Engine Controls - Remove/install/overhaul - 4.2L: Removal & Installation Ford Econoline E350

Removal & Installation

Disconnect negative battery cable. Raise and support vehicle. Unplug Crankshaft Position (CKP) sensor wire connector from engine harness. (Scheme 16) Remove CKP sensor mounting screws. Remove CKP sensor. To install, reverse removal procedure.

Scheme 16

Disconnect negative battery cable. Remove any component necessary to gain access to PCM. For PCM location, see PCM LOCATION table. Loosen PCM connector retaining bolt (if equipped). Unplug harness connector from PCM. Remove 2 PCM mounting bolts. Remove PCM cover and PCM. To install, reverse removal procedure.

PCM LOCATION

1. Disconnect the battery ground cable. Partially drain the cooling system. Remove the air cleaner assembly. Disconnect the engine harness from the water tube and remove the bolt. Position the heater water outlet tube aside.
2. CMP sensor is located on camshaft sychronizer. (Scheme 17) Disconnect the CMP sensor electrical connector. Mark orientation of the CMP sensor electrical connector. Remove the bolts from CMP sensor and remove the CMP sensor. To install, reverse removal procedure. Tighten CMP sensor to specification. See «TORQUE SPECIFICATIONS»(ref-24210-S13895383842001010400000).

Scheme 17

Removal

1. Rotate the crankshaft until the No. 1 cylinder is at Top Dead Center (TDC) of the compression stroke. Remove the CMP sensor. See «CAMSHAFT POSITION (CMP) SENSOR»(ref-24210-S33334053822001010400000) .
2. Disconnect the Exhaust Gas Recirculation (EGR) valve vacuum hose. Remove the EGR valve tube upper fitting. Remove the EGR valve nut and the bolts. Remove the EGR valve and adapter assembly. Remove the camshaft synchronizer retaining bolt.
3. Disconnect the coolant hose from the water outlet tube and position the tube out of the way. Remove the camshaft synchronizer.

Installation

1. Install the Syncro Positioning Tool (T96T-12200-A) on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing. (Scheme 17) During installation, the arrow on the syncro positioning tool will rotate clockwise as the gears engage. Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment tool is 54 degrees from the centerline of the engine.
2. Position the water outlet tube and connect the coolant hose. Install the camshaft synchronizer retaining bolt. Reuse the EGR valve adapter gasket and install the EGR valve and adapter assembly. Install the EGR valve tube upper fitting.
3. Connect the EGR valve vacuum hose. Install the CMP sensor. See «CAMSHAFT POSITION (CMP) SENSOR»(ref-24210-S33334053822001010400000).

Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove fuel tank. Using fuel tank lock ring wrench, carefully rotate lock ring counterclockwise to release pump. See FUEL TANK LOCK RING WRENCH IDENTIFICATION table. Remove fuel pump from tank.

FUEL TANK LOCK RING WRENCH IDENTIFICATION

Wipe seal area of tank clean. Position new "O" ring seal onto pump, using grease to hold it in position. Position fuel pump in tank so fuel return hose is not kinked. Install lock ring. DO NOT overtighten pump lock ring, as it may leak. Install fuel tank.

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-24210-S10080664952001010400000). Remove throttle body assembly. See «THROTTLE BODY»(ref-24210-S23918276172001010400000).
2. Disconnect fuel supply and return line connections at fuel supply manifold. Remove fuel supply manifold retaining bolts. Remove fuel supply manifold with injectors by pulling upwards on injectors using a rocking action. Carefully disengage fuel injectors from supply manifold. To install, reverse removal procedure. (Scheme 18)

Scheme 18

Remove fuel supply manifold. See FUEL SUPPLY MANIFOLD . Disconnect wiring harness from injector(s). Remove injector retaining clips(s). Remove injectors from fuel supply manifold, using a rocking/pulling motion.

Lubricate NEW injector "O" rings with light oil. DO NOT use silicone grease. To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-24210-S10080664952001010400000) .
2. Remove vacuum hose from fuel pressure regulator. Remove 2 mounting screws from fuel pressure regulator. Remove fuel pressure regulator, gasket, and "O" ring.

Lubricate "O" ring with light oil. DO NOT use silicone grease. Ensure regulator and manifold gasket surfaces are clean and dry. To complete installation, reverse removal procedure.

Unplug electrical connector from HO2S. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Carefully remove HO2S sensor from exhaust pipe.

When replacing HO2S, coat threads with anti-seize compound before installation. New sensors should already have this compound applied to threads. Install HO2S sensor. Reconnect wiring connector to HO2S. Reconnect negative battery terminal.

Removal & Installation (Fuel Line Coupler)

1. Disengage locking tabs on connector retainer. Separate retainer halves. Disengage fitting from regulator by pushing fitting toward regulator and inserting Fuel Line Coupling Key (T90P-9550-A). (Scheme 19)
2. To reconnect fuel line coupling, push coupler tube assembly firmly into coupler body recess until fully engaged. Pull gently on both ends of coupler to ensure engagement. See «FUEL SUPPLY MANIFOLD»(ref-24210-S09010386502001010400000).

Scheme 19

1. Remove air cleaner and duct assembly. Disconnect accelerator cable and spring from throttle lever. Disconnect cruise control actuator (if equipped). Remove accelerator cable bracket and set aside.
2. Disconnect electrical connectors and vacuum lines as necessary. Remove 2 bolts and 2 nuts retaining throttle body assembly to intake manifold. On all models, remove throttle body.

Clean gasket mating surfaces. Clean and oil bolt threads. Install NEW gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.