1991 1999 ford explorer chilton User Manual

							Timing belt assembly on the 2.3L and 2.5L engine
Click to enlarge
Releasing the timing belt tensioner using a special tool
Rotate the engine so that No. 1 cylinder is at TDC on the compression stroke. Check that the timing
marks are aligned on the camshaft and crankshaft pulleys. An access plug is provided in the cam belt
cover so that the camshaft timing can be checked without removal of the cover or any other parts. Set
the crankshaft to TDC by aligning the timing mark on the crank pulley with the TDC mark on the belt
cover. Look through the access hole in the belt cover to make sure that the timing mark on the cam
drive sprocket is lined up with the pointer on the inner belt cover.
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Always turn the engine in the normal direction of rotation. Backward rotation may cause the timing
belt to jump time, due to the arrangement of the belt tensioner.
Drain cooling system. Remove the upper radiator hose as necessary. Remove the fan blade and water
pump pulley bolts.
2. 
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.
Loosen the alternator retaining bolts and remove the drive belt from the pulleys. Remove the water
pump pulley.
3. 
Loosen and position the power steering pump mounting bracket and position it aside.
4. 
Remove the four timing belt outer cover retaining bolts and remove the cover. Remove the crankshaft
pulley and belt guide.
5. 
Loosen the belt tensioner pulley assembly, then position a camshaft belt adjuster tool (T74P-6254-A
or equivalent) on the tension spring rollpin and retract the belt tensioner away from the timing belt.
Tighten the adjustment bolt to lock the tensioner in the retracted position.
6. 
Remove the timing belt.
7. 
To install: Install the new belt over the crankshaft sprocket and then counterclockwise over the auxiliary and
camshaft sprockets, making sure the lugs on the belt properly engage the sprocket teeth on the
pulleys. Be careful not to rotate the pulleys when installing the belt.
8. 
Release the timing belt tensioner pulley, allowing the tensioner to take up the belt slack. If the spring
does not have enough tension to move the roller against the belt (belt hangs loose), it might be
necessary to manually push the roller against the belt and tighten the bolt.
9. 
The spring cannot be used to set belt tension; a wrench must be used on the tensioner assembly. Rotate the crankshaft two complete turns by hand (in the normal direction of rotation) to remove the
slack from the belt, then tighten the tensioner adjustment and pivot bolts to specifications. Refer to the
necessary illustrations. Make sure the belt is seated properly on the pulleys and that the timing marks
are still in alignment when No. 1 cylinder is again at TDC/compression.
10. 
Install the crankshaft pulley and belt guide.
11. 
Install the timing belt cover.
12. 
Install the water pump pulley and fan blades. Install upper radiator hose if necessary. Refill the
cooling system.
13. 
Position the alternator and drive belts, then adjust and tighten it to specifications.
14. 
Start the engine and check the ignition timing. Adjust the timing, if necessary.
15. 
Timing Chain Cover & Oil Seal
REMOVAL & INSTALLATION
2.9L Engines HOW TO USE THIS BOOK
Timing Chain Cover & Oil Seal 375 
						

							Removing the front seal (cover installed) on the 2.9L engine
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Installing the front seal (cover installed) on the 2.9L engine Front cover alignment tool on the 2.9L engine
Disconnect the negative battery cable.
1. 
Remove the oil pan as described under Oil Pan removal and installation.
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							Drain the coolant. Remove the radiator.
3. 
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.
Remove the A/C compressor and the power steering bracket, if so equipped, and position them out of
the way. DO NOT disconnect the A/C refrigerant lines.
4. 
Remove the alternator, drive belt(s) and, if equipped, the Thermactor pump.
5. 
Remove the fan.
6. 
Remove the water pump and the heater and radiator hoses.
7. 
Remove the drive pulley from the crankshaft.
8. 
Remove the front cover retaining bolts. If necessary, tap the cover lightly with a plastic hammer to
break the gasket seal. Remove the front cover. If the front cover plate gasket needs replacement,
remove the two screws and remove the plate. If necessary, remove the guide sleeves from the cylinder
block.
9. 
If the front cover oil seal needs replacement use the following procedure: Support the front cover to prevent damage while driving out the seal.
1. 
Drive out the seal from front cover with Front Cover Aligner, T74P-6019-A, or equivalent.
2. 
Support the front cover to prevent damage while installing the seal.
3. 
Coat the new front cover oil seal with Lubriplate® or equivalent. Install the new seal in the
front cover.
4. 
10. 
To install: Clean the front cover mating surfaces of gasket material. Apply sealer to the gasket surfaces on the
cylinder block and back side of the front cover plate. Install the guide sleeves, with new seal rings,
with the chamfered end toward the front cover, if removed. Position the gasket and the front cover
plate on the cylinder block. Temporarily install the four front cover screws to position the gasket and
cover plate in plate. Install and tighten the two cover plate attaching bolts, then remove the four
screws that were temporarily installed.
11. 
Apply gasket sealer to the front cover gasket surface. Place the gasket in position on the front cover.
12. 
Place the front cover on the engine and start all the retaining screws two or three turns. Center the
cover by inserting Front Cover Aligner, Tool T74P-6019-A, or equivalent in oil seal.
13. 
Torque the front cover attaching screws to 13-16 ft. lbs.
14. 
Install the belt drive pulley.
15. 
Install the oil pan as described under Oil Pan removal and installation.
16. 
Install the water pump, heater hose, A/C compressor, alternator, Thermactor pump and drive belt(s).
Adjust drive belt tension.
17. 
Fill and bleed the cooling system.
18. 
Connect the negative batter cable.
19. 
Operate the engine at fast idle speed and check for coolant and oil leaks.
20. 
3.0L Engine
The A/C system must be discharged to remove the front cover. Have the A/C refrigerant reclaimed by a
MVAC certified shop. The front seal can be serviced with the engine in the vehicle. Remove the
crankshaft damper, then follow the seal replacement procedure under installation.
Disconnect the negative battery cable.
1. 
Drain the cooling system and crankcase.
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REMOVAL & INSTALLATION 377 
						

