1991 1999 ford explorer chilton User Manual

Disconnect the fuel supply and return lines from the injector fuel rail
Label all of the electrical connections on the lower intake manifold ... ... then disconnect them. Next, remove the valve covers
Disconnect the fuel supply and return lines from the injector fuel rail.
11. 
Label and disconnect all of the electrical connections on the lower manifold assembly.
12. 
Remove the valve covers.
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294 REMOVAL & INSTALLATION 

Remove the lower intake manifold attaching bolts ...
... then lift the manifold from the engine
Remove the lower intake manifold bolts. Tap the manifold lightly with a plastic mallet and remove it.
14. 
Remove the old intake gasket from the cylinder heads and engine block
Clean all surfaces of old gasket material.
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REMOVAL & INSTALLATION 295 

To install:
Apply RTV silicone gasket material at the junction points of the heads and manifold.
16. 
This material will set within 15 minutes, so work quickly! Install new manifold gaskets and again apply the RTV material.
17. 
Intake manifold and gasket installation for the 4.0LClick to enlarge
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296 REMOVAL & INSTALLATION 

Intake manifold torque sequence for the 4.0L
Position the manifold and install the nuts hand-tight. Tighten the nuts in 4 stages, using the sequence
shown, to 18 ft. lbs.
18. 
Once again, apply RTV material to the manifold/head joints.
19. 
Install the valve covers using new gaskets.
20. 
The following procedures are for installing the upper intake manifold. Position a new gasket and install the upper manifold. Tighten the nuts to 18 ft. lbs.
2. 
Install the EDIS coil.
3. 
Connect the fuel and return...

Ford does not specify a sequence, but it is recommended that you start tightening in the middle and
work you way out to the ends. Repeat the tightening sequence several times until the bolts will no longer
turn at the specified torque.
The following procedures are for installing the upper intake manifold. Install the upper manifold.
14. 
Attach both VMV hoses to the manifold.
15. 
Install the attaching bolts and tighten to specification. See the note above.
16. 
Attach any vacuum and electrical...

Upper intake manifold bolt loosening sequence
Click to enlarge
Loosen and remove the upper intake manifold attaching bolts in the sequence given.
14. 
Remove the upper manifold and its gasket.
15. 
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.
CAUTION
Fuel lines on fuel injected vehicles will remain pressurized after the engine is shut off. Fuel pressure must be
relieved before servicing the fuel...

Hot water tube assembly and its mounting points
Click to enlarge
Disconnect the heater hoses from the hot water tube. Also remove the tube from the lower manifold.
17. 
Label and disconnect any electrical components, sensors or vacuum lines connected to the lower
manifold.
18. 
Disconnect the upper radiator hose from the water outlet.
19. 
Loosen the water pump bypass hose clamp at the pump.
20. 
Remove the rear engine ground strap.
21. 
Remove the camshaft synchronizer with the Camshaft Position (CMP)...

Lower intake manifold loosening sequence
Click to enlarge
Loosen and remove the lower manifold attaching bolts in the sequence given.
4. 
Remove the lower manifold and its gasket from the engine.
5. 
To install: Ensure that all of the gasket mating surfaces are clean and free or grease, oil or dirt. Also ensure that
the EGR passages in the manifolds and heads are clear.
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REMOVAL & INSTALLATION 301 

Intake manifold gasket and sealant points. Note that points (1) and (5) are sealed with RTV
silicone
Apply a  1
/16  in. (1.6mm) bead of silicone sealer to the points where the cylinder block rails meet the
cylinder heads.
7. 
Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets
interlocked with the seal tabs. Make sure the holes in the gaskets are aligned with the holes in the
cylinder heads.
8. 
Apply a  1
/16  in. (1.6mm) bead of sealer to the outer end of...

Lower intake manifold bolt tightening sequence
Click to enlarge
Install the lower manifold attaching bolts and tighten, in sequence shown, to specification in two steps
as follows: Tighten all bolts to 5-10 ft. lbs. (6-14 Nm).
1. 
Tighten all bolts to 4-6 ft. lbs. (12-17 Nm).
2. 
11. 
Install the camshaft synchronizer. Refer to Section 4.
12. 
Install the rear engine ground strap.
13. 
Tighten the water pump bypass hose clamp at the water pump.
14. 
Install the upper radiator hose to the water outlet....