Engine Controls - Remove/install/overhaul Lincoln Town Car III

INTRODUCTION

Note. Information for Escort applies to Escort ZX2, unless otherwise indicated.

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.

COMPUTERIZED ENGINE CONTROLS

Removal & Installation

Disconnect negative battery cable. Remove any component necessary to gain access to PCM. Loosen PCM connector retaining bolt (if equipped). Unplug harness connector from PCM. Remove 2 PCM mounting bolts. Remove PCM cover and PCM. To install, reverse removal procedure.

POWERTRAIN CONTROL MODULE LOCATION

Removal & Installation (2.0L SOHC - VIN P)

Disconnect negative battery cable. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEM. Remove fuel injection supply manifold. See appropriate article in ENGINES. Disconnect wiring from CMP sensor. Remove sensor retaining bolt and remove sensor. Inspect CMP sensor "O" ring and replace if necessary. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Removal & Installation (2.0L DOHC - VIN Z & 3)

CMP sensor is located on rear of cylinder head above exhaust manifold. Disconnect negative battery cable. On Contour and Mystique, remove air conditioning pipe, coolant pipe and power steering pipe retaining nuts from cylinder head. Also remove dipstick tube, engine lifting hook and exhaust manifold heat shield. On Escort and Focus, remove air cleaner outlet tube and breather pipe. On all models, disconnect wiring from CMP sensor. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Removal & Installation (2.5L VIN G & L)

CMP sensor is located on front of left cylinder head. Disconnect negative battery cable. Disconnect CMP sensor harness connector. Remove CMP sensor retaining bolt and CMP sensor. (Scheme 1) Ensure "O" ring is properly located and in good condition. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 1

Removal & Installation (3.0L DOHC - VIN S)

CMP sensor is located on left side of timing cover. Disconnect negative battery cable. Disconnect CMP sensor harness connector. Remove CMP sensor retaining bolt and CMP sensor. (Scheme 1) Ensure "O" ring is properly located and in good condition. To install, reverse removal procedure. Tighten CMP sensor bolts to specification. See TORQUE SPECIFICATIONS.

Removal & Installation (3.0L VIN U & 2)

1. CMP sensor is located on top of CMP synchronizer assembly. Disconnect negative battery cable. Remove the accelerator cable shield. Disconnect accelerator cable, speed control actuator cable and throttle return spring from throttle body lever. Remove 2 bolts retaining accelerator cable bracket and position aside.
2. Loosen the clamp and disconnect the hose. Detach the spark plug wire retainer. Detach the wiring harness from the intake manifold support. Release the fuel charging wiring harness from the valve cover studs. Position the wiring harness away from the camshaft position sensor.
3. Disconnect CMP sensor harness connector. Remove CMP sensor mounting bolts and CMP sensor. To install, reverse removal procedure. Tighten CMP sensor bolts to specification. See «TORQUE SPECIFICATIONS»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) . If CMP synchronizer removal and installation is necessary, see «CMP SYNCHRONIZER»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__cmp-synchronizer) .

Removal & Installation (3.8L)

CMP sensor is located on top of CMP synchronizer assembly. Disconnect the battery ground cable. Disconnect the CMP connector. Remove the CMP bolts and remove CMP sensor. To install, reverse the removal procedure.

Removal & Installation (3.9L - VIN A)

CMP sensor is located on top rear of left cylinder head. Disconnect negative battery cable. Remove wiper motor. Remove harness bracket nut and stud from rear of left cylinder head and position aside. Disconnect CMP sensor harness connector. Remove CMP sensor mounting bolts. Remove CMP sensor. To install, reverse removal procedure. Tighten CMP sensor bolts to specification. See TORQUE SPECIFICATIONS .

Removal & Installation (4.6L VIN W, V, X & 9)

CMP sensor is located on left side of timing cover. Disconnect negative battery cable. Remove bolts retaining power steering pump reservoir and position aside. Disconnect CMP sensor harness connector. Remove CMP sensor retaining bolt and CMP sensor. (Scheme 1) Ensure "O" ring is properly located and in good condition. To install, reverse removal procedure. Tighten CMP sensor bolts to specification. See TORQUE SPECIFICATIONS.

CMP SYNCHRONIZER

Removal (3.0L VIN U & 2)

1. Disconnect negative battery cable. Note position of CMP sensor electrical connector. Remove CMP sensor. See «REMOVAL & INSTALLATION (3.0L VIN U & 2)»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__removal-installation-30l-vin-u) under CAMSHAFT POSITION SENSOR (CMP). Before removing CMP synchronizer assembly, set piston No. 1 to Top Dead Center (TDC) of compression stroke.
2. Apply reference marks on CMP synchronizer assembly and engine. Remove CMP synchronizer assembly hold-down bolt and clamp. Remove CMP synchronizer assembly. Oil pump drive shaft may come out with synchronizer. If so, retrieve oil pump driveshaft before proceeding.

Installation (3.0L VIN U & 2)

Note. After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled, if the engine has not been rotated from Top Dead Center (TDC) of the compression stroke on the No. 1 cylinder.

1. Install Synchro Positioner (303-589) on CMP synchronizer assembly (CMP sensor removed). (Scheme 2) Turn CMP synchronizer shaft clockwise until tool boss engages with notch in CMP synchronizer assembly. Tool should fit squarely in top of CMP synchronizer assembly.
2. Ensure piston No. 1 is in TDC position on compression stroke. Install oil pump drive shaft in CMP synchronizer assembly. Lubricate CMP synchronizer gear with engine oil. Arrow on synchro positioner will rotate clockwise until CMP synchronizer is fully seated. Insert CMP synchronizer assembly into engine.
3. When installed, synchro positioner should point approximately 38 degrees from centerline of engine. (Scheme 3) Install and tighten CMP synchronizer hold-down clamp bolt. If synchro positioner is not pointing in correct direction, remove CMP synchronizer assembly and return to step 1. If CMP synchronizer is installed correctly, remove synchro positioner.
4. Install CMP sensor and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul). Connect CMP sensor harness connector and negative battery cable.

