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Ford - E 350 Van - Workshop Manual - 1987 - 1987
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Summary of Content
Factory Workshop Manual
Make
Ford
Model
E 350 Van
Engine and year
V8-460 7.5L VIN L 4-BBL (1987)
Please navigate through the PDF using the options
provided by OnlyManuals.com on the sidebar.
This manual was submitted by
Anonymous
Date
1st January 2018
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries
Code 11 - 20: Testing and Inspection
12
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries > Page 8
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries > Page 9
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
13
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries > Page 10
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries > Page 11
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
14
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries > Page 12
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries > Page 13
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
15
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries > Page 14
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries > Page 15
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
16
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries > Page 16
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries > Page 17
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
18
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries > Page 18
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries > Page 19
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
19
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries > Page 20
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16
17 18 19 ) > System Information > System Diagnosis > There are 3 additional entries > Page 21
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26
27 28 29 ) > System Information > System Diagnosis > There are 2 additional entries
Code 21 - 30: Testing and Inspection
21
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26
27 28 29 ) > System Information > System Diagnosis > There are 2 additional entries > Page 26
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26
27 28 29 ) > System Information > System Diagnosis > There are 2 additional entries > Page 27
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
22
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26
27 28 29 ) > System Information > System Diagnosis > There are 2 additional entries > Page 28
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26
27 28 29 ) > System Information > System Diagnosis > There are 2 additional entries > Page 29
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
23
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26
27 28 29 ) > System Information > System Diagnosis > There are 2 additional entries > Page 30
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26
27 28 29 ) > System Information > System Diagnosis > There are 2 additional entries > Page 31
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
24
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26
27 28 29 ) > System Information > System Diagnosis > There are 2 additional entries > Page 32
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26
27 28 29 ) > System Information > System Diagnosis > There are 2 additional entries > Page 33
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
25
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26
27 28 29 ) > System Information > System Diagnosis > There are 2 additional entries > Page 34
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26
27 28 29 ) > System Information > System Diagnosis > There are 2 additional entries > Page 35
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
29
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26
27 28 29 ) > System Information > System Diagnosis > There are 2 additional entries > Page 36
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26
27 28 29 ) > System Information > System Diagnosis > There are 2 additional entries > Page 37
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36
37 38 39 ) > System Information > System Diagnosis > There are 2 additional entries
Code 31 - 40: Testing and Inspection
31
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36
37 38 39 ) > System Information > System Diagnosis > There are 2 additional entries > Page 42
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36
37 38 39 ) > System Information > System Diagnosis > There are 2 additional entries > Page 43
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
32
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36
37 38 39 ) > System Information > System Diagnosis > There are 2 additional entries > Page 44
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36
37 38 39 ) > System Information > System Diagnosis > There are 2 additional entries > Page 45
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
33
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36
37 38 39 ) > System Information > System Diagnosis > There are 2 additional entries > Page 46
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36
37 38 39 ) > System Information > System Diagnosis > There are 2 additional entries > Page 47
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
34
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36
37 38 39 ) > System Information > System Diagnosis > There are 2 additional entries > Page 48
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36
37 38 39 ) > System Information > System Diagnosis > There are 2 additional entries > Page 49
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
35
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36
37 38 39 ) > System Information > System Diagnosis > There are 2 additional entries > Page 50
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36
37 38 39 ) > System Information > System Diagnosis > There are 2 additional entries > Page 51
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
38
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36
37 38 39 ) > System Information > System Diagnosis > There are 2 additional entries > Page 52
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36
37 38 39 ) > System Information > System Diagnosis > There are 2 additional entries > Page 53
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries
Code 81 - 90: Testing and Inspection
81
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries > Page 58
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries > Page 59
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
82
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries > Page 60
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries > Page 61
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
83
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries > Page 62
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries > Page 63
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
84
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries > Page 64
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries > Page 65
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
85
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries > Page 66
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries > Page 67
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
87
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries > Page 68
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries > Page 69
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
89
Quick Test: KOEO Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries > Page 70
Quick Test: KOER Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86
87 88 89 ) > System Information > System Diagnosis > There are 3 additional entries > Page 71
For complete diagnosis of the Engine Control system, See: Powertrain Management/Computers
and Control Systems/Testing and Inspection
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio
Control Relay > Component Information > Locations
Audio Control Relay: Locations
Right Of Radio, Near Amplifier
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Power Door Lock Relay: Locations
Lower Cowl Near Fuse Block
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module >
Component Information > Locations
Cruise Control Module: Locations
Under LH Side Of I/P, With Speed Control
LH Side Of I/P, Near Steering Column
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module >
Component Information > Locations > Page 85
Cruise Control Module: Testing and Inspection
Use only a multi-meter of 5000 ohm/volt rating or higher when performing amplifier test.
``On'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground on models exc. 1983-87
Ranger, 1984-87 Bronco II and 1986-87 Aerostar or white wire w/purple stripe and ground on
1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar.
3. Battery voltage should be indicated when ``On'' switch on steering column is depressed and
held. If battery voltage is not indicated, check horn relay and perform control switch test.
4. Release ``On'' button. Voltmeter should indicate 7.8 volts indicating ``On'' circuit is engaged. If
voltage does not remain, check amplifier ground, fuses or circuit breakers or replace amplifier with
known good amplifier and repeat test.
5. Replace as necessary.
``Off'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground.
3. Depress ``Off'' button. Voltage should drop to zero indicating ``On'' circuit is de-energized.
4. If voltage does not drop to zero, perform ``Control Switch Test.''
``Set-Accelerate'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground.
3. Depress ``On'' switch, then hold ``Set-Accel'' button on steering wheel. Voltmeter should indicate
4.5 volts. Rotate steering wheel back and forth and check for voltmeter fluctuations. If reading
varies more than .5 volts, perform ``Control Switch Test.''
``Coast'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground.
3. Depress ``On'' switch, then depress and hold ``Coast'' button on steering wheel. Voltmeter
should indicate 1.5 volts. Rotate steering wheel back and forth and check for voltage fluctuations. If
reading varies more than .5 volts, perform ``Control Switch Test.''
``Resume'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground.
3. Depress and hold ``Resume'' button. Voltmeter should indicate 6.5 volts.
If all circuits are functioning properly, perform ``Servo Assembly
Test'' using a known good amplifier. Do not replace amplifier before performing servo test.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations
Blower Motor Relay: Locations
LH Side Of Dash
LH Corner Of Engine Compartment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module >
Component Information > Technical Service Bulletins > Speedometer Display - Parts Return
Speedometer Module: Technical Service Bulletins Speedometer Display - Parts Return
TSB # MEMO 122187
December 21, 1987
To: All Ford and Lincoln Mercury Dealers
Subject: Request for Return of Speedo Display Assemblies E5SZ-17B383-AR E5SZ-17B383-CR
E69Z-17B383-B
Because the subject parts may not meet Ford's high quality requirements, all unused subject parts
should be withdrawn from inventory and returned to your facing P.D.C. within 30 days from the
date of this letter. Use the least expensive mode of transportation for your return. Replacement
stock is available for ordering immediately.
You are requested to complete a separate FPS-340 form in accordance with the instructions on the
front of this form. Annotate "Returned Per FPSD Instructions Purge No. PN 1042" in the
Customer's Detail Explanation Section and use Reason Code J (unsatisfactory Service Stock).
You will receive full credit in your parts statement for the price of each unused part returned, plus
the prepaid transportation cost. In order to receive return credit, all parts must be received at the
Parts Distribution Center within 30 days from the date of this letter. Material other than subject
parts received on this return will be sent back to you freight collect.
Any questions should be referred to your Zone Manager or facing P.D.C. Manager.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Horn Relay: Locations
Horn Relay Location
Under LH Side Of I/P.
Under LH Side Of I/P, With Speed Control
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 99
Underneath LH Side Of I/P
Below LH Side Of I/P
Horn Relay With Speed Control
Bronco F-150 thru F-350, E-150 thru E-350 and Super F Series The horn relay is use on vehicles
equipped with speed control and is located under the left side of the instrument panel, left of the
steering column and is mounted on the outboard attaching screw of the speed control amplifier
module.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 100
Horn Relay: Testing and Inspection
Fig. 3 Speed control wiring diagram. 1981---83 E-100-350 & 1984-87 E-150-350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 101
Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 102
Fig. 5 Speed control wiring diagram. 1982---83 F-100-350, 1984---87 F-150-350 & 1982---87
Bronco
1981-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Locate horn relay wire connector marked X and Y, Figs. 3, 4 and 5.
2. Using connector X, locate wire 460, then using a suitable voltmeter, check for battery voltage at
male side of connector.
3. Using connector Y, locate wire 1, then using a suitable voltmeter, check for battery voltage at
female side of connector. Depress horn, voltmeter should read zero and horn should sound. If
battery voltage remains, circuit is open. Connectors should remain connected during testing.
4. Check horn relay by momentarily grounding circuit 1 to chassis. This bypasses horn switch and
horn should sound. If horn does not sound, check for battery voltage at connector X wire 6 during
relay operation. If voltage is present at circuit 6 during relay operation, an open circuit is indicated
between horn and connector X.
5. If relay does not operate with battery voltage present at circuit 460 and circuit 1 is grounded,
replace relay.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations
Trailer Lighting Relay: Locations
LH Rear Fender Below LH Tail Light
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Protection
Relay > Component Information > Locations
Power Protection Relay: Locations
Trailer Tow With Auxiliary Battery Above LH Headlight
LH Front Fender
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
Engine Control Module: Customer Interest Engine - Lack of Power and/or No Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 120
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 121
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 122
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 123
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 124
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 125
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 126
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition
Engine Control Module: All Technical Service Bulletins Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 132
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 133
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 134
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 135
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 136
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 137
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 138
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Engine Control Module: > 90116 > May > 90 > Body/Frame - Arc Welding Precautions
Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions
Article No. 90-11-6
EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM
ARC WELDING
FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90
TAURUS
LINCOLN-MERCURY: 1985-86 CAPRI
1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90
SABLE
MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER
ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative
battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs
because the arc welding process can produce high electrical currents in the body of a vehicle when
the negative battery ground cable is left connected.
ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground
cable,
CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY
ELECTRIC WELDING EQUIPMENT
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Engine Control Module: > 90116 > May > 90 > Body/Frame - Arc Welding Precautions
Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions
Article No. 90-11-6
EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM
ARC WELDING
FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90
TAURUS
LINCOLN-MERCURY: 1985-86 CAPRI
1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90
SABLE
MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER
ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative
battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs
because the arc welding process can produce high electrical currents in the body of a vehicle when
the negative battery ground cable is left connected.
ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground
cable,
CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY
ELECTRIC WELDING EQUIPMENT
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page
148
Engine Control Module: Locations
Under RH Side Of Dashboard
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation >
Electronic Control Assembly (ECA)
Engine Control Module: Description and Operation Electronic Control Assembly (ECA)
Fig. 6 Electronic control assembly
The ECA is the brain of the EEC-IV system and is comprised of a processor and calibration
assembly, Fig. 6. The processor receives input signals from the various sensors. The information
obtained is used by the processor to activate engine control systems to obtain optimum emission
control and performance. The calibration assembly is a permanent memory device that contains
information. The processor applies the sensor inputs to the stored information to determine when
and how long the various control systems should be applied.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation >
Electronic Control Assembly (ECA) > Page 151
Engine Control Module: Description and Operation Failure Mode Effects Management
FMEM is an alternate system strategy in the ECA designed to allow improved vehicle drive should
one or more sensor inputs fail. When a sensor input is perceived to be out-of-limits by the ECA, an
alternative strategy will be initiated. The ECA will substitute a fixed in-limit sensor value and will
continue to monitor the faulty sensor input. If the faulty sensor operates within limits, the ECA will
return to the normal Engine Running mode (strategy). Code 98 will be displayed when FMEM is in
effect. The MIL ``Check Engine'' light will remain ON when the FMEM is in effect.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Under RH Side Of Dashboard
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 155
Main Relay (Computer/Fuel System): Description and Operation
Fig. 12 EEC relay type, system application & relay locations
EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power
relays also provide reverse battery protection and increased load handling to improve ignition
switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine
applications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > EGR Control Module > Component Information > Locations
EGR Control Module: Locations
Behind LH Side Of Instrument Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Choke Relay > Component Information > Locations
Choke Relay: Locations
LH Fender Apron Near Dash
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer
Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down
Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down
^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY
CHARGE
^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF
Article No. 90-18-3 FORD:
1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD
1986-90 TAURUS
LINCOLN-MERCURY: 1983-87 LYNX
1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86
CAPRI, MARQUIS 1986-90 SABLE
LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1988-90 F SUPER DUTY
ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been
shut off. There may also be a no start condition or a discharged battery. These conditions are
caused by a sticking fuel pump relay.
ACTION: Install a new fuel pump relay. Refer to the following procedure for service details.
1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for
troubleshooting details.
2. Install a new fuel pump relay, if the old one is defective.
3. Check the vehicle for proper operation.
PART NUMBER PART NAME
F19Z-9345-A Fuel Pump Relay Assy.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901803A 1985-86 LTD/Marquis 0.6 Hr.
(includes pinpoint test)
901803A 1990 Town Car (includes 0.4 Hr.
pinpoint test)
901803A All Other Cars (includes 0.5 Hr.
pinpoint test)
901803A All Trucks (includes pinpoint 0.5 Hr.
test)
DEALER CODING
BASIC PART NO. CONDITION CODE
9345 09
OASIS CODES: 404000, 603300, 203000, 203100, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down
Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut
Down
^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY
CHARGE
^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF
Article No. 90-18-3 FORD:
1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD
1986-90 TAURUS
LINCOLN-MERCURY: 1983-87 LYNX
1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86
CAPRI, MARQUIS 1986-90 SABLE
LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1988-90 F SUPER DUTY
ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been
shut off. There may also be a no start condition or a discharged battery. These conditions are
caused by a sticking fuel pump relay.
ACTION: Install a new fuel pump relay. Refer to the following procedure for service details.
1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for
troubleshooting details.
2. Install a new fuel pump relay, if the old one is defective.
3. Check the vehicle for proper operation.
PART NUMBER PART NAME
F19Z-9345-A Fuel Pump Relay Assy.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901803A 1985-86 LTD/Marquis 0.6 Hr.
(includes pinpoint test)
901803A 1990 Town Car (includes 0.4 Hr.
pinpoint test)
901803A All Other Cars (includes 0.5 Hr.
pinpoint test)
901803A All Trucks (includes pinpoint 0.5 Hr.
test)
DEALER CODING
BASIC PART NO. CONDITION CODE
9345 09
OASIS CODES: 404000, 603300, 203000, 203100, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Shut-off Solenoid Relay > Component Information > Locations
Fuel Shut-off Solenoid Relay: Locations
LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Under RH Side Of Dashboard
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 183
Main Relay (Computer/Fuel System): Description and Operation
Fig. 12 EEC relay type, system application & relay locations
EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power
relays also provide reverse battery protection and increased load handling to improve ignition
switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine
applications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: >
88209 > Sep > 88 > Engine - No Start or Hard Start Condition
Ignition Control Module: Customer Interest Engine - No Start or Hard Start Condition
^ NO START - ALL EEC IV WITH TFI
^ HARD START - ALL EEC IV WITH TFI
Article No. 88-20-9
FORD: 1987-88 ALL
LINCOLN-MERCURY: 1987-88 ALL
LIGHT TRUCK: 1987-88 ALL
ISSUE: A no start condition or hard start condition may be caused by a poor connection at the thick
film ignition (TFI) module mating connector on the wire harness.
ACTION: Inspect the TFI module to make sure a good connection is present. Refer to the following
procedure for service details.
1. Locate the TFI module. Check it and the mating connector on the wire harness to make sure
they are properly seated and latched.
2. With the engine running, pull on the wire harness at the base of the connector shell. The pull
should be hard enough to draw the wires straight and taut. If any of the above symptoms are
observed or the engine stops running, inspect the wire harness and connector terminals for
damage. Repair or replace the damaged components as necessary.
3. Grasp the connector shell and TFI module. Twist them back and forth. If any of above symptoms
are observed or the engine stops running, remove the TFI module and inspect for terminal blade
mislocation or bending. If the terminal blades are mislocated or bent, replace the TFI module.
4. Inspect the connector shell for the following items.
a. The red retainer clip should be present. If it is missing, install a new retainer clip.
b. The connector seal should be in place and seated to the connector at the latch base. If it is not
properly seated, install and fully seat a new seal.
NOTE: IF THE ABOVE SYMPTOMS ARE STILL PRESENT AFTER COMPLETING THE TSB,
REFER TO THE ENGINE/ EMISSIONS/DIAGNOSIS MANUAL.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty,
Emissions, and Major Component Coverage OPERATION: 882009A TIME: 0.4 Hr. - 1988
Continental, Thunderbird/ Cougar, Taurus/Sable with a 3.8L Engine
0.7 Hr. - 1987-88 Aerostar, Econoline 0.6 Hr. - All Other Vehicles
DLR. CODING: Basic Part No. 12A297 Condition Code: 44
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer Interest: >
87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition
Ignition Control Module: Customer Interest Engine - Stalling and/or A No Start Condition
^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No.
EEC IV VEHICLES 87-6-10
^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES
FORD 1984-87 ALL
LINCOLN-MERCURY 1984-87 ALL
MERKUR 1985-87 XR4Ti
LIGHT TRUCK 1984-87 ALL
ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may
be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI
module housing. This condition will result in a service code 14.
ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and
prevent further concerns.
NOTE: The distributor does not have to be removed to perform this repair.
1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior,
(mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures
and do not perform Steps 2 and 3.
2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper
towel.
3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A).
4. Clear service code 14 from memory.
PART NUMBER PART NAME CLASS
D7AZ-19A331-A Silicone Grease AM
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME:
1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code:
09
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 88209 > Sep > 88 > Engine - No Start or Hard Start Condition
Ignition Control Module: All Technical Service Bulletins Engine - No Start or Hard Start Condition
^ NO START - ALL EEC IV WITH TFI
^ HARD START - ALL EEC IV WITH TFI
Article No. 88-20-9
FORD: 1987-88 ALL
LINCOLN-MERCURY: 1987-88 ALL
LIGHT TRUCK: 1987-88 ALL
ISSUE: A no start condition or hard start condition may be caused by a poor connection at the thick
film ignition (TFI) module mating connector on the wire harness.
ACTION: Inspect the TFI module to make sure a good connection is present. Refer to the following
procedure for service details.
1. Locate the TFI module. Check it and the mating connector on the wire harness to make sure
they are properly seated and latched.
2. With the engine running, pull on the wire harness at the base of the connector shell. The pull
should be hard enough to draw the wires straight and taut. If any of the above symptoms are
observed or the engine stops running, inspect the wire harness and connector terminals for
damage. Repair or replace the damaged components as necessary.
3. Grasp the connector shell and TFI module. Twist them back and forth. If any of above symptoms
are observed or the engine stops running, remove the TFI module and inspect for terminal blade
mislocation or bending. If the terminal blades are mislocated or bent, replace the TFI module.
4. Inspect the connector shell for the following items.
a. The red retainer clip should be present. If it is missing, install a new retainer clip.
b. The connector seal should be in place and seated to the connector at the latch base. If it is not
properly seated, install and fully seat a new seal.
NOTE: IF THE ABOVE SYMPTOMS ARE STILL PRESENT AFTER COMPLETING THE TSB,
REFER TO THE ENGINE/ EMISSIONS/DIAGNOSIS MANUAL.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty,
Emissions, and Major Component Coverage OPERATION: 882009A TIME: 0.4 Hr. - 1988
Continental, Thunderbird/ Cougar, Taurus/Sable with a 3.8L Engine
0.7 Hr. - 1987-88 Aerostar, Econoline 0.6 Hr. - All Other Vehicles
DLR. CODING: Basic Part No. 12A297 Condition Code: 44
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure
Technical Service Bulletin # 872110 Date: 871021
TFI Module/PIP Sensor - New Diagnostic Procedure
EEC IV - TFI MODULE AND PIP SENSOR - Article No.
NEW DIAGNOSTIC PROCEDURE 87-21-10
FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88
TAURUS
LINCOLN-MERCURY: 1983 MARK VI
1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN
CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES
ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been
developed. This new procedure allows the technician to take a direct path when testing the TFI
module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003).
ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB.
Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose
or broken conditions.
^ Check that the TFI module is securely fastened to the distributor base.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00002.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to a shorting bar type connector used to set base
timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition, refer to Intermittent Diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
206
Functional Schematic
TFI-IV
The TFI-IV system electrical schematic is shown below. For detailed information, refer to the
vehicle wiring diagram.
Ignition Coil Secondary Voltage (Crank Mode)
TFI-IV Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
207
Ignition Coil Secondary Voltage
(Run Mode) TFI-IV Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
208
TFI-IV Part 2
Test 3
Stator - TFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
209
TFI-IV Part 2
Test 4 & 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
210
Stator - TFI-IV TFI-IV Part 2
Test 5
TFI Module
TFI-IV Part 2
Test 6
Ignition Coils - Secondary & Primary Resistance
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
211
Ignition Coil Primary Resistance TFI-IV Part 2
Test 7 & 8
Ignition Coil Secondary
Resistance
TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
212
Part 2
Test 8
EEC-IV - TFI-IV
TFI-IV Part 2
Test 9
Ignition Coil Supply Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
213
TFI-IV Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
214
TFI-IV Part 2
Test 11
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose,
or broken conditions.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
215
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00003.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to shorting bar type connector used to set base timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition refer to Intermittent Diagnosis.
Functional Schematic
TFI-IV
Closed Bowl
Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For
detailed information, refer to the vehicle wiring diagram.
Ignition Coil Secondary Voltage - Crank Mode
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
216
TFI-IV
Closed Bowl
Distributor Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
217
Ignition Coil Secondary
Voltage - Run Mode TFI-IV
Closed Bowl
Distributor Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
218
TFI-IV
Closed Bowl
Distributor Part 2
Test 3
Stator
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
219
TFI-IV
Closed Bowl
Distributor Part 2
Test 4, 5 & 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
220
Stator TFI-IV
Closed Bowl
Distributor Part 2
Test 5
Stator TFI-IV
Closed Bowl
Distributor Part 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
221
Test 6
TFI Module
TFI-IV
Closed Bowl
Distributor Part 2
Test 7
Ignition Coil, Primary & Secondary
Ignition Coil Primary Resistance TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
222
Closed Bowl
Distributor Part 2
Test 8
Ignition Coil Secondary
Resistance
TFI-IV
Closed Bowl
Distributor Part 2
Test 9
EEC IV - Wiring
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
223
TFI-IV
Closed Bowl
Distributor Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
224
TFI IV
Closed Bowl
Distributor Part 2
Test 11
Ignition Coil, TFI & Stator Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
225
Ignition Coil Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 12
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
226
TFI Supply Voltage TFI-IV
Closed Bowl
Distributor Part 2
Test 13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
227
Stator Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 14
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
228
TFI IV
Closed Bowl
Distributor Part 2
Test 15
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Ignition Control Module: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition
Ignition Control Module: All Technical Service Bulletins Engine - Stalling and/or A No Start
Condition
^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No.
EEC IV VEHICLES 87-6-10
^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES
FORD 1984-87 ALL
LINCOLN-MERCURY 1984-87 ALL
MERKUR 1985-87 XR4Ti
LIGHT TRUCK 1984-87 ALL
ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may
be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI
module housing. This condition will result in a service code 14.
ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and
prevent further concerns.
NOTE: The distributor does not have to be removed to perform this repair.
1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior,
(mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures
and do not perform Steps 2 and 3.
2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper
towel.
3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A).
4. Clear service code 14 from memory.
PART NUMBER PART NAME CLASS
D7AZ-19A331-A Silicone Grease AM
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME:
1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code:
09
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure
Technical Service Bulletin # 872110 Date: 871021
TFI Module/PIP Sensor - New Diagnostic Procedure
EEC IV - TFI MODULE AND PIP SENSOR - Article No.
NEW DIAGNOSTIC PROCEDURE 87-21-10
FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88
TAURUS
LINCOLN-MERCURY: 1983 MARK VI
1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN
CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES
ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been
developed. This new procedure allows the technician to take a direct path when testing the TFI
module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003).
ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB.
Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose
or broken conditions.
^ Check that the TFI module is securely fastened to the distributor base.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00002.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to a shorting bar type connector used to set base
timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition, refer to Intermittent Diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
238
Functional Schematic
TFI-IV
The TFI-IV system electrical schematic is shown below. For detailed information, refer to the
vehicle wiring diagram.
Ignition Coil Secondary Voltage (Crank Mode)
TFI-IV Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
239
Ignition Coil Secondary Voltage
(Run Mode) TFI-IV Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
240
TFI-IV Part 2
Test 3
Stator - TFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
241
TFI-IV Part 2
Test 4 & 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
242
Stator - TFI-IV TFI-IV Part 2
Test 5
TFI Module
TFI-IV Part 2
Test 6
Ignition Coils - Secondary & Primary Resistance
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
243
Ignition Coil Primary Resistance TFI-IV Part 2
Test 7 & 8
Ignition Coil Secondary
Resistance
TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
244
Part 2
Test 8
EEC-IV - TFI-IV
TFI-IV Part 2
Test 9
Ignition Coil Supply Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
245
TFI-IV Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
246
TFI-IV Part 2
Test 11
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose,
or broken conditions.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
247
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00003.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to shorting bar type connector used to set base timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition refer to Intermittent Diagnosis.
Functional Schematic
TFI-IV
Closed Bowl
Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For
detailed information, refer to the vehicle wiring diagram.
Ignition Coil Secondary Voltage - Crank Mode
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
248
TFI-IV
Closed Bowl
Distributor Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
249
Ignition Coil Secondary
Voltage - Run Mode TFI-IV
Closed Bowl
Distributor Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
250
TFI-IV
Closed Bowl
Distributor Part 2
Test 3
Stator
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
251
TFI-IV
Closed Bowl
Distributor Part 2
Test 4, 5 & 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
252
Stator TFI-IV
Closed Bowl
Distributor Part 2
Test 5
Stator TFI-IV
Closed Bowl
Distributor Part 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
253
Test 6
TFI Module
TFI-IV
Closed Bowl
Distributor Part 2
Test 7
Ignition Coil, Primary & Secondary
Ignition Coil Primary Resistance TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
254
Closed Bowl
Distributor Part 2
Test 8
Ignition Coil Secondary
Resistance
TFI-IV
Closed Bowl
Distributor Part 2
Test 9
EEC IV - Wiring
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
255
TFI-IV
Closed Bowl
Distributor Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
256
TFI IV
Closed Bowl
Distributor Part 2
Test 11
Ignition Coil, TFI & Stator Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
257
Ignition Coil Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 12
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
258
TFI Supply Voltage TFI-IV
Closed Bowl
Distributor Part 2
Test 13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
259
Stator Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 14
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page
260
TFI IV
Closed Bowl
Distributor Part 2
Test 15
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 261
Ignition Control Module: Locations
The distributor is located on the top of the engine towards the front, The TFI ignition module is
attached to the distributor base.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 262
Ignition Control Module: Description and Operation
Typical Ignition System
The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic
pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short
period of time. High voltage is created each time the magnetic field is built up and collapsed. The
red ignition module wire provides operating voltage for the module's electronic components in the
Run mode. The white module wire and start bypass provide increased voltage for the module and
coil during Start mode.
Ignition Modules
Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control
signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the
Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this
second signal, the UIM provides additional spark timing control for certain operating conditions by
shutting off the ignition coil current flow at a different time than with just the distributor pick-up
signal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 263
Module Identification Chart
For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura
Spark II has 6 wire connector while Dura Spark III has a 5 wire connector.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 264
Ignition Control Module: Service and Repair
Open Bowl Distributor
1. Remove distributor cap and adapter. Position cap and wires aside.
2. Disconnect TFI wiring.
3. Remove distributor from engine using tool T82L-12270-A or equivalent to remove security-type
hold-down bolt, if equipped.
4. Place distributor on workbench and remove 2 TFI module screws, Fig. 2.
5. Pull right side of module down distributor mounting flange and then back up to disengage
module terminals from connector in distributor base. Module may then be pulled toward flange and
away from distributor. Do not attempt to lift module from mounting surface before moving entire TFI
module toward distributor flange, as pins at distributor/module connector will break otherwise.
6. Coat metal base plate of TFI ignition module with 1/32 inch thick layer of silicone grease
D7AZ-19A331-A, or equivalent.
7. Place TFI module on distributor base mounting flange. Carefully position TFI module assembly
toward distributor bowl and securely engage 3 distributor connector pins.
8. Install 2 TFI module mounting screws and torque to 9---35 inch lbs.
9. Install distributor on engine.
10. Install distributor cap and adapter.
11. Connect TFI wiring.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 265
12. Check and, if necessary adjust engine timing according to decal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
RH Fender Apron
On RH Front Fender Or Radiator Support
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations
Power Window Relay: Locations
Lower LH Cowl, Near Fuse Block
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Relay > Component Information > Diagrams > Diagram Information and Instructions
Windshield Washer Relay: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 279
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 280
Windshield Washer Relay: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 281
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Locations
Wiper Control Module: Locations
Upper LH Side Of I/P
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Diagram Information and Instructions
Wiper Relay: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 289
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 290
Wiper Relay: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 291
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Radio
Power Boost Switch > Component Information > Locations
Radio Power Boost Switch: Locations
Attached To RH Cowl
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Pressure Sensor/Switch > Component Information > Locations
Brake Fluid Pressure Sensor/Switch: Locations
On LH Frame At No. 2 Crossmember
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
Top Of Parking Brake Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations
Wheel Speed Sensor: Locations
At Rear Axle
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications
TEMPERATURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Coolant Temperature Sensor
Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor
Near Front Of Valve Cover
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Coolant Temperature Sensor > Page 314
Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Switch (For
Computer)
RH Side Of V8-302/5.
Top Forward RH Side Of Engine, Under Water Outlet
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Page 315
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Fig. 7 Engine coolant temperature (ECT) sensor
The ECT, Fig. 7, sensor detects the temperature of engine coolant and supplies information to the
ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine
control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture.
On models with an electronic instrument cluster, the ECT output is used to control the coolant
temperature indicator.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information >
Specifications
Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations
Temperature Sensor (Gauge): Locations
LH Side Of V8-460/7.
LH Front Of Engine
Applicable to: 5L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Testing and Inspection
Brake Switch (Cruise Control): Testing and Inspection
Perform this test only when brake application will not disconnect the speed control system.
1. Check operation of stop lamps by applying approximately 6 lbs. of pressure to brake pedal. If
more than 6 lbs. is required, check brake pedal actuation and stop lamp switch.
2. If stop lamps do not function properly, check bulbs, circuit fuse or stop lamp switch.
3. If stop lamps function properly, check for battery voltage at 6 way connector using black wire
w/green stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 series, or white wire
w/pink stripe on 1981-82 F-100-350 and Bronco series, or white wire w/purple stripe on 1983
F-100-350, Bronco and Ranger, 1984-87 F-150-350, Ranger, 1984-87 Bronco II and 1986-87
Aerostar.
4. Depress brake pedal until stop lamps are illuminated. Check voltage at red wire w/black stripe on
1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 models, or the light green wire on
1981-83 F-100-350 and Bronco, 1984-87 F-150-350 and Bronco, 1983-87 Ranger, 1984-87 Bronco
II and 1986-87 Aerostar. The difference between the two voltage readings must not exceed 1.5
volts. If voltage is greater, a high resistance exists in the circuit and must be found and corrected.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Service and Repair
Clutch Switch: Service and Repair
1. Remove bracket mounting screw(s).
2. Disconnect electrical connector and remove switch and bracket assembly.
3. Remove switch from bracket.
4. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Locations
Cruise Control Switch: Locations
Part Of Steering Wheel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions
Cruise Control Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 334
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 335
Cruise Control Switch: Electrical Diagrams
Fig. 38 Horn & Speed Control Wiring Circuit (Part 1 of 2)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 336
Fig. 38 Horn & Speed Control Wiring Circuit (Part 2 of 2)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Page 337
Cruise Control Switch: Testing and Inspection
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986 Aerostar Disconnect 6 way
connector from control switch at the amplifier, then perform the following checks:
1. Connect a voltmeter between light blue-black hash lead and ground, then depress the ``On''
button and check for battery voltage.
2. Turn ignition ``Off,'' then connect an ohmmeter between light blue-black hash lead and ground.
3. Rotate steering wheel throughout its full range while making the following checks:
a. Depress ``Off'' button and check for a reading of 0-1 ohm. b. Depress ``Set'' button and check for
a reading of 646-714 ohms. c. Depress and hold ``Coast'' switch and check for a reading of
114-126 ohms. d. On models with ``Resume,'' depress and hold ``Resume'' switch and check for a
reading of approximately 2200 ohms.
4. If resistance values are not as specified, inspect wiring, slip rings, turn signal copper brushes,
speed control switch and steering column for proper ground. Check for proper ground by
connecting an ohmmeter between upper steering column flange and a suitable ground. Resistance
should be less then 1/2 ohm. Rotate steering wheel throughout its full range and ensure flexible
coupling has a resistance of less than 1 ohm.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Page 338
Cruise Control Switch: Service and Repair
1. Remove steering wheel pad attaching screws from behind steering wheel.
2. While pulling pad away from steering wheel, disconnect horn and speed control wire connectors
and remove pad.
3. Remove retaining nuts securing the speed control switches and trim plate retainer to the steering
wheel pad.
4. Disconnect wiring connector on rear of steering wheel pad assembly, then remove switch and
trim retainer assembly.
5. Remove speed control switches by snapping out of plastic retainer.
6. To remove the ground brush, remove steering wheel for access.
7. Snap the ground brush assembly out of the turn signal switch.
8. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Testing and Inspection
Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark
green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and
Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and
1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40
ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading
indicates an open coil.
2. Replace sensor if a correct reading has not been obtained.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations
Oil Pressure Sender: Locations
LH Side Of V8-460/7.
Top Center Rear Of Engine
Applicable to: 5L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations > Auxiliary Blower Switch
Blower Motor Switch: Locations Auxiliary Blower Switch
Behind Heater Control Assembly
RH Side Of Control Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Locations > Auxiliary Blower Switch > Page 351
Blower Motor Switch: Locations Front Blower Switch
LH Side Of Control Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Locations
Evaporator Temperature Sensor / Switch: Locations
A/C EVAPORATOR DE-ICING SWITCH
RH Dash Panel
RH Dash Panel Attached To Evaporator
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Service and Repair > Cycling Clutch Switch Replace
Refrigerant Pressure Sensor / Switch: Service and Repair Cycling Clutch Switch Replace
The clutch cycling pressure switch is mounted on a schrader type fitting on the accumulator.
Replacement of switch does not require discharge of refrigerant from system.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Service and Repair > Cycling Clutch Switch Replace > Page 359
Refrigerant Pressure Sensor / Switch: Service and Repair HR-980
The clutch cycling pressure switch is mounted on a schrader type fitting on the accumulator.
Replacement of switch does not require discharge of refrigerant from system.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations
Door Switch: Locations
Inside Doors
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Fuel Tank Sending Unit - Connector Replacement
Fuel Gauge Sender: Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement
FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT
WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT
Article No. 89-14-6
FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO,
THUNDERBIRD 1986-89 TAURUS
LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX
1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE
LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER
Figure 1
ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire
harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire
harness and cutting off the connector.
ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the
following procedure for service details.
1. Disconnect the battery ground.
2. Cut the connector from the new harness.
3. Leave 6-8 inches of wiring lead on the connector.
4. Remove the old connector from the fuel tank sending unit.
5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector.
6. Match the wire colors.
7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1.
8. Using a heat gun, seal the splice.
CAUTION: DO NOT USE AN OPEN FLAME.
9. Connect the battery ground.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Fuel Tank Sending Unit - Connector Replacement > Page 368
10. Check the operation of the fuel gauge.
PART NUMBER PART NAME CLASS
E9FZ-9A400-A Wire Harness - Fuel Pump C
OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2300, 2310, 2400, 2770, 4500
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Fuel Tank Sending Unit - Connector Replacement > Page 369
Fuel Gauge Sender: Technical Service Bulletins Fuel Sender - Auxiliary Port Rubber Cap
Replacement
Article No. FUEL SYSTEM - 5.8L/7.5L - FUEL SENDER
87-7-26 AUXILIARY PORT - SERVICE REPLACEMENT RUBBER PORT CAP
LIGHT TRUCK: 1983-87 E-350
ISSUE: Recreational vehicles with cut away chassis are equipped with an auxiliary fuel port on the
fuel gauge sending unit of the aft fuel tank. The port is provided as a fuel source for a generator set
or other gasoline-powered accessories. When the auxiliary port is not used, it is covered with a
rubber port cap and clamped.
ACTION: If the rubber port cap requires replacement, use a new type service part EOPZ-9G270-A
(color coded with red paint). Be sure cap is securely clamped.
PART NUMBER PART NAME CLASS
EOPZ-9G270-A Port Cap C
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Locations > Auxiliary Tank Fuel Gauge Sender
Fuel Gauge Sender: Locations Auxiliary Tank Fuel Gauge Sender
Attached To Rear Fuel Tank
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Locations > Auxiliary Tank Fuel Gauge Sender > Page 372
Fuel Gauge Sender: Locations Fuel Gauge Sender
Attached To Main Or Front Fuel Tank
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
Top Of Parking Brake Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Turbo Boost Gauge
Sending Unit > Component Information > Locations
Turbo Boost Gauge Sending Unit: Locations
LH Side Of Diesel Engine
Front LH Side Of Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Manual Transmission
Backup Lamp Switch: Locations Manual Transmission
Rear Of V8-302/5.
Attached To Shifter Assembly
Applicable to: 0L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Manual Transmission > Page 384
Backup Lamp Switch: Locations 3-Speed Manual Transmission
Attached To Transmission Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Brake Light Switch: Locations
Top Of Brake Support
Top Of Brake Pedal Support
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 388
Brake Light Switch: Service and Repair
Fig. 6 Stop light switch replacement. Exc. 1980---83 E-100 w/manual brakes.
Fig. 7 Stop light switch replacement. 1980---83 E-100 w/manual brakes
1. Disconnect battery ground cable.
2. Disconnect electrical connector from switch, Figs. 6 and 7.
3. Remove hairpin retainer, then slide stop light switch, pushrod, nylon washers and bushings away
from pedal and remove the switch from vehicle.
4. Reverse procedure to install. Ensure stop light switch wires are of sufficient length to allow full
travel of the brake pedal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations
Door Switch: Locations
Inside Doors
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Locations
Hazard Warning Switch: Locations
Upper LH Side Of Steering Column
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Diagram Information and Instructions
Hazard Warning Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 397
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 398
Fig. 35 Hazard Lights Wiring Circuit. With Stop & Turn Signals
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Locations
Headlamp Dimmer Switch: Locations
LH Floor Board
LH Floor Board
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Diagram Information and Instructions
Headlamp Dimmer Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 404
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 405
Fig. 36 Headlamps Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations
Headlamp Switch: Locations
Behind LH Side Of I/P
I/P Left Of Steering Column
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions
Headlamp Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 411
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 412
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 413
Headlamp Switch: Electrical Diagrams
Fig. 36 Headlamps Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 414
Headlamp Switch: Testing and Inspection
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 415
Headlamp Switch: Service and Repair
Fig. 5 Light Switch
E-100---350
1. Disconnect battery ground cable.
2. Remove knob and shaft assembly by depressing release button on switch housing and pulling
straight out.
3. Remove bezel or mounting nut from switch, Fig. 4.
4. Disconnect electrical connector from switch and remove switch from vehicle.
5. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
Turn Signal Switch: Locations
Upper LH Side Of Steering Column
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Diagram Information and Instructions
Turn Signal Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 421
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 422
Fig. 35 Hazard Lights Wiring Circuit. With Stop & Turn Signals
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 423
Turn Signal Switch: Service and Repair
1. Disconnect battery ground cable.
2. Remove horn switch, then the steering wheel.
3. Remove turn signal switch lever by unscrewing from steering column.
4. On 1981---87 F-100---350 and Bronco models, remove lower steering column shroud.
5. On 1981---87 E-100---350 models, remove upper and lower steering column shrouds.
6. On all models, disconnect electrical connector from turn signal switch and remove switch
attaching screws.
7. On all models with tilt column and 1980 E-100---350, F-100---350 and Bronco with fixed column,
remove wires and terminals from steering column electrical connector, after noting color code and
location of each connector. Remove plastic cover sleeve, if equipped, from wiring harness, then lift
switch assembly out through top of column. On 1981---87 E-100---350 models equipped with tilt
column and automatic transmission, disconnect transmission selector indicator light electrical
connector from turn signal switch harness prior to removing the switch.
8. On all models with fixed column, except 1980 E-100---350, F-100---350 and Bronco, remove
switch assembly by lifting out of column while guiding connector plug through opening in shift
socket. On 1981---87 E-100---350 models equipped with fixed column and automatic transmission,
remove transmission selector indicator light assembly with turn signal switch.
9. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation
Air Flow Meter/Sensor: Description and Operation
The vane air flow meter measures air flowing into the engine and is mounted between the air
cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a
potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and
potentiometer. The potentiometer relays vane position information to the EEC-IV module. The
EEC-IV module, then translates vane position information into the amount of air flowing into the
engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor
constantly monitors air temperature entering the engine and also transmits the information to the
EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature
information and adjusts the fuel flow to obtain the optimum air/fuel mixture required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service
Bulletins > MAP and BAP Sensor - Application Chart
Barometric Pressure Sensor: Technical Service Bulletins MAP and BAP Sensor - Application Chart
Article No. 89-1-12
^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART
^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS
FORD: 1984-87 ALL CARLINES
LINCOLN-MERCURY: 1984-89 ALL CARLINES
LIGHT TRUCK: 1984-89 ALL TRUCKLINES
This article is being republished in its entirety to include the MAP sensor application for the 2.3L
HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine.
ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L
HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP
and BAP sensor application chart has been assembled to assist technicians in making sure the
correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy,
erratic engine idle or hesitation on acceleration may result.
ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the
correct service part applications.
NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF
THE FORD PARTS CATALOG.
LIGHT TRUCK MAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE
1984-86 2.3L OHC All E6TZ-9F479-A MAP
1986-87 3.0L EFI All E6FZ-9F479-A MAP
1988-89 3.0L EFI All E7FZ-9F479-A MAP
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
4.9L EFI 5.0L EFI 7.5L EFI
1988-89 5.8L EFI All E7FZ-9F479-A MAP
PASSENGER CAR MAP AND BAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE
1984-89 1.6L EFI All E7FZ-12A644-A BAP
1.9L EFI 2.3L Turbo
1989 3.0 "SHO" All E7FZ-12A644-A BAP
1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP
(Mustang)
1989 5.0L Mass Air All E8FZ-12A644-A BAP
1984 2.3L HSC FBC All E6PZ-9F479-A MAP
1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP
2.5L HSC CFI
1984-85 3.8L CFI All E5SZ-9F479-A MAP
1984-85 5.0L CFI All E6TZ-9F479-A MAP
1986 2.3L OHC All E6FZ-9F479-A MAP
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service
Bulletins > MAP and BAP Sensor - Application Chart > Page 433
3.0L EFI 3.8L CFI 5.0 SEFI
1984-85 2.3L OHC All E6FZ-9F479-A MAP
1987-89 1.9L CFI All E7DZ-9F479-A MAP
2.3L HSC CFI 2.5L HSC CFI
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI
PART NUMBER PART NAME CLASS
E7FZ-12A644-A BAP Sensor B
E8FZ-12A644-A BAP Sensor B
E6PZ-9F479-A MAP Sensor B
E5SZ-9F479-A MAP Sensor AM
E6TZ-9F479-A MAP Sensor BM
E6FZ-9F479-A MAP Sensor B
E7DZ-9F479-A MAP Sensor B
E7FZ-9F479-A MAP Sensor B
OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 620800, 631900, 640200
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service
Bulletins > Page 434
MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service
Bulletins > Page 435
Barometric Pressure Sensor: Locations
LH Side Of Dash Panel
Inside Of LH Front Fender, Near Ignition Module Or RH Fender Apron At Wheelwell
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and
Operation
Barometric Pressure Switch: Description and Operation
Fig. 19 Ignition barometric pressure switch. 1984-87
1984---87 This switch, Fig. 19, controls spark timing and/or other electrical devices according to
barometric pressure changes. Calibration resistors in the switch assembly cause the ignition
module to vary the spark timing. Spark timing is advanced for vehicle operation above a
predetermined altitude and retarded for vehicle operation below a predetermined altitude. Some
switch assemblies control both spark timing and another device while other switch assemblies
control only one or the other.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and
Inspection > Component Testing
Barometric Pressure Switch: Testing and Inspection Component Testing
Fig. 43 Ignition barometric pressure switch resistance chart. 1985---87
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values
in chart.
3. Replace switch if resistance is not within specifications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
TEMPERATURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Coolant Temperature Sensor
Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor
Near Front Of Valve Cover
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Coolant Temperature Sensor > Page 446
Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Switch (For
Computer)
RH Side Of V8-302/5.
Top Forward RH Side Of Engine, Under Water Outlet
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 447
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Fig. 7 Engine coolant temperature (ECT) sensor
The ECT, Fig. 7, sensor detects the temperature of engine coolant and supplies information to the
ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine
control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture.
On models with an electronic instrument cluster, the ECT output is used to control the coolant
temperature indicator.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision
Technical Service Bulletin # 8918A9 Date: 890915
EVP Sensor - Manual Revision
ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR
VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED
Article No. 89-18A-9
FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG,
TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE
LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS
1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89
SABLE 1987-89 TRACER
MERKUR: 1986-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER
1986-89 AEROSTAR
ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine
Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit
internal wear problems that can cause driveability symptoms and display a Continuous Self-Test
Code 32. This is not associated to correcting the problem using the existing diagnostic procedures.
ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
680000
1985 Pinpoint Tests - DM - EGR, EVP and EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Bulletins > EVP Sensor - Manual Revision > Page 452
1985
EEC IV - Pinpoint Tests - All Vehicles 22-77
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test
1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 453
1985
22-78 EEC IV - Pinpoint Tests - All Vehicles
Neutral Drive Switch FA A/C Input PinpointTest
1986 (EGR) Systems Functional Diagnosis
1986
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 454
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1986 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 455
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1986 Quick Test: Continuous Self-Test 6.0
EEC IV - Quick Test - All Engines 18-13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 456
QUICK TEST: Continuous Self-Test 6.0
1986
18-14 EEC IV-Quick Test-All Engines
QUICK TEST: Continuous
Self-Test 6.0
Pinpoint Test - DN - EGR - EVP & EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 457
1986
EEC IV-Pinpoint Tests - All Vehicles 21-95
EGR Valve Position Sensor (EVP)
PinpointTest DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 458
21-96 1986 EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 459
EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 460
1986 21-97B
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR) Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 461
1986 EEC IV-Pinpoint Tests-All Vehicles
21-98
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
1987 (EGR) Systems - Functional Diagnosis
1987
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 462
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1987 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 463
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1987 Quick Test: Continuous Self-Test - 6.0
1987
EEC-IV Quick Test-All Engines 16-15
QUICK TEST: Continuous 6.0 Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Bulletins > EVP Sensor - Manual Revision > Page 464
16-16 1987 EEC-IV Quick Test-All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
1987
EEC IV - Pinpoint Tests - All Vehicles 19-91
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Bulletins > EVP Sensor - Manual Revision > Page 465
EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
19-92A 1987
EEC IV Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN
5.0L SEFI Passenger Car and 4.9L and 5.0L Truck
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Bulletins > EVP Sensor - Manual Revision > Page 466
1987
EEC IV-Pinpoint Tests-All Vehicles 19-92B
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Bulletins > EVP Sensor - Manual Revision > Page 467
1987 19-93-A
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 468
EEC IV-Pinpoint Tests-All Vehicles 1987 19-94
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1988
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Bulletins > EVP Sensor - Manual Revision > Page 469
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise,
replace the EGR valve.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
replace the EGR valve.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12
1988 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 2-1/2 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Bulletins > EVP Sensor - Manual Revision > Page 470
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
1988
EEC-IV - Quick Test - All Engines 16-15
QUICK TEST: Continuous
Self-Test 6.0
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Bulletins > EVP Sensor - Manual Revision > Page 471
1988 16-16
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
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Bulletins > EVP Sensor - Manual Revision > Page 472
EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
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19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
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1988
EEC-IV - Pinpoint Tests - All Vehicles 19-102A
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
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1988
19-103 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
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Bulletins > EVP Sensor - Manual Revision > Page 476
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-104
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1989
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
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Bulletins > EVP Sensor - Manual Revision > Page 477
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for
vacuum leak at EGR valve, replace the valve.
^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
check for contamination, clean the valve.
^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1989
6-12 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at
normal operating temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 1.0 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
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4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur:
^ Engine does not stall
^ Idle speed does not drop more than 100 rpm
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed
Then:
^ For vacuum leak at EGR valve, replace the valve.
^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or
equivalent.
^ Make sure there is no sand left in the valve.
^ Replace the EGR valve if necessary.
9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR
vacuum supply hose.
10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
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1989 EEC-IV - Quick Test - All Engines
14-17
QUICK TEST: Continuous 6.0 Self-Test
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1989 14-18
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
1989
EEC-IV - Quick Test - All Engines 14-19
QUICK TEST: Continuous 6.0 Self-Test
Quick Test:Diagnostic By Symptom - 7.0
1989
14-20 EEC-IV - Quick Test - All Engines
QUICK TEST: Diagnostic By Symptom 7.0
A DIAGNOSTIC BY SYMPTOM
SPECIAL NOTES:
^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous
Self-Tests before continuing with this test.
^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By
Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines.
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Bulletins > EVP Sensor - Manual Revision > Page 481
Pinpoint Test - DN - EGR - EVP & EVR
1989
EEC-IV - Pinpoint Tests-All Vehicles 17-133
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
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1989
17-134 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
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1989
EEC-IV-Pinpoint Tests - All Vehicles 17-134A
Pinpoint Test DN EGR Valve Position Sensor (EVP)
EGR Vacuum Regulator Solenoid (EVR)
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1989 17-135
EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
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1989
EEC-IV - Pinpoint Tests - All Vehicles 17-136A
EGR Valve Position Sensor (EVP)
04GPinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
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Bulletins > Page 486
EGR Valve Position Sensor: Locations
At Center Rear Of Carburetor
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications
TEMPERATURE SENSORS
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Page 490
Intake Air Temperature Sensor: Locations
LH Side Of V8-302/5.
Near Front Of RH Valve Cover
Applicable to: 0L Engine With EFI
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Page 491
Intake Air Temperature Sensor: Description and Operation
Fig. 2 Air charge temperature (ACT) sensor
This sensor, Fig. 2, provides the EFI system with air/fuel mixture temperature information. The air
charge temperature sensor is used both as a density corrector to air flow calculation and to
proportion the cold enrichment fuel flow. This sensor is similar in construction to the engine coolant
temperature sensor and is mounted on an intake manifold runner or on the air cleaner.
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Knock Sensor: Locations
LH Side Of V8-302/5.
Top Center Of Engine
Applicable to: 0L Engine With EFI
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Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
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Service Bulletins > MAP and BAP Sensor - Application Chart
Manifold Pressure/Vacuum Sensor: Technical Service Bulletins MAP and BAP Sensor - Application
Chart
Article No. 89-1-12
^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART
^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS
FORD: 1984-87 ALL CARLINES
LINCOLN-MERCURY: 1984-89 ALL CARLINES
LIGHT TRUCK: 1984-89 ALL TRUCKLINES
This article is being republished in its entirety to include the MAP sensor application for the 2.3L
HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine.
ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L
HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP
and BAP sensor application chart has been assembled to assist technicians in making sure the
correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy,
erratic engine idle or hesitation on acceleration may result.
ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the
correct service part applications.
NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF
THE FORD PARTS CATALOG.
LIGHT TRUCK MAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE
1984-86 2.3L OHC All E6TZ-9F479-A MAP
1986-87 3.0L EFI All E6FZ-9F479-A MAP
1988-89 3.0L EFI All E7FZ-9F479-A MAP
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
4.9L EFI 5.0L EFI 7.5L EFI
1988-89 5.8L EFI All E7FZ-9F479-A MAP
PASSENGER CAR MAP AND BAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE
1984-89 1.6L EFI All E7FZ-12A644-A BAP
1.9L EFI 2.3L Turbo
1989 3.0 "SHO" All E7FZ-12A644-A BAP
1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP
(Mustang)
1989 5.0L Mass Air All E8FZ-12A644-A BAP
1984 2.3L HSC FBC All E6PZ-9F479-A MAP
1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP
2.5L HSC CFI
1984-85 3.8L CFI All E5SZ-9F479-A MAP
1984-85 5.0L CFI All E6TZ-9F479-A MAP
1986 2.3L OHC All E6FZ-9F479-A MAP
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Service Bulletins > MAP and BAP Sensor - Application Chart > Page 500
3.0L EFI 3.8L CFI 5.0 SEFI
1984-85 2.3L OHC All E6FZ-9F479-A MAP
1987-89 1.9L CFI All E7DZ-9F479-A MAP
2.3L HSC CFI 2.5L HSC CFI
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI
PART NUMBER PART NAME CLASS
E7FZ-12A644-A BAP Sensor B
E8FZ-12A644-A BAP Sensor B
E6PZ-9F479-A MAP Sensor B
E5SZ-9F479-A MAP Sensor AM
E6TZ-9F479-A MAP Sensor BM
E6FZ-9F479-A MAP Sensor B
E7DZ-9F479-A MAP Sensor B
E7FZ-9F479-A MAP Sensor B
OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 620800, 631900, 640200
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Service Bulletins > Page 501
MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS
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Service Bulletins > Page 502
Manifold Pressure/Vacuum Sensor: Locations
RH Fender Apron With EEC
RH Fender Well
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Engine - Lack of Power/No Start Diagnosis
Oxygen Sensor: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
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NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
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Engine - Lack of Power/No Start Diagnosis > Page 508
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
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Engine - Lack of Power/No Start Diagnosis > Page 509
Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination
Article No. 93-23-6
11/10/93
^ EGO SENSORS - SILICONE CONTAMINATION
^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED
^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO)
SENSORS
FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO,
THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE
LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94
CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89
TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE,
F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94
VILLAGER
This TSB article is being republished in its entirety to update model applicability and to revise the
part number of the Low Volatility Sealant.
ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the
engine. Volatile silicones can migrate throughout the system during the first one hundred hours of
service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These
products are commonly sold in tubes and caulking-type cartridges.
ACTION: When service is performed on the engine, only use new low volatility silicone sealant
(F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required.
CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN
LOW VOLATILITY SILICONE SEALANT IS SPECIFIED.
PART NUMBER PART NAME CLASS
F1AZ-19662-A Low Volatility RTV Sealant B
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Engine - Lack of Power/No Start Diagnosis > Page 510
WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Page 511
Oxygen Sensor: Locations
RH Side Of 6-300/4.
RH Rear Of Engine
Applicable to: 9L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Page 512
Oxygen Sensor: Description and Operation
Fig. 8 Exhaust gas oxygen (EGO) sensor
The exhaust gas oxygen sensor supplies the ECA with a signal which indicates either a rich or lean
condition during engine operation. The sensor is threaded into the center of the exhaust manifold
on 4-140 and 6-300 engines, threaded into the rear of left and right exhaust manifold assemblies
on V6-171 engine or threaded into the rear right exhaust manifold assembly on V8-302 and 351
engine, Fig. 8.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations
Power Steering Pressure Switch: Locations
Upper LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Throttle Position Sensor - Application Chart
Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart
EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP
Article No. 89-16-4
FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO,
THUNDERBIRD
LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII,
SABLE, TOPAZ, TOWN CAR
LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES
ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to
assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely.
ACTION: Refer to one of the following TPS service replacement charts to make sure that the
correct service part is installed.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Throttle Position Sensor - Application Chart > Page 520
OASIS CODES: 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Throttle Position Sensor - Application Chart > Page 521
Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove
THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP
Article No. 89-14-7
FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT
1986-89 TAURUS
LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII,
TOPAZ, TOWN CAR 1984-87 LYNX
MERKUR: 1985-89 ALL MERKUR LINES
LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES
ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The
"Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove
a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians
think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting
with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw.
ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws,
technicians should always use a # 2 "Pozidrive" screwdriver.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
INFORMATION ONLY
OASIS CODES: 4800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications >
Electrical Specifications
THROTTLE POSITION SENSOR SPECIFICATIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications >
Electrical Specifications > Page 524
Throttle Position Sensor: Mechanical Specifications
IDLE SPEED Throttle Plate Stop Screw M/T.......................................................................................
......................................................................................625-675 rpm Throttle Plate Stop Screw A/T...
..............................................................................................................................................................
.............600-700 rpm
TORQUE VALUES
Air Bypass Valve To Lower Manifold....................................................................................................
...........................................70-100 in lb (8-11 N-m) Hose to Tank ......................................................
...................................................................................................................................25-35 in lb (3-4
N-m) Fuel Injector Manifold to Fuel Charging
Assembly...........................................................................................................................70-105 in lb
(8-12 N-m) Fuel Line Fittings................................................................................................................
................................................................10-15 ft lb (13-20 N-m) Fuel Pressure Regulator to Injector
Manifold......................................................................................................................................27-40
in lb (3-4.5 N-m) Retaining straps around Fuel Tank...........................................................................
..........................................................................22-30 in lb (30-41 N-m) Throttle Body to Upper
Intake Manifold.....................................................................................................................................
.......70-100 in lb (8-11 N-m) Throttle Position Sensor to Throttle
Body........................................................................................................................................11-16 in
lb (1.2-1.8 N-m) Upper Intake Manifold to Lower Intake Manifold
Bolts.....................................................................................................................12-18 ft lb (16-24
N-m)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page
525
Throttle Position Sensor: Locations
RH Side Of V8-351/5.
At Front Of Carburetor
Applicable to: 8L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > EEC-IV
Using Breakout Box
Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box
Throttle Position Sensor
NOTE: This procedure can be used to check and adjust level "C" sensor only.
1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle.
2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive
lead into test socket 47 and the negative lead into socket 46 of the breakout box.
3. Turn the ignition ON, but DO NOT start the vehicle.
4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP)
sensor mounting screws and rotate the sensor until the voltage falls within this range.
5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m).
6. While observing the DVOM, move the throttle through the entire range of motion. The reading
should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt.
7. If the TP sensor cannot be adjusted, replace the sensor.
8. Perform an EEC-IV quick test on the vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > EEC-IV
Using Breakout Box > Page 528
Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment
Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker,
as equipped. With engine not running, compare voltage reading against specifications and adjust
as needed.
Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and
connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust
TPS to specified value.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vacuum Switch > Component Information > Locations
Vacuum Switch: Locations
RH Fender Apron At Wheelwell
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications
VEHICLE SPEED SENSOR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 535
Vehicle Speed Sensor: Locations
At LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection >
Speed Control/Speedometer
Vehicle Speed Sensor: Testing and Inspection Speed Control/Speedometer
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark
green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and
Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and
1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40
ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading
indicates an open coil.
2. Replace sensor if a correct reading has not been obtained.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection >
Page 538
Vehicle Speed Sensor: Service and Repair
1. Separate electrical connector leading to the amplifier assembly.
2. Disconnect upper and lower speedometer cables at the speed sensor. Remove speed sensor.
3. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision
Technical Service Bulletin # 8918A9 Date: 890915
EVP Sensor - Manual Revision
ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR
VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED
Article No. 89-18A-9
FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG,
TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE
LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS
1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89
SABLE 1987-89 TRACER
MERKUR: 1986-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER
1986-89 AEROSTAR
ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine
Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit
internal wear problems that can cause driveability symptoms and display a Continuous Self-Test
Code 32. This is not associated to correcting the problem using the existing diagnostic procedures.
ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
680000
1985 Pinpoint Tests - DM - EGR, EVP and EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 544
1985
EEC IV - Pinpoint Tests - All Vehicles 22-77
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test
1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 545
1985
22-78 EEC IV - Pinpoint Tests - All Vehicles
Neutral Drive Switch FA A/C Input PinpointTest
1986 (EGR) Systems Functional Diagnosis
1986
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 546
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1986 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 547
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1986 Quick Test: Continuous Self-Test 6.0
EEC IV - Quick Test - All Engines 18-13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 548
QUICK TEST: Continuous Self-Test 6.0
1986
18-14 EEC IV-Quick Test-All Engines
QUICK TEST: Continuous
Self-Test 6.0
Pinpoint Test - DN - EGR - EVP & EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 549
1986
EEC IV-Pinpoint Tests - All Vehicles 21-95
EGR Valve Position Sensor (EVP)
PinpointTest DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 550
21-96 1986 EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 551
EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 552
1986 21-97B
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR) Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 553
1986 EEC IV-Pinpoint Tests-All Vehicles
21-98
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
1987 (EGR) Systems - Functional Diagnosis
1987
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 554
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1987 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 555
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1987 Quick Test: Continuous Self-Test - 6.0
1987
EEC-IV Quick Test-All Engines 16-15
QUICK TEST: Continuous 6.0 Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 556
16-16 1987 EEC-IV Quick Test-All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
1987
EEC IV - Pinpoint Tests - All Vehicles 19-91
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 557
EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
19-92A 1987
EEC IV Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN
5.0L SEFI Passenger Car and 4.9L and 5.0L Truck
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 558
1987
EEC IV-Pinpoint Tests-All Vehicles 19-92B
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 559
1987 19-93-A
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 560
EEC IV-Pinpoint Tests-All Vehicles 1987 19-94
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1988
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 561
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise,
replace the EGR valve.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
replace the EGR valve.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12
1988 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 2-1/2 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 562
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
1988
EEC-IV - Quick Test - All Engines 16-15
QUICK TEST: Continuous
Self-Test 6.0
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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> EVP Sensor - Manual Revision > Page 563
1988 16-16
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 564
EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 565
19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 566
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-102A
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 567
1988
19-103 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 568
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-104
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1989
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 569
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for
vacuum leak at EGR valve, replace the valve.
^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
check for contamination, clean the valve.
^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1989
6-12 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at
normal operating temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 1.0 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 570
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur:
^ Engine does not stall
^ Idle speed does not drop more than 100 rpm
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed
Then:
^ For vacuum leak at EGR valve, replace the valve.
^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or
equivalent.
^ Make sure there is no sand left in the valve.
^ Replace the EGR valve if necessary.
9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR
vacuum supply hose.
10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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> EVP Sensor - Manual Revision > Page 571
1989 EEC-IV - Quick Test - All Engines
14-17
QUICK TEST: Continuous 6.0 Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 572
1989 14-18
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
1989
EEC-IV - Quick Test - All Engines 14-19
QUICK TEST: Continuous 6.0 Self-Test
Quick Test:Diagnostic By Symptom - 7.0
1989
14-20 EEC-IV - Quick Test - All Engines
QUICK TEST: Diagnostic By Symptom 7.0
A DIAGNOSTIC BY SYMPTOM
SPECIAL NOTES:
^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous
Self-Tests before continuing with this test.
^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By
Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 573
Pinpoint Test - DN - EGR - EVP & EVR
1989
EEC-IV - Pinpoint Tests-All Vehicles 17-133
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 574
1989
17-134 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 575
1989
EEC-IV-Pinpoint Tests - All Vehicles 17-134A
Pinpoint Test DN EGR Valve Position Sensor (EVP)
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 576
1989 17-135
EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 577
1989
EEC-IV - Pinpoint Tests - All Vehicles 17-136A
EGR Valve Position Sensor (EVP)
04GPinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> Page 578
EGR Valve Position Sensor: Locations
At Center Rear Of Carburetor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Description and Operation
Air Flow Meter/Sensor: Description and Operation
The vane air flow meter measures air flowing into the engine and is mounted between the air
cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a
potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and
potentiometer. The potentiometer relays vane position information to the EEC-IV module. The
EEC-IV module, then translates vane position information into the amount of air flowing into the
engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor
constantly monitors air temperature entering the engine and also transmits the information to the
EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature
information and adjusts the fuel flow to obtain the optimum air/fuel mixture required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations
Fuel Tank Selector Switch: Locations
LH Side Of Instrument Panel Near Fuse Block
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions
Fuel Tank Selector Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 588
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 589
Fuel Tank Selector Switch: Electrical Diagrams
Fig. 28 Fuel Tank Selector Wiring Circuit. V8-351/5.8L Fuel Injected & V8-460/7.5L Non Hot Fuel
Handling
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 590
Fig. 26 Fuel Tank Selector Wiring Circuit. V8-302/5.0L & V8-460/7.5L Hot Fuel Handling
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 591
Fig. 29 Fuel Tank Selector Wiring Circuit. V8-460/7.5L Hot Fuel Cutaway
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Inertia Fuel Shutoff Switch: Locations
The inertia switch is located on the passenger side cowl panel, just forward of the right front door.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Throttle Position Sensor - Application Chart
Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart
EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP
Article No. 89-16-4
FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO,
THUNDERBIRD
LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII,
SABLE, TOPAZ, TOWN CAR
LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES
ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to
assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely.
ACTION: Refer to one of the following TPS service replacement charts to make sure that the
correct service part is installed.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Throttle Position Sensor - Application Chart > Page 599
OASIS CODES: 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Throttle Position Sensor - Application Chart > Page 600
Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove
THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP
Article No. 89-14-7
FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT
1986-89 TAURUS
LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII,
TOPAZ, TOWN CAR 1984-87 LYNX
MERKUR: 1985-89 ALL MERKUR LINES
LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES
ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The
"Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove
a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians
think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting
with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw.
ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws,
technicians should always use a # 2 "Pozidrive" screwdriver.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
INFORMATION ONLY
OASIS CODES: 4800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical
Specifications
THROTTLE POSITION SENSOR SPECIFICATIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Specifications > Page 603
Throttle Position Sensor: Mechanical Specifications
IDLE SPEED Throttle Plate Stop Screw M/T.......................................................................................
......................................................................................625-675 rpm Throttle Plate Stop Screw A/T...
..............................................................................................................................................................
.............600-700 rpm
TORQUE VALUES
Air Bypass Valve To Lower Manifold....................................................................................................
...........................................70-100 in lb (8-11 N-m) Hose to Tank ......................................................
...................................................................................................................................25-35 in lb (3-4
N-m) Fuel Injector Manifold to Fuel Charging
Assembly...........................................................................................................................70-105 in lb
(8-12 N-m) Fuel Line Fittings................................................................................................................
................................................................10-15 ft lb (13-20 N-m) Fuel Pressure Regulator to Injector
Manifold......................................................................................................................................27-40
in lb (3-4.5 N-m) Retaining straps around Fuel Tank...........................................................................
..........................................................................22-30 in lb (30-41 N-m) Throttle Body to Upper
Intake Manifold.....................................................................................................................................
.......70-100 in lb (8-11 N-m) Throttle Position Sensor to Throttle
Body........................................................................................................................................11-16 in
lb (1.2-1.8 N-m) Upper Intake Manifold to Lower Intake Manifold
Bolts.....................................................................................................................12-18 ft lb (16-24
N-m)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Throttle Position Sensor: Locations
RH Side Of V8-351/5.
At Front Of Carburetor
Applicable to: 8L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
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Using Breakout Box
Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box
Throttle Position Sensor
NOTE: This procedure can be used to check and adjust level "C" sensor only.
1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle.
2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive
lead into test socket 47 and the negative lead into socket 46 of the breakout box.
3. Turn the ignition ON, but DO NOT start the vehicle.
4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP)
sensor mounting screws and rotate the sensor until the voltage falls within this range.
5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m).
6. While observing the DVOM, move the throttle through the entire range of motion. The reading
should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt.
7. If the TP sensor cannot be adjusted, replace the sensor.
8. Perform an EEC-IV quick test on the vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Using Breakout Box > Page 607
Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment
Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker,
as equipped. With engine not running, compare voltage reading against specifications and adjust
as needed.
Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and
connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust
TPS to specified value.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation
Hall Effect Sensor: Description and Operation
Profile Ignition Pickup
The PIP signal is created in the Hall Effect and Stator assembly and indicates crankshaft position
and engine RPM Fig. 21. The PIP signal is fed to both the TFI module and the ECA.
PIP Sensor
COMPONENTS The Hall Effect device is made up of a voltage regulator, a Hall voltage generator,
Darlington amplifier, Schmitt trigger, and an open collector output stage integrated in a single
monolithic silicon chip Fig. 22. A signal is produced when a ferrous material is passed through the
opening and the flux lines decrease. The Hall generator (Hall device) sends a sine wave signal to
the Darlington amplifier. The Darlington amplifier inverts the signal. When the signal is low the
output is high. When the signal is high the output is low. This output then goes to the Schmitt
trigger. The Schmitt trigger shapes the signal into a square wave (digital high) signal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 612
PIP Signal Operation
OPERATION The output signal to the Darlington amplifier is high when the window (on the
armature) allows the magnetic field to reach the Hall device (switch off) Fig. 23. When the TAB
shunts the magnetic field (closes) away from the Hall device the signal is low to the Darlington
amplifier (switch on).
Hall Effect Sensor
In other words when one of the windows or openings is in the gap between the Hall device and the
permanent magnet, the field stays strong and the voltage is high since the magnetic path is
complete from the magnet, through the Hall device, and back to the magnet. In this case the switch
is off and the Hall Effect does not send a signal. When the TAB enters the gap, the armature cuts
off the magnetic path to the Hall device and its voltage drops. In this case the switch is on and the
Hall Effect device sends a signal. The signal is switched On and Off as long as the armature is
rotating (distributor is turning) and opening and closing the magnetic path. This is the signal used
by the ECA to interpret crankshaft position and engine RPM. The signal can also be used by the
TFI module if the SPOUT signal from the ECA is lost.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 613
Signature PIP
SIGNATURE PIP Some Electronic Engine Control (EEC) vehicles are equipped with a signature
profile ignition pickup signal. The regular type armature used for the PIP signal has the same size
tabs and windows. In a signature PIP signal armature, one of the tabs is narrower than the others
Fig. 25. The narrower tab provides a different signal to the ECA when it passes through the Hall
Effect switch. When the ECA sees the narrow tab it knows when to properly pulse the fuel injectors.
This system is used on cars and trucks where the ECA needs to know when to pulse certain
injectors. For example, on sequential electronic fuel injection (SEFI) systems, each injector is
pulsed to coincide with its intake valve opening. With the signature PIP, the ECA knows when the
No. 1 cylinder needs to be supplied with fuel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page 614
Hall Effect Sensor: Service and Repair
Removal Do not attempt to replace stator without an arbor press.
1. Remove distributor. Remove rotor, then the TFI module.
2. If distributor uses push on type rotor, remove two retaining screws holding armature, then the
armature. Hold gear to loosen armature screws, do not hold armature.
3. Mark stator, armature, gear and collar with felt tip pen to aid in reassembly.
4. Remove and discard pins in gear and collar if equipped.
5. Invert distributor and place in Axle Bearing Seal Plate and press off gear using Bearing Removal
Tool.
6. Deburr and polish shaft with emery paper and wipe clean so that shaft slides out freely from
distributor base.
7. Remove shaft assembly, then the thrust washer from shaft. Next remove octane rod.
8. Remove stator assembly screws, then the stator assembly from top of bowl.
9. Inspect base bushing for wear of signs of excess heat concentration, replace distributor
assembly if damaged.
10. Inspect base O-ring for cuts or damage and replace as necessary.
11. Inspect base for cracks and wear, replace distributor assembly if damage is found.
Installation
1. Place stator assembly over bushing and press down to seat.
2. Place stator connector in position, tab should fit in notch on base with fastening eyelets aligned
with screw holes.
3. Install stator screws and Torque to 15-35 inch lbs. Next install octane rod.
4. Install thrust washer on top of bushing, then apply lubricant to distributor shaft below armature.
Do not over lubricate.
5. Insert shaft through base bushing, then place collar, if equipped, over shaft and line up mark on
armature and collar to aid alignment with original drill hole. Use a suitable drift punch to assure
proper alignment.
6. Drill holes through shaft and collar should align on both sides of shaft. If holes do not align, collar
may be 180 degrees out of alignment on shaft. Rotate collar on shaft one half rotation, then check.
7. Insert new roll pin through collar and shaft, pin should be flush with both sides of collar when
seated.
8. If distributor uses push on type rotor, place a 1/2 inch deep well socket over shaft, invert and
place on arbor plate.
9. If distributor uses screw down type rotor, invert and place on arbor plate.
10. Place distributor gear on shaft and line up marks on armature and gear. Hole in shaft and gear
must line up as accurately as possible to assure ease of roll pin insertion.
11. Place a 5/8 inch deep well socket over shaft and gear, then press gear to align with original drill
hole.
12. If gear holes do not align, gear must be removed and repressed on. Drift punch will not align
holes, as in collar, holes should align.
13. Insert new roll pin through gear and shaft, pin should extrude evenly on both sides.
14. Install armature, if removed, and Torque screws to 25-35 inch lbs.
15. Install TFI module, rotor, then distributor.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Doors and Ignition - Lock Service Tips
Ignition Switch Lock Cylinder: Technical Service Bulletins Doors and Ignition - Lock Service Tips
Article No. 87-24-2
12/04/87
LOCKS - DOORS AND IGNITION - GENERAL LOCK SERVICE TIPS
FORD: 1987-88 ESCORT/EXP, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, CROWN
VICTORIA
LINCOLN-MERCURY: 1987 LYNX 1987-88 TOPAZ, SABLE, COUGAR, GRAND MARQUIS,
MARK VII, CONTINENTAL, LINCOLN TOWN CAR
LIGHT TRUCK: 1987-88 AEROSTAR, RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO
ISSUE: Two types of key systems are used on Ford vehicles. The five (5) bit key system uses one
(1) key to operate the ignition lock and a second to operate the outside door locks. The ten (10) bit
key system uses one (1) key to operate the ignition lock and the outside door locks. The ten (10) bit
key system services the ignition lock as a separate service part so the door locks would not have to
be replaced in the event of an ignition lock failure.
ACTION: If service is required for the five (5) bit key system, the ignition and door locks are
serviced separately. Refer to the appropriate Shop Manual for removal and installation procedures.
If service is required for the ten (10) bit key system, a ten (10) bit ignition lock with partially cut keys
is available. Refer to the following service procedure.
NOTE:
Customers concerned with the heads of the new ten (10) bit ignition service keys not matching the
original keys may be resolved by ordering blank keys from Rotunda. Cut the two (2) blank keys
ordered from Rotunda on tumbler station numbers 1, 2, 3, 4, and 6 to match the new ten (10) bit
ignition service keys supplied with the new service ignition lock.
1. Remove the ignition lock cylinder. Refer to the appropriate Shop Manual.
FIGURE 2
2. Using the Ford Rotunda key code cutting package, tool number 011-00003, measure the depth
of the cut on the number six (6) tumbler station of the original key. Use this measurement to
determine the correct service ignition lock set. Refer to the chart in Figure 2.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Doors and Ignition - Lock Service Tips > Page 620
3. Using the original ignition key, decode tumbler station numbers 5, 7, 8, 9, and 10.
4. Cut the new service key on tumbler station numbers 5, 7, 8, 9, and 10.
5. Check the operation of the new service key in the new ignition lock and outside door locks.
6. Install the new service ignition lock.
NOTE:
Retain both the original and new service key tabs for future key code identification.
OTHER APPLICABLE ARTICLES: 86-23-4
WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
LH Side Of V8-302/5.
Top Center Of Engine
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 624
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations
Seat Belt Buckle Switch: Locations
Part Of Driver`s Seatbelt
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Locations
Clutch Switch: Locations
LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Locations > Page 633
Clutch Switch: Testing and Inspection
Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized
tools near this switch.
1. If the switch is open when the clutch pedal is released, speed control will not operate. This must
be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher
when performing the clutch switch test.
2. Disconnect switch pigtail connector from speed control harness connector and connect an
ohmmeter to the two switch connector terminals.
3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With
clutch pedal fully depressed, the circuit should be open.
4. If switch does not function as described, remove and replace switch.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Doors and Ignition - Lock Service
Tips
Ignition Switch Lock Cylinder: Technical Service Bulletins Doors and Ignition - Lock Service Tips
Article No. 87-24-2
12/04/87
LOCKS - DOORS AND IGNITION - GENERAL LOCK SERVICE TIPS
FORD: 1987-88 ESCORT/EXP, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, CROWN
VICTORIA
LINCOLN-MERCURY: 1987 LYNX 1987-88 TOPAZ, SABLE, COUGAR, GRAND MARQUIS,
MARK VII, CONTINENTAL, LINCOLN TOWN CAR
LIGHT TRUCK: 1987-88 AEROSTAR, RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO
ISSUE: Two types of key systems are used on Ford vehicles. The five (5) bit key system uses one
(1) key to operate the ignition lock and a second to operate the outside door locks. The ten (10) bit
key system uses one (1) key to operate the ignition lock and the outside door locks. The ten (10) bit
key system services the ignition lock as a separate service part so the door locks would not have to
be replaced in the event of an ignition lock failure.
ACTION: If service is required for the five (5) bit key system, the ignition and door locks are
serviced separately. Refer to the appropriate Shop Manual for removal and installation procedures.
If service is required for the ten (10) bit key system, a ten (10) bit ignition lock with partially cut keys
is available. Refer to the following service procedure.
NOTE:
Customers concerned with the heads of the new ten (10) bit ignition service keys not matching the
original keys may be resolved by ordering blank keys from Rotunda. Cut the two (2) blank keys
ordered from Rotunda on tumbler station numbers 1, 2, 3, 4, and 6 to match the new ten (10) bit
ignition service keys supplied with the new service ignition lock.
1. Remove the ignition lock cylinder. Refer to the appropriate Shop Manual.
FIGURE 2
2. Using the Ford Rotunda key code cutting package, tool number 011-00003, measure the depth
of the cut on the number six (6) tumbler station of the original key. Use this measurement to
determine the correct service ignition lock set. Refer to the chart in Figure 2.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Doors and Ignition - Lock Service
Tips > Page 639
3. Using the original ignition key, decode tumbler station numbers 5, 7, 8, 9, and 10.
4. Cut the new service key on tumbler station numbers 5, 7, 8, 9, and 10.
5. Check the operation of the new service key in the new ignition lock and outside door locks.
6. Install the new service ignition lock.
NOTE:
Retain both the original and new service key tabs for future key code identification.
OTHER APPLICABLE ARTICLES: 86-23-4
WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
Location For C6 Transmission
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 643
Neutral Safety Switch: Service and Repair
Fig. 8 Neutral safety switch replacement. Exc. automatic overdrive transmission
EXC. AUTOMATIC OVERDRIVE TRANSMISSION
1. Disconnect battery ground cable.
2. Remove downshift linkage rod return spring from low-reverse servo cover.
3. Apply penetrating oil to outer lever attaching nut, then remove transmission downshift outer lever
attaching nut and lever.
4. Remove neutral safety switch attaching bolts, then disconnect electrical connectors and remove
switch from vehicle.
5. To install, position switch on transmission and secure with attaching bolts. Do not tighten bolts at
this time.
6. Place transmission manual lever in neutral position, then insert a .091 inch gauge pin through
gauge pin holes, Fig. 8.
7. Tighten switch attaching bolts, then remove gauge pin.
8. Install outer downshift lever and retaining nut.
9. Install downshift linkage rod return spring between lever and retaining clip on low-reverse servo
cover.
10. Reconnect electrical connectors, then check operation of switch.
W/AUTOMATIC OVERDRIVE TRANSMISSION
1. Disconnect battery ground cable.
2. Raise and support vehicle.
3. Disconnect electrical connector at neutral safety switch, lifting connector straight up.
4. Using suitable socket, remove neutral safety switch and O-ring seal.
5. Reverse procedure to install, installing new O-ring seal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations
Power Steering Pressure Switch: Locations
Upper LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations
Power Window Switch: Locations
On Driver`s Door Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Diagram Information and Instructions
Windshield Washer Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 658
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 659
Windshield Washer Switch: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 660
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations
Wiper Switch: Locations
Upper LH Side Of I/P
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Diagram Information and Instructions
Wiper Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 666
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 667
Wiper Switch: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 668
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Page 669
Wiper Switch: Testing and Inspection
Fig. 4 Wiper Switch Continuity Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Page 670
Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Page 671
Fig. 5 Wiper Switch Continuity Test
1. Check continuity between switch terminals, Figs. 4 through 6.
2. To detect marginal operation of switch, rotate or slide switch control knob while each reading is
being taken.
3. If switch does not show continuity or if poor continuity exists at any switch position, replace
switch.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Page 672
Wiper Switch: Service and Repair
E-100---350
1. Disconnect battery ground cable.
2. Remove wiper switch knob.
3. Remove ignition switch bezel from finish panel.
4. Remove light switch knob and shaft assembly by depressing release button on switch housing
and pulling straight out.
5. Remove 2 lower attaching screws from finish panel, then pry the 2 upper retainers away from
instrument panel.
6. Disconnect wiper switch electrical connector, then remove switch attaching screws and the
switch from vehicle.
7. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Tire Wear - Toe
Set Prior Vehicle Service
Alignment: Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service
Article No. 86-24-28
TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES
LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE
Certain model vehicles have a significant weight change on the front axle between manufacture by
Ford and placement into service. This occurs when incomplete vehicles are completed by a body
company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.).
This weight change can affect toe setting so these vehicles require that toe be reset.
Figure 25
The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the
intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE
ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Tire Wear - Toe
Set Prior Vehicle Service > Page 678
Alignment: Technical Service Bulletins Front Tires - Irregular Wear Pattern
Article No. 86-24-27
TIRE WEAR - FRONT - IRREGULAR PATTERN
LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS
Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel
and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire
tread/ carcass/compound design.
Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and
set to Shop Manual preferred settings for toe.
In cases of severe wear, obtain the complete alignment readings and tire information. Contact both
your Ford Representative and Tire Manufacturer's Representative for their assistance and
participation in resolving the customer's concern. Contacting the "local" tire store may not obtain
the assistance which may be available from the tire manufacturer.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Camber
Alignment: Specifications Camber
Fig.1 Ride Height
Fig.2 Ride Height
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Camber > Page 681
Camber Specifications
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Camber > Page 682
Alignment: Specifications Caster
Fig.1 Ride Height
Caster Angle Specifications
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Camber > Page 683
Alignment: Specifications Toe
Toe In ..................................................................................................................................................
........................................................................ 1/32 in
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 684
Alignment: Service and Repair
Fig. 1 Measuring Ride Height
Fig. 7 Measuring riding height. 1980---85 F-100---350 & Bronco
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 685
Fig. 8 Measuring Riding Height
Prior to checking caster and camber, ensure vehicle front ride height is within {1/8} inch side to side
1980-87 E-100-350. On 1980-87 F-100-350 models, the left side ride height should be within
0-{3/8} inch higher than the right side ride height. On 1980-87 F-150-350 (4x4) and Bronco, the
front ride heights should be within {3/16} inch side to side. Refer to Figs. 6, 7 and 8. If the vehicle
ride heights are not within specifications, redistribute load on loaded vehicles or slightly load empty
vehicles on one side. If the ride heights cannot be brought within specifications, verify correct
spring installation. The ride height variations stated, are for checking purposes only. The vehicle
does not have to operate within these specifications. Check and correct as necessary all tire
inflation pressures, then check front tires for the same size, ply rating and load range. Check front
wheel bearings and adjust as necessary. If all the above checks have been made, check wheel
alignment with suitable alignment equipment. Using the ride heights obtained earlier, compare
caster and camber readings to those listed in the ``Wheel Alignment Specifications Chart''. If the
caster and camber angles exceed the specifications, inspect front end for damaged suspension
components. Replace as necessary. Alignment equipment indicates a true reading only when the
vehicle's frame is horizontal. Therefore, if the frame is not level (due to tire, spring or load
differences), the caster angle reading must be modified to compensate for the frame angles. If the
front is higher than the rear, subtract the amount of angle from the reading. If the front is lower than
the rear, add the angle. To check frame angle, use a spirit protractor, and take the frame angle
measurement on the lower frame flange at the flat area immediately adjacent to the rear spring
front hanger.
TOE-IN, ADJUST Check the steering wheel spoke position when the front wheels are in the
straight ahead position. If the spokes are not in the normal position, they can be adjusted while
toe-in is being adjusted.
1. Loosen clamp bolts on each tie rod end sleeve.
2. Adjust toe-in. If steering wheel spokes are in their normal position, lengthen or shorten both rods
equally to obtain correct toe-in. If spokes are not in normal position, make necessary rod
adjustments to obtain correct toe-in and steering wheel spoke alignment.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Technical Service Bulletins > By Symptom
Fuel Pressure: By Symptom
Technical Service Bulletin # 911211 Date: 910612
Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Technical Service Bulletins > By Symptom > Page 691
temperatures. Refer to the following procedure for service details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Technical Service Bulletins > By Symptom > Page 692
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Technical Service Bulletin # 911211 Date: 910612
Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Technical Service Bulletins > By Symptom > Page 693
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Technical Service Bulletins > By Symptom > Page 694
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of
Power/No Start Diagnosis
Fuel Pressure: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of
Power/No Start Diagnosis > Page 700
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of
Power/No Start Diagnosis > Page 701
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Technical Service Bulletins > Page 702
Fuel Pressure: Specifications
Fuel Pressure 5-7 psi
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Technical Service Bulletins > Page 703
Fuel Pressure: Testing and Inspection
1. Connect a suitable pressure gauge (0-15 psi) to the carburetor end of the fuel line (no "T" is
required). 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the
carburetor bowl) and read the pressure after 10 seconds. The fuel
pump pressure should read 6-8 psi at normal curb idle speed, with the transmission in NEUTRAL,
the engine at normal operating temperatures, and the fuel return line closed (if present). If pump
pressure is too low or too high install a new fuel pump.
3. Reconnect fuel line at filter and install air cleaner.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision
Technical Service Bulletin # 8912A26 Date: 890627
Idle Fuel Mixture - Manual Revision
ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1986-SECTION 4-IDLE FUEL
MIXTURE-PROPANE ENRICHMENT METHOD
ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1987-SECTION 4-IDLE FUEL
MIXTURE-PROPANE ENRICHMENT METHOD
Article No. 89-12A-26
FORD: 1986 ESCORT, LTD, MUSTANG 1986-87 TEMPO 1986 THUNDERBIRD
LINCOLN-MERCURY: 1986 CAPRI, COUGAR, MARQUIS 1986-87 TOPAZ
LIGHT TRUCK: 1986 AEROSTAR 1986-87 BRONCO, ECONOLINE, F-150, F-250, F-350,
RANGER
ISSUE: The tachometer reference "or equivalent" as shown in procedure I.-B in both 1986 and
1987 Engine Emissions Diagnosis Manuals is incorrect. This also applies to procedure I.-H in the
1986 Engine Emissions Diagnosis Manual.
ACTION: Refer to the pages following this TSB article for the revised Volume H pages which show
the correct tachometer designation as: "Connect an analog tachometer, Rotunda 059-000010 or an
equivalent analog tachometer." This information should be inserted in your 1986 Engine Emissions
Diagnosis Manual, pages 4-83, 4-87, 4-90, 4-93 and the 1987 Manual, pages 4-66 and 4-69.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
INFORMATION ONLY
OASIS CODES: 680000
Pages 4-83, 4-84
1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-83
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
Passenger Car. 1.9L w/740-2V, 2.3L OHC w/YFA-IV FB, 2.3L HSC w/1949-IV, 3.8L w/2150-A-2V
and 5.0L w/4180C-4V.
Truck, Under 8500 GVW: 5.8L w/4180C-4V.
NOTE: This procedure is applicable to the above engines only. If CO and HC are not within
specification, perform appropriate electrical diagnostic procedure in Section 15.
I. Vehicle Preparation: All Carburetors as noted above.
A. Apply the parking brake, and block the wheels. Disconnect the automatic brake release, if so
equipped, and plug the vacuum connection.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. If so equipped, insure that the hot idle compensator is in a closed position and remains so
throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to insure
that HIC valve is closed.
D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L
engines) and plug the connection. (Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger Car
engines).
E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple.
(Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger car engines).
F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
G. For vehicles equipped with thermactor systems, revise the dump valve vacuum hoses as
follows: (Not applicable to 1.9L engines).
1. For dump valves with two vacuum fittings, disconnect and plug the hose(s).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 708
2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at
the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake
manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB).
3. For 2.3L OHC engines:
a. Equipped with a dump valve with two vacuum fittings: Disconnect and plug the hoses.
b. Equipped with a combination dump valve and air diverter valve: Disconnect and plug the hoses
(2-port) from the dump valve portion.
c. Equipped with feedback carburetor: Disconnect electric lead wire from electric PVS.
4. On 3.8L engine Canadian 2150A-2V applications, do not make any thermactor system
modifications.
5. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve.
1986 4-84
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
H. For 1.9L ATX/MTX vehicles equipped with (Mechanical Vacuum) Idle Speed Control (ISC):
1. With engine off:
a. Disconnect and plug the vacuum hose at the MVISC.
b. Connect an alternate vacuum source (hand vacuum pump) capable of maintaining 22 inches Hg.
to the ISC diaphragm on carburetor, and apply vacuum (retracting ISC plunger clear of throttle
linkage).
2. With engine running and transmission in Drive (ATX) or Neutral (MTX):
^ Idle speed should be equal to the ISC retracted speed specified on the emission decal, if not
readjust throttle stop adjustment screw under choke housing to specification, (fan On, A/C Off).
I. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify that the timing is set to specification; reset if necessary, Section 15.
B. Check engine curb idle rpm or A/C-off rpm, and, if necessary, reset to specification, Section 4.
NOTE: Even If the vehicle has less than 160.9 km (100 miles) of operation, set the speed to the
normal engine specification.
NOTE: Remove PCV valve from grommet, and allow PCV valve to draw underhood air during idle
fuel mixture check. (PCV should remain in vertical position).
NOTE: Escort/Lynx, has an in-line fixed orifice crankcase vent, not a conventional PCV valve. The
fixed orifice is located in the crankcase vent hose located between the vacuum fitting on the intake
manifold and the plastic fitting attached to the air cleaner tray.
Locate the crankcase vent hose and disconnect at the air cleaner end, allowing the hose to vent to
underhood air during idle fuel/air mixture check.
C. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds
before each mixture check.
NOTE: On Escort/Lynx and Tempo/Topaz, run engine until electric fan comes On.
Pages 4-87 Thru 4-90
1986
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 709
Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-87
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
2.0L TRUCK UNDER 8600 GVW w/YFA-IV
NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane
specifications are not listed for these applications. If CO and HC are not within specification,
perform appropriate electrical diagnostic procedure, Section 15.
I. Vehicle Preparation
A. Apply the parking brake and block the wheels.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
D. Disconnect and plug the hose at the air bypass valve.
E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve.
F. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify engine timing is set to specification - reset if necessary, Section 15.
B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect
idle speed control (ISC) motor from wiring harness.
C. Place A/C-heat selector in the Off position and verify that lamps are Off.
NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at
the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle
fuel mixture check).
D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds
before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step.
1986 4-88
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
E. With the engine idling at normal operating temperature gradually open the propane tool valve
and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum
and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical
position).
NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary
repeat Steps D & E with a new propane cartridge gas supply.
F. Compare measured speed gain to specified speed gain.*
1. If the measured speed gain is within specification, proceed to Step H.
NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the
carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the
above feature.
NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture
according to the reset rpm specification.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 710
2. If the measured speed gain is higher than the speed gain specification:*
Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
3. If the measured speed gain is lower than the speed gain specification:*
Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following
speed drop test:
NOTE: Speed drop test information is specified with the artificial enrichment requirements
whenever the minimum speed gain specification is "0" rpm. *
a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop
in engine speed.
b. If the measured speed drop is greater "0" and less than or equal to 30 rpm, proceed to Step G.
c. If the measured speed drop is more than 30 rpm, return the mixture screw to the position before
adjustment. Proceed to Step G.
d. If the measured speed drop is still "0" rpm repeat steps a, b, and c.
G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see
Section III.
*Refer to the Special Specifications Issue TSB Publications.
1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-89
Idle Mixture Setting Procedures
H. Reinstall PCV valve in grommet. Reconnect air bypass valve, purge valve and crankcase
closure hose. Reconnect ISC motor to wiring harness.
I. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten
the air cleaner wing nut(s) to specification.
III. Removal and Installation for Tamper-Resistant Fuel Air Adjustment Feature:
A. See appropriate carburetor disassembly instructions in Shop Manual, Group 24.
1986 4-90
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
2.8L AEROSTAR w/2150A FB
NOTE: This procedure is for the 2.8L engine only. It is not for trucks over 8500 GVW.
I. Vehicle Preparation
A. Apply the parking brake and block the wheels.
B. Verify that timing is set to specification.
C. Remove the air cleaner assembly.
D. Disconnect wiring harness from carburetor feedback solenoid, located in the rear of carburetor.
E. Remove the PCV valve from the rocker cover grommet and move away from the crankcase
vapors.
F. Disconnect the fuel evaporating purge line (from the intake manifold spacer at the purge
solenoid).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 711
G. Install purge line tester (Tool T84T-9600-A) into the end of purge line that is still connected to
the intake manifold spacer.
H. Disconnect ISC motor from wiring harness as follows: Simultaneously: 1.
Connect tachometer, Rotunda Model 059-00001, 099-00001 or equivalent.
2. Start engine.
3. Manually hold throttle above 1000 rpm.
4. Push ISC plunger until it retracts fully.
5. After plunger retracts, release throttle and quickly unplug the connection.
NOTE: Before proceeding, verify that the throttle lever is resting on the speed screw and that the
engine idles at specification for anti-dieseling rpm (750 rpm in neutral).
I. Install air cleaner assembly, but do not connect the flexible fresh air tube to the air cleaner duct
and valve assembly. Using a propane enrichment Tool T75L-9600-A or equivalent, insert the tool
hose approximately 3/4 of the way into the duct and valve assembly. If necessary, secure the hose
with tape.
J. When the above Steps have been completed, proceed to Section II.
Pages 4-93 & 4-94
1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-93
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
4.9L TRUCK UNDER 8500 GVW w/YFA-IV FB
NOTE: This procedure is for the 4.9L engine only. It is not for trucks over 8600 GVW. Propane
specifications are not listed for these applications. If CO and HC are not within specification,
perform appropriate electrical diagnostic procedure, Section 15.
I. Vehicle Preparation
A. Apply the parking brake and block the wheels. Disconnect the automatic brake release (if so
equipped), and plug the vacuum connection.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. Disconnect the flexible fresh air tube from the air cleaner duct or adapter. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
D. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify engine timing is set to specification-reset if necessary, Section 15.
B. Place A/C-heat selector in the Off position and verify that all accessories (lamps, defrost, etc.)
are Off.
1986 4-94
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 712
Figure 1 - In-Line Base Timing Connector
NOTE: Remove PCV valve from grommet locate the crankcase closure hose and disconnect at the
air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel
mixture check).
C. Verify that the idle speed control motor and the single wire connector near the distributor
(sometimes called the In-Line Base timing connector, Figure 1) are connected electrically. With the
transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each
mixture check. If check is not completed within 60 seconds, repeat this cleanout Step.
D. Return engine to idle and disconnect idle speed control motor from wiring harness. Disconnect
single wire connector near the distributor (Fig. 1). With the engine idling at normal operating
temperature, place the transmission selector in the position specified for the idle fuel mixture check.
Gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When
the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain.
(Propane cartridge must be in vertical position).
NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary
repeat Steps C and D with a new propane cartridge gas supply.
E. Compare measured speed gain to specified speed gain.*
1. If the measured speed gain is within specification, proceed to Step G.
NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the
carburetor must be removed from the vehicle. Refer to Group 24, Powertrain Shop manual for
removal of the above feature.
NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture
according to the reset rpm specification.
2. If the measured speed gain is higher than the speed gain specification:*
Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps C and D until the
measured speed rise meets the reset rpm specification,* After final adjustment, proceed to Step F.
3. If the measured speed gain is lower than the speed gain specification:*
Turn the mixture screw clockwise (lean) and simultaneously repeat Steps C and D until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step F.
F. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled. Refer to
appropriate carburetor assembly instructions in Shop Manual, Group 24.
G. Reinstall PCV valve in grommet. Reconnect idle speed control motor and crankcase closure
system, and the single wire connector near the distributor.
H. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten
the air cleaner wing nut(s) to specification, *Specified speed gain is 10 to 70 rpm, specified reset is
30 rpm.
Pages 4-65 & 4-66
1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-65
Idle Mixture Setting Procedures
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 713
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
Propane Enrichment Procedures Are Not Applicable For The Following:
^ CFI Applications.
^ EFI Applications.
^ Truck Over 8500 GVW Applications.
^ 5.8L MCU Police and Trailer Tow Vehicles w/7200 Carburetors.
1987 4-66
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
Passenger Car. 2.3L HSC w/1949-IV
Truck, Under 8500 GVW: 5.8L w/418OC-4V. NOTE:
This procedure is applicable to the above engines only. If CO and HC are not within specificatlon,
perform appropriate electrical diagnostic procedure in Section 15.
I. Vehicle Preparation: All Carburetors as noted above.
A. Apply the parking brake, and block the wheels, Disconnect the automatic brake release, If so
equipped, and plug the vacuum connection.
B. Connect an analog tachometer, Rotunda 059-000010 or equivalent analog tachometer.
C. If so equipped, ensure that the hot idle compensator is in a closed position and remains so
throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to
ensure that HIC valve is closed.
D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L
engines) and plug the connection. (Not applicable to 5.8L Truck engines).
E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple.
(Not applicable 5.8L Truck engines.)
F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
G. For vehicles equipped with Thermactor systems, revise the dump valve vacuum hoses as
follows:
1. For dump valves with two vacuum fittings, disconnect and plug the hose(s).
2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at
the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake
manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB).
3. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve.
H. When the above Steps have been completed, proceed to Section II.
Pages 4-69 & 4-70
1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-69
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
2.0L TRUCK UNDER 8500 GVW w/Aisan Carburetor
NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane
specifications are not listed for these applications. If CO and HC are not within specification,
perform appropriate electrical diagnostic procedure, Section 15.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 714
I. Vehicle Preparation
A. Apply the parking brake and block the wheels.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
D. Disconnect and plug the hose at the air bypass valve.
E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve.
F. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify engine timing is set to specification-reset if necessary, Section 15.
B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect
idle speed control (ISC) motor from wiring harness.
C. Place A/C-heat selector in the Off position and verify that lamps are Off.
NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at
the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle
fuel mixture check).
D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds
before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step.
1987 4-70
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
E. With the engine idling at normal operating temperature gradually open the propane tool valve
and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum
and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical
position).
NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary
repeat Steps D & E with a new propane cartridge gas supply.
F. Compare measured speed gain to specified speed gain.*
1. If the measured speed gain is within specification, proceed to Step H.
NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the
carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the
above feature.
NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture
according to the reset rpm specification.
2. If the measured speed gain is higher than the speed gain specification:*
Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
3. If the measured speed gain is lower than the speed gain specification:*
Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 715
4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following
speed drop test:
NOTE: Speed drop test information is specified with the artificial enrichment requirements
whenever the minimum speed gain specification is "0" rpm.*
a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop
in engine speed.
b. If the measured speed drop is greater than "0" and less than or equal to 40 rpm, proceed to Step
G.
c. If the measured speed drop is more than 40 rpm, return the mixture screw to the position before
adjustment. Proceed to Step G.
d. If the measured speed drop is still "0" rpm repeat steps a, b, and c.
G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see
Section III.
*Refer to the Special Specifications Issue TSB Publications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 724
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 725
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 726
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 727
Figure 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 728
Figure 4
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 729
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 730
Figure 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 731
Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 732
Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 733
Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 734
Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 735
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 736
serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 738
For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
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Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 740
Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
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Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
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^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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Starts/Hesitation/Stalls On Start-Up > Page 748
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 749
Figure 3
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 750
Figure 4
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 751
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 752
Figure 6
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 753
Figure 7
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 754
Figure 8
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 755
Figure 9
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 756
Figure 10
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 757
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 760
For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 761
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 762
Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 763
Idle Speed: By Symptom
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 764
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 765
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 766
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 767
Figure 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 768
Figure 4
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 769
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 770
Figure 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 771
Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 772
Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 773
Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 774
Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 775
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 776
serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 778
For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 779
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 780
Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
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^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 782
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
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If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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Figure 3
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Figure 4
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 786
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 787
Figure 6
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 788
Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 789
Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 790
Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 791
Figure 10
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 792
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 796
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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Specifications > With Automatic Transmission
Idle Speed: Specifications With Automatic Transmission
Curb Idle Speed ...................................................................................................................................
................................................ 650 rpm (in DRIVE)
Fast Idle Speed ...................................................................................................................................
........................................... 1600 rpm (in PARK) [1]
[1] On kickdown step of fast idle cam.
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Specifications > With Automatic Transmission > Page 800
Idle Speed: Specifications With Manual Transmission
Curb Idle Speed ...................................................................................................................................
................................................................. 800 rpm
Fast Idle Speed ...................................................................................................................................
........................................................... 2200 rpm [1]
[1] On kickdown step of fast idle cam.
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Adjustments > Calibration 4-98S-R11
Idle Speed: Adjustments Calibration 4-98S-R11
1. Stabilize engine temperature.
2. Place truck in Park or Neutral, turn the A/C off, and set the parking brake.
3. Remove the air cleaner.
4. Disconnect and plug the decel throttle control kicker diaphragm vacuum hose. a.
Connect a slave vacuum hose from an engine manifold vacuum source to the decel throttle control
kicker.
b. Run engine at approximately 2500 rpm for 15 seconds, then return to idle.
c. If decel throttle control rpm is not within ±50 rpm of specification, adjust the kicker.
d. Disconnect the slave vacuum hose and allow engine to return to curb idle.
5. Adjust curb idle, if necessary, using the curb idle adjusting screw with transmission in Neutral
(M/T) or Drive (A/T).
6. Goose the throttle, then recheck curb idle speed and adjust as needed.
7. Reconnect the decel throttle control vacuum hose to the diaphragm.
8. Install the air cleaner.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Adjustments > Calibration 4-98S-R11 > Page 803
Idle Speed: Adjustments Calibrations 6-97J-R12, 6-97J-R18
1. Stabilize engine temperature.
2. Place truck in Park or Neutral, turn the A/C off, and set the parking brake.
3. Remove the air cleaner.
4. Adjust curb idle, if necessary, using the curb idle adjusting screw with transmission in Neutral
(M/T) or Drive (A/T).
5. Goose the throttle, then recheck curb idle speed and adjust as needed.
6. Check/adjust dashpot clearance by totally compressing the dashpot and adjusting for .100 inch
clearance between collapsed dashpot and throttle lever at the closed throttle position.
7. Install the air cleaner.
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Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Air Filter Element: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
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Element > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 809
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 810
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information
> Locations
Fuel Filter: Locations
Fuel Filter
The fuel filter is located on the frame rail between the frame mounted high pressure pump and
engine.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information
> Locations > Page 814
Fuel Filter: Description and Operation
Clean fuel is extremely important in a fuel injection system because of the small orifice in the
injector tip through which fuel must pass. Most injection systems use three forms of filters. The first
is a fuel strainer or filter of woven plastic attached to the fuel pump inlet. This prevents
contamination from entering the fuel line and separates water from the fuel. The filter is
self-cleaning and requires no maintenance. If a fuel restriction occurs at this point, the tank
contains too much sediment or moisture and should be removed and cleaned. Additional filtration is
provided by a high capacity inline filter to remove contamination larger than 20 microns (0.0050
inch). This filter is designed to last the life of the vehicle. The final line of defense against fuel
contamination is in the fuel injector. Each injector contains its own inlet filter screen to prevent
contamination from reaching the tip.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information
> Locations > Page 815
Fuel Filter: Service and Repair
Fuel Filter
REMOVAL
1. Shut engine off. De-pressurize fuel system. Use caution to prevent combustion from fuel
spillage.
2. Raise vehicle on hoist.
3. Loosen screw clamp so that filter slides rearward easily.
4. Remove push connect fittings at both ends of the filter. Install new retainer clips in each push
connect fitting.
5. Remove fuel filter from metal bracket by rotating the fuel line, being careful not to kink the fuel
line, and sliding the filter rearward.
Fuel Filter
INSTALLATION
1. Place filter into the bracket with flow arrow pointing toward tab of the bracket. Slide filter forward
until it rests against tab of the bracket.
2. Tighten retaining screw of the screw clamp to 1.3-2.1 ft. lb.
3. Install push-connect fittings onto filter ends.
4. Turn ignition switch from RUN/OFF position several times, without starting engine. Check for fuel
leaks.
5. Lower vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing
Connector > Component Information > Description and Operation
Ignition Timing Connector: Description and Operation
Fig. 20 Ignition Timing Vacuum Switch
Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition
module to retard spark timing. The switch is closed above the vacuum setting and the ignition
module is in the non-retard spark timing mode. Calibration resistors inside the switch control the
amount of retard.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing
Connector > Component Information > Description and Operation > Page 823
Ignition Timing Connector: Testing and Inspection
Ignition Timing Vacuum Switch
Ignition Timing Vacuum Switch Test Chart
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less
than'' values in the Ignition Timing vacuum Switch Test chart.
3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured
across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart.
4. Replace switch if resistance is not within specifications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and
Indicators > System Information > Diagrams
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Ignition Cable: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 831
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 832
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 833
Ignition Cable: Technical Service Bulletins Ignition System - Diagnostics Manual Correction
Article No. 89-5A-4
EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION
FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND
CROWN VICTORIA
LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ,
GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR
LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES
1986-88 AEROSTAR
ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989
Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service
information directs technicians to use a substitute coil instead of a resistance test.
ACTION: Refer to this TSB for revised ignition coil and secondary wire test information.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 680000
1989
Ignition Systems, Timing Procedures and Diagnostics 13-51
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 834
Ignition Coil and Secondary Wire
TFI-IV
And
TFI With CCD
Part 2
Test 7 1989 13-52
Ignition Systems, Timing Procedures and Diagnostics
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 835
EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2
Test 8
1989 Ignition Systems, Timing Procedures and Diagnostics
13-65
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 836
Ignition Coil And Secondary Wire
TFI-IV
Closed Bowl
Distributor
Part 2
Test 8 1989 13-66
Ignition Systems, Timing Procedures and Diagnostics
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 837
EEC-IV - Wiring TFI-IV
Closed Bowl
Distributor Part 2
Test 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Technical Service Bulletins > Page 838
Ignition Cable: Testing and Inspection
Spark Plug Wire Resistance
*** UPDATED BY TSB #85-9-33
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Advance Unit > Component Information > Specifications
DISTRIBUTOR TIMING ADVANCE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism
Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism
The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly
is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm
assembly used depends on the engine calibration.
Single Diaphragm Assembly
SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the
armature to stator relationship to give spark advance. The stator assembly position is changed by
means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm
assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance
spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached
to the stator assembly, makes the the stator assembly move with respect to the armature. This
changes the initial armature to stator relationship set during initial timing, causing spark advance.
The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly,
is attached to the distributor base.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 845
Dual Diaphragm Assembly
DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in
the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum
advance port causes the advance diaphragm and attached rod to move, otherwise the action is the
same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard
diaphragm to move, compressing the retard spring, which controls the rate of spark retard.
Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by
the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm
rod moves causing the attached stator assembly to change position with respect to the armature. In
this instance the direction of the stator assembly movement is opposite that occurring during
vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port
overrides any spark retard caused by vacuum being applied to the retard port.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 846
Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism
Distributor - Exploded view
The centrifugal advance mechanism varies the relationship of the armature to the stator assembly.
The armature is mounted to the sleeve and plate assembly which rotates in relation to the
distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine
RPM. The movement of the weights change the initial relationship of the armature to the stator
assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor
shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by
calibrated springs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Advance Unit > Component Information > Description and Operation > Page 847
Distributor Advance Unit: Service and Repair
1. Remove distributor cap and rotor.
2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup
assembly.
3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link.
4. Carefully remove unit from distributor.
5. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap
> Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Distributor Cap: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap
> Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 852
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Cap
> Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 853
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor
> Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Ignition Rotor: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor
> Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 858
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor
> Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 859
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor
Plate W/ Pick-up Sensor > Component Information > Service and Repair
Distributor Plate W/ Pick-up Sensor: Service and Repair
1. Remove distributor cap and rotor.
2. Remove vacuum advance unit and magnetic pickup assembly.
3. Remove attaching screws and lift base plate from distributor.
4. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Spark Plug: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 867
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 868
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Technical Service Bulletins > Page 869
Spark Plug: Specifications
Spark Plugs 5-10 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
ENGINE YEAR CLEARANCE
V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165
V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150
On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications > Page 873
Valve Clearance: Locations
FRONT TO REAR 6-300 E-I-E-I-E-I-E-I-E-I-E-I V6-232 Right I-E-I-E-I-E V6-232 Left E-I-E-I-E-I
V8-255, 302 Left Bank E-I-E-I-E-I-E-I V8-255, 302 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Right
Bank I-E-I-E-I-E-I-E V8-351, 400 Left Bank E-I-E-I-E-I-E-I V8-460 Left Bank E-I-E-I-E-I-E-I V8-460
Right Bank I-E-I-E-I-E-I-E
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications > Page 874
Valve Clearance: Adjustments
Fig. 2 Positioning crankshaft for valve clearance check
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications > Page 875
Fig. 3 Checking collapsed tappet clearance
Valves, Adjust To provide a means to compensate for dimensional changes in the valve train and
provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve
clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance
is more than the maximum, the longer pushrod should be used. To check the valve clearance,
proceed as follows:
1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of
compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one
quarter turn clockwise (90°) from position No. 2, Fig. 2.
2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 3, and check the clearance on the following valves:
a. On V8-302 and 460 engines, check intake valve Nos. 1 , 7 and 8; exhaust valve Nos. 1, 4 and 5.
b. On V8-351, check intake valve Nos. 1, 4 and No. 8; exhaust valve Nos. 1, 3 and 7.
3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 3, and check the clearance on the following valves:
a. On V8-301 and 460 engines check intake valve Nos. 4 and 5; exhaust valve Nos. 2 and 6. b. On
V8-351 engines, check intake valve Nos. 3 and 7; exhaust valve Nos. 2 and 6.
4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or
equivalent and check the clearance on the following valves:
a. V8-302 and 460 engines check intake valve Nos. 2, 3 and 6; exhaust valve Nos. 3, 7 and 8. b.
On V8-351 engines, check intake valve Nos. 2, 5 and 6; exhaust valve Nos. 4, 5 and 8.
Valve Arrangement
Front to Rear
V8-302 Left Bank..................................................................................................................................
...........................................................E-I-E-I-E-I-E-I V8-302 Right Bank.............................................
..............................................................................................................................................I-E-I-E-IE-I-E V8-351 Right Bank......................................................................................................................
.....................................................................I-E-I-E-I-E-I-E V8-351 Left Bank......................................
.......................................................................................................................................................E-IE-I-E-I-E-I V8-460 Left Bank.................................................................................................................
............................................................................E-I-E-I-E-I-E-I V8-460 Right Bank............................
..............................................................................................................................................................
.I-E-I-E-I-E-I-E
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise
Drive Belt: Customer Interest Accessory Drive Belt - Chirp or Squeal Noise
Article No. 94-10-19
05/18/94
^ ACCESSORY DRIVE BELT - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR
OR LOSS - VEHICLES WITH 4.9L ENGINE
^ ENGINE - 4.9L - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR OR LOSS
^ NOISE - "CHIRP"/"SQUEAL" SOUND FROM FEAD BELT - VEHICLES WITH 4.9L ENGINE
LIGHT TRUCK: 1987-94 ECONOLINE, F-150-350 SERIES
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 884
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 885
This TSB article is being republished in its entirety to provide specific bolt number references in
Figures 3 and 4.
ISSUE: Front-end accessory drive belt (FEAD) belt noise may be heard and excessive belt edge
wear or loss may occur.
^ The "chirp" noise may occur at constant engine speeds and all engine loads. It is caused by
belt/pulley misalignment.
^ The belt "squeal" noise is intermittent and is heard during engine speed variations, usually at
engine start up. The noise is caused by belt slippage.
^ Belt edge wear and/or belt loss is caused by belt mistracking across the automatic belt tensioner.
If the automatic belt tensioner is out of parallel, the belt can be "driven" to either flange of the
pulley, causing belt edge wear and in some cases, the loss of the belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 886
ACTION: Use the following service procedure to correct these conditions.
BELT CHIRP
1. Start the engine and while idling, wet the ribbed side of belt by spraying water on the belt where
it enters the A/C compressor pulley.
2. Listen for belt "chirp" as the belt dries at the entrance point of each grooved pulley to identify the
noisy pulley.
3. If the "chirp" is at the power steering pulley entry, check for belt mistracking on the tensioner
pulley, otherwise go to Step 13.
4. Check press of the power steering pulley. The pulley hub should be flush with the end of the
pump shaft.
5. If the pulley is flush, start engine and while idling, visually compare the size of the gaps between
the belt and front and rear flange of the tensioner pulley. If the larger gap is twice as wide as the
smaller gap, Figure 2, proceed with Step 6, otherwise, go to Step 13.
6. Mark the accessory drive belt with an arrow to denote rotation of belt. Remove belt.
7. Loosen all fasteners attaching A/C bracket to cylinder block and cylinder head. See Figures 3
and 4.
8. Tighten nuts # 3 (and, on 1987-93 model only, bolts # 4) on side of cylinder block to 62 N-m (46
lb.ft).
9. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
10. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
11. Install the accessory drive belt. Be sure belt is installed with arrow mark denoting original
rotation of belt.
12. Start engine and check for belt "chirp" noise.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 887
13. Remove the accessory drive belt and replace it with a new service replacement belt. See
Figure 1 for correct belt usage.
BELT SQUEAL - F-SERIES
1. Remove the accessory drive belt automatic tensioner assembly. Refer to the appropriate Truck
service Manual, Section 03-05, for the removal procedure.
2. Replace it with automatic tensioner assembly (E7TZ-6B209-G). Refer to the appropriate Truck
service Manual, Section 03-05, for the installation procedure.
3. Replace the accessory drive belt.
BELT SQUEAL - ECONOLINE (A/C EQUIPPED MODELS ONLY)
1. Remove and discard the accessory drive belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 888
2. Remove 90 mm diameter pulley from automatic tensioner assembly. Discard bolt, pulley and
bearing dust shield. Refer to Figure 5.
3. Install new 76 mm pulley, bearing, dust shield and bolt assembly (E7UZ-8678-A) to automatic
tensioner assembly. See Figure 5.
4. Install new accessory drive belt. (1987-93 models - E7UZ-8620-J, 1994 models - E8TZ-8620-S).
BELT EDGE WEAR AND LOSS
1. Remove and replace accessory drive belt with new service replacement belt. See Figure 1 for
correct parts usage.
2. Start engine and while idling, observe location of belt on automatic tensioner pulley. If belt tracks
near the pulley flange, Figure 2, replace with automatic tensioner (E7TZ-6B209-G).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 889
3. Start engine and observe belt movement. If belt moves too far rearward on tensioner pulley,
proceed as follows:
a. With belt installed, loosen all A/C bracket fasteners. Belt tension will pull A/C bracket inboard
towards the engine. (Refer to Figures 3 and 4 for bolt and nut position identification.)
b. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
c. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
d. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
4. Start engine and observe belt movement. If belt moves too far forward on tensioner pulley,
proceed as follows:
a. Remove accessory drive belt and loosen all A/C bracket fasteners.
b. Pull A/C bracket toward driver's side of vehicle.
c. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
d. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
e. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-9-14 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic
Warranty Coverage For All Other Models, Emission Warranty For Belt Loss On Vehicles Equipped
With Thermactor Pumps
OPERATION DESCRIPTION TIME
941019A Correct Belt Chirp 0.6 Hr.
E-Series
941019B Correct Belt Chirp 0.5 Hr.
F-Series
941019C Additional Time To Adjust 0.3 Hr.
A/C Bracket If Gap Is Too Large - E&F; Series
941019D Correct Belt Squeal 0.5 Hr.
E-Series
941019E Correct Belt Squeal 0.3 Hr.
F-Series
941019F Correct Belt Edge Wear or
0.6 Hr.
Belt Loss - E-Series
941019G Correct Belt Edge Wear Or
0.4 Hr.
Belt Loss - F-Series
941019H Additional Time To Adjust 0.2 Hr.
A/C Bracket To Correct Belt Tracking - E&F; Series
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 890
DEALER CODING
BASIC PART NO. CONDITION CODE
6B209 56
OASIS CODES: 497000, 702000, 702000, 790000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest: > 94110 > Jan > 94 > Accessory Drive Belt - Noise/Excessive Wear
Drive Belt: Customer Interest Accessory Drive Belt - Noise/Excessive Wear
Article No. 94-1-10
01/12/94
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - EXCESSIVE IDLER/TENSIONER PULLEY
WEAR
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - NEW BELT FOR ABRASIVE
ENVIRONMENT
^ NOISE - "THUMP" FROM FRONT END ACCESSORY DRIVE (FEAD) BELT - BELT EDGE
STARTS TO FRAY
LIGHT TRUCK: 1987-93 BRONCO, ECONOLINE, F-150-350 SERIES
ISSUE: Front End Accessory Drive (FEAD) belts have a cloth backing which can trap abrasive
particles, resulting in belt wear and erosion of the idler pulleys.
ACTION: Replace the current FEAD belt with a new neoprene-backed belt which does not retain
abrasive particles or promote pulley wear. Refer to the following procedure for service details.
1. Inspect the tensioner and idler pulleys for wear of the drive surfaces.
NOTE:
NOMINAL PULLEY DIAMETER IS 90 mm (3.453") OR 76 mm (2.916"); PULLEYS WORN TO 88
mm (3.377") OR 74 mm (2.839") SHOULD BE REPLACED.
2. Select the appropriate neoprene-backed belt and install per standard belt routing (refer to
Service Manual Section 03-05).
3. Insure that all belt vee's are in all pulley grooves.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest: > 94110 > Jan > 94 > Accessory Drive Belt - Noise/Excessive Wear > Page 895
Parts Block
OTHER APPLICABLE ARTICLES: 89-10-11 WARRANTY STATUS: Eligible Under The Provisions
Of The Bumper To Bumper Warranty Coverage For 1992-93 Models And Eligible Under Basic
Warranty Coverage For Other Model Years. Emission Warranty Coverage Applies If Vehicle Is
Equipped With Thermactor System
OPERATION DESCRIPTION TIME
940110A Replace Belt - 0.3 Hr.
F-Series/Bronco
940110B Replace Belt And Tensioner 0.4 Hr.
- F-Series/Bronco
940110C Replace Belt - Econoline 0.4 Hr.
940110D Replace Belt And Tensioner 0.5 Hr.
- Econoline
DEALER CODING
BASIC PART NO. CONDITION CODE
8620 30
OASIS CODES: 497000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise
Drive Belt: All Technical Service Bulletins Accessory Drive Belt - Chirp or Squeal Noise
Article No. 94-10-19
05/18/94
^ ACCESSORY DRIVE BELT - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR
OR LOSS - VEHICLES WITH 4.9L ENGINE
^ ENGINE - 4.9L - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR OR LOSS
^ NOISE - "CHIRP"/"SQUEAL" SOUND FROM FEAD BELT - VEHICLES WITH 4.9L ENGINE
LIGHT TRUCK: 1987-94 ECONOLINE, F-150-350 SERIES
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 901
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 902
This TSB article is being republished in its entirety to provide specific bolt number references in
Figures 3 and 4.
ISSUE: Front-end accessory drive belt (FEAD) belt noise may be heard and excessive belt edge
wear or loss may occur.
^ The "chirp" noise may occur at constant engine speeds and all engine loads. It is caused by
belt/pulley misalignment.
^ The belt "squeal" noise is intermittent and is heard during engine speed variations, usually at
engine start up. The noise is caused by belt slippage.
^ Belt edge wear and/or belt loss is caused by belt mistracking across the automatic belt tensioner.
If the automatic belt tensioner is out of parallel, the belt can be "driven" to either flange of the
pulley, causing belt edge wear and in some cases, the loss of the belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 903
ACTION: Use the following service procedure to correct these conditions.
BELT CHIRP
1. Start the engine and while idling, wet the ribbed side of belt by spraying water on the belt where
it enters the A/C compressor pulley.
2. Listen for belt "chirp" as the belt dries at the entrance point of each grooved pulley to identify the
noisy pulley.
3. If the "chirp" is at the power steering pulley entry, check for belt mistracking on the tensioner
pulley, otherwise go to Step 13.
4. Check press of the power steering pulley. The pulley hub should be flush with the end of the
pump shaft.
5. If the pulley is flush, start engine and while idling, visually compare the size of the gaps between
the belt and front and rear flange of the tensioner pulley. If the larger gap is twice as wide as the
smaller gap, Figure 2, proceed with Step 6, otherwise, go to Step 13.
6. Mark the accessory drive belt with an arrow to denote rotation of belt. Remove belt.
7. Loosen all fasteners attaching A/C bracket to cylinder block and cylinder head. See Figures 3
and 4.
8. Tighten nuts # 3 (and, on 1987-93 model only, bolts # 4) on side of cylinder block to 62 N-m (46
lb.ft).
9. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
10. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
11. Install the accessory drive belt. Be sure belt is installed with arrow mark denoting original
rotation of belt.
12. Start engine and check for belt "chirp" noise.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 904
13. Remove the accessory drive belt and replace it with a new service replacement belt. See
Figure 1 for correct belt usage.
BELT SQUEAL - F-SERIES
1. Remove the accessory drive belt automatic tensioner assembly. Refer to the appropriate Truck
service Manual, Section 03-05, for the removal procedure.
2. Replace it with automatic tensioner assembly (E7TZ-6B209-G). Refer to the appropriate Truck
service Manual, Section 03-05, for the installation procedure.
3. Replace the accessory drive belt.
BELT SQUEAL - ECONOLINE (A/C EQUIPPED MODELS ONLY)
1. Remove and discard the accessory drive belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 905
2. Remove 90 mm diameter pulley from automatic tensioner assembly. Discard bolt, pulley and
bearing dust shield. Refer to Figure 5.
3. Install new 76 mm pulley, bearing, dust shield and bolt assembly (E7UZ-8678-A) to automatic
tensioner assembly. See Figure 5.
4. Install new accessory drive belt. (1987-93 models - E7UZ-8620-J, 1994 models - E8TZ-8620-S).
BELT EDGE WEAR AND LOSS
1. Remove and replace accessory drive belt with new service replacement belt. See Figure 1 for
correct parts usage.
2. Start engine and while idling, observe location of belt on automatic tensioner pulley. If belt tracks
near the pulley flange, Figure 2, replace with automatic tensioner (E7TZ-6B209-G).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 906
3. Start engine and observe belt movement. If belt moves too far rearward on tensioner pulley,
proceed as follows:
a. With belt installed, loosen all A/C bracket fasteners. Belt tension will pull A/C bracket inboard
towards the engine. (Refer to Figures 3 and 4 for bolt and nut position identification.)
b. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
c. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
d. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
4. Start engine and observe belt movement. If belt moves too far forward on tensioner pulley,
proceed as follows:
a. Remove accessory drive belt and loosen all A/C bracket fasteners.
b. Pull A/C bracket toward driver's side of vehicle.
c. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
d. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
e. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-9-14 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic
Warranty Coverage For All Other Models, Emission Warranty For Belt Loss On Vehicles Equipped
With Thermactor Pumps
OPERATION DESCRIPTION TIME
941019A Correct Belt Chirp 0.6 Hr.
E-Series
941019B Correct Belt Chirp 0.5 Hr.
F-Series
941019C Additional Time To Adjust 0.3 Hr.
A/C Bracket If Gap Is Too Large - E&F; Series
941019D Correct Belt Squeal 0.5 Hr.
E-Series
941019E Correct Belt Squeal 0.3 Hr.
F-Series
941019F Correct Belt Edge Wear or
0.6 Hr.
Belt Loss - E-Series
941019G Correct Belt Edge Wear Or
0.4 Hr.
Belt Loss - F-Series
941019H Additional Time To Adjust 0.2 Hr.
A/C Bracket To Correct Belt Tracking - E&F; Series
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 907
DEALER CODING
BASIC PART NO. CONDITION CODE
6B209 56
OASIS CODES: 497000, 702000, 702000, 790000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 94110 > Jan > 94 > Accessory Drive Belt - Noise/Excessive Wear
Drive Belt: All Technical Service Bulletins Accessory Drive Belt - Noise/Excessive Wear
Article No. 94-1-10
01/12/94
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - EXCESSIVE IDLER/TENSIONER PULLEY
WEAR
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - NEW BELT FOR ABRASIVE
ENVIRONMENT
^ NOISE - "THUMP" FROM FRONT END ACCESSORY DRIVE (FEAD) BELT - BELT EDGE
STARTS TO FRAY
LIGHT TRUCK: 1987-93 BRONCO, ECONOLINE, F-150-350 SERIES
ISSUE: Front End Accessory Drive (FEAD) belts have a cloth backing which can trap abrasive
particles, resulting in belt wear and erosion of the idler pulleys.
ACTION: Replace the current FEAD belt with a new neoprene-backed belt which does not retain
abrasive particles or promote pulley wear. Refer to the following procedure for service details.
1. Inspect the tensioner and idler pulleys for wear of the drive surfaces.
NOTE:
NOMINAL PULLEY DIAMETER IS 90 mm (3.453") OR 76 mm (2.916"); PULLEYS WORN TO 88
mm (3.377") OR 74 mm (2.839") SHOULD BE REPLACED.
2. Select the appropriate neoprene-backed belt and install per standard belt routing (refer to
Service Manual Section 03-05).
3. Insure that all belt vee's are in all pulley grooves.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 94110 > Jan > 94 > Accessory Drive Belt - Noise/Excessive Wear > Page 912
Parts Block
OTHER APPLICABLE ARTICLES: 89-10-11 WARRANTY STATUS: Eligible Under The Provisions
Of The Bumper To Bumper Warranty Coverage For 1992-93 Models And Eligible Under Basic
Warranty Coverage For Other Model Years. Emission Warranty Coverage Applies If Vehicle Is
Equipped With Thermactor System
OPERATION DESCRIPTION TIME
940110A Replace Belt - 0.3 Hr.
F-Series/Bronco
940110B Replace Belt And Tensioner 0.4 Hr.
- F-Series/Bronco
940110C Replace Belt - Econoline 0.4 Hr.
940110D Replace Belt And Tensioner 0.5 Hr.
- Econoline
DEALER CODING
BASIC PART NO. CONDITION CODE
8620 30
OASIS CODES: 497000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Drive Belt: > 8718 > Jan > 87 > Accessory Drive Belt - `V' Ribbed Belt Cracking
Drive Belt: All Technical Service Bulletins Accessory Drive Belt - `V' Ribbed Belt Cracking
ACCESSORY DRIVE BELT - "V" RIBBED BELT Article No.
CRACKING 87-1-8
FORD 1983 FAIRMONT; 1983-86 LTD; 1983-87 ESCORT, EXP, MUSTANG, THUNDERBIRD,
CROWN VICTORIA; 1984-87 TEMPO; 1986-87 TAURUS
LINCOLN-MERCURY 1983 LN7, ZEPHYR, MARK VI; 1983-86 CAPRI, MARQUIS; 1983-87 LYNX,
GRAND MARQUIS, COUGAR, LINCOLN TOWN CAR; 1984-87 TOPAZ, MARK VII; 1986-87
SABLE
MERKUR 1985-87 XR4Ti
LIGHT TRUCK 1987 E SERIES, F SERIES
ISSUE: Minor cracks of the accessory belt ribs are a normal wear condition. Besides the normal
cracking, Front Wheel Drive (FWD) vehicles may also have a build-up of belt dust (a black,
fluffy-looking material) in the general path of the accessory drive belt.
Figure 3
ACTION: This belt dust and the minor belt cracking does not require the accessory drive belt to be
replaced. Replacing the belt is only necessary after cracking has caused "rib chunk out", see
Figure 3. When two or more ribs next to each other lose a section 1-1/2 inch or longer, the belt
should be replaced.
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Drive Belt: > 8718 > Jan > 87 > Accessory Drive Belt - `V' Ribbed Belt Cracking
Drive Belt: All Technical Service Bulletins Accessory Drive Belt - `V' Ribbed Belt Cracking
ACCESSORY DRIVE BELT - "V" RIBBED BELT Article No.
CRACKING 87-1-8
FORD 1983 FAIRMONT; 1983-86 LTD; 1983-87 ESCORT, EXP, MUSTANG, THUNDERBIRD,
CROWN VICTORIA; 1984-87 TEMPO; 1986-87 TAURUS
LINCOLN-MERCURY 1983 LN7, ZEPHYR, MARK VI; 1983-86 CAPRI, MARQUIS; 1983-87 LYNX,
GRAND MARQUIS, COUGAR, LINCOLN TOWN CAR; 1984-87 TOPAZ, MARK VII; 1986-87
SABLE
MERKUR 1985-87 XR4Ti
LIGHT TRUCK 1987 E SERIES, F SERIES
ISSUE: Minor cracks of the accessory belt ribs are a normal wear condition. Besides the normal
cracking, Front Wheel Drive (FWD) vehicles may also have a build-up of belt dust (a black,
fluffy-looking material) in the general path of the accessory drive belt.
Figure 3
ACTION: This belt dust and the minor belt cracking does not require the accessory drive belt to be
replaced. Replacing the belt is only necessary after cracking has caused "rib chunk out", see
Figure 3. When two or more ribs next to each other lose a section 1-1/2 inch or longer, the belt
should be replaced.
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 922
Drive Belt: Specifications
A belt in operation 10 minutes is considered a used belt. 1988-89 Automatic tensioner used.
Deflection method: Table lists deflection at midpoint of belt segment. Strand Tension method: Use
a strand tension gauge. Measurements are in pounds.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 923
Drive Belt: Diagrams
Routing of Engine Accessory Drive Belts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 924
Drive Belt: Adjustments
A belt in operation 10 minutes is considered a used belt. 1988-89 Automatic tensioner used.
Deflection method: Table lists deflection at midpoint of belt segment. Strand Tension method: Use
a strand tension gauge. Measurements are in pounds.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Air Filter Element: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 931
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 932
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Locations
Fuel Filter: Locations
Fuel Filter
The fuel filter is located on the frame rail between the frame mounted high pressure pump and
engine.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Locations > Page 936
Fuel Filter: Description and Operation
Clean fuel is extremely important in a fuel injection system because of the small orifice in the
injector tip through which fuel must pass. Most injection systems use three forms of filters. The first
is a fuel strainer or filter of woven plastic attached to the fuel pump inlet. This prevents
contamination from entering the fuel line and separates water from the fuel. The filter is
self-cleaning and requires no maintenance. If a fuel restriction occurs at this point, the tank
contains too much sediment or moisture and should be removed and cleaned. Additional filtration is
provided by a high capacity inline filter to remove contamination larger than 20 microns (0.0050
inch). This filter is designed to last the life of the vehicle. The final line of defense against fuel
contamination is in the fuel injector. Each injector contains its own inlet filter screen to prevent
contamination from reaching the tip.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Locations > Page 937
Fuel Filter: Service and Repair
Fuel Filter
REMOVAL
1. Shut engine off. De-pressurize fuel system. Use caution to prevent combustion from fuel
spillage.
2. Raise vehicle on hoist.
3. Loosen screw clamp so that filter slides rearward easily.
4. Remove push connect fittings at both ends of the filter. Install new retainer clips in each push
connect fitting.
5. Remove fuel filter from metal bracket by rotating the fuel line, being careful not to kink the fuel
line, and sliding the filter rearward.
Fuel Filter
INSTALLATION
1. Place filter into the bracket with flow arrow pointing toward tab of the bracket. Slide filter forward
until it rests against tab of the bracket.
2. Tighten retaining screw of the screw clamp to 1.3-2.1 ft. lb.
3. Install push-connect fittings onto filter ends.
4. Turn ignition switch from RUN/OFF position several times, without starting engine. Check for fuel
leaks.
5. Lower vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins
> Oil Filter - Heavy Duty Motorcraft Filter Now Available
Oil Filter: Technical Service Bulletins Oil Filter - Heavy Duty Motorcraft Filter Now Available
Article No. 86-25-17
OIL FILTER - 7.5L ENGINE - HEAVY DUTY MOTORCRAFT FILTER NOW AVAILABLE
LIGHT TRUCK 1974-87 E-250/350, F-250/350
A heavy duty Motorcraft oil filter (FL-1 HP) is now available for use on the 7.5L engine. It is
recommended that vehicles subject to severe service, as outlined in the Owner Guide or off-road
driving, use Motorcraft Oil Filter (FL-1 HP) at all normal oil change intervals.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins
> A/C - Filtering Refrigerant After Compressor Replacement
Technical Service Bulletin # 98-12-5 Date: 980622
A/C - Filtering Refrigerant After Compressor Replacement
Article No. 98-12-5
06/22/98
AIR CONDITIONING - FILTERING REFRIGERANT
AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS
FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS
1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86
CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92
MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII
1995-98-MYSTIQUE 1999 COUGAR
LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150,
F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98
EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER
1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to revise the Service Procedure and to update
the model years.
ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the
refrigerant system cleaned to remove any debris or contaminants that may be present to prevent
damage to the replacement compressor.
ACTION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins
> A/C - Filtering Refrigerant After Compressor Replacement > Page 946
Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor.
Refer to the following Service Procedure for details.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 96-15-5
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major
Component Warranty Coverage For All Other Lincoins
OPERATION DESCRIPTION TIME
981205A Kit Installation 1.2 Hrs.
981205B Extra Time For Refrigerant 0.4 Hr.
(R-12) Recovery
DEALER CODING
CONDITION
BASIC PART NO. CODE
19703 49
OASIS CODES: 208000, 208999
Service Procedure
THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C
FLUSHER.
CAUTION
THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT
SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND
BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM
IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED
BEFORE STARTING THE FILTERING PROCEDURE.
Each Service Filter Kit includes the following items:
^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice
tube)
^ One (1) Instruction Sheet
NOTE
ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY
WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET
WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM
FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE
TUBE AFTER FILTERING IS COMPLETE.
CAUTION
FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN
THE APPROPRIATE SERVICE OR WORKSHOP MANUAL.
1. Before removing any refrigerant system components, recover the refrigerant from the system
following the recycling methods outlined In the appropriate Service/Workshop Manual.
2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container.
3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The
quantity of the new oil to be added is the amount to match that drained from the old accumulator
plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction
accumulator/drier part number.
CAUTION
REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12
SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a
SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE
TO SYSTEM COMPONENTS.
4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube
part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and
the evaporator, replace the liquid line assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins
> A/C - Filtering Refrigerant After Compressor Replacement > Page 947
5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1.
a. Be sure orifice inlet is toward the condenser.
b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible
refrigerant hose of 2500 psi burst rating. Individual fittings are also available.
6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a
calibrated container.
7. Drain the oil from the replacement compressor into a clean calibrated container.
NOTE:
IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD
COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP
MANUAL PROCEDURES.
8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10
service compressor does not contain any oil and can be used with an R-12 or an R-134a system.
CAUTION
REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL
WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT
IN DAMAGE TO SYSTEM COMPONENTS.
^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz),
pour the same amount of clean refrigerant oil into the new compressor.
^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3
oz) of clean refrigerant oil into the new compressor.
9. Install the new compressor following Service/Workshop Manual procedures. Make sure all
mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if
necessary.
10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures.
11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make
sure they do not interfere with other engine compartment components. If necessary, use tie straps
to make adjustments.
12. Set the A/C control on Max A/C, high blower and temperature control at full cold.
a. Start engine and let idle briefly.
b. Be sure A/C system is operating properly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins
> A/C - Filtering Refrigerant After Compressor Replacement > Page 948
13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at
800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system
operating.
14. Stop the engine.
NOTE:
IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE
PROCEEDING.
15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from
the liquid line.
16. Discard the filter. It can be used one (1) tie only.
17. Reconnect the liquid line back into the system.
18. Evacuate, charge and leak test the system. Make any necessary adjustments.
19. Check the operation of the system in all models.
PART NUMBER PART NAME
F8VZ-19E773-AA Filter Kit
F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only)
F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant
Systems Only)
NOTE
THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS
THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR
TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service
Bulletins > Recalls for Coolant Line/Hose: > NHTSA88V133000 > Aug > 88 > Recall 88V133000: Cooling System Hose
Replacement
Coolant Line/Hose: Recalls Recall 88V133000: Cooling System Hose Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > NHTSA88V133000 > Aug > 88 > Recall 88V133000:
Cooling System Hose Replacement
Coolant Line/Hose: All Technical Service Bulletins Recall 88V133000: Cooling System Hose
Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > NHTSA89V139000 > Aug > 89 > Recall 89V139000: Heater Hose Rerouting/Repair
Heater Hose: Recalls Recall 89V139000: Heater Hose Rerouting/Repair
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN UNDERHOOD FIRE. RE-ROUTE AND REPAIR HOSE, AS
NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: GAS CHASSIS - CUTAWAY AND VAN AMBULANCES.
1985 FORD TRUCK E350 1986 FORD TRUCK E350 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > NHTSA89V150000 > Aug > 89 > Recall 89V150000: Heater Hose Rerouting
Heater Hose: Recalls Recall 89V150000: Heater Hose Rerouting
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN
UNDERHOOD FIRE. RE-ROUTE HOSE AS NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: AMBULANCES BUILT ON FORD E350 CHASSIS.
