1991 1999 ford explorer chilton User Manual

Upper intake manifold torque sequence on the 2.3L and 2.5L engine
Engage the four electrical connectors to the injectors.
19. 
Install the engine oil dipstick, then connect the fuel return and supply lines to the fuel supply
manifold.
20. 
The following procedures are for installing the upper intake manifold. Make sure the gasket surfaces of the upper and lower intake manifolds are clean. Place a gasket on the
lower intake manifold assembly, then place the upper intake manifold in position.
2. 
Install...

If you only need to remove the upper intake manifold, stop at this point. Otherwise, continue with the
procedure to also remove the lower intake manifold.
Drain coolant. Remove the upper radiator and heater supply hoses from intake manifold.
8. 
CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are
quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove
fatal in sufficient quantity....

Install distributor cap. Coat the inside of each spark plug wire connector with silicone grease with a
small screwdriver, and install the wires. Connect distributor wiring harness.
19. 
The following procedures are for installing the upper intake manifold. Apply sealing compound to the joining surfaces of the upper and lower intake manifolds. Install the
upper intake manifold gaskets.
1. 
Install upper intake manifold (plenum) assembly. Tighten the bolts in two steps to specifications.
2. 
Connect all...

First lightly oil all attaching bolts and stud threads. The intake manifold, cylinder head and cylinder
block mating surfaces should be clean and free of old silicone rubber sealer. Use a suitable solvent to
clean these areas.
14. 
Silicone sealer and intake end seal application for the 3.0L engine Click to enlarge
Intake manifold gasket positioning for the 3.0L Click to enlarge
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288 REMOVAL & INSTALLATION 

Intake manifold torque sequence for the 3.0L
Click to enlarge
Apply silicone rubber sealer (D6AZ-19562-A or equivalent) to the intersection of the cylinder block
assembly and head assembly at four corners as illustrated.
15. 
When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application.
After this time, the sealer may start to set-up and its sealing effectiveness may be reduced. In high
temperature/humidity conditions, the RTV will start to skin over in about 5...

If equipped with distributor ignition, verify base initial timing as outlined. Check and adjust engine
idle as necessary.
29. 
4.0L Engine (VIN X)
The intake manifold is a 4-piece assembly, consisting of the upper intake manifold, the throttle body, the fuel
supply manifold, and the lower intake manifold.
Disconnect the battery ground cable.
1. 
Begin the intake removal by unbolting the throttle linkage weather shield ...... then remove the air intake duct from the throttle body HOW TO USE THIS BOOK
290...

Disconnect the throttle linkage, then unbolt and remove the cable bracket
Remove the weather shield.
2. 
Remove the air cleaner intake duct.
3. 
Disconnect the throttle cable and bracket.
4. 
Label all of the electrical and vacuum connections on the intake manifold ... ... then disconnect the vacuum lines ...HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 291 

... and the electrical harness plugs
Tag and unplug all vacuum lines connected to the manifold.
5. 
Tag and disconnect all electrical wires attached to the upper manifold assembly.
6. 
Relieve the fuel system pressure.
7. 
Also, ensure that any brackets which are bolted to the manifold are unfastened
Tag and remove the spark plug wires.
8. 
Remove the EDIS ignition coil and bracket.
9.  HOW TO USE THIS BOOK
292 REMOVAL & INSTALLATION 

Remove the upper intake manifold attaching bolts ...
... then lift the manifold from the engine
Stuff rags into the intake runners, then remove the old upper intake gasket; use care when scraping
Remove the 6 attaching nuts and lift off the upper manifold.
10. 
If you only need to remove the upper intake manifold, stop at this point. Otherwise, continue with the
procedure to also remove the lower intake manifold. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 293