Scheme 2

Scheme 3

Removal (3.8L)

1. Rotate crankshaft until No. 1 cylinder is at TDC of compression stroke. Disconnect negative battery cable. Remove the EGR valve to exhaust manifold tube.
2. Note position of CMP sensor electrical connector. Remove CMP sensor. See «REMOVAL & INSTALLATION (3.8L)»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__removal-installation-38l) under CAMSHAFT POSITION SENSOR (CMP).
3. Remove the camshaft synchronizer bolt. Remove camshaft synchronizer from engine block.

Installation (3.8L)

Note. After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the CMP electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed, the alignment tool and the assembly reinstalled if the engine has not been rotated from Top Dead Center (TDC) of the compression stroke on the No. 1 cylinder.

1. Install Synchro Positioning Tool (303-630) on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing and the armature. (Scheme 4)
2. Install camshaft synchronizer housing assembly so the arrow on the Install Synchro Positioning Tool (303-630) is 54 degrees from centerline of the engine. (Scheme 5)
3. Install and tighten synchronizer hold down bolt. See «TORQUE SPECIFICATIONS»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul).
4. Remove Synchro Positioning Tool (303-630). Install CMP sensor to camshaft synchronizer. See «REMOVAL & INSTALLATION (3.8L)»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__removal-installation-38l) under CAMSHAFT POSITION SENSOR (CMP). Install the EGR valve to exhaust manifold tube. Connect the battery ground cable.

Scheme 4

Scheme 5

CKP sensor is located at rear of engine block, near flywheel. Disconnect negative battery cable. Raise and support vehicle. On Escort, remove splash shield. On all models, disconnect wiring from CKP sensor. Remove mounting bolts and CKP sensor. To install, reverse removal procedure.

CKP sensor is located at rear of engine block, near flywheel. On Escort, removal of exhaust manifold may be necessary to remove sensor. See appropriate article in ENGINES. On all models, disconnect wiring from sensor. Remove sensor mounting bolt. Remove sensor. To install, reverse removal procedure.

Removal & Installation (2.5L)

CKP sensor is located on front cover near crankshaft pulley. Disconnect negative battery cable. Raise and support vehicle. Remove splash shield from right side of engine compartment. Remove electrical connector from CKP sensor. Remove mounting bolt and CKP sensor. To install, reverse removal procedure.

Scheme 6

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
3. Disconnect the crankshaft position (CKP) sensor electrical connector.
4. Remove the bolt and the CKP sensor. To install, tighten to 10 Nm (89 lb-in). Inspect and install a new O-ring seal as necessary.
5. To install, reverse the removal procedure.

Removal & Installation (All Others)

1. CKP sensor is located on front cover near crankshaft pulley. Disconnect negative battery cable. Remove serpentine drive belt and A/C compressor if necessary. Raise and support vehicle. Remove splash shields as necessary to access CKP sensor.
2. Disconnect wiring from CKP sensor. Remove CKP sensor bolt and CKP sensor. To install, reverse removal procedure. Tighten CKP sensor bolt to specification. See «TORQUE SPECIFICATIONS»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) . Evacuate and recharge A/C system as necessary.

FUEL SYSTEM

FUEL SYSTEM PRESSURE RELEASE

1. Remove fuel filler cap to release fuel tank pressure. Remove relief valve (Schrader valve) cap. Relief valve is located on fuel supply manifold. Using Fuel Pressure Gauge (T80L-9974-B), release fuel pressure from relief valve.
2. If fuel pressure gauge is not available, disconnect electrical connector to Inertia Fuel Shutoff (IFS) switch. For IFS switch location, see «IFS SWITCH LOCATION»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) table. Crank engine for 15 seconds to reduce system pressure. Turn ignition switch to OFF position. Reconnect IFS switch connector.

IFS SWITCH LOCATION

FUEL LINE CONNECTOR

Note. Three types of fuel couplings are used. Use illustrations to identify proper servicing procedures. (Scheme 7), (Scheme 8) or (Scheme 9).

Removal (Spring Lock Coupling)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release). Using Spring Lock Coupling Remover (D87L-9280-A, D87L-9280-B or T83P-19623-C), remove retaining clip from coupling. Place remover over coupling so protrusion is positioned on cage opening side of coupling. (Scheme 7)
2. Close remover over coupling. Push remover into cage opening to release female fitting from garter spring. Separate male and female halves of coupling. Remove tool from disconnected spring lock coupling.

Scheme 7

Installation

1. Ensure garter spring in cage of male fitting is not damaged. Replace if necessary. Clean all dirt from both pieces of coupling. Check "O" rings for damage, and replace using proper fuel resistant "O" rings (if necessary).
2. Lubricate NEW "O" rings and inside of female fitting with clean engine oil. Snap fitting together. Install retaining clip onto coupling. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line. (Scheme 7)

Removal (Hairpin Clip Fitting)

Hairpin clip type fittings are used on 5/16" and 3/8" fuel lines. To disconnect fuel lines, remove hairpin clip from fitting. (Scheme 8) Spread each clip leg about 1/8" to disengage body. While pulling lightly on triangular end of clip, push legs into fitting. Work assembly clear of tube and fitting. Pull fitting and steel line in axial direction. Use twisting motion to pull fitting loose.

With triangular portion pointing away from fitting opening, insert clip into any 2 adjacent openings. Install clip to fully engage body. Clean end of fitting. Align fitting and tube axially, and push fitting onto tube end. When fitting is engaged, a click will be heard.

Scheme 8

Removal & Installation (Duck-Bill Type Fitting)

1. Duck-bill fittings are used on 1/2" and 1/4" fuel lines. Align slot on Disconnect Tool (T82L-9500-AH) with either tab on clip (90 degrees from slots on die of fitting) and insert tool. (Scheme 9)
2. Holding tool and tube in one hand, pull fitting away from tube. To install, reverse removal procedure. Pull on fitting to ensure it is fully engaged.