1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > NHTSA89V075000 > Apr > 89 > Recall 89V075000: Heater Hose Rerouting
Heater Hose: Recalls Recall 89V075000: Heater Hose Rerouting
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN
UNDERHOOD FIRE. RE-ROUTE AND SPLICE HOSE AS NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: BUSES BUILT ON FORD E350 CHASSIS.
1986 FORD TRUCK E350
1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement
Technical Service Bulletin # 88S99 Date: 880901
Recall - Heater/Engine Bypass Hose Replacement
At Dealers By Order as Req'd -0- % of Parts Direct Shipped to Dealers
At PDC By Now Temporary Maximum
Date in Owner Letter 9/2/88 Order Quantity of 2 Kits
RECALL NUMBER
88S99
Date: Sept., 1988
PLEASE GIVE COPIES OF THIS BULLETIN TO YOUR PARTS AND SERVICE MANAGERS
TO: All Ford and Heavy Truck Dealers
SUBJECT: Safety Recall 88S99 - Heater and Engine Bypass Hose Replacement and Muffler
Inspections/Replacement on Certain 1983 through 1987-model 5.8L-4V H.D. and 7.5L Engine
Equipped Ford Econoline-Based Ambulances
IN CARES/OASIS - YES
REFUND CLAIMING - USE FORM 1863
MODIFICATION CLAIMING - USE FORM 1864
VEHICLES AFFECTED:
Ford Motor Company is initiating a safety recall of certain 1983 through 1987-model Econoline
E250/E350- based ambulances equipped with 7.5 Liter engines as well as certain 1985 through
1987-model Econoline E250/E350-based ambulances equipped with 5.8L 4V H.D. engines. All
involved vehicles are rated over 8,500 lbs. GW.
REASONS FOR THIS RECALL:
Investigations of recent fires involving Econolinebased ambulances have disclosed a potential for
engine compartment heater or engine bypass hoses to wear-out prematurely and rupture, allowing
engine coolant to come in contact with hot engine exhaust manifolds and possibly ignite. Testing
has indicated that worn-out hoses are not able to withstand the prolonged periods of extreme
engine operating temperatures and higher engine cooling system pressures encountered during
EMS severe-duty cycles.
ACTION BY FORD: All ambulances returned for the service provided by this Safety Recall will be
modified as follows;
^ Replacement of existing engine compartment heater and bypass hoses with silicone/NOMEX
hoses.
^ Replacement of the radiator cap.
^ Replacement of the engine coolant with a 50/50 mix of water and antifreeze. This mixture of
coolant will provide freeze protection for most areas. Extreme cold-weather areas should be
provided with a 60/40 mixture of coolant and water.
^ Pressure test the cooling system.
^ Inspection and, if necessary, installation of aluminized stainless steel mufflers on 1985-87-model
7.5L dual-thermactor engine equipped vehicles.
^ High heat resistance aluminized stainless steel mufflers will be installed on those ambulances
equipped with 1985-1987 7.5L, dual thermactor air pump-equipped engines that did not have those
mufflers installed in connection with safety recall 87M53. A temporary shortage of aluminized
stainless steel mufflers last year required the use of substitute mufflers on ambulances that were
found in need of muffler replacement at that time.
^ Underbody inspection for loose, mispositioned or missing heat-shielding parts. Contact the
Special Toll-Free Econoline/Ambulance Hotline for authorization to perform modifications as a
result of this inspection.
This service will be performed at no cost. Owner/ operators win be provided with information about
replacement recommendations for engine coolant and heater and engine bypass hoses.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 983
REFUNDS: Owner/operators of 1985-87-model 7.5L dual-thermactor engine equipped vehicles will
be provided refunds for Ford-sourced aluminized stainless steel mufflers which may have been
installed at their expense under Safety Recall 87M53. DEALERS ARE INSTRUCTED TO
PROVIDE REFUNDS TO OWNERS WHO ADEQUATELY PROVE SUCH A PURCHASE AND TO
CLAIM FOR REFUNDS USING FORM 1863.
DEALER RESPONSIBILITIES:
Owners will be told that they may wish to inform the National Highway Traffic Safety Administration
if the recall is not performed without charge or within a reasonable time after the vehicle is brought
to their dealership for repair.
REPAIR CODES: REFER TO ATTACHMENT II, EXHIBIT 1 - THE "REPAIR CODES" SHOWN ON
THE REFERENCED ATTACHMENT HAVE BEEN DEVELOPED TO ASSIST YOU IN SELECTING
THE CORRECT EXHAUST SYSTEM MUFFLERS FOR SPECIFIC VEHICLES. THESE "REPAIR
CODES" WILL BE PRINTED ON THE OWNER LETTER AND THE CLAIM FORM 1864. USE THE
CODES TO DETERMINE REQUIRED MUFFLERS AND WHEN PREPARING CLAIM FORMS
AND SERVICE DOCUMENTS.
CARES/OASIS: Dealers are to check the CARES and OASIS programs todetermine if an affected
vehicle is involved in other recalls.
CLAIM FORMS: USE CLAIM FORM 1864 FOR THE MODIFICATIONS REQUIRED FOR THIS
RECALL. USE CLAIM FORM 1863 FOR REFUNDS TO OWNERS WHO PREVIOUSLY PAID FOR
INSTALLATION Of FORD-SOURCED ALUMINIZEDSTAINLESS STEEL MUFFLERS. Refer to
Attachment I for preparation instructions.
PARTS Refer to Attachment II.
REQUIREMENTS:
LABOR ALLOWANCE: Refer to Attachment II.
TECHNICAL INSTRUCTIONS:
Refer to Attachment III.
OWNER NOTIFICATION:
Owner/operators will be notified with the letter shown on Attachment IV.
FPSD ASSISTANCE: Contact your FPSD District Service Engineer with any problems you have
concerning this recall. Additionally, a special toll-free Econoline/Ambulance Technical Hotline is
available to assist in resolving unusual repair issues technicians may encounter.
Personnel are available daily from 7:30 A.M. to 6:00 P.M., Eastern Time to provide technical
assistance by calling 1-800-445-1571.
Administrative Instructions
SAFETY RECALL 88S99 ADMINISTRATIVE INSTRUCTIONS Attachment I VEHICLES
AFFECTED:
Certain 1983 through 1987-model Econoline E250/E350- based ambulances equipped with 7.5
Liter engines as well as certain 1985 through 1987-model Econoline E250/E330- based
ambulances equipped with 5.8 Liter 4V H.D. Engines. All affected vehicles are rated over 8,500 lbs.
GVW.
REPORTING COMPLETIONS: Only the Form 1864 will be accepted for reimbursement for
modifications performed under this recall. Upon completion of the required service, the Form 1864
must be completely filled out and signed by authorized dealer personnel. CLAIM SUBMISSION:
The claims must be entered through the Direct Warranty Entry (DWE) system. Dealers without
DWE capability must mail the second copy of the Form 1864 for reimbursement. Should your
dealership receive pre-printed Forms 1864 with a seven digit claim number, you must drop the first
digit and enter only the last six digits. You must sight verify the claim number for accuracy. It is
important that all claims be filed for all completed units so you will be reimbursed and our records
will show completion.
REFUNDS: Refund requests submitted under Safety Recall 88S99 are governed by the following
guidelines:
^ Owner/operators of 1985-87 model ambulances with 7.5L dual thermactor engines are eligible for
a refund if they paid for a muffler replacement under Safety Recall 87M53 and the replacement
muffler was the new ribbed design, aluminized stainless steel muffler (See Attachment II, Exhibit 2
for eligible muffler part numbers). Paid repair orders or invoices presented by the owner/operator
requesting a refund must show one of the eligible muffler part numbers.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 984
^ Refunds include return of any deductible amount owners may have paid.
^ A copy of the paid repair orders or parts purchase receipts must be retained in your service file
for at least one year following the date of Company notification of payment.
^ Owner refund requests must be submitted on separate Warranty Claim Form 1863. In addition to
the information shown for the special preparation of Owner Refund
claims (Reference: Warranty and Policy Manual - Subject 6.1, Page 18), please enter the
information shown below:
Causal Basic Part Number - 88S99
Condition Code - OB
Labor Operation - REFUND
Administrative Allowance - 0.2 Hr.
Program Code - 88S99
^ An administrative allowance of 0.2 hours will be allowed for processing each eligible owner
refund request. To claim the allowance, enter ALLOW in the Labor Operation No. column and 0.2
in the Scheduled Time column. Extend the 0.2 hours at your authorized warranty labor rate and
enter the result in the Amount column.
^ Please provide prompt refund to all eligible owners who respond to this recall with proper repair
documentation.
Labor and Parts Ordering Instructions
SAFETY RECALL 88S99 LABOR AND PARTS ORDERING INSTRUCTIONS
Attachment II
PARTS ORDERING: Service parts required for this recall may be ordered through normal
channels. Refer to the following material and Attachment II, Exhibits 1 and 2.
Coolant Ordering
^ Since most areas will require a 50/50 mixture of antifreeze and water, order and claim for the
amount of coolant required to service each ambulance using the following information:
- In extreme cold weather areas use a 60/40 mixture, order and claim appropriately.
- Order enough coolant (Ford Part Number E2FZ-19549-AA, or equivalent) to fill the entire engine
cooling system. In most cases, 3 gallons of antifreeze and 3 gallons of water should be adequate to
attain a 50/50 mix
Service Part Number
Description Class Dealer Price
E2FZ-19549-AA Coolant, Engine V $8.65/Gallon a/
E3UZ-18472-C Kit, Heater Hose BG $64.65
E8UZ-8597-A Hose, Engine Bypass (5.8L Engs.
CG $2.25
Only)
a/ Based on $51.90, Carton 6 Gallons, order this part number or use locally purchased equivalent.
Use dealer aquisition cost for locally purchased equivalent.
Scheduled Time
LABOR OPERATIONS: Basic Labor Operation (Hours)
Inspection of the Ambulance Underbody and Exhaust System, Installation of Heater and Engine
Bypass Hose Improvement
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 985
Modifications. . . . . . . . . . . . . 2.1 Insert in Box "B" of Form 1864
LABOR OPERATIONS: (Cont'd.)
Scheduled Time
Basic Labor Operation (Hours)
Supplemental Labor Operations (Additive to Above)
Replacement of the Exhaust System Muffler, and Attaching Parts (7.5L Dual-Thermactor Engine
Equipped Vehicles . . . . . . . .
0.8 Insert in Box "B" of Form 1864
Note: Use this supplemental time when replacing mufflers on 7.5L Dual-Thermactor Engine
equipped vehicles. This time may also be used when replacing mufflers performed at owners'
expense.)
Additional Time to Access Engine Bypass Hoses on 7.5L Engine Equipped Vehicles . . . . . . . . . . . .
.
0.4 Insert in Box "B" of Form 1864
Administrative Allowance (Additive to Above)
Administrative Allowance . . . . . 0.1 Hr.
The Supplemental Labor Operations and the 0.1 hour administrative allowance must be added
before inserting the total labor time in Box "B" of the Form 1864.
Repair Code Description
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 986
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 987
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Technical Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTIONS
Attachment III
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 988
TECHNICAL INSTRUCTIONS:
Inspections:
^ Underbody - All Vehicles
1. Inspect the underbody and exhaust system for missing, loose or mispositioned heat-shielding
parts (Refer to Safety Recall 87M53 instructions).
If you discover any conditions as a result of this inspection that requires modification, please
contact the Special Toll-Free Econoline/Ambulance Hotline, 1-800-445-1571, for authorization.
Contact your District Office if the Hotline is not available.
^ Mufflers - All Vehicles
2. Refer to Attachment III, Exhibit 1. Remove the exhaust system muffler heat shields.
3. Inspect the muffler per the instructions contained in Attachment III, Exhibit 1.
^ Replace unacceptable mufflers and attaching parts at the OWNERS EXPENSE ON:
i) 1983 through 1987-model 7.5L single-thermactor engine equipped vehicles; ii) 1985 through
1987-model, 5.8L 4V H.D. engine equipped vehicles.
^ Replace any mufflers that are not Ford-sourced aluminized stainless steel and attaching parts at
FORD EXPENSE on 1985 through 1987-model, 7.5L dual thermactor engine equipped vehicles.
^ Heater and Bypass Hose Replacement:
4. Refer to Attachment III, Exhibit 2. Replace the engine compartment heater and engine bypass
hoses as shown on the referenced attachment. Note: The 5.8L 4V H.D. engines require a formed
bypass hose. This is not in the heater hose/bypass parts kit. Order this hose separately.
5. Pressure test the cooling system and replace existing radiator cap.
NOTE: Owners will be instructed to retorque hose clamps to 2.5-3.0 N-m (22-26 in.lbs.) when
coolant leakage is observed.
MODIFICATION DECAL: Prepare an "Authorized Modifications" decal (Form FPS-8262) as shown
below. Affix the decal to a flat clean surface on
the radiator support. (Order the "Authorized Modifications" decal on your Weekly Stock Order Pad.)
Specific Technical Repair Code and Parts Ordering Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
Exhaust System-Ford Components-Correct Routing and Retention
1983-1985 7.5L MODELS (MODELS WITH SINGLE AIR PUMP) 1985-1/2-1987 5.8L MODELS
(OVER 8500 GVW WITH 4 BARREL CARBURETOR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 989
FIGURE 1
The Ford exhaust system as shown in Figure 1, provides the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheatng.
FIGURE 3
Inspect the exhaust system for leaks or ruptures. FOR 5.8L ONLY, it may be necessary to remove
the heat shields as shown in Figure 3. Inspect the muffler outer wrapper lock seam for separation.
If any such problems are found, notify the customer and request permission to repair the problem,
at the customer's expense. Note any such problems and the customer's reaction to your repair
request on your internal repair order form and retain in your records.
If a non-Ford exhaust system or exhaust components is noted on the unit, inform the customer of
the potential for durability reduction, exhaust flow restriction, or overheating as indicated above.
Note any such discrepancy and the customer's reaction on your internal repair order form and
retain in your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 990
FIGURE 1
ALL 5.8L AND ONLY CALIFORNIA CALIBRATION 7.5L: If the unit is not equiped with the all-steel
hangers shown in Figure 1, order and install the Ford Service Part as indicated in the attached
chart. SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
FIGURE 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 991
1985-1/2 - 1987 7.5L MODELS (MODELS WITH DUAL AIR PUMPS - SEE FIGURE 5)
FIGURE 2
The Ford exhaust system as shown in Figure 2, provdes the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheating.
FIGURE 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 992
FIGURE 4
Remove the heat shields covering the muffler by removing the retaining clamps securing the
shields as shown in Figure 3. If the muffler is a non-Ford design or is a non-ribbed design (Figure
4), remove the Muffler and Outlet Pipe Assembly and replace with the heavy duty ribbed muffler
assembly as indicated in the attached chart.
If the muffler is the heavy duty type (ribbed design - Figure 4), installed during the 1987 M53 recall,
inspect the entire surface of the muffler for cracks or openings. If any such openings are found,
replace the Muffler and Outet Pips Assembly with a new heavy duty ribbed muffler assembly.
Advise the Ambulance Technical Hot Line 1-800-445-1571, if you find a ribbed muffler with cracks
or openings.
FIGURE 2
If the unit is not equipped with the all-steel hangers as shown in Figure 2, order and install the Ford
Service Part as indicated in the attached chart. ATTACHMENT III EXHIBIT 1 PAGE 3 OF 3
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 993
KIT NUMBER E3UZ-18472-C HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED
AMBULANCES WITH 7.5L OR 5.8L 4V H.D. ENGINES SPECIAL NOTE: The following instructions
describe the installation procedure for the heater hose/bypass hose improvement package. It is
designed specially for Ford E-350 and E-250 (over 8500 pounds GVWR) based ambulances. The
original Ford heater hose system has probably been modified by the ambulance body builder. It is
not possible to identify all the designs and modifications used by these manufacturers. If you
encounter difficulties not anticipated in these instructions, contact the Ford Ambulance Recall
Hotline on 1-800-445-1571. PARTS LIST
Item Description Part Number Quantity
1 Silicons Hose - 5/8" I.D. *EST-M2D309-A 96"
2 Hose Clamp 388652-S2 20
3 "Y" Fitting D8UH-18663-AA 2
4 Tie Strap - 1/4" Wide 384213-S 10
5 Radiator Cap E5TH-8100-AA 1
*Engineering Specification Number
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 994
FIGURE 1
HEATER HOSE REMOVAL
1. Close the shutoff valves that connect the rear heater unit to the Ford installed heater hoses (See
Figure 1). Be sure to close both the supply and return hose valves. Failure to close these valves
could cause coolant fill problems later.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 995
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT.
2. Drain the coolant from the radiator by removing the radiator cap and carefully opening the drain
cock at the bottom of the radiator. After the coolant has drained from the radiator, close the drain
cock and discard the radiator cap.
3. Disconnect and remove any objects, such as thermactor pump filter/silencer or coolant overflow
bottle, obstructing access to the heater hoses.
4. Inspect the hoses for chaffing or cuts (See Figure 1). Note the position of any straps or clamps
for securing the new hoses at time of installation.
5. Disconnect the vacuum line from the water supply valve.
6. Disconnect the inlet and outlet hoses from the heater core, engine block, and rear heater shutoff
valves (See Figure 1). Loosen each clamp and cut the hose first to prevent core damage. DO NOT
twist hoses in the removal process. Disconnect the hoses from any locating clips. Discard all hose
clamps.
NOTE: DO NOT disconnect the hoses routed from the shutoff valves to the rear heater unit.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 996
FIGURE 1
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 997
FIGURE 2
HEATER HOSE INSTALLATION
1. Using hoses (Item 1), hose clamps (Item 2) and "Y" fittings (Item 3), assemble duplicate hose
layouts of the removed hose assemblies (Figure 1).
NOTE: The hoses leading from the "Y" fittings may have to be slightly longer than the original
hoses to avoid any kinks or bends. This is due to the replacement fittings having a different angle in
the "Y" than the original "Y" or "T" fittings. Silicone hoses require the special clamps Included in the
kit to prevent cutting the hose. DO NOT use any other type of clamp.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 1 OF 5
on 1-800-445-1571 if you have any questions.
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
2. Remove the vacuum operated water supply valve from the old hose assembly and install it into
the new hose assembly.
NOTE: Make sure that the flow arrow stamped on the valve is pointing toward the heater core.
3. Torque the clamps (Item 2) to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
4. Connect the hose assemblies with clamps (Item 2) to the engine block, heater core and rear shut
off valves.
5. Torque the clamps to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
6. Connect the vacuum line to the water supply valve.
7. Using tie straps (Item 4), secure the hoses to an adjacent engine component to prevent chaffing
or cutting during engine operation. The hoses may be secured in a manner similar to the original
method if the removed hoses were not damaged as noted earlier. If the original hoses were
damaged, route the hoses and secure them in a manner to prevent hose damage during engine
operation.
WATER BYPASS HOSE REMOVAL AND INSTALLATION FOR VEHICLES WITH 7.5L ENGINES
1. Remove the distributer vacuum hose to improve accessibility to the water bypass hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 998
FIGURE 2
2. Remove the water bypass hose and clamps (See Figure 2). Discard the clamps.
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
CAUTION: DO NOT ALTER (CUT OFF) THE INTAKE MANIFOLD AND/OR THE WATER PUMP
HOSE CONNECTIONS. ANY
DAMAGE SUCH AS SHARP EDGES, TO THESE CONNECTIONS WILL RESULT IN DAMAGE
TO THE NEW BYPASS HOSE DURING INSTALLATION.
4. Using the removed hose as a pattern, cut a piece of silicone hose (Item 1) to the proper length
and position it on the intake manifold bypass connection.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 3 OF 5
on 1-800-445-1571 if you have any questions
FIGURE 3
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D ENGINES
5. Position two (2) new hose clamps (Item 2) on the new hose, installed in Step 4, toward the
intake manifold. (See Figure 3.)
6. Bend (double over) the new bypass hose downward and slide the hose on to the water pump
bypass hose connection. (See Figure 3.)
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 999
FIGURE 4
FOR VEHICLES WITH 5.8L ENGINES
1. Remove the distributor vacuum hose to improve accessibility to the water bypass hose.
2. Remove the water bypass hose and clamps (See Figure 4). Discard the clamps.
Don't forget... ATTACHMENT III
call the Special Econline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 4 OF 5
on 1-800-445-1571 if you have any questions!
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
4. Position a new formed bypass hose (Part number E8UZ-8597-A) on the intake manifold bypass
connection.
5. Position two (2) new hose clamps (Item 2) on the new hose toward the intake manifold.
6. Bend and slide the hose on to the water pump bypass hose connection.
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to:) 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose, PRESSURE TEST COOLING SYSTEM
1. Reinstall all of the objects such as the thermactor pump filter/silencer or coolant overflow bottle,
that obstructed access to the heater hoses.
2. Fill the cooling system with a coolant mixture of 50/50 Ford Long Life Coolant E2FZ-19549-AA
(ESE-M97B44-A) or equivalent and water, to 38 mm (1.5 inches) below the cap seal.
3. Install radiator cap (Item 5)
WARNING: DO NOT STAND IN LINE WITH OR NEAR THE RADIATOR FAN WHEN THE
ENGINE IS RUNNING.
4. Start the engine, let it warm until the upper radiator hose is hot, shut off the engine. Allow the
engine to cool, remove the cap and check the coolant level. Fill as required.
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1000
5. Using the Rotunda Cooling System Pressurization Kit 021-00012, pressurize the cooling system
to 20 psi and check for leaks. Be sure to follow the instructions in the kit on the recommmended
method of connecting the tester to the radiator.
6. If any leaks are found, correct as needed.
7. Pressure test the cooling system until no leaks we found.
8. Rechock the coolant level in the radiator to make sure that it is 38 mm (1.5 inches ) below the
cap seal. If it is not, fill as required.
9. Reinstall the radiator cap and add coolant to the overflow bottle as required.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 5 OF 5
on 1-800-445-1571 if you have any questions!
Owner & Operator Letter Information
Attachment IV
September 2, 1988
Dear Owner/Operator:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
Ford Motor Company has determined that a defect which relates to Motor Vehicle Safety evists in
certain 1983-1987 Econoline-based ambulances equipped with 7.5 liter or 5.8 liter 4V H.D. V8
engines. Due to the prolonged periods of extreme engine operating temperatures and cooling
system pressures encountered during EMS severe-duty cycles, heater or engine bypass hoses
may wear-out prematurely and burst. Engine coolant ("antifreeze") from a burst hose may cause a
fire if it sprays onto an overheated engine exhaust manifold, especially if the coolant is
overconcentrated.
Ford Motor Company is now asking that you return your Econoline-based ambulance to your Ford
or Ford Heavy Truck Dealer for corrective action.
COOLING SYSTEM SERVICE
At no cost to you, your dealer will:
- replace certain "rubber" heater hoses installed by Ford Motor Company when the vehicle was
manufactured (ie., up to the auxiliary heater shut-off valves), with new "SILICONE/NOMEX" heater
hose;
- replace engine bypass hoses
- replace the engine coolant (with a proper 50/50 mixture);
- install a new radiator cap;
- pressure test the cooling system.
Most ambulances also have auxiliary heater systems. The ambulance body manufacturer typically
installs these heater systems. While these hoses are not part of this safety recall, we strongly
recommend that you consider replacing all non-silicone/Nomex @ auxiliary heater hoses also. THE
COST OF REPLACING THE AUXILIARY HEATER HOSES WILL BE AT YOUR EXPENSE. IF
LEAKS ARE FOUND IN OTHER COMPONENTS OF THE ENGINE COOLING SYSTEM, WHEN
THE SYSTEM IS PRESSURE TESTED SUCH AS THE RADIATOR OR RADIATOR HOSES, THE
COST OF REPAIRING THOSE COMPONENTS WILL BE AT YOUR EXPENSE.
FOR ALL HEATER SYSTEM HOSE REPLACEMENTS, FORD RECOMMENDS THAT YOU
SPECIFY HOSES MADE ONLY FROM THE "SILICONE/NOMEX" MATERIAL. SILICONE HOSES
ALSO REQUIRE SPECIAL HOSE CLAMPS TO PREVENT CUTTING THE HOSE. USE ONLY
THE HOSE CLAMPS RECOMMENDED BELOW WITH SILICONE HOSES.
When purchasing replacements, the following parts should be specified:
Ford Service Motorcraft Brand
Part Name Part Number Part Number
- SILICONE/NOMEX E8TZ-18472-H KH-15
Heater Hose - 25 foot lengths
- Formed Water Pump Bypass E8UZ-8597-A KMS-1776
Hose (for 5.8L 4V H.D. Engine)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1001
- Hose Clamps D9AZ-8287-C YF-842
It is important also that the proper torque be used when attaching the special hose clamps required
for SILICONE/NOMEX hoses. Your dealer will properly torque clamps when they install the heater
and engine bypass hoses on your ambulance. If you should notice coolant seepage, retorque the
clamps to 2.5 to 3.0 N-m (22-26 in.lbs.).
These parts are available through your Ford, Lincoln-Mercury or Ford Heavy Truck Dealer. They
are also available through any Motorcraft parts distributor.
Ford recommends that you always replace these SILICONE/NOMEX HEATER SYSTEM hoses
every 48,000 miles or 48 months, whichever comes first. Non-silicone hoses should be replaced
every 24,000 miles or 24 months, whichever comes first.
It is important that your ambulance cooling system have the proper anti-freeze coolant and water
mixture for adequate freeze protection. Please read and observe the recommendations on the
attachment, "The Importance of Proper Cooling System Anti-freeze Mixtures".
EXHAUST SYSTEM SERVICE
^ Certain 198-5-1987 Model Ambulances with 7.5 Liter/Dual Thermactor Engines
Ambulances with 7.5 Liter V8 engines and a dual-thermactor emission system will have a new
aluminized stainless steel muffler installed. Mufflers and installation will be free of charge.
Some of these ambulances may have already had new alumunized stainless steel mufflers
installed during the earlier recall. These vehicles will not need new mufflers.
^ Refunds for Certain Later Model Muffler Replacements
As noted above, some of these ambulances with 7.5 liter/dual thermactor engines may have
received the new aluminized stainless steel mufflers during the service for the earlier Safety Recall
87M53. If you paid to have these new aluminized stainless steel mufflers installed, you are entitled
to a refund for the costs of parts and labor. If you are entitled to this refund, please present your
paid receipt to any Ford or Ford Heavy Truck Dealer who will process a refund for you.
This receipt must show the date of repair, the part numbers for the new aluminized stainless steel
muffler and attaching parts as well as the parts and labor costs.
^ Other 7.5 Liter and 5.8 Liter 4V H.D. Engine Equipped Ambulances
Ambulances with 7.5 Liter V8 engines and a single thermactor emission system as well as all
1985-1987 model ambulances with 5.8 Liter 4V H.D. V8 engines will only have the muffler
inspected. Replacement of defective mufflers will be the owner's responsibility.
SCHEDULE SERVICE AT ANY FORD OR FORD HEAVY TRUCK DEALER NOW
Since the cooling system parts, mufflers and instructions are now available, we urge you to
schedule this service as quickly as possible.
NOTE: ANY FORD OR FORD HEAVY TRUCK DEALER CAN DO THE COOLING SYSTEM AND
MUFFLER SERVICE.
Before you return your vehicle for this service, we urge you to review the cooling system
information sent to you in June, 1988. Some cooling system maintenance may be needed now.
COMPUTER FORM
The computer form included with this letter may include a special part code. Your dealer will need
to know this code when you call to make an appointment. The code, located in the box labeled "Kit
Code", half way down the right side of the form, will be a single digit number from 1 through 8.
IMPORTANT NOTE
If your vehicle is not operated solely on propane and has not yet been modified to correct a fuel
system over-pressurization concern, announced in July, 1987 as Safety Recall 87M53, or has only
received the earlier (prior to late-October, 1987) Phase I fuel system modifications, you need to
have these modifications done as promptly as possible. You may want to have all of the required
services performed together.
NOTE: ONLY OUR SPECIALLY TRAINED DEALERS CAN WORK ON THE FUEL SYSTEM AND
SYSTEM MODIFICATIONS.
A listing of our specially trained dealers is enclosed.
THANK YOU FOR YOUR CONTINUED COOPERATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1002
We are sorry that we must inconvenience you again by asking you to return your Econoline-based
ambulance to your Ford or Ford Heavy Truck dealer. However we do wish to maintain your
confidence in our vehicle. Thank you for your continued cooperation in this matter of mutual
concern. THE IMPORTANCE OF PROPER COOLING SYSTEM ANTI-FREEZE MIXTURE
It is extremely important that the proper anti-freeze mixture be used in your ambulance cooling
system, and that it be maintained at recommended levels.
Ford recommends that a reasonably fresh 50% anti-freeze concentrate and 50% water mixture be
maintained in the cooling system of your ambulances at all times. This mixture provides adequate
freeze protection for most areas (50/50 mixtures provide protection to - 35~F). It also provides
optimum engine cooling and corrosion protection for the system.
Increasing the anti-freeze concentration above 50% will reduce engine cooling and result in hotter
engine operation. If you are in extremely cold area, it is permissible to use a 60% anti-freeze
concentrate and 40% water providing protection to approximately - 60~F, but only during the winter
months. (This is a revised coolant manufacturer recommendation from the information sent to you
in June, 1988, in a Motorcraft booklet "Cooling System Operation and Maintenance", dated April,
1979). The mixture should be returned to 50/50 at the end of your cold season. As the concentrate
percentage gets larger beyond 60% concentrate, the freeze protection is less. A 100% anti-freeze
concentration only protects your cooling system to - 8~F.
Decreasing the anti-freeze concentration below 40% reduces corrosion and freeze protection
(40/60 mixtures provides protection to - 10~F).
Remember:
^ Maintain cooling system mixtures at 50/50. Do not allow the mixture to be above 60/40.
^ Replace your cooling system mixture annually.
^ Replace lost coolant with a 50/50 mixture. Keep a pre-mixed supply of 50/50 mixture to refill the
system.
^ Do not refill your system with pure anti-freeze.
^ Regularly inspect and repair any cooling system leaks.
^ Replace cooling system hoses before they fail. Follow the Ford recommended replacement
intervals.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Recalls for Heater Hose: > NHTSA88V133000 > Aug > 88 > Recall 88V133000: Cooling System Hose Replacement
Heater Hose: Recalls Recall 88V133000: Cooling System Hose Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > NHTSA89V139000 > Aug > 89 > Recall 89V139000: Heater Hose
Rerouting/Repair
Heater Hose: All Technical Service Bulletins Recall 89V139000: Heater Hose Rerouting/Repair
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN UNDERHOOD FIRE. RE-ROUTE AND REPAIR HOSE, AS
NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: GAS CHASSIS - CUTAWAY AND VAN AMBULANCES.
1985 FORD TRUCK E350 1986 FORD TRUCK E350 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > NHTSA89V150000 > Aug > 89 > Recall 89V150000: Heater Hose
Rerouting
Heater Hose: All Technical Service Bulletins Recall 89V150000: Heater Hose Rerouting
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN
UNDERHOOD FIRE. RE-ROUTE HOSE AS NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: AMBULANCES BUILT ON FORD E350 CHASSIS.
1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > NHTSA89V075000 > Apr > 89 > Recall 89V075000: Heater Hose
Rerouting
Heater Hose: All Technical Service Bulletins Recall 89V075000: Heater Hose Rerouting
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN
UNDERHOOD FIRE. RE-ROUTE AND SPLICE HOSE AS NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: BUSES BUILT ON FORD E350 CHASSIS.
1986 FORD TRUCK E350
1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement
Technical Service Bulletin # 88S99 Date: 880901
Recall - Heater/Engine Bypass Hose Replacement
At Dealers By Order as Req'd -0- % of Parts Direct Shipped to Dealers
At PDC By Now Temporary Maximum
Date in Owner Letter 9/2/88 Order Quantity of 2 Kits
RECALL NUMBER
88S99
Date: Sept., 1988
PLEASE GIVE COPIES OF THIS BULLETIN TO YOUR PARTS AND SERVICE MANAGERS
TO: All Ford and Heavy Truck Dealers
SUBJECT: Safety Recall 88S99 - Heater and Engine Bypass Hose Replacement and Muffler
Inspections/Replacement on Certain 1983 through 1987-model 5.8L-4V H.D. and 7.5L Engine
Equipped Ford Econoline-Based Ambulances
IN CARES/OASIS - YES
REFUND CLAIMING - USE FORM 1863
MODIFICATION CLAIMING - USE FORM 1864
VEHICLES AFFECTED:
Ford Motor Company is initiating a safety recall of certain 1983 through 1987-model Econoline
E250/E350- based ambulances equipped with 7.5 Liter engines as well as certain 1985 through
1987-model Econoline E250/E350-based ambulances equipped with 5.8L 4V H.D. engines. All
involved vehicles are rated over 8,500 lbs. GW.
REASONS FOR THIS RECALL:
Investigations of recent fires involving Econolinebased ambulances have disclosed a potential for
engine compartment heater or engine bypass hoses to wear-out prematurely and rupture, allowing
engine coolant to come in contact with hot engine exhaust manifolds and possibly ignite. Testing
has indicated that worn-out hoses are not able to withstand the prolonged periods of extreme
engine operating temperatures and higher engine cooling system pressures encountered during
EMS severe-duty cycles.
ACTION BY FORD: All ambulances returned for the service provided by this Safety Recall will be
modified as follows;
^ Replacement of existing engine compartment heater and bypass hoses with silicone/NOMEX
hoses.
^ Replacement of the radiator cap.
^ Replacement of the engine coolant with a 50/50 mix of water and antifreeze. This mixture of
coolant will provide freeze protection for most areas. Extreme cold-weather areas should be
provided with a 60/40 mixture of coolant and water.
^ Pressure test the cooling system.
^ Inspection and, if necessary, installation of aluminized stainless steel mufflers on 1985-87-model
7.5L dual-thermactor engine equipped vehicles.
^ High heat resistance aluminized stainless steel mufflers will be installed on those ambulances
equipped with 1985-1987 7.5L, dual thermactor air pump-equipped engines that did not have those
mufflers installed in connection with safety recall 87M53. A temporary shortage of aluminized
stainless steel mufflers last year required the use of substitute mufflers on ambulances that were
found in need of muffler replacement at that time.
^ Underbody inspection for loose, mispositioned or missing heat-shielding parts. Contact the
Special Toll-Free Econoline/Ambulance Hotline for authorization to perform modifications as a
result of this inspection.
This service will be performed at no cost. Owner/ operators win be provided with information about
replacement recommendations for engine coolant and heater and engine bypass hoses.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement >
Page 1024
REFUNDS: Owner/operators of 1985-87-model 7.5L dual-thermactor engine equipped vehicles will
be provided refunds for Ford-sourced aluminized stainless steel mufflers which may have been
installed at their expense under Safety Recall 87M53. DEALERS ARE INSTRUCTED TO
PROVIDE REFUNDS TO OWNERS WHO ADEQUATELY PROVE SUCH A PURCHASE AND TO
CLAIM FOR REFUNDS USING FORM 1863.
DEALER RESPONSIBILITIES:
Owners will be told that they may wish to inform the National Highway Traffic Safety Administration
if the recall is not performed without charge or within a reasonable time after the vehicle is brought
to their dealership for repair.
REPAIR CODES: REFER TO ATTACHMENT II, EXHIBIT 1 - THE "REPAIR CODES" SHOWN ON
THE REFERENCED ATTACHMENT HAVE BEEN DEVELOPED TO ASSIST YOU IN SELECTING
THE CORRECT EXHAUST SYSTEM MUFFLERS FOR SPECIFIC VEHICLES. THESE "REPAIR
CODES" WILL BE PRINTED ON THE OWNER LETTER AND THE CLAIM FORM 1864. USE THE
CODES TO DETERMINE REQUIRED MUFFLERS AND WHEN PREPARING CLAIM FORMS
AND SERVICE DOCUMENTS.
CARES/OASIS: Dealers are to check the CARES and OASIS programs todetermine if an affected
vehicle is involved in other recalls.
CLAIM FORMS: USE CLAIM FORM 1864 FOR THE MODIFICATIONS REQUIRED FOR THIS
RECALL. USE CLAIM FORM 1863 FOR REFUNDS TO OWNERS WHO PREVIOUSLY PAID FOR
INSTALLATION Of FORD-SOURCED ALUMINIZEDSTAINLESS STEEL MUFFLERS. Refer to
Attachment I for preparation instructions.
PARTS Refer to Attachment II.
REQUIREMENTS:
LABOR ALLOWANCE: Refer to Attachment II.
TECHNICAL INSTRUCTIONS:
Refer to Attachment III.
OWNER NOTIFICATION:
Owner/operators will be notified with the letter shown on Attachment IV.
FPSD ASSISTANCE: Contact your FPSD District Service Engineer with any problems you have
concerning this recall. Additionally, a special toll-free Econoline/Ambulance Technical Hotline is
available to assist in resolving unusual repair issues technicians may encounter.
Personnel are available daily from 7:30 A.M. to 6:00 P.M., Eastern Time to provide technical
assistance by calling 1-800-445-1571.
Administrative Instructions
SAFETY RECALL 88S99 ADMINISTRATIVE INSTRUCTIONS Attachment I VEHICLES
AFFECTED:
Certain 1983 through 1987-model Econoline E250/E350- based ambulances equipped with 7.5
Liter engines as well as certain 1985 through 1987-model Econoline E250/E330- based
ambulances equipped with 5.8 Liter 4V H.D. Engines. All affected vehicles are rated over 8,500 lbs.
GVW.
REPORTING COMPLETIONS: Only the Form 1864 will be accepted for reimbursement for
modifications performed under this recall. Upon completion of the required service, the Form 1864
must be completely filled out and signed by authorized dealer personnel. CLAIM SUBMISSION:
The claims must be entered through the Direct Warranty Entry (DWE) system. Dealers without
DWE capability must mail the second copy of the Form 1864 for reimbursement. Should your
dealership receive pre-printed Forms 1864 with a seven digit claim number, you must drop the first
digit and enter only the last six digits. You must sight verify the claim number for accuracy. It is
important that all claims be filed for all completed units so you will be reimbursed and our records
will show completion.
REFUNDS: Refund requests submitted under Safety Recall 88S99 are governed by the following
guidelines:
^ Owner/operators of 1985-87 model ambulances with 7.5L dual thermactor engines are eligible for
a refund if they paid for a muffler replacement under Safety Recall 87M53 and the replacement
muffler was the new ribbed design, aluminized stainless steel muffler (See Attachment II, Exhibit 2
for eligible muffler part numbers). Paid repair orders or invoices presented by the owner/operator
requesting a refund must show one of the eligible muffler part numbers.
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Page 1025
^ Refunds include return of any deductible amount owners may have paid.
^ A copy of the paid repair orders or parts purchase receipts must be retained in your service file
for at least one year following the date of Company notification of payment.
^ Owner refund requests must be submitted on separate Warranty Claim Form 1863. In addition to
the information shown for the special preparation of Owner Refund
claims (Reference: Warranty and Policy Manual - Subject 6.1, Page 18), please enter the
information shown below:
Causal Basic Part Number - 88S99
Condition Code - OB
Labor Operation - REFUND
Administrative Allowance - 0.2 Hr.
Program Code - 88S99
^ An administrative allowance of 0.2 hours will be allowed for processing each eligible owner
refund request. To claim the allowance, enter ALLOW in the Labor Operation No. column and 0.2
in the Scheduled Time column. Extend the 0.2 hours at your authorized warranty labor rate and
enter the result in the Amount column.
^ Please provide prompt refund to all eligible owners who respond to this recall with proper repair
documentation.
Labor and Parts Ordering Instructions
SAFETY RECALL 88S99 LABOR AND PARTS ORDERING INSTRUCTIONS
Attachment II
PARTS ORDERING: Service parts required for this recall may be ordered through normal
channels. Refer to the following material and Attachment II, Exhibits 1 and 2.
Coolant Ordering
^ Since most areas will require a 50/50 mixture of antifreeze and water, order and claim for the
amount of coolant required to service each ambulance using the following information:
- In extreme cold weather areas use a 60/40 mixture, order and claim appropriately.
- Order enough coolant (Ford Part Number E2FZ-19549-AA, or equivalent) to fill the entire engine
cooling system. In most cases, 3 gallons of antifreeze and 3 gallons of water should be adequate to
attain a 50/50 mix
Service Part Number
Description Class Dealer Price
E2FZ-19549-AA Coolant, Engine V $8.65/Gallon a/
E3UZ-18472-C Kit, Heater Hose BG $64.65
E8UZ-8597-A Hose, Engine Bypass (5.8L Engs.
CG $2.25
Only)
a/ Based on $51.90, Carton 6 Gallons, order this part number or use locally purchased equivalent.
Use dealer aquisition cost for locally purchased equivalent.
Scheduled Time
LABOR OPERATIONS: Basic Labor Operation (Hours)
Inspection of the Ambulance Underbody and Exhaust System, Installation of Heater and Engine
Bypass Hose Improvement
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Page 1026
Modifications. . . . . . . . . . . . . 2.1 Insert in Box "B" of Form 1864
LABOR OPERATIONS: (Cont'd.)
Scheduled Time
Basic Labor Operation (Hours)
Supplemental Labor Operations (Additive to Above)
Replacement of the Exhaust System Muffler, and Attaching Parts (7.5L Dual-Thermactor Engine
Equipped Vehicles . . . . . . . .
0.8 Insert in Box "B" of Form 1864
Note: Use this supplemental time when replacing mufflers on 7.5L Dual-Thermactor Engine
equipped vehicles. This time may also be used when replacing mufflers performed at owners'
expense.)
Additional Time to Access Engine Bypass Hoses on 7.5L Engine Equipped Vehicles . . . . . . . . . . . .
.
0.4 Insert in Box "B" of Form 1864
Administrative Allowance (Additive to Above)
Administrative Allowance . . . . . 0.1 Hr.
The Supplemental Labor Operations and the 0.1 hour administrative allowance must be added
before inserting the total labor time in Box "B" of the Form 1864.
Repair Code Description
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Page 1027
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Page 1028
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Technical Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTIONS
Attachment III
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Page 1029
TECHNICAL INSTRUCTIONS:
Inspections:
^ Underbody - All Vehicles
1. Inspect the underbody and exhaust system for missing, loose or mispositioned heat-shielding
parts (Refer to Safety Recall 87M53 instructions).
If you discover any conditions as a result of this inspection that requires modification, please
contact the Special Toll-Free Econoline/Ambulance Hotline, 1-800-445-1571, for authorization.
Contact your District Office if the Hotline is not available.
^ Mufflers - All Vehicles
2. Refer to Attachment III, Exhibit 1. Remove the exhaust system muffler heat shields.
3. Inspect the muffler per the instructions contained in Attachment III, Exhibit 1.
^ Replace unacceptable mufflers and attaching parts at the OWNERS EXPENSE ON:
i) 1983 through 1987-model 7.5L single-thermactor engine equipped vehicles; ii) 1985 through
1987-model, 5.8L 4V H.D. engine equipped vehicles.
^ Replace any mufflers that are not Ford-sourced aluminized stainless steel and attaching parts at
FORD EXPENSE on 1985 through 1987-model, 7.5L dual thermactor engine equipped vehicles.
^ Heater and Bypass Hose Replacement:
4. Refer to Attachment III, Exhibit 2. Replace the engine compartment heater and engine bypass
hoses as shown on the referenced attachment. Note: The 5.8L 4V H.D. engines require a formed
bypass hose. This is not in the heater hose/bypass parts kit. Order this hose separately.
5. Pressure test the cooling system and replace existing radiator cap.
NOTE: Owners will be instructed to retorque hose clamps to 2.5-3.0 N-m (22-26 in.lbs.) when
coolant leakage is observed.
MODIFICATION DECAL: Prepare an "Authorized Modifications" decal (Form FPS-8262) as shown
below. Affix the decal to a flat clean surface on
the radiator support. (Order the "Authorized Modifications" decal on your Weekly Stock Order Pad.)
Specific Technical Repair Code and Parts Ordering Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
Exhaust System-Ford Components-Correct Routing and Retention
1983-1985 7.5L MODELS (MODELS WITH SINGLE AIR PUMP) 1985-1/2-1987 5.8L MODELS
(OVER 8500 GVW WITH 4 BARREL CARBURETOR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
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Page 1030
FIGURE 1
The Ford exhaust system as shown in Figure 1, provides the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheatng.
FIGURE 3
Inspect the exhaust system for leaks or ruptures. FOR 5.8L ONLY, it may be necessary to remove
the heat shields as shown in Figure 3. Inspect the muffler outer wrapper lock seam for separation.
If any such problems are found, notify the customer and request permission to repair the problem,
at the customer's expense. Note any such problems and the customer's reaction to your repair
request on your internal repair order form and retain in your records.
If a non-Ford exhaust system or exhaust components is noted on the unit, inform the customer of
the potential for durability reduction, exhaust flow restriction, or overheating as indicated above.
Note any such discrepancy and the customer's reaction on your internal repair order form and
retain in your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Page 1031
FIGURE 1
ALL 5.8L AND ONLY CALIFORNIA CALIBRATION 7.5L: If the unit is not equiped with the all-steel
hangers shown in Figure 1, order and install the Ford Service Part as indicated in the attached
chart. SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
FIGURE 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Page 1032
1985-1/2 - 1987 7.5L MODELS (MODELS WITH DUAL AIR PUMPS - SEE FIGURE 5)
FIGURE 2
The Ford exhaust system as shown in Figure 2, provdes the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheating.
FIGURE 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
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Page 1033
FIGURE 4
Remove the heat shields covering the muffler by removing the retaining clamps securing the
shields as shown in Figure 3. If the muffler is a non-Ford design or is a non-ribbed design (Figure
4), remove the Muffler and Outlet Pipe Assembly and replace with the heavy duty ribbed muffler
assembly as indicated in the attached chart.
