Fuel Injection System - Multi-Point Ford Club Wagon E350

COMPONENT TESTING

Note. Specific component testing information not available. Refer to any tests performed during REMOVAL & INSTALLATION or OVERHAUL procedures

DESCRIPTION

The Electronic Fuel Injection (EFI) system on the 2.3L, 2.9L, 3.0L and 5.0L engines is a multi-point, pulse time fuel injection system, with a mass airflow sensor. Fuel is metered into intake air stream, according to engine demand, through injectors mounted on a tuned intake manifold.

An on-board electronic engine control (EEC-IV) module accepts inputs from various engine sensors to compute required fuel flow rate necessary to maintain correct air/fuel ratio throughout RPM range.

The EEC-IV computer sends a command to injectors to meter approximate quantity of fuel. System will automatically sense and compensate for changes in altitude. It will also permit push-starting of vehicle if necessary (M/T only).

FUEL DELIVERY

The fuel delivery sub-system consists of a low pressure fuel pump (mounted in fuel tank), a fuel filter/reservoir and a high pressure electric fuel pump. Pump delivers fuel from fuel tank through a 20-micron fuel filter to a fuel charging manifold assembly. The fuel charging manifold assembly incorporates electrically actuated injectors directly above each engine intake port.

When energized, injectors spray a metered quantity of fuel into intake air stream. On 2.3L and 2.9L engines, all injectors are energized simultaneously (once per crankshaft revolution). On 3.0L engines, the injectors are energized in 2 groups of 3 injectors. Each group is activated once every other crankshaft revolution. On 5.0L engines, a bank of 4 injectors is energized once every crankshaft revolution, followed by second bank of injectors during next crankshaft revolution.

The length of time that injectors are energized (injector "on time" or "pulse width") is controlled by EEC module. A constant fuel pressure drop is maintained across injector nozzles by a pressure regulator.

FUEL PRESSURE REGULATOR

The regulator is positioned downstream from injectors. Excess fuel not required by engine passes through regulator and returns to fuel tank through a fuel return line.

The regulator is a diaphragm operated relief valve. One side of diaphragm senses fuel pressure and other side senses intake manifold vacuum. Nominal fuel pressure is established by an applied spring preload on diaphragm. Balancing one side of diaphragm with manifold pressure maintains a constant fuel pressure drop across injectors.

FUEL PUMP CONTROL

The electrical system has a fuel pump relay, controlled by EEC module, which provides power to fuel pump under various operating conditions. When ignition switch is in "OFF" position, EEC power and fuel pump relay contacts are open.

After engine starts, and ignition switch is returned to "ON" position, power to fuel pump is again supplied through fuel pump relay. EEC module senses engine speed and shuts off fuel pump relay when engine stops (or when engine speed falls below 120 RPM).

AIR THROTTLE BODY ASSEMBLY OPERATION

The throttle body assembly controls airflow to engine through a single (2.3L, 2.9L and 3.0L engines) or a double (5.0L engine) butterfly valve. Throttle position is controlled by multiple-link, progressive opening throttle linkage or a conventional cable/cam throttle linkage. Throttle body is a single piece die casting made of aluminum. It has a single (2.3L, 2.9L and 3.0L engines) or a dual (5.0L engine) bore with an air by-pass channel around throttle plate.

This by-pass channel controls both cold and warm engine idle airflow control as regulated by an air by-pass valve assembly mounted to air cleaner (2.3L engine), upper intake manifold (2.9L engine) or throttle body (3.0L and 5.0L engines). Valve assembly is an electro- mechanical device controlled by EEC module.

It incorporates a linear actuator which positions a variable area metering valve. It also features a preset stop to locate W.O.T. position, a throttle body mounted throttle position sensor, canister purge ports for evaporative emission control (2.9L and 5.0L engines), an adjustment screw to set throttle plate at minimum idle airflow position (2.3L and 3.0L engines), crankcase ventilation pressure tube (2.9L engine), closed throttle stop-set screw (2.9L engine), provision for EGR valve and sensor mounting (3.0L engine), a built in torsional return spring (3.0L engine) and individual ported vacuum taps for PCV and EVAP control signals (3.0L engine).

FUEL SUPPLY MANIFOLD ASSEMBLY

The fuel supply manifold assembly delivers fuel at high pressure from vehicle fuel supply line to injectors. Assembly consists of 2 banks of stamped fuel rails connected by a crossover connection (5.0L engine), or 2 preformed tubes or stampings, one for fuel supply and one for fuel return (2.3L and 2.9L engines). On 3.0L engines the assembly consists of a single preformed tube or stamping with one (1) injector connector for each injector.

Fuel pressure manifold assembly has injector connectors and a mounting flange to fuel pressure regulator. It also has mounting attachments which locate fuel manifold assembly and provide injector retention. On 2.3L, 2.9L and 3.0L engines, manifold is also equipped with a fuel pressure relief valve on fuel supply tube.

FUEL INJECTORS

The injector nozzles meter and atomize fuel delivered to engine. Injectors are mounted in lower intake manifold and direct fuel just ahead of engine intake valves.

Injector bodies consist of a solenoid actuated pintle and needle valve assembly. An electrical control signal from EEC module activates injector solenoid, causing pintle to move upward off seat, allowing fuel to flow.

Since injector flow orifice diameter is fixed and fuel pressure drop across injector tip is constant, fuel flow to engine is regulated by length of time solenoid remains energized. Atomization is obtained by contouring pintle at point where fuel separates.

