Carburetor - Motorcraft 7200 Vv 2-bbl Ford LTD Crown Victoria I

COMPONENT TESTING

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

APPLICATION

MOTORCRAFT CARBURETOR NO.

IDENTIFICATION

Carburetor part number is stamped on left side of upper throttle body or on metal identification tag. The upper line contains part number prefix and suffix. A design change code (if any) is included on the lower line. An assembly date code is also included on the lower line. (Scheme 1)

Motorcraft 7200 VV Carburetor Identification. Scheme 1

DESCRIPTION

The model 7200 VV (variable venturi) carburetor changes venturi opening size to allow for varying engine speed and load conditions. This is done by dual venturi valves which are controlled by engine vacuum and throttle position.

Depending upon engine demands, venturi valve positions change to determine amount of airflow through carburetor. The venturi valves are connected to 2 tapered main metering rods. As venturi valve position changes, the metering rods adjust the amount of fuel flow through the main metering jets.

The carburetor changes air/fuel ratio in response to commands from the MCU control module. The system uses a stepper motor to regulate amount of bleed air allowed into main metering fuel system. The greater the amount of air entering the system, the leaner the air/fuel ratio.

TESTING

Note. Before performing continuity tests, disconnect stator terminal of alternator for alternator powered choke. Reconnect stator terminal after testing.

CHOKE CAP CONTINUITY

1. With ignition off, connect a test light between battery positive terminal and choke cap terminal. Test light should light, indicating continuity. If the test light is on, perform the appropriate «CIRCUIT CONTINUITY (ALTERNATOR POWERED CHOKE)»(/ford/ltd-crown-victoria/i-1983-1991/remont/testing-diagnostics/#carburetor-motorcraft-7200-vv-2-bbl__circuit-continuity-alternator-powered-choke) test or the «CIRCUIT CONTINUITY (BATTERY POWERED CHOKE)»(/ford/ltd-crown-victoria/i-1983-1991/remont/testing-diagnostics/#carburetor-motorcraft-7200-vv-2-bbl__circuit-continuity-battery-powered-choke) test.
2. If test light is not on, connect a jumper wire between choke cap clamp shroud and battery negative terminal. Connect test light between battery positive terminal and choke cap terminal. Test light should be on. If test light is on, replace choke cap.
3. If test light is not on, connect a jumper wire directly to choke cap ground. If test light is on, correct poor contact between choke cap clamp shroud and choke cap ground.

CIRCUIT CONTINUITY (ALTERNATOR POWERED CHOKE)

Connect test light between choke cap ground and battery negative terminal. Start engine. Test light should be on. If test light is not on, locate and repair open circuit between choke cap and alternator stator terminal. If no open in circuit is found, check alternator output.

CIRCUIT CONTINUITY (BATTERY POWERED CHOKE)

1. With engine and ignition off, disconnect oil pressure switch from harness. Using a jumper wire in place of switch, complete choke circuit. Connect test light between battery negative terminal and choke cap terminal.
2. Turn ignition on, but do not start engine. Test light should be on, indicating continuity. If test light is not on, locate and repair open circuit. Turn ignition off. Check fuse, fusible link, connectors, etc. in choke circuit.
3. Remove jumper wire and connect harness to oil pressure switch. Turn ignition on, but do not start engine. Test light is not on. If test light is not on, replace oil pressure switch. Start engine. Test light should be on. If test light is not on, replace oil pressure switch.

ADJUSTMENTS

Note. For on-vehicle adjustments not covered in this article, see appropriate TUNE-UP article.

FLOAT LEVEL ADJUSTMENT

Note. The model 7200 VV (variable venturi) carburetor is NOT sensitive to fuel float level. Adjusting only the float level will generally not correct starting or driveability problems.

1. Remove upper body assembly. Remove upper body gasket. If necessary, construct a gauge to specified float level setting. Turn upper body assembly upside-down.
2. Using gauge, measure distance from surface of upper body to bottom of float. (Scheme 2) To adjust, bend fuel level adjustment tab away from inlet needle to decrease setting, and toward inlet needle to increase setting.

