1994
1994 Ford
Ford Explorer
Explorer
1994
1994 ENGINE
ENGINE PERFORMANCE
PERFORMANCE Removal,
Removal, Overhaul
Overhaul &
& Installation
Installation -- 4.0L
4.0L
1994 ENGINE PERFORMANCE
Removal, Overhaul & Installation - 4.0L
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 COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION section before
disconnecting battery.
IGNITION SYSTEM
DISTRIBUTOR
Removal & Installation
1. Disconnect wiring harness from distributor. Mark position of No. 1 cylinder wire tower on distributor
base or housing for installation reference. See Fig. 5 .
2. Loosen distributor cap hold-down screws. Remove cap carefully to prevent damaging rotor blade and
spring. Position cap and attached wires aside.
3. Remove rotor by pulling upward from the distributor shaft. Remove distributor hold-down bolt and
clamp. Remove distributor. Cover distributor opening in engine with clean shop towel. To install, reverse
removal procedure.
CAMSHAFT POSITION (CMP) SENSOR (CALIFORNIA)
NOTE: CMP sensor may be refered to as CID sensor.
Removal
Position crankshaft to TDC of cylinder No. 1. Disconnect negative battery cable. Remove upper intake
manifold. See UPPER INTAKE MANIFOLD & THROTTLE BODY under FUEL SYSTEM. Unplug
harness connector from CMP sensor. Remove CMP sensor holdown and CMP sensor.
Installation
1. Lubricate oil pump drive pinion, flange and O-ring. DO NOT get oil above mounting flange.
2. Rotate crankshaft until TDC mark on damper is accessible. Place a mark on the damper at 26 degrees
After Top Dead Center 1.34 inches (34 mm) counterclockwise from TDC mark. See Fig. 1 . Rotate
crankshaft to position No. 1 cylinder at TDC.
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Mitchell
Mitchell
Repair
Repair
Information
Information
Company,
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LLC.
LLC.
1994 Ford Explorer
1994 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4.0L
Fig. 1: Marking Cranshaft Damper
Courtesy of FORD MOTOR CO.
3. Align sensor rotor with trailing edge of vane lined up with short mark at the left hand side of the plastic
window. See Fig. 2 . Position the sensor above its hole at right angles to the block rear face with wiring
connector pointing rearward.
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1994 Ford Explorer
1994 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4.0L
Fig. 2: Aligning Sensor In Window
Courtesy of FORD MOTOR CO.
4. Install assembled sensor and oil pump drive gear into engine. As assembly is pushed into place, sensor
vane will rotate clockwise toward center of window. See Fig. 3 . Rotate sensor counterclockwise. Install
clamp and screw finger tight. Rotate sensor back to position at right angles to back of [Link] Fig. 4 .
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1994 Ford Explorer
1994 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4.0L
Fig. 3: Installing Sensor In Engine
Courtesy of FORD MOTOR CO.
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1994 Ford Explorer
1994 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4.0L
Fig. 4: Location While Installing Clamp & Screw
Courtesy of FORD MOTOR CO.
5. Connect CID Testing Wiring Harness (T94T-50-B) to sensor as follows:
Red harness wire to battery positive terminal.
Black harness wire to battery negative terminal.
White harness lead to voltmeter positive lead.
Voltmeter negative lead to battery negative terminal.
Rotate engine 2 revolutions to take up slack in timing chain, and verify that No. 1 cylinder is on
compression stroke. Continue to rotate crankshaft until 26 degree ATDC mark lines up with timing
pointer.
NOTE: Voltmeter will register battery voltage when sensor closes and completes
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1994 Ford Explorer
1994 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4.0L
circuit.
NOTE: Final movement to set sensor must be counterclockwise direction.
6. While rotating sensor, note exact point where sensor switches from zero to battery voltage.
Rotate sensor clockwise past switching point from battery voltage to zero volts. Rotate sensor
counterclockwise and stop at exact point voltmeter switches from zero volts to battery voltage. Tighten
CMP sensor hold down bolt to specification. See TORQUE SPECIFICATIONS . Disconnect testing
harness and connect sensor harness.
CRANKSHAFT POSITION SENSOR (CKP)
Removal
Disconnect negative battery cable. Unplug crankshaft sensor wire connector from engine harness. Remove
crankshaft sensor mounting screws. Remove crankshaft sensor. See Fig. 5 .
Installation
Place crankshaft sensor into position. Install and tighten mounting screws. Reconnect crankshaft sensor wiring.
Fig. 5: Locating Crankshaft Sensor (4.0L)
Courtesy of FORD MOTOR CO.
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1994 Ford Explorer
1994 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4.0L
FUEL SYSTEM
FUEL SYSTEM PRESSURE RELEASE
WARNING: ALWAYS relieve fuel pressure before disconnecting any fuel injection-
related component. DO NOT allow fuel to contact engine or electrical
components.
Disconnect negative battery cable. Remove fuel cap to release fuel tank pressure. Using EFI Pressure Gauge
(T80L-9974-B), release fuel pressure from relief valve. Relief valve is located on fuel supply manifold.
FUEL PUMP
Removal
Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM . Remove fuel
tank. Using Wrench (T74P-9275-A), carefully rotate lock ring counterclockwise to release pump. Remove fuel
pump from tank.
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
NOTE: Ensure engine is clean before removing fuel supply manifold assembly.
Removal
1. Disconnect negative battery cable. Remove snow/ice shield. Remove air inlet tube from air cleaner to
throttle body. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL
SYSTEM.
