How to Overhaul & Installation - Gasoline the Engine Controls - Removal Ford Econoline I

INTRODUCTION

Note. References to Econoline include Cutaway and RV Cutaway. References to Pickup include Cab & Chassis.

Removal, overhaul, and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

COMPUTERIZED ENGINE CONTROLS

POWERTRAIN CONTROL MODULE

PCM LOCATION

Removal & Installation (F150/F250 Light Duty)

Disconnect the battery ground cable. Disconnect the solenoid electrical and vacuum connections. Disconnect the windshield washer hose locator. Remove the solenoid bracket. Loosen the retainer and disconnect the Powertrain Control Module (PCM) electrical connector. Remove the right front door sill plate. Remove the right kick panel. Remove the clip and remove the PCM. To install, reverse removal procedure.

Removal & Installation (All Others)

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.

CAMSHAFT POSITION (CMP) SENSOR

Camshaft position sensor is used for timing pulsing of fuel injectors. Camshaft sensor signal is also used by Coil On Plug (COP) engines to determine firing of ignition coils. See CAMSHAFT POSITION (CMP) SENSOR or CMP SYNCHRONIZER under FUEL SYSTEM (GASOLINE ENGINES) .

CRANKSHAFT POSITION (CKP) SENSOR

Note. Engine front cover design precisely locates CKP sensor. No CKP sensor adjustment is necessary.

Removal & Installation

Disconnect negative battery cable. Raise and support vehicle. Unplug Crankshaft Position (CKP) sensor wire connector from engine harness. (Scheme 1) Remove CKP sensor mounting screws. Remove CKP sensor. To install, reverse removal procedure.

Scheme 1

Removal & Installation (3.3L)

Remove the lower intake manifold. See LOWER INTAKE MANIFOLD under REMOVAL & INSTALLATION in 3.3L V6 - VIN T article in ENGINES. Disconnect the heater core hose from the coolant crossover tube. Release the clamp and remove the lower radiator hose from the coolant crossover tube. Remove the water bypass hose from the thermostat housing. Remove the coolant crossover tube. (Scheme 2) Disconnect the Knock Sensor (KS) electrical connector. Remove the KS bolt and remove KS.

Scheme 2

Removal & Installation (5.4L)

Remove intake manifold. See appropriate MECHANICAL article in ENGINES. Disconnect electrical connector. Remove retaining bolt and remove sensor. To install, reverse removal procedure.

Disconnect the Coil On Plug (COP) electrical connectors. Remove the COP bolt and Remove the COP. Remove any foreign debris from the spark plug wells with compressed air. Remove the spark plugs. To install, reverse removal procedure.

Removal & Installation (Windstar 3.8L)

Note. On Windstar 3.8L, spark plugs on right side of engine are accessed from under vehicle.

Removal & Installation (4.6L)

Remove intake manifold. See INTAKE MANIFOLD under REMOVAL & INSTALLATION in 4.6L V8 - VIN W & 6 article in ENGINES. Disconnect Cylinder Head Temperature (CHT) sensor electrical connector. Remove CHT sensor. To install, reverse removal procedure.

Removal & Installation (2.5L)

CMP sensor is mounted on left front of engine, behind oil pump sprocket. Disconnect negative battery cable. Remove accessory drive belt. Disconnect CMP sensor connector. Remove CMP sensor mounting bolts. Remove CMP sensor. To install, reverse removal procedure.

Scheme 3

1. CMP sensor is located on top of engine, near intake manifold. (Scheme 3)
2. Disconnect negative battery cable.
3. Before removing, note position of electrical connector on CMP sensor. Disconnect CMP sensor electrical connector.
4. Remove CMP sensor screws and CMP sensor. To install, reverse removal procedure. Ensure CMP sensor electrical connector is pointing in original direction. Tighten CMP sensor to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__torque-specifications).

Note. If the synchronizer is turned while removing the CMP sensor, it must be re-aligned before CMP sensor is installed. See CMP SYNCHRONIZER .

