1991 1999 ford explorer chilton User Manual

Remove the coil pack mounting bracket attaching bolts ...
... then remove the coil pack and bracket from the engine
Remove the valve cover bolts and load distribution pieces. The washers must be installed in their
original positions, so keep track of them.
5. 
Remove the valve cover. It will probably be necessary to tap the cover loose with a plastic or rubber
mallet.
6. 
Remove the valve cover gaskets.
7.  HOW TO USE THIS BOOK
264 REMOVAL & INSTALLATION 

Remove the valve cover hold-down bolts ...
... then remove the cover from the engine. A slight tap with a soft-faced hammer helps to break the seal
Remove the old valve cover gasket and discard
To install:
Clean all gasket material from the cover and head.
3.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 265 

Rocker arm cover installation on 4.0L engines
Click to enlarge
Installation is the reverse of removal. Always use a new gasket coated with sealer. If any of the RTV
silicone gasket material was removed from the mating area of the head(s) and intake manifold, replace
it. Torque the bolts to 3-5 ft. lbs.
4. 
Reconnect the negative battery cable. Start the engine and run to normal operating temperature and
check for oil and fuel leaks.
5. 
4.0L SOHC Engine (VIN E)
Always use new gaskets when installing the...

Remove the valve cover hold-down bolts and remove the cover from the engine. Discard the old
valve cover gasket.
7. 
A gentle tap with a soft hammer may help to break the seal on the gasket. WARNING
Never pry between the valve cover and the cylinder head. Damage to the machined sealing surface, or
distortion to the valve cover could occur, resulting in an oil leak.
To install:
Thoroughly clean the mating surfaces of the engine and cover.
3. 
Install a new gasket to the cover and place the cover in...

5.0L Engines
To remove the valve covers, the upper intake manifold must be removed. Obtain a new gasket for the
intake assembly before removing it. If only the right-hand valve cover is to be removed, the intake
manifold can remain on the engine, however, you will need to remove the throttle body assembly from
the upper intake manifold.
Disconnect the negative battery cable.
1. 
CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are
quite...

Tighten the 5.0L engine valve cover hold-down bolts in the sequence shown
Click to enlarge
Install all of the hold-down bolts and tighten to specifications in the sequence given.
4. 
Connect all wires and lines disconnected from the engine.
5. 
Install the coil packs and the spark plug wires to the coils.
6. 
Install the upper intake manifold.
7. 
Refill the cooling system.
8. 
Connect the negative battery cable.
9. 
Allow the engine to reach normal operating temperature (upper radiator hose hot) and...

Rotate the camshaft so that the base circle of the cam is against the cam follower you intend to
remove.
2. 
Use a special valve spring compressing tool to remove the follower
If removing more than one cam follower, label them so they can be returned to their original position.
Using special tool T88T-6565-BH (for 2.3L and 2.5L engines), T97T-6565-A (for 4.0L engines) or
equivalent, depress the valve spring, as necessary, a000nd slide the cam follower over the lash
adjuster and out from under the...

Exploded view of the 5.0L engine rocker arm assembly
The rocker arm and pushrod may then be removed from the engine. Keep all rocker arms and
pushrods in order so they may be installed in their original locations.
3. 
Installation is the reverse of removal. Lubricate the rocker arm assemblies with SAE 50W engine oil.
Insure that the fulcrums are properly seated into the cylinder head (3.0L engines) or the fulcrum guide
(5.0L engines). Tighten the rocker arm fulcrum bolts to specifications.
4. 
Rocker Arm...

To remove the rocker shaft, first remove the valve cover, then loosen the shaft retaining bolts ...
... and remove the assembly from the cylinder head
To install:
If equipped, loosen the valve lash adjusting screws a few turns. Apply engine oil to the assembly to
provide the initial lubrication.
4.  HOW TO USE THIS BOOK
272 REMOVAL & INSTALLATION 

Rocker arm shaft assembly installation on the 2.9L engine
Rocker arm shaft installation on the 4.0L engine HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 273