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Fuel Charging & Controls - 4.6l (2v) Ford Crown Victoria II

Fuel System 72 illustrations ~1900 words

FUEL CHARGING AND CONTROLS - 4.6L (2V) GENERAL SPECIFICATIONS

ItemSpecification
Lubricants and Chemicals
SAE 5W-20 Premium Synthetic Blend Motor OilWSS-M2C153-H
XO-5W20-QSP

FUEL CHARGING AND CONTROLS - 4.6L (2V) GENERAL SPECIFICATIONS

FUEL CHARGING AND CONTROLS - 4.6L (2V) TORQUE SPECIFICATIONS

DescriptionNmLb-ftLb-in
Throttle body-to-intake manifold (1)
Engine coolant temperature sensor2015
Fuel injection supply manifold temperature sensor4030
Fuel supply retaining bracket nut and bolt2518
Accelerator controls bracket bolts653
Generator mounting bracket bolt1089
Fuel injection supply manifold-to-intake manifold1089
Fuel charging wiring to intake manifold bolts1089
(1) Refer to the procedure.
(1)Refer to the procedure.

FUEL CHARGING AND CONTROLS - 4.6L (2V) TORQUE SPECIFICATIONS

Scheme 1

Scheme 1: Fuel Charging And Controls
Scheme 1: Fuel Charging And Controls

The fuel injection supply manifold (gasoline)

  1. delivers fuel to the fuel injector.
  2. receives fuel from the fuel supply line.

The fuel shut-off solenoid (natural gas)

  1. is normally closed.
  2. opens when the key is in the RUN or START position.
  3. shuts off the fuel supply if the vehicle is shut off or if the inertia fuel shut-off is triggered.

The throttle body

  1. controls air supply to the upper intake manifold by positioning the throttle plate.
  2. connects the accelerator cable and, if equipped the speed control actuator cable to the throttle plate.
  3. is not adjustable.
  4. cannot be cleaned.

The fuel injector

  1. uses the replacement O-rings if needed.
  2. is electrically operated by the powertrain control module (PCM).
  3. has an internal solenoid that opens a needle valve to inject fuel into the lower intake manifold.
  4. atomizes the fuel as the fuel is delivered.
  5. is deposit resistant.

The fuel pressure relief valve

  1. is used to inspect and relieve fuel pressure.

The fuel pressure regulator

CAUTIONUse O-rings that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse O-rings.
  1. maintains a constant fuel pressure throughout the fuel system and to the fuel injector.
  2. is spring-loaded and operated by the intake manifold vacuum.

The fuel injection supply manifold (natural gas)

  1. delivers fuel to the fuel injector.
  2. receives fuel from the fuel supply line.
  3. provides mounting surfaces for the fuel temperature sensor and the fuel pressure sensor.
  4. provides mounting surface for the main fuel shut-off solenoid.

Fuel System Service Precautions - Natural Gas

WARNINGDo not modify system configuration or components or install new components with parts not especially designed for use with natural gas. Ford Motor Company has specially designed the materials, components and system configuration for the natural gas vehicles and each particular system is precisely calibrated for efficient operation. The use of different parts or materials can produce an untested configuration that can result in fire or cause engine damage. Failure to follow these instructions may result in personal injury.
WARNINGIt is important that your natural gas vehicle be properly maintained by Ford natural gas trained personnel. If a problem occurs, it is important that properly trained personnel diagnose the cause. If the problem relates to the fuel system, proper part replacement is imperative to keep the vehicle operating at normal performance. Natural gas components and gasoline fuel components are not interchangeable. If the vehicle is not serviced in accordance with natural gas fueled vehicle procedures, damage can occur and the warranty may be invalidated. Failure to follow these instructions may result in personal injury.
WARNINGFuel supply lines are always pressurized. When servicing fuel-related components, do not smoke or carry lighted tobacco or an open flame of any type. Flammable mixtures may be present and can ignite. Failure to follow these instructions may result in personal injury.
WARNINGThe fuel system is always pressurized to 655 kpa (95 psig) downstream of the fuel pressure regulator and up to 20700 kpa (3000 psig) upstream of the fuel pressure regulator. Use care when servicing the fuel system. Fuel pressure must be relieved prior to any fuel system service. Failure to follow these instructions may result in personal injury.

Fuel Charging and Controls

Idle Speed Adjustment

Fuel Injection Component Cleaning (Natural Gas)

ItemSpecification
SAE Premium Synthetic Blend XO-5W20-DSPWSS-M2C153-H

MATERIAL SPECIFICATION

WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
WARNINGDo not modify the system configuration or components, or install components or parts not specially designed for use with natural gas. Ford Motor Company has specially designed the materials, components and system configuration for the 4.6L Crown Victoria natural gas vehicles, and each particular system is precisely calibrated for efficient operation. The use of different parts or materials can produce an untested configuration that could result in fire or personal injury, or cause engine damage.

