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removing intake manaffold on a 1997 ford explorer 4 0 sohc

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1997 Ford Explorer/ Mountaineer Intake Manifold Upper Repair Manual

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Intake Manifold — Upper 1. Disconnect the battery ground cable. 2. Remove the air cleaner outlet tube; refer to Section 303-12 3. Disconnect the ignition coil electrical connector and the noise suppressor electrical connector. 4. Disconnect the idle air control (IAC) electrical connector. 5. Disconnect the EGR backpressure transducer electrical connector. 6. Disconnect the EVR solenoid electrical and vacuum connectors. 7. Disconnect the brake booster vacuum hose from the upper intake manifold. 8. Disconnect the vacuum connector from the upper intake manifold 9. Disconnect the vacuum connector from the fuel pressure regulator and remove the vacuum harness from the engine. 10. Disconnect the throttle position (TP) sensor electrical connector. 11. Disconnect the hoses from the EGR backpressure transducer ports. 12. Disconnect the six spark plug wires from the spark plugs. 13. Disconnect the spark plug wires from the seven retaining clips. 14. Remove the four ignition coil bolts and the ignition coil from the upper intake manifold. 15. Raise and support the vehicle; refer to Section 100-02 . 16. Access the LH exhaust manifold through the wheel well and disconnect the EGR inlet tube from the exhaust manifold (9430). 17. Lower the vehicle. 18. Disconnect the EGR inlet tube from the EGR valve and remove the EGR inlet tube. 19. Remove the EGR valve bolts and the EGR valve and gasket. 20. Remove the oil level indicator tube bracket nut and remove the oil level indicator tube (6754). 21. Remove the EGR outlet tube bracket stud bolt and remove the EGR outlet tube from the upper intake manifold. 22. Disconnect the accelerator cable assembly from the upper intake manifold bracket. 23. Remove the upper intake manifold nuts and remove the upper intake manifold and gasket. Installation 1. NOTE: Before installing the upper intake manifold, the EGR port must be clean and free of obstruction. Use combustion chamber cleaner and a suitable wire brush to remove carbon buildup from the EGR passages. Clean and inspect all surfaces. Install new seals and new gaskets. Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to clean the upper and lower intake manifold gasket surfaces. Position the upper intake manifold gasket on the fuel injection supply manifold. 2. Position the upper intake manifold and install the six nuts.

1995-1997 FORD EXPLORER TRANSFER CASE BINDING OR SHUDDER DIAGNOSTICS VEHICLES WITH 4.0L ENGINE SERVICE TIP

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TRANSFER CASE BINDING OR SHUDDER DIAGNOSTICS VEHICLES WITH 4.0L ENGINE SERVICE TIP ISSUE to the Data Link Connector (DLC) underneath The diagnostic procedure for binding or shudder the steering wheel. Monitor for any Diagnostic from transfer case in slow, tight turns while in 4 Trouble Codes (DTCs) set by the transfer case Auto mode may be inaccurate for some vehicles. that could indicate incorrect speed sensor function. Codes could include, but are not ACTION limited to: Diagnose transfer case binding or shudder concerns using the following Diagnostic Procedure. •P1836 – Front propshaft sensor circuit failure •P1837 – Rear propshaft sensor circuit failure DIAGNOSTIC PROCEDURE •P1874 – Hall effect sensor power short circuit to battery 1997 EXPLORER •P1875 – Hall effect sensor power circuit 1. Test drive the vehicle in 4 Auto, 4 High and 4 failure Low. Evaluate the vehicle in each of these NOTE modes. The vehicle should bind in turns in both ADDITIONAL CODES COULD BE SET AS WELL. 4 High and 4 Low, but not in 4 Auto. The 4 PLEASE REFER TO THE APPROPRIATE YEAR High mode is intended for severe winter EXPLORER SERVICE MANUAL FOR COMPLETE weather or off-road driving only. It is not LISTING AND EXPLANATION. intended for use on dry or merely wet pavement. 3. If any of the DTCs in the above Step 2 are set, remove the corresponding speed sensor and 2. Verify the instrument panel has the proper 4X4 replace accordingly. Drive the vehicle to verify if selection label (Figure 1). Proceed to 1995-97 the shudder/binding has been eliminated. Send Explorer heading, Step 1. replaced speed sensor to the Ford Warranty 1995-97 EXPLORER Parts Return Center, Canton, MI. NOTE 4. Using NGS Tester, monitor the Parameter 4 AUTO IS THE FAR LEFT SWITCH POSITION Identification Display (PID) on the transfer case ON 1997 MODELS AND IS THE MIDDLE clutch duty cycle. If the 4 Auto mode reads POSITION ON 1996 MODELS. something higher than one (1), verify speed sensors have not set any Generic Electronic 1. If during test driving, the vehicle shudders or Module (GEM) DTCs and follow the speed binds in 4 Auto during slow forward or reverse sensor diagnostic procedure in the above Step parking lot maneuvers, proceed to Step 2. 2. Verify the following while checking PID: Mode Duty Cycle Indicator 4 Auto 0 or 1 4 High 13 4 Low 38 at 5 MPH 5. If the speed sensor circuits are functional, inspect for water contamination in the transfer case oil

