1991 1999 ford explorer chilton User Manual

							
CHARGING
CAUTION
The chemical reaction which takes place in all batteries generates explosive hydrogen gas. A spark can cause
the battery to explode and splash acid. To avoid personal injury, be sure there is proper ventilation and take
appropriate fire safety precautions when working with or near a battery.
A battery should be charged at a slow rate to keep the plates inside from getting too hot. However, if some
maintenance-free batteries are allowed to discharge until they are almost dead, they may have to be charged
at a high rate to bring them back to life. Always follow the charger manufacturers instructions on charging
the battery.
REPLACEMENT
When it becomes necessary to replace the battery, select one with an amperage rating equal to or greater than
the battery originally installed. Deterioration and just plain aging of the battery cables, starter motor, and
associated wires makes the batterys job harder in successive years. This makes it prudent to install a new
battery with a greater capacity than the old.
Belts
All 1991-92 engines, except the 4.0L, have manual belt tension adjustment. All 1993-99 engines use a
serpentine belt with an automatic adjusting belt tensioner, and no adjustment is possible.
INSPECTION
Inspect the belts for signs of glazing or cracking. A glazed belt will be perfectly smooth from slippage, while
a good belt will have a slight texture of fabric visible. Cracks will usually start at the inner edge of the belt and
run outward. All worn or damaged drive belts should be replaced immediately. It is best to replace all drive
belts at one time, as a preventive maintenance measure, during this service operation.
There are typically 3 types of accessory drive belts found on vehicles today Click to enlarge
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CHARGING 57 
						

							An example of a healthy drive belt
Deep cracks in this belt will cause flex, building up heat that will eventually lead to belt failure The cover of this belt is worn, exposing the critical reinforcing cords to excessive wear HOW TO USE THIS BOOK
58 INSPECTION 
						

							Installing too wide a belt can result in serious belt wear and/or breakage
ADJUSTMENT
Belt tension can be checked by pressing on the belt at the center point of its longest straight run. The belt
should give about  1
/4 - 1
/2  in. If the belt is loose, it will slip. If the belt is too tight it will damage bearings in the
driven unit. Those units being driven, such as the alternator, power steering pump or compressor, have a bolt
which when loosened allows the unit to move for belt adjustment. Sometimes it is necessary to loosen the
pivot bolt also, to make the adjustment. HOW TO USE THIS BOOK
ADJUSTMENT 59 
						

							Belt routing and tension adjustments-1991-92 models with the 2.3L engine
Click to enlarge
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60 ADJUSTMENT 
						

							Belt routing and tension adjustments-1991-92 Ranger with the 2.9L engine
Click to enlarge
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ADJUSTMENT 61 
						

							Belt routing and tension adjustments-1991-92 models with the 3.0L engine and A/C
Click to enlarge
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62 ADJUSTMENT 
						

							Belt routing and tension adjustments-1991-92 models with the 3.0L engine and no A/C
Click to enlarge
Checking ribbed belt alignment Click to enlarge
REMOVAL & INSTALLATION
Non-Serpentine
To remove a drive belt, simply loosen the accessory being driven and move it on its pivot point to free the
belt. Then, remove the belt. If an idler pulley is used, it is often necessary, only, to loosen the idler pulley to
provide enough slack to slip the belt from the pulley.
It is important to note, however, that on engines with many driven accessories, several or all of the belts may
have to be removed to get at the one to be replaced.
Disconnect the negative battery cable for safety. This will help assure that no one mistakenly cranks
the engine over with your hands between the pulleys.
1. 
Accessories which can be moved will have a slot in its mounting bracket. Some engines utilize a
movable idler pulley for tension adjustment. Also, some may have a  1
/2  square hole for using a  1
/2
square drive breaker bar to aid in removal and tensioning.
Loosen the mounting bolts for the accessory or idler pulley.
2. 
Move the accessory to relieve the belt tension enough to allow removal.
3. 
Remove the belt from the pulleys.
4. 
To install: Route the new belt over the pulleys. Insure that the belt is properly seated on all of the pulleys.
5. 
Insure that the belt is properly seated on all of the pulleys. Move the accessory to apply tension on the belt.
6. 
WARNING
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REMOVAL & INSTALLATION 63 
						

							It is not recommended to pry on aluminum or plastic housings as damage to the accessory can occur.
When the proper tension is attained, tighten the mounting bolts.
7. 
Once the belt is installed, take another look at all the pulleys to double check your installation.
8. 
Connect the negative battery cable, then start and run the engine to check belt operation.
9. 
Once the engine has reached normal operating temperature, turn the ignition OFFand check that the
belt tension is within the proper adjustment range.
10. 
Serpentine
All 1993-99 engines utilize one wide-ribbed V-belt to drive the engine accessories such as the water pump,
alternator, air conditioner compressor, air pump, etc. Because this belt uses a spring loaded tensioner for
adjustment, belt replacement tends to be somewhat easier than it used to be on engines where accessories were
pivoted and bolted in place for tension adjustment. Basically, all belt replacement involves is to pivot the
tensioner to loosen the belt, then slide the belt off of the pulleys. The two most important points are to pay
CLOSE attention to the proper belt routing (since serpentine belts tend to be snaked all different ways
through the pulleys) and to make sure the V-ribs are properly seated in all the pulleys.
Belt routing diagram-2.3L and 2.5L enginesClick to enlarge
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64 REMOVAL & INSTALLATION 
						

							Belt routing diagram-3.0L engines
Click to enlarge
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REMOVAL & INSTALLATION 65 
						

							Belt routing diagram-4.0L engines (VIN code X)
Click to enlarge
Belt routing diagram-4.0L SOHC engines (VIN code E) HOW TO USE THIS BOOK
66 REMOVAL & INSTALLATION