Unit Overhaul/Fuel Charging Assembly
1982 Mark VI, 1983 Lincoln/Mark VI, Crown Victoria/Grand Marquis, Continental; 1984-85 Continental & Mark VII; 1983-87 Cougar & Thunderbird; 1984--6 Capri & Mustang; 1984-86 LTD & Marquis; 1984-85 Crown Victoria, Grand Marquis &Town Car
To prevent damage to the throttle plates, the fuel charging assembly should be supported on a work stand. If stand is not available, use four bolts 5/16 X 2 1/2 inches as stands. Install nuts on bolts above and below the throttle body.
Fig. 15 Fuel charging assembly exploded view. V8 engine units shown, V6 engine units similar:
Fig. 15b Fuel charging assembly exploded view. V8 engine units shown, V6 engine units similar:
Disassembly
Any screws painted blue are metric.
1. Remove air cleaner stud, then invert assembly and remove the four screws in throttle body, Fig. 15.
2. Separate upper body from throttle body and remove gasket (12).
3. Remove upper body screws (14) and pressure regulator (2).
4. Disconnect wiring from injector (17), then remove injector retaining screw (11) and injector retainer (13).
5. Loosen wiring harness retaining screw (18), then pinch on tabs and remove wiring harness from upper body.
6. Remove injectors by pulling them out. Identify each injector as to choke side or throttle side.
7. Remove fuel diagnostic valve cap (16) and valve assembly (15).
8. Drill out choke cap retaining rivets, then remove retaining ring (35), choke cap (34) and gasket (31).
9. Remove thermostat lever screw (32) and lever (33), then remove fast idle cam assembly (27, 28).
10. Remove fast idle control and rod positioner (26).
11. Remove screws (19), control diaphragm cover assembly (21), control modulator spring (22) and pulldown control diaphragm (24).
12. Remove fast idle retaining nut (37), fast idle cam adjuster lever (38) fast idle lever (40) and E-ring (49).
13. Scribe a mark on potentiometer (42) and throttle body (45) and remove connector bracket retaining screws (43).
14. Remove potentiometer retaining screws (41) and potentiometer (42).
15. Remove throttle positioner retaining screw (67) and throttle positioner assembly.
16. Using a 1/16 inch punch, carefully drive out roll pin (50).
17. Remove throttle plate retaining screws (46) and throttle plate. Note exact location of throttle plates as to choke side and throttle plate side.
18. Remove O-ring, if used, and slide throttle shaft assembly while disengaging throttle return spring (54).
Assembly
*** UPDATED BY TSB #86-24-14
1. Install fuel pressure valve assembly (15) and torque to 48-84 inch lbs. Install valve cap (16) and torque to 5-10 inch lbs., Fig. 15.
2. Install wiring harness (17) and screw (18) into upper body. Torque to 8-10 inch lbs.
3. Lubricate O-rings (3) on injectors (9) with light oil and push injectors into upper body. Make sure to install in their original positions.
4. Install injector retainer (13) and retainer screw (11). Torque to 36-60 inch lbs.
5. Connect fuel charging connectors to injectors.
6. Lubricate fuel pressure regulator O-ring with light oil, then install O-ring (3) and gasket (4) on fuel pressure regulator (2).
7. Install pressure regulator on upper body and install screws (14). Torque to 27---40 inch lbs.
8. Install throttle shaft assembly and secure throttle shaft to proper boss, then install throttle plates (47) and retaining screws (46) in their original locations. Torque screws to 10-15 inch lbs. After installing throttle plate, cycle throttle shaft several times to insure freedom of operation.
9. Install roll pin (50), an equal distance through throttle shaft. Use care not to damage throttle shaft when installing pin. Cycle shaft several times to insure freedom of operation.
10. Position potentiometer on throttle shaft with its scribe mark at 12 o'clock position. Hold potentiometer firmly against throttle body and rotate potentiometer clockwise until its scribe mark aligns with scribe mark on throttle body, then install retaining screws.
11. Install E-ring (49), fast idle lever (40), fast idle return spring (39a), if equipped, fast idle adjustment lever (38) and fast idle retaining nut (37). Torque nut to 16---20 inch lbs.
12. Install pulldown control diaphragm (24), control modulator spring (22) and retaining screws (19). Torque retaining screws to 13---19 inch lbs.
13. Install fast idle cam assembly (27), thermostat lever (33) and screw (32). Torque screw to 13-19 inch lbs. Thermostatic lever should be straight down when properly installed.
14. Install gasket (31), choke cap (34), retaining ring (35) and rivets (36).
15. Install gasket (12) on throttle body, then place upper body on throttle body.
16. Holding upper body and throttle body in place, invert and install the four retaining screws (44) and air cleaner stud. Install all screws and stud before tightening.