1991 1999 ford explorer chilton User Manual

							Reconnect the engine control sensor wiring to the sensor.
9. 
Position the bracket, with the power steering pump attached, to the engine.
10. 
Install the three compressor/power steering bracket retaining bolts and tighten securely.
11. 
Install the A/C compressor to the mounting bracket and tighten the four mounting bolts.
12. 
Install the accessory drive belt.
13. 
Connect the negative battery cable. Start the engine and check for leaks.
14. 
1991-94 2.9L and 3.0L Engines
Refer to Section 2 in this manual for distributor removal and installation.
1995-99 3.0L, 4.0L (VIN X), 5.0L and 1994 California only 2.3L Engines
If the camshaft position sensor housing does not contain a plastic locator cover tool, a special service
tool such as T89P-12200-A, or equivalent, must be obtained prior to installation. Failure to follow this
procedure may result in improper stator alignment. This will result in the fuel system being out of time
with the engine, possibly causing engine damage.
Disconnect the negative battery cable.
1. 
Remove the ignition coil, radio capacitor and ignition coil bracket.
2. 
Disengage the wiring harness connector from the CMP sensor.
3. 
Prior to removing the camshaft position sensor, set the No. 1 cylinder to 10° After Top Dead Center
(ATDC) of the compression stroke. Note the position of the sensor electrical connection. When
installing the sensor, the connection must be in the exact same position.
Position the No. 1 cylinder at 10° ATDC, then matchmark the CMP sensor terminal connector
position with the engine assembly.
4. 
Remove the camshaft position sensor retaining screws and sensor.
5. 
Remove the retaining bolt and hold-down clamp.
6. 
The oil pump intermediate shaft should be removed with the camshaft sensor housing. Remove the CMP sensor housing from the front engine cover.
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REMOVAL & INSTALLATION 557 
						

							Exploded view of the Camshaft Position (CMP) sensor mounting for the 3.0L engine-4.0L and
5.0L engines are similar
Click to enlarge
To install: If the plastic locator cover is not attached to the replacement camshaft position sensor, attach a
synchro positioning tool, such as Ford Tool T89P-12200-A or equivalent. To do so, perform the
following: Engage the sensor housing vane into the radial slot of the tool.
1. 
Rotate the tool on the camshaft sensor housing until the tool boss engages the notch in the
sensor housing. The cover tool should be square and in contact with the entire top
surface of the camshaft position sensor housing.
2. 
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558 REMOVAL & INSTALLATION 
						

							Attach the CMP synchro positioning tool to the housing
CMP sensor positioning for the 3.0L (75°) and 4.0L (60°) engines Click to enlarge
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REMOVAL & INSTALLATION 559 
						

							CMP sensor positioning for the 5.0L engine
Click to enlarge
Transfer the oil pump intermediate shaft from the old camshaft position sensor housing to the
replacement sensor housing.
9. 
Install the camshaft sensor housing so that the drive gear engagement occurs when the arrow on the
locator tool is pointed approximately 7° counterclockwise (the sensor terminal connector should be
aligned with its matchmarks) from the face of the cylinder block.
10. 
Install the hold-down clamp and bolt, then tighten the bolt to 15-22 ft. lbs. (20-7 Nm).
11. 
Remove the synchro positioning tool.
12. 
CAUTION
If the sensor connector is positioned correctly, DO NOT reposition the connector by rotating the sensor
housing. This will result in the fuel system being out of time with the engine. This could possibly cause
engine damage. Remove the sensor housing and repeat the installation procedure beginning with step one.
Install the sensor and retaining screws, tighten the screws to 22-8 inch lbs. (2-4 Nm).
13. 
Attach the engine control sensor wiring connector to the sensor.
14. 
Install the ignition coil bracket, radio ignition capacitor and ignition coil.
15. 
Connect the negative battery cable.
16. 
4.0L SOHC Engine (VIN E) Disconnect the negative battery cable.
1. 
Disconnect the engine control sensor wiring from the camshaft position sensor.
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560 REMOVAL & INSTALLATION 
						

