1991 1999 ford explorer chilton User Manual

The following procedures are for installing the upper intake manifold.
Upper intake manifold bolt tightening sequenceClick to enlarge
Install the upper intake manifold using a new gasket. Tighten the attaching bolts in the sequence given
to the proper specification.
38. 
Install the intake cover plate.
39. 
Install the ignition coils to the engine and connect the harness plug and spark plug wires to them.
40. 
If equipped, install the EGR spacer (throttle body) coolant hoses.
41. 
Install the...

Exhaust Manifold
REMOVAL & INSTALLATION CAUTION
Allow the engine to cool before attempting to remove the manifolds. Serious injury can result from contact
with hot exhaust manifolds.
2.3L and 2.5L Engines
Disconnect the negative battery cable.
1. 
Remove the air cleaner outlet tube.
2. 
Remove the EGR transducer lines at the tube. Loosen and remove the EGR valve-to-exhaust
manifold tube.
3. 
Exploded view of the 2.3L and 2.5L engine exhaust manifold Click to enlarge
Disconnect the exhaust pipe from the...

2.9L Engines
Disconnect the attaching nuts from the muffler inlet pipe.
1. 
Remove the manifold attaching bolts.
2. 
Exploded view of both left and right-hand exhaust manifolds on the 2.9L engine Click to enlarge
Lift the manifold from the cylinder head.
3. 
To install: Position the manifold on the heads and install and tighten the attaching bolts to specification.
4. 
Install and tighten the inlet pipe attaching nuts.
5. 
3.0L Engine Disconnect the negative battery cable. Raise and safely support the...

If removing the left side exhaust manifold remove the oil level indicator tube retaining nut, rotate the
dipstick assembly out of the way. Also, if equipped, loosen the EGR tube flare nut at the valve and
remove the tube bolt at the manifold.
3. 
Exploded view of both left and right-hand exhaust manifolds on the 3.0L engine Click to enlarge
Remove the manifold to exhaust pipe attaching nuts, then separate the exhaust pipe from the
manifold.
4. 
Remove the exhaust manifold attaching bolts and the...

Position the exhaust manifold on the cylinder head and install the manifold attaching bolts. Tighten
them to 18 ft. lbs.
8. 
Connect (replace gasket if so equipped) the exhaust pipe to the manifold, then tighten the attaching
nuts to 30 ft. lbs. TIGHTEN BOTH NUTS IN EQUAL AMOUNTS TO CORRECTLY SEAT INLET
PIPE FLANGE.
9. 
If installing the left side manifold, install the oil tube dipstick assembly (apply sealer to the tube) as
necessary. Also reattach the EGR tube and components if removed.
10. 
Install...

Exploded view of the right-hand exhaust manifold on the 4.0L engine
Click to enlarge
Raise and safely support the vehicle.
2.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 309 

To remove the exhaust manifold, first remove the exhaust pipe-to-manifold bolts from
underneath
Remove the exhaust pipe-to-manifold bolts.
3. 
Lower the vehicle.
4. 
Unbolt the hot air intake shroud, which wraps around the manifold and covers some of the attaching bolts
HOW TO USE THIS BOOK
310 REMOVAL & INSTALLATION 

Remove the shroud ...
If removing the left-hand manifold, disconnect the power steering pump hoses.
5. 
If removing the right-hand manifold, remove the hot air intake shroud which is bolted around the
manifold.
6. 
... then unbolt the manifold ...... and lift it from the engine
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 311 

Unbolt and remove the manifold.
7. 
Clean and lightly oil all fastener threads.
8. 
Installation is the reverse of removal. Replace all gaskets if so equipped. Torque the manifold bolts to
19 ft. lbs.; the exhaust pipe nuts to 20 ft. lbs. TIGHTEN BOTH EXHAUST PIPE RETAINING
NUTS IN EQUAL AMOUNTS TO CORRECTLY SEAT INLET PIPE FLANGE.
9. 
If installing the left-hand manifold, reconnect the power steering pump hoses, then fill and bleed the
system.
10. 
Connect the negative battery cable and run the engine...

5.0L Engine
When installing the manifolds, always use new gaskets. Disconnect the negative battery cable.
1. 
Remove the accessory drive belt.
2. 
For the right-hand manifold, proceed as follows: Drain the cooling system.
1. 
Disconnect the alternator wires.
2. 
Remove the drive belt tensioner.
3. 
Disconnect the heater hot water tube from the water pump.
4. 
Remove the alternator bracket bolts and then remove the assembly.
5. 
3. 
For the left-hand manifold, proceed as follows:
4. 
Example of the 5.0L...