AIR INTAKE MANIFOLD OPERATION

The air intake manifold is a 2-piece (upper and lower) aluminum casting. Runner lengths are tuned to optimize engine torque and power output. Manifold provides mounting flanges for throttle body assembly, fuel supply manifold, accelerator control brackets, EGR valve and supply tube.

Vacuum taps are provided to support various engine accessories. Pockets for injectors are machined to prevent air and fuel leakage. Pockets in which injectors are mounted are placed to direct injector fuel spray immediately in front of each intake valve.

PRELIMINARY CHECKS

The following systems and components must be in good condition and operating properly before beginning diagnosis of injection system

1. All support systems and wiring.
2. Battery connections and specific gravity.
3. Ignition system.
4. Compression pressure.
5. Fuel supply system pressure and flow.
6. All electrical connections and terminals.
7. Vacuum lines, fuel hoses and pipe connections.
8. Air cleaner and air ducts.
9. Engine coolant level.

Note. Some vehicles may not include all components listed in this article.

ENGINE DOES NOT CRANK

Check starting and charging systems.

ENGINE CRANKS BUT DOES NOT START

1. Ensure fuel tank is not empty. DO NOT assume that fuel gauge is correct. Check ignition system for strong secondary current at spark plugs. If none exists or current is weak, repair ignition system problem before continuing with injection diagnosis.
2. Check fuel lines and fittings for leaks. If no leaks are found, check fuel delivery system for proper operation, pressure and volume. Reset inertia switch if necessary.

HARD TO START (ENGINE COLD)

Check Idle Speed Control (ISC) motor. ISC motor could be inoperative. See appropriate TESTS/CODES article in the COMPUTERIZED ENGINE CONTROLS section.

ROUGH IDLE (ENGINE COLD)

Check for leaking or inoperative fuel injector(s). Check fuel injector operation. Check for leaking injector "O" ring seal. Perform injector/regulator leakage test.

STALL, STUMBLE, HESITATION (ENGINE HOT OR COLD)

Check for throttle position sensor failure. See appropriate TESTS/CODES article in the COMPUTERIZED ENGINE CONTROLS section.

HARD START (ENGINE HOT)

1. Check for excessive fuel pressure. Clean and repair fuel return line and/or fuel pressure regulator.
2. Check for contaminated fuel pressure regulator valve and seat. Clean and repair fuel pressure regulator as required. Check fuel pressure bleed down after engine is turned off.
3. Check for leaking or inoperative fuel injector. Check fuel injector operation. Check for leaking injector "O" ring seal. Perform injector leakage test.

ROUGH IDLE (ENGINE HOT)

Check for leaking or inoperative fuel injector. Check fuel injector operation. Check for leaking injector "O" ring seal. Perform injector leakage test.

STALLS ON DECELERATION OR QUICK STOP

Throttle positioner may be functioning improperly. Service as required. Intake manifold or fuel charging assembly gaskets may be leaking. Replace leaking gaskets as needed.

LACK OF POWER

Fuel filter may be clogged. Check fuel delivery and repair as needed.

REDUCED TOP SPEED/POWER

1. Throttle linkage may be binding. Clean and service as required. Fuel pump volume may be low. Test fuel delivery system. Fuel filter may be clogged. Locate cause, and replace as required.
2. Injectors may be plugged or pressure regulator may be damaged. Repair or replace as needed.

SURGE AT CRUISE

Fuel filter may be clogged. Locate cause and replace filter. Fuel pump pressure or volume may be low. Test fuel delivery system. Fuel may be contaminated. Drain fuel and clean out system as necessary.

FUEL PUMP CONTROL TEST

When ignition is turned on, EEC power relay is energized, closing its contacts. Power is provided to both fuel pump relay and a timing device in EEC module. Fuel pump runs through contacts of fuel pump relay. If ignition is not turned on within one (1) second, timing device in EEC module will create an open ground circuit.

Opening ground circuit de-energizes fuel pump relay (opening its contacts), which in turn de-energizes fuel pump. This circuitry provides for pre-pressurization of fuel system. When ignition switch is turned to "START" position, EEC module operates fuel pump relay to provide fuel for starting engine while cranking. (Scheme 22), (Scheme 23) and (Scheme 24).

INERTIA SWITCH TEST

In event of a collision, electrical contacts in inertia switch open and fuel pump automatically shuts off. Fuel pump will shut off even if engine does not stop running. The engine, however, will stop a few seconds after fuel pump stops. It is not possible to restart engine until inertia switch is manually reset.

On Aerostar (2.3L engine), Bronco II, F-Series and Ranger, inertia switch is located on toe-board to right of transmission hump. On Aerostar (3.0L engine), switch is located in engine compartment. On E-Series, the switch is on passenger side cowl panel, just forward of right front door. To reset inertia switch, depress button on top of switch. (Scheme 22), (Scheme 23) and (Scheme 24).