Float Level Adjustment Perform float level adjustment with gasket removed. Scheme 2

FLOAT DROP ADJUSTMENT

1. With upper body and gasket removed, hold upper body in upright position and allow float to hang. If necessary, construct a gauge to specified float drop setting.
2. Using gauge, measure the distance from surface of upper body to bottom of float. To adjust, bend the float lever stop tab away from the hinge pin to increase setting and toward the hinge pin to decrease setting.

Float Drop Adjustment Perform float drop adjustment with gasket removed. Scheme 3

ACCELERATOR PUMP LEVER LASH ADJUSTMENT

Adjust curb idle speed. Using a feeler gauge, measure clearance between accelerator pump stem and pump lever. If clearance is not to specification, tighten or loosen nut on end of link to obtain specified clearance.

Accelerator Pump Lever Lash Adjustment. Scheme 4

COLD ENRICHMENT ROD (CER) & CONTROL VACUUM REGULATOR (CVR)

Note. The CER mechanism affects carburetor air/fuel mixture in all RPM ranges. Choke CER and CVR adjustment procedures must be performed in the following sequence.

Scheme 5

1. Remove carburetor. Position dial indicator on carburetor, with indicator stem on top of cold enrichment rod. (Scheme 5) Remove choke diaphragm cover and spring. Use a 1/4" drill bit to remove choke cap retaining screw heads. Carefully remove choke cap and remove remaining portion of screws. (Scheme 5): CER Initial Adjustment This is the initial set-up procedure.
2. Compress idle speed positioner (if equipped) and insert a 5/16"-1/2" (7.94-12.7 mm) spacer between positioner stem and throttle lever contact paddle. Using a rubber band, hold positioner in compressed position. Fast idle lever should be away from cam and cam should rotate freely.
3. Install Stator Cap (T77L-9848-A7) as weight to rotate choke thermostat lever counterclockwise and seat CER. Install dial indicator on carburetor with tip on top of CER. Set dial indicator to zero and raise weight slightly to check zero setting.

CVR Swivel Assembly Replacement

1. Remove "E" clip and hinge pin. Turn CER adjustment nut counterclockwise until nut disengages from rod. Remove CVR and swivel assembly. Replace with new assembly. NOTE: Adjustment nut cavities are filled with epoxy after final adjustment. To adjust, the existing parts must be removed and new parts installed. Choke control rod is designed to break. If rod breaks during adjustment a new rod must be installed.
2. With control rod in place, install swivel assembly and tighten CER adjustment nut to lower and locate into position. Connect lever to swivel. Install hinge pin and "E" clip. Perform CER run position adjustment.

CER Run Position (75°F) Adjustment

Install stator cap and rotate clockwise to index position. Dial indicator reading should be 0.125" (3.18 mm) at 75°F (24°C). (Scheme 6) Adjust reading by turning choke adjustment nut clockwise to increase reading, or counterclockwise to decrease.

CER Run Position (75°F) Adjustment Rotate choke adjustment nut to adjust reading. Scheme 6

CER Start Position (0°F) Adjustment

Remove stator cap. Rotate choke thermostat lever clockwise until CER travel stop screw is bottomed on choke seal retainer (full travel). Dial indicator reading should be 0.490" (12.4 mm) at 0°F (18°C). (Scheme 7) Adjust reading by turning screw with a 5/64" Allen wrench. Turn screw clockwise to increase reading. Turn counterclockwise to decrease.

CER Start Position (0°F) Adjustment Turn CER travel stop screw to adjust reading. Scheme 7

Choke Diaphragm Start Position (Warm Engine)

Push in diaphragm assembly. Dial indicator reading should be 0.460" (11.7 mm) at 75°F (24°C). Adjust reading by rotating diaphragm clockwise to decrease reading or counterclockwise to increase. see scheme 8

Control Vacuum Rod Position

1. Seat CER using stator cap weight and check dial indicator for zero reading. Reset dial indicator, if necessary. Remove stator cap weight. Depress CVR until seated. Dial indicator reading should be 0.250" (6.3 mm).
2. Adjust reading by holding CVR with 3/8" wrench and turning adjustment screw with a 3/32" Allen wrench. Turn screw clockwise to decrease reading or counterclockwise to increase. Install original choke diaphragm cover and spring.

