REMOVAL & INSTALLATION
Distributor Cap and Rotor
See Figures 1, 2, 3, 4, 5, 6 and 7
- Disconnect the negative battery cable.
- If equipped, remove the distributor cap cover, then disengage the electrical connector, if applicable.
Fig. Fig. 1: If equipped, remove the distributor cap cover
Fig. Fig. 2: Disengage the electrical connector
- If necessary, tag and remove the spark plug wires from the cap.
- Loosen the distributor hold-down screws.
- Remove the distributor cap by lifting it straight off the distributor to prevent damage to the rotor blade and spring.
Fig. Fig. 3: Lift the distributor cap straight up to prevent damage to the rotor blade and spring
- Matchmark the position of the rotor, then pull it upward to remove it from the distributor shaft and armature.
Fig. Fig. 4: Matchmark the position of the rotor for installation purposes
Fig. Fig. 5: Pull the rotor upward to remove it from the distributor shaft and armature
To install:
- Install the rotor according to the marks made during removal, making sure to align the locating boss on the rotor with the hole on the armature, then fully seat the rotor on the distributor shaft.
Fig. Fig. 6: View of the spring, blade and the locating boss on the rotor
- Position the distributor cap on the housing, noting the square alignment locator, if equipped. Tighten the hold-down screws to 18-23 inch lbs. (2.0-2.6 Nm).
Fig. Fig. 7: Location of the square alignment indicator on the distributor cap
- If removed, connect the spark plug wires to their correct location on the distributor cap as tagged during removal.
- If equipped, install the distributor cap cover, then connect the negative battery cable.
Ignition Coil
See Figures 8, 9, 10, 11 and 12
- Disconnect the negative battery cable.
- Disconnect the distributor-to-ignition coil wire from the ignition coil.
Fig. Fig. 8: Disconnect the distributor-to-ignition coil wire-early model 2.5L shown
- Disengage the TFI-IV harness or the engine control sensor wiring connector from the ignition coil, as applicable.
Fig. Fig. 9: Disengage the engine wiring connector from the coil-early model 2.5L shown
- On the 3.8L engine, disengage the engine control wiring connector from the radio ignition interference capacitor.
- Remove the ignition coil retaining screws and the ignition coil and radio interference capacitor (if equipped) from the ignition coil mounting bracket.
Fig. Fig. 10: Remove the ignition coil retaining screws
- Remove the ignition coil cover from the ignition coil by releasing the locking tabs on both sides of the cover, then remove the ignition coil.
Fig. Fig. 11: Ignition coil and related components-late model 3.0L shown
Fig. Fig. 12: Ignition coil and related components-late model 3.8L shown
To install:
- Install the ignition coil, then attach ignition coil cover, making sure the cover is firmly in place.
- If removed, connect the ignition coil and radio interference capacitor, then install the ignition coil retaining screws. Tighten the retaining screws to 25-35 inch lbs. (2.8-4.0 Nm).
- Connect the coil wire, then engage any electrical connectors that were removed.
- Connect the negative battery cable.
Ignition Control Module (ICM)
In earlier models, the ICM was referred to as the TFI-IV Ignition Module; the name was later changed to Ignition Control Module (ICM).
2.5L AND 3.0L ENGINES
See Figure 13
- Remove the distributor cap and position it away from the work area, with the wires still attached.
- Disengage the engine control sensor wiring connector (late model vehicles) or the TFI-IV harness connector from the ignition control module.
- Remove the distributor from the engine. For details, please refer to the procedure located later in this section.
- Place the distributor on a work bench, then remove the two module retaining screws.
Do NOT attempt to lift the module from the mounting surface before moving the entire module toward the distributor flange! This will cause the pins to break at the distributor/module connector.
- Pull the right-hand side of the module down toward the distributor mounting flange and back up to disengage the module terminals from the connector in the distributor housing. The module may then be pulled toward the flange and away from the distributor.
