1991 1999 ford explorer chilton User Manual

If the lamp illuminates, the problem lies with the engine not being properly grounded.
1. 
If the lamp does not illuminate, skip to Step 4.
2. 
Connect the original wire to the oil pressure switch. While sitting in the vehicle, turn the ignition
switch to the ONposition without actually starting the engine. Observe the other lights on the
instrument cluster. If all of the other lights illuminate when turning the ignition switch ON, the oil pressure
switch is defective and must be replaced.
1. 
If none of...

Oil pressure and level switches used on the 3.0L engine
Click to enlarge
Disconnect the negative battery cable.
1. 
Disconnect the wiring at the sender/switch.
2. 
Remove the oil pressure sender/switch from the engine.
3. 
To install: Coat the threads with electrically conductive sealer and thread the unit into place. Tighten the
sender/switch to 10-18 ft. lbs (13-24 Nm).
4. 
Attach the wiring to the sender/switch and connect the negative battery cable.
5.  HOW TO USE THIS BOOK
244 REMOVAL & INSTALLATION 

Low Oil Level Sensor
The low oil level sensor is located in the engine oil pan on all models
TESTING
Use the accompanying diagnostic chart to help pinpoint low oil level sensor malfunctioning.
The ignition switch should be turned OFFfor a minimum of 5 minutes between checks to ensure that
the electronic relay, which has a 5 minute timer, has reset.
Low oil level indicator diagnostic chartClick to enlarge
HOW TO USE THIS BOOK
Low Oil Level Sensor 245 

Low oil level indicator wiring schematic
Click to enlarge
REMOVAL & INSTALLATION
Always install a new gasket whenever the oil level sensor is removed Turn the engine OFF.
1. 
Raise the front of the vehicle and install jackstands beneath the frame. Firmly apply the parking brake
and place blocks in back of the rear wheels.
2. 
Typical low oil level sensor mounting-note: the sensor is constantly submerged in oil, therefore, drain some oil out of the engine before removing it
Drain at least 2 quarts (1.9...

Disconnect the sensor wiring.
4. 
Remove the sensor from the oil pan using a 1 in. (26mm) socket or wrench. Discard the old gasket.
5. 
To install: Install a new gasket onto the sensor.
6. 
When installing the new gasket, the flange faces the sensor and the words panside should face the oil
pan.
Install the sensor and gasket assembly into the oil pan. Tighten the sensor to 13-20 ft. lbs. (17-27
Nm).
7. 
Connect the electrical wire to the sensor.
8. 
Lower the front of the vehicle and remove the wheel...

SPECIFICATION CHARTS
Troubleshooting Basic Starting System ProblemsClick to enlarge
SPECIFICATION CHARTS 249 

Troubleshooting Basic Charging System Problems
Click to enlarge
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
250 SPECIFICATION CHARTS 

ENGINE MECHANICAL
Engine
REMOVAL & INSTALLATION
In the process of removing the engine, you will come across a number of steps which call for the removal of a
separate component or system, such as disconnect the exhaust system or remove the radiator. In most
instances, a detailed removal procedure can be found elsewhere in this manual.
It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so
many different model and engine combinations have been...

Drain the cooling system.
5. 
Remove the cooling fan, shroud, radiator and all cooling system hoses.
6. 
On all models except the 1996 Explorer with the 5.0L engine and all 1997-99 Explorer/Mountaineer
models, label and detach all engine wiring and vacuum hoses which will interfere with engine
removal. Position the wire harness out of the way.
7. 
On 1996 Explorers with the 5.0L engine and all 1997-99 Explorer/Mountaineer models, the engine
wiring harness is removed with the engine. Only label and detach...

Engine mounting points for 2.3L and 2.5L engines
Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 253