1997-2006 Ford Explorer Sport 2-dr Overhead Console Modification Service Manual

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Technical Service Bulletin Overhead Console Modification 1997-06 Explorer Sport 2-dr, 2001-06 SportTrac, 1996-01 Explorer 4-dr: Most moonroof and popup sunroof applications require no console modification. Spoiler sunroofs without flush motors require shortening the console. Simply cut the console at the last flip down pocket for a clean vertical wall (no cap required). The entire console is then easily covered in new cloth. Optional – make a cover plate and wrap just the plate in matching headliner cloth. Most full size sunroofs fit the flat spots between the ribs.

2000 Ford Windstar Intake Manifold-Lower Removal And installation manual

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Intake Manifold—Lower Removal 1. Partially drain the cooling system. For additional information, refer to Section 303-03 . 2. Remove the upper intake manifold (9424). For additional information, refer to Intake Manifold—Upper in this section. 3. Remove the fuel supply manifold (9F792). For additional information, refer to Section 303-04B . 4. Disconnect the EGR vacuum tube (9E498). 5. Disconnect the EGR-to-exhaust manifold tube (9D477). * Loosen the nut. 6. Disconnect the upper radiator hose (8260). * Reposition the clamp. * Disconnect the hose. 7. Disconnect the heater hose (18472). * Compress the fitting * Disconnect the hose. 8. Disconnect the intake manifold runner control (IMRC). 9. Position the water bypass tube (8555) aside. 1. Remove the bolts. 2. Position the tube aside. 10. NOTE: Note the location of the six long bolts. Remove the lower intake manifold (9J447). 1. Remove the bolts. 2. Remove the intake manifold. 11. Remove the intake manifold runner control (IMRC) if necessary. For additional information, refer to Section 303-14 . 12. Remove and discard the lower intake manifold sealing components. Installation 1. Refer to the illustration for intake manifold sealing component locations. 2. Install the lower intake manifold front and rear end seals. 1. Apply a bead of sealant to the intake manifold front and rear end seal mounting points as indicated. * Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. 3. Install the lower intake manifold front and rear end seals. 3. Install the intake manifold gaskets (9439). 4. Install the intake manifold runner control (IMRC) if required. For additional information, refer to Section 303-14 . 5. NOTE: The lower intake manifold must be installed within four minutes of applying sealant. Position the lower intake manifold. 1. Apply a bead of sealant to the lower intake manifold mounting at the points indicated. * Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. 3. Position the lower intake manifold.

1999 FORD EXPLORER/ RANGER TRANSMISSION-4R44E OR 5R55E-SLIPPING SHIFT/ DELAYED OR NO ENGAGEMENT REPAIR MANUAL

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SERVICE PROCEDURE F87Z-7A100-DB Main Control (4.0L EI Explorer) F87Z-7A100-EB Main Control (4.0L SOHC Explorer) 1. Perform normal diagnosis for this concern. XL2Z-7L491-AA Bracket XL2Z-7G383-AA Electronic Pressure Control (EPC) 2. Perform Line Pressure Tests as listed in the Solenoid 1999 Explorer/Mountaineer, Ranger Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The 3. If pressures are low, perform Pinpoint Test for Provisions Of Bumper To the EPC solenoid. Bumper Warranty Coverage And Emissions Warranty 4. Inspect the bracket that attaches the Torque Coverage Converter Clutch (TCC), Shift Solenoid B OPERATION DESCRIPTION TIME (SSB), Shift Solenoid D/Coast Clutch Solenoid 991610A Replace Electronic 1.2 Hrs. (SSD/CCS), and EPC solenoids to the main Pressure Control (EPC) control for damage. If the bracket is damaged, Solenoid And Clean Main replace both the bracket and solenoid. Control (Includes Time For 5. If the bracket is not damaged, inspect the Road Test) – 4R44E Or solenoid for the affected date code (refer to the 5R55E following Manufacturing Date Code Chart) and 991610B For Line Pressure And ID marking (Figure 1, Views 1, 2, and 3). If the Pinpoint Tests, Use “A” solenoid is one of the affected, replace it. Time As Outlined In The Warranty And Policy MANUFACTURING DATE CODE Manual Date Code Month/Year DEALER CODING 868xx August 1998 CONDITION 869xx September 1998 BASIC PART NO. CODE 870xx October 1998 7G383 01 871xx November 1998 OASIS CODES: 501000, 502000, 50300