Engine Controls - Adjustments: Other Ford Aerostar I

ENGINE MECHANICAL

Before performing any on-vehicle adjustments to fuel or ignition systems, ensure engine mechanical condition is okay.

VALVE CLEARANCE

Note. Valve cover(s) must be removed before performing valve adjustment. See appropriate article in the ENGINES section for removal and installation procedures.

Gasoline Engines

Note. Ignition timing on 2.3L with DIS and 4.0L with EDIS is not adjustable.

Initial Timing (TFI-IV)

1. Place transmission in Park or Neutral. Ensure A/C and heater are off. Connect inductive timing light and tachometer to engine. With engine off, disconnect the single-wire in-line spout (Yellow/Light Green wire near distributor) connector or remove shorting bar from the double-wire spout connector. Start and warm engine to normal operating temperature.
2. With engine at idle speed, check/adjust initial timing to 10 degrees BTDC. Turn engine off and reconnect the single-wire in-line spout connector or reinstall shorting bar on double-wire spout connector. Start engine and check timing advance to verify distributor is advancing beyond initial setting. Remove test equipment and reconnect all disconnected components.

Static Timing

1. Remove fast idle bracket and solenoid from injection pump. Using Pump Mounting Wrench (T83T-9000-B), loosen nuts holding injection pump to pump mounting adapter. Install Rotating Wrench (T83T-9000-C) on front of pump, and rotate to align timing mark on pump mounting flange with timing mark on pump mounting adapter. (Scheme 4)
2. Align timing marks to within.030". Remove rotating wrench and tighten nuts to 84 INCH lbs. (9.5 N.m). Ensure timing marks are aligned. Install fast idle bracket and solenoid.

Scheme 4

Dynamic Timing

Note. Engine must be at normal operating temperature of 192-212°F (89-100°C) when checking/setting dynamic timing.

1. Bring engine to normal operating temperature. Stop engine, and install Dynamic Timing Meter (078-00200) into timing probe hole until it almost touches vibration damper. (Scheme 5)
2. Attach clamp from Timing Meter Adapter (078-00201) to line pressure sensor on No. 1 injector nozzle ("F" Series) or No. 4 injector nozzle ("E" Series), and connect to dynamic timing meter. Connect dynamic timing meter to battery and dial in minus 20 degrees offset on meter.
3. Disconnect cold start advance terminal connector from solenoid terminal. (Scheme 6) With transmission in Neutral and rear wheels raised, start engine. Using Throttle Control Tool (D83T-9000-E), set engine speed to 2000 RPM with no accessory load.
4. Observe injection timing on dynamic timing meter. Injection timing should be 8.5 degrees BTDC at 2000 RPM. Apply battery voltage to cold start advance solenoid. Activating cold start advance solenoid terminal can increase engine speed. Adjust throttle if necessary.
5. Timing at 2000 RPM should be at least one degree before the timing obtained in first timing check. If the advance is less than one degree, replace fuel injection pump top cover assembly. If dynamic timing is not within +/- 2 degrees of specification, adjust pump timing.

Scheme 5

Scheme 6

Fast idle speed is computer controlled. Adjustment procedures are not available.

7.3L Diesel

1. Connect tachometer. Place transmission in Neutral or Park. Start engine and bring to normal operating temperature. Disconnect fast idle solenoid from harness and apply battery voltage to activate solenoid.
2. Rev engine momentarily to set solenoid. Fast idle should be 800-850 RPM. Adjust by turning solenoid plunger. (Scheme 6) Recheck fast idle and adjust if necessary. Reconnect solenoid connector.

2.9L, 4.0L & 7.5L Without Sludge Tolerant Throttle Body

1. With engine off, disconnect negative battery cable for at least 5 minutes then reconnect it. Start engine and allow idle speed to stabilize for 2 minutes. Snap throttle open and return to idle. Lightly depress and release accelerator.
2. Allow engine to idle. Ensure electric cooling fan is off. If engine idle is okay, idle speed adjustment is not required. If engine does not idle properly, turn ignition off. Disconnect idle speed control air by-pass solenoid.
3. Place A/T in Park (Neutral on M/T). Start engine and run at 2500 RPM for 30 seconds. Apply parking brake. Check idle speed. If idle speed is not 600-725 RPM (2.9L), 550-725 RPM (4.0L) or 500-800 RPM (7.5L), turn throttle plate stop screw to obtain specification. see scheme 6 Turn ignition off. Reconnect idle speed control air by-pass solenoid and recheck idle speed.
4. If idle speed is still not correct, perform a KOEO self-test. Check for fault codes, especially TPS fault code. If fault codes are present, repair as necessary. See appropriate TESTS W/CODES article in the ENGINE PERFORMANCE Section. If TPS fault code is present, check for proper TPS output. See «THROTTLE POSITION SENSOR (TPS)»(ref-22706-S30918114772001010300000). If fault codes are not present, exit this procedure and refer to H - TEST W/O CODES article.
5. Move throttle plate to ensure it is not stuck in bore and linkage is not keeping throttle from closing. Start engine and stabilize for 2 minutes. Snap throttle open and return to idle. With engine idling, lightly depress and release accelerator. If idle problem is still present, refer to H - TEST W/O CODES article to locate other possible causes of high idle.