HIGH PRESSURE FUEL PUMP TEST

1. Check fuel tank(s) for adequate fuel supply. DO NOT assume fuel gauge is correct. Check for fuel leakage at all fittings and lines. To check for electrical continuity to fuel pump, locate fuel pump connector at rail mounted (high pressure) fuel pump. Disconnect connector from body wiring harness and connect a volt/ ohmmeter (VOM) across body connector.
2. With ignition off, measure resistance. If resistance is 5 ohms or less, go to step 4. If resistance is 5 ohms or more, connect lead of VOM to ground lead of body wiring harness and check for continuity to ground. If there is no continuity, repair wiring or body ground and repeat step 2.
3. If there is continuity, attach VOM to Pink/Black H wire of body connector and check continuity to ground. If not okay, it will be necessary to check wiring at pump-sender. If wiring checks okay, check continuity across pump terminals. If not okay, replace pump-sender assembly. Check for a good connection at pump-sender connector.
4. Set meter to read voltage and turn ignition on. Voltage should rise to 12 volts for one (1) second and then return to zero (0). If voltage is not within specification, check electrical circuit and repair as required.
5. Attach VOM to pump harness leads and check continuity across leads. If okay, go to step 6. If not, check at pump terminals. If not okay at pump terminals, replace pump.
6. Check fuel pump pressure and flow as follows: with an assistant in vehicle, raise vehicle on a hoist and attach pressure gauge to fuel diagnostic valve. As a preliminary check, turn ignition on, and check pressure gauge reading. Gauge should read 30-40 psi if pump is operating properly and other system components are okay. Go to next step.
7. Disconnect fuel return line at fuel rail. Use care to avoid fuel spillage. Connect hose from fuel rail fitting to a calibrated container of at least one quart capacity. Replace fuel pump relay with modified relay. See «MODIFYING FUEL CUT-OFF RELAY»(/ford/club-wagon-e350/1985-1988/remont/testing-diagnostics/#fuel-injection-system-multi-point__modifying-fuel-cut-off-relay) in this article. Take ground lead to a convenient location on vehicle and ground it. This procedure should run fuel pump. Energize fuel pump for 10 seconds.
8. Allow fuel to drain from return hose into container and observe volume. Fuel pump is operating properly if fuel pressure reaches 35-45 psi, fuel flow is a minimum of 5.6 oz. in 10 seconds, and fuel pressure remains a minimum of 30 psi immediately after de-energization.
9. If all 3 conditions are met, fuel pump is operating normally. If conditions are not met, check for engine and electrical problems. If okay, go to next step.
10. Check for engine and electrical problems. If fuel pressure meets specification but fuel flow does not, check for blocked filter(s), fuel supply lines, and/or tank selector valve. After correcting any blockages, repeat above tests. If fuel flow still does not meet specification, replace pump.
11. If both fuel pressure and fuel flow meet specification but system will not stay pressurized after pumps are turned off, check for leaking injectors or regulator. If they are both okay, replace fuel pump. If there is no fuel flow or fuel pressure is observed, fuel system should be checked as in step 10. If system is okay, replace fuel pump.

MODIFYING FUEL CUT-OFF RELAY

1. Using relay (E3EB-9345-BA, CA, DA or E3TF-9345-AA), drill a 1/8" hole in-line with pins, and as close to relay base as possible. NOTE: Part of relay skirt may be cut away to provide easier access to pins.
2. Solder a 16-18 gauge jumper wire between pins 2 and 4. Feed one end of an 8-10 ft. flexible wire through hole drilled in relay skirt and solder to pin No. 1. (Scheme 7) NOTE: Leads should be soldered as close to relay base as possible to permit insertion of relay into socket with minimum interference.
3. Solder an alligator clip to other end of 8-10 ft. flexible wire.

Modifying Fuel Pump Cut-Off Relay. Scheme 7

LOW PRESSURE FUEL PUMP TESTING & OPERATION

1. Open fuel line at high pressure pump inlet. Connect hose to line from fuel tank. Route hose to a one (1) quart, calibrated container. Disconnect high pressure fuel pump electrical connector from body wiring harness.
2. Replace fuel pump relay with modified relay. See «MODIFYING FUEL CUT-OFF RELAY»(/ford/club-wagon-e350/1985-1988/remont/testing-diagnostics/#fuel-injection-system-multi-point__modifying-fuel-cut-off-relay) in this article. Ground wire coming from relay to a convenient ground point to energize fuel pump and measure flow for 10 seconds. NOTE: It may be necessary to momentarily block fuel hose to prime low pressure pump with outlet open and no back pressure on outlet; this is normal.
3. If fuel pump produces a minimum flow of 16 oz. of fuel in 10 seconds, pump is operating correctly. If there is no flow from pump, check electrical circuit, and also for inlet line restriction. Replace pump if required.

Removal (5.0L Engine)

Remove reservoir shield (if equipped) by removing either 3 or 4 screws. Unscrew lower canister, using a flexible strap type oil filter wrench, and slide filter and canister out from frame rail. Fuel filter canister will be full of fuel. On Econoline, it may be necessary to remove canister mounting bolts and pull reservoir away from frame rail to gain access to remove lower canister. On all vehicles, empty fuel from fuel filter canister. Remove filter canister and "O" ring.

Installation

Install new filter cartridge into fuel filter canister. Position NEW "O" ring so that it is seated in the "O" ring groove of the canister. While keeping canister level, so as not to dislodge "O" ring, position canister to bottom of reservoir housing and tighten loosely by hand. If the reservoir assembly was removed from frame rail, install and tighten mounting bolts. Using an oil filter wrench, complete filter canister tightening by turning canister about 1/6 of a turn past initial "O" ring compression. The rubber grommet on the filter will automatically seat on the piloted stud of the upper housing as the canister is tightened.

