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ive got a friend with a 96 explorer 4.0 6 banger. if its driven long enough to get up to temperature and then parked and let sit for 20 mins it will not start. it attempts to but sputters right out. it takes about a half an hour of sitting before it will start again. he has replaced the cts and maf as well as plugs and wires recently. i drove it the other night and it did it to me. i unplugged the mass air and tried and had no change. it had spark as best as i could check by myself, coming out of the coil. when cranking it over the tach does not bounce at all? i know on some cars the tach will jump while cranking, does the explorer? im thinking its possibly a crank sensor, but it never shuts off during the drive. it will also throw a po420 every once in a while. any thoughts?
I don't have the factory service information for 1996, couldn't find the spec on the CD for 1998, but for 2000 the fuel pressure spec is 65 +/- 8 psi. I suspect that will be the same for your 1996.
When you turn the key to the ON position, you should hear the fuel pump prime for about 2 seconds. If this is not happening, start by checking the fuel pump relay. If you are getting fuel, then the problem is probably spark related. Maybe a bad Crankshaft Position Sensor.
As fuel pumps age they will fail to provide sufficient fuel pressure. In the early stages they will run like they should (although sometimes louder than usual) but not generate sufficient fuel pressure and resulting in symptoms just like described. And since they run constantly during vehicle operation they get hot and often are less reliable when hot. As they cool they may work well enough to get the vehicle started again. Since they are immersed in fuel when the tank is full sometimes a weak pump will work fine when the tank is full and cause more issues when the tank is low.
Checking for spark when the vehicle won't start is also valid and the Crankshaft Position Sensor (CKP) has been a known trouble item.