Things I learned from my 4.0 ohv engine rebuild

[Maniak]

I got my clown motor built and it is running in the explorer..

Before I get to the pics.. Here are a few things I picked up using a 91 donor motor to rebuild and put into my '92

• The Wire Harness connector that connects the engine harness to the under hood harness is different between the '91 and '92 explorer
• The A/C compressor for a '92 explorer has guide pins while the a/c compressor from a '91 does not. This means that if you use a '91 a/c compressor bracket that you need to pull the guide pins out of the a/c compressor
• The #1 cylinder is on the passenger side (I always thought it was on the drivers side)
• '91 Explorers have two different serpantine(sp?) belt sizes. The short one for a '91 explorer will not fit a '92 explorer
• Check the lower intake/timing cover clearance. I had to grind a little off the lower intake since it was hitting the timing cover which could cause issues with sealing
• Check for clearance between the drivers head and an advanced adapters 7004r adapter ring. The head/adapter were touching so I clearanced the adapter to play it safe
• Fuel lines/Fuel Pressure regulators for a '91 and a '92 are different. The fuel rail was the same, but the connectors to the regulator were different

Thats all that I can think of at this moment.. if I remember more later I'll add them.. Overall, it wasn't bad.. If I would have used the long block off the '91 and not some brackets etc then this would have been very straight forward.

All in all, it went pretty well.. We did break one exhaust bolt (broke it after we took the exhaust out of the truck).. We cut the exhaust off a in front of the cat and took the engine/exhaust out in one piece. We lost an o-ring on an injector when we put on the fuel rail.. (that put gas everywhere when we were checking the fuel system for leaks). It took longer that we liked to get oil pressure, but we cranked the engine over for more than a minute using the starter (in 10 second incriments).. It still took almost 2 minutes to get oil pressure once it started (good thing we assembled/prelubed everything with lucas)

Now for the pics..

 

[pope_face]

Well, it certainly is bright... not my style, but that's a clean engine.

Looks good.

 

[schmidlkofer]

ha makes me wanna pull mine and paint it...uhhh red blue and black maybe kidding.

 

[wolfnutts]

wow what purty colors do u have any pics of the engine an trans out of trk all hooked up ??
i cant tell from ur pic but are both ac lines running across front of engine ?? as im sure u know one line on a 1991 runs across tha back of the intake an then up to compressor did u make a custom hose or is that how a 92 routes the ac hose ??

 

[Maniak]

wow what purty colors do u have any pics of the engine an trans out of trk all hooked up ??
i cant tell from ur pic but are both ac lines running across front of engine ?? as im sure u know one line on a 1991 runs across tha back of the intake an then up to compressor did u make a custom hose or is that how a 92 routes the ac hose ??

Factory '92 a/c hose runs behind the engine. Many years ago I replaced the hose (it was leaking) and the new hose ran in front of the engine. I've been using that hose ever since.

Also, I didn't take the trans out of the truck, just the engine and part of the exhuast. I didn't take pic of the completed engine (with water pump etc). The closest I have are the pics in the first post with the engine on the engine stand which is almost completed (no water pump but just about everythign else is on)