 
Connect the two hoses to the DPFE transducer.
2. 
10. 
Raise and safely support the vehicle.
11. 
Install the exhaust inlet pipe-to-manifold attaching bolts and tighten to 25-32 ft. lbs. (34-46 Nm).
12. 
Lower the vehicle and reconnect the negative battery cable.
13. 
Start the engine and check for leaks.
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312 REMOVAL & INSTALLATION 
						

							
5.0L Engine
When installing the manifolds, always use new gaskets. Disconnect the negative battery cable.
1. 
Remove the accessory drive belt.
2. 
For the right-hand manifold, proceed as follows: Drain the cooling system.
1. 
Disconnect the alternator wires.
2. 
Remove the drive belt tensioner.
3. 
Disconnect the heater hot water tube from the water pump.
4. 
Remove the alternator bracket bolts and then remove the assembly.
5. 
3. 
For the left-hand manifold, proceed as follows:
4. 
Example of the 5.0L engine exhaust manifold. Left-hand manifold shown, right-hand manifold is similar
Click to enlarge
Remove A/C compressor bolts and position it off to the side.
1. 
Remove the oil level indicator tube nut and tube.
2. 
Raise and safely support the vehicle.
5. 
Remove the exhaust inlet pipe-to-manifold bolts.
6. 
Lower vehicle to a suitable height to access the manifold-to-engine attaching bolts.
7. 
Access to the manifold-to-engine bolts is through the wheel well opening. Remove the pushpins securing the fender apron, and remove it for access to the manifold attaching
bolts.
8. 
Label and disconnect the spark plug wires from the side of the engine whose manifold is to be
removed.
9. 
Remove the exhaust manifold attaching bolts.
10. 
Lower the vehicle and remove the manifold.
11. 
Discard the old gasket.
12. 
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REMOVAL & INSTALLATION 313