Engine Controls - Remove/install/overhaul Ford Probe I

INTRODUCTION

Removal, overhaul and installation procedures (when given by manufacturer) are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a simple tightening specification may be supplied.

DISASSEMBLY - PROBE 2.2L NON-TURBO

1. Remove distributor rotor and cover. Mark relation of drive gear to lower shaft. Remove retaining pin from drive gear. Remove retaining screw from center of signal rotor.
2. Pull signal rotor and pin from upper shaft using Two-Jaw Puller (D80L-1002-L). Note direction of arrow stamped into rotor. Mark and disconnect two wires from pick-up coil for installation reference. Remove 2 screws from pick-up coil. Remove pick-up coil.
3. Remove 2 screws and pick-up coil mounting bracket. Remove "E" clip from stator plate. Remove 2 diaphragm mounting screws and vacuum diaphragm. Remove 2 screws and stator plate. Remove upper shaft. Remove 2 retaining screws and lower shaft from distributor housing. Remove 2 "E" clips. Remove bearing and retainer from lower shaft. Remove seal from distributor housing.

REASSEMBLY - PROBE 2.2L NON-TURBO

1. Install seal into distributor housing. Install retainer and bearing onto lower shaft. Install weights and springs onto lower shaft. Install new "E" clips. Install upper shaft onto lower shaft. NOTE: Ensure weight pivot pins engage advance mechanism.
2. Install upper and lower shaft assembly into distributor housing. Install stator plate into distributor housing. Install 2 retaining screws. Install vacuum diaphragm, "E" clip and 2 attaching screws.
3. Install pick-up coil mounting plate and pick-up coil. Install pick-up wiring harness and wires. Using a socket and the palm of your hand, press signal rotor and pin onto upper shaft until it bottoms against shoulder of upper shaft. Note direction of arrow stamped into signal rotor.
4. Install signal rotor retaining screw. Align groove in drive gear with the alignment mark on distributor housing. Install retaining pin. Install cover, gasket, and rotor.

DISASSEMBLY - ALL OTHERS

1. Remove 2 TFI-IV module screws. Pull right side of module down distributor mounting flange and back up to disengage module terminals from connector in distributor base. Remove module by pulling toward flange and away from distributor. CAUTION: Attempting to remove ignition module without first moving entire module toward distributor flange will cause module pins to break at connector.
2. Hold gear and loosen armature screws, DO NOT hold armature. Remove screws and armature. Using a felt tip pen, mark armature and gear for installation reference. Remove and discard roll pin in gear.
3. Place distributor in Axle Bearing Remover (T75L-1165-B). Press off gear using arbor press and Pinion Bearing Cone Remover (D79L-4621-A). Using emery cloth, remove burrs from distributor shaft. Remove shaft from distributor assembly.
4. Remove screw and octane rod assembly. Save octane rod and screw for installation. Remove stator assembly screws and stator.
5. Inspect base bushing, "O" ring, and distributor housing for wear, cracks, or other damage. If necessary, replace "O" ring. If distributor housing or bushings are worn, replace entire distributor assembly.

REASSEMBLY - ALL OTHERS

1. Place stator assembly over bushing and press down to seat. Place stator connector in position. Tab should fit in notch of base and fastening eyelets should align with screw holes. Position wires away from moving parts. Install and tighten stator screws.
2. Install octane rod through distributor base hole. Place end of rod onto same post as original stator. Install and tighten octane rod screw. Lubricate distributor shaft, just below armature, with light oil. DO NOT over lubricate.
3. Install shaft through base bushing. Place a 1/2" deep well socket over shaft, invert assembly and place in arbor press. Place distributor drive gear on shaft. Align marks made during removal.
4. Place a 5/8" deep well socket over shaft and gear. Press gear until holes align with holes in shaft. If holes do not line up, press gear off and try once more. DO NOT try to align holes using a drift or roll pin.
5. Insert new roll pin through gear and shaft. If armature was removed, install armature. Tighten armature screws. Check distributor for freedom of rotation. If armature contacts stator, replace distributor.
6. Wipe back of TFI ignition module and distributor mounting plate clean. Apply Silicone Dielectric Compound (D7AZ-19A331-A) to back of module and spread evenly.
7. Turn distributor base upside-down so that stator connector is in full view. Insert TFI module. Ensure that module pins are inserted into stator connector.
8. Fully seat TFI ignition module into connector and against base. Install and tighten TFI module screws. (Scheme 1)

Scheme 1

OXYGEN SENSOR PRECAUTIONS

O2 sensor is equipped with a permanent pigtail which must be protected when the sensor is removed. Ensure sensor is free of contaminants and avoid using cleaning solvents of any type. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Always use anti-seize compound on threads prior to installation.

Note. Fuel pressure must first be released before performing work on fuel injection components.

2.2L

Disconnect electrical connector to inertia switch located on left side of luggage compartment. Remove fuel cap to release fuel tank pressure. Crank engine for 15 seconds to reduce system pressure.

ALL OTHERS

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.

