1991 1999 ford explorer chilton User Manual
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Exploded view of the 3.0L engine throttle body/upper intake manifold assembly Click to enlarge HOW TO USE THIS BOOK REMOVAL & INSTALLATION 621
Exploded view of the 4.0L engine throttle body assembly and related components Click to enlarge View of the 5.0L engine throttle body assembly and related components Click to enlarge The 3.0L engines throttle body is a 1 piece casting which includes the upper intake manifold. In order to remove the throttle body, the entire upper manifold must be removed. Refer to Section 3 for the proper procedures. Loosen the air inlet tube clamps, then separate the tube from the throttle body and air cleaner housing. Remove the tube from the vehicle. 1. If equipped, remove the throttle linkage shield. 2. HOW TO USE THIS BOOK 622 REMOVAL & INSTALLATION
To remove the throttle body, first remove the air intake hose, then the linkage shield Next, disconnect the throttle control cable(s) from the throttle body ... ... as well as any electrical connections...HOW TO USE THIS BOOK REMOVAL & INSTALLATION 623
... and vacuum fittings. Make sure to label them to assure proper installation Detach the accelerator and speed control (if equipped) cables from the throttle body lever. 3. Label and disengage the engine wiring harness connectors from the Throttle Position (TP) sensor and the Idle Air Control (IAC) valve; both are mounted on the throttle body. 4. Remove the throttle body-to-upper intake attaching bolts ... Remove the four mounting nuts, then carefully separate the throttle body from the upper intake manifold. 5. HOW TO USE THIS BOOK 624 REMOVAL & INSTALLATION
... then remove the throttle body assembly Remove the old gasket and thoroughly clean the mating surfaces of both pieces Remove and discard the old throttle body-to-intake manifold gasket. 6. To install: If scraping is necessary to clean the remaining gasket material off of the mating surfaces, take care to avoid scratching or gouging the soft aluminum. Clean the gasket mating surfaces of any residual gasket material. 7. Install the throttle body, along with a new gasket, onto the upper intake manifold. Install and tighten the mounting nuts in a crisscross pattern to specifications. 8. Engage the TP sensor and IAC valve wiring connectors and remove the temporary labels. 9. Reattach the accelerator and speed control cables, if applicable, to the throttle body lever. 10. If removed, install the throttle linkage shield. 11. Install the air inlet tube between the air cleaner housing and the throttle body. Tighten the tube clamps until snug. 12. Fuel Supply Manifold and Injectors HOW TO USE THIS BOOK Fuel Supply Manifold and Injectors 625
REMOVAL & INSTALLATION Remove the upper intake manifold. Be sure to depressurize the fuel system before disconnecting any fuel lines. 1. Disconnect the fuel supply and return line retaining clips. 2. Detach the vacuum line from the fuel pressure regulator. 3. Disconnect the fuel chassis inlet and outlet fuel hoses from the fuel supply manifold. 4. Exploded view of the 2.3L and 2.5L engine fuel supply rail and injectors Click to enlarge HOW TO USE THIS BOOK 626 REMOVAL & INSTALLATION
Exploded view of the 2.9L engine fuel supply rail and injectors Click to enlarge HOW TO USE THIS BOOK REMOVAL & INSTALLATION 627
Exploded view of the 3.0L engine fuel supply rail and injectors Click to enlarge Exploded view of the 4.0L engine fuel supply rail and injectors Click to enlarge HOW TO USE THIS BOOK 628 REMOVAL & INSTALLATION
Exploded view of the 5.0L engine fuel supply rail For fuel supply manifold removal, unbolt the upper intake, then disconnect the injector wire harness plugs Label and disconnect the fuel injector wire harness plugs. 5. On the 2.3L and 2.5L engine, remove the two fuel supply manifold retaining bolts. 6. On the 4.0L (VIN X) engine, remove the six upper intake manifold attaching studs. 7. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 629
On the 4.0L (VIN X) engine, remove the 6 manifold mounting studs which retain the supply manifold On all other engines, remove the four fuel supply manifold retaining bolts. 8. Carefully disengage the fuel rail assembly from the fuel injectors by lifting and gently rocking the rail. 9. Some models use small retaining clips to secure the injectors in the supply manifold Click to enlarge Lift upwards with a rocking motion to disengage the injectors, then remove the supply manifold HOW TO USE THIS BOOK 630 REMOVAL & INSTALLATION