1991 1999 ford explorer chilton User Manual
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Remove the jackshaft sprocket (arrow) bolt Install a pin in the jackshaft tensioner to hold it in the locked position. 5. Loosen and remove the jackshaft sprocket bolt. 6. Remove the jackshaft sprocket and chain assembly. 7. View of the left-hand front cassette retaining bolt (arrow) Remove the left-hand front cassette retaining bolt and remove the cassette (chain and tensioner assembly). 8. HOW TO USE THIS BOOK 404 REMOVAL & INSTALLATION
Position the engine to gain access to the rear of the engine. Ensure that the flywheel is removed. 9. The rear jackshaft plug (arrow) must be removed from the back of the engine block View of the right-hand rear cassette retaining bolt Remove the rear jackshaft plug from the back of the engine block. 10. Remove the right-hand rear cassette retaining bolt and spacer. 11. Remove the rear jackshaft sprocket retaining bolt (arrow)HOW TO USE THIS BOOK REMOVAL & INSTALLATION 405
Loosen and remove the rear jackshaft sprocket bolt, then remove the cassette (chain and tensioner assembly). 12. If the balance shaft chain is to be serviced, do it before installing the timing chains. 13. To install: Thoroughly clean all gasket mating surfaces. Use new gaskets and coat them with a sealer/adhesive. 14. Install the right-hand rear cassette and the sprocket-to-jackshaft bolt. 15. Install the rear cassette retaining bolt. 16. Install the rear jackshaft plug. 17. Install the front cassette and its retaining bolt. 18. Position jackshaft sprocket and chain on the engine and remove the tensioner pin. 19. Install the jackshaft sprocket bolt and tighten in two stages. Stage 1: 32-35 ft. lbs. (43-47 Nm) 1. Stage 2: Turn an additional 65-75° 2. 20. Install the cylinder heads. Time the chains as outlined in the cylinder head procedure. 21. Install the front cover and tighten all of the bolts. 22. Install the ladder frame and oil pan. 23. Install the engine into the vehicle. 24. Run the engine and check for leaks. 25. 5.0L Engine Remove the engine front cover. 1. Rotate the engine until the No. 1 piston is at TDC. Align the timing marks on the camshaft sprocket to the crankshaft sprocket. 2. Remove the camshaft sprocket retaining bolt. 3. Slide the crankshaft and camshaft sprockets and chain forward until all three components are removed. 4. To install: Position the crank and camshaft sprockets and chain assembly to the engine. 5. HOW TO USE THIS BOOK 406 REMOVAL & INSTALLATION
Timing chain assembly alignment marks on the 5.0L engine Click to enlarge Ensure that the timing marks on the two sprockets are aligned. 6. Install the camshaft sprocket bolt and washer. Tighten to 40-45 ft. lbs. (54-61 Nm). 7. Install the front cover. 8. Start the engine and check for leaks. 9. TIMING CHAIN DEFLECTION Remove the timing chain tensioner. 1. Rotate the crankshaft counterclockwise (as viewed from the front of the engine) to take up the slack on the left hand side of the chain. 2. Mark a reference point on a block approximately at mid-point of the chain. Measure from this point to the chain. 3. Rotate the crankshaft in the opposite direction to take up the slack on the right hand side of the chain. Force the left hand side of the chain out with your fingers and measure the distance between the reference point and the chain. The deflection is the difference between the two measurements. 4. If the deflection measurement exceeds specification, replace the timing chain and sprockets. 5. If the wear on the tensioner face exceeds 1.5mm, replace the tensioner. 6. When installing the crankshaft sprocket, fill the keyway chamfer cavity with EOAZ-19554-AA Threadlock and Sealer or equivalent, flush with the front face of the sprocket. 7. HOW TO USE THIS BOOK TIMING CHAIN DEFLECTION 407
Camshaft and Auxiliary Shaft Sprockets and Seals This procedure applies to 2.3L and 2.5L engines only. REMOVAL & INSTALLATION The cylinder front cover, camshaft and auxiliary shaft seals are replaced in the same manner with the same tools after the respective gear has been removed. Always use a new attaching bolt when replacing the camshaft sprocket or use new Teflon® sealing tape on the threads of the old bolt. To remove the sprockets, first remove the timing cover and belt, then use tool T74P-6256-B, or equivalent to remove its retaining bolt and pull the cam drive sprocket. The same tool is used in exactly the same manner to remove the auxiliary shaft sprocket, as well as to hold the sprockets while the attaching bolts are installed and tightened. A front cover seal remover tool T74P-6700-B or equivalent is used to remove all the seals. When