1991 1999 ford explorer chilton User Manual

							Use the camshaft chain tensioner tool and install it into the RH cylinder head. Access to the
chain tensioner is through the fender well.
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
tool on the RH 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 RH cylinder head.
5. 
Install the camshaft gear removal tool on the RH cylinder head.
6. 
WARNING
The RH camshaft sprocket bolt uses left-hand threads.
Ensure that the bolts on the camshaft gear positioning/holding tool are tight, then tighten the
RH camshaft sprocket bolts to 63 ft. lbs. (85 Nm).
7. 
Remove the camshaft chain tensioner tool.
8. 
Install the RH hydraulic camshaft tensioner and tighten to 35-39 ft. lbs. (47-53 Nm).
9. 
Remove the camshaft gear positioning/holding tool, camshaft holding tool and the crankshaft
holding tool.
10. 
Install the RH exhaust manifold.
-96. 
Rasie and safely support the vehicle.
-95. 
Install the exhaust inlet pipes to the manifolds.
-94. 
Lower the vehicle.
-93. 
Install the engine oil dipstick and tube.
-92. 
Install the crankcase vent separator and the spring clip.
-91. 
Lubricate the injector o-rings with SAE 50W oil and install them.
-90. 
Install both valve covers.
-89. 
Install the fuel injection supply manifold.
-88. 
Tighten the upper fuel line bracket.
-87. 
Install the spark plug wires to the plugs.
-86. 
Install the thermostat housing assembly.
-85. 
Install the thermostat bypass hose.
-84. 
Connect both heater hoses to the engine and install the mounting bracket.
-83. 
Install the EGR valve and connect the supply tube.
-82. 
Position the engine wiring harness and connect all of the electrical plugs which were removed.
-81. 
Position both engine accessory brackets to the engine and install the attaching bolts.
-80. 
Attach the alternator electrical connections.
-79. 
Install the accessory drive belt, top radiator hose and tube, as well as the engine fan/clutch assembly
and shroud.
-78. 
Install the lower and upper intake manifolds.
-77. 
Refill and bleed the cooling system.
-76. 
Connect the negative battery cable then start and run the engine. Check for leaks.
-75. 
5.0L Engine
According to the manufacturer, you must use new cylinder head bolts when installing the head(s). Disconnect the negative battery cable.
1. 
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 HOW TO USE THIS BOOK
354 REMOVAL & INSTALLATION 
						

							
sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is
contaminated or is several years old.
Remove one or both valve covers.
3. 
Remove the upper and lower intake manifolds.
4. 
Remove the accessory drive belt.
5. 
If the LH cylinder head is being removed, proceed as follows: Remove the A/C compressor/power steering mounting bracket and position it out of the way.
1. 
Remove the engine oil dipstick and tube.
2. 
6. 
If the RH cylinder head is being removed, proceed as follows: Disconnect the alternator electrical harness.
1. 
Unbolt the alternator mounting bracket and remove it from the engine.
2. 
7. 
Remove the exhaust manifolds from the engine.
8. 
Loosen the rocker arm bolts so that the rockers can be rotated to the side.
9. 
Remove the pushrods, keeping them in order so that they can be installed to their original locations.
10. 
Remove and discard the cylinder head bolts. Lift the cylinder head from the engine and discard the
old gasket.
11. 
To install: Thoroughly clean all of the gasket mating surfaces.
12. 
Position a new cylinder head gasket to the engine block, then install the cylinder head.
13. 
Fig. 27: Cylinder head bolt tightening sequence for the 5.0L engine
Install new cylinder head bolts and tighten in three steps: Tighten all bolts in sequence to 25-37 ft. lbs. (34-47 Nm).
1. 
Tighten all bolts in sequence to 45-1 ft. lbs. (7-18 Nm).
2. 
Tighten all bolts an additional 85-95° ( 1
/4  turn).
3. 
14. 
Ensure that the oil passages within the pushrods are clear and install them in the engine.
15. 
Lubricate the ends of the pushrods with SAE 50W engine oil. Thoroughly coat the rocker arms with SAE 50W engine oil and rotate them back to their proper
positions. tighten the attaching bolts to 18-25 ft. lbs. (24-34 Nm).
16. 
Install the exhaust manifolds.
17. 
If the RH cylinder head was removed, proceed as follows: Attach the alternator mounting bracket and to the engine.
1. 
Connect the alternator electrical harness.
2. 
18. 
If the LH cylinder head was removed, proceed as follows: Install the engine oil dipstick and tube.
1. 
Install the A/C compressor/power steering mounting bracket to the engine.
2. 
19. 
Install the lower and upper intake manifolds.
20. 
Install the one or both valve covers.
21. 
Refill and bleed the cooling system.
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							Connect the negative battery cable, then start and run the engine. Check for leaks.
23. 
Oil Pan
REMOVAL & INSTALLATION
2.3L and 2.5L Engines
Oil pan on the 1994 2.3L engine-1995-99 engines similarClick to enlarge
Disconnect the battery ground cable.
1. 
Remove the engine assembly from vehicle.
2. 
CAUTION
Do NOT turn the engine assembly upside down with the oil pan still attached. Sludge and debris in the oil pan
will fall into the cylinders, pistons and connecting rods, possibly causing rapid wear. Sludge may also plug the
engine oil pickup screen.
Mount the engine assembly on an engine stand with the engine mounted in the upright position.
3. 
Remove the oil pan mounting bolts.
4. 
Remove the oil pan from the engine.
5. 
Remove and discard the oil pan gasket. Thoroughly clean all gasket mating surfaces.
6. 
To install:
Wait no longer than 4 minutes after applying silicone gasket sealant to install the oil pan. HOW TO USE THIS BOOK
356 Oil Pan 
						

