1991 1999 ford explorer chilton User Manual

Remove the starter motor (arrow) mounting bolts ...
Remove the starter mounting bolts and remove the starter.
4. 
... then remove the starter-be careful, the starter motor can be quite heavy
To install:
Position the starter motor against the engine and install the mounting bolts. Tighten the mounting
bolts to 15-19 ft. lbs. (21-27 Nm).
5. 
Install the starter solenoid connector by pushing it straight on. Ensure that the connector locks in
position with a notable click.
6. 
Install the starter cable nut...

Label all of the wires on the starter relay before removing them
Also remove any protective caps
Remove the push-on connectors by pulling them straight off
Disconnect the positive battery cable from the battery terminal.
3. 
Remove the nut securing the positive battery cable to the relay.
4.  HOW TO USE THIS BOOK
RELAY REPLACEMENT 233 

Remove the cable securing nuts ...
Remove the positive cable and any other wiring under that cable.
5. 
... then remove all of the cables from the relay
Label and remove the push-on wires from the front of the relay.
6. 
Remove the nut and disconnect the cable from the starter side of the relay.
7.  HOW TO USE THIS BOOK
234 RELAY REPLACEMENT 

Remove the relay-to-fender apron attaching screws ...
... then remove the relay from the fender
Remove the relay mounting bolts and remove the relay.
8. 
To install: Install the relay and mounting bolts. Tighten the mounting bolts until snug.
9. 
Attach all wiring to the relay.
10. 
If equipped, install the power distribution box cover.
11. 
Connect the positive (+) cable to the battery.
12. 
Connect the negative (-) cable to the battery.
13. 
Chilton® Automotive Information Systems. © 2004 Thomson...

SENDING UNITS
Introduction
This section describes the operating principles of sending units, warning lights and gauges. Sensors
which provide information to the Electronic Control Module (ECM) are covered in Section 4 of this
manual.
Instrument panels contain a number of indicating devices (gauges and warning lights). These devices are
composed of two separate components. One is the sending unit, mounted on the engine or other remote part of
the vehicle, and the other is the actual gauge or light in the...

Temperature gauge diagnostic chart
Click to enlarge
HOW TO USE THIS BOOK
238 TESTING 

Temperature gauge and sending unit wiring schematic
Click to enlarge
Remove the coolant temperature sender from the engine block.
1. 
Attach an ohmmeter to the sender unit as follows: Attach one lead to the metal body of the sender unit (near the sender units threads).
1. 
Attach the other lead to the sender units wiring harness connector terminal.
2. 
2. 
With the leads still attached, place the sender unit in a pot of cold water so that neither of the leads is
immersed in the water. The portion of the...

The sending unit uses a push-on wire connector. To remove, simply pull straight up from the
sender
Disconnect the wiring at the sender.
3. 
Remove the coolant temperature sender from the engine.
4. 
To install: Coat the threads on the sender with Teflon® tape or electrically conductive sealer, then install the
sender. Tighten the sender to 107-143 inch lbs. (12-16 Nm).
5. 
Attach the wiring to the sender and connect the negative battery cable.
6. 
If necessary, add antifreeze to replace any lost coolant,...

Oil Pressure Sender and Switch
Oil pressure senders are used for oil pressure gauges, whereas the oil pressure switches are used for
vehicles equipped only with a low oil pressure warning lamp.
The oil pressure senders/switches are located as follows: 2.3L, 2.5L engine-Left side rear of the engine, in the cylinder head
· 
3.0L engine-Behind the right cylinder head, in the engine block
· 
2.9L and 4.0L engines-Left side front of the engine, below the cylinder head in the engine block
· 
5.0L...

Oil pressure gauge diagnostic chart
Click to enlarge
Oil Pressure Sender
Use the accompanying diagnostic chart to help pinpoint oil pressure sender and oil pressure gauge
malfunctioning.
Oil Pressure Switch To test the oil pressure switch, open the hood and locate the switch.
1. 
Disconnect the wire from the switch. Attach one end of a jumper wire to the terminal on the end of
the wire, then touch the other end of the jumper wire to a good engine ground (any bare metal engine
surface). Have an assistant...