Throttle Body: Service and Repair

WARNING: Do not modify the fuel system configuration or components, or replace components with parts not specially designed for use with fuel methanol. Ford Motor Company has specially-designed the materials, components and system configuration for methanol-fueled vehicles and each particular system is precisely calibrated for efficient operation. the use of different parts or materials could produce an untested configuration that could result in fire, personal injury, or could cause engine damage.

REMOVAL

1. Disconnect battery ground cable.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy.

2. Remove crankcase ventilation tube and aspirator hoses from air cleaner outlet tube.

3. Loosen engine air cleaner tube clamp at throttle body and air cleaner outlet tube.

4. Relieve fuel pressure.

WARNING: Cover hoses with shop cloth to prevent accidental fuel spray into eyes.

5. Remove snowshield from Idle Air Control (IAC) valve.

6. Remove accelerator cable retaining bolt and disconnect accelerator cable and throttle valve control actuating cable from throttle body.

7. Remove two accelerator cable bracket retaining bolts from side of throttle body. Remove accelerator cable bracket.

8. Mark location and remove vacuum hoses attached to intake manifold vacuum outlet fitting and cap and EGR valve.

9. Disconnect Differential Pressure Feedback (DPFE) sensor hoses from EGR valve to exhaust manifold tube.

10. Loosen EGR valve to exhaust manifold tube nut at EGR valve.

11. Remove crankcase ventilation tube from fitting on throttle body.

12. Disconnect fuel charging wiring connections to IAC valve, DPFE and throttle position sensors.

13. Remove generator brace retaining nuts from generator mounting bracket and throttle body stud. Remove brace.

14. Loosen and remove five throttle body retaining bolts and one stud bolt noting their locations.

15. Lift and remove throttle body from intake manifold. Discard intake manifold upper gasket.

INSTALLATION

NOTE:
- The throttle body is to be replaced as an assembly only for the FF vehicle. Reuse original intake manifold vacuum outlet fitting and cap, EGR valve and DPFE assembly with new throttle body.

- Lightly oil all bolt and stud threads prior to installation.

1. Clean and inspect sealing surfaces of intake manifold and throttle body.

CAUTION: Use care when cleaning gasket surfaces as aluminum gouges easily which forms leak paths.

2. Install guide pins (if available) in front and rear bolt holes.

3. Place new intake manifold upper gasket over guide pins.

4. Aligning bolt holes, install throttle body on intake manifold. Install four center retaining bolts and hand tighten. Remove guide pins if used. Install stud bolt and remaining retaining bolt. Tighten retaining bolts to 20-30 Nm (15-22 lb ft).

5. Install generator brace to throttle body mounting stud and generator mounting bracket. Tighten nuts to 12-20 Nm (9-15 lb ft).

6. Install EGR valve to exhaust manifold tube to EGR valve and EGR valve tube to manifold connector. Tighten EGR valve to exhaust manifold tube nut to 35-65 Nm (26-48 lb ft).

7. Connect DPFE sensor hoses to EGR valve to exhaust manifold tube. Check hoses for cracked or deformed condition and replace as necessary.

8. Connect premarked vacuum lines to their original locations on intake manifold vacuum outlet fitting and cap and EGR valve. Check hoses for cracked or deformed condition and replace as necessary.

9. Connect electrical connections to throttle position sensor, DPFE sensor, and intake air temperature sensor.

10. Install crankcase ventilation tube to throttle body.

11. Install accelerator cable bracket to side of throttle body. Tighten retaining bolts to 17 Nm (13 lb ft).

12. Connect accelerator cable and throttle valve control actuating cable to throttle body lever. Install accelerator cable retaining bolt. Tighten to 1.4 Nm (13 lb in).

13. Install air cleaner outlet tube to throttle body. Tighten engine air cleaner tube clamp to 1.4-2.5 Nm (12-22 lb in). Connect crankcase ventilation tube and aspirator hose to their original locations.

14. Connect battery ground cable.

15. Start engine and check for vacuum, exhaust and fuel leaks.

16. Check engine idle. Adjust as necessary.

NOTE: This adjustment must be performed if the throttle body is removed for any reason and if throttle plate idle adjustment screw position is changed.

17. Adjust throttle valve control actuating cable.

18. Install snowshield onto idle air control valve. Tighten retaining screw to 1.4 Nm (12 lb in).