Ford Falcon. Manual — part 223

303-14-106

Powertrain Control Management

303-14-106

REMOVAL AND INSTALLATION (Continued)

Ensure that that there are no fuel leaks in

9. Torque the security bolts on the PCM until the

the engine compartment, the engine, fuel

heads break off.

injectors and fuel lines.

HEGO Sensor (I6 & V8 Engines)

Ensure that there are no flammable liquids

and fumes present in the work area. Eg

Removal

solvents, inks, paints, thinners, cleaning

1. Remove the HEGO sensor.

fluids, open fuel containers etc.

1. Disconnect the electrical connector

Use necessary precautions to confine

2. Remove the screws

debris from the grinder.

3. Using a 22mm ring spanner, remove the

Use protective goggles and gloves for

sensor

personal safety.

3. Use a blade screwdriver to unscrew the security

I6 Engine

bolts.

4. Release the wiring harness locking bar and

remove the harness from the PCM.

V8 Engine

Item

Description

1

PCM Module

2

Security bolt

5. Remove

the

PCM.

Installation
1. Secure the wiring harness to the correct PCM

connector pockets. They are keyed so that they

only fit one way and both the A and B pocket

connectors are different.

2. For new PCMs, perform the Module Configuration

operation in the "Module Programming" section.

Item

Description

3. For new PCMs, perform the Parameter Reset

operation as detailed in this section to re-train the

1

HEGO Sensor (LHS only)

Smartshield security system.

2

HEGO Sensor (LHS & RHS)

4. For new PCMs, retrain the audio system to the

Installation

new PCM ID code. This procedure can be carried

1. To Install, reverse the removal procedure.

out by using the WDS tester.

NOTE: Make sure the thread is cleaned and that a

5. Temporarily secure the PCM to the bracket with

suitable anti-seize compound is applied to the thread

new security bolts. DO NOT BREAK THE HEADS

before installing the sensor.

OFF YET.

6. Clear the PCM fault codes

NOTE: Make sure the sensor’s flylead is routed away

from the steering intermediate shaft. Check for any

7. Remove the WDS and test-drive the vehicle.

exhaust leakage around the sensor.

8. Reconnect the WDS tester and run a KOEO and

KOER test on the PCM. Rectify faults if required.

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303-14-107

Powertrain Control Management

303-14-107

REMOVAL AND INSTALLATION (Continued)

HEGO Sensor (Turbo)

Installation
1. Push the BPS into the aluminum duct.

Removal

2. Refit the retaining bolt and tighten.

1. Remove the HEGO sensor.

3. Reconnect the harness to the BPS.

1. Disconnect the electrical connector

2. Remove the screws

Turbocharger Wastegate Control

3. Using a 22mm ring spanner, remove the

Solenoid

sensor

Removal

I6 Engine

1. Remove the Wastegate Control Solenoid.

1. Disconnect the electrical connector.

2. Slide solenoid up and away from its retaining

bracket.

Installation
1. To Install, reverse the removal procedure.
NOTE: Make sure the thread is cleaned and that a

suitable anti-seize compound is applied to the thread

Installation

before installing the sensor.

1. To Install, reverse the removal procedure.

NOTE: Make sure the sensor’s flylead is routed away

from the steering intermediate shaft. Check for any

Reverse Gear Switch

exhaust leakage around the sensor.

Removal

Boost Pressure Sensor (Turbo Engine)

1. Remove the Reverse Gear Switch

1. Disconnect the electrical connector

Removal

2. Remove the retaining bolt

1. Disconnect the wire harness from the BPS

connector.

3. Remove the sensor

2. Unscrew the retaining bolt.
3. Gently pull the sensor out vertically from the

aluminum duct.

Installation
1. To Install, reverse the removal procedure.

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303-14-108

Powertrain Control Management

303-14-108

REMOVAL AND INSTALLATION (Continued)

Temperature and Manifold Absolute

Fuel Rail (I6 Engine)

Pressure (T-MAP) Sensor

Removal

Removal

1. Ensure the area of the fuel rail and intake

1. Remove the Electronic Throttle Body and then

manifold injectors are clean of all dirt, grit etc.

disconnect the engine wiring harness from the

Prior to the removal of injectors.

T-MAP connector.

2. Relieve fuel system residual pressure.

2. Remove the two screws securing the T-MAP

3. Remove intake air duct.

sensor to the inlet manifold.

4. Disconnect the wiring harness from the fuel

3. Carefully withdraw the sensor from the manifold.

injectors at the connector.