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  1. Start the vehicle and idle at 1,500 rpm for five minutes, then turn the engine off. If the vehicle won't start due to clogged injectors, the injectors may be completely stuck closed. If this is the case, attempt to free them by applying 12 volts directly to the injector coil. Apply battery voltage to the injector coil where the red wire from circuit 361 connects. Ground the other side of the connector momentarily and listen for an audible click to confirm injector opening. If an injector remains stuck, wait ten seconds and repeat the above steps. If an injector remains stuck, install a new injector.
  2. Vent the fuel lines. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information-natural-gas)
  3. Remove the bolts and position the fuel pressure regulator shield aside. NOTE: Lubricate the fuel system O-ring seals with clean engine oil prior to installation to hold the seals and ease the installation. NOTE: Install new fuel system O-ring seals, using approved O-ring seals only. O-ring seals that are approved for natural gas use are identified with a yellow stripe.
  4. Remove the filter bowl drain plug and discard the O-ring seal. Install the drain plug and install a new O-ring seal when finished. Lubricate the O-ring seal with clean engine oil.
  5. Remove the filter bowl and discard the O-ring seal.
  6. Check for dirt or oil in the filter bowl. Clean as necessary.
  7. Inspect the filter element. If it appears to be discolored with dark deposits, install a new filter element.
  8. Fill the filter bowl to the top with isopropyl alcohol (with a strength of at least 90 percent by volume) with the filter in place.
  9. Install the filter bowl.
  10. Start the engine and idle at 1,500 rpm for five minutes.
  11. Check the system for leaks.

Removal

WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
CAUTIONThe throttle body bore and plate area have a special coating and cannot be cleaned.

Note. Gasoline engine shown, natural gas is similar.

Scheme 4

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Scheme 5
  1. Remove the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/crown-victoria/ii-1997-2011/remont/removal-installation/#intake-air-distribution-filtering) .
  2. Disconnect the throttle position (TP) sensor electrical connector.
  3. Disconnect the throttle return spring, and the accelerator and speed control cables.
  4. Remove the four bolts and the throttle body.

Scheme 6

Scheme 6: Installation
Scheme 6: Installation

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  1. Install a new throttle body (TB) gasket, the throttle body, and the bolts. Tighten the bolts in two stages. Stage 1: Tighten to 9 Nm (80 lb-in) Stage 2: Rotate an additional 90 degrees.
  2. Connect the throttle return spring, and the accelerator and speed control cables.
  3. Connect the throttle position (TP) sensor electrical connectors.
  4. Install the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/crown-victoria/ii-1997-2011/remont/removal-installation/#intake-air-distribution-filtering) .

All Vehicles

WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.

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  1. Position the power steering pump out of the way. For additional information, refer to «POWER STEERING»(/ford/crown-victoria/ii-1997-2011/remont/manual-power-steering/#power-steering-system) .
  2. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/crown-victoria/ii-1997-2011/remont/removal-installation/#intake-air-distribution-filtering) .
  3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#battery-mounting-and-cables) .
  4. Remove the wiper mounting arm and pivot shaft. For additional information, refer to «WIPERS AND WASHERS»(/ford/crown-victoria/ii-1997-2011/remont/wiperwasher-systems/#wiper-system-washer-system) .
  5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor.
  6. Disconnect the eight ignition coils.
  7. Disconnect the eight fuel injector electrical connectors.
  8. Disconnect the fuel temperature sensor.
  9. Disconnect the fuel pressure sensor.
  10. Disconnect the main fuel shut-off solenoid connector.
  11. Disconnect the engine bulkhead connectors.
  12. Disconnect the electrical connectors.
  13. Disconnect the LH heated oxygen sensor connector and the transmission electrical connector.
  14. Disconnect the RH heated oxygen sensor connector.
  15. Disconnect the evaporative emission (EVAP) canister purge valve.
  16. Disconnect the EGR vacuum regulator solenoid.
  17. Disconnect the connector.
  18. Disconnect the A/C cycling switch.
  19. Raise the vehicle. For additional information, refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
  20. Disconnect the crankshaft position (CKP) sensor and the power steering pressure (PSP) sensor electrical connectors.
  21. Disconnect the A/C compressor and the wiring harness retainers.
  22. Disconnect the engine oil pressure sensor.
  23. Disconnect the power steering electrical connector.
  24. Lower the vehicle.
  25. Separate the fuel charging wiring from the rear of the intake manifold and remove from the vehicle.

Scheme 26

Scheme 26: Installation
Scheme 26: Installation

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  1. Position the fuel charging wiring in the vehicle and attach to the rear of the intake manifold.
  2. Raise the vehicle. For additional information, refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
  3. Connect the engine oil pressure sensor.
  4. Connect the power steering electrical connector.
  5. Connect the A/C compressor and wiring harness retainers.
  6. Connect the CKP and the PSP electrical connectors.
  7. Install the power steering pump. For additional information, refer to «POWER STEERING»(/ford/crown-victoria/ii-1997-2011/remont/manual-power-steering/#power-steering-system)
  8. Lower the vehicle.
  9. Connect the A/C cycling switch.
  10. Connect the connector.
  11. Connect the EGR vacuum regulator solenoid.
  12. Connect the evaporative emission canister purge valve.
  13. Connect the RH heated oxygen sensor connector.
  14. Connect the LH heated oxygen sensor connector and the transmission electrical connectors.
  15. Connect the radio ignition interference capacitor.
  16. Connect the engine bulkhead connectors.
  17. Connect the main fuel shut-off solenoid connector.
  18. Connect the fuel pressure sensor connector.
  19. Connect the fuel temperature sensor connector.
  20. Connect the eight fuel injector electrical connectors.
  21. Connect the eight ignition coils.
  22. Connect the idle air control valve and the throttle position sensor.
  23. Install the wiper mounting arm and pivot shaft. For additional information, refer to «WIPERS AND WASHERS»(/ford/crown-victoria/ii-1997-2011/remont/wiperwasher-systems/#wiper-system-washer-system) .
  24. Connect the battery ground cable.
  25. Install the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/crown-victoria/ii-1997-2011/remont/removal-installation/#intake-air-distribution-filtering) .

