1991 1999 ford explorer chilton User Manual

							Clean the gasket mating surfaces. Inspect the manifold for cracks and damaged gasket mating
surfaces. Replace if damaged.
13. 
Position the exhaust manifold and gasket to the cylinder head and install all of the bolts finger-tight.
14. 
For installing the left-hand manifold, proceed as follows: Position the A/C compressor to its bracket and install the attaching bolts. Tighten the bolts to
16-21 ft. lbs. (21-29 Nm).
1. 
Install the drive belt.
2. 
15. 
For installing the right-hand manifold, proceed as follows: Install generator bracket to the cylinder head.
1. 
Connect heater hot water tube to the water pump.
2. 
Install the drive belt tensioner. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
3. 
Connect the alternator wires.
4. 
Install the accessory drive belt.
5. 
Refill the cooling system.
6. 
16. 
Raise and safely support the vehicle to allow access to the exhaust manifold-to-engine attaching
bolts.
17. 
Tighten the exhaust manifold bolts to 26-35 ft. lbs. (35-44 Nm).
18. 
Connect the spark plug wires to the plugs.
19. 
Install the fender apron and its pushpins.
20. 
Raise and safely support the vehicle to allow access to the exhaust inlet-to-manifold pipe fasteners.
21. 
Install the inlet pipe bolts to the exhaust manifold and tighten to 26-33 ft. lbs. (34-46 Nm).
22. 
Lower the vehicle.
23. 
If installing the left-hand manifold, install the oil level indicator tube and its securing nut.
24. 
Connect the negative battery cable, start the engine and check for leaks.
25. 
Radiator
REMOVAL & INSTALLATION Drain the cooling system. Remove the overflow tube from the coolant recovery bottle and from the
radiator.
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.
If necessary, remove the air cleaner outlet tube from the throttle body.
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314 Radiator 
						

							Exploded view of the 2.3L and 2.5L engine radiator and related components
Click to enlarge
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REMOVAL & INSTALLATION 315 
						

							Exploded view of the 4.0L engine radiator and related components-2.9L and 3.0L engines are
similar
Click to enlarge
Remove the retaining bolts at the top of the shroud, and position the shroud over the fan, clear of the
radiator.
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316 REMOVAL & INSTALLATION 
						

							To remove the radiator, first remove the air intake tube, then unbolt the shroud and position it
over the fan
If equipped with the 5.0L engine, remove the engine fan and the radiator shroud from the vehicle.
4. 
If equipped with an automatic transmission, disconnect the transmission cooling lines from the bottom
of the radiator.
5. 
Disconnect the upper and lower hoses from the radiatorRemove the radiator retaining bolts ...HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 317 
						

							... then lift the radiator up and out of the vehicle
Disconnect the upper and lower hoses from the radiator.
6. 
Remove the radiator retaining bolts or the upper supports and lift the radiator from the vehicle.
7. 
Install the radiator in the reverse order of removal. Fill the cooling system and check for leaks. On
automatic transmission equipped vehicles, run the engine until normal operating temperature is
reached, then check the transmission fluid level. Correct as needed.
8. 
Engine Fan
REMOVAL & INSTALLATION
Refer to exploded view illustration before starting this service procedure. WARNING
The following procedures for removing the fan clutch gives the factory recommended loosening and
tightening directions for the fan hub nut. However, it has been our experience that certain aftermarket parts
manufacturers have changed this to enable use of universal fit parts. We recommend trying the factory
direction first, then, if the nut doesnt seem to be moving, reverse the direction. Placing too much load on the
water pump snout will break it.
2.3L and 2.5L Engines HOW TO USE THIS BOOK
318 Engine Fan 
						

							Exploded view of the engine fan for the 2.3L and 2.5L engine
Click to enlarge
The 2.3L and 2.5L engine does not use a fan hub nut. It is retained by four bolts which also secure the
pump pulley to the water pump.
If not equipped with A/C, disconnect the overflow tube from the fan guard, then unbolt and remove
the guard.
1. 
If equipped with A/C, disconnect the overflow tube from the shroud, remove the mounting screws and
lift the shroud off the brackets. Place the shroud behind the fan.
2. 
Remove the 4 clutch/fan assembly-to-pulley screws and remove the clutch/fan assembly. Vehicles
equipped with A/C should remove the clutch/fan and shroud together.
3. 
If necessary, remove the fan-to-clutch bolts to separate the fan from the clutch.
4. 
Installation is the reverse of removal. Torque the fan-to-clutch screws to 55-70 inch lbs. (6-8 Nm);
the fan/clutch assembly-to-pulley bolts to 12-18 ft. lbs. (16-24 Nm).
5. 
2.9L and 3.0L Engines HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 319 
						

