1991 1999 ford explorer chilton User Manual
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Remove the old gaskets and thoroughly clean all of the mating surfaces Thoroughly clean all of the gasket and sealing surfaces and remove all traces of the old gaskets, oil, grease and/or dirt. Use new gaskets and apply a thin layer of sealant/adhesive to them. 12. If the specialized tools arent available, the front seal can be replaced using normal hand tools. Before installing the cover, use a punch to carefully knock the old seal out of the cover, and a seal driver to seat the new seal. Place the cover on a bench and carefully knock the old seal out of the cover using a hammer and punch Use an ordinary seal driver, and seat a new seal into the cover at the same position as the old one Install the front cover and attaching bolts. Refer to the necessary illustration. 13. If the front seal needs to be replaced, proceed as follows: Using Front Cover Seal Removal Tool T74P-6700-A, or its equivalent, remove the front seal. 1. Lubricate the engine front cover and oil seal lip inner lip with engine oil. 2. Using Crankshaft Seal Replacer/Cover Aligner T88T-6701-A, or its equivalent, install the new seal into the front cover. 3. 14. Install the crankshaft timing sensor. 15. Install the drive pulley/damper. 16. Install the water pump. 17. Install the fan. 18. HOW TO USE THIS BOOK 384 REMOVAL & INSTALLATION
Install the alternator. 19. Install the power steering pump. 20. Install the air conditioning compressor. 21. Install the oil pan. 22. Fill the cooling system. 23. Fill the crankcase with the proper grade and amount of engine oil. Connect the negative battery cable. Start the engine and check for leaks, then roadtest the vehicle for proper operation. 24. 4.0L SOHC Engine (VIN E) According to the manufacturer, the engine must be removed in order to service the front cover. However, the front seal can be serviced with the engine in the vehicle. Remove the crankshaft damper, then follow the seal replacement procedure under installation. Remove the engine from the vehicle. 1. Remove the oil pan and ladder frame. 2. For ladder frame removal procedures, refer to the oil pump removal and installation procedure in this section. Remove the water pump. 3. Remove the crankshaft pulley and damper. 4. Remove the front cover attaching bolts and remove the cover. 5. Inspect the oil seal. If the seal needs replacing, follow the procedures under installation. 6. To install: Thoroughly clean all gasket mating surfaces. Use new gaskets and coat them with a sealer/adhesive. 7. Install the front cover and tighten all of the bolts. 8. If the front seal needs to be replaced, proceed as follows: Using Front Cover Seal Removal Tool T74P-6700-A, or its equivalent, remove the front seal. 1. Lubricate the engine front cover and oil seal inner lip with engine oil. 2. Using Crankshaft Seal Replacer/Cover Aligner T88T-6701-A, or its equivalent, install the new seal into the front cover. 3. 9. Install the crankshaft damper and pulley. Install a new crankshaft pulley bolt and tighten to specifications 10. WARNING Never hammer on the damper. Use an appropriate damper installation tool to press the damper onto the crankshaft snout. Install the water pump. 11. Install the ladder frame and oil pan. 12. Install the engine into the vehicle. 13. Run the engine and check for leaks. 14. 5.0L Engine According to the manufacturer, the engine must be removed in order to service the front cover. However, the front seal can be serviced with the engine in the vehicle. Remove the crankshaft damper, then follow the seal replacement procedure under installation. Remove the engine from the vehicle. 1. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 385
Remove the water pump by-pass hose. 2. Remove the Crankshaft Position Sensor (CPS). 3. Remove the crankshaft pulley and damper. 4. Remove the oil pan. 5. The front cover and the water pump are removed as an assembly. Remove the front cover attaching bolts and remove the cover. 6. Inspect the oil seal. If the seal needs replacing, follow the procedures under installation. 7. To install: Thoroughly clean all gasket mating surfaces. Use new gaskets and coat them with a sealer/adhesive. 8. Install the front cover/water pump assembly and tighten all of the bolts. 9. View of the front cover seal removal tool Using the seal replacer tool to install a new front seal If the front seal needs to be replaced, proceed as follows: Using Front Cover Seal Removal Tool T70P-6B070-B, or its equivalent, remove the front seal. 1. Lubricate the engine front cover and oil seal lip inner lip with engine oil. 2. Using Crankshaft Seal Replacer/Cover Aligner T88T-6701-A, or its equivalent, install the new seal into the front cover. 3. 10. Install the oil pan. 11. Install the crankshaft damper and pulley. 12. HOW TO USE THIS BOOK 386 REMOVAL & INSTALLATION
