Engine Controls - Removal & Installation: Removal & Installation Ford Explorer III

Removal & Installation (4.0L)

Note. Intake manifold torque sequence is not available from manufacturer.

1. Disconnect negative battery cable. Remove air cleaner outlet pipe. Disconnect accelerator and the speed control cables from throttle body. Remove accelerator cable and speed control cable from bracket. Position cables away from intake manifold. Disconnect accelerator cable and speed control cable routing clips. Disconnect vacuum hoses.
2. Disconnect Idle Air Control (IAC) valve and Throttle Position (TP) sensor electrical connectors. Remove wiring anchor. Disconnect Exhaust Gas Recirculation (EGR) valve vacuum hose and Evaporative (EVAP) emission canister purge solenoid vapor hose.
3. Disconnect EGR tube from EGR valve. Disconnect wiring harness pin-type retainer. Disconnect EVR solenoid vacuum and electrical connections. Remove EVR solenoid bracket bolts and EVR solenoid. Disconnect EGR valve-to-manifold tube at EGR valve. Disconnect PCV hose at rear of intake manifold. Disconnect spark plug wires for right bank at ignition coils.
4. Remove eight intake manifold bolts. (Scheme 1) Disconnect Knock Sensor (KS) electrical connector retainer. Remove intake manifold. Clean and inspect sealing surfaces, inspect gaskets and install new gaskets if necessary. To install, reverse the removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-156578-S42473217232003072200000).

Scheme 1

Removal & Installation (4.6L)

1. Disconnect negative battery cable. Relieve fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-156578-S29722979192003072200000) under FUEL SYSTEMS. Drain cooling system. Disconnect fuel line from fuel supply manifold. See «FUEL LINE FITTINGS»(ref-156578-S03113040992003072200000) under FUEL SYSTEMS. Disconnect upper radiator hose from thermostat housing. Disconnect brake booster vacuum hose. Disconnect heater hose from intake manifold. Disconnect accelerator and speed control cables from throttle body and bracket, and position cables aside.
2. Remove EGR tube. Disconnect fuel rail ground wire. Disconnect PCV hose and throttle by-pass hose. Remove generator upper bracket. Disconnect Idle Air Control (IAC) valve and the Throttle Position (TP) sensor electrical connectors. Disconnect vacuum hose from throttle body adapter and fuel pressure regulator. Disconnect vacuum hoses from EGR valve and evaporative canister purge solenoid.
3. Disconnect differential pressure feedback EGR system electrical connector. Remove differential feedback EGR system from the EGR tube. Remove IAC inlet hose and crankcase ventilation tube. Disconnect fuel rail ground wire. Disconnect DPFE sensor and 8 fuel injector connectors. Separate wire harness locators and knock sensor connector from back of intake manifold. Remove crankcase vent tube and vacuum hose assembly. Remove EGR coolant hoses.
4. Remove 8 ignition coil bolts and ignition coils. Remove 4 fuel supply manifold bolts and fuel supply manifold with injectors. Remove generator support bracket. Remove thermostat housing and thermostat. Remove intake manifold bolts and intake manifold. (Scheme 2) Remove the intake manifold gasket and clean the mating surfaces. To install, reverse the removal procedure. Tighten intake manifold bolts in sequence. (Scheme 3) Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-156578-S42473217232003072200000). Fill and bleed cooling system.

Scheme 2

Scheme 3

Remove air cleaner outlet tube. Disconnect accelerator cable and speed control cable from throttle body. Disconnect throttle return spring (4.6L). Disconnect throttle position sensor. Remove 4 throttle body bolts and remove throttle body. (Scheme 4)or (Scheme 5). To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 4

Scheme 5

Programming VID Block For Replacement PCM

A new PCM will contain the latest strategy and calibration level for a particular vehicle. However, the VID block will be blank and will need programming. There are 2 procedures available. The first is an automatic data transfer from the old PCM to the new PCM and the second is manual data entry into the new PCM.

Automatic data transfer will be performed if the old PCM is capable of communicating. This is done by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The stored data can now be downloaded to the new PCM after it has been replaced.