Removal & Installation (3.3L Villager)

CMP sensor is located inside of distributor and is not serviceable. If CMP sensor is defective, replace distributor.

Scheme 4

1. Disconnect negative battery cable. Partially drain cooling system
2. Remove air cleaner assembly.
3. Disconnect fuel charging wiring harness from heater water outlet tube. Remove heater water outlet tube bolt. (Scheme 4) Position water outlet tube aside.
4. Noting installed position of CMP sensor electrical connector, disconnect CMP sensor connector.
5. Remove CMP sensor mounting bolts. Remove CMP sensor from CMP synchronizer assembly. (Scheme 3)
6. To install CMP sensor, reverse removal procedure. Tighten CMP sensor-to-synchronizer assembly bolts to 40-70 INCH lbs. (4.5-7.8 N.m). Tighten water outlet tube hold down bolt to 71-97 INCH lbs. (8-11 N.m).
7. Fill and bleed air from cooling system. See «BLEEDING»(/ford/econoline/i-1985-2013/remont/accessory-drive-belts/#engine-cooling-system-specifications-drive-belt-routing__bleeding) in SPECIFICATIONS & DRIVE BELT ROUTING article in ENGINE.

Removal (3.0L)

1. Rotate crankshaft until No. 1 piston is at TDC of compression stroke. Ensure TDC mark on crankshaft aligns with timing mark. Note position of electrical connector on CMP sensor.
2. Disconnect negative battery cable. Remove CMP sensor from synchronizer. See «REMOVAL & INSTALLATION (3.0L, 3.8L, 4.0L & 5.0L)»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal).
3. Remove camshaft synchronizer bolt. (Scheme 13)
4. Lift camshaft synchronizer assembly out of block.

Scheme 5

1. Install Synchro Positioning Tool (303-589) on synchronizer by rotating tool until it engages the notch in the camshaft synchronizer housing and the armature. (Scheme 5)
2. Install camshaft synchronizer housing assembly so the arrow on the Synchro Positioning Tool (303-589) is 38 degrees from centerline of the engine with sychronizer assembly fully installed. (Scheme 6)and (Scheme 7). During installation the arrow on the synchro positioning tool will rotate clockwise until the oil pump intermediate shaft and camshaft gear engages.
3. Install and tighten camshaft synchronizer hold down bolt. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__torque-specifications).
4. Install CMP sensor to camshaft synchronizer. See «REMOVAL & INSTALLATION (3.0L, 3.8L, 4.0L & 5.0L)»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal).

Removal (3.8L)

1. Rotate crankshaft until No. 1 cylinder is at TDC of compression stroke.
2. Note position of CMP sensor electrical connector. Remove CMP sensor. See «REMOVAL & INSTALLATION (3.0L, 3.8L, 4.0L & 5.0L)»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal).
3. Remove the camshaft synchronizer bolt. (Scheme 13)
4. Remove camshaft synchronizer from engine block.

Installation (3.8L)

1. Install Synchro Positioning Tool (303-630) on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing and the armature. (Scheme 17)
2. Install camshaft synchronizer housing assembly so the arrow on the Install Synchro Positioning Tool (303-630) is 54 degrees from centerline of the engine. (Scheme 8)
3. Install and tighten synchronizer hold down bolt. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__torque-specifications).
4. Remove Synchro Positioning Tool (303-630). Install CMP sensor to camshaft synchronizer. See «REMOVAL & INSTALLATION (3.0L, 3.8L, 4.0L & 5.0L)»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal).

Removal (4.0L)

1. Position crankshaft to TDC of cylinder No. 1 compression stroke. Note position of electrical connector on CMP sensor. Installation requires that the connector be located in the same position.
2. Disconnect negative battery cable.
3. On Explorer models only, remove upper intake manifold. See «REMOVAL & INSTALLATION (4.0L VIN X)»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__removal-installation-40l-vin-x) under UPPER INTAKE MANIFOLD.
4. On all models, remove CMP sensor. See «REMOVAL & INSTALLATION (3.0L, 3.8L, 4.0L & 5.0L)»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal) .
5. Remove camshaft synchronizer hold-down bolt. Lift camshaft synchronizer from engine block.