WARNING Never hammer on the damper. Use an appropriate damper installation tool to press the damper onto the crankshaft snout. Install the Crankshaft Position Sensor (CPS) and the water pump by-pass hose. 13. Install the engine into the vehicle. 14. Run the engine and check for leaks. 15. Timing Chain and Gears REMOVAL & INSTALLATION 2.9L Engine Drain the cooling system and crankcase. Remove the oil pan and radiator. 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. Remove the cylinder front cover and water pump, drive belt, and camshaft timing gear. 2. Use the clutch aligner T71P-P-7137-H or equivalent and remove the crankshaft sprocket. 3. To install: Align the keyway in the gear with the key, then slide the gear onto the shaft, making sure that it seats tight against the spacer. 4. Feed the timing chain around the crankshaft sprocket and then around the camshaft sprocket. Install the camshaft sprocket together with timing chain as an assembly. Align all necessary timing marks. Check the camshaft end play. Refer to checking camshaft. If not within specifications, replace the thrust plate. 5. Align the keyway in the crankshaft gear with key in the crankshaft, and align the timing marks. Install the gear, using a crankshaft sprocket replacer tool. 6. Install the cylinder front cover following the procedures in this section. Install the oil pan and radiator. 7. Fill and bleed the cooling system and crankcase. 8. Start the engine and adjust the ignition timing. 9. Operate the engine at fast idle and check all hose connections and gaskets for leaks. 10. 3.0L Engine Disconnect the negative battery cable. 1. Drain the cooling system and crankcase. 2. 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 Timing Chain and Gears 387
Remove the timing cover. 3. Timing mark alignment-3.0L engineClick to enlarge Timing chain mounting-3.0L engine Click to enlarge Rotate crankshaft until No. 1 piston is at TDC and timing marks are aligned in the correct position. 4. HOW TO USE THIS BOOK 388 REMOVAL & INSTALLATION
Remove the camshaft sprocket retaining bolt and washer. Check timing chain deflection for excessive wear. 5. Slide sprockets and timing chain forward and remove as assembly. 6. To install: Clean timing cover and oil pan sealing surfaces. Clean and inspect all parts. The camshaft retaining bolt has a drilled oil passage for timing chain assembly lubrication. Clean oil passage with solvent. Do not replace with standard bolt. 7. Slide sprockets and timing chain on as assembly with timing marks in the correct location. Install camshaft retaining bolt and washer. Torque bolt to 46 ft. lbs. Lubricate the timing chain assembly. 8. Install timing cover assembly. Install retaining bolts with pipe sealant and tighten as outlined. 9. Refill and bleed cooling system. Connect the negative battery cable. Start engine check for coolant, oil and exhaust leaks. 10. 4.0L Engine (VIN X) Review the complete service procedure before starting this repair. Refer to the necessary service procedures in this section. Disconnect the negative battery cable. 1. Drain the cooling system. 2. 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. To remove the timing chain and sprockets, first remove the engine front cover Remove the front cover. 3. Remove the radiator. 4. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 389
Timing chain mounting-4.0L engine Click to enlarge Rotate the engine by hand until the No.1 cylinder is at TDC compression, and the timing marks are aligned. 5. HOW TO USE THIS BOOK 390 REMOVAL & INSTALLATION
Remove the tensioner lower attaching bolt ...HOW TO USE THIS BOOK REMOVAL & INSTALLATION 391
... and install a holding clip in the bolt hole and the slot on the rubbing block HOW TO USE THIS BOOK 392 REMOVAL & INSTALLATION
Unbolt and remove the tensionerHOW TO USE THIS BOOK REMOVAL & INSTALLATION 393