							Apply a 0.24 inch (6mm) bead of silicone gasket sealant in six places; on both sides of the rear main
cap and front cover humps and along the seams for the cover-to-engine block.
7. 
Position and press into place the new oil pan gasket onto the oil pan mounting flange.
8. 
Using a straight edge, line up the oil pan to the engine block.
9. 
Install the oil pan mounting bolts. The 2 long bolts are installed in the two rear pan holes (holes 15
and 18 shown in the illustration) near the flywheel.
10. 
Tighten the oil pan bolts, in sequence, to 124-141 inch lbs. (14-16 Nm).
11. 
Install the engine assembly into the vehicle.
12. 
Connect the negative battery cable. Fill the engine with the proper amount and type of engine oil. Add
all necessary fluids and be sure that all components are installed/connected correctly.
13. 
2.9L Engines Disconnect the battery ground cable.
1. 
Remove the carburetor air cleaner assembly.
2. 
Remove the fan shroud and position it over the fan.
3. 
Remove the distributor cap with the wires still attached, and position it forward of the dash panel.
4. 
Remove the distributor and cover the opening with a clean rag.
5. 
Remove the nuts attaching the front engine mounts to the cross member.
6. 
Remove the engine oil dipstick tube.
7. 
Raise the truck on a hoist and support with jackstands.
8. 
Drain the engine crankcase and remove the oil filter.
9. 
CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including
cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should
be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after
exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.
Remove the transmission fluid filler tube and plug the hole in the pan, On automatic transmission
models.
10. 
Disconnect the muffler inlet pipes.
11. 
If equipped with an oil cooler, disconnect the bracket and lower the cooler.
12. 
Remove the starter motor.
13. 
On automatic transmission models, position the cooler lines out of the way.
14. 
Disconnect the front stabilizer bar and position it forward.
15. 
Position a jack under the engine and raise the engine until it touches the dash panel. Install wooden
blocks between the front motor mounts and the no. 2 crossmember.
16. 
Lower the engine onto the blocks and remove the jack.
17. 
Remove the oil pan attaching bolts and lower the pan assembly.
18. 
Installation is the reverse of the removal procedure
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REMOVAL & INSTALLATION 357 
						

							Oil pan gasket positioning on the 2.9L engine
Click to enlarge
Oil pan bolt torque sequence on the 2.9L engine Click to enlarge
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358 REMOVAL & INSTALLATION 
						

							
3.0L Engine
Disconnect the negative battery cable.
1. 
Remove the oil level dipstick.
2. 
Remove the fan shroud. Leave the fan shroud over the fan assembly.
3. 
Remove the motor mount nuts from the frame.
4. 
WARNING
On models equipped with distributor ignition, failure to remove the distributor will damage or break it when
the engine is lifted.
If equipped, mark and remove the distributor assembly from the engine.
5. 
Raise and support the vehicle safely. Remove the oil level sensor wire.
6. 
Drain the engine oil from the crankcase into a suitable container and dispose of it properly.
7. 
CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including
cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should
be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after
exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.
Remove the starter motor from the engine.
8. 
Remove the transmission inspection cover.
9. 
Remove the right hand axle I-Beam. The brake caliper must be removed and secured out of the way.
Refer to the necessary service procedures.
10. 
Remove the oil pan attaching bolts, using a suitable lifting device, raise the engine about 2 inches.
Remove the oil pan from the engine block.
11. 
Oil pan fits tightly between the transmission spacer plate and oil pump pickup tube. Use care when
removing the oil pan from the engine.
Clean all gasket surfaces on the engine and oil pan. Remove all traces of old gasket and/or sealer.
12. 
To install: Apply a 4mm bead of RTV sealer to the junctions of the rear main bearing cap and block, and the
front cover and block. The sealer sets in 15 minutes, so work quickly!
13. 
Apply adhesive to the gasket mating surfaces and install oil pan gasket.
14. 
Install the oil pan on the engine block.
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REMOVAL & INSTALLATION 359 
						