Removal & Installation (2.3L Engine)

1. Remove fuel filler cap. Release pressure from fuel system by opening pressure relief valve on fuel line. Relief valve is located in upper right hand corner of engine compartment. Use EFI Pressure Gauge (T80L-9974-A) or equivalent for this procedure. NOTE: Cap on relief valve must be removed.
2. Disconnect injector electrical connectors. Remove 2 fuel supply manifold retaining bolts. Carefully disengage manifold and fuel injectors from engine. Remove manifold and injectors.
3. To install, lubricate new "O"-rings with light grade oil and install 2 on each injector (one per injector if injectors were not removed from fuel supply manifold). Never use silicone grease.
4. Install fuel injector supply manifold and injectors into intake manifold, ensuring injectors are seated. Secure fuel manifold assembly using 2 retaining bolts. Tighten to 15-22 ft. lbs. (20-30 N.m). Connect injector electrical connectors. (Scheme 8)

2.3L Engine Multi-Point Fuel Injection System. Scheme 8

Removal & Installation (2.9L Engine)

1. Open hood and install protective covers. Disconnect battery negative cable. Remove air inlet tube from air cleaner-to- throttle body. Remove fuel cap to relieve tank pressure.
2. Disconnect vacuum hose from fuel pressure regulator. Using a hand vacuum pump, apply about 25 INCH Hg. (84.2 kPa) pressure to pressure regulator. Fuel pressure will be released in fuel tank through fuel return hose. This releases pressure from fuel system.
3. Disconnect electrical connectors at air by-pass valve, throttle position sensor, EGR sensor and air charge temperature sensor (ACT). Remove air inlet tube from air cleaner-to-throttle body. Remove snow/ice shield to expose throttle linkage. Disconnect throttle cable from ball stud. Disconnect upper intake manifold vacuum connectors, both front and rear fittings including EGR valve and vacuum line-to-fuel pressure regulator.
4. Disconnect PCV closure tube from under throttle body and disconnect PCV vacuum tube from under manifold. Remove canister purge line from fitting near power steering pump. Disconnect EGR tube from EGR valve by removing flange nut. Loosen bolt which retains A/C line at upper rear of upper manifold and disengage retainer.
5. Remove 6 upper intake manifold retaining bolts. Remove upper intake and throttle body as an assembly from lower intake manifold. Using Spring Lock Coupling (T81P-19623-G/G1) or equivalent, disconnect crossover fuel hose from fuel supply manifold. (Scheme 20)and (Scheme 21).
6. Disconnect fuel supply and return line connections at fuel supply manifold. Remove 4 fuel supply manifold retaining bolts. Carefully disengage fuel supply manifold from lower intake manifold. The fuel injectors are retained in fuel supply manifold with clips.
7. Remove retainer clips and inspect for corrosion and damage. Remove injector from fuel supply manifold and wipe cup with clean dry cloth.
8. To install, ensure injector caps and recesses are clean and free of contamination. Lightly grease recesses. Locate 3 injectors on right side recess of intake manifold. Then locate 3 on left.
9. Position and press down firmly until attachment holes line up and install fasteners. To complete installation, reverse removal procedures and tighten 4 fuel supply manifold retaining bolts to 71-102 INCH lbs. (8-11 N.m). (Scheme 9)

2.9L Engine Multi-Point Fuel Injection System. Scheme 9

Removal & Installation (3.0L Engine)

1. Open hood and install protective covers. Ensure ignition key is in "OFF" position. Disconnect negative battery lead and secure out of way. Remove fuel cap to relieve fuel tank pressure.
2. Release pressure from fuel system at fuel pressure relief valve on fuel rail assembly. Use Fuel Pressure Gauge (T80L-9974-A) or equivalent. To gain access to fuel pressure relief valve, valve cap must first be removed.
3. Disconnect push connect fuel supply and return lines using Fuel Line Coupling Disconnect Tool (T81P-19623-G). Disconnect wiring harness at fuel injectors. Disconnect wiring harness at throttle position (TP) sensor, air by-pass valve and air charge temperature (ACT) sensor.
4. Remove engine air cleaner outlet tube between air cleaner and air throttle body by loosening 2 clamps. If required, remove snow shield by removing retaining nut on top of shield and 2 bolts on side. Disconnect vacuum hoses at vacuum fittings on intake manifold.
5. Disconnect and remove accelerator and speed control cables from accelerator mounting bracket and throttle lever. Remove transmission (TV) linkage from throttle lever, if equipped. Remove 4 retaining bolts and 2 stud bolts and lift air intake throttle body assembly from guide pins on lower intake assembly.
6. Remove and discard gasket from lower intake manifold assembly. Carefully disengage fuel rail assembly/fuel supply manifold from fuel injectors by lifting and gently rocking rail. Remove injectors by lifting while gently rocking side to side. Place removed components in a clean container to avoid dirt or other contamination.
7. Clean and oil manifold bolt threads. To install, reverse removal procedure, using new manifold gaskets. When installing injectors, see «FUEL INJECTORS R & I»(/ford/club-wagon-e350/1985-1988/remont/testing-diagnostics/#fuel-injection-system-multi-point) in this article. Tighten fuel rail assembly/fuel supply manifold retaining bolts to 6-8 ft. lbs. (8-12 N.m). (Scheme 10)

3.0L Engine Multi-Point Fuel Injection System. Scheme 10

Removal & Installation (5.0L Engine)

