Engine Controls - Removal & Installation: Other Ford Explorer III

COMPUTERIZED ENGINE CONTROLS

Disconnect negative battery cable. PCM is located on right rear of engine compartment, mounted on cowl. Loosen PCM connector retaining bolts. Unplug harness connectors from PCM. Remove 2 PCM mounting nuts. (Scheme 19) Remove glovebox. Remove bolt and PCM. To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS.

Scheme 19

Making Changes To The VID Block

A PCM which is programmed may require changes to be made to certain VID information to accommodate vehicle hardware. Refer to PCM/MODULE REPROGRAMMING on the Scan Tool.

CAMSHAFT POSITION SENSOR

Note. Numbers in parenthesis refer to numbers in illustration.

CRANKSHAFT POSITION SENSOR

Note. Numbers in parenthesis refer to numbers in illustration.

Note. Engine design precisely locates Crankshaft Position (CKP) sensor. No CKP sensor adjustment is necessary.

Disconnect negative battery cable. Raise and support vehicle. On 4.6L engines, remove A/C compressor to gain access. On all engines, disconnect Crankshaft Position (CKP) sensor wire connector from engine harness (1). Remove CKP sensor mounting bolt(s) (2). Remove CKP sensor. To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

Scheme 20

Scheme 21

CYLINDER HEAD TEMPERATURE SENSOR

Note. Numbers in parenthesis refer to numbers in illustration.

Remove the generator. Disconnect electrical connector (1) and remove cylinder head temperature sensor (2). (Scheme 22) To install, reverse removal procedure.

Scheme 22

ENGINE COOLANT TEMPERATURE SENSOR

Note. Numbers in parenthesis refer to numbers in illustration.

Disconnect negative battery cable. Drain cooling system. Disconnect Engine Coolant Temperature (ECT) sensor connector (1). (Scheme 23) Release retaining clip (2). Remove ECT sensor (3). To install, reverse removal procedure. Fill and bleed cooling system.

Scheme 23

FUEL TANK PRESSURE SENSOR

Note. Numbers in parenthesis refer to numbers in illustration.

Fuel tank pressure sensor is located on top of fuel tank in fuel vapor hose. Disconnect battery ground cable. Raise on hoist. Disconnect fuel tank pressure sensor connector (1). (Scheme 24) Disconnect fuel vapor hose from each side (2 and 3). Remove fuel tank pressure sensor (4). To install, reverse removal procedure.

Scheme 24

Unplug electrical connector from Heated Oxygen Sensor (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. Tighten HO2S sensor to specification. See TORQUE SPECIFICATIONS . Reconnect wiring connector to HO2S. Reconnect negative battery cable. To complete installation, reverse removal procedure.

INERTIA FUEL SHUTOFF SWITCH

Remove the right front scuff plate and kick panel. Remove the Inertia Fuel Shutoff (IFS) switch connector and 2 retaining bolts. Remove IFS switch. (Scheme 25) To install, reverse removal procedure. Tighten IFS bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 25

KNOCK SENSOR

Note. Numbers in parenthesis refer to numbers in illustration.

Remove intake manifold. See INTAKE MANIFOLD under AIR INDUCTION SYSTEMS. Disconnect knock sensor connector (1). (Scheme 26)or (Scheme 27). Remove knock sensor bolt(s) (2). Remove knock sensor(s) (3). To install, reverse removal procedure.

Scheme 26

Scheme 27

Disconnect negative battery cable. Remove air cleaner outlet tube. (Scheme 28) Disconnect Mass Airflow (MAF) sensor connector. Remove 4 mounting bolts and remove MAF sensor. To install, reverse removal procedure.

Scheme 28

EVAP CANISTER PURGE VALVE

Note. Numbers in parenthesis refer to numbers in illustration.

Disconnect the battery ground cable. Evaporative (EVAP) canister purge valve is located near brake master cylinder. Disconnect the EVAP canister purge valve vacuum hose (1) and fuel vapor hoses (2). (Scheme 29) Disconnect EVAP canister purge valve connector (3). Remove mounting nuts (4) and EVAP canister purge valve (5). To install, reverse the removal procedure. Perform after repair procedure. See AFTER REPAIR PROCEDURE under EMISSION SYSTEMS & SUB-SYSTEMS.

Scheme 29

EVAP CANISTER VENT SOLENOID

Note. Numbers in parenthesis refer to numbers in illustration.

Disconnect the battery ground cable. Evaporative (EVAP) canister vent solenoid is located in engine compartment on inside of left frame rail. Raise vehicle on hoist. Disconnect the EVAP canister vent solenoid electrical connector (1) and vapor hoses (2) and (3). (Scheme 30) Remove EVAP canister purge valve (4). To install, reverse the removal procedure. Perform after repair procedure. See AFTER REPAIR PROCEDURE under EMISSION SYSTEMS & SUB-SYSTEMS.