positioning this tool, make sure that the jaws are gripping the thin edge of the seal very tightly before operating the jack-screw portion of the tool. To install the seals, a cam and auxiliary shaft seal replacer T74P-6150-A or equivalent with a stepped, threaded arbor is used. The tool acts as a press, using the internal threads of the various shafts as a pilot. Camshafts, Bearings and Lifters REMOVAL & INSTALLATION 2.3L and 2.5L Engine The following procedure covers camshaft removal and installation with the cylinder head on or off the engine. If the cylinder head has been removed, follow Steps 7-9 then skip to Step 12. Drain the cooling system. Remove the air cleaner assembly and disconnect the negative battery cable. 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 spark plug wires from the plugs, disconnect the retainer from the valve cover and position the wires out of the way. Disconnect rubber vacuum lines as necessary. 2. Remove all drive belts. Remove the alternator mounting bracket-to-cylinder head mounting bolts, position bracket and alternator out of the way. 3. Disconnect and remove the upper radiator hose. Disconnect the radiator shroud. 4. Remove the fan blades and water pump pulley and fan shroud. Remove cam belt and valve covers. 5. Align engine timing marks at TDC for No. 1 cylinder. Remove cam drive belt. 6. Remove the rocker arms (camshaft followers). 7. Remove the camshaft drive gear and belt guide using a suitable puller. Remove the front oil seal with a sheet metal screw and slide hammer. 8. Remove the camshaft retainer located on the rear mounting stand by unbolting the two bolts. 9. Jack up the front of the vehicle and support on jackstands. Remove the front motor mount bolts. Disconnect the lower radiator hose from the radiator. Disconnect and plug the automatic transmission 10. HOW TO USE THIS BOOK 408 Camshaft and Auxiliary Shaft Sprockets and Seals
cooler lines. Position a piece of wood on a floor jack and raise the engine carefully as far as it will go. Place blocks of wood between the engine mounts and crossmember pedestals. 11. Remove the camshaft by carefully withdrawing toward the front of the engine. Caution should be used to prevent damage to cam bearings, lobes and journals. 12. Check the camshaft journals and lobes for wear. Inspect the cam bearings, if worn (unless the proper bearing installing tool is on hand), the cylinder head must be removed for new bearings to be installed by a machine shop. 13. Exploded view of the camshaft mounting-2.3L and 2.5L engine Click to enlarge Camshaft installation is in the reverse order of service removal procedure. Coat the camshaft with a heavy SF (or better) grade oil before sliding it into the cylinder head. Install a new front seal. Apply a coat of sealer or teflon tape to the cam drive gear bolt before installation. After any procedure requiring removal of the rocker arms, each lash adjuster must be fully collapsed after assembly, then 14. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 409
released. This must be done before the camshaft is turned. Refill cooling system. Start engine and check for leaks. Roadtest the vehicle for proper operation. 15. 2.9L Engines Disconnect the battery ground cable from the battery. 1. Drain the oil from the crankcase. 2. 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. Remove the radiator, fan and spacer, drive belt and pulley. 3. Label and remove the spark plug wires from the spark plugs. 4. Remove the distributor cap with spark plug wires as an assembly. 5. Disconnect the distributor wiring harness and remove the distributor. 6. Remove the alternator. 7. Remove the intake manifold as described earlier. 8. Remove the rocker arm covers and rocker arm and shaft assemblies as described in this section. Label and remove the push rods and the tappets, so they can be reinstalled in the same location. 9. Remove the oil pan as described in this section. 10. Remove the crankshaft damper. 11. Remove the engine front cover and water pump as an assembly. 12. Remove the camshaft gear attaching bolt and washer, and slide gear and chain off camshaft. 13. Remove the camshaft thrust plate. 14. Carefully remove the camshaft from the block, avoiding any damage to the camshaft bearings. 15. Remove the camshaft drive gear and spacer ring. 16. To install: Oil the camshaft journals with a heavy SF grade (or better) engine oil and apply Lubriplate® or equivalent lubricant to the cam lobes. Install the spacer ring with the chamfered side toward the camshaft. Insert the camshaft key. 17. HOW TO USE THIS BOOK 410 REMOVAL & INSTALLATION
