1991 1999 ford explorer chilton User Manual

							Remove the old gaskets and thoroughly clean all of the mating surfaces
Thoroughly clean all of the gasket and sealing surfaces and remove all traces of the old gaskets, oil,
grease and/or dirt. Use new gaskets and apply a thin layer of sealant/adhesive to them.
12. 
If the specialized tools arent available, the front seal can be replaced using normal hand tools. Before
installing the cover, use a punch to carefully knock the old seal out of the cover, and a seal driver to seat
the new seal.
Place the cover on a bench and carefully knock the old seal out of the cover using a hammer and punch
Use an ordinary seal driver, and seat a new seal into the cover at the same position as the old one Install the front cover and attaching bolts. Refer to the necessary illustration.
13. 
If the front seal needs to be replaced, proceed as follows: Using Front Cover Seal Removal Tool T74P-6700-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 T88T-6701-A, or its equivalent, install the
new seal into the front cover.
3. 
14. 
Install the crankshaft timing sensor.
15. 
Install the drive pulley/damper.
16. 
Install the water pump.
17. 
Install the fan.
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							Install the alternator.
19. 
Install the power steering pump.
20. 
Install the air conditioning compressor.
21. 
Install the oil pan.
22. 
Fill the cooling system.
23. 
Fill the crankcase with the proper grade and amount of engine oil. Connect the negative battery cable.
Start the engine and check for leaks, then roadtest the vehicle for proper operation.
24. 
4.0L SOHC Engine (VIN E)
According to the manufacturer, the engine must be removed in order to service the front cover.
However, the front seal can be serviced with the engine in the vehicle. Remove the crankshaft damper,
then follow the seal replacement procedure under installation.
Remove the engine from the vehicle.
1. 
Remove the oil pan and ladder frame.
2. 
For ladder frame removal procedures, refer to the oil pump removal and installation procedure in this
section.
Remove the water pump.
3. 
Remove the crankshaft pulley and damper.
4. 
Remove the front cover attaching bolts and remove the cover.
5. 
Inspect the oil seal. If the seal needs replacing, follow the procedures under installation.
6. 
To install: Thoroughly clean all gasket mating surfaces. Use new gaskets and coat them with a sealer/adhesive.
7. 
Install the front cover and tighten all of the bolts.
8. 
If the front seal needs to be replaced, proceed as follows: Using Front Cover Seal Removal Tool T74P-6700-A, or its equivalent, remove the front
seal.
1. 
Lubricate the engine front cover and oil seal inner lip with engine oil.
2. 
Using Crankshaft Seal Replacer/Cover Aligner T88T-6701-A, or its equivalent, install the
new seal into the front cover.
3. 
9. 
Install the crankshaft damper and pulley. Install a new crankshaft pulley bolt and tighten to
specifications
10. 
WARNING
Never hammer on the damper. Use an appropriate damper installation tool to press the damper onto the
crankshaft snout.
Install the water pump.
11. 
Install the ladder frame and oil pan.
12. 
Install the engine into the vehicle.
13. 
Run the engine and check for leaks.
14. 
5.0L Engine
According to the manufacturer, the engine must be removed in order to service the front cover.
However, the front seal can be serviced with the engine in the vehicle. Remove the crankshaft damper,
then follow the seal replacement procedure under installation.
Remove the engine from the vehicle.
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REMOVAL & INSTALLATION 385 
						

							Remove the water pump by-pass hose.
2. 
Remove the Crankshaft Position Sensor (CPS).
3. 
Remove the crankshaft pulley and damper.
4. 
Remove the oil pan.
5. 
The front cover and the water pump are removed as an assembly. Remove the front cover attaching bolts and remove the cover.
6. 
Inspect the oil seal. If the seal needs replacing, follow the procedures under installation.
7. 
To install: Thoroughly clean all gasket mating surfaces. Use new gaskets and coat them with a sealer/adhesive.
8. 
Install the front cover/water pump assembly and tighten all of the bolts.
9. 
View of the front cover seal removal tool
Using the seal replacer tool to install a new front seal
If the front seal needs to be replaced, proceed as follows: Using Front Cover Seal Removal Tool T70P-6B070-B, 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 T88T-6701-A, or its equivalent, install the
new seal into the front cover.
3. 
10. 
Install the oil pan.
11. 
Install the crankshaft damper and pulley.
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386 REMOVAL & INSTALLATION 
						

