1991 1999 ford explorer chilton User Manual

							Remove the rocker shafts and, keeping them in order, the pushrods
Remove the rocker shaft assembly.
9. 
Remove the pushrods, keeping them in order so they may be installed in their original locations.
10. 
Loosen and remove the cylinder head attaching bolts ...... then lift the cylinder head from the engine HOW TO USE THIS BOOK
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							Loosen the cylinder head attaching bolts in reverse of the torque sequence, then remove the bolts and
discard them. They cannot be re-used.
11. 
Lift off the cylinder head(s).
12. 
Remove and discard the old cylinder head gasket
Remove and discard the old cylinder head gasket(s).
13. 
To install: Clean the cylinder heads, intake manifolds, valve rocker arm cover and cylinder block gasket surfaces
of all traces of old gasket material and/or sealer. Refer to the following overhaul procedures for
cylinder head component removal, valve replacement, resurfacing, etc.
14. 
With rags placed in the cylinder bores, scrape the gasket mating surfaces clean
Lightly oil all bolt and stud bolt threads except those specifying special sealant. Position the new head
gasket(s) on the cylinder block, using the dowels for alignment. The dowels should be replaced if
damaged.
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							Fig. 14: Cylinder head installation for the 4.0L engine
Click to enlarge
Fig. 15: Cylinder head torque sequence for the 4.0L engine
The cylinder head(s) and intake manifold are torqued alternately and in sequence, to assure a correct
fit and gasket crush.
Position the cylinder head(s) on the block.
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							Apply a bead of RTV silicone gasket material to the mating joints of the head and block at the 4
corners. Install the intake manifold gasket and again apply the sealer.
17. 
This sealer sets within 15 minutes, so work quickly! Install the lower intake manifold and install the bolts and nuts for the manifold and head(s). Tighten
all fasteners finger-tight.
18. 
Tighten the intake manifold fasteners, in sequence, to 36-15 inch lbs.
19. 
WARNING
Do not re-use the old head bolts. ALWAYS use new head bolts!
Torque the head bolts, in sequence, to 5 ft. lbs.
20. 
Tighten the intake manifold fasteners, in sequence, to 6-11 ft. lbs.
21. 
Tighten the head bolts, in sequence, an additional 80-85 degrees tighter. 85 degrees is a little less
than  1
/4  turn,  1
/4  turn would equal 90 degrees.
22. 
Torque the intake manifold fasteners, in sequence, to 11-15 ft. lbs.; then, in sequence, to 15-18 ft.
lbs.
23. 
Dip each pushrod in heavy engine oil then install the pushrods in their original locations.
24. 
Install the rocker shaft assembly(ies) and tighten the bolts to 46-52 ft. lbs., front to rear, in several
equal stages.
25. 
Apply another bead of RTV sealer at the 4 corners where the intake manifold and heads meet.
26. 
Install the valve covers, using new gaskets coated with sealer. Torque the bolts to 36-6 inch lbs. After
2 minutes, re-torque the cover bolts.
27. 
Install the upper intake manifold. Torque the nuts to 15-18 ft. lbs.
28. 
Install the exhaust manifold(s).
29. 
Install the spark plugs and wires.
30. 
If the left head was removed, install the power steering pump, compressor and drive belt.
31. 
If the right head was removed, install the EDIS coil and bracket, alternator and bracket, and the drive
belt.
32. 
Install the air cleaner.
33. 
Fill the cooling system. See Section 1.
34. 
At this point, its a good idea to change the engine oil. Coolant contamination of the engine oil often
occurs during cylinder head removal.
Connect the battery ground cable.
35. 
Start the engine and check for leaks.
36. 
4.0L SOHC Engine (VIN E)
If only one cylinder head is to be removed, only follow the procedures which apply. The following tools,
or their equivalents are absolutely necessary to properly perform this procedure:
Cam chain tensioner tool T97T-6K254-A
· 
Cam gear removal tool T97T-82-F
· 
Cam gear torque adapter T97T-82-G
· 
Camshaft gear positioning/holding tool T97T-82-B
· 
Camshaft gear positioning/holding tool adapter T97T-82-A
· 
Camshaft holding tool T97T-82-C
· 
Crankshaft holding tool T97T-6303-A
· 
Camshaft holding tool adapter T97T-82-D
· 
Disconnect the negative battery cable.
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							Drain the cooling system.
2. 
CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and
could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in
sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is
contaminated or is several years old.
Remove the upper and lower intake manifolds.
3. 
Remove the engine fan/clutch assembly and the shroud.
4. 
Remove the top radiator hose and connecting tube.
5. 
Disengage the accessory drive belt.
6. 
Disconnect the alternator electrical harness, then unbolt the bracket from the engine and remove it,
alternator and all.
7. 
Unbolt the air conditioner compressor/power steering mounting bracket and position it off to the side.
8. 
Label and disconnect the complete engine wire harness, including injectors, sensors, etc., from the
engine and position it out of the way.
9. 
Disconnect the EGR valve supply tube, then remove the valve.
10. 
Remove the heater hose bracket from the engine and disconnect the transmission dipstick tube.
11. 
Disconnect both heater hoses from the engine.
12. 
Remove the thermostat housing bypass hose.
13. 
Remove the thermostat housing assembly from the engine.
14. 
Label and disconnect the spark plug wires from the plugs.
15. 
