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Electronic Engine Controls: Removal & Installation Ford Explorer V

Engine Control Systems 10 illustrations ~1695 words

Removal

  1. Remove the ACL outlet pipe. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
  2. Disconnect the CMP electrical connector.
  3. Remove the bolt and the CMP sensor.

Installation

  1. NOTE: Lubricate the CMP sensor O-ring seal with clean engine oil before installing the CMP sensor. Install the CMP sensor and bolt. Tighten to 10 Nm (89 lb-in).
  2. Connect the CMP electrical connector.
  3. Install the ACL outlet pipe. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .

Note. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

Scheme 5

Scheme 5: Removal
Scheme 5: Removal

Scheme 6

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Scheme 6

Scheme 7

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Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12
  1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
  2. Remove the RH fender splash shield. REFER to «FENDER SPLASH SHIELD»(ref-517609-S36660239832012121200000) .
  3. Loosen the 4 retainers and remove the underbody shield.
  4. NOTE: Turn the engine in the normal direction of rotation only. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the TDC marked tooth on the crankshaft pulley (located on the 20th tooth counterclockwise from the missing tooth) at the 6 o'clock position.
  5. Remove the 2 bolts, the 2 nuts and the RH halfshaft bracket.
  6. Remove the engine plug bolt.
  7. Install the 303-507 .
  8. NOTE: The 303-507 will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation. NOTE: The engine front cover is shown removed in graphic for clarity. Rotate the crankshaft slowly clockwise until the crankshaft contacts the 303-507 . The TDC marked tooth on the crankshaft pulley will align with the center line of the CKP sensor.
  9. Disconnect the CKP sensor electrical connector.
  10. Remove the 2 CKP sensor bolts and the CKP sensor.

Scheme 13

Scheme 13
Scheme 13
  1. Install the CKP sensor and the 2 CKP sensor bolts. Do not torque at this time.
  2. Connect the CKP sensor electrical connector.
  3. Install the 303-1521 . If the 303-1521 does not align with the TDC marked tooth on the crankshaft pulley, loosen the 2 CKP sensor bolts and adjust the sensor until the tool is installed. Tighten the 2 CKP sensor bolts to 7 Nm (62 lb-in). Remove the 303-1521 .
  4. Remove the 303-507 .
  5. Install the engine plug bolt. Tighten to 20 Nm (177 lb-in).
  6. Install the RH halfshaft bracket, the 2 bolts and the 2 nuts. Tighten to 25 Nm (18 lb-ft).
  7. Install the underbody shield and tighten the 4 retainers.
  8. Install the RH fender splash shield. REFER to «FENDER SPLASH SHIELD»(ref-517609-S36660239832012121200000) .
  9. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
  2. Remove the nut, bolt and the heat shield.
  3. Remove the rubber grommet cover.
  4. Remove the bolt and the CKP sensor from the engine block.
  5. Disconnect the CKP sensor electrical connector and remove the CKP sensor.
  1. Connect the CKP sensor electrical connector.
  2. Install the CKP sensor and bolt. Tighten to 10 Nm (89 lb-in).
  3. Install the rubber grommet cover.
  4. Install the heat shield and the nut and bolt. Tighten to 10 Nm (89 lb-in).
  1. Install the PCM to the bracket and install the 4 bolts. Tighten to 8 Nm (71 lb-in).
  2. Install the PCM and bracket assembly and the 2 nuts. Tighten to 8 Nm (71 lb-in).
  3. Connect the 2 PCM electrical connectors. Attach the wiring harness retainer from the cowl.
  4. Install the cowl panel. REFER to «COWL PANEL»(ref-517609-S10800986242012121200000) .
  5. Restore the module configuration. Carry out the module configuration restore steps of the PMI procedure. REFER to «MODULE CONFIGURATION»(ref-517596-S41023052042012121200000) .
  6. Reprogram the PATS. Carry out the Parameter Reset procedure: PATS without IA, REFER to «PASSIVE ANTI-THEFT SYSTEM (PATS) PARAMETER RESET - WITHOUT INTELLIGENT ACCESS»(ref-517598-S12268425512012121200000) . PATS with IA, REFER to «PASSIVE ANTI-THEFT SYSTEM (PATS) PARAMETER RESET - WITH INTELLIGENT ACCESS»(ref-517599-S23706497312012121200000) .
  7. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
  1. If servicing the PCM, the module configuration must be retrieved before the PCM is removed. Connect the scan tool to the vehicle. Allow the scan tool to identify the vehicle and obtain configuration data. All PMI information will automatically be retrieved by the scan tool.
  2. Remove the cowl panel. REFER to «COWL PANEL»(ref-517609-S10800986242012121200000) .
  3. Disconnect the 3 PCM electrical connectors.
  4. Remove the 2 nuts and the PCM.

Note. PCM replacement DOES NOT require new keys or programming of keys.

Note. After the PCM is installed, the module configuration must be restored. Using the scan tool, perform the PMI procedure following the on-screen instructions.

Note. After the PCM is installed, the PATS must be reprogrammed. Carry out the Parameter Reset procedure. For vehicles without Intelligent Access, REFER to PASSIVE ANTI-THEFT SYSTEM (PATS) PARAMETER RESET - WITHOUT INTELLIGENT ACCESS . For vehicles with Intelligent Access, REFER to PASSIVE ANTI-THEFT SYSTEM (PATS) PARAMETER RESET - WITH INTELLIGENT ACCESS .