							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.
Remove the cooling fan.
3. 
Loosen the water pump pulley bolts. Loosen and remove the accessory drive belts. Remove the water
pump pulley.
4. 
Remove the alternator adjusting arm and brace assembly. Remove the heated air intake duct from the
engine.
5. 
Remove the upper motor mount retaining nuts. Remove the A/C compressor upper bolts, then remove
the front cover front nuts on vehicles with automatic transmission and A/C.
6. 
Raise the vehicle. Remove the A/C compressor bolts and bracket if so equipped and position the
assembly aside.
7. 
Remove the crankshaft pulley and damper assembly. Remove the oil pan. Refer to the necessary
service procedures in this section.
8. 
According to the manufacturer, you must remove the water pump to remove the cover. However, we
have found that on some models and/or years the water pump can be left bolted to the cover, thereby
reducing some of the labor. Try removing the cover with the water pump attached first.
Lower the vehicle. Remove the lower radiator hose. Remove the water pump.
9. 
If necessary, remove the crankshaft position sensor.
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378 REMOVAL & INSTALLATION 
						

							Front cover removal-3.0L
Click to enlarge
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REMOVAL & INSTALLATION 379 
						

							Front cover bolt installation chart-3.0L
Click to enlarge
Remove the timing cover to cylinder block attaching bolts. Carefully remove the timing cover from
the cylinder block.
11. 
Inspect the oil seal. If the seal needs replacing, follow the procedures under installation.
12. 
To install: Clean timing cover and oil pan sealing surfaces. Clean and inspect all parts. The camshaft retaining
bolt has a drilled oil passage for timing chain assembly lubrication. Clean oil passage with solvent. Do
not replace with standard bolt.
13. 
Install timing cover assembly. Install retaining bolts with pipe sealant and tighten as outlined. Refer to
the necessary illustration.
14. 
If the front seal needs to be replaced, proceed as follows: Using Front Cover Seal Removal Tool T70P-6B070-A, or its equivalent, remove the front
seal.
1. 
Lubricate the engine front cover and oil seal lip inner lip with engine oil.
2. 
Using Crankshaft Seal Replacer/Cover Aligner T82L-6316-A, or its equivalent, install the
new seal into the front cover.
3. 
15. 
If necessary, install the crankshaft position sensor.
16. 
Install oil pan and water pump. Refer to the necessary procedures in this section.
17. 
Install crankshaft damper and pulley assembly.
18. 
Install drive belt components. Install drive belts and adjust.
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							Fill crankcase. Refill and bleed cooling system. Connect the negative battery cable. Start engine check
for coolant, oil and exhaust leaks.
20. 
4.0L Engine (VIN X)
Review the complete service procedure before starting this repair. Refer to the necessary service
procedures in this section. The front seal can be serviced with the engine in the vehicle. Remove the
crankshaft damper, then follow the seal replacement procedure under installation.
Disconnect the negative battery cable. Remove/lower the oil pan.
1. 
Drain the cooling system.
2. 
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.
To remove the front cover, remove the fan, shroud and unbolt the front cover-to-accessory bracket brace ...
... then remove the brace. Also remove the damper and any other obstructions to the cover
Remove the engine fan and shroud.
3. 
Remove the air conditioning compressor and position it out of the way. DO NOT disconnect the
refrigerant lines!
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REMOVAL & INSTALLATION 381 
						

							Remove the power steering pump and position it out of the way. DO NOT disconnect the hoses!
5. 
Remove the alternator.
6. 
Remove the water pump.
7. 
Remove the drive pulley/damper from the crankshaft.
8. 
Remove the crankshaft timing sensor.
9. 
Front cover mounting-4.0L engineClick to enlarge
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							Remove the front cover attaching bolts
Dont forget about the oil pan-to-front cover attaching bolts!
Remove the front cover attaching bolts. It may be necessary to tap the cover loose with a plastic
mallet.
10. 
Inspect the oil seal. If the seal needs replacing, follow the procedures under installation.
11. 
To install: HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 383