Scheme 9

Removal & Installation (LS)

1. Turn ignition off. Disconnect the battery ground cable. Relieve the fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release).
2. Raise and support the vehicle. Remove the left front wheel and tire assembly. Remove the left wheel well splash shield screws and pin-type fasteners. (Scheme 10)
3. Disconnect the fuel line R-clip fittings. (Scheme 11)
4. Remove the bolt at the fuel filter bracket and remove the filter. (Scheme 12)
5. If necessary, separate the filter from the bracket for reuse. To install, reverse the removal procedure.

Scheme 10

Scheme 11

Scheme 12

Removal & Installation (CONTOUR)

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

WARNING: The fuel system remains pressurized for a long time after the ignition is switched off. The fuel pressure must be relieved before attempting any repairs to prevent personal injury. Failure to follow these instructions may result in personal injury.

1. Relieve the fuel system pressure.
2. Raise and support the vehicle.
3. Disconnect the fuel lines from the fuel filter.
4. Remove the fuel filter.
5. To install, reverse the removal procedure.

Removal & Installation (CONTINENTAL)

WARNING: Fuel supply lines on all vehicles equipped with fuel injected engines will remain pressurized for long periods of time after engine shutdown. Fuel system pressure must be relieved prior to fuel system service to prevent possible injury or fire hazard.

1. Disconnect the battery negative cable.
2. Relieve the fuel pressure.
3. Raise the vehicle on a hoist
4. Remove the fuel filter. Disconnect the R-clip fittings. Loosen the clamp. Remove the fuel filter.
5. To install, reverse the removal procedure.

Removal & Installation (COUGAR)

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

WARNING: The fuel system remains pressurized for a long time after the ignition is switched off. The fuel pressure must be relieved before attempting any repairs to prevent personal injury. Failure to follow these instructions may result in personal injury.

1. Relieve the fuel system pressure.
2. Raise and support the vehicle.
3. Disconnect the fuel filter intake and outlet line connectors
4. Remove the fuel filter.
5. To install, reverse the removal procedure.

Removal & Installation (TOWN CAR & CROWN VICTORIA & GRAND MARQUIS)

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning the air suspension switch located in the luggage compartment on the LH side to the off position. Failure to do so may result in unexpected inflation or deflation of the air springs which may result in shifting of the vehicle during these operations.

1. Disconnect the battery ground cable.
2. Relieve the system pressure.
3. Raise the vehicle on a hoist
4. NOTE: Make sure the rubber boot of the forward 90° fuel line is still glued in place. Remove the fuel filter. Disconnect the R-clip fittings. Loosen the clamp. Remove the fuel filter.
5. NOTE: Install a new R-clip (5/16) to connector Follow the removal procedure in reverse order..

Removal & Installation (ESCORT)

WARNING: Do not smoke or carry an open flame of any type when working on or near any fuel-related component. Do not work on fuel-related components when the engine is hot. Leaking fuel may contact hot engine components and be ignited, resulting in possible personal injury.

1. Disconnect the battery negative cable.
2. Relieve the fuel pressure.
3. NOTE: Place a suitable container below the fuel filter. Loosen the fuel filter bracket clamp bolt.
4. Remove the fuel filter. Remove the fuel line clips and disconnect the fuel lines. Remove the fuel filter from the bracket.
5. NOTE 1: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven. NOTE 2: Install using new fuel line clips. To install, reverse the removal procedure.

Removal & Installation (FOCUS)

WARNING: Do not smoke or carry an open flame of any type when working on or near any fuel-related component. Do not work on fuel-related components when the engine is hot. Leaking fuel may contact hot engine components and be ignited, resulting in possible personal injury.

1. Depressurize the fuel system.
2. Disconnect the battery ground cable.
3. Disconnect the evaporative emission pipe.
4. Remove the fuel filter outlet pipe
5. Disconnect the fuel filter inlet pipe
6. Remove the fuel filter and bracket.
7. Remove the fuel filter. Remove the bolt. Slide out the fuel filter.
8. WARNING: Do 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 ignite. Failure to follow these instructions may result in personal injury NOTE: Observe the direction of flow arrow.
9. To install, reverse the removal procedure.
10. Initialize the door window motors.

Removal & Installation (MUSTANG)

WARNING: Fuel supply lines on all vehicles equipped with fuel injected engines will remain pressurized for long periods of time after engine shutdown. Fuel system pressure must be relieved prior to fuel system service to prevent possible personal injury or a fire hazard.

1. Disconnect the battery.
2. Relieve the fuel system pressure
3. Raise the vehicle.
4. Disconnect the filter push connect fittings.
5. Unsnap the filter from the bracket and remove.
6. To install, reverse the removal procedure.

Removal & Installation (SABLE & TAURUS)

1. Disconnect the battery ground cable
2. Relieve the fuel pressure.
3. Raise the vehicle
4. Remove the fuel filter. Disconnect the R-clip fittings. Loosen the clamp. Remove the fuel filter.
5. To install, reverse the removal procedure.

CAMSHAFT POSITION SENSOR

For Camshaft Position Sensor (CMP) removal & installation procedures, see CAMSHAFT POSITION SENSOR (CMP) under IGNITION SYSTEM.

For CMP synchronizer removal & installation procedures, see CMP SYNCHRONIZER under IGNITION SYSTEM.

FUEL PUMP MODULE

Note. Fuel pump module may also be referred to as Fuel Delivery Module (FDM).

Removal & Installation (Continental, Taurus & Sable)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Drain fuel from tank. Raise and support vehicle. Remove fuel tank filler and recirculation hoses. Disconnect fuel pump module electrical connector. Remove fuel filter supply line. On Continental, remove 2 vapor tube fittings at right rear and right front of fuel tank. On Taurus and Sable, remove vapor tube fitting at fuel tank.
2. On all models, position a support under fuel tank. Remove 2 fuel tank support strap bolts and move fuel tank support straps away from fuel tank. Carefully lower fuel tank. Remove any dirt from around fuel pump module flange area. Using Fuel Tank Retainer Ring Wrench (D90P-9275-A), remove fuel pump module retainer ring. Remove fuel pump module and discard fuel pump module mounting gasket.
3. Clean fuel pump module mounting flange, fuel tank mounting surface and gasket surface. Install NEW gasket on fuel pump module mounting flange. Install fuel pump module into fuel tank. On Taurus and Sable, ensure stop is felt when aligning raised arrow on top of fuel pump module with dot on fuel tank. On all models, install fuel pump module retainer ring and tighten against stops. To complete installation, reverse removal procedure. Fill fuel tank and check for leaks.

