Engine Controls - Remove/install/overhaul Ford Econoline E350

INTRODUCTION

Note. Unless specified otherwise, references to Pickup include F350 Super Duty commercial chassis.

Removal, overhaul and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

Removal & Installation

1. Disconnect distributor from wiring harness. Mark position of No. 1 cylinder wire tower on distributor base for reference when installing distributor.
2. Loosen distributor cap hold-down screws. Remove cap carefully to prevent damaging rotor blade and spring. Position cap and attached wires aside.
3. Remove rotor by pulling upward from the distributor shaft. Remove distributor hold-down bolt and clamp. Remove distributor. Cover distributor opening in cylinder block or head with clean shop towel. To install, reverse removal procedure.

Scheme 1

Scheme 2

Removal (2.3L)

1. Disconnect negative battery cable. Remove accessory belt(s). Remove crankshaft pulley, hub and belt guide. Remove timing belt outer cover retaining bolt. Release 8 cover interlocking tabs.
2. Remove timing belt cover. Disconnect crankshaft sensor wire connector from engine harness. Remove crankshaft sensor 4-wire connector by prying out on Red retaining clip. (Scheme 3) CAUTION: Always turn engine in direction of normal rotation (clockwise as viewed from front of engine).
3. Rotate crankshaft and position crankshaft keyway at 10 o'clock position to place vane window of inner and outer vane cups over crankshaft timing sensor. Remove crankshaft sensor retaining bolts and plastic wire harness retainer. Remove crankshaft sensor.

Scheme 3

Installation

1. Position crankshaft sensor wires behind inner timing belt cover. Hold crankshaft sensor in place and install bolts finger tight. DO NOT tighten. Reconnect wire connectors to engine harness.
2. With Crankshaft Sensor Positioner (T89P-6316-A) in place, rotate crankshaft until outer vane of crankshaft pulley hub assembly engages both sides of crankshaft sensor positioner. (Scheme 4) Tighten crankshaft sensor bolts. CAUTION: Always turn engine in direction of normal rotation (clockwise as viewed from front of engine).
3. Rotate crankshaft until vane on crankshaft pulley hub assembly is no longer engaged in crankshaft sensor positioner. Remove crankshaft sensor positioner. Install NEW plastic wire harness retainer and trim off excess.
4. Rotate crankshaft 90 degrees (1/4 turn) clockwise and measure outer vane-to-sensor air gap. Air gap must be.018-.039" (.46-1.0 mm). To complete installation, reverse removal procedure.

Scheme 4

Removal (4.0L)

Disconnect negative battery cable. Disconnect crankshaft (variable reluctance) sensor wire connector from engine harness. Remove crankshaft sensor mounting screws. Remove crankshaft sensor. (Scheme 5)

Place crankshaft sensor in correct position. Install mounting screws and tighten. Reconnect crankshaft sensor wire connector.

Scheme 5

FUEL PRESSURE RELEASE

Disconnect negative battery cable. Remove fuel cap to release fuel tank pressure. Using EFI Pressure Gauge (T80L-9974-B), release fuel pressure from relief valve. Relief valve is located on fuel supply manifold.

Removal (Except Van)

Release fuel pressure. See FUEL PRESSURE RELEASE under FUEL SYSTEM (GASOLINE). Remove fuel tank. Using hammer and brass drift punch, carefully tap lock ring counterclockwise to release pump. Remove fuel pump from tank.

Wipe seal area of tank clean. Position a new "O" ring seal on pump. Position fuel pump in tank so fuel return hose is not kinked. Install lock ring. Using hammer and brass drift punch, drive ring around clockwise to lock pump in place. DO NOT overtighten pump lock ring, as it may leak. Install fuel tank.

Removal & Installation (Van - High Pressure Fuel Pump)

Release fuel pressure. See FUEL PRESSURE RELEASE under FUEL SYSTEM (GASOLINE). Locate fuel pump on left rail. Remove fuel pump bracket attaching screws. Remove fuel pump hoses. Remove fuel pump from bracket. (Scheme 6) To install, reverse removal procedure.

Removal & Installation (Van - Low Pressure Fuel Pump)

Van low pressure (boost) fuel pump is located inside the fuel tank. Removal and installation procedures are the same as removal and installation procedures for Aerostar, Bronco, Explorer, Pickup and Ranger.

