1991 1999 ford explorer chilton User Manual
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Rocker arm positioning-3.0L engines Click to enlarge Coat the tappets with 50W engine oil and place them in their original locations. 37. Apply 50W engine oil to both ends of the pushrods. Install the pushrods in their original locations. 38. Pivot the rocker arms into position. Tighten the fulcrum bolts to 8 ft. lbs. 39. Rotate the engine until both timing marks are at the tops of their sprockets and aligned. Tighten the following fulcrum bolts to 18 ft. lbs.: No.1 intake ¨ No.2 exhaust ¨ No.4 intake ¨ No.5 exhaust ¨ 40. Rotate the engine until the camshaft timing mark is at the bottom of the sprocket and the crankshaft timing mark is at the top of the sprocket, and both are aligned. Tighten the following fulcrum bolts to 18 ft. lbs.: No.1 exhaust ¨ No.2 intake ¨ No.3 intake and exhaust ¨ No.4 exhaust ¨ No.5 intake ¨ No.6 intake and exhaust ¨ 41. Now, tighten all the bolts to 24 ft. lbs. 42. Turn the engine by hand to 0 BTDC of the power stroke on No. 1 cylinder. 43. Install the engine front cover and water pump assembly. 44. Install the oil pan. 45. Install the crankshaft damper/pulley and tighten the retaining bolt to 107 ft. lbs. 46. HOW TO USE THIS BOOK 414 REMOVAL & INSTALLATION
Install the intake manifold and tighten the mounting bolts to the specifications and in the sequence described under Intake Manifold removal and installation. 47. Install the valve covers. 48. Install the injector harness. 49. If equipped, install the distributor. 50. Install the cap and wires. 51. Install the throttle body. 52. Install the alternator. 53. Install the power steering pump. 54. Install the compressor. 55. Connect all wires. 56. Connect all vacuum lines. 57. Install the radiator and condenser. 58. Install the fan and clutch. 59. Install the fuel lines. 60. Install the starter. 61. Refill the cooling system. 62. Replace the oil filter and refill the crankcase with the specified amount of engine oil. 63. Reconnect the battery ground cable. 64. Start the engine and check the ignition timing and idle speed. Adjust if necessary. Run the engine at fast idle and check for coolant, fuel, vacuum or oil leaks. 65. 4.0L Engine (VIN X) Disconnect the negative battery cable. 1. Drain the engine oil into a suitable container and dispose of it properly. 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. Drain the cooling system. 3. 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 radiator. 4. Remove the condenser. 5. Remove the fan and spacer, and shroud. 6. Remove the air cleaner hoses. 7. Tag and remove the spark plug wires. 8. Remove the EDIS ignition coil and bracket. 9. Remove the crankshaft pulley/damper. 10. Remove the clamp. bolt and oil pump drive from the rear of the block. 11. Remove the alternator. 12. Relieve the fuel system pressure. 13. Remove the fuel lines at the fuel supply manifold. 14. Remove the upper and lower intake manifolds as previously described. 15. Remove the rocker arm covers. 16. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 415
Remove the rocker shaft assemblies. 17. Remove the pushrods. Identify them for installation. They must be installed in their original positions! 18. Remove the tappets. Identify them for installation. 19. Remove the oil pan as previously described. 20. Remove the engine front cover and water pump. 21. Place the timing chain tensioner in the retracted position and install the retaining clip. 22. Turn the engine by hand until the timing marks align at TDC of the power stroke on No.1 piston. 23. Check the camshaft end-play. If excessive, youll have to replace the thrust plate. 24. Remove the camshaft gear attaching bolt and washer, then slide the gear off the camshaft. 25. Remove the camshaft thrust plate. 26. Carefully slide the camshaft out of the engine block, using caution to avoid any damage to the camshaft bearings. 27. To install: Oil the camshaft journals and cam lobes with a heavy (50W) SG grade (or better) engine oil. 28. Install the camshaft in the block, using caution to avoid any damage to the camshaft bearings. 29. Install the thrust plate. Make sure that it covers the main oil gallery. Tighten the attaching screws to 96 inch lbs. 30. HOW TO USE THIS BOOK 416 REMOVAL & INSTALLATION
Camshaft installation-4.0L engines Click to enlarge HOW TO USE THIS BOOK REMOVAL & INSTALLATION 417