REMOVAL - SPRING LOCK COUPLING

1. Using Spring Lock Coupling Remover (D87L-9280-A for 3/8" or D87L-9280-B for 1/2"), remove clip from coupling. Place remover over coupling so intrusion is positioned on cage opening side of coupling. (Scheme 2)
2. Close remover over coupling. Push remover into cage opening to release female fitting from garter spring. Pull male and female halves of coupling apart. Remove tool from disconnected spring lock coupling.

Scheme 2

1. Ensure garter spring in cage of male fitting is not damaged, replace if necessary. Clean all dirt from both pieces of coupling. Check "O" rings for damage and replace using proper fuel resistant "O" rings, (if necessary).
2. Lubricate "O" rings and inside of female fitting with clean engine oil. Snap fitting together. Install retaining clip onto coupling. Ensure horseshoe portion of clip is over the coupling. (Scheme 3) DO NOT install retaining clip over rubber fuel line.

Scheme 3

REMOVAL - HAIRPIN CLIP COUPLING

Remove hairpin clip from fitting. Spread each clip leg about 1/8" to disengage body. Push legs into fitting. While pulling lightly on triangular end of clip. Work it clear of tube and fitting. Pull fitting and steel line in axial direction. Use twisting motion while pulling fitting loose.

INSTALLATION - HAIRPIN CLIP COUPLING

Insert clip into any 2 adjacent openings with triangular portion pointing away from fitting opening. Install clip to fully engage the body. Clean end of fitting. Align fitting and tube axially and push fitting onto tube end. When fitting is engaged, a definite click will be heard.

REMOVAL

1. Disconnect negative battery cable. Drain coolant. Remove accelerator cables and air duct from throttle body. Mark and remove all vacuum hoses from throttle body.
2. Disconnect all electrical connections at throttle body. Remove engine lifting bracket mounting bolts from throttle body and engine block. Remove coolant line/EGR hose retaining bracket from throttle body. Remove all brackets from upper intake manifold.
3. Remove PCV hose from upper intake manifold. Mark and remove vacuum lines from upper intake manifold. Remove upper intake manifold retaining nuts and bolts. Remove upper intake manifold and gasket.

INSTALLATION

Clean gasket surface. Install new gasket and position upper intake manifold onto lower intake manifold. Install upper intake manifold bolts and nuts and tighten to 14-19 ft. lbs. (19-25 N.m). To complete installation, reverse removal procedure. Refill cooling system.

UPPER INTAKE MANIFOLD TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE in this article. Remove negative battery cable. Remove upper intake manifold. See UPPER INTAKE MANIFOLD in this article.
2. Remove electrical connectors from fuel injectors and engine coolant temperature switch (ATX only). Carefully bend wire harness retainer brackets away from intake manifold.
3. Remove fuel line from pulsation damper. See FUEL LINE CONNECTOR. Remove fuel return line bracket from intake manifold. Remove fuel return line.
4. Remove fuel rail attaching bolts, spacers and insulators. Remove fuel rail with injectors, pressure regulator and pulsation damper attached.

Position grommets and new "O" rings onto fuel injectors. Using engine oil, lightly lubricate "O" rings. To complete installation, reverse removal procedure. Ensure injectors are seated properly.

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove fuel supply and return lines. See FUEL LINE CONNECTOR. Remove negative battery cable. Remove wiring harness from injectors.
2. Remove throttle body. See THROTTLE BODY. Remove injector retaining bolts. Carefully disengage fuel rail from injectors. Disconnect vacuum line from fuel pressure regulator. Remove fuel rail assembly.

When installing fuel rail assembly, use new "O" rings. Push fuel rail down to ensure all injector "O" rings are fully seated in fuel rail cups and intake manifold. Install fuel rail retaining bolts. Tighten to specifications. To complete installation, reverse removal procedure.

FUEL RAIL TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

INJECTOR - PORT FUEL INJECTION (PFI) SYSTEMS

Injectors may be removed after fuel rail has been removed from intake manifold. See FUEL RAILS. Install new "O" rings on injectors. Inspect injector "plastic hat" (covering the injector pintle) and washer for signs of deterioration. Replace as necessary.

1. Disconnect negative battery cable. Remove accelerator cables and air duct from throttle body. Mark and disconnect all vacuum and coolant hoses from throttle body. Disconnect all wire connections from throttle body.
2. Remove engine lifting bracket mounting bolt from throttle body. Remove coolant line/EGR hose retaining bracket from throttle body. Remove throttle body attaching bolts and throttle body. Remove gasket.

Note. No. 2 throttle plate is preset at the factory to begin opening after the No. 1 throttle plate approximately 25 degrees (MTX) or 10 degrees (ATX).

Clean gasket surfaces. Position new gasket and throttle body onto intake manifold. Install attaching bolts and tighten to specification. To complete installation, reverse removal procedure.

Note. DO NOT remove thin protective coating from throttle plates or bores.

1. Disconnect negative battery cable. Remove air duct hose. Remove idle speed control solenoid shield. Disconnect throttle and TV cable from throttle body linkage.
2. Mark and remove vacuum hoses at vacuum tree. Loosen EGR tube nut (if equipped) at EGR valve. Remove or rotate tube out of way. Remove PCV hose. Disconnect electrical connections from throttle body.
3. On Probe models, remove fuel bracket bolt from throttle body. On all other models, remove retaining nuts from alternator brace, remove brace. On all models, remove 6 throttle body retaining bolts. Remove throttle body assembly from intake manifold. Discard old gasket.

