1991 1999 ford explorer chilton User Manual

Engine mounting points for 3.0L engines
Click to enlarge
HOW TO USE THIS BOOK
254 REMOVAL & INSTALLATION 

Engine mounting points 4.0L engines
Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 255 

Engine mounting points 5.0L engines
Click to enlarge
HOW TO USE THIS BOOK
256 REMOVAL & INSTALLATION 

Engine damper mounting for 4.0L engines
Click to enlarge
Remove the front engine support insulator-to-crossmember retaining fasteners.
22. 
If equipped, remove the engine damper mounting bracket from the engine. The bracket may use two
TORX® bolts for the lower mounting points.
23. 
Partially lower the vehicle and support it with jackstands in the new position.
24. 
Support the transmission with a floor jack.
25. 
Using a engine crane or hoist, lift the engine out of the vehicle. Be sure to lift the...

Seat the left-hand side, front engine support insulator locating pin prior to the right-hand side, front
engine support insulator.
Lower the engine onto the front engine support insulators.
30. 
Detach the engine crane or hoist from the engine.
31. 
Remove the floor jack from beneath the transmission fluid pan.
32. 
Tighten the two installed engine-to-transmission bolts, then raise and securely support the vehicle on
jackstands.
33. 
Install and tighten the remaining engine-to-transmission bolts.
34....

Exploded view of the 2.3L and 2.5L engine rocker arm cover
Click to enlarge
Remove the valve cover gasket from the cover.
3. 
To install: Thoroughly clean the gasket mating surfaces on the cover and the cylinder head.
4. 
Install a new gasket to the valve cover.
5. 
Place the valve cover onto the cylinder head and install all of the retaining bolts finger-tight.
6. 
Alternately tighten the bolts to the proper specification.
7. 
If removed, install the EGR supply tube.
8. 
Install any electrical...

Install the throttle body to the intake manifold.
10. 
Install any splash shielding removed from around the throttle body.
11. 
Install the air intake hose and attach the wire harness connections which were removed.
12. 
Reconnect the negative battery cable.
13. 
Start the engine and check for leaks.
14. 
2.4L Engines Disconnect the negative battery cable. Remove the air cleaner and attaching parts. Label each spark
plug wire prior to its removal in order to ease the installation of the wires on the...

Click to enlarge
Attach the transmission fluid level indicator tube and the bracket to the rocker arm cover.
11. 
After ensuring all rocker arm cover reinforcement washers are installed in their original position,
tighten the rocker arm cover screws to the proper specification.
12. 
Install the spark plug wires.
13. 
Install the PCV valve and hose.
14. 
Install the engine oil fill cap.
15. 
Connect the vacuum line at the canister purge (connect the power brake hose, if so equipped) solenoid
and connect...

Rocker arm cover installation on 3.0L engines
Click to enlarge
Install all remaining components in reverse order of removal procedure. Connect the ignition wires to
the spark plugs and reconnect the negative battery cable. Start the engine and run to normal operating
temperature, then check for oil and vacuum leaks.
4. 
4.0L Engine (VIN X)
Failure to install new valve cover gaskets and valve cover reinforcement pieces will result in oil leaks. Disconnect the negative battery cable. Tag and remove the...

To remove the valve cover, first disconnect the crankcase breather vent tube
Label and unplug any electrical connections ...
... as well as vacuum fittings which will inhibit valve cover removal HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 263