Removal (Contour, Cougar & Mystique)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Remove rear seat cushion. Remove rubber grommet from floor pan. Clean area to prevent contamination in fuel tank. For vehicles without returnless fuel systems, go to next step. For vehicles with returnless fuel systems, go to step 3 .
2. Returnable Fuel System Disconnect fuel pump module connector. Disconnect fuel feed and return lines from fuel pump module by squeezing tabs on fuel lines together and carefully pulling fuel lines from fuel pump module. Using Fuel Tank Sender Wrench (D84P-9275-A), turn retainer ring counterclockwise and remove retainer ring. Remove fuel pump module. Cover fuel tank opening. Remove and discard "O" ring.
3. Returnless Fuel System Disconnect fuel feed line from fuel pump module by squeezing tabs on fuel line together and carefully pulling fuel line from fuel pump module. Using Fuel Tank Sender Wrench (310-065A), turn retainer ring counterclockwise and remove retainer ring. Remove fuel pump module. Cover fuel tank opening. Remove and discard "O" ring.

Ensure fuel pump and mounting surface is clean. Lubricate NEW "O" ring with suitable grease. Carefully install fuel pump module into fuel tank. To complete installation, reverse removal procedure. Pressurize fuel system and check for leaks.

Removal & Installation (Crown Victoria, Grand Marquis & Town Car)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Drain fuel from fuel tank. Open fuel filler door. Remove 3 fuel filler pipe bolts. Raise and support vehicle. Remove fuel tank filler pipe from fuel tank.
2. Disconnect fuel pump module connector located above No. 4 crossmember. Disconnect fuel lines from fuel pump module. Disconnect vapor tube from "T" fitting on right side of vehicle. Disconnect vapor tube from canister tube. Position a support under fuel tank. Remove fuel tank support strap nuts and move fuel tank support straps away from fuel tank. Carefully lower fuel tank. Remove and discard fuel tank mounting studs.
3. Disconnect pressure transducer connector on top rear corner of fuel tank. Remove any dirt from around fuel pump module flange area. Remove 6 fuel pump module retaining bolts. Remove fuel pump module. Remove and discard fuel pump module gasket. To install, reverse removal procedure. Tighten fuel pump module retaining bolts in a star sequence to 80-107 INCH lbs. (9-12 N.m).

Removal (Escort)

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Depress 2 clips securing front of rear seat cushion, and remove rear seat cushion. Disconnect 2 wiring harness connectors from fuel pump module.
2. Remove 4 screws retaining fuel pump module access cover and remove access cover. Remove any dirt from around fuel pump module flange area. Disconnect fuel line from fuel pump module. Remove retainer ring and open fuel pump module cover. Push inwards on locking tabs and remove fuel pump module.

Clean fuel pump module mounting flange, fuel tank mounting surface and gasket surface. Install NEW gasket on fuel pump module mounting flange. Install fuel pump module. Ensure fuel pump module locking tabs are fully seated to outside edge of fuel tank. Install fuel pump module cover retainer ring. To complete installation, reverse removal procedure. Fill fuel tank and check for leaks.

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Drain fuel from fuel tank. Remove rear muffler hanger from rubber insulator. Remove front muffler hangers from rubber insulators. Remove 2 nuts retaining exhaust pipe to flex pipe and secure aside.
2. Remove heatshield from between front muffler and floor pan. Note position and location of retaining clamp and clip and disconnect fuel tank vent pipes and filler pipe. Disconnect in-line fuel coupling and evaporative emission pipe. Disconnect Fuel Vapor Vent (FVV) valve. Position a support under fuel tank.
3. Remove fuel tank support strap bolt and move fuel tank support strap away from fuel tank. Partially lower fuel tank. Disconnect fuel pump module electrical connector. Disconnect fuel tank pressure sensor electrical connector. Disconnect fuel supply line from fuel pump module. Remove fuel tank.
4. Using Fuel Tank Sender Unit Wrench (310-069), remove fuel pump module retainer ring. Rotate fuel pump module counterclockwise and lift fuel pump module from fuel tank. Remove and discard fuel pump module seal. To install, reverse removal procedure. Tighten fuel pump module retainer ring to 59 ft. lbs. (80 N.m). Carry out evaporative emission system leak test.

Removal (LS)

Note. LS uses a saddle-type fuel tank consisting of 2 fuel sending units and 2 fuel pump modules. A Jet Pump Module (JPM) in left half of fuel tank supplies fuel to right half, which contains Fuel Delivery Module (FDM). FDM supplies fuel under pressure to fuel injection supply manifold.

Note. Both sides of fuel tank must be drained individually to ensure all possible fuel is removed.

Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. Release 2 latches at front of rear seat cushion and remove rear seat cushion and any insulation padding covering both fuel pump module access covers. Remove FDM and JPM access covers. Drain fuel from fuel tank. Use following procedures for appropriate fuel pump module removal

1. Fuel Delivery Module (FDM) To remove FDM (right saddle tank fuel pump module), press release tabs on fuel lines at FDM. Turn fuel lines slightly and pull straight up to remove fuel line connector. Disconnect electrical connector to FDM. Using Fuel Sender Wrench (310-069), remove FDM retainer ring. Position FDM flange clear of fuel tank opening. Press lock tabs and release FDM from tank mounting flange. Remove FDM from fuel tank.