Scheme 6

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-pressure-release) under FUEL SYSTEM (GASOLINE). Disconnect fuel supply and return lines. See «PUSH-CONNECT FITTINGS»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) under FUEL SYSTEM (GASOLINE).
2. Remove upper intake manifold and throttle body assembly. See «UPPER INTAKE MANIFOLD & THROTTLE BODY - 2.3L»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) under FUEL SYSTEM (GASOLINE). Disconnect wiring harness from injectors. Remove fuel supply manifold retaining bolts. Carefully disengage manifold and fuel injectors from engine. Remove manifold and injectors. (Scheme 7)

1. To install, reverse removal procedure. Lubricate NEW "O" rings with a light oil. Install 2 "O" rings on each injector (one per injector if injectors were not removed from fuel supply manifold). DO NOT use silicone grease.
2. Install fuel injector supply manifold and injectors in intake manifold; ensure injectors are seated. Secure fuel manifold assembly with retaining bolts. Connect injector wiring harness.

Scheme 7

Removal (2.9L)

1. Disconnect negative battery cable. Remove air inlet tube from air cleaner to throttle body. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-pressure-release) under FUEL SYSTEM (GASOLINE). NOTE: Ensure engine is clean before removing fuel supply manifold assembly.
2. Remove upper intake manifold and throttle body assembly. See «UPPER INTAKE MANIFOLD & THROTTLE BODY - 2.9L»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) under FUEL SYSTEM (GASOLINE). Disconnect crossover fuel hose, fuel supply, and fuel return line from fuel supply manifold. See «PUSH-CONNECT FITTINGS»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) under FUEL SYSTEM (GASOLINE).
3. Remove fuel supply manifold retaining bolts. Carefully remove fuel supply manifold from lower intake manifold. Remove fuel injector retainer clips, and inspect for corrosion and damage. Remove injector(s) from fuel supply manifold and wipe injector recesses clean with dry cloth.

1. To install, clean injectors and injector recesses. Lightly grease recesses. Check "O" rings for correct seating. Install 3 injectors on right recess of intake manifold, then install 3 on left.
2. Position and press down firmly on fuel rail to ensure fuel injectors are fully seated in fuel rail and intake manifold. Install fasteners. To complete installation, reverse removal procedure. (Scheme 8)

Scheme 8

Removal (3.0L)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-pressure-release) under FUEL SYSTEM (GASOLINE). Remove throttle body. Disconnect fuel supply and return lines. See «PUSH-CONNECT FITTINGS»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) under FUEL SYSTEM (GASOLINE).
2. Disconnect wiring harness at fuel injectors. (Scheme 9) Disconnect vacuum hose from fuel pressure regulator. Remove fuel assembly manifold bolts (2 on each side). Carefully disengage fuel supply manifold from fuel injectors by lifting and gently rocking rail.
3. Remove injectors from fuel supply manifold using a slight lifting/rocking motion. Place removed components in a clean container to avoid dirt or other contamination.

Lubricate NEW injector "O" rings with a light oil. DO NOT use silicone grease. Carefully install fuel supply manifold and injectors into lower manifold, one side at a time. To complete installation, reverse removal procedure.

Scheme 9

1. Disconnect negative battery cable. Remove snow/ice shield. Remove air inlet tube from air cleaner to throttle body. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-pressure-release) under FUEL SYSTEM (GASOLINE). NOTE: Ensure engine is clean before removing fuel supply manifold assembly.
2. Remove upper intake manifold and throttle body assembly. See «UPPER INTAKE MANIFOLD & THROTTLE BODY - 4.0L»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) under FUEL SYSTEM (GASOLINE). Disconnect fuel supply line fitting at fuel manifold.
3. Disconnect fuel return line from fuel pressure regulator. See «PUSH-CONNECT FITTINGS»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) under FUEL SYSTEM (GASOLINE). Remove fuel manifold retaining bolts. Remove fuel manifold. Remove injectors from manifold. (Scheme 10)

Lubricate NEW injector "O" rings with a light oil. DO NOT use silicone grease. Carefully install fuel supply manifold and injectors into lower manifold, one side at a time. To complete installation, reverse removal procedure.

