1991 1999 ford explorer chilton User Manual

Remove the jackshaft sprocket (arrow) bolt
Install a pin in the jackshaft tensioner to hold it in the locked position.
5. 
Loosen and remove the jackshaft sprocket bolt.
6. 
Remove the jackshaft sprocket and chain assembly.
7. 
View of the left-hand front cassette retaining bolt (arrow)
Remove the left-hand front cassette retaining bolt and remove the cassette (chain and tensioner
assembly).
8.  HOW TO USE THIS BOOK
404 REMOVAL & INSTALLATION 

Position the engine to gain access to the rear of the engine. Ensure that the flywheel is removed.
9. 
The rear jackshaft plug (arrow) must be removed from the back of the engine block View of the right-hand rear cassette retaining bolt
Remove the rear jackshaft plug from the back of the engine block.
10. 
Remove the right-hand rear cassette retaining bolt and spacer.
11. 
Remove the rear jackshaft sprocket retaining bolt (arrow)HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 405 

Loosen and remove the rear jackshaft sprocket bolt, then remove the cassette (chain and tensioner
assembly).
12. 
If the balance shaft chain is to be serviced, do it before installing the timing chains.
13. 
To install: Thoroughly clean all gasket mating surfaces. Use new gaskets and coat them with a sealer/adhesive.
14. 
Install the right-hand rear cassette and the sprocket-to-jackshaft bolt.
15. 
Install the rear cassette retaining bolt.
16. 
Install the rear jackshaft plug.
17. 
Install the front...

Timing chain assembly alignment marks on the 5.0L engine
Click to enlarge
Ensure that the timing marks on the two sprockets are aligned.
6. 
Install the camshaft sprocket bolt and washer. Tighten to 40-45 ft. lbs. (54-61 Nm).
7. 
Install the front cover.
8. 
Start the engine and check for leaks.
9. 
TIMING CHAIN DEFLECTION Remove the timing chain tensioner.
1. 
Rotate the crankshaft counterclockwise (as viewed from the front of the engine) to take up the slack
on the left hand side of the chain.
2. 
Mark...

Camshaft and Auxiliary Shaft Sprockets and Seals
This procedure applies to 2.3L and 2.5L engines only.
REMOVAL & INSTALLATION
The cylinder front cover, camshaft and auxiliary shaft seals are replaced in the same manner with the same
tools after the respective gear has been removed. Always use a new attaching bolt when replacing the
camshaft sprocket or use new Teflon® sealing tape on the threads of the old bolt. To remove the sprockets,
first remove the timing cover and belt, then use tool T74P-6256-B,...

cooler lines.
Position a piece of wood on a floor jack and raise the engine carefully as far as it will go. Place blocks
of wood between the engine mounts and crossmember pedestals.
11. 
Remove the camshaft by carefully withdrawing toward the front of the engine. Caution should be
used to prevent damage to cam bearings, lobes and journals.
12. 
Check the camshaft journals and lobes for wear. Inspect the cam bearings, if worn (unless the proper
bearing installing tool is on hand), the cylinder head must...

released. This must be done before the camshaft is turned.
Refill cooling system. Start engine and check for leaks. Roadtest the vehicle for proper operation.
15. 
2.9L Engines Disconnect the battery ground cable from the battery.
1. 
Drain the oil from the crankcase.
2. 
CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including
cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should
be worn when...

Camshaft thrust plate installation-2.9L engine
Click to enlarge
Install the camshaft in the block, carefully avoiding damage to the bearing surfaces.
18. 
Install the thrust plate so that it covers the main oil gallery.
19. 
Check the camshaft end play. The spacer ring and thrust plate are available in two thicknesses to
permit adjusting the end play.
20. 
Install camshaft gear as described under timing gear removal and installation.
21. 
Install the engine front cover and water pump as an assembly.
22....

Install the radiator.
31. 
Fill the cooling system to the proper level with a 50\50 mix of antifreeze and bleed cooling system.
32. 
Fill the crankcase with oil.
33. 
Connect the battery ground cable to the battery.
34. 
Run the engine and check and adjust the engine timing and idle speed.
35. 
Run the engine at fast idle speed and check for coolant, fuel, vacuum and oil leaks.
36. 
3.0L Engine Disconnect the negative battery cable.
1. 
Remove the air cleaner hoses.
2. 
Remove the fan and spacer, and...

Remove the camshaft gear attaching bolt and washer, then slide the gear off the camshaft.
30. 
Remove the camshaft thrust plate.
31. 
Carefully slide the camshaft out of the engine block, using caution to avoid any damage to the
camshaft bearings.
32. 
To install: Oil the camshaft journals and cam lobes with heavy SG engine oil (50W). Install the spacer ring with
the chamfered side toward the camshaft, then insert the camshaft key.
33. 
Install the camshaft in the block, using caution to avoid any damage...