1991 1999 ford explorer chilton User Manual

Refill and bleed the cooling system.
23. 
Connect the negative battery cable, start the engine and check for leaks.
24. 
Cylinder Head
REMOVAL & INSTALLATION
Before installing the cylinder heads, have them cleaned and professionally checked. If there is a
problem, generally, it will not go away by simply installing new gaskets. Cylinder heads can and do
warp, which is the major cause of gasket failure. This is usually due to overheating.
2.3L and 2.5L Engine Disconnect the negative battery cable.
1....

To install:
Position head gasket on the block.
29. 
Clean rocker arm cover (cam cover).
30. 
Install valve cover gasket to the valve cover.
31. 
Position cylinder head to block.
32. 
Install cylinder head retaining bolts and tighten to specifications.
33. 
Fig. 1: 2.3L and 2.5L cylinder head bolt tightening sequence Click to enlarge
Connect oil sending unit lead wires.
34. 
Install the timing belt idler spring stop to the cylinder head.
35.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 335 

Position the timing belt idler to the cylinder head, and install its retaining bolts.
36. 
Install the eight exhaust manifold retaining bolts and/or stud bolts.
37. 
Install four nuts and/or stud bolts retaining heat stove to exhaust manifold.
38. 
Align the cam gear with pointer.
39. 
Align the crank pulley (TDC) with the pointer on the timing belt cover.
40. 
Position the timing belt to the pulleys (cam and auxiliary).
41. 
Loosen idler retaining bolts to tension the belt, then rotate the engine and...

Gaskets are marked with the words FRONT and TOP for correct positioning. Left and right cylinder
head gaskets are not interchangeable. Use new cylinder head bolts.
Cylinder head alignment studs on the 2.9L engineClick to enlarge
Cylinder head torque sequence for the 2.9L engine
Install the fabricated alignment dowels in the cylinder block and install the cylinder head assemblies
on the cylinder block, one at a time.
14. 
Remove the alignment dowels and install new cylinder head attaching bolts. Tighten...

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. Always drain the coolant into a sealable container. Coolant should be reused unless
it is contaminated or several years old.
Disconnect the battery ground cable.
2. 
Remove the air cleaner.
3. 
Relieve fuel pressure. Disconnect fuel lines as...

Cylinder head gasket positioning for the 3.0L
Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 339 

Cylinder head installation & bolt torque sequence for the 3.0L
Click to enlarge
HOW TO USE THIS BOOK
340 REMOVAL & INSTALLATION 

Valve rocker arm installation procedure and collapsed lifter gap clearance check for the 3.0L
engine
Click to enlarge
Position the cylinder head(s) on the block and install new attaching bolts. Tighten the head bolts in
sequence to 5 ft. lbs. Back off all bolts one full turn (36 degrees). Retighten the cylinder head bolts in
sequence, in two steps to 37 ft. lbs. Final tighten to 11 ft. lbs.
22. 
Install intake manifold as outlined.
23. 
Dip each pushrod in heavy engine oil then install the pushrods in...

WARNING
The fulcrums must be fully seated in the cylinder head and pushrods must be seated in the rocker arm sockets
prior to final tightening.
Lubricate all rocker arm assemblies with heavy engine oil. If the original valve train components are
being installed, a valve clearance check is not required. If, however, a component has been replaced,
the valve clearance should be checked.
26. 
Install the exhaust manifold(s).
27. 
Install the dipstick tube and spark plugs.
28. 
Position the rocker arm cover...

Remove the upper and lower intake manifolds as described earlier.
5. 
If the left cylinder head is being removed: Remove the accessory drive belt.
1. 
Remove the air conditioning compressor.
2. 
Remove the power steering pump and bracket assembly. DO NOT disconnect the hoses. Tie
the assembly out of the way.
3. 
Remove the spark plugs.
After removing the intake manifold, loosen the accessory mounting bracket bolts ...
... then remove the bracket and accessory
4. 
6. 
If the right head is being removed:...