1991 1999 ford explorer chilton User Manual
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If the lamp illuminates, the problem lies with the engine not being properly grounded. 1. If the lamp does not illuminate, skip to Step 4. 2. Connect the original wire to the oil pressure switch. While sitting in the vehicle, turn the ignition switch to the ONposition without actually starting the engine. Observe the other lights on the instrument cluster. If all of the other lights illuminate when turning the ignition switch ON, the oil pressure switch is defective and must be replaced. 1. If none of the other lights illuminate, there is a problem with power supply to the instrument cluster and gauges. 2. 4. REMOVAL & INSTALLATION Oil pressure and level switches used on the 2.9L and 4.0L engines Click to enlarge HOW TO USE THIS BOOK REMOVAL & INSTALLATION 243
Oil pressure and level switches used on the 3.0L engine Click to enlarge Disconnect the negative battery cable. 1. Disconnect the wiring at the sender/switch. 2. Remove the oil pressure sender/switch from the engine. 3. To install: Coat the threads with electrically conductive sealer and thread the unit into place. Tighten the sender/switch to 10-18 ft. lbs (13-24 Nm). 4. Attach the wiring to the sender/switch and connect the negative battery cable. 5. HOW TO USE THIS BOOK 244 REMOVAL & INSTALLATION
Low Oil Level Sensor The low oil level sensor is located in the engine oil pan on all models TESTING Use the accompanying diagnostic chart to help pinpoint low oil level sensor malfunctioning. The ignition switch should be turned OFFfor a minimum of 5 minutes between checks to ensure that the electronic relay, which has a 5 minute timer, has reset. Low oil level indicator diagnostic chartClick to enlarge HOW TO USE THIS BOOK Low Oil Level Sensor 245
Low oil level indicator wiring schematic Click to enlarge REMOVAL & INSTALLATION Always install a new gasket whenever the oil level sensor is removed Turn the engine OFF. 1. Raise the front of the vehicle and install jackstands beneath the frame. Firmly apply the parking brake and place blocks in back of the rear wheels. 2. Typical low oil level sensor mounting-note: the sensor is constantly submerged in oil, therefore, drain some oil out of the engine before removing it Drain at least 2 quarts (1.9 liters) of engine oil out of the pan. 3. HOW TO USE THIS BOOK 246 TESTING
Disconnect the sensor wiring. 4. Remove the sensor from the oil pan using a 1 in. (26mm) socket or wrench. Discard the old gasket. 5. To install: Install a new gasket onto the sensor. 6. When installing the new gasket, the flange faces the sensor and the words panside should face the oil pan. Install the sensor and gasket assembly into the oil pan. Tighten the sensor to 13-20 ft. lbs. (17-27 Nm). 7. Connect the electrical wire to the sensor. 8. Lower the front of the vehicle and remove the wheel blocks. 9. Refill the crankcase to the proper level. 10. Start the engine and check for leaks. 11. Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 247
SPECIFICATION CHARTS Troubleshooting Basic Starting System ProblemsClick to enlarge SPECIFICATION CHARTS 249
Troubleshooting Basic Charging System Problems Click to enlarge Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK 250 SPECIFICATION CHARTS
ENGINE MECHANICAL Engine REMOVAL & INSTALLATION In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as disconnect the exhaust system or remove the radiator. In most instances, a detailed removal procedure can be found elsewhere in this manual. It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure. Removal and installation of the engine can be made easier if you follow these basic points: If you have to drain any of the fluids, use a suitable container. · Always tag any wires or hoses and, if possible, the components they came from before disconnecting them. · Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation. · After unbolting the transmission or transaxle, always make sure it is properly supported. · If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside. · When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them. · Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected. · After the engine is clear of the compartment, place it on an engine stand or workbench. · After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined in this manual. · On vehicles equipped with air conditioning, it is vital to refer to Section 1 prior to performing this procedure. On 1991-93 models, it is not necessary to have the A/C system evacuated since the A/C compressor can be unbolted from the engine, and positioned out of the way, without disconnecting any of the refrigerant lines. On 1994-99 models equipped with air conditioning, have the system discharged and evacuated by a MVAC, EPA-certified, automotive technician. Have the A/C compressor removed from the engine. 1. Disconnect the negative battery cable. 2. Remove the hood. 3. Remove the air intake tube and the accessory drive belt. 4. CAUTION When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old. ENGINE MECHANICAL 251
Drain the cooling system. 5. Remove the cooling fan, shroud, radiator and all cooling system hoses. 6. On all models except the 1996 Explorer with the 5.0L engine and all 1997-99 Explorer/Mountaineer models, label and detach all engine wiring and vacuum hoses which will interfere with engine removal. Position the wire harness out of the way. 7. On 1996 Explorers with the 5.0L engine and all 1997-99 Explorer/Mountaineer models, the engine wiring harness is removed with the engine. Only label and detach the harness connectors from components which must be removed. Also unplug the harness at the main bulkhead (firewall), transmission and PCM connections. 8. On 1991-93 models equipped with air conditioning, unbolt the A/C compressor from the engine without disconnecting the refrigerant lines and position it out of the way. 9. Unbolt the power steering pump from the engine and position it out of the way. The fluid lines do not have to be disconnected. 10. Detach the accelerator and transmission control cables from the throttle body, and the control cables mounting bracket from the engine. 11. Release fuel system pressure, then disconnect the fuel supply and return lines from the engine. 12. Remove any remaining mounting brackets and/or drive belt tensioners. 13. Raise the vehicle and safely support it on jackstands. 14. 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 changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. Drain the engine oil and remove the oil filter. 15. Detach the exhaust system from the exhaust manifolds. 16. Remove the starter motor and starter motor wiring from the engine. 17. Label and detach any under vehicle engine wiring, which will interfere with engine removal. 18. On vehicles equipped with automatic transmissions, matchmark the position of the torque converter to the flywheel. Remove the bolts. 19. Remove all of the engine-to-transmission bolts. 20. All Ford engines use a plate between the engine and the transmission. Some models may have a smaller, removable, flywheel/flexplate If equipped, remove the transmission oil cooler line retainers-to-engine bolts. 21. HOW TO USE THIS BOOK 252 REMOVAL & INSTALLATION
Engine mounting points for 2.3L and 2.5L engines Click to enlarge HOW TO USE THIS BOOK REMOVAL & INSTALLATION 253