							Exploded view of the engine fan for the 2.9L and 3.0L engines
Click to enlarge
If necessary, remove the air cleaner outlet tube.
1. 
Using Strap Wrench D79L-6731-A and Fan Clutch Nut Wrench T83T-6312-B, or their equivalents,
loosen the large nut attaching the clutch to the water pump hub.
2. 
According to the manufacturer, the nut uses LH threads and is loosened clockwise. Remove the two upper fan shroud retaining bolts. If the overflow hose is routed through the fan
shroud, remove it from the shroud.
3. 
Lift up on the fan shroud to disengage the lower mounting clips.
4. 
Remove the fan/clutch assembly and the fan shroud together.
5. 
If necessary, remove the fan-to-clutch bolts to separate the fan from the clutch.
6. 
To install: Installation is the reverse of removal. Torque the fan-to-clutch bolts to 55-70 inch lbs. (6-8 Nm);
the hub nut to 30-100 ft. lbs. (41-135 Nm) for 1991-95 models and 34-46 ft. lbs. (46-63 Nm) for
1996-99 models. Dont forget, the nut uses LH threads and is tightened counterclockwise.
7. 
4.0L Engine (VIN X) HOW TO USE THIS BOOK
320 REMOVAL & INSTALLATION 
						

							Exploded view of the engine fan for the 4.0L engine
Click to enlarge
Before attempting to unfasten the engine fan, check the fan shroud for indications of normal or reverse threads
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 321 
						

							Remove the air intake tube. You will need these specialized tools to unfasten the fan clutch nut
If necessary, remove the air cleaner outlet tube.
1. 
According to the manufacturer, the nut uses RH threads and is loosened counterclockwise. Using Fan Clutch Pulley Holder T84T-6312-C and Fan Clutch Nut Wrench T84T-6312-D, or their
equivalents, loosen the large nut attaching the clutch to the water pump hub.
2. 
Using the special tools, loosen the fan clutch nut in the direction indicated on the shroud.
Some models have enough room between the shroud and the engine to remove the fan without
unbolting the shroud.
Remove the two upper fan shroud retaining bolts. If the overflow hose is routed through the fan
shroud, remove it from the shroud.
3. 
Lift up on the fan shroud to disengage the lower mounting clips.
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322 REMOVAL & INSTALLATION 
						

							Remove the fan and clutch assembly from the vehicle
Remove the fan/clutch assembly and the fan shroud together.
5. 
If necessary, remove the fan-to-clutch bolts to separate the fan from the clutch.
6. 
To install: Installation is the reverse of removal. Torque the fan-to-clutch bolts to 55-70 inch lbs. (6-8 Nm);
the hub nut to 30-100 ft. lbs. (41-135 Nm) for 1991-95 models and 34-46 ft. lbs. (46-63 Nm) for
1996-99 models. Dont forget, the nut uses RH threads and is tightened clockwise.
7. 
4.0L SOHC (VIN E) and 5.0L Engines If necessary, remove the air cleaner outlet tube.
1. 
Using Fan Clutch Pulley Holder T84T-6312-C and Fan Clutch Nut Wrench T84T-6312-D for the
4.0L engine, or Holder T96T-6312-A and Wrench T96T-6312-B for the 5.0L engine, loosen the
large nut attaching the clutch to the water pump hub.
2. 
WARNING
The manufacturer does not specify a loosening or tightening direction. Using extreme care, try loosening the
nut in one direction first. If it does not move, change directions. Applying too much force to the end of the
water pump will break it.
Remove the two upper fan shroud retaining bolts. If the overflow hose is routed through the fan
shroud, remove it from the shroud.
3. 
Lift up on the fan shroud to disengage the lower mounting clips.
4. 
Remove the fan/clutch assembly and the fan shroud together.
5. 
If necessary, remove the fan-to-clutch bolts to separate the fan from the clutch.
6. 
To install: Installation is the reverse of removal. Torque the fan-to-clutch bolts to 14-19 ft. lbs. (19-26 Nm);
the hub nut to 34-46 ft. lbs. (46-63 Nm). Tighten the nut in the reverse direction of removal.
7. 
Water Pump HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 323