Installation (4.0L)

Scheme 6

Scheme 7

Scheme 8

1. It is very important to coat the gear on the camshaft synchronizer with engine oil prior to installation. Failure to do so could result in gear failure upon engine start up.
2. Install Synchro Positioning Tool (303-638) on camshaft synchronizer by rotating the tool until it engages into notch in camshaft synchronizer housing and the armature. (Scheme 9)
3. Install camshaft synchronizer into engine block with Synchro Positioning Tool (303-638) attached. The arrow on the special tool should be pointing to 60 degrees off the engine centerline. (Scheme 10)
4. Rotate Synchro Positioning Tool (303-638) clockwise slightly to engage the oil pump the oil pump intermediate shaft. Continue downward motion, twisting the tool lightly until the synchronizer gear engages the camshaft gear.
5. With the synchronizer clamp flange seated against the engine block, the arrow on the Synchro Positioning Tool (303-638) points 15 degrees from centerline of engine. (Scheme 11)
6. Install hold-down. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__torque-specifications).
7. Remove Synchro Positioning Tool (303-638) from camshaft synchronizer. Install CMP sensor to synchronizer. See «REMOVAL & INSTALLATION (3.0L, 3.8L, 4.0L & 5.0L)»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal). Connect negative battery cable.
8. On Explorer models, install upper intake manifold. See «REMOVAL & INSTALLATION (4.0L VIN X)»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__removal-installation-40l-vin-x) under UPPER INTAKE MANIFOLD.

Removal (4.2L)

Scheme 9

Scheme 10

Scheme 11

1. Rotate crankshaft until No. 1 cylinder is at TDC of compression stroke.
2. Remove CMP sensor. See «REMOVAL & INSTALLATION (4.2L)»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal).
3. Disconnect EGR valve vacuum hose. Remove EGR valve tube upper fitting.
4. Remove EGR valve bolts and nut. Remove EGR valve. (Scheme 12)
5. Remove CMP synchronizer bolt. (Scheme 13)
6. Lift out CMP synchronizer. Oil pump drive shaft may come out with camshaft synchronizer. (Scheme 14)

Installation (4.2L)

Scheme 12

1. Install Synchro Positioning Tool (T96T-12200-A) on camshaft synchronizer by rotating tool until it engages notch in camshaft synchronizer housing. (Scheme 15)
2. With No. 1 cylinder at TDC of compression stroke, install camshaft synchronizer housing assembly so the arrow on the Synchro Positioning Tool (T96T-12200-A) is 54 degrees from centerline of engine. (Scheme 16)
3. Install and tighten the synchronizer hold down bolt. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__torque-specifications).
4. Install EGR valve and adapter gasket. Install bolts and nut and tighten to 89 INCH lbs. (10 N.m). Install EGR valve tube upper fitting. Tighten fitting to 25-35 ft. lbs. (34-47 N.m). Install EGR vacuum hose.
5. Remove Synchro Positioning Tool (T96T-12200-A). Install CMP sensor. See «REMOVAL & Installation (4.2L)»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal).

Removal (5.0L)

1. Set engine so cylinder No. 1 is at TDC on compression stroke. Disconnect negative battery cable.
2. Note position of electrical connector for reassembly reference. Disconnect CMP sensor electrical connector. Remove 2 screws and CMP sensor from synchronizer. (Scheme 3)
3. Place reference marks on camshaft synchronizer housing and engine. Remove synchronizer bolt and clamp. (Scheme 13)
4. Remove camshaft synchronizer from engine block.

Installation (5.0L)

Scheme 13

1. Install Synchro Positioning Tool (303-630) on camshaft synchronizer. (Scheme 17) Ensure aligning tabs and notches are properly engaged.
2. Ensure cylinder No. 1 is at TDC on compression stroke. Install camshaft synchronizer assembly into engine. Ensure arrow on Synchro Positioning Tool (303-630) is pointing directly forward (parallel to crankshaft centerline). (Scheme 18)
3. Install hold-down clamp and tighten bolt to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__torque-specifications). Remove Synchro Positioning Tool (303-630).
4. Remove Synchro Positioning Tool (303-630). Install CMP sensor on synchronizer. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__torque-specifications). Reconnect wiring to CMP sensor. Ensure electrical connector is facing front of engine. Connect negative battery cable.

