1991 1999 ford explorer chilton User Manual

Remove the rocker shafts and, keeping them in order, the pushrods
Remove the rocker shaft assembly.
9. 
Remove the pushrods, keeping them in order so they may be installed in their original locations.
10. 
Loosen and remove the cylinder head attaching bolts ...... then lift the cylinder head from the engine HOW TO USE THIS BOOK
344 REMOVAL & INSTALLATION 

Loosen the cylinder head attaching bolts in reverse of the torque sequence, then remove the bolts and
discard them. They cannot be re-used.
11. 
Lift off the cylinder head(s).
12. 
Remove and discard the old cylinder head gasket
Remove and discard the old cylinder head gasket(s).
13. 
To install: Clean the cylinder heads, intake manifolds, valve rocker arm cover and cylinder block gasket surfaces
of all traces of old gasket material and/or sealer. Refer to the following overhaul procedures for
cylinder...

Fig. 14: Cylinder head installation for the 4.0L engine
Click to enlarge
Fig. 15: Cylinder head torque sequence for the 4.0L engine
The cylinder head(s) and intake manifold are torqued alternately and in sequence, to assure a correct
fit and gasket crush.
Position the cylinder head(s) on the block.
16.  HOW TO USE THIS BOOK
346 REMOVAL & INSTALLATION 

Apply a bead of RTV silicone gasket material to the mating joints of the head and block at the 4
corners. Install the intake manifold gasket and again apply the sealer.
17. 
This sealer sets within 15 minutes, so work quickly! Install the lower intake manifold and install the bolts and nuts for the manifold and head(s). Tighten
all fasteners finger-tight.
18. 
Tighten the intake manifold fasteners, in sequence, to 36-15 inch lbs.
19. 
WARNING
Do not re-use the old head bolts. ALWAYS use new head bolts!...

Drain the cooling system.
2. 
CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and
could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in
sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is
contaminated or is several years old.
Remove the upper and lower intake manifolds.
3. 
Remove the engine fan/clutch assembly and the shroud.
4....

Fig. 17: Remove the LH camshaft sprocket bolt (arrow)
Fig. 18: Remove the LH cassette (chain guide assembly) retaining bolt
Remove the LH hydraulic chain tensioner and the camshaft sprocket bolt.
25. 
Remove the LH cassette (chain guide) retaining bolt.
26. 
Remove the eight 12 mm and two 8 mm bolts, in sequence, from the LH cylinder head.
27. 
Remove the cylinder head and discard the old gasket.
28. 
WARNING
The RH exhaust manifold must be removed before the RH cylinder head to avoid breaking the...

Remove the RH exhaust manifold.
29. 
Fig. 19: The cam gear torque adapter tool (arrow) is necessary for the removal of the RH camshaft sprocket bolt
Remove the RH hydraulic chain tensioner. Access to the tensioner is through the RH fender well.
30. 
WARNING
The RH camshaft sprocket bolt uses left-hand threads.
Use the cam gear torque adapter tool to remove the RH camshaft sprocket bolt.
31. 
Fig. 20: Remove the RH cassette retaining bolt (arrow)
Remove the RH cassette retaining bolt.
32. 
WARNING
HOW TO...

You must remove the camshaft sprocket from the chain and cassette to gain clearance to remove the cylinder
head and avoid breaking the cassette.
Fig. 21: Remove the RH camshaft sprocket and fasten a rubber band around the chain and the cassette to prevent the chain from dropping into the engine
Hold the chain to the cassette with a rubber band to aid removal and prevent the chain from falling into
the cylinder block.
Remove the RH camshaft sprocket from the cassette.
33. 
Remove the eight 12mm and two...

Fig. 23: Before installing the LH cylinder head, fasten a rubber band around the chain and
cassette to keep the sprocket from being disturbed
Install a rubber band to the LH cassette to hold the chain and sprocket in place.
40. 
Install the LH cylinder head gasket.
41. 
Position the LH cylinder head to the engine block and install the attaching bolts. Tighten the bolts in
three stages: first tighten to 26 ft. lbs. (35 Nm), second, rotate 90°, third, rotate an additional 90°.
42. 
Install the RH camshaft...

Fig. 25: You will need to align the slots on the camshaft to install the camshaft holding tool to
the cylinder head
Fig. 26: With the camshaft gear positioning/holding tool installed, the sprocket bolt can be properly tightened
To properly time the left-hand cylinder head camshaft, proceed as follows: Use the camshaft chain tensioner tool and install it into the LH cylinder head.
1. 
Rotate the crankshaft one revolution.
2. 
Position the crankshaft at top dead center of number one cylinder and install...