1991 1999 ford explorer chilton User Manual

Clean the gasket mating surfaces. Inspect the manifold for cracks and damaged gasket mating
surfaces. Replace if damaged.
13. 
Position the exhaust manifold and gasket to the cylinder head and install all of the bolts finger-tight.
14. 
For installing the left-hand manifold, proceed as follows: Position the A/C compressor to its bracket and install the attaching bolts. Tighten the bolts to
16-21 ft. lbs. (21-29 Nm).
1. 
Install the drive belt.
2. 
15. 
For installing the right-hand manifold, proceed as...

Exploded view of the 2.3L and 2.5L engine radiator and related components
Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 315 

Exploded view of the 4.0L engine radiator and related components-2.9L and 3.0L engines are
similar
Click to enlarge
Remove the retaining bolts at the top of the shroud, and position the shroud over the fan, clear of the
radiator.
3.  HOW TO USE THIS BOOK
316 REMOVAL & INSTALLATION 

To remove the radiator, first remove the air intake tube, then unbolt the shroud and position it
over the fan
If equipped with the 5.0L engine, remove the engine fan and the radiator shroud from the vehicle.
4. 
If equipped with an automatic transmission, disconnect the transmission cooling lines from the bottom
of the radiator.
5. 
Disconnect the upper and lower hoses from the radiatorRemove the radiator retaining bolts ...HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 317 

... then lift the radiator up and out of the vehicle
Disconnect the upper and lower hoses from the radiator.
6. 
Remove the radiator retaining bolts or the upper supports and lift the radiator from the vehicle.
7. 
Install the radiator in the reverse order of removal. Fill the cooling system and check for leaks. On
automatic transmission equipped vehicles, run the engine until normal operating temperature is
reached, then check the transmission fluid level. Correct as needed.
8. 
Engine Fan
REMOVAL &...

Exploded view of the engine fan for the 2.3L and 2.5L engine
Click to enlarge
The 2.3L and 2.5L engine does not use a fan hub nut. It is retained by four bolts which also secure the
pump pulley to the water pump.
If not equipped with A/C, disconnect the overflow tube from the fan guard, then unbolt and remove
the guard.
1. 
If equipped with A/C, disconnect the overflow tube from the shroud, remove the mounting screws and
lift the shroud off the brackets. Place the shroud behind the fan.
2. 
Remove the 4...

Exploded view of the engine fan for the 2.9L and 3.0L engines
Click to enlarge
If necessary, remove the air cleaner outlet tube.
1. 
Using Strap Wrench D79L-6731-A and Fan Clutch Nut Wrench T83T-6312-B, or their equivalents,
loosen the large nut attaching the clutch to the water pump hub.
2. 
According to the manufacturer, the nut uses LH threads and is loosened clockwise. Remove the two upper fan shroud retaining bolts. If the overflow hose is routed through the fan
shroud, remove it from the shroud.
3....

Exploded view of the engine fan for the 4.0L engine
Click to enlarge
Before attempting to unfasten the engine fan, check the fan shroud for indications of normal or reverse threads
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 321 

Remove the air intake tube. You will need these specialized tools to unfasten the fan clutch nut
If necessary, remove the air cleaner outlet tube.
1. 
According to the manufacturer, the nut uses RH threads and is loosened counterclockwise. Using Fan Clutch Pulley Holder T84T-6312-C and Fan Clutch Nut Wrench T84T-6312-D, or their
equivalents, loosen the large nut attaching the clutch to the water pump hub.
2. 
Using the special tools, loosen the fan clutch nut in the direction indicated on the shroud....

Remove the fan and clutch assembly from the vehicle
Remove the fan/clutch assembly and the fan shroud together.
5. 
If necessary, remove the fan-to-clutch bolts to separate the fan from the clutch.
6. 
To install: Installation is the reverse of removal. Torque the fan-to-clutch bolts to 55-70 inch lbs. (6-8 Nm);
the hub nut to 30-100 ft. lbs. (41-135 Nm) for 1991-95 models and 34-46 ft. lbs. (46-63 Nm) for
1996-99 models. Dont forget, the nut uses RH threads and is tightened clockwise.
7. 
4.0L SOHC (VIN...