FUEL SYSTEM PRESSURE RELEASE

1. Remove fuel tank cap. Using Fuel Pressure Gauge (T80L-9974-B), release pressure from system at pressure relief valve (Schrader valve) located on fuel injection manifold rail.
2. If fuel pressure gauge is not available, disconnect Inertia Fuel Shutoff (IFS) switch. See «INERTIA FUEL SHUTOFF (IFS) SWITCH LOCATION»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal) table. Remove fuel filler cap to release fuel tank pressure. Crank engine for 15 seconds to release system pressure.

INERTIA FUEL SHUTOFF (IFS) SWITCH LOCATION

Removal & Installation (Except Explorer & Mountaineer)

Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove fuel tank. Remove screws or lock ring and fuel pump tank unit. Wipe seal area of tank clean. Position NEW seal onto pump mounting flange (if necessary), using grease to hold it in position. Position fuel pump in tank to original position. Install screws or lock ring. DO NOT overtighten lock ring, as it may leak. Install fuel tank. See TORQUE SPECIFICATIONS .

Removal (Explorer & Mountaineer)

Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE .

Scheme 14

1. Remove fuel tank.
2. Clean the area around the fuel pump assembly mounting flange before loosening bolts.
3. Disconnect the electrical connector from the fuel pressure transduce.
4. Remove the fuel pump assembly mounting flange bolts and remove the fuel pump assembly.

Installation (Explorer & Mountaineer)

1. Clean the fuel pump assembly mounting flange and the fuel tank mounting surfaces.
2. Install the fuel pump assembly. Position the fuel pump assembly in the tank. Align the arrow on the fuel pump flange with the dimple on the fuel tank. Install the 6 bolts. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__torque-specifications) .
3. Connect the electrical connector to the fuel pressure transduce, and connect all hoses and lines (as necessary).
4. Install the fuel tank. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__torque-specifications) .

Fuel Filter Removal & Installation - Econoline & Cutaway

1. Disconnect the battery ground cable.
2. Relieve the fuel system pressure.
3. Disconnect the fuel lines from the fuel filter.
4. Loosen the clamp and slide the fuel filter rearward to remove.

To install, follow the removal procedure in reverse order.

Fuel Filter Removal & Installation - Expedition & Navigator

1. Relieve the fuel pressure.
2. Raise and support the vehicle.
3. Use the Fuel Line Disconnect tool to disconnect fuel lines from the fuel filter
4. Loosen the worm clamp and slide the fuel filter forward to remove.

To install, reverse the removal procedure.

Fuel Filter Removal & Installation - Explorer & Mountaineer

1. Relieve the fuel pressure.
2. Raise and support the vehicle.
3. Remove the fuel filter Disconnect the fuel lines. Remove the fuel filter from the fuel filter support.
4. Install the fuel filter. Position the fuel filter in the fuel filter support. Install the fuel lines.

Fuel Filter Removal & Installation - F 150 & F 250

1. Relieve the fuel pressure.
2. Raise and support the vehicle.
3. Use the Fuel Line Disconnect Tool to disconnect the fuel lines from the fuel filter.
4. Install the fuel filter. NOTE: When installing fuel lines to the fuel filter, push the lines onto the ports until a definite "click" is heard, then pull on the fittings to ensure they are engaged.
5. Connect the fuel lines.

Fuel Filter Removal & Installation - F Series, Cab & Chassis

1. Relieve the fuel pressure.
2. Raise and support the vehicle.
3. Use the fuel line disconnect tool to disconnect the fuel lines from the fuel filter.
4. When installing fuel lines to the fuel filter, push the lines onto the ports until a definite "click" is heard, then pull on the fittings to make sure they are engaged.
5. Install the fuel filter.
6. Connect the fuel lines.