1. Disconnect battery negative cable. Remove fuel tank and pressure relief valve caps. Install EFI Pressure Gauge (T80L-9974-A) at pressure relief valve and depressurize fuel system. Remove upper intake manifold and throttle body assembly.
2. Disconnect crossover fuel hose using Spring Lock Coupler (T81P-19623-G; T83P-19623-C for 5/8" line). Install coupler over coupling. (Scheme 20)and (Scheme 21). Push coupler along tube, and into coupling, to release female fitting from garter spring. Pull spring lock coupling apart. Remove coupler from disconnected spring lock coupling.
3. Disconnect fuel supply and return line connections at fuel supply manifold. See «PUSH-CONNECT FITTINGS»(/ford/club-wagon-e350/1985-1988/remont/testing-diagnostics/#fuel-injection-system-multi-point) in this article for proper removal. Remove 2 fuel supply manifold retaining bolts. Carefully disengage fuel supply manifold from lower intake manifold.
4. To install, reverse removal procedures and tighten fuel supply manifold to 15-22 ft. lbs. (20-30 N.m). (Scheme 11)

5.0L Engine Multi-Point Fuel Injection System. Scheme 11

Removal (2.3L Engine)

1. Disconnect electrical connections at throttle position sensor, injector wiring harness, knock sensor, air charge temperature sensor and engine coolant temperature sensor. (Scheme 14)
2. To disconnect upper intake manifold fitting connections, remove vacuum lines at upper intake manifold vacuum tee, EGR valve and fuel pressure regulator. Remove throttle linkage shield, and disconnect throttle linkage and cruise control cables.
3. Unbolt accelerator cable, and move cable aside. Disconnect air intake, air by-pass and crankcase vent hoses. Disconnect PCV hose from fitting on underside of upper intake manifold.
4. Disconnect coolant by-pass line at lower intake manifold. Disconnect EGR tube from EGR valve by removing flange nut. Remove 4 upper intake manifold retaining nuts. Remove upper intake manifold and throttle body assembly.

Remove old manifold separation gasket. DO NOT allow gasket particles to fall into lower manifold. To install, reverse removal procedure, using new manifold gasket. Tighten manifold retaining bolts alternately to 15-22 ft. lbs. (20-30 N.m).

Removal (2.9L Engine)

1. Disconnect electrical connectors at air by-pass valve, throttle position sensor, EGR sensor and air charge temperature sensor (ACT). Remove air inlet tube from air cleaner-to-throttle body.
2. Remove snow/ice shield to expose throttle linkage. Disconnect throttle cable from ball stud. Disconnect upper intake manifold vacuum connectors, both front and rear fittings including EGR valve, and vacuum line-to-fuel pressure regulator.
3. Disconnect PCV closure tube from under throttle body and disconnect PCV vacuum tube from under manifold. Remove canister purge line from fitting near power steering pump. Disconnect EGR tube from EGR valve by removing flange nut.
4. Loosen bolt which retains A/C line at upper rear of upper manifold and disengage retainer. Remove 6 upper intake manifold retaining bolts. Remove upper intake and throttle body as an assembly from lower intake manifold. (Scheme 12)

Note. If lower intake manifold was removed, fill and bleed cooling system.

2.9L Engine Upper Intake Manifold & Temp. Sens. Location. Scheme 12

1. Clean and inspect mounting faces of lower and upper intake manifold. Position new gasket on lower intake mounting face. Use of alignment studs may be helpful.
2. Install upper intake manifold and throttle body assembly to lower manifold making sure gasket remains in place. Align EGR tube in valve. Install 6 upper intake manifold retaining bolts and tighten to specifications.
3. Engage A/C line retainer cut and tighten bolt to 71-102 INCH lbs. (8-22 N.m). Tighten EGR tube, flare fitting and tighten lower retainer nut at exhaust manifold. Install canister purge line to fitting.
4. Connect PCV vacuum hose to bottom of upper manifold and PCV closure hose to throttle body. Connect vacuum lines to vacuum tree, EGR valve and fuel pressure regulator.
5. Connect throttle cable to throttle body and install snow/ice shield. Connect electrical connector at air by-pass valve, TPS sensor, EGR sensor and ACT sensor.

Removal (3.0L Engine)

1. Open hood and install protective covers. Ensure ignition key in "OFF" position. Disconnect negative battery lead and secure out of way. Remove fuel cap to relieve fuel tank pressure.
2. Release pressure from fuel system at fuel pressure relief valve on fuel rail assembly. Use Fuel Pressure Gauge (T80L-9974-A) or equivalent. To gain access to fuel pressure relief valve, valve cap must first be removed.
3. Disconnect push connect fuel supply and return lines using Fuel Line Coupling Disconnect Tool (T81P-19623-G). Disconnect wiring harness at fuel injectors. Disconnect wiring harness at throttle position (TP) sensor, air by-pass valve and air charge temperature (ACT) sensor.
4. Remove engine air cleaner outlet tube between air cleaner and air throttle body by loosening 2 clamps. If required, remove snow shield by removing retaining nut on top of shield and 2 bolts on side. Disconnect vacuum hoses at vacuum fittings on intake manifold.
5. Disconnect and remove accelerator and speed control cables from accelerator mounting bracket and throttle lever. Remove transmission (TV) linkage from throttle lever, if equipped. Remove 4 retaining bolts and 2 stud bolts and lift air intake throttle body assembly from guide pins on lower intake assembly. Remove and discard gasket from lower intake manifold assembly.