Camshaft thrust plate installation-2.9L engine Click to enlarge Install the camshaft in the block, carefully avoiding damage to the bearing surfaces. 18. Install the thrust plate so that it covers the main oil gallery. 19. Check the camshaft end play. The spacer ring and thrust plate are available in two thicknesses to permit adjusting the end play. 20. Install camshaft gear as described under timing gear removal and installation. 21. Install the engine front cover and water pump as an assembly. 22. Install the crankshaft pulley and secure with washer and attaching bolt. Torque the bolt to 85-96 ft. lbs. 23. Install the oil pan, as described in this section. 24. Position the tappets in their original locations. Apply Lubriplate® or equivalent to both ends of the push rods. 25. Install the push rods in same location as removed. Install the intake manifold, as described earlier. 26. Install the oil baffles and rocker arm and shaft assemblies. Tighten the rocker arm stand bolts to 43-50 ft. lbs. Adjust the valves and install the valve rocker arm covers. 27. Install the water pump pulley, fan spacer, fan, and drive belt. Adjust the belt tension. 28. Install the alternator. 29. Install the distributor, distributor wiring harness and distributor cap and plug wires. Connect the plug wires to the spark plugs. Refer to Distributor removal and installation in this manual. 30. Before installing plug wires, coat inside of each boot with silicone lubricant using a small screwdriver. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 411
Install the radiator. 31. Fill the cooling system to the proper level with a 50\50 mix of antifreeze and bleed cooling system. 32. Fill the crankcase with oil. 33. Connect the battery ground cable to the battery. 34. Run the engine and check and adjust the engine timing and idle speed. 35. Run the engine at fast idle speed and check for coolant, fuel, vacuum and oil leaks. 36. 3.0L Engine Disconnect the negative battery cable. 1. Remove the air cleaner hoses. 2. Remove the fan and spacer, and shroud. 3. Drain the cooling system. Remove the radiator. 4. 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 condenser. 5. Relieve the fuel system pressure. 6. Remove the fuel lines at the fuel supply manifold. 7. Tag and disconnect all vacuum hoses in the way. 8. Tag and disconnect all wires in the way. 9. Remove the engine front cover and water pump. 10. Remove the alternator. 11. Remove the power steering pump and secure it out of the way. DO NOT disconnect the hoses! 12. Remove the air conditioning compressor and secure it out of the way. DO NOT disconnect the hoses! 13. Remove the throttle body. See Section 5. 14. Remove the fuel injection harness. See Section 5. 15. Drain the engine oil into a suitable container and dispose of it properly. 16. 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. Turn the engine by hand to 0 BTDC of the power stroke on No. 1 cylinder. 17. Disconnect the spark plug wires from the plugs. 18. If equipped, remove the distributor cap with the spark plug wires as an assembly. 19. If equipped, matchmark the rotor, distributor body and engine. Disconnect the distributor wiring harness and remove the distributor. 20. Remove the rocker arm covers. 21. Remove the intake manifold as previously described. 22. Loosen the rocker arm bolts enough to pivot the rocker arms out of the way and remove the pushrods. Identify them for installation. They must be installed in their original positions! 23. Remove the tappets. Identify them for installation. 24. Remove the crankshaft pulley/damper. 25. Remove the starter. 26. Remove the oil pan as previously described. 27. Turn the engine by hand until the timing marks align at TDC of the power stroke on No.1 piston. 28. Check the camshaft end-play. If excessive, youll have to replace the thrust plate. 29. HOW TO USE THIS BOOK 412 REMOVAL & INSTALLATION
Remove the camshaft gear attaching bolt and washer, then slide the gear off the camshaft. 30. Remove the camshaft thrust plate. 31. Carefully slide the camshaft out of the engine block, using caution to avoid any damage to the camshaft bearings. 32. To install: Oil the camshaft journals and cam lobes with heavy SG engine oil (50W). Install the spacer ring with the chamfered side toward the camshaft, then insert the camshaft key. 33. Install the camshaft in the block, using caution to avoid any damage to the camshaft bearings. 34. Install the thrust plate. Tighten the attaching screws to 84 inch lbs. 35. Rotate the camshaft and crankshaft as necessary to align the timing marks. Install the camshaft gear and chain. Tighten the attaching bolt to 46 ft. lbs. 36. Camshaft installation-3.0L enginesClick to enlarge HOW TO USE THIS BOOK REMOVAL & INSTALLATION 413