1. Jet Pump Module (JPM) To remove JPM (left saddle tank fuel module), raise and support vehicle. Remove bolts and nuts retaining exhaust heatshield to exhaust system. Loosen, but DO NOT remove left and right fuel tank support strap bolts. Lower straps and fuel tank approximately 1". Lower vehicle.
2. Press release tabs on fuel lines at JPM. Turn fuel lines slightly and pull straight up to remove fuel line connector. Disconnect electrical connector to JPM. Using Fuel Sender Wrench (310-069), remove JPM retainer ring. Position JPM flange clear of fuel tank opening. Press lock tabs and release JPM from tank mounting flange. Remove JPM from fuel tank.

To install FDM or JPM, NEW module assembly flange gaskets must be used. Align module with in-tank retaining bracket and push down on module until latches snap into position onto bracket. Tighten fuel pump retainer ring to 59 ft lbs. (80 N.m). Ensure fuel line tubes are fully seated into outlet connector fittings. To complete installation, reverse removal procedure. Fill fuel tank and check for leaks.

Removal (Mustang)

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Drain fuel from tank. Raise vehicle on hoist. Remove bolt retaining fuel filler pipe to fuel tank and disconnect inlet and return hose connections to fuel tank.
2. Disconnect electrical connector from fuel pump module. Disconnect vapor tube fitting at left front of fuel tank. Disconnect EVAP canister tube and hose. Support fuel tank. Remove front 2 fuel tank support straps and position aside. Partially lower fuel tank and disconnect fuel line. Outer edge of pipe-to-tank filler grommet must be carefully cut away or damage to filler pipe check valve may occur.
3. Carefully remove filler pipe grommet from fuel tank and discard. Lower and remove fuel tank. Remove any dirt from around fuel pump module flange area. Remove 6 fuel pump module bolts. Pull fuel pump module assembly up and out of fuel tank until fuel pump module locking tabs are accessible. Squeeze locking tabs together and remove fuel pump module from fuel tank, lifting straight up and out.

1. Clean fuel pump module mounting flange, fuel tank mounting surface and gasket surface. Install NEW gasket on fuel pump module mounting flange. Align fuel pump module with fuel tank retainer. Install fuel pump module by pushing down on module until module tabs click and engage in retainer.
2. Ensure fuel outlet tube points toward front of vehicle. To complete installation, reverse removal procedure. Tighten fuel pump bolts in a star sequence to 89 INCH lbs. (10 N.m). Fill fuel tank and check for leaks.

FUEL INJECTION SUPPLY MANIFOLD & INJECTORS

Removal (2.0L SOHC - Contour, Cougar & Mystique)

1. Ensure ignition switch is turned to OFF position. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Remove air cleaner outlet tube and resonator. Disconnect fuel supply and return lines. See «FUEL LINE CONNECTOR»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-line-connector) . Remove fuel supply and return hose clamp. Disconnect vacuum hose and electrical connector from fuel pressure sensor. Remove accelerator cable retaining clip. Disconnect accelerator cable from bracket.
2. On vehicles equipped with cruise control, disconnect cruise control cable from throttle body. Remove cruise control cable from bracket. On all vehicles, disconnect fuel injector electrical connectors. Remove variable camshaft timing solenoid electrical connector grommet from engine cover. Disconnect variable camshaft timing solenoid electrical connector. Position fuel injection wiring harness aside. Remove fuel injection supply manifold and injectors as a unit.

Removal (2.0L DOHC - Escort)

1. Ensure ignition switch is turned to OFF position. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Disconnect spring lock coupling. Remove air cleaner outlet tube. Remove throttle body. See «THROTTLE BODY»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) .
2. Disconnect wiring from fuel injectors. Disconnect vacuum hose and electrical connector from fuel pressure sensor. Remove screws retaining fuel injection wiring harness and position aside. Remove 3 bolts retaining fuel injection supply manifold and remove fuel injection supply manifold.

Removal (2.0L SOHC - Escort)

1. Ensure ignition switch is turned to OFF position. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Disconnect CKP and CMP harness connectors. Disconnect 2 main engine wiring harness connectors located above right wheelwell. Disconnect wiring harness sheath from fuel injection supply manifold.
2. Disconnect vacuum hose and electrical connector from fuel pressure sensor. Disconnect fuel supply and return lines. See «FUEL LINE CONNECTOR»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-line-connector) . Remove wiring harness from injectors. Remove 2 bolts retaining fuel injection supply manifold. Carefully disengage fuel injection supply manifold from fuel injectors. Remove fuel injection supply manifold.

Removal (2.0L DOHC - Focus)

1. Ensure ignition switch is turned to OFF position. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Remove air cleaner outlet tube and resonator. Disconnect fuel supply and return lines. See «FUEL LINE CONNECTOR»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-line-connector) . Remove fuel supply and return hose clamp. Disconnect vacuum hose and electrical connector from fuel pressure sensor. Remove accelerator cable retaining clip. Disconnect accelerator cable from bracket.
2. On vehicles equipped with cruise control, disconnect cruise control cable from throttle body. Remove cruise control cable from bracket. On all vehicles, disconnect fuel injector electrical connectors. Remove variable camshaft timing solenoid electrical connector grommet from engine cover. Disconnect variable camshaft timing solenoid electrical connector. Position fuel injection wiring harness aside. Remove fuel injection supply manifold and injectors.

Removal (2.0L SOHC - Focus)

1. Ensure ignition switch is turned to OFF position. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Disconnect vacuum hose and electrical connector from fuel pressure sensor. Disconnect fuel supply and return lines.
2. Disconnect fuel injector electrical connectors. Remove 2 bolts retaining fuel injection supply manifold. Carefully disengage fuel injection supply manifold from fuel injectors. Remove fuel injection supply manifold. Remove 2 bolts retaining fuel pressure sensor and remove sensor. Carefully remove fuel injectors and discard "O" rings.

Position NEW "O" rings onto fuel injectors. Lightly lubricate "O" rings with clean 5W-30 engine oil. To complete installation, reverse removal procedure. Ensure injectors are properly seated. Tighten fuel injection supply manifold bolts to specification. See TORQUE SPECIFICATIONS .