  1. Install the PCM and the 2 nuts. Tighten to 8 Nm (71 lb-in).
  2. Connect the 3 PCM electrical connectors.
  3. Install the cowl panel. REFER to «COWL PANEL»(ref-517609-S10800986242012121200000) .
  4. NOTE: If the PMI procedure was not successful in downloading the data from the vehicles original PCM, then the oil life data of the vehicle is lost. If this occurs, and the oil life cannot be determined through service history or customer interview, it is recommended the vehicle engine oil and filter be changed and the oil minder reset. Restore the PCM configuration. Using the scan tool, perform the PMI procedure following the on-screen instructions.
  5. Reprogram the PATS. Carry out the Parameter Reset procedure: PATS without IA, REFER to «PASSIVE ANTI-THEFT SYSTEM (PATS) PARAMETER RESET - WITHOUT INTELLIGENT ACCESS»(ref-517598-S12268425512012121200000) . PATS with IA, REFER to «PASSIVE ANTI-THEFT SYSTEM (PATS) PARAMETER RESET - WITH INTELLIGENT ACCESS»(ref-517599-S23706497312012121200000) .
  1. Disconnect the MAF sensor electrical connector.
  2. Remove the 2 screws and the MAF sensor.
  1. Install the MAF sensor and the 2 screws. Tighten to 2 Nm (18 lb-in).
  2. Connect the MAF sensor electrical connector.
  1. To install, reverse the removal procedure. Do not reuse the CHT sensor, install a new sensor.

Scheme 14

Scheme 14: Exploded View
Scheme 14: Exploded View
ItemService Part NumberDescriptionTool NumberMaterial NameNotes
1CHT sensor electrical connector (part of 12A581 )
26G004CHT sensor10 Nm (89 lb-in)
  1. Remove the lower intake manifold. REFER to «LOWER INTAKE MANIFOLD»(ref-517529-S36284724522012121200000) .
  2. Disconnect the CHT sensor electrical connector.
  3. Remove and discard the CHT sensor.
  1. NOTE: Do not reuse the CHT sensor, install a new sensor. Install a new CHT sensor. Tighten to 10 Nm (89 lb-in).
  2. Connect the CHT sensor electrical connector.
  3. Install the lower intake manifold. REFER to «LOWER INTAKE MANIFOLD»(ref-517529-S36284724522012121200000) .
  1. To install, reverse the removal procedure. Apply a light coat of anti-seize lubricant to the threads of the HO2S .
  1. Remove the engine appearance cover.
  2. Disconnect the HO2S electrical connector.
  3. NOTE: If necessary, lubricate the HO2S with penetrating and lock lubricant to assist in removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S .
  1. Apply anti-seize to the threads of the HO2S .
  2. NOTE: The correct torque wrench setting must be calculated when using the Exhaust Gas Oxygen Sensor Socket to install the HO2S . REFER to Torque Wrench Adapter Formulas in the Appendix illustration. Using the Exhaust Gas Oxygen Sensor Socket, install the HO2S . Tighten to 48 Nm (35 lb-ft).
  3. Connect the HO2S electrical connector.
  1. To install, reverse the removal procedure. Apply a light coat of anti-seize lubricant to the threads of the CMS.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
  2. Disconnect the CMS electrical connector.
  3. NOTE: If necessary, lubricate the CMS with penetrating and lock lubricant to assist in removal. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS.
  1. Apply anti-seize to the threads of the CMS.
  2. NOTE: The correct torque wrench setting must be calculated when using the Exhaust Gas Oxygen Sensor Socket to install the CMS. REFER to Torque Wrench Adapter Formulas in the Appendix illustration. Using the Exhaust Gas Oxygen Sensor Socket, install the CMS. Tighten to 48 Nm (35 lb-ft).
  3. Connect the CMS electrical connector.
  1. To install, reverse the removal procedure.
  1. Remove the thermostat housing. REFER to «THERMOSTAT HOUSING - 3.5L TI-VCT»(ref-517561-S18157139852012121200000) .
  2. Remove the lower intake manifold. REFER to «LOWER INTAKE MANIFOLD»(ref-517529-S36284724522012121200000) .
  3. Remove the coolant tube and discard the O-ring seal.
  4. Disconnect the KS electrical connector.
  5. Remove the 2 bolts and the KS.
  1. Install the KS and the 2 bolts. Tighten to 20 Nm (177 lb-in).
  2. Connect the KS electrical connector.
  3. Install a new O-ring seal on the coolant tube.
  4. NOTE: Lubricate the new O-ring seal with clean engine coolant. Install the coolant tube.
  5. Install the lower intake manifold. REFER to «LOWER INTAKE MANIFOLD»(ref-517529-S36284724522012121200000) .
  6. Install the thermostat housing. REFER to «THERMOSTAT HOUSING - 3.5L TI-VCT»(ref-517561-S18157139852012121200000) .
  1. To install, reverse the removal procedure.
  1. Remove the LH or RH valve cover. REFER to «VALVE COVER - LH»(ref-517529-S19117177882012121200000) , or «VALVE COVER - RH»(ref-517529-S08327364782012121200000) .
  2. Remove the bolt and the VCT oil control solenoid.
  1. NOTE: The VCT oil control solenoid bolt must be tightened in 2 stages. Install the VCT oil control solenoid and tighten the bolt in 2 stages. Stage 1: Tighten to 8 Nm (71 lb-in). Stage 2: Tighten an additional 20 degrees.
  2. Install the LH or RH valve cover. REFER to «VALVE COVER - LH»(ref-517529-S19117177882012121200000) , or «VALVE COVER - RH»(ref-517529-S08327364782012121200000) .

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