If the muffler is the heavy duty type (ribbed design - Figure 4), installed during the 1987 M53 recall,
inspect the entire surface of the muffler for cracks or openings. If any such openings are found,
replace the Muffler and Outet Pips Assembly with a new heavy duty ribbed muffler assembly.
Advise the Ambulance Technical Hot Line 1-800-445-1571, if you find a ribbed muffler with cracks
or openings.
FIGURE 2
If the unit is not equipped with the all-steel hangers as shown in Figure 2, order and install the Ford
Service Part as indicated in the attached chart. ATTACHMENT III EXHIBIT 1 PAGE 3 OF 3
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Page 1034
KIT NUMBER E3UZ-18472-C HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED
AMBULANCES WITH 7.5L OR 5.8L 4V H.D. ENGINES SPECIAL NOTE: The following instructions
describe the installation procedure for the heater hose/bypass hose improvement package. It is
designed specially for Ford E-350 and E-250 (over 8500 pounds GVWR) based ambulances. The
original Ford heater hose system has probably been modified by the ambulance body builder. It is
not possible to identify all the designs and modifications used by these manufacturers. If you
encounter difficulties not anticipated in these instructions, contact the Ford Ambulance Recall
Hotline on 1-800-445-1571. PARTS LIST
Item Description Part Number Quantity
1 Silicons Hose - 5/8" I.D. *EST-M2D309-A 96"
2 Hose Clamp 388652-S2 20
3 "Y" Fitting D8UH-18663-AA 2
4 Tie Strap - 1/4" Wide 384213-S 10
5 Radiator Cap E5TH-8100-AA 1
*Engineering Specification Number
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Page 1035
FIGURE 1
HEATER HOSE REMOVAL
1. Close the shutoff valves that connect the rear heater unit to the Ford installed heater hoses (See
Figure 1). Be sure to close both the supply and return hose valves. Failure to close these valves
could cause coolant fill problems later.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Page 1036
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT.
2. Drain the coolant from the radiator by removing the radiator cap and carefully opening the drain
cock at the bottom of the radiator. After the coolant has drained from the radiator, close the drain
cock and discard the radiator cap.
3. Disconnect and remove any objects, such as thermactor pump filter/silencer or coolant overflow
bottle, obstructing access to the heater hoses.
4. Inspect the hoses for chaffing or cuts (See Figure 1). Note the position of any straps or clamps
for securing the new hoses at time of installation.
5. Disconnect the vacuum line from the water supply valve.
6. Disconnect the inlet and outlet hoses from the heater core, engine block, and rear heater shutoff
valves (See Figure 1). Loosen each clamp and cut the hose first to prevent core damage. DO NOT
twist hoses in the removal process. Disconnect the hoses from any locating clips. Discard all hose
clamps.
NOTE: DO NOT disconnect the hoses routed from the shutoff valves to the rear heater unit.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Page 1037
FIGURE 1
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement >
Page 1038
FIGURE 2
HEATER HOSE INSTALLATION
1. Using hoses (Item 1), hose clamps (Item 2) and "Y" fittings (Item 3), assemble duplicate hose
layouts of the removed hose assemblies (Figure 1).
NOTE: The hoses leading from the "Y" fittings may have to be slightly longer than the original
hoses to avoid any kinks or bends. This is due to the replacement fittings having a different angle in
the "Y" than the original "Y" or "T" fittings. Silicone hoses require the special clamps Included in the
kit to prevent cutting the hose. DO NOT use any other type of clamp.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 1 OF 5
on 1-800-445-1571 if you have any questions.
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
2. Remove the vacuum operated water supply valve from the old hose assembly and install it into
the new hose assembly.
NOTE: Make sure that the flow arrow stamped on the valve is pointing toward the heater core.
3. Torque the clamps (Item 2) to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
4. Connect the hose assemblies with clamps (Item 2) to the engine block, heater core and rear shut
off valves.
5. Torque the clamps to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
6. Connect the vacuum line to the water supply valve.
7. Using tie straps (Item 4), secure the hoses to an adjacent engine component to prevent chaffing
or cutting during engine operation. The hoses may be secured in a manner similar to the original
method if the removed hoses were not damaged as noted earlier. If the original hoses were
damaged, route the hoses and secure them in a manner to prevent hose damage during engine
operation.
WATER BYPASS HOSE REMOVAL AND INSTALLATION FOR VEHICLES WITH 7.5L ENGINES
1. Remove the distributer vacuum hose to improve accessibility to the water bypass hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Page 1039
FIGURE 2
2. Remove the water bypass hose and clamps (See Figure 2). Discard the clamps.
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
CAUTION: DO NOT ALTER (CUT OFF) THE INTAKE MANIFOLD AND/OR THE WATER PUMP
HOSE CONNECTIONS. ANY
DAMAGE SUCH AS SHARP EDGES, TO THESE CONNECTIONS WILL RESULT IN DAMAGE
TO THE NEW BYPASS HOSE DURING INSTALLATION.
4. Using the removed hose as a pattern, cut a piece of silicone hose (Item 1) to the proper length
and position it on the intake manifold bypass connection.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 3 OF 5
on 1-800-445-1571 if you have any questions
FIGURE 3
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D ENGINES
5. Position two (2) new hose clamps (Item 2) on the new hose, installed in Step 4, toward the
intake manifold. (See Figure 3.)
6. Bend (double over) the new bypass hose downward and slide the hose on to the water pump
bypass hose connection. (See Figure 3.)
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
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Page 1040
FIGURE 4
FOR VEHICLES WITH 5.8L ENGINES
1. Remove the distributor vacuum hose to improve accessibility to the water bypass hose.
2. Remove the water bypass hose and clamps (See Figure 4). Discard the clamps.
Don't forget... ATTACHMENT III
call the Special Econline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 4 OF 5
on 1-800-445-1571 if you have any questions!
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
4. Position a new formed bypass hose (Part number E8UZ-8597-A) on the intake manifold bypass
connection.
5. Position two (2) new hose clamps (Item 2) on the new hose toward the intake manifold.
6. Bend and slide the hose on to the water pump bypass hose connection.
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to:) 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose, PRESSURE TEST COOLING SYSTEM
1. Reinstall all of the objects such as the thermactor pump filter/silencer or coolant overflow bottle,
that obstructed access to the heater hoses.
2. Fill the cooling system with a coolant mixture of 50/50 Ford Long Life Coolant E2FZ-19549-AA
(ESE-M97B44-A) or equivalent and water, to 38 mm (1.5 inches) below the cap seal.
3. Install radiator cap (Item 5)
WARNING: DO NOT STAND IN LINE WITH OR NEAR THE RADIATOR FAN WHEN THE
ENGINE IS RUNNING.
4. Start the engine, let it warm until the upper radiator hose is hot, shut off the engine. Allow the
engine to cool, remove the cap and check the coolant level. Fill as required.
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Page 1041
5. Using the Rotunda Cooling System Pressurization Kit 021-00012, pressurize the cooling system
to 20 psi and check for leaks. Be sure to follow the instructions in the kit on the recommmended
method of connecting the tester to the radiator.
6. If any leaks are found, correct as needed.
7. Pressure test the cooling system until no leaks we found.
8. Rechock the coolant level in the radiator to make sure that it is 38 mm (1.5 inches ) below the
cap seal. If it is not, fill as required.
9. Reinstall the radiator cap and add coolant to the overflow bottle as required.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 5 OF 5
on 1-800-445-1571 if you have any questions!
Owner & Operator Letter Information
Attachment IV
September 2, 1988
Dear Owner/Operator:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
Ford Motor Company has determined that a defect which relates to Motor Vehicle Safety evists in
certain 1983-1987 Econoline-based ambulances equipped with 7.5 liter or 5.8 liter 4V H.D. V8
engines. Due to the prolonged periods of extreme engine operating temperatures and cooling
system pressures encountered during EMS severe-duty cycles, heater or engine bypass hoses
may wear-out prematurely and burst. Engine coolant ("antifreeze") from a burst hose may cause a
fire if it sprays onto an overheated engine exhaust manifold, especially if the coolant is
overconcentrated.
Ford Motor Company is now asking that you return your Econoline-based ambulance to your Ford
or Ford Heavy Truck Dealer for corrective action.
COOLING SYSTEM SERVICE
At no cost to you, your dealer will:
- replace certain "rubber" heater hoses installed by Ford Motor Company when the vehicle was
manufactured (ie., up to the auxiliary heater shut-off valves), with new "SILICONE/NOMEX" heater
hose;
- replace engine bypass hoses
- replace the engine coolant (with a proper 50/50 mixture);
- install a new radiator cap;
- pressure test the cooling system.
Most ambulances also have auxiliary heater systems. The ambulance body manufacturer typically
installs these heater systems. While these hoses are not part of this safety recall, we strongly
recommend that you consider replacing all non-silicone/Nomex @ auxiliary heater hoses also. THE
COST OF REPLACING THE AUXILIARY HEATER HOSES WILL BE AT YOUR EXPENSE. IF
LEAKS ARE FOUND IN OTHER COMPONENTS OF THE ENGINE COOLING SYSTEM, WHEN
THE SYSTEM IS PRESSURE TESTED SUCH AS THE RADIATOR OR RADIATOR HOSES, THE
COST OF REPAIRING THOSE COMPONENTS WILL BE AT YOUR EXPENSE.
FOR ALL HEATER SYSTEM HOSE REPLACEMENTS, FORD RECOMMENDS THAT YOU
SPECIFY HOSES MADE ONLY FROM THE "SILICONE/NOMEX" MATERIAL. SILICONE HOSES
ALSO REQUIRE SPECIAL HOSE CLAMPS TO PREVENT CUTTING THE HOSE. USE ONLY
THE HOSE CLAMPS RECOMMENDED BELOW WITH SILICONE HOSES.
When purchasing replacements, the following parts should be specified:
Ford Service Motorcraft Brand
Part Name Part Number Part Number
- SILICONE/NOMEX E8TZ-18472-H KH-15
Heater Hose - 25 foot lengths
- Formed Water Pump Bypass E8UZ-8597-A KMS-1776
Hose (for 5.8L 4V H.D. Engine)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement >
Page 1042
- Hose Clamps D9AZ-8287-C YF-842
It is important also that the proper torque be used when attaching the special hose clamps required
for SILICONE/NOMEX hoses. Your dealer will properly torque clamps when they install the heater
and engine bypass hoses on your ambulance. If you should notice coolant seepage, retorque the
clamps to 2.5 to 3.0 N-m (22-26 in.lbs.).
These parts are available through your Ford, Lincoln-Mercury or Ford Heavy Truck Dealer. They
are also available through any Motorcraft parts distributor.
Ford recommends that you always replace these SILICONE/NOMEX HEATER SYSTEM hoses
every 48,000 miles or 48 months, whichever comes first. Non-silicone hoses should be replaced
every 24,000 miles or 24 months, whichever comes first.
It is important that your ambulance cooling system have the proper anti-freeze coolant and water
mixture for adequate freeze protection. Please read and observe the recommendations on the
attachment, "The Importance of Proper Cooling System Anti-freeze Mixtures".
EXHAUST SYSTEM SERVICE
^ Certain 198-5-1987 Model Ambulances with 7.5 Liter/Dual Thermactor Engines
Ambulances with 7.5 Liter V8 engines and a dual-thermactor emission system will have a new
aluminized stainless steel muffler installed. Mufflers and installation will be free of charge.
Some of these ambulances may have already had new alumunized stainless steel mufflers
installed during the earlier recall. These vehicles will not need new mufflers.
^ Refunds for Certain Later Model Muffler Replacements
As noted above, some of these ambulances with 7.5 liter/dual thermactor engines may have
received the new aluminized stainless steel mufflers during the service for the earlier Safety Recall
87M53. If you paid to have these new aluminized stainless steel mufflers installed, you are entitled
to a refund for the costs of parts and labor. If you are entitled to this refund, please present your
paid receipt to any Ford or Ford Heavy Truck Dealer who will process a refund for you.
This receipt must show the date of repair, the part numbers for the new aluminized stainless steel
muffler and attaching parts as well as the parts and labor costs.
^ Other 7.5 Liter and 5.8 Liter 4V H.D. Engine Equipped Ambulances
Ambulances with 7.5 Liter V8 engines and a single thermactor emission system as well as all
1985-1987 model ambulances with 5.8 Liter 4V H.D. V8 engines will only have the muffler
inspected. Replacement of defective mufflers will be the owner's responsibility.
SCHEDULE SERVICE AT ANY FORD OR FORD HEAVY TRUCK DEALER NOW
Since the cooling system parts, mufflers and instructions are now available, we urge you to
schedule this service as quickly as possible.
NOTE: ANY FORD OR FORD HEAVY TRUCK DEALER CAN DO THE COOLING SYSTEM AND
MUFFLER SERVICE.
Before you return your vehicle for this service, we urge you to review the cooling system
information sent to you in June, 1988. Some cooling system maintenance may be needed now.
COMPUTER FORM
The computer form included with this letter may include a special part code. Your dealer will need
to know this code when you call to make an appointment. The code, located in the box labeled "Kit
Code", half way down the right side of the form, will be a single digit number from 1 through 8.
IMPORTANT NOTE
If your vehicle is not operated solely on propane and has not yet been modified to correct a fuel
system over-pressurization concern, announced in July, 1987 as Safety Recall 87M53, or has only
received the earlier (prior to late-October, 1987) Phase I fuel system modifications, you need to
have these modifications done as promptly as possible. You may want to have all of the required
services performed together.
NOTE: ONLY OUR SPECIALLY TRAINED DEALERS CAN WORK ON THE FUEL SYSTEM AND
SYSTEM MODIFICATIONS.
A listing of our specially trained dealers is enclosed.
THANK YOU FOR YOUR CONTINUED COOPERATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement >
Page 1043
We are sorry that we must inconvenience you again by asking you to return your Econoline-based
ambulance to your Ford or Ford Heavy Truck dealer. However we do wish to maintain your
confidence in our vehicle. Thank you for your continued cooperation in this matter of mutual
concern. THE IMPORTANCE OF PROPER COOLING SYSTEM ANTI-FREEZE MIXTURE
It is extremely important that the proper anti-freeze mixture be used in your ambulance cooling
system, and that it be maintained at recommended levels.
Ford recommends that a reasonably fresh 50% anti-freeze concentrate and 50% water mixture be
maintained in the cooling system of your ambulances at all times. This mixture provides adequate
freeze protection for most areas (50/50 mixtures provide protection to - 35~F). It also provides
optimum engine cooling and corrosion protection for the system.
Increasing the anti-freeze concentration above 50% will reduce engine cooling and result in hotter
engine operation. If you are in extremely cold area, it is permissible to use a 60% anti-freeze
concentrate and 40% water providing protection to approximately - 60~F, but only during the winter
months. (This is a revised coolant manufacturer recommendation from the information sent to you
in June, 1988, in a Motorcraft booklet "Cooling System Operation and Maintenance", dated April,
1979). The mixture should be returned to 50/50 at the end of your cold season. As the concentrate
percentage gets larger beyond 60% concentrate, the freeze protection is less. A 100% anti-freeze
concentration only protects your cooling system to - 8~F.
Decreasing the anti-freeze concentration below 40% reduces corrosion and freeze protection
(40/60 mixtures provides protection to - 10~F).
Remember:
^ Maintain cooling system mixtures at 50/50. Do not allow the mixture to be above 60/40.
^ Replace your cooling system mixture annually.
^ Replace lost coolant with a 50/50 mixture. Keep a pre-mixed supply of 50/50 mixture to refill the
system.
^ Do not refill your system with pure anti-freeze.
^ Regularly inspect and repair any cooling system leaks.
^ Replace cooling system hoses before they fail. Follow the Ford recommended replacement
intervals.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > NHTSA88V133000 > Aug > 88 > Recall 88V133000: Cooling System
Hose Replacement
Heater Hose: All Technical Service Bulletins Recall 88V133000: Cooling System Hose
Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Technical Service Bulletins >
Recalls for Radiator Hose: > NHTSA88V133000 > Aug > 88 > Recall 88V133000: Cooling System Hose Replacement
Radiator Hose: Recalls Recall 88V133000: Cooling System Hose Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Radiator Hose: > NHTSA88V133000 > Aug > 88 > Recall 88V133000: Cooling System
Hose Replacement
Radiator Hose: All Technical Service Bulletins Recall 88V133000: Cooling System Hose
Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Recycled Engine Coolant - Service Tips
Coolant: Technical Service Bulletins Recycled Engine Coolant - Service Tips
Article No. 95-18-2
09/11/95
^ COOLANT - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP
^ COOLING SYSTEM - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP
FORD: 1980 and after CROWN VICTORIA, MUSTANG, THUNDERBIRD 1981 and after ESCORT
1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE
1994 and after ASPIRE 1995 and after CONTOUR
LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN
CAR 1981-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE
1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 and
after MYSTIQUE
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after
BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and
after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after
WINDSTAR
This TSB is being republished in its entirety to include warranty information when using recycled
coolant
ISSUE: Ford Motor Company authorizes the use of recycled engine coolant that, when properly
processed and reinhibited, meets Ford specification ESE-M97B44-A. At this time, the Rotunda
Coolant Recycler (181-00003) process is the only approved coolant recycling method available
through Ford that is capable of producing recycled engine coolant that meets Ford specification
ESE-M97B44-A.
ACTION: Refer to the following Service Procedure for coolant processing and reinhibiting using
Rotunda Coolant Recycler (181-00003).
NOTE:
WHILE TESTING SHOWS THAT RECYCLED ENGINE COOLANT CAN PROVIDE ACCEPTABLE
PERFORMANCE, THE COOLANT PRODUCED FROM ROTUNDA EQUIPMENT IS INTENDED
FOR USE WITHIN DEALERSHIPS ON WARRANTY AND CUSTOMER PAY REPAIRS ONLY
AND NOT INTENDED FOR RETAIL SALE. THERE ARE REGULATORY, PACKAGING AND
LABELING CONCERNS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Recycled Engine Coolant - Service Tips > Page 1066
ASSOCIATED WITH THE RETAIL SALE OF CHEMICAL PRODUCTS.
CAUTION:
THE REINHIBITOR CHEMICALS PROVIDED WITH THIS EQUIPMENT ARE NOT
APPROPRIATE FOR USE ON MEDIUM/HEAVY TRUCK APPLICATIONS.
WARNING:
ROTUNDA PREMIUM COOLANT REINHIBITORS # 1 AND # 2 HAVE BEEN SPECIFICALLY
FORMULATED TO WORK WITH ROTUNDA COOLANT RECYCLER (181-00003).
USE OF ANY OTHER CHEMICAL ADDITIVES WITH THIS SYSTEM WILL VOID ALL
WARRANTIES FOR THE EQUIPMENT AND FOR THE FINAL COOLANT PRODUCT.
SERVICE PROCEDURE
DIRECTIONS FOR PROCESSING USED ENGINE COOLANT WITH ROTUNDA COOLANT
RECYCLER
1. Close the drain valve on the unit.
2. Open the fill valve.
3. Pour used engine coolant into the funnel on the side of the unit.
NOTE:
MAXIMUM CAPACITY 15 25 GALLONS (95 L).
4. Insert the outlet hoses of the recycler into clean, properly labeled containers. One (1) container
is for the outlet process water and the other container is for distilled ethylene glycol.
5. Push the "ON" switch on the front to start the operation. The unit will process 1 gallon (3.8 L) per
hour of operation and will automatically shut off when cycle is complete.
6. Add reinhibitor following the directions in this article.
7. Open the drain valve to drain the residue from the distillation vessel. Dispose of residue in
accordance with all local. state and federal regulations.
ADDING REINHIBITOR CHEMICALS
1. Process the coolant according to the directions listed in this article
2. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 1 to each gallon of distilled ethylene glycol.
3. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 2 to each gallon of distilled ethylene glycol.
4. Mix well.
5. Check the pH level of the coolant. The pH level must be between 9 and 11.
6. Add enough water to the concentrated coolant to produce a 50/50 mixture of coolant and water.
NOTE:
THE CONCENTRATED COOLANT MUST BE MIXED WITH WATER TO MEET THE
NECESSARY ENGINE FREEZE PROTECTION.
7. Check the coolant freeze point of the 50% coolant solution. Freeze point should be -34°F
(-37°C).
Consult the Rotunda Coolant Recycler Manual for more detailed operating instructions. Call
1-800-ROTUNDA, 8 AM to 8 PM EST, for inquiries regarding the Rotunda Coolant Recycler and to
order the Reinhibitor (187-R0001).
PART NUMBER PART NAME
Rotunda # 187-R0001 Rotunda Premium Coolant Reinhibitor
WARRANTY CLAIMS: Dealer can claim recycled engine coolant by Ford approved process via a
warranty repair on an 1863 claim as follows:
Part Number: RECCOOL (not a valid part number, but it is recognized on an 1863 claim).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Recycled Engine Coolant - Service Tips > Page 1067
Quantity: Indicate the number of QUARTS of recycled coolant used.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-16-6 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 402000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Recycled Engine Coolant - Service Tips > Page 1068
Coolant: Technical Service Bulletins Engine Coolant - Recycled Coolant Not Authorized
Article No. 90-4-10
COOLING SYSTEM - USE OF RECYCLED ENGINE COOLANT - SERVICE TIP
FORD: 1984-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90
TAURUS 1988-90 FESTIVA 1989-90 PROBE
LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX
1984-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90
SABLE 1987-90 TRACER
MERKUR: 1985-90 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1984-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1986-90 AEROSTAR
MEDIUM/HEAVY TRUCK: 1984-90 C SERIES, F & B SERIES, L SERIES 1986-90 CARGO
SERIES
ISSUE: Ford Motor Company does not authorize the use of recycled engine coolant nor do they
sanction the use of any machines or devices that recycle engine coolant.
Recycled engine coolant is not equivalent to the factory fill OEM coolant, the Ford premium cooling
system fluid (E2FZ-19549-AA) or the Ford heavy duty low silicate cooling fluid (E6HZ-19549-A).
The quality of engine coolant degenerates with use. Recycling used engine coolant is very difficult
to do without exposing the used coolant to additional foreign substances. Merely adding an additive
to the coolant will not restore it.
ACTION: Use new engine coolant that meets Ford Motor coolant specifications for the engine
being serviced.
Properly dispose of the used coolant.
WARNING: THE DISPOSAL OF ALL USED ENGINE COOLANT MUST ALWAYS BE DONE IN
ACCORDANCE WITH ALL APPLICABLE FEDERAL, STATE AND LOCAL LAWS AND
REGULATIONS.
PART NUMBER PART NAME CLASS
E2FZ-19549-AA Coolant System Fluid - Ford V
Premium
E6HZ-19549-A Coolant System Fluid - Ford V
Heavy Duty Low Silicate (For use in diesel powered med/hvy trucks)
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
4300
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Coolant Capacity 28 qts
..............................................................................................................................................................
..........................................
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications > Page 1071
Coolant: Fluid Type Specifications
COOLING SYSTEM FLUID, PREMIUM
Ford Part No.
U.S.A (Except Oregon)
............................................................................................................................................................
E2FZ-19549-AA or -B Canada ............................................................................................................
.............................................................................................. CXC-8-B Oregon ..................................
.............................................................................................................................................................
F5FZ-19549-CC
Ford Specification ................................................................................................................................
................................................... ESE-M97B44-A
COOLING SYSTEM FLUSH
Ford Part No. .......................................................................................................................................
................................................... F1AZ-19A503-A Ford Specification .................................................
..................................................................................................................................... ESR-M14P7-A
Coolant Mixture with Water .................................................................................................................
...................................................................... 50%
Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the
correct coolant type.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T
- Mercon V ATF Usage
Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage
TSB 06-14-4
07/24/06
MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID.
FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993
Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996
Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996
Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004
Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650,
F-750
LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator
2002-2003 Blackwood
MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer
1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner
MERKUR: 1985-1989 XR4TI
This article supersedes TSB 01-15-7 to update the vehicle application chart.
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a
service fluid.
ACTION Beginning immediately all automatic transmission / transaxle applications requiring
MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission
Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R)
Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will
only continue for however long it takes to deplete what remains in inventory.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T
- Mercon V ATF Usage > Page 1076
Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R)
Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V
For proper fluid application on current and past model vehicles equipped with automatic
transmissions I transaxles refer to the fluid usage chart. (Figure 1)
CAUTION
AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL
ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T
- Mercon V ATF Usage > Page 1077
CAUTION
MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND
MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS
RECOMMENDING THAT PARTICULAR FLUID.
USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION
DAMAGE.
CAUTION
THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY
DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS).
USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE
TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE
FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE.
CAUTION
DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES,
TREATMENTS OR CLEANING AGENTS.
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T
- Mercon V ATF Usage > Page 1078
Fluid - A/T: Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid
TRANSMISSION - AUTOMATIC/MANUAL - Article No.
NEW FLUID AND USAGE CHART 87-18-14
FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS,
THUNDERBIRD, FORD
LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior
TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II,
AEROSTAR
ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart),
(XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON"
transmission fluid, where specified, will improve cold weather shift effort and synchronized
operation.
ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic
transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles.
NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual
transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the
transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent.
PART NUMBER PART NAME CLASS
XT-2-QDX MERCON - Quart V
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T
- Mercon V ATF Usage > Page 1079
XT-2-DDX MERCON - 55 Gallon V
Drum
E5RY-19C547-A Semi-Synthetic Oil B
OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS:
"INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Refill Capacity
Fluid - A/T: Specifications
TYPE MA
CAPACITY, Initial Refill*: C-6 5.0 qt (US)
With the engine at operating temperature, shift
transmission through all gears. Check fluid level in PARK
and add fluid as needed
Others 3.0 qt (US)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Refill Capacity >
Page 1082
Fluid - A/T: Specifications
Fluid Capacity Note: C6 units, 11.8 qts.; automatic overdrive units, 12
qts. Approximate. Make final check with dipstick.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
Drivetrain - Lubricant Usage
Fluid - M/T: Technical Service Bulletins Drivetrain - Lubricant Usage
Article No. 89-8-16
^ DRIVETRAIN - LUBRICATION USAGE
^ TRANSMISSION - MANUAL - LUBRICATION USAGE
LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER
1984-89 BRONCO II 1986-89 AEROSTAR
ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain
lubrication usage chart for light trucks has been put together to assist technicians in the event
service is required.
FIGURE 1
FIGURE 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
Drivetrain - Lubricant Usage > Page 1087
ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage.
Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage.
PART NUMBER PART NAME CLASS
D8DZ-19C547-A Standard Transmission BG
Lubricant - 5 gallons C1AZ-19590-BA
Long Life Lubricant B
(molybdenum disulfide) - 14.5 ounces
DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B
tube
D7AZ-19584-AA Multi-Purpose Grease - 15 B
ounce aerosol can
XT-2-QDX Transmission Fluid (Mercon) - V
quart can (pkg. of 12)
C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG
C8AZ-19B546-A Additive Friction Modifier - 4 AM
ounce bottle
D7AZ-19590-A Disc Brake Caliper Slide AM
Grease - 4 ounce tube
E8TZ-19590-A Grease - 14.5 ounces B
E1TZ-19590-A Automatic Hublock Grease - 5 B
ounce tube
E5RY-19C547-A Merkur Synthetic Manual B
Transmission Fluid
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 5970
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
Drivetrain - Lubricant Usage > Page 1088
Fluid - M/T: Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid
TRANSMISSION - AUTOMATIC/MANUAL - Article No.
NEW FLUID AND USAGE CHART 87-18-14
FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS,
THUNDERBIRD, FORD
LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior
TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II,
AEROSTAR
ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart),
(XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON"
transmission fluid, where specified, will improve cold weather shift effort and synchronized
operation.
ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic
transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles.
NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual
transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the
transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent.
PART NUMBER PART NAME CLASS
XT-2-QDX MERCON - Quart V
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
Drivetrain - Lubricant Usage > Page 1089
XT-2-DDX MERCON - 55 Gallon V
Drum
E5RY-19C547-A Semi-Synthetic Oil B
OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS:
"INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
Page 1090
Fluid - M/T: Specifications
Type 1987 5-speed Mercon(R) Automatic Transmission Fluid
All others 80W EP
CAPACITY, Refill: 3-speed 3.5 pt (US)
4-speed ex. OD 7.0 pt (US)
W/OD 4.5 pt (US)
5-speed 7.4 pt (US)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service
Bulletins > Drivetrain - Lubricant Usage
Fluid - Differential: Technical Service Bulletins Drivetrain - Lubricant Usage
Article No. 89-8-16
^ DRIVETRAIN - LUBRICATION USAGE
^ TRANSMISSION - MANUAL - LUBRICATION USAGE
LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER
1984-89 BRONCO II 1986-89 AEROSTAR
ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain
lubrication usage chart for light trucks has been put together to assist technicians in the event
service is required.
FIGURE 1
FIGURE 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service
Bulletins > Drivetrain - Lubricant Usage > Page 1095
ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage.
Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage.
PART NUMBER PART NAME CLASS
D8DZ-19C547-A Standard Transmission BG
Lubricant - 5 gallons C1AZ-19590-BA
Long Life Lubricant B
(molybdenum disulfide) - 14.5 ounces
DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B
tube
D7AZ-19584-AA Multi-Purpose Grease - 15 B
ounce aerosol can
XT-2-QDX Transmission Fluid (Mercon) - V
quart can (pkg. of 12)
C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG
C8AZ-19B546-A Additive Friction Modifier - 4 AM
ounce bottle
D7AZ-19590-A Disc Brake Caliper Slide AM
Grease - 4 ounce tube
E8TZ-19590-A Grease - 14.5 ounces B
E1TZ-19590-A Automatic Hublock Grease - 5 B
ounce tube
E5RY-19C547-A Merkur Synthetic Manual B
Transmission Fluid
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 5970
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications
Fluid - Differential: Capacity Specifications
TYPE: Standard 90 HP
Limited-Slip 90 HP*
8.8" & 10 1/4" has removable cover, 9.0" does not
CAPACITY, Refill: Front: Dana 44 3.8 pt (US)
LIMITED-SLIP OR TRACTION-LOK IDENTIFICATION: Label on door
lock pillar shows letter and number
Dana 50 4.0 pt (US)
Dana 60 5.8 pt (US)
Rear: Ford w/8.8" ring gear* 5.5 pt (US)
10 1/4 ring gear* 6.5 pt (US)
Dana 60 & 61 6.0 pt (US)
Dana 70 HD 7.4 pt (US)
Dana 70 6.5 pt (US)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications > Page 1098
Fluid - Differential: Fluid Type Specifications
BL Self-adjusting Brake Lubricant
EC Ethylene Glycol Coolant
Mix 50/50 with water to at least -20°F (-29°C) protection
EP Extreme Pressure Gear Lubricant
Ford Part No. D8DZ-19C547-A
FA Automatic Transmission Fluid, Type F
GL-5 Gear Oil, API Service GL-5
HBH Hydraulic Brake Fluid, Extra
Heavy-Duty
HP Hypoid Gear Oil
Ford Part No. E0AZ-19580-A
HP* Hypoid Gear Oil for Limited-Slip
or Traction-Lok Differential
LM Lithium Grease, with Polyethylene
LS Steering Gear Lubricant
MA MERCONAutomatic Transmission
Fluid
MH Manifold Heat Valve Solvent
SG Motor Oil, API Service SG
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service
Bulletins > Drivetrain - Lubricant Usage
Fluid - Transfer Case: Technical Service Bulletins Drivetrain - Lubricant Usage
Article No. 89-8-16
^ DRIVETRAIN - LUBRICATION USAGE
^ TRANSMISSION - MANUAL - LUBRICATION USAGE
LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER
1984-89 BRONCO II 1986-89 AEROSTAR
ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain
lubrication usage chart for light trucks has been put together to assist technicians in the event
service is required.
FIGURE 1
FIGURE 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service
Bulletins > Drivetrain - Lubricant Usage > Page 1103
ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage.
Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage.
PART NUMBER PART NAME CLASS
D8DZ-19C547-A Standard Transmission BG
Lubricant - 5 gallons C1AZ-19590-BA
Long Life Lubricant B
(molybdenum disulfide) - 14.5 ounces
DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B
tube
D7AZ-19584-AA Multi-Purpose Grease - 15 B
ounce aerosol can
XT-2-QDX Transmission Fluid (Mercon) - V
quart can (pkg. of 12)
C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG
C8AZ-19B546-A Additive Friction Modifier - 4 AM
ounce bottle
D7AZ-19590-A Disc Brake Caliper Slide AM
Grease - 4 ounce tube
E8TZ-19590-A Grease - 14.5 ounces B
E1TZ-19590-A Automatic Hublock Grease - 5 B
ounce tube
E5RY-19C547-A Merkur Synthetic Manual B
Transmission Fluid
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 5970
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
TYPE MERCON(R) Automatic Transmission Fluid
CAPACITY, Refill: NP208 9.0 pt (US)
Warner 1345 6.5 pt (US)
Warner 1356 4.0 pt (US)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications > Page 1106
Fluid - Transfer Case: Fluid Type Specifications
BL Self-adjusting Brake Lubricant
EC Ethylene Glycol Coolant
Mix 50/50 with water to at least -20°F (-29°C) protection
EP Extreme Pressure Gear Lubricant
Ford Part No. D8DZ-19C547-A
FA Automatic Transmission Fluid, Type F
GL-5 Gear Oil, API Service GL-5
HBH Hydraulic Brake Fluid, Extra
Heavy-Duty
HP Hypoid Gear Oil
Ford Part No. E0AZ-19580-A
HP* Hypoid Gear Oil for Limited-Slip
or Traction-Lok Differential
LM Lithium Grease, with Polyethylene
LS Steering Gear Lubricant
MA MERCONAutomatic Transmission
Fluid
MH Manifold Heat Valve Solvent
SG Motor Oil, API Service SG
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine - Correct Oil Fill Level Markings
Engine Oil: Technical Service Bulletins Engine - Correct Oil Fill Level Markings
Article No. OIL DIPSTICK - CORRECT ENGINE OIL FILL
87-9-5 LEVEL MARKINGS - GASOLINE ENGINES
FORD: 1987 ALL CAR LINES
LINCOLN-MERCURY: 1987 ALL CAR LINES
LIGHT TRUCK: 1987 ALL LIGHT TRUCK LINES
ISSUE: The "markings" on the engine oil level dipstick (indicator) are being read incorrectly. This
incorrect reading results in overfilling the engine with oil in newly delivered vehicles during the
"prep" procedure.
Figure 4 - Article 87-9-5
ACTION: Do not fill engine oil to the "MAX" oil level line marked on the dipstick. The "MAX" line
represents a tolerance limit that is about 1/2 quart above the specified (normal) engine oil operating
level. A correctly filled engine should show an oil fill level reading in the crosshatched area of the
dipstick, Figure 4. During new vehicle delivery or right after an oil change, the oil fill reading should
be at the full mark on the new style dipstick and in the upper crosshatched area on the old style
dipstick. Refer to the following specification chart for proper fill requirements.
OTHER APPLICABLE ARTICLES: 87-5-20, 87-7-23 WARRANTY STATUS: "INFORMATION
ONLY"
1987 ENGINE OIL LEVEL SPECIFICATION CHART
Oil Fill With Filter
Engine Models Change
Car 1.9L N.A. EFI 4.0 Qts.
2.3L OHC N.A. EFI/TC 5.0 Qts.
2.3L/2.5L HSC/PENTA 4.5 Qts.
3.0L All 4.5 Qts.
3.8L All 5.0 Qts.
5.0L All 5.0 Qts.
5.8L All 5.0 Qts.
Truck 2.0L Ranger 5.0 Qts.
2.3L Ranger 5.0 Qts.
2.9L Ranger 5.0 Qts.
3.0L Aerostar 4.5 Qts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine - Correct Oil Fill Level Markings > Page 1111
4.9L All 6.0 Qts.
5.0L All 6.0 Qts.
5.8L All 6.0 Qts.
6.1L/7.0L All 9.0 Qts.
7.5L All 6.0 Qts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine oil capacity ...............................................................................................................................
........................................................... 5.0 Qts.(4.7L)
Note: Add 1 Qt. with filter change.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications > Page 1114
Engine Oil: Fluid Type Specifications
BL Self-adjusting Brake Lubricant
EC Ethylene Glycol Coolant
Mix 50/50 with water to at least -20°F (-29°C) protection
EP Extreme Pressure Gear Lubricant
Ford Part No. D8DZ-19C547-A
FA Automatic Transmission Fluid, Type F
GL-5 Gear Oil, API Service GL-5
HBH Hydraulic Brake Fluid, Extra
Heavy-Duty
HP Hypoid Gear Oil
Ford Part No. E0AZ-19580-A
HP* Hypoid Gear Oil for Limited-Slip
or Traction-Lok Differential
LM Lithium Grease, with Polyethylene
LS Steering Gear Lubricant
MA MERCONAutomatic Transmission
Fluid
MH Manifold Heat Valve Solvent
SG Motor Oil, API Service SG
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Identification of Non Approved Refrigerants
Technical Service Bulletin # 99-19-6 Date: 990920
A/C - Identification of Non Approved Refrigerants
Article No. 99-19-6
09/20/99
^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS
^ AIR CONDITIONING - PURGING AIR FROM SYSTEM
FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD
1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA
1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO
II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD,
RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000
WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991
CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO
SERIES 1997-1998 AEROMAX, LOUISVILLE
LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII
2000 LS 1998-2000 NAVIGATOR
MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR
1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI
1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER
1997-2000 MOUNTAINEER
MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Identification of Non Approved Refrigerants > Page 1119
This TSB article is being republished in its entirety to add model year vehicles
ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are
being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved
refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety,
durability, and performance concerns if they are installed in Ford A/C systems. Identification of the
type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent
dealer service equipment and refrigerant supplies from being contaminated with non-approved
refrigerants.
ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a
recovery machine to prevent cross-contamination of the recovery machine and other A/C systems
being serviced with that recovery machine. Refer to the following text.
OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4
SUPERSEDES: 98-12-8
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles
OPERATION DESCRIPTION TIME
991906A Test A/C System For 0.3 Hr.
Contaminated Refrigerant
DEALER CODING
CONDITION
BASIC PART NO. CODE
R-12 49
OASIS CODES: 208000, 208999
A/C Refrigerant Analyzer Function
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Identification of Non Approved Refrigerants > Page 1120
Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for
use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a
quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or
flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system
and automatically purge air from the system.
The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from
automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes
through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor
calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid
Crystal Display (LCD).
The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the
sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green
"PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity
levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will
light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and
"HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards.
The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or
above. The analyzer eliminates the effect of air
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Identification of Non Approved Refrigerants > Page 1121
when determining the refrigerant sample content because air is not considered a contaminant
although air can affect A/C system performance. Air will automatically be purged until a pure
refrigerant with a less than 2% by weight air measurement is reached.
Recovery of Contaminated Refrigerant
If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12
recovery/recycling equipment. Take the following actions:
1. Repeat the test to verify contaminated refrigerant is present.
2. Advise the customer of the contaminated A/C system and any additional cost to repair the
system. The customer may wish to return to the service facility which performed the last A/C
service.
3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant. This equipment must only be used to recover
contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C
service facility in your area which has the proper equipment for refrigerant recovery.
Repairing A Contaminated A/C System
Once the contaminated refrigerant is removed from the system it will be necessary to repair the
system. Ford recommends that you do the following to be sure a quality repair is made:
1. Determine the cause of the failure.
2. Determine which parts will need to be replaced.
3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated
refrigerant.
4. Install a new suction/accumulator.
5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present
in the system.
6. Evacuate the system for 45 minutes.
7. Recharge the system, verify proper operation, and leak test.
Disposal of Contaminated Refrigerant
Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are
companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not
evaluated the processes of the listed refrigerant disposal companies and is not endorsing or
promoting their companies Business transactions are between the dealership and disposal
companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip
cylinder shipping.
^ Omega Refrigerant Reclamation
^ 5263 North Fourth St.
^ Irwindale, CA 91706
^ (310) 698-0991 FAX: (310) 696-7908
^ Full Cycle Global
^ 2966 Wireton
^ Blue Island, IL 60406
^ (708) 388-8551 FAX: (708) 399-6550
^ U.S. Refrigerant Reclaim, Inc.
^ 12420 North Green River Road
^ Evansville, IN 47711
^ (800) 207-5931 FAX: (812) 867-1463
^ Full Cycle Global
^ 343 South Airline Highway
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
A/C - Identification of Non Approved Refrigerants > Page 1122
^ Gonzales, LA 70737
^ (504) 644-5333 FAX: (504) 644-1609
^ CFC Reclamation
^ 1321 Swift North
^ Kansas City, MO 64116
^ (816) 471-2511
^ Full Cycle Global
^ 550 James St.
^ Lakewood, NJ 08701
^ (908) 370-3400 FAX: (908) 370-3088
^ National Refrigerants, Inc.
^ 11401 Roosevelt Blvd.
^ Philadelphia, PA 19154
^ (215) 698-6620 FAX: (215) 602-8205
^ Gartech Refrigerant Reclamation
^ 2002 Platinum
^ Garland, TX 75042
^ (214) 272-4070 FAX: (214) 272-6548
^ Refrigerant Reclaim Services
^ 121 S. Norwood Dr.
^ Hurst, TX 76053-7807
^ (817) 282-0022 FAX: (800) 831-6182
^ Full Cycle Global
^ 2055 Silber, Suite 109
^ Houston, TX 77055
^ (713) 681-7370 FAX: (713) 681-9947
^ Refrigerant Reclaim, Inc.
^ 122 Old Stage Coach Road
^ Dumfries, VA 22026
^ (800) 238-5902 FAX: (703) 441-0393
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants
Technical Service Bulletin # 99-19-6 Date: 990920
A/C - Identification of Non Approved Refrigerants
Article No. 99-19-6
09/20/99
^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS
^ AIR CONDITIONING - PURGING AIR FROM SYSTEM
FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD
1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA
1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO
II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD,
RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000
WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991
CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO
SERIES 1997-1998 AEROMAX, LOUISVILLE
LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII
2000 LS 1998-2000 NAVIGATOR
MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR
1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI
1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER
1997-2000 MOUNTAINEER
MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants >
Page 1128
This TSB article is being republished in its entirety to add model year vehicles
ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are
being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved
refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety,
durability, and performance concerns if they are installed in Ford A/C systems. Identification of the
type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent
dealer service equipment and refrigerant supplies from being contaminated with non-approved
refrigerants.
ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a
recovery machine to prevent cross-contamination of the recovery machine and other A/C systems
being serviced with that recovery machine. Refer to the following text.
OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4
SUPERSEDES: 98-12-8
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles
OPERATION DESCRIPTION TIME
991906A Test A/C System For 0.3 Hr.
Contaminated Refrigerant
DEALER CODING
CONDITION
BASIC PART NO. CODE
R-12 49
OASIS CODES: 208000, 208999
A/C Refrigerant Analyzer Function
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants >
Page 1129
Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for
use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a
quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or
flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system
and automatically purge air from the system.
The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from
automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes
through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor
calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid
Crystal Display (LCD).
The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the
sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green
"PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity
levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will
light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and
"HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards.
The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or
above. The analyzer eliminates the effect of air
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants >
Page 1130
when determining the refrigerant sample content because air is not considered a contaminant
although air can affect A/C system performance. Air will automatically be purged until a pure
refrigerant with a less than 2% by weight air measurement is reached.
Recovery of Contaminated Refrigerant
If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12
recovery/recycling equipment. Take the following actions:
1. Repeat the test to verify contaminated refrigerant is present.
2. Advise the customer of the contaminated A/C system and any additional cost to repair the
system. The customer may wish to return to the service facility which performed the last A/C
service.
3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant. This equipment must only be used to recover
contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C
service facility in your area which has the proper equipment for refrigerant recovery.
Repairing A Contaminated A/C System
Once the contaminated refrigerant is removed from the system it will be necessary to repair the
system. Ford recommends that you do the following to be sure a quality repair is made:
1. Determine the cause of the failure.
2. Determine which parts will need to be replaced.
3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated
refrigerant.
4. Install a new suction/accumulator.
5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present
in the system.
6. Evacuate the system for 45 minutes.
7. Recharge the system, verify proper operation, and leak test.
Disposal of Contaminated Refrigerant
Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are
companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not
evaluated the processes of the listed refrigerant disposal companies and is not endorsing or
promoting their companies Business transactions are between the dealership and disposal
companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip
cylinder shipping.
^ Omega Refrigerant Reclamation
^ 5263 North Fourth St.
^ Irwindale, CA 91706
^ (310) 698-0991 FAX: (310) 696-7908
^ Full Cycle Global
^ 2966 Wireton
^ Blue Island, IL 60406
^ (708) 388-8551 FAX: (708) 399-6550
^ U.S. Refrigerant Reclaim, Inc.
^ 12420 North Green River Road
^ Evansville, IN 47711
^ (800) 207-5931 FAX: (812) 867-1463
^ Full Cycle Global
^ 343 South Airline Highway
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants >
Page 1131
^ Gonzales, LA 70737
^ (504) 644-5333 FAX: (504) 644-1609
^ CFC Reclamation
^ 1321 Swift North
^ Kansas City, MO 64116
^ (816) 471-2511
^ Full Cycle Global
^ 550 James St.
^ Lakewood, NJ 08701
^ (908) 370-3400 FAX: (908) 370-3088
^ National Refrigerants, Inc.
^ 11401 Roosevelt Blvd.
^ Philadelphia, PA 19154
^ (215) 698-6620 FAX: (215) 602-8205
^ Gartech Refrigerant Reclamation
^ 2002 Platinum
^ Garland, TX 75042
^ (214) 272-4070 FAX: (214) 272-6548
^ Refrigerant Reclaim Services
^ 121 S. Norwood Dr.
^ Hurst, TX 76053-7807
^ (817) 282-0022 FAX: (800) 831-6182
^ Full Cycle Global
^ 2055 Silber, Suite 109
^ Houston, TX 77055
^ (713) 681-7370 FAX: (713) 681-9947
^ Refrigerant Reclaim, Inc.
