Engine Controls - Electronic Engine Controls - Gasoline Models -- E-Series Ford Cutaway E350 Super Duty

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The electronic engine controls consist of the following

1. Camshaft Position (CMP) sensor
2. Catalyst Monitor Sensor (CMS)
3. Crankshaft Position (CKP) sensor
4. Cylinder Head Temperature (CHT) sensor
5. Heated Oxygen Sensor (HO2S)
6. Knock Sensor (KS)
7. Mass Air Flow (MAF) sensor
8. PCM
9. Throttle Position (TP) sensor

The PCM needs the following inputs to calibrate the engine correctly

1. Air temperature
2. Throttle position
3. Crankshaft position
4. Camshaft position
5. Engine rpm
6. Cylinder head temperature
7. Amount of engine detonation
8. Engine coolant temperature
9. Mass airflow

Camshaft Position (CMP) Sensor

The CMP sensor

1. sends the PCM a signal indicating camshaft position used for fuel synchronization and coil firing.

For removal and installation, refer to CAMSHAFT POSITION (CMP) SENSOR .

Crankshaft Position (CKP) Sensor

The CKP sensor

1. sends the PCM a signal indicating crankshaft position.
2. is essential for calculating spark timing.

For removal and installation, refer to CRANKSHAFT POSITION (CKP) SENSOR .

Cylinder Head Temperature (CHT) Sensor

The CHT sensor

1. is mounted into the front of the left cylinder head and is not connected to any coolant passages.
2. sends a signal to the PCM indicating the cylinder head temperature.

For removal and installation, refer to CYLINDER HEAD TEMPERATURE (CHT) SENSOR .

Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS)

The HO2S and CMS

1. have the ability to create a voltage signal dependent on exhaust oxygen content.
2. provide feedback information to the PCM used to calculate fuel delivery.

For removal and installation, refer to HEATED OXYGEN SENSOR (HO2S) AND CATALYST MONITOR SENSOR - EXPLODED VIEW and HEATED OXYGEN SENSOR (HO2S) or CATALYST MONITOR SENSOR .

Knock Sensor (KS) Sensor

The KS

1. is located in the intake valley of the cylinder block.
2. sends a signal to the PCM indicating engine detonation.

For removal and installation, refer to KNOCK SENSOR (KS) .

Mass Air Flow (MAF) Sensor

The MAF sensor

1. sends the PCM a signal indicating mass airflow rate of air entering the engine.
2. incorporates the Intake Air Temperature (IAT) sensor.

For removal and installation, refer to MASS AIR FLOW (MAF) SENSOR .

Throttle Position (TP) Sensor

The TP sensor

1. sends the PCM a signal indicating the throttle plate angle.
2. is the main input to the PCM from the driver.

For removal and installation, refer to THROTTLE POSITION (TP) SENSOR - 5.4L or THROTTLE POSITION (TP) SENSOR - 6.8L .

Refer to the INTRODUCTION - GASOLINE MODELS .

Material

MATERIAL SPECIFICATIONS

Note. 4.6L shown in illustration, 5.4L and 6.8L similar.

Scheme 11

PARTS DESCRIPTION CHART

Removal and Installation

1. Remove the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .
2. Disconnect the Camshaft Position (CMP) sensor electrical connector.
3. Remove the bolt and the CMP sensor. Inspect the O-ring seal for damage and install new if necessary. Lubricate the O-ring seal and with clean engine oil prior to installation. To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure.

MATERIAL SPECIFICATIONS

Scheme 12

PARTS DESCRIPTION CHART

Scheme 13

Scheme 14

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Remove the splash shield.
3. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the A/C compressor pulley.
4. Disconnect and detach the Crankshaft Position (CKP) sensor electrical connector and position the wiring harness aside.
5. Detach the wiring harness from the bracket.
6. Disconnect the A/C compressor electrical connector.
7. Loosen the 3 bolts enough to slide the A/C compressor down 25.4 mm (1 in), allowing access for CKP sensor removal. To install, tighten to 25 Nm (18 lb-ft).
8. Remove the CKP sensor bolt and the CKP sensor. Inspect the O-ring seal for damage and replace if necessary. Lubricate the O-ring seal with clean engine oil prior to installation. To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.

Special Tool(s)

SPECIAL TOOL(S) DESCRIPTION CHART Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 15

Scheme 16

PARTS DESCRIPTION CHART

Removal

1. If servicing the PCM, connect the scan tool to the vehicle. Allow the scan tool to identify the vehicle and obtain configuration data. All programmable module information will automatically be retrieved by the VCM .
2. Remove the Air Cleaner (ACL) assembly and ACL outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .
3. Disconnect the 3 PCM electrical connectors.
4. Remove the 2 retaining nuts and PCM.

Installation

1. Install the PCM and the 2 retaining nuts. Tighten to 7 Nm (62 lb-in).
2. Connect the 3 PCM electrical connectors.
3. Install the ACL assembly and ACL outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .
4. Restore the module configurations for the IC module and the PCM. Carry out the module configuration restore steps of the Programmable Module Installation (PMI) procedure. For additional information, refer to «MODULE CONFIGURATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/communication-devices/#module-configuration-system-e-series) .

