• HEADINGS
  • INTRODUCTION
  • IGNITION SYSTEM
    • DISTRIBUTOR
      • Removal
      • Installation
      • Distributor Overhaul
    • CAMSHAFT POSITION (CMP) SENSOR
    • CRANKSHAFT POSITION (CKP) SENSOR
      • Removal & Installation
    • POWERTRAIN CONTROL MODULE
      • Removal & Installation
  • FUEL SYSTEM
    • CAMSHAFT POSITION (CMP) SENSOR
      • Removal & Installation
    • CMP SYNCHRONIZER
      • Removal
      • Installation
    • FUEL SYSTEM PRESSURE RELEASE
    • FUEL PUMP
      • Removal
      • Installation
    • FUEL SUPPLY MANIFOLD ASSEMBLY
      • Removal & Installation
    • FUEL INJECTORS
      • Installation
    • FUEL PRESSURE REGULATOR
      • Removal
      • Installation
    • HEATED OXYGEN SENSOR (HO2S)
      • Removal
      • Installation
    • PUSH-CONNECT FITTINGS
      • Spring Lock Coupling
      • Removal & Installation (Fuel Line Coupler)
    • UPPER INTAKE MANIFOLD & THROTTLE BODY
      • Removal
      • Installation
  • TORQUE SPECIFICATIONS
• FIGURES
  • Fig. 1: Exploded View Of Distributor
  • Fig. 2: Locating Crankshaft Position (CKP) Sensor (Typical)
  • Fig. 3: Exploded View Of CMP Synchronizer Assembly (Typical)
  • Fig. 4: Installing Synchro Positioner On Synchronizer Assembly (Typical)
  • Fig. 5: Identifying Synchronizer Alignment
  • Fig. 6: Multiport Fuel Injection System
  • Fig. 7: Locating Heated Oxygen Sensors (5.0L)
  • Fig. 8: Disconnecting Fuel Lines With Spring Lock Coupler
  • Fig. 9: Disconnecting Fuel Line Coupler With Key
• TABLES
  • PCM LOCATIONS
  • INERTIA FUEL SHUTOFF (IFS) SWITCH LOCATION
  • FUEL TANK LOCK RING WRENCH IDENTIFICATION
  • SPRING LOCK COUPLER IDENTIFICATION
  • TORQUE SPECIFICATIONS

N - REMOVE/INSTALL/OVERHAUL - 5.0L

1996 ENGINE PERFORMANCE Ford Motor Co. - Removal, Overhaul & Installation

INTRODUCTION

Removal, overhaul, and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

CAUTION:

When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See the COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section before disconnecting battery.

IGNITION SYSTEM

DISTRIBUTOR

Removal

1. Remove high tension leads and distributor cap. Rotate crankshaft in direction of normal rotation until piston No. 1 is at TDC of compression stroke. Disconnect negative battery cable.
2. Ensure timing marks are aligned. Disconnect distributor wiring from harness. Mark distributor rotor-to-housing and housing-to-engine position for installation reference. Remove distributor hold-down bolt(s) and clamp.
3. If necessary, use Distributor Hold-Down Wrench (T82L-12270-A) to remove bolt. Remove distributor. Inspect distributor "O" ring and replace if necessary.

Installation

1. Ensure engine is at TDC of compression stroke. Rotate distributor rotor so reference marks nearly align. Insert distributor drive into engine.
2. When installing distributor, rotor will rotate. Ensure reference marks are aligned when distributor is fully engaged in engine. To complete installation, reverse removal procedure. Set base ignition timing. See the ADJUSTMENTS - 5.0L article.

Distributor Overhaul

1. Using an Allen wrench, hold distributor shaft from turning while removing armature bolts. DO NOT clamp shaft. Remove screws and armature. Place witness marks on drive gear, thrust collar and shaft. Using a felt-tip pen, mark shaft and gear for installation reference. Remove and discard roll pin from gear.
2. Place distributor in Axle Bearing Remover (T75L-1165-B). Press off gear using arbor press and Pinion Bearing Cone Remover (D79L-4621-A). Remove shaft. Using emery cloth, remove burrs from distributor shaft. Remove shaft from distributor assembly. See Fig. 1 .
3. Remove thrust washer from distributor (if equipped), and save for installation. Remove screw and octane rod. Remove stator assembly screws and stator.
4. 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.

Fig. 1: Exploded View Of Distributor
Courtesy of FORD MOTOR CO.

CAMSHAFT POSITION (CMP) SENSOR

See CAMSHAFT POSITION (CMP) SENSOR or CMP SENSOR & SYNCHRONIZER under FUEL SYSTEM .