Scheme 8

Scheme 9

1. Depress choke diaphragm rod until diaphragm bottoms out. Rotate choke thermostat lever clockwise until choke shaft lever pin contacts fast idle intermediate lever. Dial indicator reading should be 0.350" (8.9 mm) at 0°F (18°C). (Scheme 9)
2. If reading is not to specification, remove choke diaphragm cover and install a new cover. Adjust reading by turning screw with a 5/64" Allen wrench. Turn screw clockwise to increase reading or counterclockwise to decrease. Apply sealing liquid on screw to secure adjustment. Install lead ball plug over adjustment screw.

FAST IDLE CAM ADJUSTMENT

1. Position fast idle lever on 2nd step of fast idle cam. Install stator cap and rotate clockwise until fast idle lever contacts fast idle cam adjustment screw. Dial indicator reading should be 0.360" (9.14 mm).
2. If adjustment is necessary, rotate fast idle cam adjustment screw. Remove stator cap. Assemble choke cap, gasket, and retainer with breakaway screws. Remove dial indicator and rubber band. Install carburetor and adjust idle speeds.

Scheme 10

Scheme 11

1. Using a center punch, remove expansion plug covering venturi valve limiter adjustment screw. Using a 5/32" Allen wrench, remove (WOT) adjustment screw and spring. Hold throttle plates wide open and apply light closing pressure on venturi valve.
2. Measure gap between venturi valve and air horn wall. Using a 5/64" Allen wrench, turn venturi valve limiter adjustment screw on venturi valve arm to set closing gap. Using a 5/32" Allen wrench, install (WOT) adjustment screw and spring.
3. Apply light opening pressure on venturi valve. Measure maximum open gap between venturi valve and air horn wall. Using a 5/32" Allen wrench, turn (WOT) adjustment screw until maximum open gap is set to specification. Install new expansion plug in access hole.

Upper Body

1. Install carburetor on holding stand to prevent damage to throttle plates. Remove fuel inlet fitting, filter, gasket, and spring. Remove "E" clip from accelerator pump and choke control rod, then disengage rods.
2. Remove air cleaner stud. Remove 7 screws holding air horn and note position of screws. Remove upper body, invert it and place on clean work bench. Remove float hinge pin, float assembly and gasket.
3. Remove fuel inlet valve, seat and gasket. Remove accelerator pump link retaining screw and nut. Remove accelerator pump adjustment nut, link, overtravel spring, "E" clip and washer.
4. Remove accelerator pump rod and dust seal. Remove "E" clip from choke hinge pin and slide pin out. Remove cold enrichment rod adjustment nut by turning counterclockwise. NOTE: Epoxy on nut cavity may cause choke control rod to break. If rod breaks, a new rod and swivel assembly must be installed.
5. Remove cold enrichment rod lever, adjustment swivel, control vacuum regulator and adjustment nut as an assembly. Disassemble as required. Slide rod out of upper body. Remove the 2 Torx head screws while holding the venturi valve cover with Cover Holder (T81L-2100-H15).
6. Invert carburetor, holding venturi valve cover in place. Remove valve cover, gasket and bearings as an assembly. Using Pivot Pin Remover and Installer (T77L-9928-A), press tapered plugs out of venturi valve pivot pins.
7. Push venturi pivot pins out and slide venturi valve to rear, freeing it from housing. Remove venturi valve pivot pin bushings. Remove metering rod pins (on outboard side of venturi valve), metering rods, and springs. NOTE: Identify throttle/choke rods for proper reassembly. Always block venturi valve wide open when working on the jets.
8. Using Jet Plug Remover (T77L-9533-B), remove plugs in upper body housing. Using Jet Wrench (T77L-9533-A), turn main metering jets clockwise, counting number of turns until they bottom in housing. Note number of turns for reassembly reference. Turn jet assembly counterclockwise to remove.
9. Remove "O" rings and identify jets as throttle or choke side, for reassembly reference. Remove accelerator pump plunger and disassemble. Remove venturi valve limiter adjustment screw from throttle side of venturi valve. Remove 1/8" pipe plug in fuel inlet boss for cleaning.

