1991 1999 ford explorer chilton User Manual

							Unless new pistons are installed, be sure to install the pistons in the cylinders from which they were
removed. The numbers on the connecting rod and bearing cap must be on the same side when
installed in the cylinder bore. If a connecting rod is ever transposed from one engine or cylinder to
another, new bearings should be fitted and the connecting rod should be numbered to correspond with
the new cylinder number. The notch on the piston head goes toward the front of the engine.
2. 
Install all of the rod bearing inserts into the rods and caps.
3. 
Most rings are marked to show which side of the ring should face up when installed to the pistonInstall the rings to the pistons. Install the oil control ring first, then the second compression ring and
finally the top compression ring. Use a piston ring expander tool to aid in installation and to help
reduce the chance of breakage.
4. 
Install the piston and rod assembly into the block using a ring compressor and the handle of a hammer
Make sure the ring gaps are properly spaced around the circumference of the piston. Fit a piston ring
compressor around the piston and slide the piston and connecting rod assembly down into the cylinder
bore, pushing it in with the wooden hammer handle. Push the piston down until it is only slightly
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ASSEMBLY 485 
						

							below the top of the cylinder bore. Guide the connecting rod onto the crankshaft bearing journal
carefully, to avoid damaging the crankshaft.
Check the bearing clearance of all the rod bearings, fitting them to the crankshaft bearing journals.
Follow the procedure in the crankshaft installation above.
6. 
After the bearings have been fitted, apply a light coating of assembly oil to the journals and bearings.
7. 
Turn the crankshaft until the appropriate bearing journal is at the bottom of its stroke, then push the
piston assembly all the way down until the connecting rod bearing seats on the crankshaft journal. Be
careful not to allow the bearing cap screws to strike the crankshaft bearing journals and damage them.
8. 
After the piston and connecting rod assemblies have been installed, check the connecting rod side
clearance on each crankshaft journal.
9. 
Install the auxiliary/balance shaft(s)/assembly(ies).
10. 
Prime and install the oil pump and the oil pump intake tube.
11. 
Except the 2.3L, 2.5L and 4.0L SOHC (VIN E) Engines
Camshaft, Lifters and Timing Assembly
Install the camshaft.
1. 
Install the lifters/followers into their bores.
2. 
Install the timing gears/chain assembly.
3. 
CYLINDER HEAD(S)
Install the cylinder head(s) using new gaskets.
1. 
Assemble the rest of the valve train (pushrods and rocker arms and/or shafts).
2. 
2.3L, 2.5L and 4.0L SOHC (VIN E) Engines
CYLINDER HEAD(S)
Install the cylinder head(s) using new gaskets.
1. 
Install the timing sprockets/gears and the belt/chain assemblies.
2. 
Engine Covers and Components
Install the timing cover(s) and oil pan. Refer to your notes and drawings made prior to disassembly and install
all of the components that were removed. Install the engine into the vehicle.
Engine Start-up and Break-in
STARTING THE ENGINE
Now that the engine is installed and every wire and hose is properly connected, go back and double check that
all coolant and vacuum hoses are connected. Check that your oil drain plug is installed and properly tightened.
If not already done, install a new oil filter onto the engine. Fill the crankcase with the proper amount and
grade of engine oil. Fill the cooling system with a 50/50 mixture of coolant/water.
Connect the vehicle battery.
1. 
Start the engine. Keep your eye on your oil pressure indicator; if it does not indicate oil pressure
within 10 seconds of starting, turn the vehicle OFF.
2. 
WARNING
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486 ASSEMBLY 
						

							
Damage to the engine can result if it is allowed to run with no oil pressure. Check the engine oil level to make
sure that it is full. Check for any leaks and if found, repair the leaks before continuing. If there is still no
indication of oil pressure, you may need to prime the system.
Confirm that there are no fluid leaks (oil or other).
3. 
Allow the engine to reach normal operating temperature (the upper radiator hose will be hot to the
touch).
4. 
At this point any necessary checks or adjustments can be performed, such as ignition timing.
5. 
Install any remaining components or body panels which were removed.
6. 
BREAKING IT IN
Make the first miles on the new engine, easy ones. Vary the speed but do not accelerate hard. Most
importantly, do not lug the engine, and avoid sustained high speeds until at least 100 miles. Check the engine
oil and coolant levels frequently. Expect the engine to use a little oil until the rings seat. Change the oil and
filter at 500 miles, 1500 miles, then every 3000 miles past that.
KEEP IT MAINTAINED
Now that you have just gone through all of that hard work, keep yourself from doing it all over again by
thoroughly maintaining it. Not that you may not have maintained it before, heck you could have had one to
two hundred thousand miles on it before doing this. However, you may have bought the vehicle used, and the
previous owner did not keep up on maintenance. Which is why you just went through all of that hard work.
See?
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
STARTING THE ENGINE 487 
						

							
SPECIFICATION CHARTS
Engine Specifications-2.3L EngineClick to enlarge
SPECIFICATION CHARTS 489 
						

							Engine Specifications-2.3L Engine
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490 SPECIFICATION CHARTS 
						

							Engine Specifications-2.5L Engine
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SPECIFICATION CHARTS 491 
						

							Engine Specifications-2.5L Engine
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492 SPECIFICATION CHARTS 
						

							Engine Specifications-2.9L Engine
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SPECIFICATION CHARTS 493 
						

							Engine Specifications-2.9L Engine
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494 SPECIFICATION CHARTS 
						

							Engine Specifications-3.0L Engine
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SPECIFICATION CHARTS 495