CRANKSHAFT POSITION (CKP) SENSOR

NOTE:

Engine front cover design precisely locates CKP sensor. No CKP sensor adjustment is necessary.

Removal & Installation

Disconnect negative battery cable. Raise and support vehicle. Unplug Crankshaft Position (CKP) sensor wire connector from engine harness. See Fig. 2 . Remove CKP sensor mounting screws. Remove CKP sensor. To install, reverse removal procedure.

Fig. 2: Locating Crankshaft Position (CKP) Sensor (Typical)
Courtesy of FORD MOTOR CO.

CAUTION:

When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See the COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section before disconnecting battery.

POWERTRAIN CONTROL MODULE

Removal & Installation

Disconnect negative battery cable. Remove any component necessary to gain access to PCM. Loosen PCM connector retaining bolt (if equipped). Unplug harness connector from PCM. Remove 2 PCM mounting bolts. Remove PCM cover and PCM. To install, reverse removal procedure.

PCM LOCATIONS

Model	Location
Explorer	In Cowl Area (Passenger Side)

FUEL SYSTEM

CAMSHAFT POSITION (CMP) SENSOR

Removal & Installation

Note position of electrical connector on CMP sensor. Unplug harness connector from CMP sensor. Remove CMP sensor screws and CMP sensor. To install, reverse removal procedure. Tighten CMP sensor to specification. See TORQUE SPECIFICATIONS .

Fig. 3: Exploded View Of CMP Synchronizer Assembly (Typical)
Courtesy of FORD MOTOR CO.

CMP SYNCHRONIZER

CAUTION:

Synchro Positioner for 5.0L (T96T-12200-A) is required to properly reinstall synchronizer. See Fig. 3 . Failure to use synchro positioner during installation will cause fuel injection to be out of time and may cause engine damage.

Removal

1. Position crankshaft to TDC of cylinder No. 1, on compression stroke. Note position of electrical connector on CMP sensor.
2. Disconnect negative battery cable. Unplug harness connector from CMP sensor. Remove CMP sensor screws and CMP sensor from positioner. Remove synchronizer hold-down bolt and CMP synchronizer.

CAUTION:

Do not rotate crankshaft while synchronizer is removed from engine.

Installation

1. Install Synchro Positioner (T96T-12200-A) on synchronizer housing. See Fig. 4 . Rotate synchronizer shaft until vane on shaft aligns with slot on synchro positioner. Rotate synchro positioner until engaged into notch in housing. Dip drive gear in engine oil.

   Fig. 4: Installing Synchro Positioner On Synchronizer Assembly (Typical)
   Courtesy of FORD MOTOR CO.

NOTE:

If camshaft position sensor electrical connector is not positioned properly, DO NOT reposition the connector by rotating the synchronizer assembly. This will result in the fuel system being out of time with the engine, possibly causing engine damage. Remove the synchronizer assembly and repeat this step.

2. Install synchronizer assembly into engine. Ensure synchro positioner is pointing directly forward (parallel to crankshaft centerline). See Fig. 5 . Synchronizer electrical connector should be located in original position.
3. Install hold-down clamp and tighten bolt to specification. See TORQUE SPECIFICATIONS . Install CMP sensor to synchronizer and tighten to specification. Reconnect wiring to CMP sensor. Connect negative battery cable.

Fig. 5: Identifying Synchronizer Alignment
Courtesy of FORD MOTOR CO.

FUEL SYSTEM PRESSURE RELEASE

WARNING:

ALWAYS relieve fuel pressure before disconnecting any component under fuel pressure. DO NOT allow fuel to contact engine or electrical components.

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. See INERTIA FUEL SHUTOFF (IFS) SWITCH LOCATION table. Remove fuel cap to release fuel tank pressure. Crank engine for 15 seconds to release system pressure.

INERTIA FUEL SHUTOFF (IFS) SWITCH LOCATION

Application	Location
Explorer	Under Instrument Panel, Near Right Side Of Transmission Hump

FUEL PUMP

Removal

Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM. Remove fuel tank. Using fuel tank lock ring wrench, carefully rotate lock ring counterclockwise to release pump. See FUEL TANK LOCK RING WRENCH IDENTIFICATION table. Remove fuel pump from tank.

FUEL TANK LOCK RING WRENCH IDENTIFICATION

Application	Tool No.
Explorer	T90T-9275-A

Installation

Wipe seal area of tank clean. Position new "O" ring seal onto pump, using grease to hold it in position. Position fuel pump in tank so fuel return hose is not kinked. Install lock ring. DO NOT overtighten pump lock ring, as it may leak. Install fuel tank.

