Crankshaft Position Sensor: Service and Repair

*** UPDATED BY TSB #915B19

Crankshaft Position Sensor Connector:

1. Disconnect the crankshaft timing sensor assembly electrical connector.
2. If the colors differ from the image, make a chart showing the locations of the wires (by color). Remove the wires from the sensor connector by removing the red retaining clip and then the wires.
3. Remove the accessory drive belts.

Timing Belt Cover Area Exploded View:

4. Remove the four crankshaft pulley assembly bolts and remove the pulley.
5. Remove the timing belt outer cover.
6. Rotate the crankshaft until the keyway is at the ten o'clock position. This will place the vane window of both the inner and outer cups over the crankshaft timing sensor assembly.
7. Remove the two crankshaft timing sensor assembly retaining bolts.
8. Remove the plastic wire harness retainer that holds the sensor harness to its mounting bracket.
9. Remove the crankshaft timing sensor assembly, sliding the electrical wires out from behind the inner timing belt cover.
10. Remove the large electrical connector from the new crankshaft timing sensor assembly.

Crankshaft Position Sensor:

11. Position the crankshaft timing sensor assembly by sliding the electrical wires behind the inner timing belt cover, then loosely install the retaining bolts. Do not tighten the bolts at this time.
12. Install the large electrical connector onto the crankshaft timing sensor harness.
NOTE: Make sure the wires are located in their original positions. Refer to the chart made in step 2.
13. Reconnect the crankshaft timing sensor electrical connectors to the engine harness.

Aligning Crankshaft Position Sensor:

14. Rotate the crankshaft so that the outer vane on the crankshaft pulley hub engages both sides of the crankshaft Hall effect sensor positioner (Ford T89P-6316-A, or equivalent), then tighten the sensor retaining bolts to 22-31 lbs. in. (2.5-3.5 N-m).
15. Rotate the crankshaft until the crankshaft pulley vane clears the positioning tool, then remove the tool.
16. Install a new plastic wire harness retainer to secure the crankshaft timing sensor harness to its mounting bracket, trimming off any excess retainer.
17. Install the timing belt outer cover.
18. Install the crankshaft pulley assembly and tighten the four attaching bolts to 20-28 lbs. ft. (28-38 N-m).
19. Install the accessory drive belts.