Manual data entry must be performed if the old module is damaged and/or incapable of communicating. Remove and replace the old PCM. Using a compatible Scan Tool select and execute MODULE/PARAMETER REPROGRAMMING referring to the manufacturers users manual. Important, make certain that all parameters are included. Failure to properly program Tire Size in revolutions per mile, (rev/mile equals 63,360 divided by the tire circumference in inches) Axle Ratio, 4x4/4x2, and/or Manual/Electronic shift on the fly (MSOF/ESOF) may result in codes: P1635, P1639. You may be instructed to contact the AS BUILT data center for the information needed to manually update the VID block with the scan tool. Contact the center only if the old PCM cannot be used or the data is corrupt. For Ford Lincoln Mercury technician's, contact your National Hotline or the Professional Technician Society (PTS) web sight for AS BUILT data. Non Ford technicians, use the Fed World web site at fedworld.gov. Select AUTO SERVICE INFORMATION and search for CALIBRATIONS or VEHICLE CALIBRATIONS then specify vehicle manufacturer, model name and model year as required.

Disconnect Camshaft Position (CMP) sensor (1). (Scheme 6) Remove CMP sensor bolt (2). Remove CMP sensor (3). To install, reverse removal procedure. Tighten CMP sensor bolt to specification. See TORQUE SPECIFICATIONS.

Scheme 6

Camshaft Position (CMP) sensor is located at front of left cylinder head. Disconnect negative battery cable. Disconnect CMP sensor connector (1). (Scheme 7) Remove CMP sensor mounting bolt (2). Remove CMP sensor (3). To install, reverse removal procedure. Tighten CMP sensor mounting bolt to specification. See TORQUE SPECIFICATIONS.

Scheme 7

Disconnect negative battery cable. Disconnect Idle Air Control (IAC) valve connector (1). (Scheme 8) Remove wire harness retainer (2) and splash shield spacer nut (3). Remove IAC valve bolts (4) and remove IAC valve (5). To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 8

Disconnect negative battery cable. Disconnect air inlet tube assembly from Idle Air Control (IAC) valve (1). (Scheme 9) Disconnect IAC valve connector (2). Remove IAC valve bolts (3) and remove IAC valve (4). Remove IAC valve gasket (5). To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 9

Removal (4.0L)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-156578-S29722979192003072200000). Remove intake manifold. See «INTAKE MANIFOLD»(ref-156578-S31229534672003072200000) under AIR INDUCTION SYSTEMS. Disconnect fuel supply line. See «FUEL LINE FITTINGS»(ref-156578-S03113040992003072200000). (Scheme 10) Remove bolt and bracket at fuel supply line fitting.
2. Disconnect wiring harness at fuel injectors. Disconnect vacuum hose from fuel pressure damper. Remove fuel rail bolts. Carefully disengage fuel injectors by lifting and gently rocking rail.
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.

Scheme 10

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. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-156578-S29722979192003072200000). Disconnect negative battery cable. Remove air cleaner outlet tube. Remove crankcase vent tube. Remove brake booster vacuum tube bracket bolt and brake booster vacuum tube. Disconnect Throttle Position (TP) sensor and Idle Air Control (IAC) solenoid electrical connectors. Disconnect accelerator cable, speed control actuator cable (if equipped) and return spring. Disconnect EVAP vapor hose. Disconnect EGR vacuum hose. Disconnect EGR tube from EGR valve.
2. Disconnect PCV coolant hoses. Remove IAC and crankcase air inlet tubes. Remove PCV valve and tube. Remove throttle body adapter bolts and remove throttle body adapter. (Scheme 11) Disconnect ground wire from intake manifold. Disconnect fuel injector connectors. (Scheme 12) Remove 4 fuel injection supply manifold bolts. Remove fuel injection supply manifold with injectors.
3. Remove injectors by using a rocking motion. To install, reverse removal procedure. Install new "O" rings on the fuel injectors. Lubricate the new fuel injector "O" rings with clean engine oil. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-156578-S42473217232003072200000).

Scheme 11

Scheme 12

Disconnect negative battery cable. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove 2 mounting bolts from fuel pressure relief valve (1). (Scheme 13) Remove fuel pressure relief valve (2). Remove and discard "O" ring (3).

Scheme 13

Lubricate NEW "O" ring with light oil. DO NOT use silicone grease. Ensure fuel pressure relief valve and manifold gasket surfaces are clean and dry. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Disconnect negative battery cable. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect vacuum hose to fuel pulse damper (1). (Scheme 14) Remove 2 mounting bolts from fuel pulse damper (2). Remove fuel pulse damper (3). Remove and discard "O" ring (4).

Scheme 14

Lubricate NEW "O" ring with light oil. DO NOT use silicone grease. Ensure fuel pulse damper and manifold gasket surfaces are clean and dry. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Disconnect negative battery cable. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect vacuum hose to fuel pulse damper (1). (Scheme 15) Remove snap ring from fuel pulse damper (2). Remove fuel pulse damper (3). Remove and discard "O" ring (4). To install, reverse removal procedure.

Scheme 15