Removal (2.5L Contour, Cougar & Mystique - With Returnless Fuel System)

1. Ensure ignition switch is turned to OFF position. Remove air cleaner assembly outlet tube. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Disconnect fuel supply line from fuel injection supply manifold. Remove upper intake manifold. See «UPPER INTAKE MANIFOLD»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) .
2. Disconnect 6 fuel injector electrical connectors. Disconnect vacuum hose from fuel pressure regulator. Disconnect Intake Manifold Runner Control (IMRC) operating rod. Remove 4 bolts retaining fuel injection supply manifold. Remove fuel injection supply manifold and injectors as a unit. Remove fuel injectors from supply manifold. Remove and discard fuel injector "O" rings.

Removal (2.5L Contour, Cougar & Mystique - Without Returnless Fuel System)

1. Ensure ignition switch is turned to OFF position. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Remove air cleaner outlet tube and air intake bypass hose. Remove Positive Crankcase Ventilation (PCV) hoses. Disconnect negative battery cable. Remove upper intake manifold. See «UPPER INTAKE MANIFOLD»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) .
2. Remove fuel injector wiring harness retainers and position aside. Disconnect 6 fuel injector electrical connectors. Disconnect vacuum hose from fuel pressure regulator. Disconnect Intake Manifold Runner Control (IMRC) operating rod. Remove fuel supply and return line clips. Disconnect fuel supply and return hoses from fuel injection supply manifold.
3. Remove 4 bolts retaining fuel injection supply manifold. Remove fuel injection supply manifold and injectors as a unit. Carefully remove fuel injectors from fuel injection supply manifold. Remove and discard fuel injector "O" rings.

Position NEW "O" rings onto fuel injectors. Lightly lubricate "O" rings with clean 5W-30 engine oil. To complete installation, reverse removal procedure. Ensure fuel injectors are properly seated. Tighten fuel injection supply manifold bolts to specification. See TORQUE SPECIFICATIONS .

Removal (3.0L DOHC - VIN S)

1. Ensure ignition switch is turned to OFF position. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Remove upper intake manifold. See «UPPER INTAKE MANIFOLD»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) . Disconnect fuel charging electrical connector from engine control electrical connector located on rear side of wiring shield behind lower intake manifold.
2. Disconnect electrical connector and vacuum hose from fuel pressure sensor. Disconnect Positive Crankcase Ventilation (PCV) tube and position aside. Disconnect fuel supply line. See «FUEL LINE CONNECTOR»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-line-connector) . Remove lower intake manifold. See «LOWER INTAKE MANIFOLD (3.0L DOHC)»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) .
3. Place lower intake manifold upside down and remove 4 retaining bolts and fuel injection supply manifold. Disconnect 6 fuel injector electrical connectors. Carefully disengage injectors from fuel injection supply manifold by rocking fuel injector and pulling upward. Place injectors in a clean container. Remove and discard fuel injector "O" rings.

When installing fuel injection supply manifold assembly, use NEW "O" rings. Lubricate "O" rings with clean 5W-30 engine oil. Push fuel injection supply manifold down to ensure all injector "O" rings are fully seated in fuel injection supply manifold cups and lower intake manifold. Install fuel injection supply manifold bolts and tighten to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure. Check for leaks when completed.

Removal (3.0L Except DOHC - VIN U & 2)

1. Ensure ignition switch is turned to OFF position. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Remove upper intake manifold. See «UPPER INTAKE MANIFOLD»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) . Disconnect fuel supply line. See «FUEL LINE CONNECTOR»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-line-connector) .
2. Disconnect electrical connector and vacuum hose from fuel pressure sensor. Disconnect 6 fuel injector electrical connectors. Remove 4 fuel injection supply manifold retaining bolts. Carefully remove fuel injection supply manifold and injectors as a unit. Remove fuel injectors and discard "O" rings.

When installing fuel injection supply manifold assembly, use NEW "O" rings. Lubricate "O" rings with clean 5W-30 engine oil. Push fuel injection supply manifold down to ensure all injector "O" rings are fully seated in fuel injection supply manifold cups and intake manifold. Install fuel injection supply manifold bolts and tighten to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure. Check for leaks when completed.

Removal (3.8L - VIN 4)

1. Ensure ignition switch is turned to OFF position. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Remove fuel supply line. See «FUEL LINE CONNECTOR»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-line-connector) . Remove upper intake manifold. See «UPPER INTAKE MANIFOLD»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) .
2. Disconnect 6 fuel injector electrical connectors. Disconnect electrical connector and vacuum hose from fuel pressure sensor. Remove 4 fuel injection supply manifold bolts. Separate wiring harness from fuel injection supply manifold. Remove fuel injection supply manifold and fuel injectors as a unit. Remove retaining clips and remove fuel injectors from fuel injection supply manifold and discard "O" rings.

When installing fuel injection supply manifold assembly, use NEW "O" rings. Push fuel injection supply manifold down to ensure all injector "O" rings are fully seated in fuel injection supply manifold cups and intake manifold. Install fuel injection supply manifold bolts and tighten to specification. See TORQUE SPECIFICATIONS . Reinstall fuel injector retaining clips. To complete installation, reverse removal procedure.

Removal (3.9L - VIN A)

1. Ensure ignition switch is turned to OFF position. Remove pin-type retainers and remove engine appearance cover. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Remove air cleaner outlet tube. Disconnect vacuum hose from fuel pressure sensor at jumper connection, not at sensor.
2. Disconnect fuel pressure sensor electrical connector. Remove fuel supply line. See «FUEL LINE CONNECTOR»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-line-connector) . Disconnect 8 fuel injector electrical connectors. Remove throttle body heater return hose from retaining clip and position aside. Disconnect camshaft sensor harness connector.
3. Squeeze tabs on air assist hose fittings by hand and pull straight back to disconnect air assist hose from intake manifold and Idle Air Control (IAC) valve. Remove 4 fuel injection supply manifold bolts. Remove fuel injection supply manifold and fuel injectors as a unit. Remove clips retaining fuel injectors, remove fuel injectors and discard "O" rings.