- Remove the module from the distributor.
Fig. Fig. 13: The ignition control module (or TFI ignition module, as applicable), is located on the distributor
To install:
- Coat the metal base of the module with Silicone Dielectric Compound D7AZ-19A331-A, or equivalent meeting Ford specifications, approximately 1 / 32 in. (0.79mm) thick.
- Place the module on the distributor housing mounting flange.
- Carefully position the module toward the distributor housing, then align the three distributor connecting pins.
- Install the two module retaining screws, then starting with the upper right-hand screw, tighten the screws to 15-35 inch lbs. (1.7-4.0 Nm).
- Install the distributor as explained later in this section.
- Install the distributor cap, then tighten the mounting screws to 18-23 inch lbs. (2.0-2.6 Nm).
- Engage the engine control sensor wiring connector or TFI-IV harness connector, as applicable, to the module.
- Connect the negative battery cable.
- Using an inductive timing light, check the timing and adjust as necessary. This procedure is covered later in this section.
3.8L ENGINE
See Figure 14
- Disconnect the negative battery cable.
- Remove the screws attaching the cowl vent screen to the top of the cowl.
- Separate the engine compartment cowl seal strip from the cowl vent screen and the cowl dash extension panel in the area of the ignition control module.
- Lift the cowl vent screen off to allow access to the ignition control module/TFI module assembly.
The connector latch is underneath the ICM/TFI shroud. Press upward to unlatch.
- Disengage the engine control sensor wiring connector from the ICM or TFI, as applicable.
The ignition control module and heatsink are mounted with the heatsink fins pointed downward.
- Remove the two retaining nuts attaching the ICM/TFI and heatsink to the dash panel, then remove the ICM/TFI and the heatsink.
- Remove the two module retaining screws, then remove the ICM or TFI from the heatsink.
- While holding the module connector shroud with one hand, pull the seal off the other end of the module.
Fig. Fig. 14: Location of the ignition control module-3.8L engines only
To install:
- Coat the metal base of the ICM or TFI module uniformly with Silicone Dielectric Compound D7AZ-19A331-A or equivalent, about 1 / 32 in. (0.79mm) thick.
- Place the module onto the heatsink. Install the retaining screws, then tighten them to 15-35 inch lbs. (1.7-4.0 Nm).
- Push the seal over the module connector shroud and heatsink studs with the metal part toward the heatsink.
- Insert the module and heatsink into the cowl dash extension panel enough to have the mounting studs protrude into the engine compartment side.
- Hand-tighten the retaining nuts to 44-70 inch lbs. (5-8 Nm).
- Engage the engine control sensor wiring connector to the module.
- Install the cowl vent screen and retaining screws, then install the engine compartment cowl panel and seal strip.
- Connect the negative battery cable.
Distributor
See Figures 15, 16, 17, 18 and 19
- Disconnect the negative battery cable.
- Disconnect the engine control sensor wiring from the distributor.
- With a marker, chalk or crayon, mark the position of the No. 1 cylinder distributor cap wire tower on the distributor housing for installation reference.
- Loosen the distributor cap hold-down screws, then pull the cap straight up and off the distributor to prevent damage to the distributor rotor blade and spring.
- Position the distributor cap with the ignition wires intact, out of the way.
Fig. Fig. 15: Position the cap with the wires intact out of the way for ease of removal
- Matchmark the position of the rotor, then remove it by pulling it upward from the distributor shaft and armature.
- Disconnect the hold-down clamp and distributor retaining bolt, then remove the distributor from the engine by pulling it upward.
Fig. Fig. 16: Removing the distributor hold-down bolt. Note: The preferred method requires the removal of the rotor when removing the distributor.
Fig. Fig. 17: Lift the distributor from the engine; once the distributor is lifted partly out it, may be tilted slightly and removed
- Cover the distributor opening in the cylinder block or engine front cover, as applicable, with a clean rag to prevent any foreign material or debris from entering the engine.