Fuel Filter Removal & Installation - Ranger

1. Relieve the fuel pressure.
2. Raise and support the vehicle.
3. On flexible fuel vehicles, disconnect the push-connect and hairpin clip fittings.
4. Remove the filter from the bracket.
5. On gasoline vehicles, disconnect the push connect fittings and remove the filter from the bracket.

To install, reverse the removal procedure.

Fuel Filter Removal & Installation - Villager

1. Relieve the fuel pressure.
2. Raise and support the vehicle.
3. Remove the fuel filter splash shield. Remove the nuts. Remove the bolts.
4. Remove the fuel filter. Disconnect the fuel lines from the fuel filter. Remove the fuel filter bracket nuts.

Note. Make sure to install the fuel filter with the arrow facing forward.

To install, reverse the removal procedure.

Fuel Filter Removal & Installation - Windstar

1. Disconnect the battery ground cable.
2. Relieve the fuel pressure.
3. Raise the vehicle.
4. Disconnect the R-clip fittings.
5. Remove the bolt and remove the filter and bracket. Remove the filter from the bracket.

To install, reverse the removal procedure.

Removal (2.5L)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__fuel-system-pressure-release). Remove upper intake manifold and throttle body assembly. See «UPPER INTAKE MANIFOLD»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__upper-intake-manifold).
2. Disconnect fuel supply and return lines. Disconnect wiring harness from injectors. Remove fuel supply manifold bolts. Carefully disengage manifold and fuel injectors from engine. Remove manifold and injectors. Remove injectors from fuel rail by using a rocking motion. (Scheme 21)

1. To install, reverse removal procedure. Lubricate NEW "O" rings with light oil. Install 2 "O" rings onto each injector (one per injector if injectors were not removed from fuel rail). DO NOT use silicone grease.
2. Install fuel rail and injectors in intake manifold. Ensure injectors are seated. Secure fuel manifold assembly with retaining bolts. Connect injector wiring harness.

Note. On Villager, some fuel injectors can be accessed and removed without removing fuel rail.

Removal (3.3L Villager)

Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. To remove rear fuel injectors, remove upper intake manifold. See UPPER INTAKE MANIFOLD . Disconnect spark plug wires. Remove air tube screws and hose clamps. Disconnect fuel injector electrical connector. Move fuel injector harness aside. Remove fuel injector screws. Remove fuel injector(s).

Replace injector "O" rings, grommet and insulator. Lubricate NEW injector "O" rings with light oil. DO NOT use silicone grease. Carefully install fuel rail and tighten injector caps to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__fuel-system-pressure-release). Disconnect negative battery cable. Partially drain cooling system. Remove power steering reservoir bracket. Remove accelerator cable splash shield. Disconnect vacuum hose from fuel pressure regulator.
2. Disconnect fuel supply and return line connections at fuel supply manifold. Disconnect coolant inlet hose. Disconnect fuel injector wiring harness connectors. Remove coolant hose. Remove brake booster bracket and tube. Remove PCV hose.
3. Remove EGR valve-to-exhaust manifold tube. Disconnect EGR valve and EGR transducer hoses. Disconnect Vapor Management Valve (VMV) hose. Remove fuel rail bolts. Remove fuel rail with injectors. Remove injectors by using a rocking motion. (Scheme 21) To install, reverse removal procedure.

Removal & Installation (5.4L & 6.8L)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__fuel-system-pressure-release). Disconnect negative battery cable. Disconnect vacuum hose from fuel pressure regulator. Remove fuel hose clamps.
2. Disconnect fuel supply and return line connections at fuel supply manifold. Disconnect fuel injector wiring harness connectors. Remove PCV hose.
3. Remove EGR valve-to-exhaust manifold tube. Disconnect EGR valve and EGR transducer hoses. Disconnect Vapor Management Valve (VMV) hose. Remove fuel supply manifold retaining bolts. Remove fuel supply manifold with injectors by pulling on injectors while using a rocking motion. Carefully disengage fuel injectors from supply manifold. To install, reverse removal procedure. (Scheme 21)

