1991 1999 ford explorer chilton User Manual

							Exploded view of the 5.0L engine oil pan
Click to enlarge
Remove the oil pan bolts.
3. 
Remove the oil pan and gasket.
4. 
Installation is the reverse of removal. Use RTV sealer at the four corners of the block and pan.
Tighten the four oil pan end attaching bolts to 12-18 ft. lbs. (16-25 Nm) and the 18 oil pan bolts to
110-144 inch lbs. (13-16 Nm).
5. 
Oil Pump HOW TO USE THIS BOOK
364 Oil Pump 
						

							
REMOVAL & INSTALLATION
Except 4.0L SOHC (VIN E), 5.0L, 1995-97 2.3L and 1998-99 2.5L Engines
The oil pumps are not serviceable. If defective, they must be replaced. Follow the service procedures under Oil Pan Removal and remove the oil pan assembly.
1. 
Remove the oil pick-up and tube assembly from the pump.
2. 
Remove the oil pump retainer bolts and remove the oil pump.
3. 
To install: Prime the oil pump with clean engine oil by filling either the inlet or outlet port with clean engine oil.
Rotate the pump shaft to distribute the oil within the pump body.
4. 
Install the pump and tighten the mounting bolts to: 14-21 ft. lbs. (19-29 Nm) on 17-7 2.3L engines
¨ 
6-10 ft. lbs. (8-14 Nm) on 2.9L engines
¨ 
30-40 ft. lbs. (41-54 Nm) on 3.0L engines
¨ 
13-15 ft. lbs. (18-20 Nm) on 4.0L engines
¨ 
5. 
WARNING
Do not force the oil pump if it does not seat readily. The oil pump driveshaft may be misaligned with the
distributor or shaft assembly. If the pump is tightened down with the driveshaft misaligned, damage to the
pump could occur. To align, rotate the intermediate driveshaft into a new position.
Install the oil pick-up and tube assembly to the pump. If there is a gasket between the pump and the
pick-up, use a new gasket when installing.
6. 
Install the oil pan as previously described.
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REMOVAL & INSTALLATION 365 
						

							Oil pump installation on the 1991-94 2.3L engine
Click to enlarge
Oil pump installation on the 3.0L engines Click to enlarge
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366 REMOVAL & INSTALLATION 
						

							Oil pump installation on the 4.0L engines
Click to enlarge
198-97 2.3L and 1998-99 2.5L Engines
The oil pump is located on the front of the engine and is turned by the timing belt. Disconnect the negative battery cable.
1. 
Remove the timing belt.
2. 
Detach the camshaft position sensor (CMP) electrical connector.
3. 
Remove the oil pump sprocket bolt and sprocket.
4. 
Use a prybar or drift through one of the holes in the pump sprocket to keep it from turning while
loosening the bolt.
Unbolt the camshaft position sensor.
5. 
Remove the four bolts retaining the oil pump to the engine block.
6. 
Remove the oil pump from the front of the engine and discard the pump-to-block gasket.
7. 
Inspect the oil pump and O-rings and replace as necessary. Clean all gasket mating surfaces
thoroughly.
8. 
Installation is the reverse of the removal procedure, however note the following:
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REMOVAL & INSTALLATION 367 
						

							Prime the oil pump and with 8 ounces (236ml) of new engine oil and lubricate the O-rings
with same.
1. 
Use a new pump-to-block gasket.
2. 
Tighten the oil pump bolts to 2-123 inch lbs. (10-14 Nm), the camshaft position sensor bolts
to 45-61 inch lbs. (5-7 Nm) and the oil pump sprocket bolt to 30-40 ft. Lbs. (40-55 Nm).
3. 
4.0L SOHC (VIN E) and 5.0L Engines
The oil pump cannot be removed with the engine in the vehicle. Remove the engine.
1. 
Remove the oil pan.
2. 
Remove the two oil pick-up attaching bolts (arrows)-4.0L engine shown
On the 4.0L engine, remove the eight ladder frame bolts in the oil pan area
Unbolt the oil pick-up tube.
3. 
On the 4.0L engine, remove the eight ladder frame bolts which were under the oil pan.
4. 
On the 4.0L engine, remove the two rear outer ladder frame bolts.
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368 REMOVAL & INSTALLATION 
						

							The two rear ladder frame bolts (arrows) on the 4.0L engine use TORX® drive fasteners
View of the side ladder frame bolts (arrow) on the 4.0L engine
On the 4.0L engine, remove the seven LH and the eight RH ladder frame bolts.
6. 
On the 4.0L engine, lift the ladder frame from the engine.
7. 
Remove the two oil pump attaching bolts and the pump.
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REMOVAL & INSTALLATION 369 
						

							Remove the two oil pump attaching bolts-4.0L engine shown
Exploded view of the 5.0L engine oil pump and pick-up assembly Click to enlarge
Installation is the reverse of removal. Submerge the pump in clean engine oil to prime it. Tighten the
pump attaching bolts to 13-15 ft. lbs. (17-21 Nm) for the 4.0L engine and 23-31 ft. lbs. (30-43 Nm)
for the 5.0L engine.
9. 
Crankshaft Damper
REMOVAL & INSTALLATION Disconnect the negative battery cable for safety.
1. 
Remove the engine fan/clutch assembly and shroud.
2. 
Remove the accessory drive belt.
3. 
If equipped, unbolt the crankshaft pulley from the damper.
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370 Crankshaft Damper 
						

							With the engine fan and shroud removed, unbolt the crankshaft damper from the crankshaft
Assemble a puller to the damper ...
... then tighten the center bolt to remove the damper from the crankshaft
Remove the damper-to-crankshaft snout attaching bolt.
5. 
Assemble a puller to the damper and remove it.
6. 
To install: HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 371 
						

							Inspect the front cover seal and replace if necessary.
7. 
Apply multi-purpose grease to the front cover seal rubbing surface.
8. 
Apply a small amount of RTV sealant to the damper keyway groove.
9. 
Align the groove with the crankshaft keyway and install the damper.
10. 
WARNING
Never hammer on the damper to install it.
Use a crankshaft damper installation tool to press the damper onto the crankshaft.
11. 
Install the damper-to-crankshaft snout and tighten to specifications.
12. 
Install the crankshaft pulley and the accessory drive belt.
13. 
Install the engine fan/clutch assembly and the shroud.
14. 
Connect the negative battery cable. Run the engine and check for oil leaks.
15. 
Timing Belt and Cover
This procedure applies to the 2.3L and 2.5L engine only.
TROUBLESHOOTING
Should the camshaft drive belt/timing belt jump timing by a tooth or two, the engine could still run; but very
poorly. To visually check for correct timing of the crankshaft, auxiliary shaft, and the camshaft follow this
procedure:
There is an access plug provided in the cam drive belt cover so that the camshaft timing cam be
checked without moving the drive belt cover.
Remove the access plug.
1. 
Turn the crankshaft until the timing marks on the crankshaft indicate TDC.
2. 
Make sure that the timing mark on the camshaft drive sprocket is aligned with the pointer on the inner
belt cover.
3. 
Never turn the crankshaft of any of the overhead cam engines in the opposite direction of normal
rotation. Backward rotation of the crankshaft may cause the timing belt to slip and alter the timing.
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
372 Timing Belt and Cover 
						

							Timing belt cover on the 2.3L and 2.5L engine
Click to enlarge
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REMOVAL & INSTALLATION 373