1991 1999 ford explorer chilton User Manual

Remove the old gaskets and thoroughly clean all of the mating surfaces
Thoroughly clean all of the gasket and sealing surfaces and remove all traces of the old gaskets, oil,
grease and/or dirt. Use new gaskets and apply a thin layer of sealant/adhesive to them.
12. 
If the specialized tools arent available, the front seal can be replaced using normal hand tools. Before
installing the cover, use a punch to carefully knock the old seal out of the cover, and a seal driver to seat
the new seal.
Place the...

Install the alternator.
19. 
Install the power steering pump.
20. 
Install the air conditioning compressor.
21. 
Install the oil pan.
22. 
Fill the cooling system.
23. 
Fill the crankcase with the proper grade and amount of engine oil. Connect the negative battery cable.
Start the engine and check for leaks, then roadtest the vehicle for proper operation.
24. 
4.0L SOHC Engine (VIN E)
According to the manufacturer, the engine must be removed in order to service the front cover.
However, the front seal...

Remove the water pump by-pass hose.
2. 
Remove the Crankshaft Position Sensor (CPS).
3. 
Remove the crankshaft pulley and damper.
4. 
Remove the oil pan.
5. 
The front cover and the water pump are removed as an assembly. Remove the front cover attaching bolts and remove the cover.
6. 
Inspect the oil seal. If the seal needs replacing, follow the procedures under installation.
7. 
To install: Thoroughly clean all gasket mating surfaces. Use new gaskets and coat them with a sealer/adhesive.
8. 
Install the...

WARNING
Never hammer on the damper. Use an appropriate damper installation tool to press the damper onto the
crankshaft snout.
Install the Crankshaft Position Sensor (CPS) and the water pump by-pass hose.
13. 
Install the engine into the vehicle.
14. 
Run the engine and check for leaks.
15. 
Timing Chain and Gears
REMOVAL & INSTALLATION
2.9L Engine Drain the cooling system and crankcase. Remove the oil pan and radiator.
1. 
CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted...

Remove the timing cover.
3. 
Timing mark alignment-3.0L engineClick to enlarge
Timing chain mounting-3.0L engine Click to enlarge
Rotate crankshaft until No. 1 piston is at TDC and timing marks are aligned in the correct position.
4.  HOW TO USE THIS BOOK
388 REMOVAL & INSTALLATION 

Remove the camshaft sprocket retaining bolt and washer. Check timing chain deflection for excessive
wear.
5. 
Slide sprockets and timing chain forward and remove as assembly.
6. 
To install: Clean timing cover and oil pan sealing surfaces. Clean and inspect all parts. The camshaft retaining
bolt has a drilled oil passage for timing chain assembly lubrication. Clean oil passage with solvent. Do
not replace with standard bolt.
7. 
Slide sprockets and timing chain on as assembly with timing marks in the...

Timing chain mounting-4.0L engine
Click to enlarge
Rotate the engine by hand until the No.1 cylinder is at TDC compression, and the timing marks are
aligned.
5.  HOW TO USE THIS BOOK
390 REMOVAL & INSTALLATION 

Remove the tensioner lower attaching bolt ...HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 391 

... and install a holding clip in the bolt hole and the slot on the rubbing block HOW TO USE THIS BOOK
392 REMOVAL & INSTALLATION 

Unbolt and remove the tensionerHOW TO USE THIS BOOK
REMOVAL & INSTALLATION 393