Scheme 15

Removal (All Others)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__fuel-system-pressure-release). Remove throttle body and upper intake manifold assembly. See «UPPER INTAKE MANIFOLD»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__upper-intake-manifold). Disconnect fuel supply and return lines.
2. Disconnect wiring harness at fuel injectors. Disconnect vacuum hose from fuel pressure regulator. Remove fuel rail bolts. Carefully disengage fuel injectors by lifting and gently rocking rail. (Scheme 21)
3. Remove injectors from fuel rail, using a slight lifting/rocking motion. Place removed components in a clean container to avoid dirt or other contamination.

Lubricate NEW injector "O" rings with light oil. DO NOT use silicone grease. Carefully install fuel supply manifold and injectors into lower manifold, one side at a time. To complete installation, reverse removal procedure.

Disconnect negative battery cable. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . On 4.2L engines, remove upper intake manifold. See INTAKE MANIFOLD . On all engines, remove vacuum hose from fuel pressure regulator. Remove 2 mounting screws from fuel pressure regulator. Remove fuel pressure regulator. Remove and discard "O" ring (and gasket if applicable).

Lubricate NEW "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 cable. To complete installation, reverse removal procedure.

Push Connect Coupling

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__fuel-system-pressure-release). Disconnect safety clip from male hose. (Scheme 22) Install Fuel Line Disconnect (T90T-9550-S) and push it into fitting. Separate fittings.
2. Before installation, lubricate tube end with clean engine oil. Align tube to fitting and push until a click is heard. Pull on fitting to ensure engagement. Install safety clip.

Scheme 16

"R" Clip Coupling

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__fuel-system-pressure-release). Remove shipping tab by bending tab downward. Spread "R" clip and push clip into fitting. (Scheme 23) Separate fitting from tube.
2. Before installation, lubricate male tube end with clean engine oil. Insert "R" clip into fitting. Align tube and fitting. Insert tube into fitting and push together until a click is heard. Pull on connection to ensure engagement.

Scheme 17

Spring Lock Coupling

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__fuel-system-pressure-release). Place indicated spring lock coupler over coupling. See «SPRING LOCK COUPLER IDENTIFICATION»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal) table. To release female fitting from garter spring, push coupler along tube into coupling. see scheme 24
2. Pull spring lock coupling apart. Remove coupler from disconnected spring lock coupling. Check for damaged garter spring and "O" rings. Wipe end of lines with clean cloth.
3. To install, place NEW "O" rings onto tube. Lubricate ends of lines with clean engine oil. Locate White indicator ring (if equipped), which may have slipped down length of tube. Insert White indicator ring into cage of male fitting.
4. Push fitting together with a slight twisting motion. White indicator ring will pop free of cage to indicate that male fitting is properly seated over flared end of female fitting.

SPRING LOCK COUPLER IDENTIFICATION

Scheme 18

1. Remove air cleaner and duct assembly. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__fuel-system-pressure-release) under FUEL SYSTEM (GASOLINE ENGINES).
2. Disconnect accelerator cable from throttle lever. Disconnect cruise control actuator (if equipped). Remove accelerator cable bracket and set aside.
3. Disconnect electrical connectors and vacuum lines as necessary. Remove 4 throttle body retaining bolts. Remove throttle body assembly.

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.

Removal & Installation (3.0L Windstar)

See UPPER INTAKE MANIFOLD .

Remove air cleaner and duct assembly. Partially drain cooling system. Disconnect accelerator cables, electrical connectors and hoses from throttle body. Remove 4 bolts and throttle body. Clean gasket mating surfaces. To install, reverse removal procedure using NEW gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Removal (3.8L & 4.2L)

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.

DO NOT scrape gasket mating surfaces, throttle body gasket is part of upper intake manifold. Install bolts and nuts and tighten to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

1. Remove air cleaner and duct assembly. Disconnect accelerator cable from throttle lever. Disconnect cruise control actuator (if equipped). Remove accelerator cable bracket and set aside.
2. Disconnect electrical connectors, vacuum lines and vapor hose as necessary. Remove 4 bolts (or screws) retaining throttle body assembly to intake manifold. 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.

