1991 1999 ford explorer chilton User Manual

							Exploded view of the 3.0L engine throttle body/upper intake manifold assembly
Click to enlarge
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REMOVAL & INSTALLATION 621 
						

							Exploded view of the 4.0L engine throttle body assembly and related components
Click to enlarge
View of the 5.0L engine throttle body assembly and related components Click to enlarge
The 3.0L engines throttle body is a 1 piece casting which includes the upper intake manifold. In order
to remove the throttle body, the entire upper manifold must be removed. Refer to Section 3 for the
proper procedures.
Loosen the air inlet tube clamps, then separate the tube from the throttle body and air cleaner housing.
Remove the tube from the vehicle.
1. 
If equipped, remove the throttle linkage shield.
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							To remove the throttle body, first remove the air intake hose, then the linkage shield
Next, disconnect the throttle control cable(s) from the throttle body ... ... as well as any electrical connections...HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 623 
						

							... and vacuum fittings. Make sure to label them to assure proper installation
Detach the accelerator and speed control (if equipped) cables from the throttle body lever.
3. 
Label and disengage the engine wiring harness connectors from the Throttle Position (TP) sensor and
the Idle Air Control (IAC) valve; both are mounted on the throttle body.
4. 
Remove the throttle body-to-upper intake attaching bolts ...
Remove the four mounting nuts, then carefully separate the throttle body from the upper intake
manifold.
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							... then remove the throttle body assembly
Remove the old gasket and thoroughly clean the mating surfaces of both pieces
Remove and discard the old throttle body-to-intake manifold gasket.
6. 
To install:
If scraping is necessary to clean the remaining gasket material off of the mating surfaces, take care to
avoid scratching or gouging the soft aluminum.
Clean the gasket mating surfaces of any residual gasket material.
7. 
Install the throttle body, along with a new gasket, onto the upper intake manifold. Install and tighten
the mounting nuts in a crisscross pattern to specifications.
8. 
Engage the TP sensor and IAC valve wiring connectors and remove the temporary labels.
9. 
Reattach the accelerator and speed control cables, if applicable, to the throttle body lever.
10. 
If removed, install the throttle linkage shield.
11. 
Install the air inlet tube between the air cleaner housing and the throttle body. Tighten the tube clamps
until snug.
12. 
Fuel Supply Manifold and Injectors HOW TO USE THIS BOOK
Fuel Supply Manifold and Injectors 625 
						

							
REMOVAL & INSTALLATION
Remove the upper intake manifold. Be sure to depressurize the fuel system before disconnecting any
fuel lines.
1. 
Disconnect the fuel supply and return line retaining clips.
2. 
Detach the vacuum line from the fuel pressure regulator.
3. 
Disconnect the fuel chassis inlet and outlet fuel hoses from the fuel supply manifold.
4. 
Exploded view of the 2.3L and 2.5L engine fuel supply rail and injectors Click to enlarge
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							Exploded view of the 2.9L engine fuel supply rail and injectors
Click to enlarge
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REMOVAL & INSTALLATION 627 
						

							Exploded view of the 3.0L engine fuel supply rail and injectors
Click to enlarge
Exploded view of the 4.0L engine fuel supply rail and injectors Click to enlarge
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628 REMOVAL & INSTALLATION 
						

							Exploded view of the 5.0L engine fuel supply rail
For fuel supply manifold removal, unbolt the upper intake, then disconnect the injector wire harness plugs
Label and disconnect the fuel injector wire harness plugs.
5. 
On the 2.3L and 2.5L engine, remove the two fuel supply manifold retaining bolts.
6. 
On the 4.0L (VIN X) engine, remove the six upper intake manifold attaching studs.
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							On the 4.0L (VIN X) engine, remove the 6 manifold mounting studs which retain the supply
manifold
On all other engines, remove the four fuel supply manifold retaining bolts.
8. 
Carefully disengage the fuel rail assembly from the fuel injectors by lifting and gently rocking the
rail.
9. 
Some models use small retaining clips to secure the injectors in the supply manifold Click to enlarge
Lift upwards with a rocking motion to disengage the injectors, then remove the supply manifold HOW TO USE THIS BOOK
630 REMOVAL & INSTALLATION