Scheme 10

Removal & Installation (4.9L)

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-pressure-release) under FUEL SYSTEM (GASOLINE). Remove upper intake manifold assembly. See «UPPER INTAKE MANIFOLD & THROTTLE BODY - 4.9L»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) under FUEL SYSTEM (GASOLINE). Disconnect fuel supply and fuel return lines. See «PUSH-CONNECT FITTINGS»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) under FUEL SYSTEM (GASOLINE).
2. Disconnect vacuum hose from fuel pressure regulator. Remove strap surrounding fuel supply manifold, injector electrical harness, and main vacuum harness.
3. Remove fuel supply manifold retaining studs. Carefully disengage fuel supply manifold from fuel injectors, and remove manifold. To install, reverse removal procedure. Ensure injectors are well seated in manifold assembly.

Removal & Installation (5.0L, 5.8L & 7.5L)

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-pressure-release) under FUEL SYSTEM (GASOLINE). Remove upper intake manifold and throttle body assembly. See «UPPER INTAKE MANIFOLD & THROTTLE BODY - 5.0L, 5.8L & 7.5L»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) under FUEL SYSTEM (GASOLINE).
2. Disconnect fuel supply and return line connections at fuel supply manifold. See «PUSH-CONNECT FITTINGS»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) under FUEL SYSTEM (GASOLINE). Remove fuel supply manifold retaining bolts. Carefully disengage fuel supply manifold from fuel injectors. To install, reverse removal procedure. (Scheme 11)and see scheme 12.

Scheme 11

Removal (2.3L & 3.0L)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-pressure-release) under FUEL SYSTEM (GASOLINE). Disconnect wiring harness from each injector.
2. Remove fuel supply manifold. See «FUEL SUPPLY MANIFOLD ASSEMBLY - 2.3L»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) or «FUEL SUPPLY MANIFOLD ASSEMBLY - 3.0L»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) under FUEL SYSTEM (GASOLINE). Remove injectors from fuel supply manifold using a rocking/pulling motion.

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

Removal (2.9L & 4.0L)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-pressure-release) under FUEL SYSTEM (GASOLINE). Remove upper intake manifold and throttle body assembly. See UPPER INTAKE MANIFOLD & THROTTLE BODY under FUEL SYSTEM (GASOLINE).
2. Remove fuel supply manifold. See «FUEL SUPPLY MANIFOLD ASSEMBLY - 2.9L»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) or «FUEL SUPPLY MANIFOLD ASSEMBLY - 4.0L»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) under FUEL SYSTEM (GASOLINE). Remove wiring harness from injector(s). Remove injector retaining clip(s). Remove injectors from fuel supply manifold using a rocking/pulling motion.

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

Removal (4.9L, 5.0L, 5.8L & 7.5L)

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-pressure-release) under FUEL SYSTEM (GASOLINE). Remove upper intake manifold assembly. See «UPPER INTAKE MANIFOLD & THROTTLE BODY - 4.9L»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) or «UPPER INTAKE MANIFOLD & THROTTLE BODY - 5.0L, 5.8L & 7.5L»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) under FUEL SYSTEM (GASOLINE).
2. Carefully disconnect electrical lead(s) from injector(s). Remove injector(s) from fuel supply manifold using a slight rocking/pulling motion.

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

Removal (2.3L, 2.9L 3.0L & 4.0L)

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-pressure-release) under FUEL SYSTEM (GASOLINE). Remove vacuum hose at fuel pressure regulator. Remove fuel line.
2. On 3.0L models, loosen or remove fuel rail-to-intake manifold bolts for access to regulator housing screws. On all models, 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 regulator and manifold gasket surfaces are clean and dry. To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-pressure-release) under FUEL SYSTEM (GASOLINE).
2. Remove vacuum hose from fuel pressure regulator. Remove Allen head screws from fuel pressure regulator housing. Remove fuel pressure regulator, gasket, and "O" ring.

Lubricate "O" ring with a light oil. DO NOT use silicone grease. Ensure regulator and manifold gasket surfaces are clean and dry. To complete installation, reverse removal procedure.

Removal

1. Disconnect negative battery cable. locate O2 sensor mounted in the exhaust pipe below exhaust manifold or "Y" pipe junction, near catalytic converter inlet. Ensure sensor is free of contaminants. DO NOT use cleaning solvents of any type.
2. Disconnect electrical connector from O2 sensor. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Carefully remove O2 sensor from exhaust pipe.

Whenever replacing O2 sensor, coat threads with anti-seize compound before installation. New O2 sensors should already have this compound applied to threads. Install O2 sensor. Reconnect electrical connector to O2 sensor. Tighten sensor to 30 ft. lbs. (41 N.m). Reconnect negative battery terminal.

