1991 1999 ford explorer chilton User Manual
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Click to enlarge If equipped, install the oil baffle. 5. Install rocker arm shaft assembly to the cylinder head and guide adjusting screws on to the pushrods. 6. Install and tighten rocker arm stand attaching bolts to specification, two turns at a time, in sequence (from middle of shaft to the end of shaft). 7. Adjust the valve lash to the cold specified setting. Refer to Section 1 under Valve Lash Adjustment for procedures. 8. Install the valve rocker arm covers. 9. DISASSEMBLY & REASSEMBLY Remove the spring washer and pin from each end of the valve rocker arm shaft. 1. Slide the rocker arms, springs and rocker arm shaft supports off the shaft. Be sure to mark the parts for re-assembly in the same locations. 2. If it is necessary to remove the plugs from each end of the shaft, drill or pierce the plug on one end. Use a steel rod to knock out the plug on the opposite end. Working from the open end, knock out the remaining plug. 3. The oil holes in the rocker arm shaft must point down when the shaft is installed. This position of the shaft can be recognized by a notch on the front face of the shaft. 4. If the plugs were removed from the shaft, use a blunt tool and install a plug, cup side out, in each end of the shaft. 5. Install a spring washer and pin on one end of the shaft, coat the rocker arm shaft with heavy engine oil and install the parts in the same sequence they were removed. 6. Thermostat REMOVAL & INSTALLATION 2.3L and 2.5L Engines Drain the cooling system below the level of the coolant outlet housing. 1. CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old. Exploded view of the thermostat assembly for 2.3L and 2.5L enginesHOW TO USE THIS BOOK 274 DISASSEMBLY & REASSEMBLY
Disconnect the heater return hose at the thermostat housing located on the left front lower side of engine. 2. Remove the coolant outlet housing retaining bolts and slide the housing with the hose attached to one side. 3. Remove the thermostat from the outlet. 4. Remove the gasket from the engine block and clean both mating surfaces. 5. It is good practice to check the operation of a new thermostat before it is installed in an engine. Place the thermostat in a pan of boiling water. If it does not open more than 1 /4 in., do not install it in the engine. To install: Coat a new gasket with water resistant sealer and position it on the outlet of the engine. The gasket must be in place before the thermostat is installed. 6. Install the thermostat with the bridge (opposite end from the spring) inside the elbow connection and turn it clockwise to lock it in position, with the bridge against the flats cast into the elbow connection. 7. Position the elbow connection onto the mounting surface of the outlet, so that the thermostat flange is resting on the gasket and install the retaining bolts. 8. Connect the heater hose to the thermostat housing. 9. Fill the radiator and operate the engine until it reaches operating temperature. Check the coolant level and adjust as necessary. 10. 3.0L Engine Drain the cooling system. 1. CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old. Disconnect the battery ground cable. 2. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 275
Thermostat installation for the 3.0L engine Click to enlarge Remove the upper radiator hose. 3. Remove the thermostat housing bolts. 4. Remove the housing and thermostat as an assembly. 5. Remove the thermostat from the housing. 6. To install: Clean all gasket material from the housing and engine. 7. Turn the thermostat clockwise into the housing until the thermostat bridge is perpendicular to the mounting holes. 8. Position the housing on the engine, using a new gasket coated with sealer. Tighten the bolts to 5 ft. lbs. (26 Nm). 9. Install the hose, fill and bleed the cooling system, connect the battery ground cable and start the engine. Check for leaks. 10. 2.9L and 4.0L Engines Drain the cooling system. 1. CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old. Disconnect the battery ground. 2. Remove the air cleaner duct assembly. 3. Remove the upper radiator hose. 4. HOW TO USE THIS BOOK 276 REMOVAL & INSTALLATION
Exploded view of the thermostat housing for the 4.0L engine-2.9L engine is similar Click to enlarge To remove the thermostat, first remove the upper radiator hose, then the three attaching screws HOW TO USE THIS BOOK REMOVAL & INSTALLATION 277
Pull the thermostat housing from the intake manifold ... ... then remove the thermostat Ensure that the sealing ring is properly seated. Install the thermostat with the release valve facing upwards Remove the 3 thermostat housing attaching bolts. 5. Remove the thermostat housing. You may have to tap it loose with a plastic mallet or your hand. 6. Pull the thermostat from the intake manifold. 7. HOW TO USE THIS BOOK 278 REMOVAL & INSTALLATION