Scheme 30

IDLE AIR CONTROL VALVE

Note. Numbers in parenthesis refer to numbers in illustration.

Safe Fuel Handling Practices

Fire

1. Report all fires to proper authorities.
2. Flames from methanol or methanol-gasoline blends can be invisible.
3. Know locations of portable fire extinguishers, fire blankets, fire alarms and eye/wash shower facilities and learn how to use them.
4. Use a "B" or "AFFF" (light water) type fire extinguisher to fight flammable liquid fires.

First Aid

1. If gasoline has been swallowed, do not induce vomiting. Seek medical attention immediately!
2. If methanol or a methanol/gasoline blend has been swallowed, induce vomiting under the direction of a physician or Poison Control Center. Seek medical attention immediately!
3. When overcome by vapors, if safe, move victim to fresh air. If not breathing, give artificial respiration or CPR (Cardiopulmonary Resuscitation) as appropriate. Seek medical attention immediately!
4. If splashed in eyes, flush with large amounts of water for 15 minutes. Remove contact lenses, if worn. Seek medical attention.
5. If splashed on skin, remove contaminated clothing. Wash skin thoroughly with soap and water.

Health

1. All fuels can be harmful or fatal if swallowed.
2. Be aware, if fuel is swallowed, onset of serious health effects can be delayed 12 to 24 hours.
3. Fuels and products containing methanol (e.g. windshield washer fluid) can cause blindness if swallowed.
4. All fuel vapors can be harmful if inhaled.
5. All fuels can be harmful if absorbed through skin.
6. All fuels are irritating to eyes and respiratory system.
7. Some fuels made with gasoline contain benzene which is a cancer causing agent.

Handling

1. Use flammable liquid handling precautions.
2. Wear chemical goggles and nitrile gloves (additional protective clothing and equipment may be necessary in some instances).
3. Keep flammable liquids in approved, labeled, closed containers.
4. Use in well ventilated areas and control vapors. Be aware that vapors are not visible, are heavier than air, can travel along floor, and will settle in lower areas.
5. When transferring flammable liquids, bond receiving container to source and ground source to earth.
6. DO NOT smoke or use heat or spark producing equipment near vapors.
7. DO NOT eat, smoke or drink where these products are handled, processed or stored.
8. Never siphon by mouth.
9. Wash hands thoroughly after handling any fuel.

Spills

1. Notify proper authorities in the event of any spill you have not been trained to clean up.
2. Stop, contain, and clean up small spills with an absorbent material.

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. IFS switch is located behind right side of instrument panel. Remove fuel filler cap to release fuel tank pressure. Crank engine for 15 seconds to release system pressure.

FUEL LINE FITTINGS

Push Connect Coupling

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-156578-S29722979192003072200000). Disconnect safety clip from male hose. (Scheme 31) Install Fuel Line Disconnect (T90T-9550-S) and push it into fitting. Separate fittings. (Scheme 32)
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 31

Scheme 32

Quick Connect Coupling

Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Unclip tap. (Scheme 33) Depress tabs and press the clip downward. (Scheme 34) Separate the fittings. (Scheme 35)

Scheme 33

Scheme 34

Scheme 35

Squeeze Type Coupling (Quick Release Fitting)

Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. To disconnect fuel tube quick release coupling, press fuel tube quick release coupling button and pull fuel tube to disconnect. (Scheme 36) Clean and inspect fitting and tube for damage. Align the tube and fitting. Insert the tube in the fitting and push together until a click is heard. Pull on the connection to make sure it is fully engaged.

Scheme 36

Spring Lock Coupling

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-156578-S29722979192003072200000). Place indicated spring lock coupler over coupling. See «SPRING LOCK COUPLER IDENTIFICATION»(ref-156578-S30436031222003072200000) table. To release female fitting from garter spring, push coupler along tube into coupling. (Scheme 37)
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 37

See CAMSHAFT POSITION SENSOR under SENSORS.

FUEL FILTER

Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Fuel filter is mounted on frame cross rail in front of fuel tank. Remove fuel filter shield. Remove fuel filter fittings. See FUEL LINE FITTINGS. (Scheme 38) Remove bolt or clamp and fuel filter. To install, reverse removal procedure.

Scheme 38

FUEL PUMP MODULE

Note. Special tool required: Fuel Tank Lock Ring Wrench (310-057). (Scheme 39)

Note. For additional information on fuel and vapor line fittings, see FUEL LINE FITTINGS .