Clean and oil manifold bolt threads. To install, reverse removal procedure, using new manifold gaskets. When installing injectors, see FUEL INJECTORS R & I in this article. Tighten manifold bolts in correct order to 71-102 INCH lbs. (8-22 N.m). (Scheme 13)

3.0L Engine Upper Intake Manifold & Tightening Sequence. Scheme 13

1. Disconnect electrical connections at throttle position sensor, EGR position sensor and air by-pass sensor. Disconnect throttle linkage at pivot ball, and transmission linkage at throttle body.
2. Remove vacuum lines at upper intake manifold vacuum tee, EGR valve and fuel pressure regulator. Disconnect PCV system by removing hose from fitting on rear of upper intake manifold.
3. Remove 2 canister purge lines from fitting on throttle body. Remove upper intake manifold support bracket bolt. Remove 6 manifold retaining bolts. Remove upper intake manifold and throttle body as an assembly.

To install, reverse removal procedure. Use new gasket between upper and lower intake manifolds.

1. Drain engine coolant. Disconnect electrical connections at throttle position sensor, injector wiring harness, knock sensor, air charge temperature sensor and engine coolant temperature sensor. (Scheme 14)
2. To disconnect upper intake manifold fitting connections, remove vacuum lines at upper intake manifold vacuum tee, EGR valve and fuel pressure regulator. Remove throttle linkage shield. Disconnect throttle linkage and cruise control cables.
3. Unbolt accelerator cable, and move cable aside. Disconnect air intake, air by-pass and crankcase vent hoses. Disconnect PCV hose from fitting on underside of upper intake manifold.
4. Disconnect coolant by-pass line at lower intake manifold. Disconnect EGR tube from EGR valve by removing flange nut. Remove 4 upper intake manifold retaining nuts. Remove upper intake manifold and air throttle body assembly.
5. Disconnect "push-connect" fittings from fuel supply manifold and fuel return lines. See «PUSH-CONNECT FITTINGS»(/ford/club-wagon-e350/1985-1988/remont/testing-diagnostics/#fuel-injection-system-multi-point) in this article for proper removal. Remove oil dipstick bracket retaining bolt.
6. Disconnect electrical connectors from all fuel injectors, and set wiring harness aside. Remove 2 fuel supply manifold retaining bolts. Carefully remove fuel supply manifold and injectors.
7. Remove injectors from fuel supply manifold by using a slight twisting/pulling motion. Remove 4 bottom retaining bolts from lower manifold. Remove 4 upper retaining bolts from lower manifold. Remove manifold.

2.3L Engine Temperature Sensor Locations. Scheme 14

Note. Always use new gasket during installation.

Clean and oil manifold bolt threads. To install, reverse removal procedure, using new manifold gaskets. When installing injectors, see FUEL INJECTORS R & I in this article. Tighten manifold bolts in correct order. (Scheme 15)

2.3L Engine Lower Intake Manifold Tightening Sequence. Scheme 15

1. Thoroughly clean engine. Disconnect battery negative cable. Remove air cleaner and intake hose. Disconnect throttle cable. Drain coolant. Disconnect and remove hose from water outlet to radiator.
2. Remove distributor cap and spark plug wires as an assembly. Disconnect distributor wiring harness. Observe and mark location of distributor rotor and housing so ignition timing can be maintained at reassembly.
3. Remove distributor hold-down screw and clamp and lift out distributor. Remove rocker arm covers. Remove fuel lines from fuel rail. Remove hoses from throttle body. Remove throttle body and plenum.
4. Remove intake manifold attaching bolts and nuts. Note length of manifold attaching bolts during removal so that they may be installed in their original positions. Tap manifold lightly with a plastic mallet to break gasket seal. Lift off manifold and remove all old gasket material and sealing compound.

1. Apply sealing compound to joining surfaces. Place intake manifold gasket into position. Ensure that tab on right bank cylinder head gasket fits into cut-out of manifold gasket. Apply sealing compound to attaching bolt bosses on intake manifold and position intake manifold. Tighten to specifications. (Scheme 16)
2. Install throttle body and plenum assembly. Install distributor so rotor and housing are in same position marked at removal. Install distributor clamp and attaching bolt. Connect distributor wire. Install fuel line.
3. Replace rocker arm cover gaskets and reinstall rocker arm valve covers. Install distributor cap. Coat inside of each spark plug wire connector with silicone grease with a small screwdriver, and install wires. Connect distributor wiring harness.
4. Install and adjust throttle linkage. Install air cleaner and air cleaner tube at carburetor. Connect battery negative cable. Connect hoses from water outlet to radiator and by-pass hose from thermostat housing rear cover to intake manifold.
5. Refill and bleed cooling system. Recheck ignition timing and reset engine idle speed to specifications. Run engine at fast idle and check for coolant and oil leaks.

2.9L Engine Lower Intake Manifold Tightening Sequence. Scheme 16

1. Drain engine cooling system. Disconnect battery ground cable. Remove throttle body. Disconnect fuel lines. Remove fuel injector wiring harness from engine.
2. Disconnect upper radiator hose. Disconnect water outlet heater hose. Mark and remove distributor assembly. Remove intake manifold attaching bolts and studs. Remove manifold side gaskets and end seals. Manifold assembly can be removed with fuel rails and injectors in place.