Remove the fuel line upper bracket bolts.
16. 
Remove the fuel injection supply manifold.
17. 
Remove both valve covers.
18. 
Remove the six fuel injectors.
19. 
Remove the crankcase vent separator spring steel clip, then remove the separator.
20. 
Remove the engine oil dipstick and tube.
21. 
Fig. 16: The hydraulic chain tensioner is threaded into the cylinder head (arrow)
Raise and safely support the vehicle.
22. 
Unbolt both exhaust pipe inlets from the exhaust manifolds.
23. 
Lower the vehicle.
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							Fig. 17: Remove the LH camshaft sprocket bolt (arrow)
Fig. 18: Remove the LH cassette (chain guide assembly) retaining bolt
Remove the LH hydraulic chain tensioner and the camshaft sprocket bolt.
25. 
Remove the LH cassette (chain guide) retaining bolt.
26. 
Remove the eight 12 mm and two 8 mm bolts, in sequence, from the LH cylinder head.
27. 
Remove the cylinder head and discard the old gasket.
28. 
WARNING
The RH exhaust manifold must be removed before the RH cylinder head to avoid breaking the camshaft
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							Remove the RH exhaust manifold.
29. 
Fig. 19: The cam gear torque adapter tool (arrow) is necessary for the removal of the RH camshaft sprocket bolt
Remove the RH hydraulic chain tensioner. Access to the tensioner is through the RH fender well.
30. 
WARNING
The RH camshaft sprocket bolt uses left-hand threads.
Use the cam gear torque adapter tool to remove the RH camshaft sprocket bolt.
31. 
Fig. 20: Remove the RH cassette retaining bolt (arrow)
Remove the RH cassette retaining bolt.
32. 
WARNING
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You must remove the camshaft sprocket from the chain and cassette to gain clearance to remove the cylinder
head and avoid breaking the cassette.
Fig. 21: Remove the RH camshaft sprocket and fasten a rubber band around the chain and the cassette to prevent the chain from dropping into the engine
Hold the chain to the cassette with a rubber band to aid removal and prevent the chain from falling into
the cylinder block.
Remove the RH camshaft sprocket from the cassette.
33. 
Remove the eight 12mm and two 8mm bolts, in sequence, from the RH cylinder head.
34. 
Remove the cylinder head and discard the old gasket.
35. 
To install: Thoroughly clean all gasket mating surfaces. Remove all traces of old gasket material, oil, grease or
dirt.
36. 
Fig. 22: Cylinder head bolt loosening and tightening sequence for the 4.0L SOHC engine
Insure that the rubber band is holding the RH chain to the cassette.
37. 
Install the RH cylinder head gasket.
38. 
Position the RH cylinder head to the engine block and install the attaching bolts. Tighten the bolts in
three stages: first tighten to 26 ft. lbs. (35 Nm), second, rotate 90°, third, rotate an additional 90°.
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							Fig. 23: Before installing the LH cylinder head, fasten a rubber band around the chain and
cassette to keep the sprocket from being disturbed
Install a rubber band to the LH cassette to hold the chain and sprocket in place.
40. 
Install the LH cylinder head gasket.
41. 
Position the LH cylinder head to the engine block and install the attaching bolts. Tighten the bolts in
three stages: first tighten to 26 ft. lbs. (35 Nm), second, rotate 90°, third, rotate an additional 90°.
42. 
Install the RH camshaft sprocket in the cassette.
43. 
Loosely install the RH camshaft sprocket bolt.
44. 
The camshaft sprocket must turn freely on the camshaft, DO NOT tighten the bolt. Install the RH cassette retaining bolt.
45. 
Loosely install the LH camshaft sprocket bolt.
46. 
The camshaft sprocket must turn freely on the camshaft, DO NOT tighten the bolt. Install the LH cassette retaining bolt.
47. 
Fig. 24: View of the crankshaft holding tool (arrow) installed to the crankshaft pulley with its stop tight against the engine blockHOW TO USE THIS BOOK
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							Fig. 25: You will need to align the slots on the camshaft to install the camshaft holding tool to
the cylinder head
Fig. 26: With the camshaft gear positioning/holding tool installed, the sprocket bolt can be properly tightened
To properly time the left-hand cylinder head camshaft, proceed as follows: Use the camshaft chain tensioner tool and install it into the LH cylinder head.
1. 
Rotate the crankshaft one revolution.
2. 
Position the crankshaft at top dead center of number one cylinder and install the crankshaft
holding tool. The crankshaft holding tool must firmly contact the cylinder block.
3. 
Position the camshaft timing slots to properly fit the camshaft holding tool and position the
toll on the LH cylinder head. The camshaft timing slots are off-center and below the
center-line of the camshaft.
4. 
Install the camshaft gear positioning/holding tool on the LH cylinder head.
5. 
Ensure that the bolts on the camshaft gear positioning/holding tool are tight, then tighten the
LH camshaft sprocket bolts to 63 ft. lbs. (85 Nm).
6. 
Remove the camshaft chain tensioner tool.
7. 
Install the LH hydraulic camshaft tensioner and tighten to 35-39 ft. lbs. (47-53 Nm).
8. 
Remove the camshaft gear positioning/holding tool, camshaft holding tool and the crankshaft
holding tool.
9. 
48. 
To properly time the right-hand cylinder head camshaft, proceed as follows:
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