Throttle Position Sensor: Adjustments

NOTE: To check the Fuel Injection Pump Lever (FIPL) sensor for proper operation and to make any adjustments the engine MUST NOT BE RUNNING.

CAUTION: DO NOT turn the maximum throttle travel screw. This screw has been preset and should not be adjusted.

1. Perform the Key ON Engine OFF self test and wait until all service codes have been displayed.
NOTE: Hold the throttle to the floor from the start of the self test until the codes have begun to display on the scan tool.
2. After the last service codes has been displayed, press the Overdrive Cancel Switch (OCS). This will initiate the FIPL sensor adjustment mode and allow the scan tool to be used as an audible guide in setting the FIPL sensor.
NOTE: The scan tool remains in the adjustment mode for approximately ten minutes. If steps three through six are not completed in this time period, the adjustment procedure must be re-initiated from step one.
3. Remove the throttle cable from the throttle lever.

Gauge Block Inserted Between Gauge Boss And Maximum Throttle Travel Screw:

4. Insert the 0.515 inch gauge block, (Ford part #T83T-7B200-AH, or equivalent), between the gauge boss and the maximum throttle travel screw. Hold the throttle lever open against the gauge block. If the FIPL sensor is properly adjusted the scan tool will issue a steady tone. If the setting is too low the scan tool will issue a slow beep, approximately one beep per second. If the setting is too high the scan tool will issue a fast beep, approximately 4 beeps per second.
NOTE: The FIPL sensor bracket is permanently attached to the pump with tamper resistant screws. Movement of the bracket is not intended as a means for adjustment. If necessary, adjustment of the FIPL sensor may be done by utilizing the clearance between the sensor to bracket screws and the sensor.
If the FIPL sensor bracket is loose, remove the epoxy from the bracket to pump mounting screws and adjust the FIPL sensor/bracket assembly to obtain a steady tone. Once a steady tone is received, tighten the screws and reapply epoxy to the screw heads.

Fuel Injection Pump Lever (FIPL) Sensor:

5. To adjust the FIPL, loosen the two screws that attach the FIPL sensor to the mounting bracket. Rotate the FIPL sensor until the scan tool emits a steady tone, then tighten the retaining screws to 75-90 lbs. in. (8-10.5 N-m). If a steady tone cannot be obtained from the adjustment range, replace the FIPL sensor and repeat this procedure from step 1.
6. Remove the gauge block and cycle the throttle lever from idle to wide open throttle 5 times. Reinsert the gauge block to verify the setting. If the tone is not steady then repeat step 5 and readjust the sensor. If a steady tone is heard, proceed with step 7.
7. Remove the gauge block and reattach the throttle cable.
8. START the engine. Check throttle operation and transmission shift quality and scheduling.