							Oil pan installation for the 3.0L engine
Click to enlarge
Tighten the pan bolts EVENLY to 9 ft. lbs. working from the center to the end position on the oil pan.
16. 
Install low-oil level sensor connector. Lower engine assembly to original position.
17. 
Install right hand axle I-Beam. Install the brake caliper. Refer to the necessary service procedures.
18. 
Install transmission inspection cover. Install starter motor.
19. 
Lower the vehicle and install the fan shroud.
20. 
Install motor mount retaining nuts. If removed, install distributor assembly.
21. 
Replace the oil level dipstick. Connect the battery ground. Fill crankcase with the correct amount of
new engine oil. Start engine and check for leaks.
22. 
If equipped with distributor ignition, check the base ignition timing.
23. 
4.0L Engine (VIN X)
Review the complete service procedure before starting this repair. Disconnect the negative battery cable. Remove the complete engine assembly from the vehicle. Refer
to the necessary service procedures in this section.
1. 
Mount the engine on a suitable engine stand with oil pan facing up.
2. 
Remove the oil pan attaching bolts (note location of 2 spacers) and remove the pan from the engine
block.
3. 
Remove the oil pan gasket and crankshaft rear main bearing cap wedge seal.
4. 
Clean all gasket surfaces on the engine and oil pan. Remove all traces of old gasket and/or sealer.
5. 
To install: HOW TO USE THIS BOOK
360 REMOVAL & INSTALLATION 
						

							Install a new crankshaft rear main bearing cap wedge seal. The seal should fit snugly into the sides of
the rear main bearing cap.
6. 
Oil pan installation on the 4.0L engine (VIN X)Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 361 
						

							Checking oil pan alignment on the 4.0L engine (VIN X)
Click to enlarge
Position the oil pan gasket to the engine block and place the oil pan in correct position on the 4
locating studs.
7. 
Tighten the oil pan retaining bolts EVENLY to 5-7 ft. lbs.
8. 
The transmission bolts to the engine and oil pan. There are 2 spacers on the rear of the oil pan to allow
proper mating of the transmission and oil pan. If these spacers were lost, or the oil pan was replaced,
you must determine the proper spacers to install. To do this: With the oil pan installed, place a straightedge across the machined mating surface of the rear
of the block, extending over the oil pan-to-transmission mounting surface.
1. 
Using a feeler gauge, measure the gap between the oil pan mounting pad and the straightedge.
2. 
Repeat the procedure for the other side.
3. 
Select the spacers as follows: Gap = 0.011-0.020 in.; spacer = 0.010 in.
à 
Gap = 0.021-0.029 in.; spacer = 0.020 in.
à 
Gap = 0.030-0.039 in.; spacer = 0.030 in.
à 
4. 
9. 
Failure to use the correct spacers will result in damage to the oil pan and oil leakage. Install the selected spacers to the mounting pads on the rear of the oil pan before bolting the engine
and transmission together. Install the engine assembly in the vehicle.
10. 
Connect the negative battery cable. Start the engine and check for leaks.
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4.0L SOHC Engine (VIN E)
The 4.0L SOHC engine does not use an oil pan in the conventional sense. There is a separate access
panel that unbolts from what would be considered the oil pan (which is now known as the ladder
frame).
Disconnect the negative battery cable.
1. 
Raise and safely support the vehicle.
2. 
Drain the engine oil.
3. 
Exploded view of the 4.0L SOHC engine oil pan assembly
Remove the ten oil pan bolts and remove the pan.
4. 
Installation is the reverse of removal. Clean the gasket mating surfaces and install a new gasket.
Tighten the pan bolts to 6-7.4 ft. lbs. (8-10 Nm). Refill the engine with clean oil.
5. 
5.0L Engine
The oil pan cannot be removed with the engine in the vehicle. Remove the engine.
1. 
Drain the engine oil.
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REMOVAL & INSTALLATION 363