^ 122 Old Stage Coach Road
^ Dumfries, VA 22026
^ (800) 238-5902 FAX: (703) 441-0393
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor
Replacement
Technical Service Bulletin # 98-12-5 Date: 980622
A/C - Filtering Refrigerant After Compressor Replacement
Article No. 98-12-5
06/22/98
AIR CONDITIONING - FILTERING REFRIGERANT
AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS
FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS
1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86
CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92
MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII
1995-98-MYSTIQUE 1999 COUGAR
LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150,
F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98
EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER
1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to revise the Service Procedure and to update
the model years.
ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the
refrigerant system cleaned to remove any debris or contaminants that may be present to prevent
damage to the replacement compressor.
ACTION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor
Replacement > Page 1136
Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor.
Refer to the following Service Procedure for details.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 96-15-5
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major
Component Warranty Coverage For All Other Lincoins
OPERATION DESCRIPTION TIME
981205A Kit Installation 1.2 Hrs.
981205B Extra Time For Refrigerant 0.4 Hr.
(R-12) Recovery
DEALER CODING
CONDITION
BASIC PART NO. CODE
19703 49
OASIS CODES: 208000, 208999
Service Procedure
THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C
FLUSHER.
CAUTION
THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT
SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND
BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM
IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED
BEFORE STARTING THE FILTERING PROCEDURE.
Each Service Filter Kit includes the following items:
^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice
tube)
^ One (1) Instruction Sheet
NOTE
ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY
WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET
WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM
FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE
TUBE AFTER FILTERING IS COMPLETE.
CAUTION
FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN
THE APPROPRIATE SERVICE OR WORKSHOP MANUAL.
1. Before removing any refrigerant system components, recover the refrigerant from the system
following the recycling methods outlined In the appropriate Service/Workshop Manual.
2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container.
3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The
quantity of the new oil to be added is the amount to match that drained from the old accumulator
plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction
accumulator/drier part number.
CAUTION
REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12
SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a
SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE
TO SYSTEM COMPONENTS.
4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube
part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and
the evaporator, replace the liquid line assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor
Replacement > Page 1137
5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1.
a. Be sure orifice inlet is toward the condenser.
b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible
refrigerant hose of 2500 psi burst rating. Individual fittings are also available.
6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a
calibrated container.
7. Drain the oil from the replacement compressor into a clean calibrated container.
NOTE:
IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD
COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP
MANUAL PROCEDURES.
8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10
service compressor does not contain any oil and can be used with an R-12 or an R-134a system.
CAUTION
REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL
WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT
IN DAMAGE TO SYSTEM COMPONENTS.
^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz),
pour the same amount of clean refrigerant oil into the new compressor.
^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3
oz) of clean refrigerant oil into the new compressor.
9. Install the new compressor following Service/Workshop Manual procedures. Make sure all
mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if
necessary.
10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures.
11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make
sure they do not interfere with other engine compartment components. If necessary, use tie straps
to make adjustments.
12. Set the A/C control on Max A/C, high blower and temperature control at full cold.
a. Start engine and let idle briefly.
b. Be sure A/C system is operating properly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor
Replacement > Page 1138
13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at
800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system
operating.
14. Stop the engine.
NOTE:
IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE
PROCEEDING.
15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from
the liquid line.
16. Discard the filter. It can be used one (1) tie only.
17. Reconnect the liquid line back into the system.
18. Evacuate, charge and leak test the system. Make any necessary adjustments.
19. Check the operation of the system in all models.
PART NUMBER PART NAME
F8VZ-19E773-AA Filter Kit
F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only)
F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant
Systems Only)
NOTE
THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS
THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR
TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip
Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Substitutes Service Tip
Article No. 96-17-10
08/12/96
AIR CONDITIONING - USE OF R-12 REFRIGERANT SUBSTITUTES - SERVICE TIP
FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-94 TEMPO 1986-93 TAURUS 1988-93
FESTIVA 1989-93 PROBE
LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7,
ZEPHYR 1982-86 CAPRI 1982-93 COUGAR 1982-94 CONTINENTAL 1983-86 MARQUIS
1984-92 MARK VII 1984-94 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER
MERKUR: 1985-89 XR4TI 1988-90 SCORPIO
LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES 1983-93
RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993
VILLAGER
MEDIUM/HEAVY TRUCK: 1985-94 CARGO SERIES, F & B SERIES, L SERIES
This TSB article is being republished in its entirety to list Environmental Protection Agency (EPA)
reviewed NC substitutes for R-12 refrigerant.
ISSUE: A number of manufacturers are producing refrigerant products which are described as
being direct replacements for refrigerant R-12.
ACTION: If service is required, use only new or of known quality recycled refrigerant R-12. Ford
Motor Company has approved R-134a as the only refrigerant substitute for R-12.
CAUTION:
USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN
SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS.
INFORMATION FROM THE EPA
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip > Page
1143
This information has been taken from EPA documents to address Ford specific applications and
recommendations. Further EPA information on ozone-depleting substances and regulations
regarding its handling can be found on the Internet at World Wide Web site:
http://www.epa.gov/ozone/
In 1994, EPA established the Significant New Alternatives Policy (SNAP) program to review
alternatives to ozone-depleting substances like R-12. EPA examines new substitutes for their
ozone depleting, global warming, flammability, and toxicity characteristics. The SNAP process does
not test these substitutes for A/C system compatibility, reliability, durability, or performance.
Under the SNAP rule, each new refrigerant must be used in accordance with the following
conditions:
1. Unique Fittings - Each new refrigerant must be used with a unique set of fittings to prevent the
accidental mixing of different refrigerants.
2. Unique Equipment - Each refrigerant must have dedicated recovery/recycling equipment for that
refrigerant.
3. Labels - Whether a vehicle is originally designed to use a new refrigerant or is retrofitted, the
technician must apply a detailed label giving specific information about the alternative. This label
covers up information about the old refrigerant and provides valuable details on the alternative and
how it was used. The technician is required to fill in their name, company performing the retrofit,
address and the date retrofitted.
4. Remove Original Refrigerant - The original R-12 must be removed from the system prior to
charging with the new refrigerant. This will guarantee that the largest amount of clean R-12 is
available for use in vehicles that still need it.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip > Page
1144
A summary of the refrigerants reviewed under EPA's SNAP program for use in motor vehicle air
conditioning systems is in the table.
OTHER APPLICABLE ARTICLES: 91-9-7, 96-15-7
SUPERSEDES: 93-23-11
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208999, 290000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes
Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes
Article No. 94-14-3
07/13/94
Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip
FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93
FESTIVA 1989-93 PROBE
LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7,
ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK
VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER
MERKUR: 1986-89 SCORPIO, XR4TI
LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90
BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993
VILLAGER
MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000,
CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES
This TSB is being republished in its entirety to include Heavy Truck models.
ISSUE:
A number of manufacturers are producing refrigerant products which are described as being direct
replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely
damage the A/C system components.
ACTION:
If service is required, use only NEW or RECYCLED refrigerant R-12.
Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time.
R-134a is approved only for systems which specify R-134a,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes > Page 1149
and is not compatible with R-12 systems.
R-22 likewise, is not compatible with R-12 systems.
CAUTION:
USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN
SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS.
OTHER APPLICABLE ARTICLES: 91-9-7
SUPERSEDES: 93-23-11
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208999, 290000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 93206 > Sep > 93 > Air Conditioning - Use of Correct Fluorescent Tracer Dye
Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye
Article No. 93-20-6
09/29/93
AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP
FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93
FESTIVA 1989-93 PROBE
LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7,
ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK
VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER
LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90
BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER
ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may
damage the air conditioning system. Some of these materials may not be compatible with Ford A/C
systems.
ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied
Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor
Company.
NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 208999
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > 9197 > May > 91 > A/C - R12 Refrigerant Service Tips
Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Service Tips
Article No. 91-9-7
05/01/91
AIR CONDITIONING - REFRIGERANT R-12 - SERVICE TIPS
FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO,
THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE
LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS,
MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER 1991 CAPRI
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES,
RANGER 1986-91 AEROSTAR 1988-91 F SUPER DUTY 1991 EXPLORER
MEDIUM/HEAVY TRUCK: 1985-90 C SERIES 1985-91 CL-CLT-9000 SERIES, F & B SERIES, L
SERIES 1986-91 CARGO SERIES
ISSUE: A number of manufacturers are producing refrigerant products which are described as
being direct replacements for Refrigerant R-12. The use of any unauthorized substitute refrigerant
may severely damage the A/C components.
ACTION: If service is required, use only NEW or RECYCLED Refrigerant R-12.
CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY
RESULT IN SEVERE DAMAGE TO THE A/C
SYSTEM COMPONENTS.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
208000, 208200
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > Page 1158
Technical Service Bulletin # 98-12-5 Date: 980622
A/C - Filtering Refrigerant After Compressor Replacement
Article No. 98-12-5
06/22/98
AIR CONDITIONING - FILTERING REFRIGERANT
AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS
FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS
1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86
CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92
MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII
1995-98-MYSTIQUE 1999 COUGAR
LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150,
F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98
EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER
1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to revise the Service Procedure and to update
the model years.
ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the
refrigerant system cleaned to remove any debris or contaminants that may be present to prevent
damage to the replacement compressor.
ACTION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > Page 1159
Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor.
Refer to the following Service Procedure for details.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 96-15-5
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major
Component Warranty Coverage For All Other Lincoins
OPERATION DESCRIPTION TIME
981205A Kit Installation 1.2 Hrs.
981205B Extra Time For Refrigerant 0.4 Hr.
(R-12) Recovery
DEALER CODING
CONDITION
BASIC PART NO. CODE
19703 49
OASIS CODES: 208000, 208999
Service Procedure
THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C
FLUSHER.
CAUTION
THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT
SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND
BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM
IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED
BEFORE STARTING THE FILTERING PROCEDURE.
Each Service Filter Kit includes the following items:
^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice
tube)
^ One (1) Instruction Sheet
NOTE
ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY
WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET
WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM
FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE
TUBE AFTER FILTERING IS COMPLETE.
CAUTION
FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN
THE APPROPRIATE SERVICE OR WORKSHOP MANUAL.
1. Before removing any refrigerant system components, recover the refrigerant from the system
following the recycling methods outlined In the appropriate Service/Workshop Manual.
2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container.
3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The
quantity of the new oil to be added is the amount to match that drained from the old accumulator
plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction
accumulator/drier part number.
CAUTION
REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12
SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a
SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE
TO SYSTEM COMPONENTS.
4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube
part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and
the evaporator, replace the liquid line assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > Page 1160
5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1.
a. Be sure orifice inlet is toward the condenser.
b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible
refrigerant hose of 2500 psi burst rating. Individual fittings are also available.
6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a
calibrated container.
7. Drain the oil from the replacement compressor into a clean calibrated container.
NOTE:
IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD
COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP
MANUAL PROCEDURES.
8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10
service compressor does not contain any oil and can be used with an R-12 or an R-134a system.
CAUTION
REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL
WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT
IN DAMAGE TO SYSTEM COMPONENTS.
^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz),
pour the same amount of clean refrigerant oil into the new compressor.
^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3
oz) of clean refrigerant oil into the new compressor.
9. Install the new compressor following Service/Workshop Manual procedures. Make sure all
mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if
necessary.
10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures.
11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make
sure they do not interfere with other engine compartment components. If necessary, use tie straps
to make adjustments.
12. Set the A/C control on Max A/C, high blower and temperature control at full cold.
a. Start engine and let idle briefly.
b. Be sure A/C system is operating properly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > Page 1161
13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at
800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system
operating.
14. Stop the engine.
NOTE:
IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE
PROCEEDING.
15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from
the liquid line.
16. Discard the filter. It can be used one (1) tie only.
17. Reconnect the liquid line back into the system.
18. Evacuate, charge and leak test the system. Make any necessary adjustments.
19. Check the operation of the system in all models.
PART NUMBER PART NAME
F8VZ-19E773-AA Filter Kit
F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only)
F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant
Systems Only)
NOTE
THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS
THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR
TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > Page 1162
Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye
Article No. 93-20-6
09/29/93
AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP
FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93
FESTIVA 1989-93 PROBE
LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7,
ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK
VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER
LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90
BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER
ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may
damage the air conditioning system. Some of these materials may not be compatible with Ford A/C
systems.
ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied
Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor
Company.
NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 208999
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > Page 1163
Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes
Article No. 94-14-3
07/13/94
Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip
FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93
FESTIVA 1989-93 PROBE
LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7,
ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK
VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER
MERKUR: 1986-89 SCORPIO, XR4TI
LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90
BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993
VILLAGER
MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000,
CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES
This TSB is being republished in its entirety to include Heavy Truck models.
ISSUE:
A number of manufacturers are producing refrigerant products which are described as being direct
replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely
damage the A/C system components.
ACTION:
If service is required, use only NEW or RECYCLED refrigerant R-12.
Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time.
R-134a is approved only for systems which specify R-134a,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins >
Technical Service Bulletins for Refrigerant: > Page 1164
and is not compatible with R-12 systems.
R-22 likewise, is not compatible with R-12 systems.
CAUTION:
USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN
SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS.
OTHER APPLICABLE ARTICLES: 91-9-7
SUPERSEDES: 93-23-11
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208999, 290000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
With Front A/C
Refrigerant Capacity ............................................................................................................................
........................................................................ 3.5 lbs
With Front and Rear A/C
Refrigerant Capacity ............................................................................................................................
...................................................................... 4.25 lbs
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 1167
Refrigerant: Fluid Type Specifications
Type .....................................................................................................................................................
............................................... Refrigerant 12 (R-12) Ford Part Number .............................................
........................................................................................................................................
D4AZ-19B519-A
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
With Front A/C
Refrigerant Oil System Capacity .........................................................................................................
.......................................................................... 10 oz
With Front and Rear A/C
Refrigerant Oil System Capacity .........................................................................................................
.......................................................................... 10 oz
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications > Page 1172
Refrigerant Oil: Fluid Type Specifications
Compressor ................................................................................................................... 500 viscosity
(C9AZ-19557-B or Motorcraft VN-2 or equivalent)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding
Brake Bleeding: Service and Repair Manual Bleeding
NOTE: Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first
on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that
has been drained from hydraulic system.
1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to
absorb escaping brake fluid.
2. Depress brake pedal slowly by hand to floor of cab, forcing air trapped in master cylinder out at
fitting.
3. Hold pedal down and tighten fittings, then release brake pedal.
NOTE: Releasing brake pedal before fittings are tightened will allow air to enter the master
cylinder.
4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm.
5. Bleed rear brakes as follows:
RR, LR, RF, LF
WARNING: Do not bleed the brakes with the drums removed. The wheel-cylinders will over-extend
and eject the pistons.
a. Pump pedal several times, then hold pedal down firmly.
WARNING: Do not Full Stroke the brake pedal, this may damage the master cylinder. Place a 2
inch block of wood under the brake pedal to prevent Full Stroking.
b. With pedal firmly depressed, open bleeder screw on one rear brake until pedal fades to floor,
then close bleeder valve.
NOTE: Do not release the brake pedal until the bleeder valve is fully shut.
c. Repeat procedure until a continuous flow of brake fluid is released from bleeder valve.
d. Repeat steps 5a through 5c on other rear brake.
6. Bleed front brakes using same procedure as for rear brakes.
7. Fill master cylinder reservoirs to 1/4 inch from top of reservoirs.
9. Check brake operation and ensure pedal is firm, road test vehicle.
For additional information see Bleeding Notes.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding >
Page 1177
Brake Bleeding: Service and Repair Master Cylinder Bleeding
1. Support the master cylinder body in a vise, and fill both fluid reservoirs with heavy duty DOT 3
brake fluid. 2. Install plugs in the front and rear brake outlet ports. Bleed the front brake outlet
system first. 3. Loosen the plug in the front brake outlet port. Depress the secondary piston slowly
to force the air out of the master cylinder. Tighten plug while
piston is depressed or air will enter the master cylinder.
4. Repeat this procedure until air ceases to exit at the outlet port. 5. Repeat steps 3 and 4 for the
rear brake outlet port with the front brake outlet plugged. 6. Tighten the plugs and try to depress the
piston. Depressing the piston should be harder after all air is expelled. 7. Install the plastic cap. 8.
Install the master cylinder in the vehicle and bleed the hydraulic system.
For additional information see Bench Bleeding.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding >
Page 1178
Brake Bleeding: Service and Repair Pressure Bleeding
Be sure the bleeder tank contains enough of the specified brake fluid to complete the bleeding
operation. Charge the tank with approximately 69-206 kPa (10-30 psi). Never exceed 345 kPa (50
psi). Never use brake fluid that has been drained from the hydraulic system. Bleed the longest lines
first
1. Clean all dirt from the master cylinder reservoir cap.
2. Remove the master cylinder reservoir cap and fill the master cylinder reservoir with the specified
brake fluid. Install the pressure bleeder adapter
tool on the master cylinder, and attach the bleeder tank hose to the fitting on the adapter.
NOTE: Master cylinder pressure bleeder adapter tools are available from the manufacturers of
pressure bleeding equipment. Follow the manufacturer's instructions when installing the adapter.
3. Place a 3/8 inch box wrench on the bleeder fitting on the right rear brake wheel cylinder. Attach a
bleeder tube snugly to the bleeder fitting.
4. Open the valve on the bleeder tank and admit pressurized brake fluid to the master cylinder
reservoir.
5. Submerge the free end of the tube in a container partially filled with clean brake fluid, and loosen
the bleeder fitting.
6. When air bubbles no longer appear in the fluid at the submerged end of the bleeder tube, close
the bleeder fitting and remove the tube.
7. Repeat Steps 3 through 6 at the opposite wheel cylinder. On front brakes, bleed the right front
caliper first.
8. When the bleeding operation is completed, close the bleeder tank valve and remove the tank
hose from the adapter fitting.
9. Remove the pressure bleeder adapter tool. Fill the master cylinder reservoirs with the specified
brake fluid to within 3 mm (1/8 in) from the top of
the filler neck. Install the master cylinder cover.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Locations > Component Locations
Circuit Breaker: Component Locations
LH Side Of Dash Panel At Junction Block
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information >
Locations > Component Locations > Page 1184
Circuit Breaker: Fuse and Fusible Link Locations
Circuit Location Amp Windshield Wiper.....................Fuse Panel................7.5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations
Fuse: Locations
LH Shroud, Near Access Hole
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
Fuse Block: Locations
Under LH Side Of Instrument Panel, To Right Of Parking Brake.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1193
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 1194
Fig. 1 Fuse Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations
> Fuse Link F
Fusible Link: Locations Fuse Link F
RH Fender Apron With EEC
At Starter Relay
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations
> Fuse Link F > Page 1199
Fusible Link: Locations Fuse Link L
LH Fender Apron
Connected To Choke Heater Or Near Auxiliary Blower Relay
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Coolant Level Indicator Lamp > Component
Information > Description and Operation
Coolant Level Indicator Lamp: Description and Operation
This lamp will be illuminated when engine coolant level in the radiator drops below a
pre-determined level. To turn lamp off, check cooling system, then add coolant to bring system to
proper level.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > EGR Maintenance Light > Component Information
> Locations
EGR Maintenance Light: Locations
On Dash
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Emissions Maintenance Light > Component
Information > Technical Service Bulletins > Emission Maintenance Warning Module - Service
Emissions Maintenance Light: Technical Service Bulletins Emission Maintenance Warning Module
- Service
Article No. 89-22-8
^ EMISSION MAINTENANCE WARNING MODULE SERVICE INFORMATION
^ LAMP - "EMISSIONS/CHECK ENGINE" - EMISSION MAINTENANCE WARNING MODULE SERVICE INFORMATION
LIGHT TRUCK: 1985-89 BRONCO 1985-87 BRONCO II 1985-89 ECONOLINE, F-150, F-250,
F-350 1985-88 RANGER 1986-87 AEROSTAR
MEDIUM/HEAVY TRUCK: 1988-90 F & B SERIES
ISSUE: The Emission Maintenance Warning "EMW" module operates a light that is located on the
instrument panel. For 1985-87 model year vehicles, the light will display the word "EMISSIONS".
For 1988-89 model year vehicles, the light will display the words "CHECK ENGINE". When the light
is lit, it is indicating that the 60,000 mile emission maintenance should be performed. After the
maintenance is performed the EMW module must be reset to zero time. Another type of module is
the "IMS" module. This module is not part of the light circuit and does not require maintenance. At
a predetermined time, the IMS module directs the EEC IV processor to make a strategy change. A
third type of module is the "COMBO" module. This module combines the functions of the IMS and
the EMW modules.
ACTION: Refer to the following module application charts for the specific vehicle application and
location of the different types of modules.
NOTE: FOR APPLICATIONS NOT LOSTED IN THE FOLLOWING MODULE APPLICATION
CHARTS, THE "CHECK ENGINE" LIGHT IS CONTROLLED BY THE EEC IV PROCESSOR.
THESE VEHICLES DO NOT USE THE "EMW" MODULE.
1985 & 1986 MODULE APPLICATION CHART
1987 MODULE APPLICATION CHART
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Emissions Maintenance Light > Component
Information > Technical Service Bulletins > Emission Maintenance Warning Module - Service > Page 1211
1988 MODULE APPLICATION CHART
1989 MODULE APPLICATION CHART
1990 MODULE APPLICATION CHART PART NUMBER
PART NAME CLASS
E5TZ-12B514-C EMW Module - 1000 Hr BM
E5TZ-12B514-A EMW Module - 2000 Hr AM
E7TZ-12B514-A COMBO Module BM
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2300, 2500
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation
Maintenance Required Lamp/Indicator: Description and Operation
NOTE: This lamp is used only on models with Federal emissions systems.
The lamp will be illuminated after approximately 60,000 miles of operation. The amber lens is
located on the instrument panel and has the word Emissions, Emiss or EGR printed on it. On 1988
Ranger models with 2.0L/4-122 engine, the lamp lens will indicate Check Engine. After performing
the required emission control maintenance, the module must be replaced or reset, depending on
type of module used. On module equipped with reset feature, reset the module as follows:
1. Place ignition switch in the Off position.
2. On Aerostar models, the module is located under the instrument panel near the bulkhead
connector. On Bronco and F-Series, the module is attached to the instrument cluster to the left of
the steering column. On Bronco II and Ranger models, the module is located on the righthand side
of the instrument panel below the glove compartment. On E Series models, the module is located
under the lefthand side of the instrument panel.
3. On all models, insert a suitable phillips head screwdriver through .2 inch diameter hole located
on module near the reset sticker and lightly press down and hold.
4. While still lightly pressing down on screwdriver, turn ignition switch to Run position. The
emissions maintenance lamp should remain illuminated for as long as the screwdriver is pressing
down. Hold screwdriver in position for approximately five seconds.
5. Remove screwdriver, lamp should go out after approximately two to five seconds, indicating the
module has been reset. If lamp fails to go out, repeat reset procedure. Place ignition switch in the
Off position.
6. Turn ignition switch to Run position and check to ensure emission maintenance lamp is
illuminated for two to five seconds. After approximately two to five seconds the lamp should turn
off.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
Fig. 1 Jumper wire connections for resetting Check Engine Lamp.
1985-90 Models w/EEC-IV
This lamp will be illuminated when the ignition switch is placed in the On position. After engine is
started the lamp should go off, unless a problem has been detected by the EEC-IV system. After
diagnosis and repair, the Check Engine/MIL lamp will automatically reset when stored codes are
cleared from the EEC-IV system memory. After diagnosis and repair, EEC-IV memory may be
cleared of stored codes as follows:
1. With ignition switch in the Off position, connect a jumper wire between Self Test and Self Test
Input (STI) connectors, Fig. 1.
On Aerostar, the Self Test and STI connectors are gray in color and are located on lefthand fender
apron, near the Electronic Engine Control (EEC) relay. On Bronco and F Series, the Self Test and
STI connectors are located in the area of the EEC system charcoal canister. On Bronco II and
Ranger, the Self Test connector and STI connector are red in color and they are both located on
the righthand fender apron near the Electronic Engine Control (EEC) relay. On E Series, the Self
Test and the STI connectors are located on the righthand fender apron in the area of the MAP
sensor and starter motor relay.
2. Position ignition switch in On position, then disconnect jumper wire from test connector
terminals. Disconnect jumper as soon as Check Engine lamp starts flashing.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 >
Instrument Cluster Warning Lights - Dimly Lit
Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit
Article No. 93-24-10
11/24/93
^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG,
THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO
LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND
MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ
LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91
AEROSTAR 1991-93 EXPLORER
ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of
the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch.
ACTION:
If the vehicle displays the subject symptoms and meets the following conditions, replace the
ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for
1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks,
Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the
Parts Block in this article for correct parts usage.
CONDITIONS
^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring
schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 >
Instrument Cluster Warning Lights - Dimly Lit > Page 1226
^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part
Number Chart.
NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL
HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN
IMPROVED TO CORRECT THE SUBJECT ISSUE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models
Except Lincolns. Major Component Warranty Coverage For Lincolns
OPERATION DESCRIPTION TIME
932410A Replace Ignition Switch - 0.5 Hr.
All Light and Compact Trucks
DEALER CODING
BASIC PART NO. CONDITION CODE
11572 X1
OASIS CODES: 201000, 201100, 206000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov >
93 > Instrument Cluster Warning Lights - Dimly Lit
Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit
Article No. 93-24-10
11/24/93
^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG,
THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO
LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND
MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ
LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91
AEROSTAR 1991-93 EXPLORER
ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of
the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch.
ACTION:
If the vehicle displays the subject symptoms and meets the following conditions, replace the
ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for
1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks,
Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the
Parts Block in this article for correct parts usage.
CONDITIONS
^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring
schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov >
93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1232
^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part
Number Chart.
NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL
HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN
IMPROVED TO CORRECT THE SUBJECT ISSUE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models
Except Lincolns. Major Component Warranty Coverage For Lincolns
OPERATION DESCRIPTION TIME
932410A Replace Ignition Switch - 0.5 Hr.
All Light and Compact Trucks
DEALER CODING
BASIC PART NO. CONDITION CODE
11572 X1
OASIS CODES: 201000, 201100, 206000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > Page 1233
Oil Level Warning Indicator: Description and Operation
This system is used to indicate a low engine oil level condition. The lamp will be illuminated during
engine starting. If oil level is sufficient, the lamp will go off when engine is operating. If oil level is
low the lamp will remain on until engine oil is added and the ignition switch is placed in the Off
position. The module may take a few minutes to reset. If the engine is started during this period,
the last recorded reading will be displayed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Tire Wear - Toe Set Prior Vehicle Service
Tires: Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service
Article No. 86-24-28
TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES
LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE
Certain model vehicles have a significant weight change on the front axle between manufacture by
Ford and placement into service. This occurs when incomplete vehicles are completed by a body
company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.).
This weight change can affect toe setting so these vehicles require that toe be reset.
Figure 25
The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the
intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE
ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Tire Wear - Toe Set Prior Vehicle Service > Page 1239
Tires: Technical Service Bulletins Front Tires - Irregular Wear Pattern
Article No. 86-24-27
TIRE WEAR - FRONT - IRREGULAR PATTERN
LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS
Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel
and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire
tread/ carcass/compound design.
Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and
set to Shop Manual preferred settings for toe.
In cases of severe wear, obtain the complete alignment readings and tire information. Contact both
your Ford Representative and Tire Manufacturer's Representative for their assistance and
participation in resolving the customer's concern. Contacting the "local" tire store may not obtain
the assistance which may be available from the tire manufacturer.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Tire Wear - Toe Set Prior Vehicle Service > Page 1240
Tires: Technical Service Bulletins Tires - Best Pressure For Load Application
^33GTIRE - LOAD CAPACITY VERSUS INFLATION PRESSURE
^ TIRE - P - METRIC PASSENGER TIRES USED ON LIGHT TRUCKS
^ TIRE WEAR - EFFECTS OF INFLATION AND LOAD
Article No. 89-9-16
LIGHT TRUCK: 1984-89 ALL LIGHT TRUCK LINES
ISSUE: Tire wear can be affected by inflation and load. Good tread life is dependent on maintaining
proper air pressure in the tires. Other factors that affect tire wear are:
^ alignment
^ speed
^ road surfaces
ACTION: Keep tires inflated to the recommended pressures to obtain maximum tread life. Use the
following charts and procedures to arrive at the best tire pressure for each load application.
FIGURE 1
The chart in Figure 1 shows the affect of inflation and load on tire tread life. Use the chart by finding
the specified inflation pressure for the vehicle as shown on the certification label and locating that
pressure on the specified inflation pressure on the chart. The affects of actual air pressure and load
can now be read directly off the chart.
Tire load carrying capacity is a function of tire design and inflation pressures. Each tire has molded
into the sidewall a maximum pressure for a specific usage. Use the following guidelines to
determine load carrying capacity.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Tire Wear - Toe Set Prior Vehicle Service > Page 1241
FIGURE 2
^ For P-metric passenger tires on passenger cars, the values are as shown on the tire.
^ For P-metric passenger tires on light trucks, the load ratings are reduced to 91% to reflect the
"harsher" truck environment, Figure 2.
^ For light truck style tires used on light trucks, the values are as shown for tires used in single
wheel applications.
^ For light truck style tires used in dual wheel applications, the tire capacities are derated.
Often, inflation pressures for specific vehicles are less than maximum capacity because the load to
be carried is less than the maximum tire capacity.
Inflation pressures for originally installed size tires on a vehicle are shown on the vehicle
certification label along with the tire size and rated capacity for the axle system. Check the size and
inflation information on the label to properly inflate the tires. Be sure that the same size tire is
actually on the vehicle and then inflate it to the label's specified pressure. If other than original size
tires are on the vehicle, the label's pressures are probably not correct
To find proper pressures for other than original tires, use the following procedure.
1. Obtain both front and rear axle capacity ratings (GAWRR and GAWRF).
2. Divide each number by 2 to obtain the capacity at the tire.
FIGURE 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Tire Wear - Toe Set Prior Vehicle Service > Page 1242
3. For single wheel usage, look up the pressure in the proper chart which will meet the needed
capacity, Figure 3.
4. Check the tire side wall label to see if it permits inflation to that pressure. If lower load range tires
were installed (i.e., C vs. D or E), the tires may not have the needed capability.
5. Divide the value found in Step 2 by 2 again to obtain individual tire requirements for dual rear
wheels.
6. Using a dual wheel inflation pressure chart, Figure 3, determine correct pressure to achieve
adequate load capacities.
7. Consult the local tire outlet or the tire manufacturer's home office about tires not shown in the
tables.
OTHER APPLICABLE ARTICLES: 87-10-11
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 3300
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes
Wheels: Customer Interest Wheel - Mounting Surface Distorted Lug/Pilot Holes
Article No. 91-11-16
05/30/91
^ WHEEL - DISTORTED PILOT HOLES OR LUG HOLES - WITH 16 X 6 SINGLE STEEL
WHEELS
^ VIBRATION - WHEEL MOUNTING SURFACE DISTORTED - WITH 16 X 6 SINGLE STEEL
WHEELS
LIGHT TRUCK: 1985-91 E-250-350, F-250-350
ISSUE: Wheel vibration may be caused by distorted pilot holes or lug holes on the wheel. This
does not allow sufficient clamp load between the lug nut, the wheel and the rotor/hub. It may also
be difficult to remove the distorted wheel from the vehicle or to place the wheel on the vehicle in a
different location.
ACTION: To determine if a wheel has been damaged and should not be reused, refer to the
following service procedure for details.
NOTE: THIS PROCEDURE ONLY APPLIES TO PART # E7UA-1015-JA (16 X 6 SINGLE STEEL
WHEEL)
INSPECT FOR WHEEL DAMAGE
1. Remove the wheel from the hub. If the wheel is difficult to remove, DO NOT reuse the wheel.
2. Visually inspect the wheel for distortion (turned-up) scallops in the pilot hole. If the pilot hole is
distorted, DO NOT reuse the wheel.
3. Inspect the distorted lug holes by placing a lug nut in the lug hole cone seat of the wheel and
inspect from the reverse side. If the lug protrudes through the lug hole, DO NOT reuse the wheel.
4. Inspect the wheel mounting surface for distortion.
a. Lay a straight edge across the mounting surface of the wheel (the surface of the wheel which
makes contact with the rear brake drum or front rotor).
b. The straight edge should contact the outer edge of the mounting surface, lying between the bolt
holes and across the center of the pilot hole.
c. The clearance between the straight edge and the pilot hole can not exceed 0.0300 inch, the
straight edge should not contact the pilot holes. If the clearance is more than 0.0300 or the straight
edge makes contact with the pilot holes, DO NOT reuse the wheel.
INSTALL WHEEL
1. Inspect for lubricants on the studs and lug nuts.
2. If lubricants are present, clean throughly using naphtha or equivalent.
3. Torque lug nuts to (140 ft.lbs./190 N-m) using a torque wrench according to the Shop Manual,
Section 04-04.
CAUTION: EXCESSIVE TORQUE MAY CAUSE DISTORTION OF THE WHEEL. INADEQUATE
TORQUE MAY NOT PROVIDE
ADEQUATE CLAMPING FORCE TO ASSURE WHEEL RETENTION.
PART NUMBER PART NAME CLASS
E5TZ-1015-B Wheel AM
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage
OPERATION DESCRIPTION TIME
911116A Wheel-Inspect 0.7 hrs
911116B Replace One Wheel And 0.4 Hr.
Dynamic Balance
911116C Replace Two Wheels And 0.8 Hr.
Dynamic Balance
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot Holes >
Page 1251
911116D Replace Three Wheels And 1.2 Hr.
Dynamic Balance
911116E Replace Four Wheels And 1.6 Hr.
Dynamic Balance
DEALER CODING
BASIC PART NO. CONDITION CODE
1015 67
OASIS CODES: 306000, 703000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot
Holes
Wheels: All Technical Service Bulletins Wheel - Mounting Surface Distorted Lug/Pilot Holes
Article No. 91-11-16
05/30/91
^ WHEEL - DISTORTED PILOT HOLES OR LUG HOLES - WITH 16 X 6 SINGLE STEEL
WHEELS
^ VIBRATION - WHEEL MOUNTING SURFACE DISTORTED - WITH 16 X 6 SINGLE STEEL
WHEELS
LIGHT TRUCK: 1985-91 E-250-350, F-250-350
ISSUE: Wheel vibration may be caused by distorted pilot holes or lug holes on the wheel. This
does not allow sufficient clamp load between the lug nut, the wheel and the rotor/hub. It may also
be difficult to remove the distorted wheel from the vehicle or to place the wheel on the vehicle in a
different location.
ACTION: To determine if a wheel has been damaged and should not be reused, refer to the
following service procedure for details.
NOTE: THIS PROCEDURE ONLY APPLIES TO PART # E7UA-1015-JA (16 X 6 SINGLE STEEL
WHEEL)
INSPECT FOR WHEEL DAMAGE
1. Remove the wheel from the hub. If the wheel is difficult to remove, DO NOT reuse the wheel.
2. Visually inspect the wheel for distortion (turned-up) scallops in the pilot hole. If the pilot hole is
distorted, DO NOT reuse the wheel.
3. Inspect the distorted lug holes by placing a lug nut in the lug hole cone seat of the wheel and
inspect from the reverse side. If the lug protrudes through the lug hole, DO NOT reuse the wheel.
4. Inspect the wheel mounting surface for distortion.
a. Lay a straight edge across the mounting surface of the wheel (the surface of the wheel which
makes contact with the rear brake drum or front rotor).
b. The straight edge should contact the outer edge of the mounting surface, lying between the bolt
holes and across the center of the pilot hole.
c. The clearance between the straight edge and the pilot hole can not exceed 0.0300 inch, the
straight edge should not contact the pilot holes. If the clearance is more than 0.0300 or the straight
edge makes contact with the pilot holes, DO NOT reuse the wheel.
INSTALL WHEEL
1. Inspect for lubricants on the studs and lug nuts.
2. If lubricants are present, clean throughly using naphtha or equivalent.
3. Torque lug nuts to (140 ft.lbs./190 N-m) using a torque wrench according to the Shop Manual,
Section 04-04.
CAUTION: EXCESSIVE TORQUE MAY CAUSE DISTORTION OF THE WHEEL. INADEQUATE
TORQUE MAY NOT PROVIDE
ADEQUATE CLAMPING FORCE TO ASSURE WHEEL RETENTION.
PART NUMBER PART NAME CLASS
E5TZ-1015-B Wheel AM
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage
OPERATION DESCRIPTION TIME
911116A Wheel-Inspect 0.7 hrs
911116B Replace One Wheel And 0.4 Hr.
Dynamic Balance
911116C Replace Two Wheels And 0.8 Hr.
Dynamic Balance
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot
Holes > Page 1257
911116D Replace Three Wheels And 1.2 Hr.
Dynamic Balance
911116E Replace Four Wheels And 1.6 Hr.
Dynamic Balance
DEALER CODING
BASIC PART NO. CONDITION CODE
1015 67
OASIS CODES: 306000, 703000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Page 1258
Wheels: Specifications
5 LUG WHEEL
1/2-20 ..................................................................................................................................................
........................................... 135 Nm (100 lb ft)
8 LUG WHEEL
9/16-18 ................................................................................................................................................
........................................... 190 Nm (140 lb ft)
NOTE: Torque specifications are for clean, dirt and paint free dry bolt and nut threads. Never use
oil or grease on studs and nuts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Wheel Bearing Torque Specification - Manual Correction
Wheel Bearing: Technical Service Bulletins Wheel Bearing Torque Specification - Manual
Correction
WHEEL BEARING - FRONT - ADJUSTING NUT TORQUE SPECIFICATION - SHOP MANUAL
CORRECTION
Article No. 88-4-15
LIGHT TRUCK: 1987-88 E-SERIES
ISSUE: The front wheel bearing adjusting nut torque specification as published in the 1987 and
1988 Light Truck Shop Manual, Volume A, Section 12-24-3, Figures 2 and 3 is incorrect.
ACTION: If service is required, torque the front wheel bearing adjusting nut to 22-25 ft.lbs. (30-33
N-m) and then back the adjusting nut off 1/8 turn as described in the Light Truck Shop Manual,
Volume A, Section 11-10-1.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 1263
Wheel Bearing: Specifications
Wheel Adjusting Nut [1] .......................................................................................................................
........................................... 30-33 Nm (22-25 ft lbs)
Bearing End Play
..............................................................................................................................................................
0.025-0.254mm (0.001-0.010 in)
[1] Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional
movement of the adjusting nut.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 1264
Wheel Bearing: Adjustments
1. Raise the vehicle until the tire clears the floor and install safety stands.
2. Remove the wheel cover.
3. Remove the grease cap from the hub. Wipe the excess grease from the end of the spindle.
Remove the cotter pin and locknut.
4. Loosen the adjusting nut three turns. Attempt to obtain running clearance between the rotor
brake surface and the disc pads by rocking the wheel,
hub and rotor assembly in and out several times to push the pads away from the rotor. If running
clearance cannot be maintained throughout bearing adjustment in Steps 5 and 6, the caliper must
be removed.
NOTE: Do not pry on the phenolic caliper piston.
5. Tighten the wheel adjusting nut to 30-33 Nm (22-25 ft lbs) while rotating the disc brake rotor in
the opposite direction.
6. Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional
movement of the adjusting nut. Bearing end play
should be 0.025-0.254mm (0.001-0.010 in). Bend the ends of the cotter pin around the castellated
flange of the locknut.
7. Check front wheel rotation. If the wheel rotates properly, reinstall the grease cap and wheel
cover. If rotation is noisy or rough, remove and inspect
the bearings. Service as required.
WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake
pedal travel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 1265
Wheel Bearing: Service and Repair
Wheel bearing lubricant is a lithium-base grease. Sodium-base grease is not compatible with
lithium-base grease and should not be intermixed. Therefore, do not lubricate front and/or rear
wheel bearings without first identifying the type of original wheel bearing lubricant. Usage of
incompatible bearing lubricants may result in premature lubricant breakdown.
REMOVAL
Front Hub And Rotor Assembly
1. Raise the vehicle until the tire clears the floor and remove the wheel and tire assembly.
2. Remove the brake caliper and secure to the underbody to prevent damage to the brake hose. It
is not necessary to disconnect the hose from the
caliper. Do not let the caliper hang with its weight on the brake hose or the hose may become
stretched, twisted or ruptured. See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair
3. Remove the grease cap, cotter pin, retainer adjusting nut and washer.
4. Remove the outer bearing cone and roller.
5. Pull the hub and rotor off the spindle and remove and discard the grease seal.
6. Remove the inner bearing cone and roller from the hub. Remove all traces of old lubricant from
bearings, hub and axle spindle.
7. Inspect the cups for scratches, pits or cracks. If the cups are worn or damaged, remove them
with a drift. Clean the inner and outer bearing cones
and rollers with solvent and dry thoroughly.
CAUTION: Do not spin the bearings dry with compressed air.
8. Inspect the cones and rollers for cracks, nicks, brinelling, or seized rollers. Inspect the grease
retainer and replace it if it is cracked, nicked, dented
or worn.
9. Cover the spindle with a clean cloth. A water dampened cloth or water based solution should be
used to remove and dust or loose dirt from the
brake assembly. Remove the cloth from the spindle carefully to prevent dirt from falling on the
spindle.
NOTE: Do not use compressed air.
INSTALLATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 1266
Installing Bearing Cups (Typical)
1. If inner or outer bearing cups were removed, install replacement inner and outer bearing cups in
the hub with the appropriate bearing cup replacer
tool. Be sure to seat the cups properly in the hub. The cups will be properly seated when they are
fully bottomed. Replace grease retainers. Polish grease retainer journal on spindle with 400 grit
sandpaper. Clean with clean cloth.
2. Pack the inside of the hub with lithium-base grease or equivalent. Fill the hub until the grease is
flush with the inside diameters of both bearing
cups. Pack the bearing cones and rollers with wheel bearing grease. Use a bearing packer for this
operation. If a packer is not available, work as much lubricant as possible between the rollers and
cages. Lubricate the cone surfaces with grease.
Installing Grease Seal (Typical)
3. Place the inner bearing cone and roller in the inner cup and install the new grease seal. Be sure
that the seal is fully seated.
4. Install the hub and rotor on the wheel spindle. Keep the hub centered on the spindle to prevent
damage to the grease retainer or the spindle threads.
5. Install the outer bearing cone and roller and the flat washer on the spindle, then install the
adjusting nut, and adjust the wheel bearing.
6. Install the retainer, new cotter pin, and grease cap.
7. Install the caliper.
8. Install the wheel and tire assembly.
9. Lower vehicle and torque the lug nuts to specification. Re-install the wheel cover or hub cap.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 1267
WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake
pedal travel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service
Bulletins > Customer Interest for Wheel Cover: > 90118 > May > 90 > Wheel Cover - Centers Damaged By Stones
Wheel Cover: Customer Interest Wheel Cover - Centers Damaged By Stones
Article No. 90-11-8
WHEEL COVERS-16 INCH TURBINE WHEEL-CENTERS
DAMAGED BY STONES
LIGHT TRUCK: 1986-90 E-250, E-350, F-250, F-350
ISSUE: The wheel cover centers may be damaged by stones and debris hitting the cover. This
condition is most noticeable during cold weather because the wheel cover material becomes very
brittle.
ACTION: Install new wheel covers made of a more durable plastic. The color of the new plastic
material is gray which will help hide any stone chips. Refer to the following Wheel Cover
Application Chart for correct parts usage.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901108A Install Wheel Covers 0.2 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
1130 01
OASIS CODES: 1052, 3300
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheel Cover: > 90118 > May > 90 > Wheel Cover - Centers Damaged By
Stones
Wheel Cover: All Technical Service Bulletins Wheel Cover - Centers Damaged By Stones
Article No. 90-11-8
WHEEL COVERS-16 INCH TURBINE WHEEL-CENTERS
DAMAGED BY STONES
LIGHT TRUCK: 1986-90 E-250, E-350, F-250, F-350
ISSUE: The wheel cover centers may be damaged by stones and debris hitting the cover. This
condition is most noticeable during cold weather because the wheel cover material becomes very
brittle.
ACTION: Install new wheel covers made of a more durable plastic. The color of the new plastic
material is gray which will help hide any stone chips. Refer to the following Wheel Cover
Application Chart for correct parts usage.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901108A Install Wheel Covers 0.2 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
1130 01
OASIS CODES: 1052, 3300
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service
Bulletins > Customer Interest for Wheel Hub: > 932514 > Dec > 93 > Full Float Rear Hub/Shaft - Lubricant Leaks
Wheel Hub: Customer Interest Full Float Rear Hub/Shaft - Lubricant Leaks
Article No. 93-25-14
12/08/93
^ AXLE - "DANA" FULL FLOAT REAR - NEW HUB/SHAFT BOLTS AND REVISED TORQUE
SPECIFICATIONS
^ AXLE - "DANA" FULL FLOAT REAR - SHAFT/HUB BOLTS LOOSEN AND LEAK AXLE LUBE SERVICE TIPS
^ LEAKS - AXLE LUBE - REAR AXLE SHAFT/HUB BOLTS LOOSEN - SERVICE TIPS
LIGHT TRUCK: 1980-94 E-350 1988-94 F SUPER DUTY
ISSUE: The rear axle shaft/hub bolts may loosen and leak axle lube. This loosening can occur due
to increased torques at the rear wheels.
ACTION: Install new higher strength flange head bolts and improved cellulose gaskets, which
clamp the joint together tighter. Refer to the following service tips and revised torque specifications.
^ Do not use higher torques specified for these bolts on previously specified hex head bolts.
^ Always replace the bolts and gaskets together rather than reusing them when servicing the wheel
end.
^ The new cellulose gaskets and new flanged head bolts are designed to be used together;
therefore, neither part should be used with older stock parts.