FUEL SUPPLY MANIFOLD ASSEMBLY

Removal & Installation

1. Disconnect negative battery cable. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove upper intake manifold and throttle body assembly. See UPPER INTAKE MANIFOLD & THROTTLE BODY .
2. Disconnect fuel supply and return line connections at fuel supply manifold. Remove fuel supply manifold retaining bolts. Remove fuel supply manifold with injectors by pulling upwards on injectors using a rocking action. Carefully disengage fuel injectors from supply manifold. To install, reverse removal procedure. See Fig. 6 .

Fig. 6: Multiport Fuel Injection System
Courtesy of FORD MOTOR CO.

FUEL INJECTORS

Remove fuel supply manifold. See procedures under FUEL SUPPLY MANIFOLD ASSEMBLY . Disconnect wiring harness from injector(s). Remove injector retaining clips(s). Remove injectors from fuel supply manifold, using a rocking/pulling motion.

Installation

Lubricate NEW injector "O" rings with light oil. DO NOT use silicone grease. To complete installation, reverse removal procedure.

FUEL PRESSURE REGULATOR

Removal

1. Disconnect negative battery cable. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE .
2. Remove vacuum hose from fuel pressure regulator. Remove 2 mounting screws from fuel pressure regulator. Remove fuel pressure regulator, gasket, and "O" ring.

Installation

Lubricate "O" ring with light oil. DO NOT use silicone grease. Ensure regulator and manifold gasket surfaces are clean and dry. To complete installation, reverse removal procedure.

HEATED OXYGEN SENSOR (HO2S)

Removal

Unplug electrical connector from HO2S. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Carefully remove HO2S sensor from exhaust pipe. See Fig. 7 .

Fig. 7: Locating Heated Oxygen Sensors (5.0L)
Courtesy of FORD MOTOR CO.

Installation

When replacing HO2S, coat threads with anti-seize compound before installation. New sensors should already have this compound applied to threads. Install HO2S sensor. Reconnect wiring connector to HO2S. Reconnect negative battery terminal.

PUSH-CONNECT FITTINGS

Spring Lock Coupling

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM. Place indicated spring lock coupler over coupling. See SPRING LOCK COUPLER IDENTIFICATION table. To release female fitting from garter spring, push coupler along tube into coupling. See Fig. 8 .
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 refrigerant 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

Application	Tool Number
3/8" Line	T81P-19623-G1
1/2" Line	T81P-19623-G2
5/8" Line	T83P-19623-C

Fig. 8: Disconnecting Fuel Lines With Spring Lock Coupler
Courtesy of FORD MOTOR CO.

Removal & Installation (Fuel Line Coupler)

1. Disengage locking tabs on connector retainer. Separate retainer halves. Disengage fitting from regulator by pushing fitting toward regulator and inserting Fuel Line Coupling Key (T90P-9550-A). See Fig. 9 .
2. To reconnect fuel line coupling, push coupler tube assembly firmly into coupler body recess until fully engaged. Pull gently on both ends of coupler to ensure engagement. See procedures under FUEL SUPPLY MANIFOLD ASSEMBLY under FUEL SYSTEM.

Fig. 9: Disconnecting Fuel Line Coupler With Key
Courtesy of FORD MOTOR CO.

UPPER INTAKE MANIFOLD & THROTTLE BODY

Removal

1. Disconnect electrical leads at air by-pass valve, throttle position sensor, and EGR position sensor. Disconnect throttle linkage at pivot ball. On A/T models, remove transmission linkage from throttle body.
2. Remove bracket from intake manifold. Position bracket and cables aside. Remove vacuum hoses at upper intake manifold vacuum tee, EGR valve, and fuel pressure regulator.
3. Disconnect PCV system by removing hose from fitting on rear of upper intake manifold. Remove 2 canister purge lines from fitting on throttle body. Disconnect heater hoses from throttle body.
4. Disconnect EGR tube from EGR valve. Remove upper intake manifold support bracket. Remove manifold retaining bolts. Remove upper intake manifold and throttle body as an assembly.

Installation

To install, reverse removal procedure. Use NEW gasket between upper and lower intake manifolds. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application	Ft. Lbs. (N.m)
Lower Intake Manifold Bolts	22-32 (30-43)
Oxygen Sensor	30 (41)
Throttle Body-To-Manifold Bolts	12-18 (16-24)
Upper Intake Manifold Bolts	12-18 (16-24)
INCH Lbs. (N.m)
Camshaft Position Sensor Bolts	22-31 (2.5-3.5)
Fuel Pressure Regulator Bolts	27-40 (3-4.5)
Fuel Supply Manifold Bolts	71-97 (8-11)
Pressure Relief Valve Cap	4-6 (.5-.7)
Thermostat Housing Bolts	71-97 (8-11)
Throttle Position Sensor Screws	18-27 (2.0-3.0)