Scheme 17

Scheme 18

1. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .
3. Disconnect the Throttle Position (TP) sensor electrical connector.
4. Remove the TP sensor. Using a suitable heat gun, apply heat to the top of the ETB until the top TP sensor bolt ear reaches approximately 55°C (130°F), this should take no more than 3 minutes using an 1,100-watt heat gun. The heat gun should be about 25.4 mm (1 in) away from the ETB . Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating the ETB . Using hand tools, quickly remove the bolt farthest from the heat source first and discard. Using hand tools, remove the remaining bolt and discard. Remove and discard the TP sensor.

Scheme 19

1. Install the new TP sensor. Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector.
3. Install the ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .
4. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .

Scheme 20

Scheme 21

1. Remove the Air Cleaner (ACL) assembly and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .
2. Disconnect the Throttle Position (TP) sensor electrical connector.
3. Remove the TP sensor. Using a suitable heat gun, apply heat to the top of the ETB until the top TP sensor bolt ear reaches approximately 55°C (130°F), this should take no more than 3 minutes using an 1,100-watt heat gun. The heat gun should be about 25.4 mm (1 in) away from the ETB . Monitor the temperature of the top TP sensor bolt ear on the ETB with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating the ETB . Using hand tools, quickly remove the bolt farthest from the heat source first and discard. Using hand tools, remove the remaining bolt and discard. Remove and discard the TP sensor.

Scheme 22

1. Install the new TP sensor. Using hand tools, install the 2 new bolts. Tighten to 3 Nm (27 lb-in).
2. Connect the TP sensor electrical connector.
3. Install the ACL assembly and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .

Scheme 23

PARTS DESCRIPTION CHART

Scheme 24

Scheme 25

1. Remove the Air Cleaner (ACL). For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .
2. Open the ACL . Release the air box clamp. Separate the inlet side from the outlet side of the ACL .
3. Release the latches and remove the Mass Air Flow (MAF) assembly.
4. Disconnect the MAF sensor electrical connector.
5. Remove the 2 screws and MAF sensor. To install, tighten to 2 Nm (18 lb-in).
6. To install, reverse the removal procedure.

Scheme 26

PARTS DESCRIPTION CHART

Scheme 27

PARTS DESCRIPTION CHART

1. For additional information, refer to the appropriate procedure(s).

SPECIAL TOOL(S) DESCRIPTION CHART Socket, Exhaust Gas Oxygen Sensor 303-476 (T94P-9472-A)

Scheme 28

MATERIAL SPECIFICATIONS

1. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .
2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
3. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S .

Scheme 29

Scheme 30

1. Install the HO2S . Apply a light coat of high temperature nickel anti-seize lubricant to the HO2S threads prior to installation. Calculate the correct torque wrench setting for the following torque. Refer to the the illustration. Using the Exhaust Gas Oxygen Sensor Socket, tighten to 46 Nm (34 lb-ft).
2. Connect the HO2S electrical connector.
3. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/exteriorinterior-trim/#interior-trim-and-ornamentation-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART Socket, Exhaust Gas Oxygen Sensor 303-476 (T94P-9472-A)

MATERIAL SPECIFICATIONS

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
3. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS . Apply penetrating and lock lubricant to the CMS to assist in removal.

1. Install the CMS . Apply a light coat of high temperature nickel anti-seize lubricant to the CMS threads prior to installation. Calculate the correct torque wrench setting for the following torque. Refer to the illustration. Using the Exhaust Gas Oxygen Sensor Socket, tighten to 46 Nm (34 lb-ft).
2. Connect the CMS electrical connector.

Knock Sensor (KS)

Note. 6.8L shown in illustration, 4.6L and 5.4L similar.

Scheme 31

PARTS DESCRIPTION CHART

1. Remove the intake manifold. For additional information, refer to «ENGINE - 4.6L (2V)»(ref-370574) for 4.6L, «ENGINE - 5.4L (2V)»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-54l-2v-e-series) for 5.4L or «ENGINE - 6.8L»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-68l-e-series) for 6.8L engines.
2. Disconnect the Knock Sensor (KS) electrical connector.
3. Remove the bolt and the KS . To install, tighten to 25 Nm (18 lb-ft).
4. To install, reverse the removal procedure.

MATERIAL SPECIFICATIONS

Note. 5.4L shown in illustration, 4.6L and 6.8L similar.

Scheme 32

PARTS DESCRIPTION CHART

1. Remove the generator. For additional information, refer to «CHARGING SYSTEM»(/ford/cutaway-e350-super-duty/2008-2012/remont/charging-system/#charging-system) .
2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
3. Remove the CHT sensor. Coat the CHT sensor threads with high temperature nickel anti-seize lubricant prior to installation. To install, tighten to 26 Nm (19 lb-ft).
4. To install, reverse the removal procedure.

See also:
• INTRODUCTION - GASOLINE MODELS
• INTAKE AIR DISTRIBUTION & FILTERING
• JACKING & LIFTING
• ANTI-THEFT - PASSIVE ANTI-THEFT SYSTEM (PATS)
• MODULE CONFIGURATION
• INTERIOR TRIM AND ORNAMENTATION
• ENGINE - 5.4L (2V)
• ENGINE - 6.8L
• CHARGING SYSTEM
• CAMSHAFT POSITION (CMP) SENSOR
• CRANKSHAFT POSITION (CKP) SENSOR
• CYLINDER HEAD TEMPERATURE (CHT) SENSOR
• HEATED OXYGEN SENSOR (HO2S) AND CATALYST MONITOR SENSOR - EXPLODED VIEW
• KNOCK SENSOR (KS)
• MASS AIR FLOW (MAF) SENSOR