Checking and replacing engine management system sensors (Fusion)

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Checking and replacing engine management system sensors


Engine Crankshaft Position Sensor installed at the rear of the engine cylinder block opposite the flywheel.

If a fault occurs in the crankshaft position sensor circuit, the engine stops running, the controller stores a fault code in memory and turns on the warning light in the instrument cluster. In this case, check the sensor for proper operation.

You will need: an 8 mm socket head and a tester.

1. Disconnect the wire from the negative terminal of the battery.

1. Disconnect the wire from the negative terminal of the battery.


2. Squeeze the latch…

2. Squeeze the latch…


3. …and disconnect the wiring harness connector from the crankshaft position sensor terminals.



3. …and disconnect the wiring harness connector from the crankshaft position sensor terminals.


4. Unscrew the sensor mounting bolt…

4. Unscrew the sensor mounting bolt…


5. …and remove the sensor from the hole in the cylinder block.

5. …and remove the sensor from the hole in the cylinder block.


6. Use a tester to measure the resistance between the sensor terminals. The nominal resistance value should be within 0.5–0.6 kOhm. If the resistance does not meet the specified limits, replace the sensor.



7. Install the engine crankshaft position sensor in the reverse order of removal.

7. Install the engine crankshaft position sensor in the reverse order of removal.


Camshaft Position Sensor mounted on top of the cylinder head. If there is a fault in the sensor circuit, the controller stores a fault code in memory and uses a bypass control program.

You will need a 10 mm wrench.

1. Disconnect the wire from the negative terminal of the battery.

1. Disconnect the wire from the negative terminal of the battery.


2. Squeeze the retainer and disconnect the sensor wiring harness connector.

2. Squeeze the retainer and disconnect the sensor wiring harness connector.


3. Unscrew the mounting bolt…



3. Unscrew the mounting bolt…


4. …and remove the sensor from the hole in the cylinder head.

4. …and remove the sensor from the hole in the cylinder head.


5. Use a tester to measure the resistance between the sensor terminals. The nominal resistance value should be within 0.5–0.6 kOhm. If the resistance does not meet the specified limits, replace the sensor.

6. Install the camshaft position sensor in the reverse order of removal.

6. Install the camshaft position sensor in the reverse order of removal.


Coolant temperature sensor installed in the coolant distributor housing, located under the ignition coil.



Note: Ignition coil removed for clarity.


The resistance at the sensor terminals is checked under different temperature conditions.

You will need: a 19 mm wrench, a tester, and a thermometer.

1. Disconnect the wire from the negative terminal of the battery.

2. Drain the fluid from the engine cooling system (see "Replacing the coolant").

Note: When replacing the sensor, you do not need to drain the coolant: after removing the sensor, plug the hole with your finger or a plug - the loss of coolant will be minimal.


Note: When replacing the sensor, you do not need to drain the coolant: after removing the sensor,…


3. Press the lock and disconnect the wiring harness connector from the sensor.

3. Press the lock and disconnect the wiring harness connector from the sensor.


4. Loosen the tightening screw and unscrew the coolant temperature sensor by hand.

4. Loosen the tightening screw and unscrew the coolant temperature sensor by hand.


5. Connect the tester to the sensor terminals and measure the resistance, and measure the current temperature with a thermometer.



5. Connect the tester to the sensor terminals and measure the resistance, and measure the current…


6. To measure the resistance at the sensor terminals under different temperature conditions, lower the sensor into hot water and check the change in its resistance as the water cools, monitoring the water temperature with a thermometer. The nominal resistance of a working sensor is given in Table 10.6.

Table 10.6. Coolant Temperature Sensor Test Data



Table 10.6. Coolant Temperature Sensor Test Data

7. If the resistance deviates from the norm, replace the sensor.

8. Screw in the coolant temperature sensor and tighten it to a torque of 12 N·m.

9. Connect the wiring harness connector to the sensor.

10. Fill with coolant.

Combined absolute pressure and intake air temperature sensor installed in the intake manifold.

You will need: TORX T20 key, tester, thermometer.



1. Disconnect the wire from the negative terminal of the battery.

2. Remove the air filter (see "Removal and installation the air filter").

2. Remove the air filter (see «Removal and installation the air filter»).


3. Press the latch..

3. Press the latch..


4. …and disconnect the wiring harness connector from the sensor terminals.

4. …and disconnect the wiring harness connector from the sensor terminals.


5. Remove the fastening screw…

5. Remove the fastening screw…


6. …and remove the absolute pressure sensor from the intake manifold.



7. Install the new sensor in the reverse order of removal.

7. Install the new sensor in the reverse order of removal.


Throttle Position Sensor built into the throttle body cover, so if the sensor fails, replace the throttle body assembly (see "Removal and installation the throttle assembly").

To replace the oxygen concentration control sensor you will need a special 22 mm socket wrench.

1. Disconnect the wire from the negative terminal of the battery.

2. Remove the air filter (see "Removal and installation the air filter").

2. Remove the air filter (see «Removal and installation the air filter»).


3. Squeeze the oxygen sensor wiring harness connector retainer…

3. Squeeze the oxygen sensor wiring harness connector retainer…


4. …and disconnect the connector.

4. …and disconnect the connector.


5. Install a special split key on the sensor and unscrew the oxygen concentration control sensor.

6. Install the new oxygen sensor in the reverse order of removal.

To replace the diagnostic oxygen concentration sensor you will need a 22 mm wrench.

1. Disconnect the wire from the negative terminal of the battery.

1. Disconnect the wire from the negative terminal of the battery.


2. Remove the heat shield, remove retainer 1 and disconnect connector 2 of the oxygen concentration sensor diagnostic wiring harness.

2. Remove the heat shield, remove retainer 1 and disconnect connector 2 of the oxygen concentration…


3. Unscrew the sensor (for clarity, this operation is shown on the removed catalytic converter)…

3. Unscrew the sensor (for clarity, this operation is shown on the removed catalytic converter)…


4. …and remove it from the exhaust manifold.

5. Install the sensor in reverse order.

5. Install the sensor in reverse order.


Knock sensor screwed into the wall of the cylinder block in its upper part under the intake manifold in the area of the 3rd cylinder.

To replace the knock sensor, you will need a 13 mm wrench.

1. Disconnect the wire from the negative terminal of the battery.

1. Disconnect the wire from the negative terminal of the battery.


2. Press the latch..

2. Press the latch..


3. …and disconnect the knock sensor wiring harness connector.

3. …and disconnect the knock sensor wiring harness connector.


4. Remove the bolt securing the knock sensor to the cylinder block…

4. Remove the bolt securing the knock sensor to the cylinder block…


5. …and remove the sensor.

6. Install the knock sensor in the reverse order of removal.

Content was created using data from this website FordBook






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