Installation (3.0L Engine)

1. The intake manifold, cylinder head and cylinder block mating surfaces should be clean and free of old silicone rubber sealer. Use a suitable solvent to clean these surfaces. Apply Silicone Rubber Sealer (D6AZ-19562-A) or equivalent to intersection of cylinder block assembly and head assembly at each of the 4 corners.
2. Install front intake manifold seal and rear intake manifold seal. Secure with retaining features. Position intake manifold gaskets in place and insert locking tabs over tabs on cylinder head gaskets. Apply Silicone Rubber Sealer (D6AZ-19562-A) over gasket in same places as in step 1.
3. Carefully lower intake manifold into position on cylinder block and cylinder heads to prevent smearing silicone sealer and causing gasketing voids. Install bolts and tighten to 11-20 ft. lbs. (15-28 N.m) in numerical sequence. (Scheme 17)
4. Install thermostat housing and new gasket. Tighten attaching bolts to 6-8 ft. lbs. (8-12 N.m). Connect PCV line at PCV valve and exhaust manifold. Connect necessary electrical connectors. Connect vacuum hoses. Apply silicone sealer to split between head and intake manifold (4 places).
5. Install rocker arm cover. Connect heater tube hose to heater elbow. Connect coolant by-pass hose. Connect radiator upper hose. Connect fuel lines at fuel charging assembly. Replace fuel lines and connector "O"-ring.
6. Install air cleaner outlet tube. Fill and bleed cooling system. Connect battery ground cable. Start engine and check for coolant, oil, or fuel leaks. Check and adjust engine idle speed, transmission throttle linkage (overdrive transmission only) and speed control.

Note. The 3.0L engine has aluminum components and requires a special unique corrosion inhabited coolant formulation to avoid any radiator damage.

3.0L Engine Lower Intake Manifold Tightening Sequence. Scheme 17

1. Disconnect battery negative cable. Remove fuel tank and pressure relief valve caps. Install EFI Pressure Gauge (T80L-9974-A) at pressure relief valve and depressurize fuel system. Remove upper intake manifold and throttle body assembly.
2. Disconnect crossover fuel hose using Spring Lock Coupler (T81P-19623-G; T83P-19623-C). Install coupler over coupling. (Scheme 20)and (Scheme 21). Push coupler along tube, and into coupling, to release female fitting from garter spring. Pull spring lock coupling apart. Remove coupler from disconnected spring lock coupling.
3. Disconnect fuel supply and return line connections at fuel supply manifold. See «PUSH-CONNECT FITTINGS»(/ford/club-wagon-e350/1985-1988/remont/testing-diagnostics/#fuel-injection-system-multi-point) in this article for proper removal. Remove 2 fuel supply manifold retaining bolts. Carefully disengage fuel supply manifold from lower intake manifold.
4. Drain cooling system. Index mark position of distributor. Remove distributor, cap and wires. Disconnect electrical connections at throttle position sensor, injector wiring harness, knock sensor, air charge temperature sensor and engine coolant temperature sensor. (Scheme 18)
5. Disconnect injector wiring harness from main engine harness assembly. (Scheme 18) Remove intake manifold ground wire. Disconnect "push-connect" fittings from fuel supply manifold and fuel return lines. See «PUSH-CONNECT FITTINGS»(/ford/club-wagon-e350/1985-1988/remont/testing-diagnostics/#fuel-injection-system-multi-point) in this article for proper removal.
6. Remove upper radiator hose from thermostat housing. Remove coolant by-pass hose. Remove heater outlet hose at intake manifold. Remove 3 air cleaner bracket attaching nuts. Remove coil bracket nut and move bracket aside.
7. Remove lower intake manifold studs and bolts. To ease installation, note position of studs and bolts as they are removed. Remove the lower intake manifold assembly.

5.0L Engine Temperature Sensor Locations. Scheme 18

Installation (5.0L Engine)

1. Clean and inspect manifold mounting surfaces. Apply RTV sealer to end seal joints. see scheme 13 Position new gaskets, and install 2 locater pins in opposite corners of manifold. Lower manifold into position.
2. Tighten intake manifold studs and bolts, in proper sequence, to 25-25 ft. lbs. (32-33 N.m). (Scheme 19) After 10 minutes, retighten bolts and studs.
3. Check for damaged crossover fuel hose garter spring and "O" rings. Replacement garter spring and "O" rings are available in Coupler Rebuild Kit (E35Y-1D690-A). Wipe end of crossover lines with clean cloth. Install new "O" rings onto tube.
4. Lubricate ends of lines with clean refrigerant oil. To complete assembly, push fitting together with a slight twisting motion. Ensure garter spring is over flared end of female fitting. To complete installation, reverse removal procedure.

5.0L Engine Intake Manifold Tightening Sequence. Scheme 19

All Except Aerostar (3/8" Straight & 5/16" Elbow Fittings)

1. Inspect visible internal portion of fitting for dirt accumulation. If dirty, fitting must be cleaned prior to removal. Slowly twist fitting on tube, then push and pull the fitting until it moves freely on tube.
2. To remove hairpin clip from fitting, bend shipping tab downward until it clears the body. Next, separate 2 clip legs (about 1/8" each) to disengage body, and then push legs into fitting. (Scheme 20)
3. Lightly pull clip from triangle end, and work clip free of tube and fitting. Grasp fitting and hose assembly, and pull straight apart. Inspect fitting and tube for parts that may have been disconnected from fitting during removal. NOTE: Always use new clip when installing fittings.
4. To install, insert new clip into any 2 adjacent openings, with triangular portion pointing away from fitting opening. Install clip fully. Legs of clip must be locked on outside of body.
5. Wipe tube end with clean cloth. Ensure fitting is clear of dirt and obstructions. Push fitting straight onto tube end. When fitting is properly engaged, a "click" will be heard. Pull on tube to ensure that fitting is fully engaged.