2. Remove upper intake manifold and throttle body assembly. See UPPER INTAKE MANIFOLD &
THROTTLE BODY under FUEL SYSTEM. Disconnect fuel supply line fitting at fuel manifold.
3. Disconnect fuel return line from fuel pressure regulator. See PUSH-CONNECT FITTINGS under
FUEL SYSTEM. Remove fuel manifold retaining bolts. Remove fuel manifold. Remove injectors from
manifold. See Fig. 6 .
Installation
Lubricate NEW injector "O" rings with a 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.
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1994 Ford Explorer
1994 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4.0L
Fig. 6: Multi-Point Fuel Injection System (4.0L)
Courtesy of FORD MOTOR CO.
FUEL INJECTORS
Removal
1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM. Remove
upper intake manifold and throttle body assembly. See UPPER INTAKE MANIFOLD & THROTTLE
BODY under FUEL SYSTEM.
2. Remove fuel supply manifold. See FUEL SUPPLY MANIFOLD ASSEMBLY under FUEL SYSTEM.
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.
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1994 Ford Explorer
1994 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4.0L
FUEL PRESSURE REGULATOR
Removal
1. Disconnect negative battery cable. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE
under FUEL SYSTEM. Remove vacuum hose at fuel pressure regulator. Remove fuel line.
2. On 3.0L models, loosen or remove fuel rail-to-intake manifold bolts for access to regulator housing
screws. On all models, remove screws from regulator housing. Remove pressure regulator, gasket, and
"O" ring.
Installation
Lubricate "O" ring with a light oil. DO NOT use silicone grease. Ensure regulator and manifold gasket surfaces
are clean and dry. To complete installation, reverse removal procedure.
HEATED EXHAUST GAS OXYGEN SENSOR (HO2S)
Removal
Disconnect negative battery cable. Locate O2 sensor, mounted in exhaust pipe below exhaust manifold, or in
"Y" pipe junction near catalytic converter inlet. See Fig. 7 . Unplug electrical connector from O2 sensor. Sensor
may be difficult to remove when engine temperature is less than 120°F (48°C). Carefully remove O2 sensor
from exhaust pipe.
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1994 Ford Explorer
1994 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4.0L
Fig. 7: Locating HO2S
Courtesy of FORD MOTOR CO.
Installation
When replacing O2 sensor, coat threads with anti-seize compound before installation. New O2 sensors should
already have this compound applied to threads. Install O2 sensor. Reconnect wiring connector to O2 sensor.
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
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1994 Ford Explorer
1994 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4.0L
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 D87L-9280-A
1/2" Line D87L-9280-B
5/8" Line T83P-19623-C
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1994 Ford Explorer
1994 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4.0L
Fig. 8: Disconnecting Fuel Lines With Spring Lock Coupler
Courtesy of FORD MOTOR CO.
Removal & Installation (Fuel Line Coupler)
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1994 Ford Explorer
1994 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4.0L
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 FUEL SUPPLY MANIFOLD
ASSEMBLY under FUEL SYSTEM.
Fig. 9: Disconnecting Fuel Line Coupler With Key
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1994 Ford Explorer
1994 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4.0L
Courtesy of FORD MOTOR CO.
UPPER INTAKE MANIFOLD & THROTTLE BODY
Removal
1. Unplug electrical connectors at air by-pass valve, throttle position sensor, and intake air temperature
sensor. Remove snow/ice shield. Remove throttle cable bracket.
2. Disconnect cable from ball stud on throttle body. Remove air cleaner-to-throttle body air inlet tube.
Disconnect upper intake manifold vacuum connectors. Disconnect PCV valve from rocker cover.
3. Disconnect spark plug wires at rear of manifold. Remove canister purge line from fitting in throttle
housing.
4. Remove A/C line-to-upper manifold bolt. Remove 6 upper manifold retaining bolts. Remove upper intake
and throttle body, as an assembly, from lower intake and fuel supply manifolds. See Fig. 10 .
Installation
Clean and oil manifold bolt threads. Install NEW manifold gasket. If injectors were removed, lubricate NEW
injector "O" rings with light oil. DO NOT use silicone grease. To complete installation, reverse removal
procedure.
Fig. 10: Upper Intake Manifold Assembly (4.0L)
Courtesy of FORD MOTOR CO.
THROTTLE POSITION SENSOR (TPS)
Removal
Remove air by-pass valve (if necessary). Unplug TPS wiring harness connector. Remove TPS retaining screws.
Remove TPS and gasket.
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1994 Ford Explorer
1994 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4.0L
Installation
Position TPS and gasket onto throttle body, with tangs aligned with throttle shaft blade. To complete
installation, reverse removal procedure.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Fuel Supply Manifold Bolts 7-10 (10-14)
Lower Intake Manifold Bolts 15-18 (20-24)
O2 Sensor 30 (41)
Throttle Body-To-Manifold Bolts 6-9 (8-12)
Upper Intake Manifold Bolts 15-18 (20-24)
INCH Lbs. (N.m)
Camshaft Position Sensor Bolts 22-31 (2.5-3.5)
Crankshaft Position Sensor Bolts 75-106 (9-12)
Fuel Pressure Regulator Bolts 71-98 (8-11)
Fuel Supply Manifold Bolts 72-84 (8-11)
Pressure Relief Valve Cap 4-6 (.5-.7)
Thermostat Housing Bolts 71-98 (8-11)
Throttle Position Sensor Screws 11-16 (1.2-1.8)
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