Removal & Installation (3/8", 1/2" & 5/8" Spring Lock Coupling)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-pressure-release) under FUEL SYSTEM (GASOLINE). Place indicated spring lock coupler over coupling. See «SPRING LOCK COUPLER IDENTIFICATION»(/ford/econoline-e350/1985-1999/remont/removal-installation/#engine-controls-removeinstalloverhaul) table. To release female fitting from garter spring, push coupler along tube into coupling. (Scheme 12)
2. Pull spring lock coupling apart. Remove coupler from disconnected spring lock coupling. Check for damaged garter spring and "O" rings. Wipe end of lines with clean cloth.
3. To install, place NEW "O" rings onto tube. Lubricate ends of lines with clean refrigerant oil. Locate White indicator ring (if equipped) which may have slipped down length of tube. Insert White indicator ring into cage of male fitting.
4. Push fitting together with a slight twisting motion. The White indicator ring should pop free of cage to indicate that male fitting is properly seated over flared end of female fitting.

SPRING LOCK COUPLER IDENTIFICATION

Scheme 12

Removal & Installation (Fuel Line Coupler)

1. Disengage locking tabs on connector retainer and separate retainer halves. Disengage fitting from regulator by pushing fitting toward regulator and inserting Fuel Line Coupling Key (T90P-9550-A). (Scheme 13)
2. Remove fuel supply manifold assembly. To install (re-engage) fuel line coupling, push coupler tube assembly firmly into coupler body recess until fully engaged. Pull gently on both ends of coupler to ensure engagement See appropriate FUEL SUPPLY MANIFOLD ASSEMBLY procedure under FUEL SYSTEM (GASOLINE).

Scheme 13

1. Remove throttle linkage shield. Disconnect throttle linkage, cruise control and kickdown cable. Unbolt accelerator cable and position aside. Disconnect wire connectors from throttle position sensor and air by-pass valve.
2. Disconnect air intake hose from throttle body. Remove air intake and PCV hoses from throttle body. Disconnect water by-pass hose. Disconnect EGR tube by removing flange nut. Remove 5 upper intake manifold retaining bolts. Remove intake manifold and throttle body assembly.

Clean gasket surfaces. DO NOT allow gasket material to fall into intake manifold. Reverse removal procedure to complete installation.

1. Disconnect electrical connectors at air by-pass valve, throttle position sensor, EGR sensor and Air Charge Temperature (ACT) sensor. Remove air cleaner-to-throttle body air inlet tube.
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. 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 retaining A/C line at upper rear of upper manifold. Disengage retainer. Remove 6 upper intake manifold retaining bolts. Remove upper intake manifold and throttle body as an assembly.

Clean and inspect mounting faces of lower and upper intake manifolds. Install the upper intake manifold and throttle body assembly to the lower manifold. To complete installation, reverse removal procedure.

1. Ensure ignition switch is in OFF position. Loosen clamps and remove engine air outlet tube between air cleaner and throttle body. Remove snow/ice shield to expose throttle linkage.
2. Remove throttle cable bracket, and disconnect cable from ball stud on throttle body. Disconnect and mark vacuum hoses at vacuum fittings on intake manifold.
3. Remove accelerator and cruise control cables from accelerator mounting bracket and throttle lever. Remove alternator support brace. Disconnect wiring harness at throttle position sensor, air by-pass valve, and air charge temperature sensor.
4. 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. (Scheme 14)

Clean and oil manifold bolt threads. Install new manifold gasket. If injectors were removed, lubricate NEW injector "O" rings with a light oil. DO NOT use silicone grease. To complete installation, reverse removal procedure.

Scheme 14

1. Disconnect electrical connectors at air by-pass valve, throttle position sensor and air charge temperature sensor. Remove snow/ice shield to expose throttle linkage. Remove throttle cable bracket.
2. Disconnect cable from ball stud on throttle body. Remove air cleaner-to-throttle body air inlet tube. Disconnect upper intake manifold vacuum connectors. Disconnect PCV valve from rocker cover.
3. Disconnect spark plug wires at rear of manifold. Remove canister purge line from fitting in throttle housing. On Aerostar, remove bolt retaining engine oil dipstick tube.
4. On all models, remove A/C line-to-upper upper manifold bolt. Remove 6 upper manifold retaining bolts. Remove upper intake and throttle body, as an assembly, from lower intake and fuel supply manifolds. (Scheme 15)

Clean and oil manifold bolt threads. Install NEW manifold gasket. If injectors were removed, lubricate NEW injector "O" rings with a light oil. DO NOT use silicone grease. To complete installation, reverse removal procedure.