Timing mark alignment-4.0L engines Click to enlarge Rotate the camshaft and crankshaft as necessary to align the timing marks. Install the camshaft gear and chain. Tighten the attaching bolt to 50 ft. lbs. 31. Remove the clip from the chain tensioner. 32. Install the engine front cover and water pump assembly. Refer to the necessary service procedures in this Section. 33. Install the crankshaft damper/pulley and tighten the retaining bolt to 107 ft. lbs. 34. Install the oil pan. 35. Coat the tappets with 50W engine oil and place them in their original locations. 36. Apply 50W engine oil to both ends of the pushrods. Install the pushrods in their original locations. 37. Install the upper and lower intake manifolds. 38. Install the rocker shaft assemblies. 39. Install the valve covers. 40. Install the fan and clutch. 41. Install the fuel lines. 42. Install the oil pump drive. 43. Install the alternator. 44. Install the EDIS coil and plug wires. Coat the inside of each wire boot with silicone lubricant. 45. Install the radiator and condenser. 46. Refill the cooling system. 47. Replace the oil filter and refill the crankcase with the specified amount of engine oil. 48. Reconnect the battery ground cable. 49. Start the engine and check the ignition timing and idle speed. Adjust if necessary. Run the engine at fast idle and check for coolant, fuel, vacuum or oil leaks. 50. HOW TO USE THIS BOOK 418 REMOVAL & INSTALLATION
4.0L SOHC Engine (VIN E) Remove the followers (2) using the valve spring compressor tool (1) 4.0L SOHC camshaft bearing cap bolt loosening and tightening sequence LEFT-HAND CAMSHAFT Disconnect the negative battery cable for safety. 1. Remove the LH valve cover. 2. Remove the LH hydraulic camshaft tensioner. 3. Remove the camshaft sprocket bolt. 4. When removing the followers, label them so that they may be returned to their original positions. Using the Valve Spring Compressor Tool ST150-A, or its equivalent, remove the camshaft roller followers. 5. Remove the camshaft bearing cap bolts and the oil rail. 6. Remove the camshaft. 7. To install: Lubricate all of the moving parts with SAE 50W engine oil. 8. Install the camshaft onto the cylinder head. 9. Position the oil rail and install the bearing caps and bolts. Tighten the bolts in two stages. Stage 1: 53.5 inch lbs. (6 Nm) 1. Stage 2: 11-12.5 ft. lbs. (15-17 Nm) 2. 10. Install the camshaft followers in the same manner as removal. 11. Install the camshaft sprocket bolt. Do not tighten the bolt. 12. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 419
Refer to the steps in the cylinder head removal and installation procedure to properly time the camshaft. 13. Install the valve cover. 14. Connect the negative battery cable. 15. Start the engine and check for leaks. 16. RIGHT-HAND CAMSHAFT Disconnect the negative battery cable for safety. 1. Remove the RH valve cover. 2. Remove the RH hydraulic camshaft tensioner. 3. The RH camshaft sprocket bolt uses left-hand threads. Using the Cam Gear Torque Adapter Tool T97T-6256-F, or its equivalent, remove the camshaft sprocket bolt. 4. When removing the followers, label them so that they may be returned to their original positions. Using the Valve Spring Compressor Tool ST150-A, or its equivalent, remove the camshaft roller followers. 5. Remove the camshaft bearing cap bolts and the oil rail. 6. Remove the camshaft. 7. To install: Lubricate all of the moving parts with SAE 50W engine oil. 8. Install the camshaft onto the cylinder head. 9. Position the oil rail and install the bearing caps and bolts. Tighten the bolts in two stages. Stage 1: 53.5 inch lbs. (6 Nm) 1. Stage 2: 11-12.5 ft. lbs. (15-17 Nm) 2. 10. Install the camshaft followers in the same manner as removal. 11. Install the camshaft sprocket bolt. Do not tighten the bolt. 12. Refer to the steps in the cylinder head removal and installation procedure to properly time the camshaft. 13. Install the valve cover. 14. Connect the negative battery cable. 15. Start the engine and check for leaks. 16. 5.0L Engine Disconnect the negative battery cable. 1. Remove the timing chain cover. 2. Remove the camshaft sprocket and chain assembly. 3. Remove the upper and lower intake manifolds. 4. Remove both valve covers. 5. Loosen the rocker arm bolts and rotate the rocker arms to the side. 6. Remove the pushrods in sequence so that they may be installed to their original positions. 7. Remove all of the lifters, also keeping them in order. 8. Remove the camshaft thrust plate bolts and the plate. 9. HOW TO USE THIS BOOK 420 REMOVAL & INSTALLATION