							Remove the sensor retaining screw and the sensor from the left-hand valve cover.
3. 
To install: Make sure the camshaft position sensor mounting surface is clean and the O-ring is positioned
correctly.
4. 
Position the sensor, then install the retaining screw and tighten it to 71-106 inch lbs. (8-12 Nm).
5. 
WARNING
Do not overtighten the screw; you may damage the sensor if the retaining screw is overtightened
Engage the wiring harness connector to the CMP sensor.
6. 
Connect the negative battery cable.
7. 
Crankshaft Position (CKP) Sensor
OPERATION
The Crankshaft Position (CKP) sensor, located on the front cover (near the crankshaft pulley) is used to
determine crankshaft position and crankshaft rpm. The CKP sensor is a reluctance sensor which senses the
passing of teeth on a sensor ring because the teeth disrupt the magnetic field of the sensor. This disruption
creates a voltage fluctuation, which is monitored by the PCM.
The CKP sensor (A) is triggered by the teeth which are machined into the crankshaft damper (B)
TESTING
Using a DVOM set to the DC scale to monitor less than 5 volts, measure the voltage between the sensor
Cylinder Identification (CID) terminal and ground by backprobing the sensor connector. If the connector
cannot be backprobed, fabricate or purchase a test harness. The sensor is okay if the voltage reading varies
more than 0.1 volt with the engine running at varying RPM. HOW TO USE THIS BOOK
Crankshaft Position (CKP) Sensor 561 
						

							... then unbolt the sensor and pull it away from the engine-crankshaft damper removed for
clarity
To install:
When installing a new sensor on the 4.0L (VIN X and E), position the sensor against the crankshaft
damper. There are small rub tabs which wear off and allow the sensor to be perfectly spaced from the
damper.
Position the sensor against the engine front cover, then install the mounting stud/bolts. Tighten them
until snug.
4. 
Install the CKP sensor cover and retaining nuts; tighten the nuts until snug.
5. 
Reattach the wiring harness connector to the CKP sensor.
6. 
Connect the negative battery cable.
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REMOVAL & INSTALLATION 563 
						

							Exploded view of the 2.3L and 2.5L Crankshaft Position (CKP) sensor
Click to enlarge
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564 REMOVAL & INSTALLATION 
						

							Exploded view of the 3.0L Crankshaft Position (CKP) sensor-5.0L engine is similar
Click to enlarge
Exploded view of the 4.0L (VIN X) Crankshaft Position (CKP) sensor-4.0L SOHC (VIN E) engine is similar
Vehicle Speed Sensor(VSS) HOW TO USE THIS BOOK
Vehicle Speed Sensor(VSS) 565 
						

							
OPERATION
The Vehicle Speed Sensor (VSS) is a magnetic pick-up that sends a signal to the Powertrain Control Module
(PCM). The sensor measures the rotation of the transmission and the PCM determines the corresponding
vehicle speed.
TESTING Turn the ignition switch to the OFFposition.
1. 
Disengage the wiring harness connector from the VSS.
2. 
Using a Digital Volt-Ohmmeter (DVOM), measure the resistance (DVOM ohmmeter function)
between the sensor terminals. If the resistance is 190-250 ohms, the sensor is okay.
3. 
Typical Vehicle Speed Sensor (VSS) and its wiring harness connections
REMOVAL & INSTALLATION
The VSS is located half-way down the right-hand side of the transmission assembly. Apply parking brake, block the rear wheels, then raise and safely support the front of the vehicle on
jackstands.
1. 
From under the right-hand side of the vehicle, disengage the wiring harness connector from the VSS.
2. 
Loosen the VSS hold-down bolt, then pull the VSS out of the transmission housing.
3. 
To install: If a new sensor is being installed, transfer the driven gear retainer and gear to the new sensor.
4. 
Ensure that the O-ring is properly seated in the VSS housing.
5. 
For ease of assembly, engage the wiring harness connector to the VSS, then insert the VSS into the
transmission assembly.
6. 
Install and tighten the VSS hold-down bolt to 62-88 inch lbs. (7-10 Nm).
7. 
Lower the vehicle and remove the wheel blocks.
8. 
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
566 OPERATION