1991 1999 ford explorer chilton User Manual

With the engine cold, locate and remove the oil pressure sending unit.
1. 
Following the manufacturers instructions, connect a mechanical oil pressure gauge and, if necessary,
a tachometer to the engine.
2. 
Start the engine and allow it to idle.
3. 
Check the oil pressure reading when cold and record the number. You may need to run the engine at a
specified rpm, so check the specifications.
4. 
Run the engine until normal operating temperature is reached (upper radiator hose will feel warm).
5. 
Check...

your particular engine.
Competent and accurate machine shop services will ensure maximum performance, reliability and engine life.
In most instances it is more profitable for the do-it-yourself mechanic to remove, clean and inspect the
component, buy the necessary parts and deliver these to a shop for actual machine work.
Much of the assembly work (crankshaft, bearings, piston rods, and other components) is well within the scope
of the do-it-yourself mechanics tools and abilities. You will have to...

CLEANING
Before the engine and its components are inspected, they must be thoroughly cleaned. You will need to
remove any engine varnish, oil sludge and/or carbon deposits from all of the components to insure an accurate
inspection. A crack in the engine block or cylinder head can easily become overlooked if hidden by a layer of
sludge or carbon.
Use a gasket scraper to remove the old gasket material from the mating surfaces
Most of the cleaning process can be carried out with common hand tools and...

Before cleaning and inspection, use a ring expander tool to remove the piston rings
Remove any oil galley plugs, freeze plugs and/or pressed-in bearings and carefully wash and degrease all of
the engine components including the fasteners and bolts. Small parts such as the valves, springs, etc., should
be placed in a metal basket and allowed to soak. Use pipe cleaner type brushes, and clean all passageways in
the components.
Use a ring expander and remove the rings from the pistons. Clean the piston ring...

... use a piece of an old ring to clean the grooves. Be careful, the ring can be quite sharp
WARNING
Use extreme care when cleaning around the cylinder head valve seats. A mistake or slip may cost you a new
seat.
When cleaning the cylinder head, remove carbon from the combustion chamber with the valves installed. This
will avoid damaging the valve seats.
REPAIRING DAMAGED THREADS
Damaged bolt hole threads can be replaced with thread repair insertsHOW TO USE THIS BOOK
REPAIRING DAMAGED THREADS 449 

Standard thread repair insert (left), and spark plug thread insert
Drill out the damaged threads with the specified size bit. Be sure to drill completely through the hole or to the bottom of a blind hole
Using the kit, tap the hole in order to receive the thread insert. Keep the tap well oiled and back it out frequently to avoid clogging the threadsHOW TO USE THIS BOOK
450 REPAIRING DAMAGED THREADS 

Screw the insert onto the installer tool until the tang engages the slot. Thread the insert into the
hole until it is  1
/4 - 1
/2  turn below the top surface, then remove the tool and break off the tang
using a punch
Several methods of repairing damaged threads are available. Heli-Coil® (shown here), Keenserts® and
Microdot® are among the most widely used. All involve basically the same principle-drilling out stripped
threads, tapping the hole and installing a prewound insert-making welding, plugging...

may want to take a moment to draw some pictures, or fabricate some labels or containers to mark the locations
of various components and the bolts and/or studs which fasten them. Modern day engines use a lot of little
brackets and clips which hold wiring harnesses and such, and these holders are often mounted on studs and/or
bolts that can be easily mixed up. The manufacturer spent a lot of time and money designing your vehicle, and
they wouldnt have wasted any of it by haphazardly placing brackets,...

Unfortunately, the only way to find out which components need replacing, is to disassemble and carefully
check each piece. After the cylinder head(s) are disassembled, thoroughly clean all of the components.
DISASSEMBLY
Except the 2.3 and 4.0L SOHC (VIN E) Engines
Before disassembling the cylinder head, you may want to fabricate some containers to hold the various parts,
as some of them can be quite small (such as keepers) and easily lost. Also keeping yourself and the
components organized will aid in...

A small magnet will help in removal of the valve locks
Be careful not to lose the small valve locks (keepers)
Remove the valve locks from the valve tip and/or retainer. A small magnet may help in removing the
locks.
4. 
Lift the valve spring, tool and all, off of the valve stem.
5.  HOW TO USE THIS BOOK
454 DISASSEMBLY