1991 1999 ford explorer chilton User Manual

Rocker arm positioning-3.0L engines
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Coat the tappets with 50W engine oil and place them in their original locations.
37. 
Apply 50W engine oil to both ends of the pushrods. Install the pushrods in their original locations.
38. 
Pivot the rocker arms into position. Tighten the fulcrum bolts to 8 ft. lbs.
39. 
Rotate the engine until both timing marks are at the tops of their sprockets and aligned. Tighten the
following fulcrum bolts to 18 ft. lbs.: No.1 intake
¨ 
No.2 exhaust
¨ 
No.4...

Install the intake manifold and tighten the mounting bolts to the specifications and in the sequence
described under Intake Manifold removal and installation.
47. 
Install the valve covers.
48. 
Install the injector harness.
49. 
If equipped, install the distributor.
50. 
Install the cap and wires.
51. 
Install the throttle body.
52. 
Install the alternator.
53. 
Install the power steering pump.
54. 
Install the compressor.
55. 
Connect all wires.
56. 
Connect all vacuum lines.
57. 
Install the radiator...

Remove the rocker shaft assemblies.
17. 
Remove the pushrods. Identify them for installation. They must be installed in their original positions!
18. 
Remove the tappets. Identify them for installation.
19. 
Remove the oil pan as previously described.
20. 
Remove the engine front cover and water pump.
21. 
Place the timing chain tensioner in the retracted position and install the retaining clip.
22. 
Turn the engine by hand until the timing marks align at TDC of the power stroke on No.1 piston.
23....

Camshaft installation-4.0L engines
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HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 417 

Timing mark alignment-4.0L engines
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Rotate the camshaft and crankshaft as necessary to align the timing marks. Install the camshaft gear
and chain. Tighten the attaching bolt to 50 ft. lbs.
31. 
Remove the clip from the chain tensioner.
32. 
Install the engine front cover and water pump assembly. Refer to the necessary service procedures in
this Section.
33. 
Install the crankshaft damper/pulley and tighten the retaining bolt to 107 ft. lbs.
34. 
Install the oil pan.
35. 
Coat the tappets...

4.0L SOHC Engine (VIN E)
Remove the followers (2) using the valve spring compressor tool (1)
4.0L SOHC camshaft bearing cap bolt loosening and tightening sequence
LEFT-HAND CAMSHAFT
Disconnect the negative battery cable for safety.
1. 
Remove the LH valve cover.
2. 
Remove the LH hydraulic camshaft tensioner.
3. 
Remove the camshaft sprocket bolt.
4. 
When removing the followers, label them so that they may be returned to their original positions. Using the Valve Spring Compressor Tool ST150-A, or its...

Refer to the steps in the cylinder head removal and installation procedure to properly time the
camshaft.
13. 
Install the valve cover.
14. 
Connect the negative battery cable.
15. 
Start the engine and check for leaks.
16. 
RIGHT-HAND CAMSHAFT
Disconnect the negative battery cable for safety.
1. 
Remove the RH valve cover.
2. 
Remove the RH hydraulic camshaft tensioner.
3. 
The RH camshaft sprocket bolt uses left-hand threads. Using the Cam Gear Torque Adapter Tool T97T-6256-F, or its equivalent, remove...

Exploded view of the camshaft and its related components on the 5.0L engine
Withdraw the camshaft from the engine, taking care not to damage the bearings or lobes and journals.
10. 
To install: Apply SAE 50W engine oil to the camshaft lobes and journals.
11. 
Carefully install the camshaft into position in the cylinder block.
12. 
Apply SAE 50W engine oil to the camshaft thrust plate.
13. 
Position the thrust plate with the groove toward the block and install the retaining bolts. Tighten to
9-12 ft. lbs....

Checking camshaft lobe lift
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2.3L, 2.5L AND 4.0L SOHC (VIN E) ENGINES
Check the lift of each lobe in consecutive order and make a note of the readings. Camshaft assembly
specifications are sometimes modified by Ford after production. Refer to a local reputable machine shop as
necessary.
Remove the air cleaner and the valve rocker arm cover.
1. 
Measure the distance between the major (A-A) and minor (B-B) diameters of each cam lobe with a
Vernier caliper and record the readings. The...

Turn the crankshaft over until the tappet is on the base circle of the camshaft lobe. At this position,
the push rod will be in its lowest position.
Zero the dial indicator. Continue to rotate the crankshaft slowly until the push rod is in the fully raised
position.
5. 
Compare the total lift recorded on the dial indicator with the specification. To check the accuracy of
the original indicator reading, continue to rotate the crankshaft until the indicator reads zero. If the lift
on any lobe is below...