1991 1999 ford explorer chilton User Manual

The fuel pressure relief valve (A) is located on the fuel supply manifold
Inertia Switch
GENERAL INFORMATION
This switch shuts off the fuel pump in the event of a collision. Once the switch has been tripped, it must be
reset manually in order to start the engine.
The inertia switch is located on the toe-board, to the right of the transmission hump, in the passenger-side
footwell.
RESETTING THE SWITCH Turn the ignition switch OFF.
1. 
Ensure that there is no fuel leaking in the engine compartment, along...

Fuel pump inertia switch and reset button location
Click to enlarge
The Inertia Fuel Shutoff (IFS) switch-when an impact occurs, the ball breaks loose from the magnet and strikes the target plate which opens the electrical contacts
Click to enlarge
HOW TO USE THIS BOOK
612 RESETTING THE SWITCH 

Cycle the ignition switch from the ONto OFFpositions several times, allowing five seconds at each
position, to build fuel pressure within the system.
4. 
Again, check the fuel system for leaks. There should be no odor of fuel as well.
5. 
If there is no leakage and/or odor of fuel, it is safe to operate the vehicle. However, it is recommended
that the entire system be checked by a professional, especially if the vehicle was in an accident severe
enough to trip the inertia switch.
6. 
Fuel Pump
REMOVAL &...

Fuel pump and sending unit used on the Regular Cab Ranger pick-up
Click to enlarge
HOW TO USE THIS BOOK
614 REMOVAL & INSTALLATION 

Fuel pump and sending unit used on the Super Cab Ranger pick-up
Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 615 

Fuel pump and sending unit used on the Explorer and Mountaineer
Click to enlarge
Insert the fuel pump assembly into the fuel tank, then secure it in place with the locking ring. Tighten
the ring until secure.
1. 
Install the tank in the vehicle.
2. 
Install a minimum of 10 gallons of fuel and check for leaks.
3. 
Install a pressure gauge on the throttle body valve and turn the ignition ONfor 3 seconds. Turn the
key OFF, then repeat the key cycle five to ten times until the pressure gauge shows at least...

TESTING
CAUTION
Fuel pressure must be relieved before attempting to disconnect any fuel lines.
The diagnostic pressure valve (Schrader valve) is located on the fuel supply manifold (rail). This valve
provides a convenient point for service personnel to monitor fuel pressure, release the system pressure prior to
maintenance, and to bleed out air which may become trapped in the system during pressure replacement. A
pressure gauge with an adapter is required to perform pressure tests.
Fuel pressure can be...

Fuel pressure test chart-part 1
Click to enlarge
HOW TO USE THIS BOOK
618 TESTING 

Fuel pressure test chart-part 2
Click to enlarge
Fuel pressure test chart-part 3 Click to enlarge
HOW TO USE THIS BOOK
TESTING 619 

Throttle Body Assembly
REMOVAL & INSTALLATION
Exploded view of the 2.3L and 2.5L engine throttle body assembly Click to enlarge
Exploded view of the 2.9L engine throttle body assembly and related components Click to enlarge
HOW TO USE THIS BOOK
620 Throttle Body Assembly