							WARNING
Never hammer on the damper. Use an appropriate damper installation tool to press the damper onto the
crankshaft snout.
Install the Crankshaft Position Sensor (CPS) and the water pump by-pass hose.
13. 
Install the engine into the vehicle.
14. 
Run the engine and check for leaks.
15. 
Timing Chain and Gears
REMOVAL & INSTALLATION
2.9L Engine Drain the cooling system and crankcase. Remove the oil pan and 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.
Remove the cylinder front cover and water pump, drive belt, and camshaft timing gear.
2. 
Use the clutch aligner T71P-P-7137-H or equivalent and remove the crankshaft sprocket.
3. 
To install: Align the keyway in the gear with the key, then slide the gear onto the shaft, making sure that it seats
tight against the spacer.
4. 
Feed the timing chain around the crankshaft sprocket and then around the camshaft sprocket. Install
the camshaft sprocket together with timing chain as an assembly. Align all necessary timing marks.
Check the camshaft end play. Refer to checking camshaft. If not within specifications, replace the
thrust plate.
5. 
Align the keyway in the crankshaft gear with key in the crankshaft, and align the timing marks. Install
the gear, using a crankshaft sprocket replacer tool.
6. 
Install the cylinder front cover following the procedures in this section. Install the oil pan and radiator.
7. 
Fill and bleed the cooling system and crankcase.
8. 
Start the engine and adjust the ignition timing.
9. 
Operate the engine at fast idle and check all hose connections and gaskets for leaks.
10. 
3.0L Engine Disconnect the negative battery cable.
1. 
Drain the cooling system and crankcase.
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. HOW TO USE THIS BOOK
Timing Chain and Gears 387 
						

							Remove the timing cover.
3. 
Timing mark alignment-3.0L engineClick to enlarge
Timing chain mounting-3.0L engine Click to enlarge
Rotate crankshaft until No. 1 piston is at TDC and timing marks are aligned in the correct position.
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388 REMOVAL & INSTALLATION 
						

							Remove the camshaft sprocket retaining bolt and washer. Check timing chain deflection for excessive
wear.
5. 
Slide sprockets and timing chain forward and remove as assembly.
6. 
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.
7. 
Slide sprockets and timing chain on as assembly with timing marks in the correct location. Install
camshaft retaining bolt and washer. Torque bolt to 46 ft. lbs. Lubricate the timing chain assembly.
8. 
Install timing cover assembly. Install retaining bolts with pipe sealant and tighten as outlined.
9. 
Refill and bleed cooling system. Connect the negative battery cable. Start engine check for coolant,
oil and exhaust leaks.
10. 
4.0L Engine (VIN X)
Review the complete service procedure before starting this repair. Refer to the necessary service
procedures in this section.
Disconnect the negative battery cable.
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 timing chain and sprockets, first remove the engine front cover
Remove the front cover.
3. 
Remove the radiator.
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REMOVAL & INSTALLATION 389 
						

							Timing chain mounting-4.0L engine
Click to enlarge
Rotate the engine by hand until the No.1 cylinder is at TDC compression, and the timing marks are
aligned.
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390 REMOVAL & INSTALLATION 
						

							Remove the tensioner lower attaching bolt ...HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 391 
						

							... and install a holding clip in the bolt hole and the slot on the rubbing block HOW TO USE THIS BOOK
392 REMOVAL & INSTALLATION 
						

							Unbolt and remove the tensionerHOW TO USE THIS BOOK
REMOVAL & INSTALLATION 393