1. Place transmission in Neutral or Park and bring engine up to normal operating temperature. Check idle speed with transmission in Neutral (M/T) or Drive (A/T). Ensure curb idle adjustment screw is against the stop. If adjustment screw is not against the stop, correct linkage.
2. Connect tachometer and check curb idle speed. Idle speed should be 600-700 RPM. Adjust idle speed using curb idle speed adjustment screw. (Scheme 6) Repeat check, and adjust again if necessary.

Note. Throttle Position Sensor (TPS) on gasoline engines is not adjustable. Replace TPS if sensor is not within specification.

1. Disconnect ECA 60-pin connector. Inspect connector for damaged pins, corrosion or loose wires; repair as necessary. Connect Breakout Box (T83L-50-EEC-IV) and reconnect ECA to breakout box. Connect digital voltmeter positive lead to pin No. 47 and negative lead to pin No. 46. Turn ignition on. Observe voltmeter reading while moving throttle slowly to wide open throttle (WOT) position. Release throttle slowly to closed position. See «TPS VOLTAGE SPECIFICATIONS TABLE»(ref-22706-S28790712462001010300000) .
2. If voltage is not as specified, ensure throttle stop screw and linkage are adjusted correctly. Remove sensor and check for damaged, corroded or misadjusted pins. If pins are okay, install sensor. Ensure sensor is seated correctly. Repeat step 1). If voltage is not as specified, perform KOEO self-test. See appropriate TESTS W/CODES article in the ENGINE PERFORMANCE Section.

Note. Two people are required to perform this procedure.

1. Perform Key On Engine Off (KOEF) Self-Test while holding the throttle wide open (WOT).
2. After last service code has been displayed, remain in Self-Test.
3. While in Self-Test, place 0.515 inch gauge block (Rotunda number T83T-7B200-AH) between the fuel pump lever travel screw and the Gauge Boss.
4. Cycle the Overdrive Cancel Switch (OCS) once.
5. Observe Self-Test Output (STO) of Star tester for: Constant Tone, Solid Light, or "STO LO" readout means the TP sensor adjustment is within range, cycle to get out of this test. Beeping Tone, Flashing light, or "STO LO" erratic readout (4 per second) adjustment is required. Beeping Tone, Flashing light, or "STO LO" erratic readout (1 per second) adjustment is required.
6. If tone is undetectable, TP sensor may have worn internal substrate. Check by trying to move sensor.
7. If TP sensor and bracket screws are tight and there are no signs of wear between the mounted parts, loosen TP sensor attachment screws and rotate sensor one way or the other until a constant tone, solid light, or "STO LO" readout is obtained. Tighten TP sensor attachment screws. Remove gauge block; Rerun quick test.
8. If bracket shows signs of wear due to movement or vibration, remove epoxy from TPS bracket screw heads. Loosen those screws and turn the TPS/bracket assembly to get block. Rerun quick test.
9. If the service codes are still present or a steady tone cannot be obtained, Replace the TP sensor.

TPS VOLTAGE SPECIFICATIONS (1)

Scheme 7

1. Install Scan tool and enter Key On Engine Off (KOEO) self-test while holding throttle in Wide Open Throttle (WOT) position. After last service code has been displayed, remain in self-test. Place a 0.515" (13.08 mm) Gauge Block (T83T-7B200-AH) between fuel pump lever travel screw and gauge boss. (Scheme 7)
2. Cycle Overdrive Cancel Switch (OCS) once. Observe Self-Test Output (STO) on Scan tool for the following conditions: Constant tone, solid light, or STO LO readout indicates throttle position sensor is within range. Cycle OCS to exit test. Fast beeping tone, flashing light, or STO LO erratic readout (4 per second) indicates throttle position sensor requires adjustment. Slow beeping tone, flashing light, or STO LO erratic readout (one per second) indicates throttle position sensor requires adjustment. No tone, solid light, or STO LO readout indicates throttle position sensor may have worn internal components. Check by trying to move sensor.
3. If FIPL sensor and bracket screws are tight and there are no signs of wear between mounted parts, loosen FIPL sensor attachment screws. (Scheme 8) Rotate sensor one way or the other until a constant tone, solid light, or STO LO readout is obtained. Tighten FIPL sensor attachment screws. Remove gauge block. Cycle throttle lever to WOT 5 times. Reinsert gauge block to verify setting.
4. If FIPL sensor bracket shows signs of wear due to movement or vibration, remove epoxy from FIPL sensor bracket screw head. (Scheme 8) Loosen screws and turn FIPL sensor/bracket assembly to get within range (indicated by constant tone, solid light or STO LO readout). Retighten screws and apply epoxy to screw heads. Remove gauge block. Cycle throttle lever to WOT 5 times. Reinsert gauge block to verify setting.

Scheme 8