When installing fuel injection supply manifold assembly, use NEW "O" rings. Push fuel injection supply manifold down to ensure all injector "O" rings are fully seated in fuel injection supply manifold cups and intake manifold. Install fuel injection supply manifold bolts and tighten to specification. See TORQUE SPECIFICATIONS . Reinstall fuel injector retaining clips. To complete installation, reverse removal procedure.

Removal (4.6L DOHC - VIN V)

1. Ensure ignition switch is turned to OFF position. Remove engine cover and air inlet tube(s) as necessary. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect fuel supply line. See «FUEL LINE CONNECTOR»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-line-connector) . Disconnect negative battery cable.
2. On Mustang, remove upper intake manifold. See «UPPER INTAKE MANIFOLD»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) . On all models, disconnect 8 fuel injector electrical connectors and position aside. Disconnect electrical connector and vacuum hose at fuel pressure sensor. Remove 4 fuel injection supply manifold bolts. Remove fuel injection supply manifold and injectors as a unit. Remove fuel injectors and discard "O" rings.

Position NEW "O" rings onto fuel injectors. Lightly lubricate "O" rings with clean 5W-30 engine oil. To complete installation, reverse removal procedure. Ensure injectors are properly seated. Tighten fuel injection supply manifold bolts to specification. See TORQUE SPECIFICATIONS .

Removal (4.6L SOHC - VIN W, X & 9)

1. Ensure ignition switch is turned to OFF position. Remove air inlet tube. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Disconnect negative battery cable. Disconnect fuel supply line. See «FUEL LINE CONNECTOR»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-line-connector) . Remove throttle body. See «THROTTLE BODY»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) .
2. Remove Idle Air Control (IAC) valve hose and position aside. Remove Positive Crankcase Ventilation (PCV) hose. Disconnect 4 right side fuel injector electrical connectors. Disconnect IAC electrical connector and main chassis vacuum hose. Remove accelerator and cruise control cable (if equipped) and position aside.
3. Disconnect electrical connector and vacuum hose at fuel pressure sensor. Disconnect ground wire electrical connector located at rear left side of intake manifold. Disconnect 4 left side fuel injector connectors. Remove Exhaust Vacuum Regulator (EVR) solenoid vacuum hoses.
4. Remove 2 bolts retaining Exhaust Gas Recirculation (EGR) pressure transducer bracket and position aside. Remove EGR-to-exhaust manifold tube. Remove vacuum hose at EGR valve. Remove 4 fuel injection supply manifold bolts. Remove fuel injection supply manifold and injectors as a unit. Remove fuel injectors and discard "O" rings.

Position NEW "O" rings onto fuel injectors. Lightly lubricate "O" rings with clean 5W-30 engine oil. To complete installation, reverse removal procedure. Ensure injectors are properly seated. Tighten fuel injection supply manifold bolts to specification. See TORQUE SPECIFICATIONS .

1. If removing fuel pressure regulator while fuel injection supply manifold assembly is still installed on engine, release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Remove upper intake manifold. See «UPPER INTAKE MANIFOLD»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) .
2. Remove vacuum hose at fuel pressure regulator. Disconnect Intake Manifold Runner Control (IMRC) operating rod. Remove 2 fuel pressure regulator mounting bolts. Remove fuel pressure regulator assembly, gasket and discard "O" ring.
3. To install, ensure sealing surfaces are clean. Lubricate NEW "O" ring with clean 5W-30 engine oil. Install NEW "O" ring and gasket on fuel pressure regulator. Install fuel pressure regulator on fuel injection supply manifold assembly, and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) . To complete installation, reverse removal procedures.

1. If removing fuel pressure sensor while fuel injection supply manifold assembly is still installed on engine, release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) . Remove electrical connector (if necessary) and vacuum hose at fuel pressure sensor.
2. Disconnect fuel supply line. See «FUEL LINE CONNECTOR»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-line-connector) . Remove 2 fuel pressure sensor mounting bolts. Remove fuel pressure sensor assembly, gasket and discard "O" ring.
3. To install, ensure sealing surfaces are clean. Lubricate NEW "O" ring with clean 5W-30 engine oil. Install NEW "O" ring and gasket on fuel pressure sensor. Install fuel pressure sensor on fuel injection supply manifold assembly, and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) .

Removal

Disconnect negative battery cable. Remove throttle body outlet tube. Disconnect throttle cables. Disconnect electrical connectors as necessary. Disconnect vacuum and coolant hoses as necessary. Remove throttle body bolts/nuts. Remove throttle body and discard throttle body gasket.

Clean and inspect gasket mating surfaces. Install NEW throttle body gasket. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Check and top-off cooling system.

1. Ensure upper intake manifold, fuel lines, brackets, fuel pressure sensor and wiring harnesses are disconnected before removing lower intake manifold. See «UPPER INTAKE MANIFOLD»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) . Remove 6 bolts retaining lower intake manifold. Remove and inspect both lower intake manifold gaskets. Replace if necessary.
2. To install, place lower intake manifold onto lower intake manifold gaskets. Working from center of lower intake manifold outward, tighten lower intake manifold bolts to specification. See «TORQUE SPECIFICATIONS»(/lincoln/town-car/iii-1997-2003/remont/removal-installation/#engine-controls-removeinstalloverhaul) .

Removal (2.5L Contour, Cougar & Mystique)

1. Remove air cleaner housing and outlet tube. Disconnect negative battery cable. Remove water pump pulley shield. Remove bolts retaining accelerator bracket. Disconnect accelerator and cruise control cable from throttle body and position aside. Remove EGR valve retaining bolts, EGR valve and discard gasket.
2. Depress Black retainer and disconnect vacuum hoses from upper intake manifold. Disconnect electrical connector and vacuum hose from EGR vacuum regulator valve. Disconnect PCV hose. Disconnect Throttle Position (TP) sensor and Idle Air Control (IAC) valve electrical connectors. Loosen upper intake manifold bolts in sequence. (Scheme 13) Remove upper intake manifold and discard gaskets.