Exploded View of "Push-Connect" Fittings. Scheme 20

All Except Aerostar (1/4" Straight Fittings)

1. Inspect visible internal portion of fitting for dirt accumulation. If dirty, fitting must be cleaned prior to removal. Slowly twist the fitting on the tube, then push and pull the fitting until it moves freely on tube.
2. Align jaws of narrow pliers (less than.2" (5 mm) wide) with openings in side of fitting case, and compress portion of clip that retains fitting in case. (Scheme 20) Pull fitting from tube. If clip has been properly disengaged, fitting can be pulled from tube with little effort.
3. Inspect fitting and tube for parts that may have been disconnected from fitting during removal. Install new replacement clip into fitting body by inserting one (1) serrated edge in first, then push other edges inward, into place. A "click" will be heard when clip is properly installed.
4. Wipe end of tube with clean cloth. Push fitting straight onto tube end. When fitting is properly engaged, a "click" will be heard. Pull on tube to ensure that fitting is fully engaged.

Aerostar (3/8", 1/2" & 5/8" Straight Fittings)

1. To disconnect the spring lock-type "push-connect" fittings, place Spring Lock Coupler (T81P-19623-G for 1/2" line; T81P-19623-G1 for 3/8" line; or T83P-19623-C for 5/8" line) over coupling. (Scheme 21)
2. Push coupler along tube, and into coupling, to release female fitting from garter spring. Pull spring lock coupling apart. Remove coupler from disconnected spring lock coupling.
3. Check for damaged garter spring and "O" rings. Replacement garter spring and "O" rings are available in Coupler Rebuild Kit (E35Y-1D690-A). Wipe end of lines with clean cloth. Install new "O" rings onto tube.
4. Lubricate ends of lines with clean refrigerant oil. To complete assembly, push fitting together with a slight twisting motion. Ensure garter spring is over flared end of female fitting.

Installing Lock Spring-Type Coupler. Scheme 21

2.3L & 5.0L Engines

1. On 2.3L engines, remove throttle linkage shield, throttle cable, cruise control cable and crankcase vent. On all engines, remove throttle position sensor wiring. Remove air by-pass and air intake hoses.
2. Remove 4 throttle body nuts. Carefully separate throttle body from upper intake manifold. Clean gasket surface, but do not allow gasket material to fall into upper intake manifold. To install, reverse removal procedure.

2.9L Engines

1. Disconnect throttle position sensor and electrical connector. Remove air inlet duct. Remove snow/ice shield and disconnect throttle cable from ball stud.
2. Disconnect air by-pass hose, PCV closure hose and canister purge hose from fittings beneath throttle body. Remove 4 screws retaining throttle body to upper intake manifold.
3. Remove and discard gasket between throttle body and upper intake manifold. Clean throttle body and upper intake manifold gasket surfaces. To install, reverse removal procedures and tighten to 71-102 INCH lbs. (8-22 N.m).

3.0L Engines

1. Remove engine air cleaner outlet tube between air cleaner and air throttle body by loosening 2 clamps. If required, remove snow shield by removing retaining nut on top of shield and 2 bolts on side.
2. Disconnect vacuum hoses at vacuum fittings on intake manifold. Disconnect and remove accelerator and speed control cables from accelerator mounting bracket and throttle lever. Remove transmission (TV) linkage from throttle lever, if equipped.
3. Remove 4 retaining bolts and 2 stud bolts. Lift air intake throttle body assembly from guide pins on lower intake assembly. Remove and discard gasket from lower intake manifold assembly.
4. Clean and oil manifold bolt threads. To install, reverse removal procedure, using new manifold gaskets. Tighten bolts to 15-22 ft. lbs. (20-30 N.m) in numbered sequence. (Scheme 13)

Removal

1. Remove fuel tank and pressure relief valve caps. Install EFI Pressure Gauge (T80L-9974-A) at pressure relief valve and depressurize fuel system. Remove vacuum line at pressure regulator.
2. Remove screws from regulator housing. Remove pressure regulator, gasket and "O" ring.

Lubricate "O" ring with a light oil. DO NOT use silicone grease. Ensure gasket surfaces of regulator and manifold are clean and dry. Install regulator on manifold. Tighten retaining screws. Install vacuum line.

1. Remove fuel tank and pressure relief valve caps. Install EFI Pressure Gauge (T80L-9974-A) at pressure relief valve, and depressurize fuel system.
2. Remove the fuel supply manifold. Refer to «FUEL SUPPLY MANIFOLD ASSEMBLY R & I»(/ford/club-wagon-e350/1985-1988/remont/testing-diagnostics/#fuel-injection-system-multi-point) . Remove the lower intake manifold. Refer to «LOWER INTAKE MANIFOLD R & I»(/ford/club-wagon-e350/1985-1988/remont/testing-diagnostics/#fuel-injection-system-multi-point) in this article. On 5.0L engines, remove upper intake manifold. See «UPPER INTAKE MANIFOLD & THROTTLE BODY ASSEMBLY»(/ford/club-wagon-e350/1985-1988/remont/testing-diagnostics/#fuel-injection-system-multi-point) in this article.
3. Remove electrical harness connector from each injector. Remove injectors from fuel supply manifold by using a slight twisting/pulling motion.

Lubricate new injector "O" rings with a light oil. DO NOT use silicone grease. To complete installation, reverse removal procedure.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Single Tank Fuel Pump Ckt Wiring Diagram (All Except 3.0L Engine). Scheme 22

Single Tank Fuel Pump Circuit Wiring Diagram (3.0L Engine). Scheme 23

Dual Tank Fuel Pump Circuit Wiring Diagram. Scheme 24

See also:
• MODIFYING FUEL CUT-OFF RELAY
• FUEL INJECTORS R & I