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Fuel Charging & Controls - 6.8l Ford Cutaway E350

Fuel System 27 illustrations ~996 words

GENERAL SPECIFICATIONS

ItemSpecification
Lubricant
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalentWSS-M2C930-A

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

DescriptionNmLb-in
Fuel rail retaining bolts1089
Throttle body bolts (1)
Fuel charge wiring harness retainer bolts1089
Transmission fluid level indicator tube bolt1089
(1) Refer to appropriate procedure in this article.
(1)Refer to appropriate procedure in this article.

TORQUE SPECIFICATIONS

Fuel Charging and Controls

The fuel charging and control system consists of the

  1. throttle body.
  2. fuel injectors.
  3. fuel charging wiring.
  4. fuel injection supply manifold.
  5. fuel rail pressure (FPR) sensor.
  6. fuel pump relay.

The fuel charging and control system is

  1. a sequential, multiport fuel injection (SFI) system.
  2. pulse width modulated.
  3. mass air flow controlled.

The fuel rail

  1. delivers fuel to the individual fuel injectors.
  2. receives fuel from the fuel supply tube.

The throttle body

  1. controls air supply to the upper intake manifold by positioning the throttle plate.
  2. is not adjustable.
  3. cannot be cleaned.

The fuel injectors

  1. are electrically operated by the powertrain control module (PCM).
  2. each have an internal solenoid that opens a needle valve to inject fuel into the lower intake manifold.
  3. atomize the fuel as the fuel is delivered.
  4. are deposit-resistant.

The fuel pump relay engages the fuel pump when energized by the powertrain control module.

The fuel charging wiring is a single harness that also includes electrical connectors for monitoring all engine functions.

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 can be ignited, resulting in possible personal injury.

Scheme 30

Scheme 30
Scheme 30
  1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
  3. Remove the engine air cleaner assembly and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#intake-air-distribution-filtering) .
  4. Disconnect the electronic throttle body (TB) electrical connector.
  5. Disconnect the throttle position (TP) sensor electrical connector.
  6. Remove the four bolts and the TB. Remove and discard the TB gasket.

Scheme 31

Scheme 31
Scheme 31

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Scheme 32
Scheme 32
  1. Install a new TB gasket. Install the TB and bolts. Tighten the bolts in two stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 90 degrees.
  2. Connect the TP sensor electrical connector. Push back the red clip.
  3. Connect the electronic TB electrical connector. Push back the red clip.
  4. Install the engine air cleaner assembly and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#intake-air-distribution-filtering) .
  5. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
  6. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .

Material

ItemSpecification
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalentWSS-M2C930-A

MATERIAL SPECIFICATION

Scheme 33

Scheme 33: Removal
Scheme 33: Removal

Scheme 34

Scheme 34
Scheme 34
  1. Remove the fuel rail. For additional information, refer to «FUEL RAIL»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-charging-controls-68l) .
  2. Remove the fuel injectors from the fuel rail.
  3. Discard the O-ring seals on each fuel injector.

Installation

  1. Install new O-ring seals on each fuel injector.
  2. Install the fuel injectors into the fuel rail.
  3. Install the fuel rail. For additional information, refer to «FUEL RAIL»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-charging-controls-68l) .

Removal and Installation

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 can be ignited, resulting in possible personal injury.

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Scheme 49
  1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
  3. Remove the engine air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#intake-air-distribution-filtering) .
  4. Disconnect the two electrical connectors and disconnect the connectors from the bracket.
  5. Disconnect the push pin retainers from the powertrain control module (PCM) bracket.
  6. Disconnect the PCM electrical connectors.
  7. Disconnect the fuel rail pressure (FRP) sensor electrical connector.
  8. Disconnect the LH radio ignition interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
  9. Disconnect the camshaft position (CMP) sensor electrical connector.
  10. Disconnect the oil pressure switch electrical connector.
  11. Disconnect the crankshaft position (CKP) sensor and the A/C compressor electrical connector. Remove the tie-strap.
  12. Disconnect the electronic throttle body (TB) electrical connector.
  13. Disconnect the throttle position (TP) sensor electrical connector.
  14. Disconnect the transmission wiring harness and the LH and RH heated oxygen (HO2S) electrical connector.
  15. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector.
  16. Disconnect the heated positive crankcase ventilation (PCV) electrical connector.
  17. Disconnect the ten ignition coil electrical connectors.
  18. Disconnect the ten fuel injector electrical connectors.
  19. Remove the retaining nut and position the transmission fluid indicator and tube aside.
  20. Remove the four bolts and the RH and LH fuel charge wiring harness retainers.
  21. Remove the fuel charge wiring harness.
  22. To install, reverse the removal procedure.

Scheme 50

Scheme 50: Removal and Installation
Scheme 50: Removal and Installation
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Disconnect the fuel pump driver module (FPDM) electrical connector.
  3. Remove the retaining nuts and FPDM.
  4. To install, reverse the removal procedure.
ItemSpecification
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalentWSS-M2C930-A

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 can be ignited resulting in possible personal injury.
WARNINGBefore working on or disconnecting any of the fuel tubes or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury.

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Scheme 56
  1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information) .
  2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
  3. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
  4. Remove the air cleaner and the air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#intake-air-distribution-filtering) .
  5. Disconnect the fuel tube spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information) .
  6. Disconnect the fuel rail pressure (FRP) sensor electrical connector and vacuum hose.
  7. Disconnect the ten fuel injector electrical connectors.
  8. Disconnect the positive crankcase ventilation (PCV) valve electrical connector and the tube from the RH valve cover.
  9. Remove the retaining nut and position the transmission fluid and indicator tube aside.
  10. Remove the retainers from the fuel charging wiring harness and position the wiring harness away from the fuel injection supply manifold.
  11. Remove the fuel injection supply manifold support bracket bolts.
  12. Remove the four retaining bolts and the fuel injection supply manifold.
  13. Remove the fuel injectors from the fuel injection supply manifold.
  14. Remove and discard the O-ring seals from each fuel injector.
  15. To install, reverse the removal procedure.

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