1991 1999 ford explorer chilton User Manual
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Checking camshaft end-play-2.9L engines Click to enlarge Push the camshaft toward the rear of the engine. Install a dial indicator (Tool D78P-4201-C or equivalent so that the indicator point is on the camshaft sprocket attaching screw. 1. Zero the dial indicator. Position a prybar between the camshaft gear and the block. Pull the camshaft forward and release it. Compare the dial indicator reading with the specification. The camshaft end-play specification is 0.0008-0.004 inch and the service limit is 0.009 inch (0.007 inch on 3.0L engine). Camshaft specifications are sometimes modified by Ford after production. 2. If the end play is excessive, check the spacer for correct installation before it is removed. If the spacer is correctly installed, replace the thrust plate. 3. The spacer ring and thrust plate are available in two thicknesses to permit adjusting the end play. Remove the dial indicator. 4. BEARING REMOVAL & INSTALLATION If excessive camshaft wear is found, or if the engine is completely rebuilt, the camshaft bearings should be replaced. Use these service repair procedures as a guide. 2.3L and 2.5L Engines HOW TO USE THIS BOOK 424 BEARING REMOVAL & INSTALLATION
Camshaft bearing installation-2.3L and 2.5L gasoline engine Click to enlarge Remove the head and place it on a work stand. 1. Remove the camshaft. 2. Using a tool such as Bearing Replacer T71P-6250-A, remove the bearings. 3. Coat the new bearings with clean 50W engine oil and install them with the tool. 4. 2.9L Engines HOW TO USE THIS BOOK BEARING REMOVAL & INSTALLATION 425
Checking oil hole alignment-2.9L engine Camshaft bearing installation on a V6 Click to enlarge Remove the engine and place it on a work stand. 1. Remove the flywheel. 2. Remove the camshaft. 3. Using a sharp punch and hammer, drive a hole in the rear bearing bore plug and pry it out. 4. Using the special tools and instructions in Cam Bearing Replacer Kit T71P-6250-A, or their equivalents, remove the bearings. 5. To remove the front and rear bearings, use the special adapter tube T72C-6250, or equivalent. 6. To install: Following the instructions in the tool kit, install the bearings. Make sure that you follow the instructions carefully. Failure to use the correct expanding collets can cause severe bearing damage! 7. Make sure that the oil holes in the bearings and block are aligned! Install a new bearing bore plug coated with sealer. 8. Install the camshaft. 9. Install the flywheel. 10. Install the engine. 11. HOW TO USE THIS BOOK 426 BEARING REMOVAL & INSTALLATION
3.0L, 4.0L (VIN X) and 5.0L Engines Remove the engine and place it on a work stand. 1. Remove the flywheel. 2. Remove the camshaft. 3. Using a sharp punch and hammer, drive a hole in the rear bearing bore plug and pry it out. 4. Using the special tools and instructions in Cam Bearing Replacer Kit T65L-6250-A, or their equivalents, remove the bearings. 5. To remove the front bearing, install the tool from the rear of the block. 6. To install: Following the instructions in the tool kit, install the bearings. Make sure that you follow the instructions carefully. Failure to use the correct expanding collets can cause severe bearing damage! 7. Make sure that the oil holes in the bearings and block are aligned! Make sure that the front bearing is installed 0.51-0.89mm below the face of the block. Install a new bearing bore plug coated with sealer. 8. Install the camshaft. 9. Install the flywheel. 10. Install the engine. 11. 4.0L SOHC Engine (VIN E) The bearings are integral with the cylinder heads and are not replaceable. If the bearing surfaces are damaged, a new cylinder head will have to be installed. Auxiliary Shaft REMOVAL & INSTALLATION 2.3L and 2.5L Engines HOW TO USE THIS BOOK BEARING REMOVAL & INSTALLATION 427