Fuel Injection Supply Manifold

ItemSpecification
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSPWSS-M2C153-H

MATERIAL SPECIFICATION

All Vehicles

WARNINGDo not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
WARNINGFuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions can result in personal injury.

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  1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#battery-mounting-and-cables) .
  2. Relieve the fuel pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information) (Gasoline) or «FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information-natural-gas) (Natural Gas).
  3. Disconnect the fuel lines. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information) (Gasoline) or «FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information-natural-gas) (Natural Gas).
  4. Remove the throttle body. For additional information, REFER to «THROTTLE BODY»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-charging-controls-46l-2v) .
  5. On gasoline engines, remove the EGR valve to exhaust manifold tube. For additional information, refer to «ENGINE EMISSION CONTROL»(/ford/crown-victoria/ii-1997-2011/remont/auxiliary-emission-control-systems/#engine-emission-control-system) .
  6. Remove the drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/crown-victoria/ii-1997-2011/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) .
  7. Disconnect the fuel temperature sensor connector.
  8. Disconnect the fuel pressure sensor connector.
  9. Disconnect the main fuel shut-off solenoid connector.
  10. Disconnect the generator cable, the electrical connector and the harness pin-type retainer.
  11. Remove the bolts and the generator mounting bracket.
  12. Remove the bolts, the return spring, and disconnect the accelerator and speed control cables.
  13. Unclip the accelerator cable and the speed control actuator cable from the two crash brackets and position aside.
  14. Separate the fuel charging wiring pin-type retainer from the crash bracket.
  15. Disconnect the vacuum lines and the electrical connector and position aside.
  16. Remove bolt and stud and remove the crash bracket.
  17. Disconnect the ground connector from the RH rear stud.
  18. Disconnect generator harness locator retainer from LH front stud.
  19. Disconnect the eight fuel injector electrical connectors.
  20. Disconnect the crankcase ventilation tube and position out of the way.
  21. Disconnect the vacuum line and the electrical connector.
  22. Disconnect the vacuum line from the evaporative emission (EVAP) canister purge valve.
  23. Remove the four studs.
  24. Remove the fuel injection supply manifold and the fuel injectors as an assembly.

Scheme 58

Scheme 58: Installation
Scheme 58: Installation

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  1. Lubricate the fuel injector pockets with clean engine oil to aid installation.
  2. Install the fuel injection supply manifold and the fuel injectors as an assembly.
  3. Tighten the fuel injection supply manifold studs to specification.
  4. Install the crash bracket.
  5. Install the bolt and the stud.
  6. Connect the vacuum line to the evaporative emission canister purge valve.
  7. Connect the vacuum line and the electrical connector.
  8. Connect the crankcase ventilation tube.
  9. Connect the eight fuel injector electrical connectors.
  10. Connect the vacuum lines and the electrical connector.
  11. Install fuel charging pin-type retainer to the crash bracket.
  12. Clip the accelerator cable and the speed control actuator cable to the two crash brackets.
  13. Connect the accelerator and speed control cables, the return springs, and install the bolts.
  14. Install the generator mounting bracket and tighten the bolts.
  15. Connect the generator cable, the electrical connector and the harness pin-type retainer.
  16. Connect the main fuel shut-off solenoid connector.
  17. Connect the fuel pressure sensor connector.
  18. Connect the fuel temperature sensor connector.
  19. Connect ground connector to RH rear stud.
  20. Connect the generator harness location retainer to the LH front stud.
  21. Install the drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(/ford/crown-victoria/ii-1997-2011/remont/accessory-drive-belts/#cooling-system-specifications-drive-belt-routing) .
  22. On gasoline engines, install the EGR valve to exhaust manifold tube. For additional information, refer to «ENGINE EMISSION CONTROL»(/ford/crown-victoria/ii-1997-2011/remont/auxiliary-emission-control-systems/#engine-emission-control-system) .
  23. Install the throttle body. For additional information, REFER to «THROTTLE BODY»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-charging-controls-46l-2v) .
  24. Connect the fuel lines. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information) (Gasoline) or «FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS»(/ford/crown-victoria/ii-1997-2011/remont/fuel-system/#fuel-system-general-information-natural-gas) (Natural Gas).
  25. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/crown-victoria/ii-1997-2011/remont/charging-system/#battery-mounting-and-cables) .

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