Ford Ranger/Explorer/Mountaineer 1991-1999
REMOVAL & INSTALLATION
Figures 1 through 5)
In the process of removing the engine, you
will come across a number of steps which call for the removal of a
separate component or system, such as "disconnect the exhaust system''
or "remove the radiator.'' In most instances, a detailed removal
procedure can be found elsewhere in this information.
virtually impossible to list each individual wire and hose which must be
disconnected, simply because so many different model and engine
combinations have been manufactured. Careful observation and common
sense are the best possible approaches to any repair procedure.
and installation of the engine can be made easier if you follow these
If you have to drain any of the fluids, use a suitable container.
Always tag any wires or hoses and, if possible, the components
they came from before disconnecting them.
Because there are so many bolts and fasteners involved, store and
label the retainers from components separately in muffin pans, jars or
coffee cans. This will prevent confusion during installation.
After unbolting the transmission or transaxle, always make sure it
is properly supported.
If it is necessary to disconnect the air conditioning system, have
this service performed by a qualified technician using a
recovery/recycling station. If the system does not have to be
disconnected, unbolt the compressor and set it aside.
When unbolting the engine mounts, always make sure the engine is
properly supported. When removing the engine, make sure that any lifting
devices are properly attached to the engine. It is recommended that if
your engine is supplied with lifting hooks, your lifting apparatus be
attached to them.
Lift the engine from its compartment slowly, checking that no
hoses, wires or other components are still connected.
After the engine is clear of the compartment, place it on an
engine stand or workbench.
After the engine has been removed, you can perform a partial or
full teardown of the engine using the procedures outlined in this
On vehicles equipped with air conditioning, it is vital to refer toprior
to performing this procedure. On 1991-93 models, it is not necessary to
have the A/C system evacuated since the A/C compressor can be unbolted
from the engine, and positioned out of the way, without disconnecting
any of the refrigerant lines.
On 1994-99 models equipped with air conditioning, have the system
discharged and evacuated by a MVAC, EPA-certified, automotive
technician. Have the A/C compressor removed from the engine.
Disconnect the negative battery cable.
Remove the hood.
Remove the air intake tube and the accessory drive belt.
When draining engine coolant, keep in mind that cats and dogs are
attracted to ethylene glycol antifreeze and could drink any that is left
in an uncovered container or in puddles on the ground. This will prove
fatal in sufficient quantity. Always drain coolant into a sealable
container. Coolant should be reused unless it is contaminated or is
several years old.
Drain the cooling system.
Remove the cooling fan, shroud, radiator and all cooling system
On all models except the 1996 Explorer with the 5.0L engine and
all 1997-99 Explorer/Mountaineer models, label and detach all engine
wiring and vacuum hoses which will interfere with engine removal.
Position the wire harness out of the way.
On 1996 Explorers with the 5.0L engine and all 1997-99
Explorer/Mountaineer models, the engine wiring harness is removed with
the engine. Only label and detach the harness connectors from components
which must be removed. Also unplug the harness at the main bulkhead
(firewall), transmission and PCM connections.
On 1991-93 models equipped with air conditioning, unbolt the A/C
compressor from the engine without disconnecting the refrigerant lines
and position it out of the way.
Unbolt the power steering pump from the engine and position it out
of the way. The fluid lines do not have to be disconnected.
Detach the accelerator and transmission control cables from the
throttle body, and the control cables' mounting bracket from the engine.
Release fuel system pressure, then disconnect the fuel supply and
return lines from the engine.
Remove any remaining mounting brackets and/or drive belt
Raise the vehicle and safely support it on jackstands.
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.
All Ford engines use a plate between the engine and the transmission.
Some models may have a smaller, removable, flywheel/flexplate
Drain the engine oil and remove the oil filter.
Detach the exhaust system from the exhaust manifolds.
Remove the starter motor and starter motor wiring from the engine.
Label and detach any under vehicle engine wiring, which will
interfere with engine removal.
On vehicles equipped with automatic transmissions, matchmark the
position of the torque converter to the flywheel. Remove the bolts.
Remove all of the engine-to-transmission bolts.
Fig. 3: Engine mounting points 4.0L engines
Fig. 5: Engine damper mounting for 4.0L engines
If equipped, remove the transmission oil cooler line
Remove the front engine support insulator-to-crossmember retaining
If equipped, remove the engine damper mounting bracket from the
engine. The bracket may use two TORX® bolts for the lower mounting
Partially lower the vehicle and support it with jackstands in the
Support the transmission with a floor jack.
Using a engine crane or hoist, lift the engine out of the vehicle.
Be sure to lift the engine slowly and check often that nothing (such as
wires, hoses, etc.) will cause the engine to hang up on the vehicle.
At this point, the engine can be installed on an engine stand.