Clean all gasket surfaces. Lightly oil all bolt threads before installation. Install guide pins (if available). Place gasket on intake manifold. Install throttle body on intake manifold. Install bolts. Tighten bolts to specifications and in sequence. (Scheme 4)

Scheme 4

TORQUE SPECIFICATIONS

FUEL PRESSURE REGULATOR - PFI ENGINES

1. If removing fuel pressure regulator while fuel rail assembly is still installed on engine, release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove vacuum line at pressure regulator. Remove 3 Allen retaining screws from regulator housing.
2. Remove pressure regulator assembly, gasket and "O" ring. Make sure gasket surfaces are clean. Lubricate "O" ring with clean engine oil. Install new "O" ring and gasket on regulator. Install fuel pressure regulator on fuel rail assembly and tighten screws.

THROTTLE POSITION SENSOR (TPS) - ALL MODELS

1. Disconnect TPS from wiring harness. Scribe marks on throttle body and TPS for reassembly reference. Remove mounting screws and TPS. Slide rotary tangs of TPS into position over throttle shaft blade with wires pointing down. Rotate TPS clockwise to installed position.
2. Failure to install TPS in this manner may result in excessive idle speeds. Align scribe marks on throttle body and TPS. Secure TPS to throttle assembly with retaining screws. Reconnect wiring.

TURBOCHARGER - 2.2L PFI TURBO

Note. The turbocharger cannot be rebuilt or overhauled. Turbocharger is serviced by replacement ONLY.

Prior to removal of turbocharger, the following precautions should be observed

1. Area surrounding turbocharger should be cleaned with a non-caustic cleaner.
2. All engine openings should be covered with clean cloth after unit removal to prevent entry of foreign matter.
3. Ensure blades are not nicked or otherwise damaged. An imbalance condition could result and lead to severe damage.
4. If any internal engine component is replaced, oil and filter should be changed and turbocharger should be flushed with clean oil.
5. Prior to installing turbocharger on engine, gently spin blades to ensure freedom of movement.

1. Disconnect negative battery cable. Drain cooling system. Disconnect throttle body inlet tube from turbocharger. Remove heat shields from exhaust manifold and turbocharger assembly.
2. Disconnect O2 sensor electrical connector (if necessary). Disconnect oil feed and return lines from turbocharger. Disconnect coolant inlet and return hose from turbocharger.
3. Remove EGR tube from exhaust manifold. Disconnect turbo boost control solenoid. Remove mounting bolt from turbocharger retaining bracket located under the turbocharger. Remove O2 sensor (if necessary).
4. Remove converter inlet pipe from turbocharger joint pipe. Remove exhaust manifold and turbocharger as an assembly. Separate exhaust manifold, turbocharger-to-converter inlet pipe, joint pipe and heat shield assembly from turbocharger.

Scheme 5

1. Fill oil cavity of turbocharger with oil. Install joint pipe and heat shield assembly onto turbocharger. Tighten mounting bolts to 27-46 ft. lbs. (37-63 N.m).
2. Install exhaust manifold onto turbocharger and tighten mounting bolts to 20-29 ft. lbs. (27-39 N.m). To complete installation, reverse removal procedure. After installation, disconnect coil wire and crank engine for 20 seconds.
3. Connect coil wire. Start engine and run at idle for 30 seconds. Stop engine, disconnect negative battery cable and depress brake pedal for at least 5 seconds to cancel malfunction code. Reconnect negative battery cable.

VANE AIR METER - 2.2L

Disconnect negative battery cable. Disconnect airflow meter electrical connector. Remove air duct from air filter cover. Remove air filter cover attaching bolts and cover. Remove vane airflow meter attaching nuts from inside air cleaner cover. Remove airflow meter. To install, reverse removal procedure.

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Drain fuel from tank. Raise vehicle on hoist. Remove exhaust pipe and shield. Remove fuel hoses and tubes.
2. See FUEL LINE CONNECTOR. Disconnect vapor crossover hose and filler hose. Support fuel tank. Remove fuel tank strap bolts. Partially lower fuel tank. Disconnect fuel lines and electrical connector from fuel gauge sender. Remove fuel tank.
3. Remove any dirt that has accumulated around fuel pump retaining flange area. Using Fuel Tank Sender Wrench (D84P-9257-A) remove fuel pump locking ring. Remove fuel pump.

1. Clean fuel pump mounting flange, fuel tank mounting surface and seal ring groove. to hold new seal ring in place during installation, apply a light coating of Long Life Lubricant (C1AZ-19590-BA) on seal ring.
2. Install seal ring in fuel ring groove. Install fuel pump and sender assembly taking care not to damage nylon filter. Ensure locating keys are in keyways and seal ring remains in place.
3. Tighten locking ring by rotating ring clockwise using Fuel Tank Sender Wrench (D84P-9257-A) until ring stops against stops. To complete installation, reverse removal procedure.