NOTE: WHEN REMOVING THE BOLTS, LOOSEN THEM BY HAND BEFORE USING AN
IMPACT WRENCH. THE SHOCK LOAD APPLIED BY A POWER TOOL MAY CAUSE THE BOLT
TO SNAP BEFORE IT RELEASES.
NOTE:
WHEN SERVICING THE REAR AXLE HUB OR SHAFT, REPLACE THE BOLTS AND GASKET
WITH THE NEW PARTS. USE THE NEW TORQUE SPECIFICATIONS.
NOTE: SPECIAL LUBRICANTS ARE REQUIRED FOR DANA FULL FLOAT REAR AXLES. USE
FORD HYPOID GEAR LUBE (C6AZ-19580-E OR EQUIVALENT), OR FOR EXTREME SERVICE
APPLICATIONS, USE FORD HIGH PERFORMANCE REAR AXLE LUBE (F1TZ-19580-B OR
EQUIVALENT). REFER TO TSB 92-3-11 FOR ADDITIONAL LUBRICANT INFORMATION.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service
Bulletins > Customer Interest for Wheel Hub: > 932514 > Dec > 93 > Full Float Rear Hub/Shaft - Lubricant Leaks > Page
1289
OTHER APPLICABLE ARTICLES: 92-3-11 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage For 1992/94 Models, Basic Warranty Coverage For All
Other Models
OPERATION DESCRIPTION TIME
932514A Replace Axle Shaft/Hub 0.4 Hr.
Gaskets And Bolts (One Side)
932514B Replace Axle Shaft/Hub 0.6 Hr.
Gaskets And Bolts (Both Sides)
DEALER CODING
BASIC PART NO. CONDITION CODE
4A140 33
OASIS CODES: 509000, 590000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheel Hub: > 932514 > Dec > 93 > Full Float Rear Hub/Shaft - Lubricant
Leaks
Wheel Hub: All Technical Service Bulletins Full Float Rear Hub/Shaft - Lubricant Leaks
Article No. 93-25-14
12/08/93
^ AXLE - "DANA" FULL FLOAT REAR - NEW HUB/SHAFT BOLTS AND REVISED TORQUE
SPECIFICATIONS
^ AXLE - "DANA" FULL FLOAT REAR - SHAFT/HUB BOLTS LOOSEN AND LEAK AXLE LUBE SERVICE TIPS
^ LEAKS - AXLE LUBE - REAR AXLE SHAFT/HUB BOLTS LOOSEN - SERVICE TIPS
LIGHT TRUCK: 1980-94 E-350 1988-94 F SUPER DUTY
ISSUE: The rear axle shaft/hub bolts may loosen and leak axle lube. This loosening can occur due
to increased torques at the rear wheels.
ACTION: Install new higher strength flange head bolts and improved cellulose gaskets, which
clamp the joint together tighter. Refer to the following service tips and revised torque specifications.
^ Do not use higher torques specified for these bolts on previously specified hex head bolts.
^ Always replace the bolts and gaskets together rather than reusing them when servicing the wheel
end.
^ The new cellulose gaskets and new flanged head bolts are designed to be used together;
therefore, neither part should be used with older stock parts.
NOTE: WHEN REMOVING THE BOLTS, LOOSEN THEM BY HAND BEFORE USING AN
IMPACT WRENCH. THE SHOCK LOAD APPLIED BY A POWER TOOL MAY CAUSE THE BOLT
TO SNAP BEFORE IT RELEASES.
NOTE:
WHEN SERVICING THE REAR AXLE HUB OR SHAFT, REPLACE THE BOLTS AND GASKET
WITH THE NEW PARTS. USE THE NEW TORQUE SPECIFICATIONS.
NOTE: SPECIAL LUBRICANTS ARE REQUIRED FOR DANA FULL FLOAT REAR AXLES. USE
FORD HYPOID GEAR LUBE (C6AZ-19580-E OR EQUIVALENT), OR FOR EXTREME SERVICE
APPLICATIONS, USE FORD HIGH PERFORMANCE REAR AXLE LUBE (F1TZ-19580-B OR
EQUIVALENT). REFER TO TSB 92-3-11 FOR ADDITIONAL LUBRICANT INFORMATION.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheel Hub: > 932514 > Dec > 93 > Full Float Rear Hub/Shaft - Lubricant
Leaks > Page 1295
OTHER APPLICABLE ARTICLES: 92-3-11 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage For 1992/94 Models, Basic Warranty Coverage For All
Other Models
OPERATION DESCRIPTION TIME
932514A Replace Axle Shaft/Hub 0.4 Hr.
Gaskets And Bolts (One Side)
932514B Replace Axle Shaft/Hub 0.6 Hr.
Gaskets And Bolts (Both Sides)
DEALER CODING
BASIC PART NO. CONDITION CODE
4A140 33
OASIS CODES: 509000, 590000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > Customer Interest: > 87721 > Apr > 87 > Wheels- Lug Nuts Bind On Studs
Wheel Fastener: Customer Interest Wheels- Lug Nuts Bind On Studs
Article No. WHEEL - LUG NUTS BIND ON STUDS - VEHICLES
87-7-21 WITH 9/16" STUDS AND SINGLE REAR WHEELS
LIGHT TRUCK: 1983-87 E-250/350, F-250/350
ISSUE: Some lug nuts may be difficult to remove due to nut crimping. The lug nuts are designed to
be free-running as opposed to a "prevailing" torque style. The freerunning nuts may have "crimped
in" against the stud when torqued.
ACTION: To correct this, use new replacement nuts which will not "crimp in" when tightened to the
recommended torque of 140 ft.lbs. (190 N-m).
CAUTION: Lug nuts should be torqued by hand, not with an impact wrench, and retorqued at
intervals specified in the Owner Guide.
PART NUMBER PART NAME CLASS
E7TZ-1120-A Lug Nut - R.H. Thread A
- Package of 4
E7TZ-1121-A Lug Nut - L.H. Thread A
- Package of 4
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP870721A - Replace lug nuts TIME:
0.5 Hr.
OPERATION: 1107B - Replace wheel studs
TIME: Refer to the appropriate Service Labor Time Standards Manual
OPERATION: "M" Time - Replace lug nut stuck on spinning stud, if required Requires District
Authorization DLR. CODING: Basic Part No. 1120 - Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper
Installation/Torqueing Procedure
Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure
Article No. 98-5A-4
^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP
^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP
FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA
1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97
PROBE 1994-97 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI
1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII
1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI
1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE
LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO
II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER
1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR
ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or
unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and
installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly
torqued wheel lug nuts may cause:
^ Brake vibration
^ Distortion of the wheel hub
^ Distortion of the brake rotor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper
Installation/Torqueing Procedure > Page 1309
^ Brake rotor runout
^ Damage to the wheel
^ Damage to the wheel nuts and studs
ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by
using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The
"ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or
uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools
will not reduce the output torque enough to prevent overtightening of the wheel lug nuts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper
Installation/Torqueing Procedure > Page 1310
NOTE:
REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE
CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO
PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE.
The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the
"ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250
lb-ft), usually this will be the lowest setting on the air impact tool.
The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set
(164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4)
lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at
1-800-ROT-UNDA (768-8632).
CAUTION:
AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE
"ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED.
NOTE:
DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE
HAND-TORQUED ONLY.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 97-17-6
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 301000, 303000, 306000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 87721 > Apr > 87 > Wheels- Lug Nuts Bind On
Studs
Wheel Fastener: All Technical Service Bulletins Wheels- Lug Nuts Bind On Studs
Article No. WHEEL - LUG NUTS BIND ON STUDS - VEHICLES
87-7-21 WITH 9/16" STUDS AND SINGLE REAR WHEELS
LIGHT TRUCK: 1983-87 E-250/350, F-250/350
ISSUE: Some lug nuts may be difficult to remove due to nut crimping. The lug nuts are designed to
be free-running as opposed to a "prevailing" torque style. The freerunning nuts may have "crimped
in" against the stud when torqued.
ACTION: To correct this, use new replacement nuts which will not "crimp in" when tightened to the
recommended torque of 140 ft.lbs. (190 N-m).
CAUTION: Lug nuts should be torqued by hand, not with an impact wrench, and retorqued at
intervals specified in the Owner Guide.
PART NUMBER PART NAME CLASS
E7TZ-1120-A Lug Nut - R.H. Thread A
- Package of 4
E7TZ-1121-A Lug Nut - L.H. Thread A
- Package of 4
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP870721A - Replace lug nuts TIME:
0.5 Hr.
OPERATION: 1107B - Replace wheel studs
TIME: Refer to the appropriate Service Labor Time Standards Manual
OPERATION: "M" Time - Replace lug nut stuck on spinning stud, if required Requires District
Authorization DLR. CODING: Basic Part No. 1120 - Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper
Installation/Torqueing Procedure
Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure
Article No. 98-5A-4
^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP
^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP
FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA
1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97
PROBE 1994-97 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI
1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII
1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI
1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE
LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO
II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER
1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR
ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or
unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and
installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly
torqued wheel lug nuts may cause:
^ Brake vibration
^ Distortion of the wheel hub
^ Distortion of the brake rotor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper
Installation/Torqueing Procedure > Page 1320
^ Brake rotor runout
^ Damage to the wheel
^ Damage to the wheel nuts and studs
ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by
using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The
"ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or
uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools
will not reduce the output torque enough to prevent overtightening of the wheel lug nuts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper
Installation/Torqueing Procedure > Page 1321
NOTE:
REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE
CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO
PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE.
The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the
"ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250
lb-ft), usually this will be the lowest setting on the air impact tool.
The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set
(164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4)
lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at
1-800-ROT-UNDA (768-8632).
CAUTION:
AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE
"ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED.
NOTE:
DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE
HAND-TORQUED ONLY.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 97-17-6
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 301000, 303000, 306000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > Page 1322
Wheel Fastener: Specifications
5 LUG WHEEL
1/2-20 ..................................................................................................................................................
........................................... 135 Nm (100 lb ft)
8 LUG WHEEL
9/16-18 ................................................................................................................................................
........................................... 190 Nm (140 lb ft)
NOTE: Torque specifications are for clean, dirt and paint free dry bolt and nut threads. Never use
oil or grease on studs and nuts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical
Service Bulletins > Page 1323
Wheel Fastener: Service and Repair
Lug Nut Torque Patterns
IMPORTANT
Check all parts, including rims, lug studs, lug nuts, and mating surfaces of hubs and tire rims for
rust, damage, or dirt. Clean mating surfaces with a wire brush to remove any foreign material.
Replace any damaged parts as needed. Careless installation of tire/rim assemblies in a vehicle is a
major cause of tire installation problems. Proper installation, including fastener torque, is essential
to economical, safe and trouble free service. Use only the proper sizes and types of fasteners for
safe and proper service. Tighten the fasteners a quarter turn at a time using the tightening
sequence diagram as a guide. This is very important to prevent misalignment of the wheel.
Continue tightening the fasteners in sequence until the fasteners are tightened to the proper torque
(See WHEEL FASTENER TORQUE).
CAUTION: Improper torque or tightening sequence can cause distortion, fatigue cracks, or
alignment problems. After driving the vehicle for a short distance, recheck the wheel fastener
torque. Parts will usually seat naturally, reducing the torque on the fasteners. Retorque all
fasteners to the proper torque.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications
Camshaft: Specifications
Camshaft Journal Diameter 2.1238-2.1248 in
Camshaft Bearing Inside Diameter 2.1258-2.1268 in
Camshaft Bearing Clearance .001-.003 in
Note: Service Limit -- 0.006 in
Camshaft End Play .001-.006 in
Note: Service Limit -- 0.009 in
Camshaft Runout Max. 0.005 in
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications > Page 1330
Camshaft: Service and Repair
V8 ENGINES
1. On Econoline models except V8-351M and 400 engines, remove grille.
2. On all models, drain cooling system, then disconnect all lines and hoses from radiator and
remove radiator.
3. Remove intake manifold, then the rocker arm covers.
4. Loosen rocker arms, then remove pushrods and valve lifters in sequence.
5. Remove timing case cover and timing chain as previously described.
6. On models equipped with A/C, remove A/C condenser attaching bolts and position condenser
aside.
7. On all models, remove camshaft thrust plate and carefully slide camshaft out through front of
engine.
8. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Specifications
Lifter / Lash Adjuster: Specifications
Lifter Bore Diameter .8752-.8767 in
Lifter Diameter .8740-.8745 in
Lifter To Bore Clearance .0007-.0027 in
Note: Service Limit -- 0.005 in
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Specifications > Page 1334
Lifter / Lash Adjuster: Service and Repair
V6-232, V8-255, 302, 351, 400, & 460
1. Remove intake manifold.
2. Remove rocker arm covers. Loosen rocker arm stud nuts or bolts and rotate rocker arms to the
side.
3. Remove pushrods in sequence so they can be installed in their original bores.
4. Using a magnet, remove the lifters and place them in a numbered rack so they can be installed
in their original bores. If lifters are stuck in their bores, it may be necessary to use a plier-type tool
to remove them.
5. The internal parts of each lifter are matched sets. Do not intermix parts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications
Rocker Arm Assembly: Specifications
Rocker Arm To Cylinder Head Bolts 18-25 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Page 1338
Rocker Arm Assembly: Service and Repair
Fig. 23 Rocker arm assembly
Fig. 24 Rocker Arm Assembly
V6-232, V8-255, 302, 351M, 351W, 400 & 460 & 1985-87 6-300 The rocker arm is supported by a
fulcrum bolt which fits through the fulcrum seat and threads into the cylinder head. To disassemble,
remove the bolt, oil deflector, fulcrum seat and rocker arm, Figs. 26 and 27. 1981-82 models
equipped with V8-255, 302 and 351W engines with low profile rocker arm fulcrums (part No.
E1TZ-6A528-A) may experience excessive oil displacement when engine is operated for extended
periods during high ambient temperatures. This problem may be corrected by replacing original
rocker arm fulcrums with part No. D7AZ-6A528-A.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications
Connecting Rod: Specifications
Connecting Rod Cap Bolts 45-50 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 1343
Connecting Rod: Service and Repair
Fig. 28 Piston & rod assembly
Fig. 29 Piston & rod assembly
Fig. 35 Piston & rod assembly. V6-232
Lubricate all parts with light engine oil. Position the connecting rod in the piston and push the pin
into place, Figs. 33, 34 and 35. Insert new piston pin retainers (when used) by spiralling them into
the piston with the fingers. Do not use pliers. Replacement pistons for the following 6-300 equipped
vehicles have an increased ring land, which raises the top compression ring .035 inch:
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 1344
1980-81 E & F-100-250 & Bronco except heavy duty. Before installing the new piston, the cylinder
ridge must be removed to ensure that the top compression ring does not contact the ridge or
deposits formed at the top of the cylinder bore. When removing the ridge, do not cut into the ring
travel area more than {1/32} inch.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications Main Cap Torque
Main Cap Torque
Main Bearing Cap Bolts 95- 105 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Locations
Engine Block Heater: Locations
RH Side Of V8-420/6.
RH Side Of Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Crankshaft Pulley 70-90 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
Piston Diameter coded red 4.3585 - 4.3591 in
coded blue 4.3597 - 4.3603 in
Piston Clearance .0022-.0030 in
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications > Page 1357
Piston: Service and Repair
Fig. 28 Piston & rod assembly
Fig. 29 Piston & rod assembly
Fig. 35 Piston & rod assembly. V6-232
Lubricate all parts with light engine oil. Position the connecting rod in the piston and push the pin
into place, Figs. 33, 34 and 35. Insert new piston pin retainers (when used) by spiralling them into
the piston with the fingers. Do not use pliers. Replacement pistons for the following 6-300 equipped
vehicles have an increased ring land, which raises the top compression ring .035 inch:
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications > Page 1358
1980-81 E & F-100-250 & Bronco except heavy duty. Before installing the new piston, the cylinder
ridge must be removed to ensure that the top compression ring does not contact the ridge or
deposits formed at the top of the cylinder bore. When removing the ridge, do not cut into the ring
travel area more than {1/32} inch.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications
Piston Pin: Specifications
Piston Pin Diameter 1.0398-1.0403 in
Pin to Piston Bore Clearance .0002-.0004 in
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
Piston Ring End Gap, Comp. 0.01 in
Piston Ring End Gap, Oil 0.01 in
Piston Ring Side Clearance, Comp. .0025-.0045 in
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
ENGINE YEAR CLEARANCE
V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165
V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150
On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System
Information > Specifications > Page 1369
Valve Clearance: Locations
FRONT TO REAR 6-300 E-I-E-I-E-I-E-I-E-I-E-I V6-232 Right I-E-I-E-I-E V6-232 Left E-I-E-I-E-I
V8-255, 302 Left Bank E-I-E-I-E-I-E-I V8-255, 302 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Right
Bank I-E-I-E-I-E-I-E V8-351, 400 Left Bank E-I-E-I-E-I-E-I V8-460 Left Bank E-I-E-I-E-I-E-I V8-460
Right Bank I-E-I-E-I-E-I-E
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System
Information > Specifications > Page 1370
Valve Clearance: Adjustments
Fig. 2 Positioning crankshaft for valve clearance check
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System
Information > Specifications > Page 1371
Fig. 3 Checking collapsed tappet clearance
Valves, Adjust To provide a means to compensate for dimensional changes in the valve train and
provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve
clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance
is more than the maximum, the longer pushrod should be used. To check the valve clearance,
proceed as follows:
1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of
compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one
quarter turn clockwise (90°) from position No. 2, Fig. 2.
2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 3, and check the clearance on the following valves:
a. On V8-302 and 460 engines, check intake valve Nos. 1 , 7 and 8; exhaust valve Nos. 1, 4 and 5.
b. On V8-351, check intake valve Nos. 1, 4 and No. 8; exhaust valve Nos. 1, 3 and 7.
3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 3, and check the clearance on the following valves:
a. On V8-301 and 460 engines check intake valve Nos. 4 and 5; exhaust valve Nos. 2 and 6. b. On
V8-351 engines, check intake valve Nos. 3 and 7; exhaust valve Nos. 2 and 6.
4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or
equivalent and check the clearance on the following valves:
a. V8-302 and 460 engines check intake valve Nos. 2, 3 and 6; exhaust valve Nos. 3, 7 and 8. b.
On V8-351 engines, check intake valve Nos. 2, 5 and 6; exhaust valve Nos. 4, 5 and 8.
Valve Arrangement
Front to Rear
V8-302 Left Bank..................................................................................................................................
...........................................................E-I-E-I-E-I-E-I V8-302 Right Bank.............................................
..............................................................................................................................................I-E-I-E-IE-I-E V8-351 Right Bank......................................................................................................................
.....................................................................I-E-I-E-I-E-I-E V8-351 Left Bank......................................
.......................................................................................................................................................E-IE-I-E-I-E-I V8-460 Left Bank.................................................................................................................
............................................................................E-I-E-I-E-I-E-I V8-460 Right Bank............................
..............................................................................................................................................................
.I-E-I-E-I-E-I-E
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications
Rocker Arm Assembly: Specifications
Rocker Arm To Cylinder Head Bolts 18-25 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Page 1375
Rocker Arm Assembly: Service and Repair
Fig. 23 Rocker arm assembly
Fig. 24 Rocker Arm Assembly
V6-232, V8-255, 302, 351M, 351W, 400 & 460 & 1985-87 6-300 The rocker arm is supported by a
fulcrum bolt which fits through the fulcrum seat and threads into the cylinder head. To disassemble,
remove the bolt, oil deflector, fulcrum seat and rocker arm, Figs. 26 and 27. 1981-82 models
equipped with V8-255, 302 and 351W engines with low profile rocker arm fulcrums (part No.
E1TZ-6A528-A) may experience excessive oil displacement when engine is operated for extended
periods during high ambient temperatures. This problem may be corrected by replacing original
rocker arm fulcrums with part No. D7AZ-6A528-A.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Specifications
Valve Cover: Specifications
Rocker Arm Cover 5-6 ft/lb ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Specifications
Valve Guide: Specifications
Guide, Inside Diameter .3433-.3443 in
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component
Information > Specifications > Page 1382
Valve Guide: Service and Repair
Valve guides in these engines are an integral part of the head and, therefore, cannot be removed.
For service, guides can be reamed oversize to accommodate one of three service valves with
oversize stems (.003 inch, .015 inch and .030 inch). Check the valve stem clearance of each valve
(after cleaning) in its respective valve guide. If the clearance exceeds the service limits of .004 inch
of the intake or .005 inch on the exhaust, ream the valve guides to accommodate the next oversize
diameter valve.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Specifications
Valve Seat: Specifications
Seat Width, Intake .060-.080 in
Seat Width, Exhaust .060-.080 in
Runout 0.002 in
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Specifications
Valve Spring: Specifications
Free Length Intake 2.06 in
Free Length Exhaust 2.06 in
Out Of Square Limit 0.078 in
Installed Height Intake 1.797-1.828 in
Installed Height Exhaust 1.797-1.828 in
Spring Pressure, Closed, Intake 76-84 lbf at 1.81 in
Spring Pressure, Closed, Exhaust 76-84 lbf at 1.81 in
Spring Pressure, Open, Intake 218-240 lbf at 1.33 in
Spring Pressure, Open, Exhaust 218-240 lbf at 1.33 in
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Specifications
Valve: Specifications
Stem Diameter Intake .3416-.3423 in
Stem Diameter Exhaust .3411-.3418 in
Maximum Tip Refinish 0.01 in
Face Angle 44 deg
Margin Intake 1/32 in
Margin Exhaust 1/32 in
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest: > 941019 > May > 94 > Accessory Drive
Belt - Chirp or Squeal Noise
Drive Belt: Customer Interest Accessory Drive Belt - Chirp or Squeal Noise
Article No. 94-10-19
05/18/94
^ ACCESSORY DRIVE BELT - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR
OR LOSS - VEHICLES WITH 4.9L ENGINE
^ ENGINE - 4.9L - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR OR LOSS
^ NOISE - "CHIRP"/"SQUEAL" SOUND FROM FEAD BELT - VEHICLES WITH 4.9L ENGINE
LIGHT TRUCK: 1987-94 ECONOLINE, F-150-350 SERIES
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest: > 941019 > May > 94 > Accessory Drive
Belt - Chirp or Squeal Noise > Page 1401
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest: > 941019 > May > 94 > Accessory Drive
Belt - Chirp or Squeal Noise > Page 1402
This TSB article is being republished in its entirety to provide specific bolt number references in
Figures 3 and 4.
ISSUE: Front-end accessory drive belt (FEAD) belt noise may be heard and excessive belt edge
wear or loss may occur.
^ The "chirp" noise may occur at constant engine speeds and all engine loads. It is caused by
belt/pulley misalignment.
^ The belt "squeal" noise is intermittent and is heard during engine speed variations, usually at
engine start up. The noise is caused by belt slippage.
^ Belt edge wear and/or belt loss is caused by belt mistracking across the automatic belt tensioner.
If the automatic belt tensioner is out of parallel, the belt can be "driven" to either flange of the
pulley, causing belt edge wear and in some cases, the loss of the belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest: > 941019 > May > 94 > Accessory Drive
Belt - Chirp or Squeal Noise > Page 1403
ACTION: Use the following service procedure to correct these conditions.
BELT CHIRP
1. Start the engine and while idling, wet the ribbed side of belt by spraying water on the belt where
it enters the A/C compressor pulley.
2. Listen for belt "chirp" as the belt dries at the entrance point of each grooved pulley to identify the
noisy pulley.
3. If the "chirp" is at the power steering pulley entry, check for belt mistracking on the tensioner
pulley, otherwise go to Step 13.
4. Check press of the power steering pulley. The pulley hub should be flush with the end of the
pump shaft.
5. If the pulley is flush, start engine and while idling, visually compare the size of the gaps between
the belt and front and rear flange of the tensioner pulley. If the larger gap is twice as wide as the
smaller gap, Figure 2, proceed with Step 6, otherwise, go to Step 13.
6. Mark the accessory drive belt with an arrow to denote rotation of belt. Remove belt.
7. Loosen all fasteners attaching A/C bracket to cylinder block and cylinder head. See Figures 3
and 4.
8. Tighten nuts # 3 (and, on 1987-93 model only, bolts # 4) on side of cylinder block to 62 N-m (46
lb.ft).
9. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
10. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
11. Install the accessory drive belt. Be sure belt is installed with arrow mark denoting original
rotation of belt.
12. Start engine and check for belt "chirp" noise.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest: > 941019 > May > 94 > Accessory Drive
Belt - Chirp or Squeal Noise > Page 1404
13. Remove the accessory drive belt and replace it with a new service replacement belt. See
Figure 1 for correct belt usage.
BELT SQUEAL - F-SERIES
1. Remove the accessory drive belt automatic tensioner assembly. Refer to the appropriate Truck
service Manual, Section 03-05, for the removal procedure.
2. Replace it with automatic tensioner assembly (E7TZ-6B209-G). Refer to the appropriate Truck
service Manual, Section 03-05, for the installation procedure.
3. Replace the accessory drive belt.
BELT SQUEAL - ECONOLINE (A/C EQUIPPED MODELS ONLY)
1. Remove and discard the accessory drive belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest: > 941019 > May > 94 > Accessory Drive
Belt - Chirp or Squeal Noise > Page 1405
2. Remove 90 mm diameter pulley from automatic tensioner assembly. Discard bolt, pulley and
bearing dust shield. Refer to Figure 5.
3. Install new 76 mm pulley, bearing, dust shield and bolt assembly (E7UZ-8678-A) to automatic
tensioner assembly. See Figure 5.
4. Install new accessory drive belt. (1987-93 models - E7UZ-8620-J, 1994 models - E8TZ-8620-S).
BELT EDGE WEAR AND LOSS
1. Remove and replace accessory drive belt with new service replacement belt. See Figure 1 for
correct parts usage.
2. Start engine and while idling, observe location of belt on automatic tensioner pulley. If belt tracks
near the pulley flange, Figure 2, replace with automatic tensioner (E7TZ-6B209-G).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest: > 941019 > May > 94 > Accessory Drive
Belt - Chirp or Squeal Noise > Page 1406
3. Start engine and observe belt movement. If belt moves too far rearward on tensioner pulley,
proceed as follows:
a. With belt installed, loosen all A/C bracket fasteners. Belt tension will pull A/C bracket inboard
towards the engine. (Refer to Figures 3 and 4 for bolt and nut position identification.)
b. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
c. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
d. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
4. Start engine and observe belt movement. If belt moves too far forward on tensioner pulley,
proceed as follows:
a. Remove accessory drive belt and loosen all A/C bracket fasteners.
b. Pull A/C bracket toward driver's side of vehicle.
c. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
d. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
e. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-9-14 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic
Warranty Coverage For All Other Models, Emission Warranty For Belt Loss On Vehicles Equipped
With Thermactor Pumps
OPERATION DESCRIPTION TIME
941019A Correct Belt Chirp 0.6 Hr.
E-Series
941019B Correct Belt Chirp 0.5 Hr.
F-Series
941019C Additional Time To Adjust 0.3 Hr.
A/C Bracket If Gap Is Too Large - E&F; Series
941019D Correct Belt Squeal 0.5 Hr.
E-Series
941019E Correct Belt Squeal 0.3 Hr.
F-Series
941019F Correct Belt Edge Wear or
0.6 Hr.
Belt Loss - E-Series
941019G Correct Belt Edge Wear Or
0.4 Hr.
Belt Loss - F-Series
941019H Additional Time To Adjust 0.2 Hr.
A/C Bracket To Correct Belt Tracking - E&F; Series
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest: > 941019 > May > 94 > Accessory Drive
Belt - Chirp or Squeal Noise > Page 1407
DEALER CODING
BASIC PART NO. CONDITION CODE
6B209 56
OASIS CODES: 497000, 702000, 702000, 790000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest: > 94110 > Jan > 94 > Accessory Drive
Belt - Noise/Excessive Wear
Drive Belt: Customer Interest Accessory Drive Belt - Noise/Excessive Wear
Article No. 94-1-10
01/12/94
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - EXCESSIVE IDLER/TENSIONER PULLEY
WEAR
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - NEW BELT FOR ABRASIVE
ENVIRONMENT
^ NOISE - "THUMP" FROM FRONT END ACCESSORY DRIVE (FEAD) BELT - BELT EDGE
STARTS TO FRAY
LIGHT TRUCK: 1987-93 BRONCO, ECONOLINE, F-150-350 SERIES
ISSUE: Front End Accessory Drive (FEAD) belts have a cloth backing which can trap abrasive
particles, resulting in belt wear and erosion of the idler pulleys.
ACTION: Replace the current FEAD belt with a new neoprene-backed belt which does not retain
abrasive particles or promote pulley wear. Refer to the following procedure for service details.
1. Inspect the tensioner and idler pulleys for wear of the drive surfaces.
NOTE:
NOMINAL PULLEY DIAMETER IS 90 mm (3.453") OR 76 mm (2.916"); PULLEYS WORN TO 88
mm (3.377") OR 74 mm (2.839") SHOULD BE REPLACED.
2. Select the appropriate neoprene-backed belt and install per standard belt routing (refer to
Service Manual Section 03-05).
3. Insure that all belt vee's are in all pulley grooves.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Customer Interest: > 94110 > Jan > 94 > Accessory Drive
Belt - Noise/Excessive Wear > Page 1412
Parts Block
OTHER APPLICABLE ARTICLES: 89-10-11 WARRANTY STATUS: Eligible Under The Provisions
Of The Bumper To Bumper Warranty Coverage For 1992-93 Models And Eligible Under Basic
Warranty Coverage For Other Model Years. Emission Warranty Coverage Applies If Vehicle Is
Equipped With Thermactor System
OPERATION DESCRIPTION TIME
940110A Replace Belt - 0.3 Hr.
F-Series/Bronco
940110B Replace Belt And Tensioner 0.4 Hr.
- F-Series/Bronco
940110C Replace Belt - Econoline 0.4 Hr.
940110D Replace Belt And Tensioner 0.5 Hr.
- Econoline
DEALER CODING
BASIC PART NO. CONDITION CODE
8620 30
OASIS CODES: 497000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise
Drive Belt: All Technical Service Bulletins Accessory Drive Belt - Chirp or Squeal Noise
Article No. 94-10-19
05/18/94
^ ACCESSORY DRIVE BELT - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR
OR LOSS - VEHICLES WITH 4.9L ENGINE
^ ENGINE - 4.9L - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR OR LOSS
^ NOISE - "CHIRP"/"SQUEAL" SOUND FROM FEAD BELT - VEHICLES WITH 4.9L ENGINE
LIGHT TRUCK: 1987-94 ECONOLINE, F-150-350 SERIES
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise > Page 1418
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise > Page 1419
This TSB article is being republished in its entirety to provide specific bolt number references in
Figures 3 and 4.
ISSUE: Front-end accessory drive belt (FEAD) belt noise may be heard and excessive belt edge
wear or loss may occur.
^ The "chirp" noise may occur at constant engine speeds and all engine loads. It is caused by
belt/pulley misalignment.
^ The belt "squeal" noise is intermittent and is heard during engine speed variations, usually at
engine start up. The noise is caused by belt slippage.
^ Belt edge wear and/or belt loss is caused by belt mistracking across the automatic belt tensioner.
If the automatic belt tensioner is out of parallel, the belt can be "driven" to either flange of the
pulley, causing belt edge wear and in some cases, the loss of the belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise > Page 1420
ACTION: Use the following service procedure to correct these conditions.
BELT CHIRP
1. Start the engine and while idling, wet the ribbed side of belt by spraying water on the belt where
it enters the A/C compressor pulley.
2. Listen for belt "chirp" as the belt dries at the entrance point of each grooved pulley to identify the
noisy pulley.
3. If the "chirp" is at the power steering pulley entry, check for belt mistracking on the tensioner
pulley, otherwise go to Step 13.
4. Check press of the power steering pulley. The pulley hub should be flush with the end of the
pump shaft.
5. If the pulley is flush, start engine and while idling, visually compare the size of the gaps between
the belt and front and rear flange of the tensioner pulley. If the larger gap is twice as wide as the
smaller gap, Figure 2, proceed with Step 6, otherwise, go to Step 13.
6. Mark the accessory drive belt with an arrow to denote rotation of belt. Remove belt.
7. Loosen all fasteners attaching A/C bracket to cylinder block and cylinder head. See Figures 3
and 4.
8. Tighten nuts # 3 (and, on 1987-93 model only, bolts # 4) on side of cylinder block to 62 N-m (46
lb.ft).
9. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
10. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
11. Install the accessory drive belt. Be sure belt is installed with arrow mark denoting original
rotation of belt.
12. Start engine and check for belt "chirp" noise.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise > Page 1421
13. Remove the accessory drive belt and replace it with a new service replacement belt. See
Figure 1 for correct belt usage.
BELT SQUEAL - F-SERIES
1. Remove the accessory drive belt automatic tensioner assembly. Refer to the appropriate Truck
service Manual, Section 03-05, for the removal procedure.
2. Replace it with automatic tensioner assembly (E7TZ-6B209-G). Refer to the appropriate Truck
service Manual, Section 03-05, for the installation procedure.
3. Replace the accessory drive belt.
BELT SQUEAL - ECONOLINE (A/C EQUIPPED MODELS ONLY)
1. Remove and discard the accessory drive belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise > Page 1422
2. Remove 90 mm diameter pulley from automatic tensioner assembly. Discard bolt, pulley and
bearing dust shield. Refer to Figure 5.
3. Install new 76 mm pulley, bearing, dust shield and bolt assembly (E7UZ-8678-A) to automatic
tensioner assembly. See Figure 5.
4. Install new accessory drive belt. (1987-93 models - E7UZ-8620-J, 1994 models - E8TZ-8620-S).
BELT EDGE WEAR AND LOSS
1. Remove and replace accessory drive belt with new service replacement belt. See Figure 1 for
correct parts usage.
2. Start engine and while idling, observe location of belt on automatic tensioner pulley. If belt tracks
near the pulley flange, Figure 2, replace with automatic tensioner (E7TZ-6B209-G).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise > Page 1423
3. Start engine and observe belt movement. If belt moves too far rearward on tensioner pulley,
proceed as follows:
a. With belt installed, loosen all A/C bracket fasteners. Belt tension will pull A/C bracket inboard
towards the engine. (Refer to Figures 3 and 4 for bolt and nut position identification.)
b. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
c. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
d. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
4. Start engine and observe belt movement. If belt moves too far forward on tensioner pulley,
proceed as follows:
a. Remove accessory drive belt and loosen all A/C bracket fasteners.
b. Pull A/C bracket toward driver's side of vehicle.
c. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
d. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
e. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-9-14 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic
Warranty Coverage For All Other Models, Emission Warranty For Belt Loss On Vehicles Equipped
With Thermactor Pumps
OPERATION DESCRIPTION TIME
941019A Correct Belt Chirp 0.6 Hr.
E-Series
941019B Correct Belt Chirp 0.5 Hr.
F-Series
941019C Additional Time To Adjust 0.3 Hr.
A/C Bracket If Gap Is Too Large - E&F; Series
941019D Correct Belt Squeal 0.5 Hr.
E-Series
941019E Correct Belt Squeal 0.3 Hr.
F-Series
941019F Correct Belt Edge Wear or
0.6 Hr.
Belt Loss - E-Series
941019G Correct Belt Edge Wear Or
0.4 Hr.
Belt Loss - F-Series
941019H Additional Time To Adjust 0.2 Hr.
A/C Bracket To Correct Belt Tracking - E&F; Series
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise > Page 1424
DEALER CODING
BASIC PART NO. CONDITION CODE
6B209 56
OASIS CODES: 497000, 702000, 702000, 790000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 94110 > Jan > 94 >
Accessory Drive Belt - Noise/Excessive Wear
Drive Belt: All Technical Service Bulletins Accessory Drive Belt - Noise/Excessive Wear
Article No. 94-1-10
01/12/94
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - EXCESSIVE IDLER/TENSIONER PULLEY
WEAR
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - NEW BELT FOR ABRASIVE
ENVIRONMENT
^ NOISE - "THUMP" FROM FRONT END ACCESSORY DRIVE (FEAD) BELT - BELT EDGE
STARTS TO FRAY
LIGHT TRUCK: 1987-93 BRONCO, ECONOLINE, F-150-350 SERIES
ISSUE: Front End Accessory Drive (FEAD) belts have a cloth backing which can trap abrasive
particles, resulting in belt wear and erosion of the idler pulleys.
ACTION: Replace the current FEAD belt with a new neoprene-backed belt which does not retain
abrasive particles or promote pulley wear. Refer to the following procedure for service details.
1. Inspect the tensioner and idler pulleys for wear of the drive surfaces.
NOTE:
NOMINAL PULLEY DIAMETER IS 90 mm (3.453") OR 76 mm (2.916"); PULLEYS WORN TO 88
mm (3.377") OR 74 mm (2.839") SHOULD BE REPLACED.
2. Select the appropriate neoprene-backed belt and install per standard belt routing (refer to
Service Manual Section 03-05).
3. Insure that all belt vee's are in all pulley grooves.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 94110 > Jan > 94 >
Accessory Drive Belt - Noise/Excessive Wear > Page 1429
Parts Block
OTHER APPLICABLE ARTICLES: 89-10-11 WARRANTY STATUS: Eligible Under The Provisions
Of The Bumper To Bumper Warranty Coverage For 1992-93 Models And Eligible Under Basic
Warranty Coverage For Other Model Years. Emission Warranty Coverage Applies If Vehicle Is
Equipped With Thermactor System
OPERATION DESCRIPTION TIME
940110A Replace Belt - 0.3 Hr.
F-Series/Bronco
940110B Replace Belt And Tensioner 0.4 Hr.
- F-Series/Bronco
940110C Replace Belt - Econoline 0.4 Hr.
940110D Replace Belt And Tensioner 0.5 Hr.
- Econoline
DEALER CODING
BASIC PART NO. CONDITION CODE
8620 30
OASIS CODES: 497000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 8718 > Jan > 87 >
Accessory Drive Belt - `V' Ribbed Belt Cracking
Drive Belt: All Technical Service Bulletins Accessory Drive Belt - `V' Ribbed Belt Cracking
ACCESSORY DRIVE BELT - "V" RIBBED BELT Article No.
CRACKING 87-1-8
FORD 1983 FAIRMONT; 1983-86 LTD; 1983-87 ESCORT, EXP, MUSTANG, THUNDERBIRD,
CROWN VICTORIA; 1984-87 TEMPO; 1986-87 TAURUS
LINCOLN-MERCURY 1983 LN7, ZEPHYR, MARK VI; 1983-86 CAPRI, MARQUIS; 1983-87 LYNX,
GRAND MARQUIS, COUGAR, LINCOLN TOWN CAR; 1984-87 TOPAZ, MARK VII; 1986-87
SABLE
MERKUR 1985-87 XR4Ti
LIGHT TRUCK 1987 E SERIES, F SERIES
ISSUE: Minor cracks of the accessory belt ribs are a normal wear condition. Besides the normal
cracking, Front Wheel Drive (FWD) vehicles may also have a build-up of belt dust (a black,
fluffy-looking material) in the general path of the accessory drive belt.
Figure 3
ACTION: This belt dust and the minor belt cracking does not require the accessory drive belt to be
replaced. Replacing the belt is only necessary after cracking has caused "rib chunk out", see
Figure 3. When two or more ribs next to each other lose a section 1-1/2 inch or longer, the belt
should be replaced.
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive Belt: > 90183 > Aug > 90
> Fuel Pump - Buzzing/Humming After Engine Shut Down
Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut
Down
^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY
CHARGE
^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF
Article No. 90-18-3 FORD:
1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD
1986-90 TAURUS
LINCOLN-MERCURY: 1983-87 LYNX
1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86
CAPRI, MARQUIS 1986-90 SABLE
LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1988-90 F SUPER DUTY
ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been
shut off. There may also be a no start condition or a discharged battery. These conditions are
caused by a sticking fuel pump relay.
ACTION: Install a new fuel pump relay. Refer to the following procedure for service details.
1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for
troubleshooting details.
2. Install a new fuel pump relay, if the old one is defective.
3. Check the vehicle for proper operation.
PART NUMBER PART NAME
F19Z-9345-A Fuel Pump Relay Assy.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901803A 1985-86 LTD/Marquis 0.6 Hr.
(includes pinpoint test)
901803A 1990 Town Car (includes 0.4 Hr.
pinpoint test)
901803A All Other Cars (includes 0.5 Hr.
pinpoint test)
901803A All Trucks (includes pinpoint 0.5 Hr.
test)
DEALER CODING
BASIC PART NO. CONDITION CODE
9345 09
OASIS CODES: 404000, 603300, 203000, 203100, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Page 1444
Drive Belt: Specifications
A belt in operation 10 minutes is considered a used belt. 1988-89 Automatic tensioner used.
Deflection method: Table lists deflection at midpoint of belt segment. Strand Tension method: Use
a strand tension gauge. Measurements are in pounds.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Page 1445
Drive Belt: Diagrams
Routing of Engine Accessory Drive Belts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Technical Service Bulletins > Page 1446
Drive Belt: Adjustments
A belt in operation 10 minutes is considered a used belt. 1988-89 Automatic tensioner used.
Deflection method: Table lists deflection at midpoint of belt segment. Strand Tension method: Use
a strand tension gauge. Measurements are in pounds.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt Tensioner: >
95135 > Jul > 95 > Drive Belt - Early Wear of Tensioner Pulley
Drive Belt Tensioner: Customer Interest Drive Belt - Early Wear of Tensioner Pulley
Article No. 95-13-5
07/03/95
ACCESSORY DRIVE BELT - EARLY WEAR OF FEAD TENSIONER PULLEY ON VEHICLES
WITH 4.9L ENGINE
LIGHT TRUCK: 1987-95 ECONOLINE, F-150-350 SERIES
ISSUE: The FEAD tensioner pulley may show signs of early wear and/or erosion on some vehicles.
ACTION: If a visual inspection determines an FEAD tensioner pulley has experienced extensive
wear or erosion, replace the tensioner pulley assembly with a new steel pulley tensioner assembly
(F5TZ-8678-EA). Refer to the appropriate Service Manual and Instruction Sheet # 6829 (included
in the kit) for service details.
PART NUMBER PART NAME
F5TZ-S678-EA Tensioner Pulley Assembly
OTHER APPLICABLE ARTICLES: 94-1-10, 94-10-19, 94-5-12
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
For 1992-95 Model Years, Basic Warranty Coverage For All Other Model Years
OPERATION DESCRIPTION TIME
951305A Replace Plastic Tensioner 0.3 Hr.
With Steel Pulley
DEALER CODING
CONDITION
BASIC PART NO. CODE
6B209 30
OASIS CODES: 402000, 497000, 499000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt Tensioner: >
941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise
Drive Belt Tensioner: Customer Interest Accessory Drive Belt - Chirp or Squeal Noise
Article No. 94-10-19
05/18/94
^ ACCESSORY DRIVE BELT - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR
OR LOSS - VEHICLES WITH 4.9L ENGINE
^ ENGINE - 4.9L - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR OR LOSS
^ NOISE - "CHIRP"/"SQUEAL" SOUND FROM FEAD BELT - VEHICLES WITH 4.9L ENGINE
LIGHT TRUCK: 1987-94 ECONOLINE, F-150-350 SERIES
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt Tensioner: >
941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1459
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt Tensioner: >
941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1460
This TSB article is being republished in its entirety to provide specific bolt number references in
Figures 3 and 4.
ISSUE: Front-end accessory drive belt (FEAD) belt noise may be heard and excessive belt edge
wear or loss may occur.
^ The "chirp" noise may occur at constant engine speeds and all engine loads. It is caused by
belt/pulley misalignment.
^ The belt "squeal" noise is intermittent and is heard during engine speed variations, usually at
engine start up. The noise is caused by belt slippage.
^ Belt edge wear and/or belt loss is caused by belt mistracking across the automatic belt tensioner.
If the automatic belt tensioner is out of parallel, the belt can be "driven" to either flange of the
pulley, causing belt edge wear and in some cases, the loss of the belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt Tensioner: >
941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1461
ACTION: Use the following service procedure to correct these conditions.
BELT CHIRP
1. Start the engine and while idling, wet the ribbed side of belt by spraying water on the belt where
it enters the A/C compressor pulley.
2. Listen for belt "chirp" as the belt dries at the entrance point of each grooved pulley to identify the
noisy pulley.
3. If the "chirp" is at the power steering pulley entry, check for belt mistracking on the tensioner
pulley, otherwise go to Step 13.
4. Check press of the power steering pulley. The pulley hub should be flush with the end of the
pump shaft.
5. If the pulley is flush, start engine and while idling, visually compare the size of the gaps between
the belt and front and rear flange of the tensioner pulley. If the larger gap is twice as wide as the
smaller gap, Figure 2, proceed with Step 6, otherwise, go to Step 13.
6. Mark the accessory drive belt with an arrow to denote rotation of belt. Remove belt.
7. Loosen all fasteners attaching A/C bracket to cylinder block and cylinder head. See Figures 3
and 4.
8. Tighten nuts # 3 (and, on 1987-93 model only, bolts # 4) on side of cylinder block to 62 N-m (46
lb.ft).
9. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
10. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
11. Install the accessory drive belt. Be sure belt is installed with arrow mark denoting original
rotation of belt.
12. Start engine and check for belt "chirp" noise.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt Tensioner: >
941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1462
13. Remove the accessory drive belt and replace it with a new service replacement belt. See
Figure 1 for correct belt usage.
BELT SQUEAL - F-SERIES
1. Remove the accessory drive belt automatic tensioner assembly. Refer to the appropriate Truck
service Manual, Section 03-05, for the removal procedure.
2. Replace it with automatic tensioner assembly (E7TZ-6B209-G). Refer to the appropriate Truck
service Manual, Section 03-05, for the installation procedure.
3. Replace the accessory drive belt.
BELT SQUEAL - ECONOLINE (A/C EQUIPPED MODELS ONLY)
1. Remove and discard the accessory drive belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt Tensioner: >
941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1463
2. Remove 90 mm diameter pulley from automatic tensioner assembly. Discard bolt, pulley and
bearing dust shield. Refer to Figure 5.