Exploded view of the camshaft and its related components on the 5.0L engine Withdraw the camshaft from the engine, taking care not to damage the bearings or lobes and journals. 10. To install: Apply SAE 50W engine oil to the camshaft lobes and journals. 11. Carefully install the camshaft into position in the cylinder block. 12. Apply SAE 50W engine oil to the camshaft thrust plate. 13. Position the thrust plate with the groove toward the block and install the retaining bolts. Tighten to 9-12 ft. lbs. (13-16 Nm). 14. Apply SAE 50W engine oil to the valve tappets and install them. If reusing the old lifters, place them in their original positions. 15. Install the pushrods to their original positions. 16. Reposition the rocker arms and tighten them as outlined earlier in this Section. 17. Install the valve covers, the lower and the upper intake manifolds. 18. Install the camshaft sprocket and chain assembly. Ensure that the timing marks on the cam and crankshaft sprockets are aligned. 19. Install the timing chain cover. 20. Connect the negative battery cable. Start the engine and check for leaks. 21. INSPECTION Camshaft Lobe Lift HOW TO USE THIS BOOK INSPECTION 421
Checking camshaft lobe lift Click to enlarge 2.3L, 2.5L AND 4.0L SOHC (VIN E) ENGINES Check the lift of each lobe in consecutive order and make a note of the readings. Camshaft assembly specifications are sometimes modified by Ford after production. Refer to a local reputable machine shop as necessary. Remove the air cleaner and the valve rocker arm cover. 1. Measure the distance between the major (A-A) and minor (B-B) diameters of each cam lobe with a Vernier caliper and record the readings. The difference in the readings on each cam diameter is the lobe lift. 2. If the readings do not meet specifications, replace the camshaft and all rocker arms. 3. Install the valve rocker arm cover and the air cleaner. 4. 2.9L, 3.0L, 4.0L (VIN X) AND 5.0L ENGINES Check the lift of each lobe in consecutive order and make a note of the reading. Camshaft assembly specifications are sometimes modify by Ford after production. Refer to a local reputable machine shop as necessary. Remove the fresh air inlet tube and the air cleaner. Remove the heater hose and crankcase ventilation hoses. Remove valve rocker arm cover(s). 1. Remove the rocker arm stud nut or fulcrum bolts, fulcrum seat and rocker arm. 2. Make sure the push rod is in the valve tappet socket. Install a dial indicator D78P-4201-B (or equivalent) so that the actuating point of the indicator is in the push rod socket (or the indicator ball socket adapter Tool 6565-AB is on the end of the push rod) and in the same plane as the push rod movement. 3. Disconnect the I terminal and the S terminal at the starter relay. Install an auxiliary starter switch between the battery and S terminals of the starter relay. Crank the engine with the ignition switch off. 4. HOW TO USE THIS BOOK 422 INSPECTION
Turn the crankshaft over until the tappet is on the base circle of the camshaft lobe. At this position, the push rod will be in its lowest position. Zero the dial indicator. Continue to rotate the crankshaft slowly until the push rod is in the fully raised position. 5. Compare the total lift recorded on the dial indicator with the specification. To check the accuracy of the original indicator reading, continue to rotate the crankshaft until the indicator reads zero. If the lift on any lobe is below specified wear limits, the camshaft and the valve tappet operating on the worn lobe(s) must be replaced. 6. Remove the dial indicator and auxiliary starter switch. 7. Install the rocker arm, fulcrum seat and stud nut or fulcrum bolts. 8. Install the valve rocker arm covers and the air cleaner. 9. Camshaft End Play 2.3L and 2.5L ENGINES Camshaft thrust plate installation-2.3L and 2.5L engines Remove the camshaft drive belt cover. Push the camshaft toward the rear of the engine. Install a dial indicator so that the indicator point is on the camshaft sprocket attaching screw or gear hub. Zero the dial indicator. Position a prybar between the camshaft sprocket or gear and the cylinder head. Pull the camshaft forward and release it. Compare the dial indicator reading with specifications. If the end play is excessive, replace the thrust plate at the rear of the cylinder head. Remove the dial indicator and install the camshaft drive belt cover. The camshaft end-play specification is 0.001-0.007 inch and the service limit is 0.003 inch. Camshaft specifications are sometimes modified by Ford after production. 2.9L, 3.0L, 4.0L AND 5.0L ENGINES HOW TO USE THIS BOOK INSPECTION 423