Auxiliary shaft installation-2.3L and 2.5L engines Click to enlarge Remove the camshaft drive belt cover. 1. Remove the drive belt. Remove the auxiliary shaft sprocket. A puller may be necessary to remove the sprocket. 2. Remove the distributor and fuel pump. 3. Remove the auxiliary shaft cover and thrust plate. 4. Withdraw the auxiliary shaft from block. 5. The distributor drive gear and the fuel pump eccentric on the auxiliary shaft must not be allowed to touch the auxiliary shaft bearings during removal and installation. Completely coat the shaft with oil before sliding it into place. Slide the auxiliary shaft into the housing and insert the thrust plate to hold the shaft. 6. HOW TO USE THIS BOOK 428 REMOVAL & INSTALLATION
Install a new gasket and auxiliary shaft cover. 7. The auxiliary shaft cover and cylinder front cover share a gasket. Cut off the old gasket around the cylinder cover and use half of the new gasket on the auxiliary shaft cover. Fit a new gasket into the fuel pump and install the pump. 8. Insert the distributor and install the auxiliary shaft sprocket. 9. Align the timing marks and install the drive belt. 10. Install the drive belt cover. 11. Check the ignition timing. 12. Rear Main Oil Seal REMOVAL & INSTALLATION Rear main seal installation for the 2.3L and 2.5L enginesClick to enlarge HOW TO USE THIS BOOK Rear Main Oil Seal 429
Removing the rear main seal Installing the rear main seal on the 2.9L engines Click to enlarge If the crankshaft rear oil seal replacement is the only operation being performed, it can be done in the vehicle as detailed in the following procedure. If the oil seal is being replaced in conjunction with a rear main bearing replacement, the engine must be removed from the vehicle and installed on a work stand. Remove the starter. 1. Remove the transmission from the vehicle, following the procedures in Section 7. 2. On a manual shift transmission, remove the pressure plate and cover assembly and the clutch disc following the procedure in Section 7. 3. Remove the flywheel attaching bolts and remove the flywheel and engine rear cover plate. 4. HOW TO USE THIS BOOK 430 REMOVAL & INSTALLATION
Use an awl to punch two holes in the crankshaft rear oil seal. Punch the holes on opposite sides of the crankshaft and just above the bearing cap to cylinder block split line. Install a sheet metal screw in each hole. Use two large screwdrivers or small pry bars and pry against both screws at the same time to remove the crankshaft rear oil seal. It may be necessary to place small blocks of wood against the cylinder block to provide a fulcrum point for the pry bars. Use caution throughout this procedure to avoid scratching or otherwise damaging the crankshaft oil seal surface. 5. To install: Clean the oil seal recess in the cylinder block and main bearing cap. 6. Clean, inspect and polish the rear oil seal rubbing surface on the crankshaft. Coat a new oil seal and the crankshaft with a light film of engine oil. Start the seal in the recess with the seal lip facing forward and install it with a seal driver. Keep the tool, T82L-6701-A (4-cyl. engines) or T72C-6165 (6-cyl. engine) straight with the centerline of the crankshaft and install the seal until the tool contacts the cylinder block surface. Remove the tool and inspect the seal to be sure it was not damaged during installation. 7. Install the engine rear cover plate. Position the flywheel on the crankshaft flange. Coat the threads of the flywheel attaching bolts with oil-resistant sealer and install the bolts. Tighten the bolts in sequence across from each other to the specifications listed in the torque chart in this section. 8. On a manual shift transmission, install the clutch disc and the pressure plate assembly following the procedure in Section 7. 9. Install the transmission, following the procedure in Section 7. 10. Flywheel and Ring Gear REMOVAL & INSTALLATION Flywheel assembly-3.0L engineClick to enlarge HOW TO USE THIS BOOK Flywheel and Ring Gear 431
Clutch pilot bearing removal HOW TO USE THIS BOOK 432 REMOVAL & INSTALLATION
Flywheel assembly-2.3L and 2.5L engines Click to enlarge Remove the transmission, following procedures in Section 7. 1. On a manual shift transmission, remove the clutch pressure plate and cover assembly and clutch disc, following the procedures in Section 7. 2. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 433