FIPL/TP Installation and Adjustments
FIPL/TP INSTALLATION AND ADJUSTMENT PROCEDURENOTE:
THE FIPL/TP SENSOR SHOULD BE CHECKED EVERY 50,000 MILES (80 000 KILOMETERS) AND, IF NEEDED, ADJUSTED.
The Fuel Injection Pump Lever (FIPL)/Throttle Position (TP) sensor is used on E-250-350, F-250-350, and F-Super Duty vehicles equipped with a 7.3L Diesel engine and an E40D automatic transmission. The FIPL/TP sensor is a potentiometer attached to the fuel injection pump and is operated by the throttle lever, Figure 1.
The FIPL/TP sensor is incorporated to provide an electrical signal, which is proportional to the amount of fuel being delivered, as an input to the Powertrain Control Module (PCM). Based on this information, the PCM provides the proper shift scheduling and torque capacity.
If a malfunction occurs in the FIPL/TP sensor circuit, the electrical signal sent to the PCM will be recognized as erroneous. When this out-of-specification signal is detected, the PCM will provide a high capacity operating mode that protects the transmission from potential damage. This operating mode includes maximum TV pressure, resulting in harsh upshifts and engagements and a singular shift schedule regardless of accelerator pedal position, resulting in the 1-2, 2-3, and 3-4 shifts occurring at a speed equal to a heavy (but not wide open) throttle setting.
If harsh or poorly scheduled shifts are encountered, perform Key-On, Engine-Off Self-Test to determine the appropriate repair to be performed and correct as necessary before proceeding. If it is necessary to service the FIPL/TP Sensor, refer to the following procedure.
NOTE:
TO CHECK THE FIPL/TP SENSOR FOR PROPER OPERATION AND TO MAKE ANY ADJUSTMENTS, THE ENGINE MUST BE TURNED OFF.
1. Perform Key-On, Engine-Off Self-Test and wait for all the fault codes to be issued.
NOTE:
THE THROTTLE MUST BE HELD TO THE FLOOR DURING KEY-ON ENGINE-OFF SELF-TEST UNTIL THE CODES HAVE BEGUN TO ISSUE FROM THE ROTUNDA SUPERSTAR II TESTER 007-0041B.
2. After the last fault code has been issued, press the Transmission Control Switch (TCS). This will initiate the FIPL/TP sensor adjustment mode and allow the "Star Tester" to be used as an "audible guide" in setting the FIPL sensor.
NOTE:
THE "STAR TESTER" REMAINS IN THE ADJUSTMENT MODE FOR ONLY 10 MINUTES. STEPS 3 THROUGH 5 MUST BE COMPLETED WITHIN THIS TIME PERIOD. IF THE 10 MINUTE TIME LIMIT IS EXCEEDED, THIS PROCEDURE MUST BE REPEATED FROM STEP 1.
3. Remove the throttle cable from the throttle lever on the right side of the fuel injection pump.
4. Insert the VRV Setting Gauge Block T92T-7B200-AH (.515") (13.08 mm) between the gauge block boss and the maximum throttle travel screw, Figure 2. Hold the throttle lever open against the gauge block. A steady tone indicates the FIPL/TP is properly adjusted.
NOTE:
THE FIPL/TP SENSOR BRACKET IS PERMANENTLY ATTACHED TO THE PUMP WITH TAMPER-PROOF SCREWS. MOVEMENT OF THE BRACKET IS NOT NORMALLY USED AS A MEANS FOR ADJUSTMENT. IF REQUIRED, ADJUSTMENT OF THE FIPL/TP SENSOR MAY BE ACCOMPLISHED BY UTILIZING THE CLEARANCE BETWEEN THE SENSOR-TO-BRACKET SCREWS AND THE SENSOR.
NOTE:
IF THE FIPL/TP SENSOR BRACKET IS LOOSE, REMOVE THE EPOXY FROM THE BRACKET-TO-PUMP MOUNTING SCREWS, ADJUST THE FIPL/TP SENSOR/BRACKET ASSEMBLY TO OBTAIN A STEADY TONE, RE-TIGHTEN THE SCREWS, AND REAPPLY EPOXY TO THE SCREW HEADS.
5. To adjust, proceed as follows:
a. Loosen the two (2) screws that attach the FIPL/TP sensor to the mounting bracket, Figure 3.
b. Rotate the FIPL/TP sensor until a steady tone is heard from the "Star Tester".
c. If the setting is too low, the "Star Tester" will issue a slow beep (1 per second). If the setting is too high, the "Star Tester" will issue a fast beep (4 per second).
d. Once a steady tone is heard, tighten the attaching screws to 8-10.5 N-m (71-93 in.lb.).
e. If the FIPL/TP sensor cannot be adjusted to obtain a steady tone, adjustment may be attempted by loosening the bracket attaching bolts and rotating the bracket.
f. If a steady tone still cannot be obtained, refer to the "DQ" pinpoint tests in the "Powertrain Control/Emissions Diagnosis Manual".
6. Remove the gauge block.
a. Cycle the throttle lever from idle to wide open throttle (WOT) five (5) times.
b. Reinsert the gauge block to verify the setting.
c. If the tone is not steady, then readjustment is necessary.
d. Repeat this procedure from Step 5.
7. Remove the gauge block. Reattach the throttle cable.
8. Start the engine. Check throttle operation and transmission shift scheduling and quality.
WARNING:
DO NOT TURN THE MAXIMUM THROTTLE TRAVEL SCREW. THIS SCREW HAS BEEN PRESET AND SHOULD NOT BE ADJUSTED.