UPPER INTAKE MANIFOLD

Note. Models not listed do not require upper intake manifold to be removed to access fuel system or engine control components.

1. Disconnect negative battery cable. Disconnect air temperature sensor. Remove air cleaner outlet tube. Remove splash shield and disconnect accelerator and cruise control cables. Disconnect harness connectors, vacuum hoses and vapor hose from throttle body.
2. Disconnect vacuum hoses from manifold vacuum tree. Disconnect and plug coolant hose from intake manifold. Remove EGR tube and EGR valve. Remove vapor tube. Evenly loosen 7 bolts and remove upper intake manifold.

Tighten upper intake manifold bolts evenly in 2 passes in sequence. see scheme 25 Tighten to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 19

Removal (3.0L Ranger)

1. Disconnect negative battery cable. Remove air cleaner outlet tube. Disconnect accelerator and cruise control cables from throttle body.
2. Disconnect harness connectors from throttle body and upper intake manifold. Remove EGR valve. Disconnect vacuum hoses from EGR valve and EGR solenoid. If necessary, remove bolts and throttle body.
3. Remove ignition coil mounting bolts and coil assembly. Remove EGR transducer. Disconnect evaporative emissions hose. Evenly loosen 3 bolts and 3 stud bolts. Remove upper intake manifold.

Tighten upper intake manifold bolts evenly in 2 passes in sequence to specification. see scheme 26 See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 20

Removal (3.0L Windstar)

1. Disconnect negative battery cable. Remove air cleaner duct hose. Partially drain engine coolant system. Relieve fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__fuel-system-pressure-release) . Remove cowl assembly. Position wire harness aside. Disconnect fuel lines, vacuum hoses and electrical connectors. Disconnect accelerator and speed control cables. Remove throttle body. Position differential pressure feedback sensor aside.
2. Remove EGR tube. Disconnect PCV hose. Remove generator support brace. Remove 6 upper intake manifold assembly bolts. Remove upper intake manifold assembly and gasket.

Clean gasket mating surfaces, using caution not to gouge plastic or aluminum parts. Install NEW gasket. Use guide pins and install upper intake manifold. Tighten bolts in sequence to specification. see scheme 26 See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

1. Drain cooling system. Disconnect negative battery cable. Remove air duct and resonance chamber. Disconnect MAP/BARO, TPS and ISC electrical connectors. Disconnect coolant hose.
2. Disconnect EVAP vacuum hose. Disconnect fuel regulator vacuum hose. Disconnect spark plug wires and move aside. Disconnect vacuum reservoir vacuum hose. Position wire harness and bracket aside. Disconnect speed control and accelerator cables. Position speed control and accelerator cables aside. Disconnect brake booster check valve vacuum hose.
3. Disconnect EGR modulator tube. Disconnect EGR tube from EGR valve. Disconnect fuel supply and return line bracket from EGR adapter plate. Unclip MAP/BARO solenoid vacuum hose. Disconnect EGR adapter plate from bracket. Disconnect MAP/BARO vacuum hoses. Remove PCV breather tube bracket bolts. Disconnect PCV breather hose from breather tube. Disconnect EGR temperature sensor electrical connector. Disconnect EVAP purge solenoid electrical connector.
4. Remove upper intake manifold bolts. Reposition upper intake manifold to access bottom of manifold. Disconnect coolant and vacuum hoses. Disconnect PCV vacuum hose. Remove upper intake manifold. Remove upper intake manifold gasket. To install, reverse removal procedure.

1. Remove cowl. Remove air cleaner outlet tube. Disconnect accelerator and speed control cables. Position accelerator cable bracket aside. Disconnect IAC and TPS connectors. Disconnect evaporative emission return tube. Remove fuel line retaining clip and wire harness retainers. Disconnect brake booster vacuum hose. Disconnect electronic vacuum regulator connectors. Disconnect all vacuum hoses.
2. Disconnect EGR sensor, PCV hose, and spark plug wires. Remove upper intake manifold bolts. Remove upper intake manifold. Remove upper intake manifold spacer.