Use NEW gaskets. Tighten upper intake manifold bolts in reverse removal sequence. (Scheme 13) See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 13

1. Disconnect negative battery cable. Drain engine cooling system. Remove engine appearance cover if necessary. Remove air cleaner outlet tube. Remove accelerator cable shield if equipped. Disconnect accelerator cable, accelerator spring, and cruise control actuator cable from throttle body lever. On LS models, remove accelerator cable bracket from throttle body and move aside.
2. On all models, disconnect electrical connectors from Throttle Position (TP) sensor and Idle Air Control (IAC) valve. Disconnect Exhaust Gas Recirculation (EGR) vacuum regulator, Evaporative Emissions (EVAP) and Positive Crankcase Ventilation (PCV) hoses. Disconnect coolant hoses at throttle body.
3. Disconnect EGR-to-exhaust tube and vacuum hose at EGR valve. Remove EGR valve. Remove EGR vacuum regulator valve. On LS models, remove cowl vent screen and windshield wipers. On all models, disconnect DPFE electrical connector. Remove stud and nut retaining DPFE transducer and position aside.
4. Remove fuel pressure sensor shield. Disconnect vacuum hose at rear of upper intake manifold. Disconnect Intake Manifold Tuning Valve (IMTV) electrical connector. Remove 2 bolts from upper intake support bracket. Remove intake manifold bolts in reverse of tightening sequence. (Scheme 14)or (Scheme 15). Remove upper intake manifold and discard upper intake manifold gaskets.

To install, reverse removal procedure. Tighten upper intake manifold bolts in sequence and to specification. See TORQUE SPECIFICATIONS. (Scheme 14)or (Scheme 15).

Scheme 14

Scheme 15

1. Disconnect negative battery cable. Remove air cleaner and air cleaner outlet tube. Drain radiator. Remove throttle body heater hose. Remove accelerator cable shield, throttle return spring, accelerator and speed control cables from throttle body. Remove 2 accelerator cable bracket bolts and position accelerator cable bracket aside.
2. Remove vacuum hose, PCV tube and evaporative emission return hose from upper intake manifold. Disconnect electrical connectors from IAC solenoid and TP sensor. Remove 3 bolts and one nut retaining upper intake manifold support bracket and remove support bracket. Disconnect EGR tube and vacuum hose from EGR valve.
3. Disconnect electrical connector and vacuum hose from EVR. Separate oxygen sensor connector retainer from bracket located near DPFE. Remove DPFE electrical connector and vacuum hoses. Disconnect engine degas hose. Remove 6 bolts retaining upper intake manifold and note location for reassembly. Remove upper intake manifold and discard upper intake manifold gasket.

Use NEW gaskets. Tighten upper intake manifold evenly starting in center, working outward. Tighten in 2 steps to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.

1. Disconnect negative battery cable. Remove air cleaner outlet tube. Disconnect electrical connector at IAC solenoid and vacuum hose located near IAC connector. Disconnect TP sensor electrical connector, evaporative emissions return tube and vacuum hoses from upper intake manifold. Disconnect accelerator and speed control cables from throttle body.
2. Remove accelerator cable from accelerator bracket. Remove solenoid bracket bolts and position bracket aside. Disconnect PCV hose. Remove 4 bolts retaining ignition coil pack and position aside. Remove upper intake manifold bolts and discard upper intake manifold gasket.

Place NEW gasket on lower intake manifold locating pins. Install upper intake manifold and tighten bolts in sequence to specification. (Scheme 16) See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 16

Removal (4.6L DOHC - VIN V - Mustang)

1. Disconnect negative battery cable. Remove air cleaner outlet tube. Disconnect accelerator cable, cruise control cable and return spring from throttle body. Remove bolts retaining accelerator and cruise control cables to bracket. Disconnect clip and position cables aside. Disconnect TP sensor electrical connector.
2. Disconnect EVAP return hose from throttle body assembly. Disconnect Idle Air Control (IAC) valve and Differential Pressure Feedback EGR (DPFE) electrical connectors. Disconnect main chassis vacuum supply line and EGR vacuum line. Disconnect DPFE hoses. Disconnect EGR valve-to-exhaust manifold tube from EGR valve.
3. Disconnect electrical connector and vacuum lines from EGR vacuum regulator solenoid. Remove PCV valve and tube as an assembly. Remove upper intake manifold bolts in sequence. (Scheme 17) Remove upper intake manifold and discard upper intake manifold gasket. Inspect and clean sealing surfaces.

Place NEW gasket on lower intake manifold. Install upper intake manifold and tighten bolts in sequence to specification. (Scheme 17) See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.

Scheme 17

Oxygen sensor is equipped with a permanent pigtail which must be protected when oxygen sensor is removed. Oxygen sensor may be difficult to remove when engine temperature is less than 120°F (48°C). If necessary use a penetrant to help in loosening oxygen sensor. Ensure oxygen sensor is free of contaminants, and avoid using cleaning solvents of any type. Always use anti-seize compound on threads prior to installation. Tighten oxygen sensor to specification. See TORQUE SPECIFICATIONS .

THROTTLE POSITION (TP) SENSOR

Note. TP sensor is not adjustable.

Disconnect TP sensor from wiring harness. Mark throttle body and TP sensor for reassembly reference. Remove mounting bolts and TP sensor. To install, align tangs on TP sensor with blades on throttle shaft and install sensor on throttle body. Align marks on throttle body and TP sensor. Secure TP sensor to throttle assembly with retaining bolts. Reconnect wiring.

4-CYLINDER

4-CYLINDER TORQUE SPECIFICATIONS

V6

V6 TORQUE SPECIFICATIONS

V8

V8 TORQUE SPECIFICATIONS

See also:
• FUEL SYSTEM PRESSURE RELEASE
• TORQUE SPECIFICATIONS
• CMP SYNCHRONIZER
• REMOVAL & INSTALLATION (3.0L VIN U & 2)
• REMOVAL & INSTALLATION (3.8L)
• FUEL LINE CONNECTOR