Remove fuel tank. See FUEL TANK. Disconnect quick connect fittings at fuel pump module. Remove lock ring using Special Tool (310-075). Remove fuel pump module. (Scheme 40) Wipe seal area of tank clean. Position NEW seal onto fuel pump module mounting flange using grease, if necessary to hold it in position. Position fuel pump in tank to original position. Install lock ring. DO NOT overtighten lock ring, as it may leak. Install fuel tank. See FUEL TANK. Tighten fasteners to specification. See TORQUE SPECIFICATIONS.

Scheme 39

Scheme 40

FUEL SUPPLY MANIFOLD & INJECTORS

FUEL PRESSURE RELIEF VALVE

FUEL PULSE DAMPER

Note. Numbers in parenthesis refer to numbers in illustration.

FUEL TANK

Note. Special tool required: Fuel Line Disconnect Tool (310-S039). (Scheme 41)

Note. For additional information on fuel and vapor line fittings, see FUEL LINE FITTINGS .

1. Disconnect the battery ground cable. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-156578-S29722979192003072200000).
2. Raise and support vehicle. Remove drive shaft. See DRIVE SHAFT in appropriate DRIVE AXLES article.
3. Drain fuel tank. See «FUEL TANK DRAINING»(ref-156578-S27749190892004050500000).
4. If equipped, remove the fuel tank skid plate and transfer case skid plate.
5. Release the squeeze-type clip on the fuel filler tube and remove fuel filler tube from tank. Disconnect the dust box rubber hose and release the fuel line retainer clip near the top rear of the fuel tank. (Scheme 42)
6. Remove the 2 fuel filter shield retaining nuts and remove the fuel filter shield. Remove the fuel supply line safety clip, install the Fuel Line Disconnect Tool (310-S039) into the fitting and separate the fuel supply line fitting. Release the squeeze-type quick release fuel vapor line fitting and release fuel vapor line. (Scheme 43)
7. Support fuel tank using suitable jack. Remove the fuel tank front support strap nut and rear support strap bolt. Remove fuel tank support straps. (Scheme 44)
8. Partially lower fuel tank. Disconnect fuel vapor hose, and fuel pump electrical connector. (Scheme 42) Remove fuel tank from vehicle.
9. If fuel tank is being replaced, transfer components as necessary. For fuel pump module, see «FUEL PUMP MODULE»(ref-156578-S33904427312003072200000).
10. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-156578-S42473217232003072200000).

Scheme 41

Scheme 42

Scheme 43

Scheme 44

See FUEL TANK PRESSURE SENSOR under SENSORS.

HEATED OXYGEN SENSOR

See HEATED OXYGEN SENSOR under SENSORS.

THROTTLE BODY

See THROTTLE BODY under AIR INDUCTION SYSTEMS.

IGNITION SYSTEMS

See CAMSHAFT POSITION SENSOR under SENSORS.

See CRANKSHAFT POSITION SENSOR under SENSORS.

See KNOCK SENSOR under SENSORS.

EVAPORATIVE EMISSIONS SYSTEM SAFETY PRECAUTIONS

AFTER REPAIR PROCEDURE

After evaporative emissions system repair, leak test the system. See EVAPORATIVE EMISSIONS SYSTEM LEAK TEST under SYSTEM TESTS (EVAPORATIVE EMISSION) in SELF-DIAGNOSTICS - CNG, FLEX-FUEL & GASOLINE article. Perform evaporative emission repair verification drive cycle. See ON-BOARD SYSTEM READINESS TEST MODE under ADDITIONAL SYSTEM FUNCTIONS in SELF-DIAGNOSTICS - CNG, FLEX-FUEL & GASOLINE article.

Disconnect negative battery cable. Raise and support vehicle. Remove fuel tank. See FUEL TANK under FUEL SYSTEMS. Disconnect hoses and electrical connectors. Remove charcoal canisters. (Scheme 45) To install, reverse removal procedure. Perform after repair procedure. See AFTER REPAIR PROCEDURE.

Scheme 45

See EVAP CANISTER PURGE VALVE under MOTORS & SOLENOIDS.

See EVAP CANISTER VENT SOLENOID under MOTORS & SOLENOIDS.

VAPOR TUBE FITTINGS

Disconnect battery ground cable. Disconnect vapor tube from the fitting. (Scheme 46) Squeeze fitting. Disconnect vapor tube from fitting. Inspect fitting and tube for damage. Remove any dirt or obstructions. Push tube into fitting until it snaps in place. Pull on the connection to make sure the fitting is secure.

Scheme 46

Remove air cleaner outlet tube. Disconnect EGR valve-to-exhaust manifold tube at EGR valve. (Scheme 47)or (Scheme 48). Disconnect EGR valve vacuum hose. Remove EGR mounting bolts and EGR valve. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 47

Scheme 48