Scheme 15

Removal (4.9L)

1. Disconnect electrical connectors at EGR Valve Positioner (EVP) sensor located on EGR valve. Disconnect throttle position sensor and air by-pass valve. Label and disconnect all vacuum hoses connected to upper intake manifold and throttle body assembly.
2. Disconnect PCV hose from fitting located on side of intake manifold. (Scheme 16) Remove throttle linkage shield. Disconnect throttle linkage and cruise control cables. Disconnect accelerator cable from bracket and position cable aside.
3. Disconnect air inlet hoses from throttle body. Disconnect EGR tube from EGR valve and exhaust manifold. Remove thermactor (air injection) tube assembly from lower intake manifold.
4. Remove nut attaching thermactor by-pass valve bracket to lower intake manifold. On van, remove nut attaching transmission filler tube. Remove tube bracket from intake manifold stud.
5. On all models, remove 7 studs retaining upper intake manifold. Remove screw and washer attaching upper intake manifold support bracket to intake manifold. Remove upper intake manifold and throttle body as an assembly.

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

Scheme 16

Removal (5.0L, 5.8L & 7.5L)

1. Disconnect electrical leads at air by-pass valve, throttle position sensor, and EGR position sensor. Disconnect throttle linkage at pivot ball. On 5.0L A/T models, remove transmission linkage from throttle body.
2. On all models, remove bracket-to-intake manifold bolts. Position bracket and cables out of way. Remove vacuum hoses at upper intake manifold vacuum tee, EGR valve, and fuel pressure regulator.
3. Disconnect PCV system by removing hose from fitting on rear of upper intake manifold. Remove 2 canister purge lines from fitting on throttle body. Disconnect heater hoses from throttle body.
4. Disconnect EGR tube from EGR valve. Remove upper intake manifold support bracket. Remove 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. Clean nozzle and surrounding area. Disconnect negative battery terminal. On van, remove engine cover. On all models, disconnect air cleaner.
2. Disconnect accelerator cable and bracket from intake manifold. Disconnect fuel filter-to-injection pump fuel line. Remove fuel filter-to-injection pump fuel line. Remove fuel line caps. Remove fuel line clamps from fuel lines to be removed.
3. Remove injection pump inlet elbow and inlet fitting adaptor. Remove injection nozzle lines from injection pump using Fuel Line Nut Wrench (T83T-9396-A). Tag lines for reassembly reference. Cap all openings.

Remove caps and install injection lines. Ensure lines are properly positioned. Reverse removal procedure to complete installation. Start engine and check for leaks.

1. Loosen but DO NOT remove fuel lines and fuel pump retaining bolts. Fuel pump should be loose. If fuel pump is not loose, apply hand pressure to break gasket seal.
2. Rotate engine until fuel pump is loose. Remove fuel lines and fuel pump retaining bolts. Remove fuel pump and gasket. To install, reverse removal procedure.

INJECTION PUMP

1. Disconnect ground cables from both batteries. On van, remove engine cover. On all models, remove air cleaner. Cover intake opening in manifold. Remove injection pump drive gear cover plate. Ensure timing marks are aligned.
2. Rotate crankshaft until No. 1 piston is at TDC of compression stroke. Remove injection pump-to-drive gear bolts. Disconnect electrical connectors at injection pump. Remove fast idle solenoid bracket assembly for access to injection pump mounting nuts.
3. Disconnect accelerator cable and speed control cable from throttle lever. Remove accelerator cable bracket and cables. If necessary, remove fuel filter and bracket. Disconnect 90-degree fuel return hose elbow at governor on injection pump. NOTE: Unless pump is being replaced or serviced, DO NOT disconnect injection lines from pump when removing pump from engine. Reference mark lines-to-pump position before disconnecting.
4. If removing injection pump with injection lines connected to pump, disconnect lines at injector nozzles. If removing injection pump without lines connected to pump, remove line retaining clips.
5. Disconnect lines from pump using Fuel Line Nut Wrench (T83T-9396-A). Remove injection lines in the following sequence: 5-6-4-8-3-1-7-2. Odd number cylinders are on right bank, with No. 1 cylinder closest to front of engine. CAUTION: Ensure No. 1 piston is at TDC of compression stroke before removing injector pump. Pulley "Y" marks should be aligned.
6. On all applications, remove 3 injection pump-to-injection pump drive gear cover nuts using Injection Pump Mounting Wrench (T86T-9000-C). On Pickup, lift injection pump (or pump with lines connected) out of engine compartment. On Van, remove injection pump (or pump with lines attached) through passenger compartment.