Scheme 12

Main Body

1. Remove venturi valve diaphragm cover screws. Tap cover lightly and remove cover, spring guide, and spring. Carefully loosen diaphragm and slide out of main body. Invert carburetor and catch accelerator pump check ball and weight.
2. Place carburetor on clean surface. Remove 5 throttle body retaining screws and remove throttle body. Using a 1 5/8" socket, remove feedback stepper motor, gasket, pintle valve and pintle spring.

Throttle Body

1. Remove throttle return control solenoid, dashpot and bracket. Disconnect kickdown return spring. Using a 1/4" drill bit, drill off choke cap retaining screw heads. Carefully remove choke cap and remove remaining portion of screws with small locking pliers.
2. Remove choke thermostatic lever and screw. Slide choke shaft and lever assembly from housing. Remove fast idle cam and "E" clip. Remove fast idle cam adjustment screw and choke diaphragm rod "E" clip that attaches rod to fast idle intermediate lever. Disengage unloader rod (if equipped).
3. Remove fast idle intermediate lever, choke control diaphragm cover screws, cover, and return spring. Remove choke control diaphragm and rod. Disassemble if necessary. Remove choke housing bushing (if necessary). CAUTION: Before pressing out choke housing bushing, be sure to file or grind off staked areas.
4. Remove idle speed adjustment screw (TSP off), throttle shaft retaining nut and spring (if equipped). Remove fast idle adjustment lever, nylon bushing, fast idle lever and fast idle adjustment screw. Remove unloader lever (if equipped). Remove the large "E" clip.
5. If throttle plates are to be removed, lightly scribe them to ensure proper reassembly. File off end of throttle plate screws. Remove screws and plates. Discard screws. To remove throttle shaft assembly, drive the limiter lever stop pin down until it is flush with the shaft.
6. Remove "E" clip next to venturi valve limiter lever. Slide throttle shaft assembly from housing and remove transmission kickdown adjustment screw (if equipped). Remove venturi valve limiter lever and bushing assembly.

1. Support throttle shaft assembly and drive out venturi valve limiter stop pin (if equipped). Discard pin. Place venturi valve limiter assembly in throttle body and slide throttle shaft into position. Install "E" clip.
2. Place throttle plates in correct position. Install new throttle plate screws and tighten until snug. Close throttle lever and center throttle plates in bore. Tighten throttle plate screws to 10-15 INCH lbs. (1.1-1.7 N.m) and stake into position.
3. Drive new venturi valve limiter stop pin into shaft, leaving 1/8" of pin exposed. Install retaining screws and "E" clip. Install fast idle lever "E" clip, nylon bushing, fast idle adjustment lever and throttle shaft retaining nut. Install choke unloader lever (if equipped). Install (TPS off) idle speed adjustment screw.
4. If choke housing bushing was removed, carefully press new bushing into housing. Support housing and stake bushing in place. Install fast idle intermediate lever, large "E" clip, fast idle cam and adjustment screw. Install choke unloader lever (if equipped).
5. Slide choke control diaphragm rod into position, engage rod and "E" clip. Slide choke shaft lever and pin assembly into housing and install choke thermostatic lever and screw. Install choke control diaphragm spring, cover and screws. Install throttle control device solenoid, dashpot and bracket.

1. Position throttle body gasket on main body and assemble main body to throttle body. Drop accelerator pump check ball and weight into pump discharge charge channel. NOTE: DO NOT install venturi valve limiter stop screw, spring and plug at this time. They are installed after carburetor is assembled and venturi valve limiter is adjusted.
2. Slide venturi valve diaphragm into position. Install diaphragm spring, spring guide and cover. Loosely install retaining screws. Depress diaphragm stem with finger to prevent pinching diaphragm between cover and housing.
3. Diagonally tighten screws to 15-22 INCH lbs. (1.7-2.5 N.m). Release stem. Install feedback motor, gasket, pintle valve, and pintle spring. Tighten motor to 8-10 ft. lbs (11-14 N.m).