To install: WARNING Do not use a sharp metal tool for scraping. Damage to the sealing surfaces could result and cause a leak. Clean all mating surfaces thoroughly. 8. Make sure that the sealing ring is properly installed on the thermostat rim. Position the thermostat in the housing making sure that the air release valve is in the up(12 oclock) position. 9. Coat the mating surfaces of the housing and engine with an adhesive type sealer. Position the new gasket on the thermostat and place the housing on the engine. Tighten the bolts to specification. 10. 5.0L Engine Drain the cooling system. 1. CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old. Disconnect the battery ground. 2. Remove the upper radiator hose. 3. Exploded view of the 5.0L engine thermostat and related components Click to enlarge Remove the 2 thermostat housing attaching bolts. 4. Loosen the bypass hose at the water pump. 5. Remove the thermostat housing. You may have to tap it loose with a plastic mallet or your hand. 6. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 279
To install: WARNING Do not use a sharp metal tool for scraping. Damage to the sealing surfaces could result and cause a leak. Align the air bleed hole on the thermostat with the notch in the housing, which is also the 12 oclock position Clean all mating surfaces thoroughly. 7. Position the thermostat in the housing making sure that the air release valve is in the up(12 oclock) position. 8. Coat the mating surfaces of the housing and engine with an adhesive type sealer. Position the new gasket on the engine and place the housing on the engine. Tighten the bolts to specifications. 9. Intake Manifold The engines covered by this manual utilize an upper and lower intake manifold assembly. If necessary, only the upper intake manifold may be removed by following the intake manifold procedure up to that point. Obviously, installation would also begin at the upper intake steps. REMOVAL & INSTALLATION WARNING Anytime the upper or lower intake manifold has been removed, cover all openings with a rag or a sheet of plastic to prevent dirt and debris from falling into the engine. 2.3L and 2.5L Engines HOW TO USE THIS BOOK 280 Intake Manifold
Exploded view of the upper and lower intake manifold assemblies on the 2.3L and 2.5L engine Click to enlarge The intake manifold is a two-piece (upper and lower) aluminum casting. Runner lengths are tuned to optimize engine torque and power output. The manifold provides mounting flanges for the air throttle body assembly, fuel supply manifold, accelerator control bracket and the EGR valve and supply tube. A vacuum fitting is installed to provide vacuum to various engine accessories. Pockets for the fuel injectors are machined to prevent both air and fuel leakage. The following procedure is for the removal of the intake manifold with the fuel charging assembly attached. Make sure the ignition is off, then drain the coolant from the radiator (engine cold). 1. CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 281
Disconnect the negative battery cable and secure it out of the way. 2. Remove the fuel filler cap to vent tank pressure. Release the pressure from the fuel system at the fuel pressure relief valve using EFI pressure gauge T80L-9974-A or equivalent. The fuel pressure relief valve is located on the fuel line in the upper right hand corner of the engine compartment. Remove the valve cap to gain access to the valve. 3. Label and unplug any electrical connectors related to the intake manifold assemblies being removed. 4. Linkage and hose location on the 2.3L and 2.5L engineClick to enlarge Disconnect the EGR valve supply tube Click to enlarge Tag and disconnect the vacuum lines at the upper intake manifold vacuum tree, at the EGR valve and at the fuel pressure regulator and canister purge line as necessary. 5. Remove the throttle linkage shield and disconnect the throttle linkage and speed control cable (if equipped). Unbolt the accelerator cable from the bracket and position the cable out of the way. 6. Disconnect the air intake hose, air bypass hose and crankcase vent hose. 7. Disconnect the PCV hose from the fitting on the underside of the upper intake manifold. 8. HOW TO USE THIS BOOK 282 REMOVAL & INSTALLATION
Loosen the clamp on the coolant bypass line at the lower intake manifold and disconnect the hose. 9. Disconnect the EGR tube from the EGR valve by removing the flange nut. 10. Upper intake manifold removal on the 2.3L and 2.5L engine Click to enlarge Remove the upper intake manifold retaining nuts. Remove the upper intake manifold and throttle body assembly. 11. If you only need to remove the upper intake manifold, stop at this point. Otherwise, continue with the procedure to also remove the lower intake manifold. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 283