1. Install NEW "O" ring on injection pump drive gear end. Install pump into position, aligning dowel on pump drive shaft with hole in drive gear. If necessary, rotate pump drive shaft to align dowel with hole.
2. Install and hand tighten 3 injection pump-to-drive gear cover nuts. Align timing mark on top radius of injection pump with mark on injection pump drive gear cover. To complete installation, reverse removal procedure.

1. Before removing nozzle assemblies, clean surrounding area and connections with clean fuel or solvent to prevent contamination. Blow area dry with compressed air. Remove fuel line retaining clamps from lines being removed.
2. Remove and cap line sensor on No. 1 cylinder to permit removal of leak-off "T" fitting to fuel filter. Disconnect fuel return hose and position out of way. Cap all open connections.
3. Remove injector and copper gasket from engine. Use "O" Ring Remover (T71P-19703-C) to remove gasket if it is not attached to injector tip. DO NOT strike injector tip against any hard surface during removal.
4. Cap both ends of injector and store in numbered holder or rack in the same way they were removed, such that injector may be installed in original cylinder.

1. Clean nozzle bore in cylinder head thoroughly before installing injector. Remove protective cap from tip. Coat threads with anti-seize compound. Install a new copper gasket on injector using a small amount of grease to retain gasket on injector.
2. Install injector into cylinder head bore and tighten. Remove caps from fuel lines and fittings. Install fuel inlet and return "T" fittings on injector. Install 2 new "O" rings on each "T" fitting. Connect fuel line to injectors.
3. Install fuel line retainer clamps and tighten. Purge injector lines if needed by loosening connector 1/2 to one turn and cranking engine until a solid stream of fuel flows from connector. Run engine and check for fuel leaks.

1. Remove all hose connections attached to fuel filter assembly. Place suitable container at end of drain hose to catch fuel and open filter drain. Remove water drain hose from fuel filter assembly.
2. Remove fuel outlet hose, located between fuel pump and filter housing. Remove fuel return hose from fuel pressure regulating valve. Remove two fuel supply hoses connecting regulator block to cylinder head fuel rails.
3. Loosen clamp at fuel pump end on hose connecting fuel filter to inlet of high pressure stage to fuel pump. Unclip wiring harness from right side of filter housing. Disconnect electrical connectors from water in fuel sensor and fuel heater.
4. Remove 2 cap screws securing fuel filter base to crankcase and remove fuel filter. Using a screwdriver or bar, remove fuel filter cap. Fuel filter element will come out with cap. Remove and discard bevel gasket. Carefully clean mating surfaces. Press in on fuel filter element locking tabs to separate element from cap.

Note. The engine will not run if fuel filter in not correctly installed in housing.

1. Apply a coating of clean diesel fuel to new bevel gasket and install onto fuel filter housing gland. Install new fuel filter element onto cap. Place new fuel filter element and cap into fuel filter housing. Allow fuel to soak into fuel filter element.
2. Tighten cap onto fuel filter housing until cap contacts aluminum housing. Mount fuel filter base to crankcase with 2 cap screws. Tighten to 24-38 ft. lbs. (33-52 N.m). To install remaining hose connections, reverse removal procedure.

Scheme 17

THROTTLE POSITION SENSOR (TPS)

Note. On 7.3L engines, a Fuel Injection Pump Lever (FIPL) sensor is used instead of a TPS. For FIPL service procedures, see appropriate ADJUSTMENTS article in the ENGINE PERFORMANCE Section.

Removal (2.3L, 2.9L, 3.0L, 4.0L & 4.9L)

Remove air by-pass valve (if necessary). Disconnect TPS wiring harness connector. Remove TPS retaining screws. Remove TPS and gasket.

Position TPS and gasket on throttle body, with tangs correctly aligned with throttle shaft blade. Reverse removal procedure to complete installation.

Disconnect TPS wiring harness connector. Scribe a reference line across TPS and throttle body. Remove TPS retaining screws. Remove TPS and gasket.

Position TPS and gasket on throttle body, with wiring harness connector parallel to venturi boxes. Rotate TPS clockwise to align scribe marks. Reverse removal procedure to complete installation.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• FUEL PRESSURE RELEASE
• PUSH-CONNECT FITTINGS