Ensure gasket surfaces are clean before using a NEW upper intake manifold gasket. Position upper intake manifold onto lower intake manifold. Evenly tighten bolts to specification. see scheme 27 See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 21

Removal & Installation (4.0L VIN E)

1. Disconnect negative battery cable. Remove air cleaner outlet tube. Disconnect accelerator cable and cruise control linkage from throttle body. Remove accelerator cable bracket.
2. Disconnect hoses from upper intake manifold and intake manifold tuning valve. Evenly loosen upper intake manifold bolts. Disconnect left and right fuel vapor hoses. Remove upper intake manifold. Inspect "O" rings and replace as necessary.
3. To install, evenly tighten upper intake manifold bolts starting in center and working outward in a crisscross pattern. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__torque-specifications) . To complete installation, reverse removal procedure.

Removal & Installation (4.0L VIN X)

1. Disconnect negative battery cable. Remove air cleaner outlet tube. Disconnect accelerator and cruise control cable from throttle body. Remove accelerator cable bracket.
2. Disconnect PCV and vacuum hoses from upper intake manifold and throttle body. Disconnect ignition coil electrical connector and secondary ignition wires.
3. Disconnect electrical connectors from throttle position sensor, idle air control valve EGR solenoid and EGR backpressure transducer.
4. On Explorer, remove EGR tube and EGR valve. On all models, evenly loosen upper intake manifold nuts. To install, replace upper intake manifold gasket (if necessary). Install upper intake manifold bolts and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__torque-specifications) . To complete installation, reverse removal procedure.

Scheme 22

1. Disconnect negative battery cable. Remove air cleaner outlet tube. Disconnect accelerator and cruise control cable from throttle body.
2. Disconnect harness connectors and vacuum hoses from upper intake manifold. Disconnect PCV hose from upper intake manifold. If necessary, remove throttle body nuts and throttle body. Evenly loosen 12 upper intake manifold bolts. Remove upper intake manifold. Inspect gaskets and replace as necessary.

Tighten upper intake manifold bolts in sequence to specification. see scheme 28 See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Remove air cleaner outlet tube. Disconnect IAC electrical connector. Remove accelerator control splash shield. Disconnect TP sensor electrical connector. Disconnect accelerator cable from throttle linkage. Remove accelerator and cruise control cables from retaining clip. Remove accelerator cable bracket.
2. Disconnect EGR valve vacuum connector. Disconnect fuel pressure regulator vacuum hose. Disconnect 2 pressure transducer hoses. Disconnect upper EGR valve-to-exhaust manifold tube fitting. Disconnect Engine Vacuum Regulator (EVR) electrical and vacuum connectors. Disconnect EGR backpressure transducer electrical connector. Remove ignition coil bracket. Disconnect accelerator cable from upper intake manifold retaining clips. Remove intake manifold cover plate.
3. Remove upper intake manifold bolts in reverse of tightening sequence. see scheme 29 Disconnect 2 vacuum connections at front of intake manifold. Disconnect Vapor Management Valve (VMV) purge line. Disconnect brake booster vacuum supply line at left rear upper intake connection. Disconnect PCV hoses. Remove upper intake manifold.

Scheme 23

1. Replace upper intake manifold gaskets (if necessary). Reconnect all hoses and electrical connectors.
2. Install upper intake manifold bolts and tighten in sequence to specification. see scheme 29 See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-gasoline-the-engine-controls-removal__torque-specifications). To complete installation, reverse removal procedure.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• COMPUTER RELEARN PROCEDURES
• INTAKE MANIFOLD
• BLEEDING
• INTAKE MANIFOLD
• FUEL SYSTEM (GASOLINE ENGINES)
• REMOVAL & INSTALLATION (4.0L VIN X)
• TORQUE SPECIFICATIONS
• FUEL SYSTEM PRESSURE RELEASE
• UPPER INTAKE MANIFOLD