1. Install 1/8" pipe plug in fuel inlet boss. Install venturi valve limiter screw in venturi valve. Lubricate "O" rings with mild soapy solution and install on main metering jets.
2. Using Jet Wrench (T77L-9533-A), install main metering jets. Turn jets clockwise until lightly seated in housing. Turn each jet counterclockwise the exact number of turns noted during disassembly. Using Plug Driver (T77L-9533-C) install jet plugs. Tap tool lightly until tool bottoms on housing.
3. Install metering rods, springs and metering rod pivot pins on venturi valve. Install venturi valve, carefully guiding metering rods into jets. Depress metering rod and then release. If springs are correctly installed, metering rods will spring back up.
4. Install the venturi valve pivot pin bushings and pivot pins. Press the tapered plugs into the pivot pins using Pivot Pin Remover and Installer (T77L-9928-A). Install the venturi valve cover plate roller bearings, gasket and screws. Tighten screws to 24-35 INCH lbs. (2.7-4.8 N.m).
5. Install accelerator pump operating rod and dust seal. Attach "E" clip and washer. Slide pump over travel spring and onto rod. Insert accelerator pump lever and swivel the assembly into the pump link. Install pump link screw and nut. Install accelerator pump adjustment nut.
6. Install fuel inlet valve seat gasket, seat and valve. Install float bowl gasket. Install float assembly and retain with float hinge pin. Check and adjust float level. Assemble accelerator pump return spring, cup and plunger. Place pump piston assembly in hole of upper body.
7. Assemble lever to swivel. Position swivel assembly and tighten CER nut 4 to 5 turns on choke control rod. Seat assembly and install choke control rod. Perform CER and CVR adjustments. Refer to the «COLD ENRICHMENT ROD (CER) & CONTROL VACUUM REGULATOR (CVR)»(/ford/ltd-crown-victoria/i-1983-1991/remont/testing-diagnostics/#carburetor-motorcraft-7200-vv-2-bbl__cold-enrichment-rod-cer-control) adjustment procedure in this article. NOTE: If choke control rod broke during disassembly, insert new rod prior to installing upper body.
8. Assemble upper body to main body. Holding pump piston assembly with finger, guide it into pump cavity in main body. Install choke control rod dust seal and tap gently to straighten retainer. Ensure that venturi valve diaphragm stem engages venturi valve.
9. Install fuel filter spring, new filter, gasket and inlet fitting. Tighten fitting to 90-125 INCH lbs. (10.2-14.1 N.m). Install air cleaner stud and tighten to 72-108 INCH lbs. (8-12 N.m). Slide cold enrichment rod into upper body. Install choke hinge pin and "E" clip.
10. Engage accelerator pump operating rod and choke control rod. Install "E" clips. Check and adjust fast idle cam. Adjust choke and install gasket and cap. Ensure thermostat spring tab is engaged in slotted choke shaft lever. Tighten screws until heads break off.
11. Install venturi valve limiter stop screw and tighten retention spring (omitted in main body reassembly). Adjust venturi valve. See «VENTURI VALVE WIDE OPEN THROTTLE (WOT) OPENING»(/ford/ltd-crown-victoria/i-1983-1991/remont/testing-diagnostics/#carburetor-motorcraft-7200-vv-2-bbl) adjustment in this article. Install plug after adjustment. Adjust accelerator pump lash after setting curb idle speed.

SPECIFICATIONS

CARBURETOR ADJUSTMENT SPECIFICATIONS

See also:
• CIRCUIT CONTINUITY (ALTERNATOR POWERED CHOKE)
• CIRCUIT CONTINUITY (BATTERY POWERED CHOKE)
• COLD ENRICHMENT ROD (CER) & CONTROL VACUUM REGULATOR (CVR)
• VENTURI VALVE WIDE OPEN THROTTLE (WOT) OPENING