To install:
CAUTION
Before installing the distributor, you must coat the entire drive gear and the camshaft distributor gear through the distributor hole with Engine Assembly Lubricant D9AZ-19579-D or equivalent.
Inspect the distributor before installing it. Inspect the O-ring. It should fit tightly and NOT have any cuts. The distributor drive gear should be free of nicks, cracks and excessive wear. When rotated, the distributor should move freely, without binding.
Fig. Fig. 18: If the O-ring is cracked or nicked, it must be replaced
TIMING NOT DISTURBED
This condition exists if the engine has not been rotated while the distributor was removed.
- Install the distributor and the rotor, aligning the distributor housing and the rotor with the marks made during removal.
- Install the distributor hold-down bolt and clamp. Only snug the bolt at this time.
- Connect the wiring harness to the distributor.
- Install the rotor and the distributor cap. Make sure the ignition wires are securely connected to the distributor cap and spark plugs. Tighten the distributor cap screws to 18-23 inch lbs. (2.0-2.6 Nm).
- Connect a suitable timing light to the engine (following the manufacturer's instructions) and connect the negative battery cable, then start the engine and set the initial timing. Timing procedures are located later in this section.
- Turn the engine OFF , then tighten the distributor hold-down bolt to 17-25 ft. lbs. (23-34 Nm) on the 2.5L engine, 14-21 ft. lbs. (19-28 Nm) on the 3.0L engine, or 20-29 ft. lbs. (27-39 Nm) on the 3.8L engine.
- Start the engine and recheck the timing to verify it did not change while tightening the hold-down bolt, then stop the engine and remove the timing light.
Fig. Fig. 19: After the distributor is installed, check the timing with a timing light
TIMING DISTURBED
This condition exists if the engine has been rotated with the distributor removed. To correctly install the distributor, the No. 1 piston must be at TDC of the compression stroke.
- Disconnect the spark plug wire and the spark plug from the No. 1 cylinder.
- Place your finger over the spark plug hole, then rotate the engine clockwise (by turning the crankshaft pulley) until compression is felt at the spark plug hole.
- With the No. 1 piston on the compression stroke, align the timing pointer with the TDC mark on the crankshaft damper.
- Align the locating boss on the rotor with the hole on the armature. Install the rotor on the distributor shaft, making sure it is fully seated on the distributor shaft. Rotate the shaft so the rotor tip is pointing toward the distributor cap's No. 1 spark plug tower position.
- While installing the distributor, continue turning the rotor slightly, so the leading edge of the vane is centered in the distributor stator assembly.
- Rotate the distributor in the block to align the leading edge of the vane and distributor stator assembly. Make sure the rotor is pointing toward the distributor cap No. 1 spark plug tower position.
If the vane and distributor stator cannot be aligned by rotating the distributor in the block, remove the distributor just enough to disengage the distributor gear from the camshaft gear. Turn the rotor enough to engage the distributor gear on another tooth of the camshaft gear. Repeat this procedure, if necessary.
- Install the distributor hold-down bolt and clamp. Only snug the bolt at this time.
- Connect the wiring harness to the distributor, then install the distributor cap. Tighten the distributor cap hold-down screws to 18-23 inch lbs. (2.0-2.6 Nm).
- Install the No. 1 spark plug and wire.
- Connect a suitable timing light (following the manufacturer's instructions) and connect the negative battery cable. Start the engine, then check and adjust the timing, as necessary.
- Turn the engine OFF , then tighten the distributor hold-down bolt. Tighten the bolt to 17-25 ft. lbs. (23-34 Nm) on the 2.5L engine, 14-21 ft. lbs. (19-28 Nm) on the 3.0L engine, or 20-29 ft. lbs. (27-40 Nm) on the 3.8L engine.
- Start the engine and recheck the timing to verify it did not change while tightening the hold-down bolt, then stop the engine and remove the timing light.