1991 1999 ford explorer chilton User Manual

							Ranger/Explorer/Mountaineer underhood maintenance component locations for the 4.0L engine
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Ranger/Explorer/Mountaineer chassis lubrication points for two-wheel drive (4x2) models Click to enlarge
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Introduction 37 
						

							Ranger/Explorer/Mountaineer chassis lubrication points for four-wheel drive (4x4) models
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Proper maintenance and tune-up is the key to long and trouble-free vehicle life, and the work can yield its
own rewards. Studies have shown that a properly tuned and maintained vehicle can achieve better gas mileage
than an out-of-tune vehicle. As a conscientious owner and driver, set aside a Saturday morning, say once a
month, to check or replace items which could cause major problems later. Keep your own personal log to jot
down which services you performed, how much the parts cost you, the date, and the exact odometer reading at
the time. Keep all receipts for such items as engine oil and filters, so that they may be referred to in case of
related problems or to determine operating expenses. As a do-it-yourselfer, these receipts are the only proof
you have that the required maintenance was performed. In the event of a warranty problem, these receipts will
be invaluable.
The literature provided with your vehicle when it was originally delivered includes the factory recommended
maintenance schedule. If you no longer have this literature, replacement copies are usually available from the
dealer. A maintenance schedule is provided later in this section, in case you do not have the factory literature. HOW TO USE THIS BOOK
38 Introduction 
						

							Important maintenance and tune-up information can be found on the emission label under the
hood
There are also several labels which give safety information ... Click to enlarge
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Introduction 39 
						

							... as well as service tips and belt routing
Air Cleaner (Element)
The air cleaner is a paper element type. The paper cartridge should be replaced every 30,000 miles, under
normal conditions. Under dusty or severe conditions, the filter should be inspected frequently and changed as
necessary.
Check the air filter more often if the vehicle is operated under severe dusty conditions and replace it as
necessary.
REMOVAL & INSTALLATION
The Ranger, Explorer and Mountaineer vehicles used two types of air cleaner housings: the square panel and
the conical (or canister) type. The square panel type retains the housing cover by bolts or, on later models, bail
clips. The conical type utilizes a full circumference clamp around the housing.
Air cleaner assembly for the 2.3L and 2.5L engineClick to enlarge
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40 Air Cleaner (Element) 
						

							Air cleaner assembly for the 3.0L and 4.0L engine-2.9L engine similar
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REMOVAL & INSTALLATION 41 
						

							Conical type air cleaner assembly for the 4.0L engine-other engines similar
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Loosen the clamp that secures the intake hose assembly to the air cleaner.
1. 
If necessary, unplug the MAF (Mass Air Flow) and/or IAT (Intake Air Temperature) sensor electrical
connector from the air cleaner housing.
2. 
Some air cleaner assemblies will have enough give in the air inlet pipe and sensor wiring harnesses to
allow filter replacement without removing or disconnecting these items.
Disconnect the hose and inlet tube from the air cleaner.
3. 
Loosen the air cleaner cover retaining screws (arrow), then gently lift the assembly up enough ... HOW TO USE THIS BOOK
42 REMOVAL & INSTALLATION 
						

							If equipped with the square panel type housing, remove the screws or bail clips attaching the air
cleaner cover.
4. 
If equipped with the conical type housing, unfasten the clamp on the air cleaner body.
5. 
... to allow the filter to be removed
Seperate the lid from the housing base.
6. 
Remove the air filter.
7. 
Installation is the reverse of removal. Dont overtighten the hose clamps! A torque of 12-15 inch lbs.
is sufficient.
8. 
Fuel Filter
REMOVAL & INSTALLATION
Clean all dirt and/or grease from the fuel filter fittings. Quick Connect fittings are used on models equipped
with a pressurized fuel system. These fittings must be disconnected using the proper procedure or the fittings
may be damaged. The fuel filter uses a hairpin clip retainer. Spread the two hairpin clip legs about  1
/8  in.
(3mm) each to disengage it from the fitting, then pull the clip outward. Use finger pressure only; do not use
any tools. Push the quick connect fittings onto the filter ends. Ford recommends that the retaining clips be
replaced whenever removed. The fuel tubes used on these fuel systems are manufactured in  5
/16  in. and  3
/8  in.
diameters. Each fuel tube takes a different size hairpin clip, so keep this in mind when purchasing new clips.
A click will be heard when the hairpin clip snaps into its proper position. Pull on the lines with moderate
pressure to ensure proper connection. Start the engine and check for fuel leaks. If the inertia switch (reset
switch) was disconnected to relieve the fuel system pressure, cycle the ignition switch from the OFFto
ONposition several times to re-charge the fuel system before attempting to start the engine. HOW TO USE THIS BOOK
Fuel Filter 43 
						

							The fuel filter is mounted to the drivers side frame rail by a bracket, which also acts as a
protective shield
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Inertia switch location Click to enlarge
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44 REMOVAL & INSTALLATION 
						

							Close up of a 
5
/16  in. push connect fitting
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REMOVAL & INSTALLATION 45 
						

							Installing fuel lines with quick-disconnect couplings-these fittings use a metal garter spring
rather than a plastic clip for line retention
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The inline reservoir type fuel filter should last the life of the vehicle under normal driving conditions. If
the filter does need to be replaced, proceed as follows:
CAUTION
If the fuel filter is being serviced with the rear of the vehicle higher than the front, or if the tank is pressurized,
fuel leakage or siphoning from the tank fuel lines could occur. to prevent this condition, maintain the vehicle
front end at or above the level of the rear of vehicle. also, relieve tank pressure by loosening the fuel fill cap.
cap should be tightened after pressure is relieved.
Shut the engine off. Depressurize the fuel system as follows:
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46 REMOVAL & INSTALLATION