4. Plug the aperture in the inlet manifold to prevent

5. Tag and disconnect fuel supply and return lines at

the ingress of foreign material.

the quick-connect fittings.

Installation

6. Disconnect vacuum hose from pressure regulator.

1. Install new o-rings on the T-MAP sensor, if

7. Disconnect the wiring loom from the fuel rail.

necessary.

8. Remove the screws attaching the fuel rail

2. Install the T-MAP sensor into the inlet manifold

brackets to the intake manifold.

with the connector at the bottom.

9. Remove the fuel injector to fuel rail retaining clips

3. Align the holes and install the T-MAP sensor

and withdraw each injector. Place each injector in

retaining screws. Tighten the screws to 3Nm.

a clean plastic bag to prevent the injectors from

4. Reconnect the harness to the T-MAP sensor.

being contaminated with foreign material. Number

each bag according to injector position. Plug the

5. Run the engine and check for vacuum leaks

apertures in the intake manifold to prevent the

around the sensor. Rectify any leaks found.

ingress of foreign material.

I6 Engine

Installation
1. Ensure the fuel rail injector mounting apertures

are clean, smear the fuel injector sealing rings

with a light coating of engine oil. DO NOT use

petroleum jelly. Insert the injectors into the fuel rail

and install retaining clips.

2. Ensure the intake manifold injector apertures and

the fuel injector tips are clean, smear the injector

sealing rings with a light coating of engine oil. DO

NOT use petroleum jelly. Insert the injectors into

the manifold and position the fuel rail, install the

retaining screws and torque screws to 19Nm.

3. Attach the injector wiring loom at the fuel rail and

connect the injector clamp.

4. Reconnect the fuel supply and return lines as

V8 Engine

tagged.

5. Start and run engine. Check for any leaks. Rectify

any faults found.

Fuel Rail (V8 Engine)

Removal
1. Ensure the area of the fuel rail and intake

manifold injectors are clean of all dirt, grit etc.

Prior to the removal of injectors.

2. Relieve fuel system residual pressure.
3. Remove intake air duct from the air cleaner and

throttle body.

4. Disconnect wiring connectors from the Throttle

Position Sensor (TP) <TPS> and Idle Air Control

Valve (IAC) <ISC>sensors.

5. Disconnect vacuum hoses and lines from the PCV

system and fuel pressure regulator.

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303-14-109

Powertrain Control Management

303-14-109

REMOVAL AND INSTALLATION (Continued)

6. Disconnect the throttle cable from the throttle

Brake Switches

linkage.

Refer to Section 206-06 for more information.

7. Remove the upper intake manifold.
8. Tag and is connect the fuel supply and return

Clutch Engagement Switch, (Manual

lines using quick-connect fittings.

Transmission)

9. Disconnect the fuel injector wiring connectors.

Removal

10. Remove the screws securing the fuel rail.

1. Gently twist the switch 45 degrees anti clockwise.

11. Remove the fuel rail and injectors as an

assembly.

2. Withdraw the switch from the bracket.

12. Remove the fuel injector from the fuel rail. Place

each injector in a clean plastic bag to prevent the

injectors from being contaminated with foreign

material. Number each bag according to injector

position. Plug the apertures in the intake manifold

to prevent the ingress of foreign material.

Installation
1. Ensure the fuel rail injector mounting apertures

are clean, smear the fuel injector sealing rings

with a light coating of engine oil. DO NOT use

petroleum jelly. Insert the injectors into the fuel

rail.

2. Ensure the intake manifold injector apertures and

the fuel injector tips are clean, smear the injector

sealing rings with a light coating of engine oil. DO 3. Unplug the wire harness connector from the

NOT use petroleum jelly. Insert the injectors into

switch.

the manifold and position the fuel rail, press down Installation

on the fuel rail and install the retaining screws.

1. Plug the wire harness connector to the switch.

Torque screws to 12Nm.

2. Insert the switch into to the bracket.

3. Connect the fuel supply and return lines.

3. While pushing the switch home into the bracket,

4. Install the upper intake manifold as described in

gently twist the switch 45 degrees clockwise to

Group 8-3, Eight Cylinder Engine.

lock the switch into the bracket.

5. Connect PCV hoses and all vacuum lines.

Pedal Position Sensor

6. Connect throttle cable to the throttle linkage.
7. Connect wiring connectors to the TP and ISC

Removal

sensors.

Refer to Adjustable pedal section.

8. Install intake air duct to the air cleaner and throttle Installation

body.

Refer to Adjustable pedal section.

9. Start and run engine. Check for any leaks. Rectify

any faults found.

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