3. Install new 76 mm pulley, bearing, dust shield and bolt assembly (E7UZ-8678-A) to automatic
tensioner assembly. See Figure 5.
4. Install new accessory drive belt. (1987-93 models - E7UZ-8620-J, 1994 models - E8TZ-8620-S).
BELT EDGE WEAR AND LOSS
1. Remove and replace accessory drive belt with new service replacement belt. See Figure 1 for
correct parts usage.
2. Start engine and while idling, observe location of belt on automatic tensioner pulley. If belt tracks
near the pulley flange, Figure 2, replace with automatic tensioner (E7TZ-6B209-G).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt Tensioner: >
941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1464
3. Start engine and observe belt movement. If belt moves too far rearward on tensioner pulley,
proceed as follows:
a. With belt installed, loosen all A/C bracket fasteners. Belt tension will pull A/C bracket inboard
towards the engine. (Refer to Figures 3 and 4 for bolt and nut position identification.)
b. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
c. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
d. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
4. Start engine and observe belt movement. If belt moves too far forward on tensioner pulley,
proceed as follows:
a. Remove accessory drive belt and loosen all A/C bracket fasteners.
b. Pull A/C bracket toward driver's side of vehicle.
c. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
d. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
e. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-9-14 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic
Warranty Coverage For All Other Models, Emission Warranty For Belt Loss On Vehicles Equipped
With Thermactor Pumps
OPERATION DESCRIPTION TIME
941019A Correct Belt Chirp 0.6 Hr.
E-Series
941019B Correct Belt Chirp 0.5 Hr.
F-Series
941019C Additional Time To Adjust 0.3 Hr.
A/C Bracket If Gap Is Too Large - E&F; Series
941019D Correct Belt Squeal 0.5 Hr.
E-Series
941019E Correct Belt Squeal 0.3 Hr.
F-Series
941019F Correct Belt Edge Wear or
0.6 Hr.
Belt Loss - E-Series
941019G Correct Belt Edge Wear Or
0.4 Hr.
Belt Loss - F-Series
941019H Additional Time To Adjust 0.2 Hr.
A/C Bracket To Correct Belt Tracking - E&F; Series
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt Tensioner: >
941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1465
DEALER CODING
BASIC PART NO. CONDITION CODE
6B209 56
OASIS CODES: 497000, 702000, 702000, 790000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt Tensioner: >
94110 > Jan > 94 > Accessory Drive Belt - Noise/Excessive Wear
Drive Belt Tensioner: Customer Interest Accessory Drive Belt - Noise/Excessive Wear
Article No. 94-1-10
01/12/94
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - EXCESSIVE IDLER/TENSIONER PULLEY
WEAR
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - NEW BELT FOR ABRASIVE
ENVIRONMENT
^ NOISE - "THUMP" FROM FRONT END ACCESSORY DRIVE (FEAD) BELT - BELT EDGE
STARTS TO FRAY
LIGHT TRUCK: 1987-93 BRONCO, ECONOLINE, F-150-350 SERIES
ISSUE: Front End Accessory Drive (FEAD) belts have a cloth backing which can trap abrasive
particles, resulting in belt wear and erosion of the idler pulleys.
ACTION: Replace the current FEAD belt with a new neoprene-backed belt which does not retain
abrasive particles or promote pulley wear. Refer to the following procedure for service details.
1. Inspect the tensioner and idler pulleys for wear of the drive surfaces.
NOTE:
NOMINAL PULLEY DIAMETER IS 90 mm (3.453") OR 76 mm (2.916"); PULLEYS WORN TO 88
mm (3.377") OR 74 mm (2.839") SHOULD BE REPLACED.
2. Select the appropriate neoprene-backed belt and install per standard belt routing (refer to
Service Manual Section 03-05).
3. Insure that all belt vee's are in all pulley grooves.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt Tensioner: >
94110 > Jan > 94 > Accessory Drive Belt - Noise/Excessive Wear > Page 1470
Parts Block
OTHER APPLICABLE ARTICLES: 89-10-11 WARRANTY STATUS: Eligible Under The Provisions
Of The Bumper To Bumper Warranty Coverage For 1992-93 Models And Eligible Under Basic
Warranty Coverage For Other Model Years. Emission Warranty Coverage Applies If Vehicle Is
Equipped With Thermactor System
OPERATION DESCRIPTION TIME
940110A Replace Belt - 0.3 Hr.
F-Series/Bronco
940110B Replace Belt And Tensioner 0.4 Hr.
- F-Series/Bronco
940110C Replace Belt - Econoline 0.4 Hr.
940110D Replace Belt And Tensioner 0.5 Hr.
- Econoline
DEALER CODING
BASIC PART NO. CONDITION CODE
8620 30
OASIS CODES: 497000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt
Tensioner: > 95135 > Jul > 95 > Drive Belt - Early Wear of Tensioner Pulley
Drive Belt Tensioner: All Technical Service Bulletins Drive Belt - Early Wear of Tensioner Pulley
Article No. 95-13-5
07/03/95
ACCESSORY DRIVE BELT - EARLY WEAR OF FEAD TENSIONER PULLEY ON VEHICLES
WITH 4.9L ENGINE
LIGHT TRUCK: 1987-95 ECONOLINE, F-150-350 SERIES
ISSUE: The FEAD tensioner pulley may show signs of early wear and/or erosion on some vehicles.
ACTION: If a visual inspection determines an FEAD tensioner pulley has experienced extensive
wear or erosion, replace the tensioner pulley assembly with a new steel pulley tensioner assembly
(F5TZ-8678-EA). Refer to the appropriate Service Manual and Instruction Sheet # 6829 (included
in the kit) for service details.
PART NUMBER PART NAME
F5TZ-S678-EA Tensioner Pulley Assembly
OTHER APPLICABLE ARTICLES: 94-1-10, 94-10-19, 94-5-12
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
For 1992-95 Model Years, Basic Warranty Coverage For All Other Model Years
OPERATION DESCRIPTION TIME
951305A Replace Plastic Tensioner 0.3 Hr.
With Steel Pulley
DEALER CODING
CONDITION
BASIC PART NO. CODE
6B209 30
OASIS CODES: 402000, 497000, 499000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt
Tensioner: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise
Drive Belt Tensioner: All Technical Service Bulletins Accessory Drive Belt - Chirp or Squeal Noise
Article No. 94-10-19
05/18/94
^ ACCESSORY DRIVE BELT - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR
OR LOSS - VEHICLES WITH 4.9L ENGINE
^ ENGINE - 4.9L - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR OR LOSS
^ NOISE - "CHIRP"/"SQUEAL" SOUND FROM FEAD BELT - VEHICLES WITH 4.9L ENGINE
LIGHT TRUCK: 1987-94 ECONOLINE, F-150-350 SERIES
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt
Tensioner: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1480
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt
Tensioner: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1481
This TSB article is being republished in its entirety to provide specific bolt number references in
Figures 3 and 4.
ISSUE: Front-end accessory drive belt (FEAD) belt noise may be heard and excessive belt edge
wear or loss may occur.
^ The "chirp" noise may occur at constant engine speeds and all engine loads. It is caused by
belt/pulley misalignment.
^ The belt "squeal" noise is intermittent and is heard during engine speed variations, usually at
engine start up. The noise is caused by belt slippage.
^ Belt edge wear and/or belt loss is caused by belt mistracking across the automatic belt tensioner.
If the automatic belt tensioner is out of parallel, the belt can be "driven" to either flange of the
pulley, causing belt edge wear and in some cases, the loss of the belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt
Tensioner: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1482
ACTION: Use the following service procedure to correct these conditions.
BELT CHIRP
1. Start the engine and while idling, wet the ribbed side of belt by spraying water on the belt where
it enters the A/C compressor pulley.
2. Listen for belt "chirp" as the belt dries at the entrance point of each grooved pulley to identify the
noisy pulley.
3. If the "chirp" is at the power steering pulley entry, check for belt mistracking on the tensioner
pulley, otherwise go to Step 13.
4. Check press of the power steering pulley. The pulley hub should be flush with the end of the
pump shaft.
5. If the pulley is flush, start engine and while idling, visually compare the size of the gaps between
the belt and front and rear flange of the tensioner pulley. If the larger gap is twice as wide as the
smaller gap, Figure 2, proceed with Step 6, otherwise, go to Step 13.
6. Mark the accessory drive belt with an arrow to denote rotation of belt. Remove belt.
7. Loosen all fasteners attaching A/C bracket to cylinder block and cylinder head. See Figures 3
and 4.
8. Tighten nuts # 3 (and, on 1987-93 model only, bolts # 4) on side of cylinder block to 62 N-m (46
lb.ft).
9. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
10. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
11. Install the accessory drive belt. Be sure belt is installed with arrow mark denoting original
rotation of belt.
12. Start engine and check for belt "chirp" noise.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt
Tensioner: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1483
13. Remove the accessory drive belt and replace it with a new service replacement belt. See
Figure 1 for correct belt usage.
BELT SQUEAL - F-SERIES
1. Remove the accessory drive belt automatic tensioner assembly. Refer to the appropriate Truck
service Manual, Section 03-05, for the removal procedure.
2. Replace it with automatic tensioner assembly (E7TZ-6B209-G). Refer to the appropriate Truck
service Manual, Section 03-05, for the installation procedure.
3. Replace the accessory drive belt.
BELT SQUEAL - ECONOLINE (A/C EQUIPPED MODELS ONLY)
1. Remove and discard the accessory drive belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt
Tensioner: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1484
2. Remove 90 mm diameter pulley from automatic tensioner assembly. Discard bolt, pulley and
bearing dust shield. Refer to Figure 5.
3. Install new 76 mm pulley, bearing, dust shield and bolt assembly (E7UZ-8678-A) to automatic
tensioner assembly. See Figure 5.
4. Install new accessory drive belt. (1987-93 models - E7UZ-8620-J, 1994 models - E8TZ-8620-S).
BELT EDGE WEAR AND LOSS
1. Remove and replace accessory drive belt with new service replacement belt. See Figure 1 for
correct parts usage.
2. Start engine and while idling, observe location of belt on automatic tensioner pulley. If belt tracks
near the pulley flange, Figure 2, replace with automatic tensioner (E7TZ-6B209-G).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt
Tensioner: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1485
3. Start engine and observe belt movement. If belt moves too far rearward on tensioner pulley,
proceed as follows:
a. With belt installed, loosen all A/C bracket fasteners. Belt tension will pull A/C bracket inboard
towards the engine. (Refer to Figures 3 and 4 for bolt and nut position identification.)
b. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
c. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
d. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
4. Start engine and observe belt movement. If belt moves too far forward on tensioner pulley,
proceed as follows:
a. Remove accessory drive belt and loosen all A/C bracket fasteners.
b. Pull A/C bracket toward driver's side of vehicle.
c. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
d. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
e. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-9-14 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic
Warranty Coverage For All Other Models, Emission Warranty For Belt Loss On Vehicles Equipped
With Thermactor Pumps
OPERATION DESCRIPTION TIME
941019A Correct Belt Chirp 0.6 Hr.
E-Series
941019B Correct Belt Chirp 0.5 Hr.
F-Series
941019C Additional Time To Adjust 0.3 Hr.
A/C Bracket If Gap Is Too Large - E&F; Series
941019D Correct Belt Squeal 0.5 Hr.
E-Series
941019E Correct Belt Squeal 0.3 Hr.
F-Series
941019F Correct Belt Edge Wear or
0.6 Hr.
Belt Loss - E-Series
941019G Correct Belt Edge Wear Or
0.4 Hr.
Belt Loss - F-Series
941019H Additional Time To Adjust 0.2 Hr.
A/C Bracket To Correct Belt Tracking - E&F; Series
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt
Tensioner: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1486
DEALER CODING
BASIC PART NO. CONDITION CODE
6B209 56
OASIS CODES: 497000, 702000, 702000, 790000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt
Tensioner: > 94110 > Jan > 94 > Accessory Drive Belt - Noise/Excessive Wear
Drive Belt Tensioner: All Technical Service Bulletins Accessory Drive Belt - Noise/Excessive Wear
Article No. 94-1-10
01/12/94
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - EXCESSIVE IDLER/TENSIONER PULLEY
WEAR
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - NEW BELT FOR ABRASIVE
ENVIRONMENT
^ NOISE - "THUMP" FROM FRONT END ACCESSORY DRIVE (FEAD) BELT - BELT EDGE
STARTS TO FRAY
LIGHT TRUCK: 1987-93 BRONCO, ECONOLINE, F-150-350 SERIES
ISSUE: Front End Accessory Drive (FEAD) belts have a cloth backing which can trap abrasive
particles, resulting in belt wear and erosion of the idler pulleys.
ACTION: Replace the current FEAD belt with a new neoprene-backed belt which does not retain
abrasive particles or promote pulley wear. Refer to the following procedure for service details.
1. Inspect the tensioner and idler pulleys for wear of the drive surfaces.
NOTE:
NOMINAL PULLEY DIAMETER IS 90 mm (3.453") OR 76 mm (2.916"); PULLEYS WORN TO 88
mm (3.377") OR 74 mm (2.839") SHOULD BE REPLACED.
2. Select the appropriate neoprene-backed belt and install per standard belt routing (refer to
Service Manual Section 03-05).
3. Insure that all belt vee's are in all pulley grooves.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt
Tensioner: > 94110 > Jan > 94 > Accessory Drive Belt - Noise/Excessive Wear > Page 1491
Parts Block
OTHER APPLICABLE ARTICLES: 89-10-11 WARRANTY STATUS: Eligible Under The Provisions
Of The Bumper To Bumper Warranty Coverage For 1992-93 Models And Eligible Under Basic
Warranty Coverage For Other Model Years. Emission Warranty Coverage Applies If Vehicle Is
Equipped With Thermactor System
OPERATION DESCRIPTION TIME
940110A Replace Belt - 0.3 Hr.
F-Series/Bronco
940110B Replace Belt And Tensioner 0.4 Hr.
- F-Series/Bronco
940110C Replace Belt - Econoline 0.4 Hr.
940110D Replace Belt And Tensioner 0.5 Hr.
- Econoline
DEALER CODING
BASIC PART NO. CONDITION CODE
8620 30
OASIS CODES: 497000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine
Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise
Engine Accessory Bracket: Customer Interest Accessory Drive Belt - Chirp or Squeal Noise
Article No. 94-10-19
05/18/94
^ ACCESSORY DRIVE BELT - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR
OR LOSS - VEHICLES WITH 4.9L ENGINE
^ ENGINE - 4.9L - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR OR LOSS
^ NOISE - "CHIRP"/"SQUEAL" SOUND FROM FEAD BELT - VEHICLES WITH 4.9L ENGINE
LIGHT TRUCK: 1987-94 ECONOLINE, F-150-350 SERIES
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine
Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1500
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine
Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1501
This TSB article is being republished in its entirety to provide specific bolt number references in
Figures 3 and 4.
ISSUE: Front-end accessory drive belt (FEAD) belt noise may be heard and excessive belt edge
wear or loss may occur.
^ The "chirp" noise may occur at constant engine speeds and all engine loads. It is caused by
belt/pulley misalignment.
^ The belt "squeal" noise is intermittent and is heard during engine speed variations, usually at
engine start up. The noise is caused by belt slippage.
^ Belt edge wear and/or belt loss is caused by belt mistracking across the automatic belt tensioner.
If the automatic belt tensioner is out of parallel, the belt can be "driven" to either flange of the
pulley, causing belt edge wear and in some cases, the loss of the belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine
Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1502
ACTION: Use the following service procedure to correct these conditions.
BELT CHIRP
1. Start the engine and while idling, wet the ribbed side of belt by spraying water on the belt where
it enters the A/C compressor pulley.
2. Listen for belt "chirp" as the belt dries at the entrance point of each grooved pulley to identify the
noisy pulley.
3. If the "chirp" is at the power steering pulley entry, check for belt mistracking on the tensioner
pulley, otherwise go to Step 13.
4. Check press of the power steering pulley. The pulley hub should be flush with the end of the
pump shaft.
5. If the pulley is flush, start engine and while idling, visually compare the size of the gaps between
the belt and front and rear flange of the tensioner pulley. If the larger gap is twice as wide as the
smaller gap, Figure 2, proceed with Step 6, otherwise, go to Step 13.
6. Mark the accessory drive belt with an arrow to denote rotation of belt. Remove belt.
7. Loosen all fasteners attaching A/C bracket to cylinder block and cylinder head. See Figures 3
and 4.
8. Tighten nuts # 3 (and, on 1987-93 model only, bolts # 4) on side of cylinder block to 62 N-m (46
lb.ft).
9. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
10. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
11. Install the accessory drive belt. Be sure belt is installed with arrow mark denoting original
rotation of belt.
12. Start engine and check for belt "chirp" noise.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine
Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1503
13. Remove the accessory drive belt and replace it with a new service replacement belt. See
Figure 1 for correct belt usage.
BELT SQUEAL - F-SERIES
1. Remove the accessory drive belt automatic tensioner assembly. Refer to the appropriate Truck
service Manual, Section 03-05, for the removal procedure.
2. Replace it with automatic tensioner assembly (E7TZ-6B209-G). Refer to the appropriate Truck
service Manual, Section 03-05, for the installation procedure.
3. Replace the accessory drive belt.
BELT SQUEAL - ECONOLINE (A/C EQUIPPED MODELS ONLY)
1. Remove and discard the accessory drive belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine
Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1504
2. Remove 90 mm diameter pulley from automatic tensioner assembly. Discard bolt, pulley and
bearing dust shield. Refer to Figure 5.
3. Install new 76 mm pulley, bearing, dust shield and bolt assembly (E7UZ-8678-A) to automatic
tensioner assembly. See Figure 5.
4. Install new accessory drive belt. (1987-93 models - E7UZ-8620-J, 1994 models - E8TZ-8620-S).
BELT EDGE WEAR AND LOSS
1. Remove and replace accessory drive belt with new service replacement belt. See Figure 1 for
correct parts usage.
2. Start engine and while idling, observe location of belt on automatic tensioner pulley. If belt tracks
near the pulley flange, Figure 2, replace with automatic tensioner (E7TZ-6B209-G).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine
Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1505
3. Start engine and observe belt movement. If belt moves too far rearward on tensioner pulley,
proceed as follows:
a. With belt installed, loosen all A/C bracket fasteners. Belt tension will pull A/C bracket inboard
towards the engine. (Refer to Figures 3 and 4 for bolt and nut position identification.)
b. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
c. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
d. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
4. Start engine and observe belt movement. If belt moves too far forward on tensioner pulley,
proceed as follows:
a. Remove accessory drive belt and loosen all A/C bracket fasteners.
b. Pull A/C bracket toward driver's side of vehicle.
c. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
d. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
e. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-9-14 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic
Warranty Coverage For All Other Models, Emission Warranty For Belt Loss On Vehicles Equipped
With Thermactor Pumps
OPERATION DESCRIPTION TIME
941019A Correct Belt Chirp 0.6 Hr.
E-Series
941019B Correct Belt Chirp 0.5 Hr.
F-Series
941019C Additional Time To Adjust 0.3 Hr.
A/C Bracket If Gap Is Too Large - E&F; Series
941019D Correct Belt Squeal 0.5 Hr.
E-Series
941019E Correct Belt Squeal 0.3 Hr.
F-Series
941019F Correct Belt Edge Wear or
0.6 Hr.
Belt Loss - E-Series
941019G Correct Belt Edge Wear Or
0.4 Hr.
Belt Loss - F-Series
941019H Additional Time To Adjust 0.2 Hr.
A/C Bracket To Correct Belt Tracking - E&F; Series
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > Customer Interest for Engine
Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1506
DEALER CODING
BASIC PART NO. CONDITION CODE
6B209 56
OASIS CODES: 497000, 702000, 702000, 790000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Engine Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise
Engine Accessory Bracket: All Technical Service Bulletins Accessory Drive Belt - Chirp or Squeal
Noise
Article No. 94-10-19
05/18/94
^ ACCESSORY DRIVE BELT - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR
OR LOSS - VEHICLES WITH 4.9L ENGINE
^ ENGINE - 4.9L - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR OR LOSS
^ NOISE - "CHIRP"/"SQUEAL" SOUND FROM FEAD BELT - VEHICLES WITH 4.9L ENGINE
LIGHT TRUCK: 1987-94 ECONOLINE, F-150-350 SERIES
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Engine Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1512
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Engine Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1513
This TSB article is being republished in its entirety to provide specific bolt number references in
Figures 3 and 4.
ISSUE: Front-end accessory drive belt (FEAD) belt noise may be heard and excessive belt edge
wear or loss may occur.
^ The "chirp" noise may occur at constant engine speeds and all engine loads. It is caused by
belt/pulley misalignment.
^ The belt "squeal" noise is intermittent and is heard during engine speed variations, usually at
engine start up. The noise is caused by belt slippage.
^ Belt edge wear and/or belt loss is caused by belt mistracking across the automatic belt tensioner.
If the automatic belt tensioner is out of parallel, the belt can be "driven" to either flange of the
pulley, causing belt edge wear and in some cases, the loss of the belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Engine Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1514
ACTION: Use the following service procedure to correct these conditions.
BELT CHIRP
1. Start the engine and while idling, wet the ribbed side of belt by spraying water on the belt where
it enters the A/C compressor pulley.
2. Listen for belt "chirp" as the belt dries at the entrance point of each grooved pulley to identify the
noisy pulley.
3. If the "chirp" is at the power steering pulley entry, check for belt mistracking on the tensioner
pulley, otherwise go to Step 13.
4. Check press of the power steering pulley. The pulley hub should be flush with the end of the
pump shaft.
5. If the pulley is flush, start engine and while idling, visually compare the size of the gaps between
the belt and front and rear flange of the tensioner pulley. If the larger gap is twice as wide as the
smaller gap, Figure 2, proceed with Step 6, otherwise, go to Step 13.
6. Mark the accessory drive belt with an arrow to denote rotation of belt. Remove belt.
7. Loosen all fasteners attaching A/C bracket to cylinder block and cylinder head. See Figures 3
and 4.
8. Tighten nuts # 3 (and, on 1987-93 model only, bolts # 4) on side of cylinder block to 62 N-m (46
lb.ft).
9. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
10. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
11. Install the accessory drive belt. Be sure belt is installed with arrow mark denoting original
rotation of belt.
12. Start engine and check for belt "chirp" noise.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Engine Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1515
13. Remove the accessory drive belt and replace it with a new service replacement belt. See
Figure 1 for correct belt usage.
BELT SQUEAL - F-SERIES
1. Remove the accessory drive belt automatic tensioner assembly. Refer to the appropriate Truck
service Manual, Section 03-05, for the removal procedure.
2. Replace it with automatic tensioner assembly (E7TZ-6B209-G). Refer to the appropriate Truck
service Manual, Section 03-05, for the installation procedure.
3. Replace the accessory drive belt.
BELT SQUEAL - ECONOLINE (A/C EQUIPPED MODELS ONLY)
1. Remove and discard the accessory drive belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Engine Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1516
2. Remove 90 mm diameter pulley from automatic tensioner assembly. Discard bolt, pulley and
bearing dust shield. Refer to Figure 5.
3. Install new 76 mm pulley, bearing, dust shield and bolt assembly (E7UZ-8678-A) to automatic
tensioner assembly. See Figure 5.
4. Install new accessory drive belt. (1987-93 models - E7UZ-8620-J, 1994 models - E8TZ-8620-S).
BELT EDGE WEAR AND LOSS
1. Remove and replace accessory drive belt with new service replacement belt. See Figure 1 for
correct parts usage.
2. Start engine and while idling, observe location of belt on automatic tensioner pulley. If belt tracks
near the pulley flange, Figure 2, replace with automatic tensioner (E7TZ-6B209-G).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Engine Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1517
3. Start engine and observe belt movement. If belt moves too far rearward on tensioner pulley,
proceed as follows:
a. With belt installed, loosen all A/C bracket fasteners. Belt tension will pull A/C bracket inboard
towards the engine. (Refer to Figures 3 and 4 for bolt and nut position identification.)
b. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
c. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
d. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
4. Start engine and observe belt movement. If belt moves too far forward on tensioner pulley,
proceed as follows:
a. Remove accessory drive belt and loosen all A/C bracket fasteners.
b. Pull A/C bracket toward driver's side of vehicle.
c. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
d. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
e. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-9-14 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic
Warranty Coverage For All Other Models, Emission Warranty For Belt Loss On Vehicles Equipped
With Thermactor Pumps
OPERATION DESCRIPTION TIME
941019A Correct Belt Chirp 0.6 Hr.
E-Series
941019B Correct Belt Chirp 0.5 Hr.
F-Series
941019C Additional Time To Adjust 0.3 Hr.
A/C Bracket If Gap Is Too Large - E&F; Series
941019D Correct Belt Squeal 0.5 Hr.
E-Series
941019E Correct Belt Squeal 0.3 Hr.
F-Series
941019F Correct Belt Edge Wear or
0.6 Hr.
Belt Loss - E-Series
941019G Correct Belt Edge Wear Or
0.4 Hr.
Belt Loss - F-Series
941019H Additional Time To Adjust 0.2 Hr.
A/C Bracket To Correct Belt Tracking - E&F; Series
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Accessory Bracket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Engine Accessory Bracket: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1518
DEALER CODING
BASIC PART NO. CONDITION CODE
6B209 56
OASIS CODES: 497000, 702000, 702000, 790000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair
Engine Mount: Service and Repair
Fig. 10 Engine mounts. V8-460 engine
V8-460
1. Support engine using a block of wood placed under oil pan and a suitable jack.
2. Remove locknuts from support bracket-to-crossmember and side rail attaching bolts.
3. Remove support bracket-to-insulator through bolts, Fig. 10.
4. Raise engine until insulator clears bracket, then remove insulator and bracket as an assembly.
5. Remove insulator-to-bracket attaching nuts and the insulator.
6. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise
Idler Pulley: Customer Interest Accessory Drive Belt - Chirp or Squeal Noise
Article No. 94-10-19
05/18/94
^ ACCESSORY DRIVE BELT - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR
OR LOSS - VEHICLES WITH 4.9L ENGINE
^ ENGINE - 4.9L - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR OR LOSS
^ NOISE - "CHIRP"/"SQUEAL" SOUND FROM FEAD BELT - VEHICLES WITH 4.9L ENGINE
LIGHT TRUCK: 1987-94 ECONOLINE, F-150-350 SERIES
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise > Page 1530
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise > Page 1531
This TSB article is being republished in its entirety to provide specific bolt number references in
Figures 3 and 4.
ISSUE: Front-end accessory drive belt (FEAD) belt noise may be heard and excessive belt edge
wear or loss may occur.
^ The "chirp" noise may occur at constant engine speeds and all engine loads. It is caused by
belt/pulley misalignment.
^ The belt "squeal" noise is intermittent and is heard during engine speed variations, usually at
engine start up. The noise is caused by belt slippage.
^ Belt edge wear and/or belt loss is caused by belt mistracking across the automatic belt tensioner.
If the automatic belt tensioner is out of parallel, the belt can be "driven" to either flange of the
pulley, causing belt edge wear and in some cases, the loss of the belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise > Page 1532
ACTION: Use the following service procedure to correct these conditions.
BELT CHIRP
1. Start the engine and while idling, wet the ribbed side of belt by spraying water on the belt where
it enters the A/C compressor pulley.
2. Listen for belt "chirp" as the belt dries at the entrance point of each grooved pulley to identify the
noisy pulley.
3. If the "chirp" is at the power steering pulley entry, check for belt mistracking on the tensioner
pulley, otherwise go to Step 13.
4. Check press of the power steering pulley. The pulley hub should be flush with the end of the
pump shaft.
5. If the pulley is flush, start engine and while idling, visually compare the size of the gaps between
the belt and front and rear flange of the tensioner pulley. If the larger gap is twice as wide as the
smaller gap, Figure 2, proceed with Step 6, otherwise, go to Step 13.
6. Mark the accessory drive belt with an arrow to denote rotation of belt. Remove belt.
7. Loosen all fasteners attaching A/C bracket to cylinder block and cylinder head. See Figures 3
and 4.
8. Tighten nuts # 3 (and, on 1987-93 model only, bolts # 4) on side of cylinder block to 62 N-m (46
lb.ft).
9. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
10. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
11. Install the accessory drive belt. Be sure belt is installed with arrow mark denoting original
rotation of belt.
12. Start engine and check for belt "chirp" noise.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise > Page 1533
13. Remove the accessory drive belt and replace it with a new service replacement belt. See
Figure 1 for correct belt usage.
BELT SQUEAL - F-SERIES
1. Remove the accessory drive belt automatic tensioner assembly. Refer to the appropriate Truck
service Manual, Section 03-05, for the removal procedure.
2. Replace it with automatic tensioner assembly (E7TZ-6B209-G). Refer to the appropriate Truck
service Manual, Section 03-05, for the installation procedure.
3. Replace the accessory drive belt.
BELT SQUEAL - ECONOLINE (A/C EQUIPPED MODELS ONLY)
1. Remove and discard the accessory drive belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise > Page 1534
2. Remove 90 mm diameter pulley from automatic tensioner assembly. Discard bolt, pulley and
bearing dust shield. Refer to Figure 5.
3. Install new 76 mm pulley, bearing, dust shield and bolt assembly (E7UZ-8678-A) to automatic
tensioner assembly. See Figure 5.
4. Install new accessory drive belt. (1987-93 models - E7UZ-8620-J, 1994 models - E8TZ-8620-S).
BELT EDGE WEAR AND LOSS
1. Remove and replace accessory drive belt with new service replacement belt. See Figure 1 for
correct parts usage.
2. Start engine and while idling, observe location of belt on automatic tensioner pulley. If belt tracks
near the pulley flange, Figure 2, replace with automatic tensioner (E7TZ-6B209-G).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise > Page 1535
3. Start engine and observe belt movement. If belt moves too far rearward on tensioner pulley,
proceed as follows:
a. With belt installed, loosen all A/C bracket fasteners. Belt tension will pull A/C bracket inboard
towards the engine. (Refer to Figures 3 and 4 for bolt and nut position identification.)
b. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
c. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
d. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
4. Start engine and observe belt movement. If belt moves too far forward on tensioner pulley,
proceed as follows:
a. Remove accessory drive belt and loosen all A/C bracket fasteners.
b. Pull A/C bracket toward driver's side of vehicle.
c. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
d. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
e. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-9-14 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic
Warranty Coverage For All Other Models, Emission Warranty For Belt Loss On Vehicles Equipped
With Thermactor Pumps
OPERATION DESCRIPTION TIME
941019A Correct Belt Chirp 0.6 Hr.
E-Series
941019B Correct Belt Chirp 0.5 Hr.
F-Series
941019C Additional Time To Adjust 0.3 Hr.
A/C Bracket If Gap Is Too Large - E&F; Series
941019D Correct Belt Squeal 0.5 Hr.
E-Series
941019E Correct Belt Squeal 0.3 Hr.
F-Series
941019F Correct Belt Edge Wear or
0.6 Hr.
Belt Loss - E-Series
941019G Correct Belt Edge Wear Or
0.4 Hr.
Belt Loss - F-Series
941019H Additional Time To Adjust 0.2 Hr.
A/C Bracket To Correct Belt Tracking - E&F; Series
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 941019 > May > 94 >
Accessory Drive Belt - Chirp or Squeal Noise > Page 1536
DEALER CODING
BASIC PART NO. CONDITION CODE
6B209 56
OASIS CODES: 497000, 702000, 702000, 790000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 94110 > Jan > 94 >
Accessory Drive Belt - Noise/Excessive Wear
Idler Pulley: Customer Interest Accessory Drive Belt - Noise/Excessive Wear
Article No. 94-1-10
01/12/94
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - EXCESSIVE IDLER/TENSIONER PULLEY
WEAR
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - NEW BELT FOR ABRASIVE
ENVIRONMENT
^ NOISE - "THUMP" FROM FRONT END ACCESSORY DRIVE (FEAD) BELT - BELT EDGE
STARTS TO FRAY
LIGHT TRUCK: 1987-93 BRONCO, ECONOLINE, F-150-350 SERIES
ISSUE: Front End Accessory Drive (FEAD) belts have a cloth backing which can trap abrasive
particles, resulting in belt wear and erosion of the idler pulleys.
ACTION: Replace the current FEAD belt with a new neoprene-backed belt which does not retain
abrasive particles or promote pulley wear. Refer to the following procedure for service details.
1. Inspect the tensioner and idler pulleys for wear of the drive surfaces.
NOTE:
NOMINAL PULLEY DIAMETER IS 90 mm (3.453") OR 76 mm (2.916"); PULLEYS WORN TO 88
mm (3.377") OR 74 mm (2.839") SHOULD BE REPLACED.
2. Select the appropriate neoprene-backed belt and install per standard belt routing (refer to
Service Manual Section 03-05).
3. Insure that all belt vee's are in all pulley grooves.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 94110 > Jan > 94 >
Accessory Drive Belt - Noise/Excessive Wear > Page 1541
Parts Block
OTHER APPLICABLE ARTICLES: 89-10-11 WARRANTY STATUS: Eligible Under The Provisions
Of The Bumper To Bumper Warranty Coverage For 1992-93 Models And Eligible Under Basic
Warranty Coverage For Other Model Years. Emission Warranty Coverage Applies If Vehicle Is
Equipped With Thermactor System
OPERATION DESCRIPTION TIME
940110A Replace Belt - 0.3 Hr.
F-Series/Bronco
940110B Replace Belt And Tensioner 0.4 Hr.
- F-Series/Bronco
940110C Replace Belt - Econoline 0.4 Hr.
940110D Replace Belt And Tensioner 0.5 Hr.
- Econoline
DEALER CODING
BASIC PART NO. CONDITION CODE
8620 30
OASIS CODES: 497000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 941019 >
May > 94 > Accessory Drive Belt - Chirp or Squeal Noise
Idler Pulley: All Technical Service Bulletins Accessory Drive Belt - Chirp or Squeal Noise
Article No. 94-10-19
05/18/94
^ ACCESSORY DRIVE BELT - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR
OR LOSS - VEHICLES WITH 4.9L ENGINE
^ ENGINE - 4.9L - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR OR LOSS
^ NOISE - "CHIRP"/"SQUEAL" SOUND FROM FEAD BELT - VEHICLES WITH 4.9L ENGINE
LIGHT TRUCK: 1987-94 ECONOLINE, F-150-350 SERIES
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 941019 >
May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1547
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 941019 >
May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1548
This TSB article is being republished in its entirety to provide specific bolt number references in
Figures 3 and 4.
ISSUE: Front-end accessory drive belt (FEAD) belt noise may be heard and excessive belt edge
wear or loss may occur.
^ The "chirp" noise may occur at constant engine speeds and all engine loads. It is caused by
belt/pulley misalignment.
^ The belt "squeal" noise is intermittent and is heard during engine speed variations, usually at
engine start up. The noise is caused by belt slippage.
^ Belt edge wear and/or belt loss is caused by belt mistracking across the automatic belt tensioner.
If the automatic belt tensioner is out of parallel, the belt can be "driven" to either flange of the
pulley, causing belt edge wear and in some cases, the loss of the belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 941019 >
May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1549
ACTION: Use the following service procedure to correct these conditions.
BELT CHIRP
1. Start the engine and while idling, wet the ribbed side of belt by spraying water on the belt where
it enters the A/C compressor pulley.
2. Listen for belt "chirp" as the belt dries at the entrance point of each grooved pulley to identify the
noisy pulley.
3. If the "chirp" is at the power steering pulley entry, check for belt mistracking on the tensioner
pulley, otherwise go to Step 13.
4. Check press of the power steering pulley. The pulley hub should be flush with the end of the
pump shaft.
5. If the pulley is flush, start engine and while idling, visually compare the size of the gaps between
the belt and front and rear flange of the tensioner pulley. If the larger gap is twice as wide as the
smaller gap, Figure 2, proceed with Step 6, otherwise, go to Step 13.
6. Mark the accessory drive belt with an arrow to denote rotation of belt. Remove belt.
7. Loosen all fasteners attaching A/C bracket to cylinder block and cylinder head. See Figures 3
and 4.
8. Tighten nuts # 3 (and, on 1987-93 model only, bolts # 4) on side of cylinder block to 62 N-m (46
lb.ft).
9. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
10. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
11. Install the accessory drive belt. Be sure belt is installed with arrow mark denoting original
rotation of belt.
12. Start engine and check for belt "chirp" noise.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 941019 >
May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1550
13. Remove the accessory drive belt and replace it with a new service replacement belt. See
Figure 1 for correct belt usage.
BELT SQUEAL - F-SERIES
1. Remove the accessory drive belt automatic tensioner assembly. Refer to the appropriate Truck
service Manual, Section 03-05, for the removal procedure.
2. Replace it with automatic tensioner assembly (E7TZ-6B209-G). Refer to the appropriate Truck
service Manual, Section 03-05, for the installation procedure.
3. Replace the accessory drive belt.
BELT SQUEAL - ECONOLINE (A/C EQUIPPED MODELS ONLY)
1. Remove and discard the accessory drive belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 941019 >
May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1551
2. Remove 90 mm diameter pulley from automatic tensioner assembly. Discard bolt, pulley and
bearing dust shield. Refer to Figure 5.
3. Install new 76 mm pulley, bearing, dust shield and bolt assembly (E7UZ-8678-A) to automatic
tensioner assembly. See Figure 5.
4. Install new accessory drive belt. (1987-93 models - E7UZ-8620-J, 1994 models - E8TZ-8620-S).
BELT EDGE WEAR AND LOSS
1. Remove and replace accessory drive belt with new service replacement belt. See Figure 1 for
correct parts usage.
2. Start engine and while idling, observe location of belt on automatic tensioner pulley. If belt tracks
near the pulley flange, Figure 2, replace with automatic tensioner (E7TZ-6B209-G).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 941019 >
May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1552
3. Start engine and observe belt movement. If belt moves too far rearward on tensioner pulley,
proceed as follows:
a. With belt installed, loosen all A/C bracket fasteners. Belt tension will pull A/C bracket inboard
towards the engine. (Refer to Figures 3 and 4 for bolt and nut position identification.)
b. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
c. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
d. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
4. Start engine and observe belt movement. If belt moves too far forward on tensioner pulley,
proceed as follows:
a. Remove accessory drive belt and loosen all A/C bracket fasteners.
b. Pull A/C bracket toward driver's side of vehicle.
c. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
d. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
e. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-9-14 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic
Warranty Coverage For All Other Models, Emission Warranty For Belt Loss On Vehicles Equipped
With Thermactor Pumps
OPERATION DESCRIPTION TIME
941019A Correct Belt Chirp 0.6 Hr.
E-Series
941019B Correct Belt Chirp 0.5 Hr.
F-Series
941019C Additional Time To Adjust 0.3 Hr.
A/C Bracket If Gap Is Too Large - E&F; Series
941019D Correct Belt Squeal 0.5 Hr.
E-Series
941019E Correct Belt Squeal 0.3 Hr.
F-Series
941019F Correct Belt Edge Wear or
0.6 Hr.
Belt Loss - E-Series
941019G Correct Belt Edge Wear Or
0.4 Hr.
Belt Loss - F-Series
941019H Additional Time To Adjust 0.2 Hr.
A/C Bracket To Correct Belt Tracking - E&F; Series
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 941019 >
May > 94 > Accessory Drive Belt - Chirp or Squeal Noise > Page 1553
DEALER CODING
BASIC PART NO. CONDITION CODE
6B209 56
OASIS CODES: 497000, 702000, 702000, 790000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 94110 >
Jan > 94 > Accessory Drive Belt - Noise/Excessive Wear
Idler Pulley: All Technical Service Bulletins Accessory Drive Belt - Noise/Excessive Wear
Article No. 94-1-10
01/12/94
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - EXCESSIVE IDLER/TENSIONER PULLEY
WEAR
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - NEW BELT FOR ABRASIVE
ENVIRONMENT
^ NOISE - "THUMP" FROM FRONT END ACCESSORY DRIVE (FEAD) BELT - BELT EDGE
STARTS TO FRAY
LIGHT TRUCK: 1987-93 BRONCO, ECONOLINE, F-150-350 SERIES
ISSUE: Front End Accessory Drive (FEAD) belts have a cloth backing which can trap abrasive
particles, resulting in belt wear and erosion of the idler pulleys.
ACTION: Replace the current FEAD belt with a new neoprene-backed belt which does not retain
abrasive particles or promote pulley wear. Refer to the following procedure for service details.
1. Inspect the tensioner and idler pulleys for wear of the drive surfaces.
NOTE:
NOMINAL PULLEY DIAMETER IS 90 mm (3.453") OR 76 mm (2.916"); PULLEYS WORN TO 88
mm (3.377") OR 74 mm (2.839") SHOULD BE REPLACED.
2. Select the appropriate neoprene-backed belt and install per standard belt routing (refer to
Service Manual Section 03-05).
3. Insure that all belt vee's are in all pulley grooves.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 94110 >
Jan > 94 > Accessory Drive Belt - Noise/Excessive Wear > Page 1558
Parts Block
OTHER APPLICABLE ARTICLES: 89-10-11 WARRANTY STATUS: Eligible Under The Provisions
Of The Bumper To Bumper Warranty Coverage For 1992-93 Models And Eligible Under Basic
Warranty Coverage For Other Model Years. Emission Warranty Coverage Applies If Vehicle Is
Equipped With Thermactor System
OPERATION DESCRIPTION TIME
940110A Replace Belt - 0.3 Hr.
F-Series/Bronco
940110B Replace Belt And Tensioner 0.4 Hr.
- F-Series/Bronco
940110C Replace Belt - Econoline 0.4 Hr.
940110D Replace Belt And Tensioner 0.5 Hr.
- Econoline
DEALER CODING
BASIC PART NO. CONDITION CODE
8620 30
OASIS CODES: 497000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Technical Service Bulletins > Engine - Oil Dipstick May Not Be Read Correctly
Engine Oil Dip Stick - Dip Stick Tube: Technical Service Bulletins Engine - Oil Dipstick May Not Be
Read Correctly
Article No. 88-8-9
FORD: 1984-88 ALL CAR LINES
LINCOLN-MERCURY: 1984-88 ALL CAR LINES
MERKUR: 1985-88 ALL CAR LINES
LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES
ISSUE: The "markings" on the engine oil level dipstick (indicator) may not be read correctly or
could possibly be misinterpreted. This can result in overfilling the engine with oil in newly delivered
vehicles or thinking that the engine has been overfilled with the specified amount of oil during oil
and filter changes.
ACTION: If service is required, use the following guidelines to make sure of correct oil fill.
NOTE: PROPER OIL FILL IS BASED ON A SPECIFIED VOLUME AND IS LISTED IN THE
"VEHICLE ENGINE OIL LEVEL CAPACITY SPECIFICATION CHART" AND THE "FLUID REFILL
CAPACITIES CHART" OF THE VEHICLE OWNERS GUIDE. USE THESE RECOMMENDED
VOLUMES WHENEVER REFILLING THE ENGINE WITH OIL.
FIGURE 6
Old Style Design Dipstick
On "MAX/ADD" style dipsticks the "MAX" line represents an allowable tolerance limit of
approximately 1/2 quart above the specified (normal) engine operating level, Figure 6. The oil level
of a properly filled engine should indicate an oil level reading in the upper crosshatched area of the
dipstick.
NOTE: DO NOT "TOP OFF" TO THE "MAX" LINE. IF THE OIL LEVEL GOES ABOVE THE "MAX"
LINE, A SUFFICIENT AMOUNT OF OIL SHOULD BE REMOVED TO BRING THE OIL LEVEL
READING BACK INTO THE CROSSHATCHED AREA OF THE DIPSTICK.
New Style Design Dipstick
On "FULL/ADD", "FULL/ADD 1 QUART" or "F" style dipsticks the oil level of an engine filled with
the correct amount of oil, as listed in the "Vehicle Oil Capacity Specification Chart" will normally
occur slightly above the "FULL" line, Figure 6. This occurs because the "FULL" mark on the
dipstick
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Technical Service Bulletins > Engine - Oil Dipstick May Not Be Read Correctly > Page
1564
represents the lowest level of oil that could occur when an engine is filled with the specified volume
of oil. This variation in oil level is due to manufacturing tolerances and oil level checking conditions.
1987-88 ENGINE OIL CAPACITY SPECIFICATION CHART
Oil Fill
With Filter
Engine Models Change
Car 1.3L All 3.9 Qts.
1.6L All 3.9 Qts.
1.9L All 4.0 Qts.
2.2L All 4.9 Qts.
2.3L OHC N.A. EFI/TC 5.0 Qts.
2.3L/2.5L HSC/PENTA 4.5 Qts.
2.9L Scorpio 5.0 Qts.
3.0L All 4.5 Qts.
3.8L All 5.0 Qts.
5.0L All 5.0 Qts.
5.8L All 5.0 Qts.
Truck 2.0L Ranger 5.0 Qts.
2.3L Ranger 5.0 Qts.
2.9L Ranger 5.0 Qts.
3.0L Aerostar 4.5 Qts.
4.9L All 6.0 Qts.
5.0L All 6.0 Qts.
5.8L All 6.0 Qts.
6.1L/7.0L All 9.0 Qts.
7.5L All 6.0 Qts.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
"INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Technical Service Bulletins > Engine - Oil Dipstick May Not Be Read Correctly > Page
1565
Engine Oil Dip Stick - Dip Stick Tube: Technical Service Bulletins Engine - Correct Oil Fill Level
Markings
Article No. OIL DIPSTICK - CORRECT ENGINE OIL FILL
87-9-5 LEVEL MARKINGS - GASOLINE ENGINES
FORD: 1987 ALL CAR LINES
LINCOLN-MERCURY: 1987 ALL CAR LINES
LIGHT TRUCK: 1987 ALL LIGHT TRUCK LINES
ISSUE: The "markings" on the engine oil level dipstick (indicator) are being read incorrectly. This
incorrect reading results in overfilling the engine with oil in newly delivered vehicles during the
"prep" procedure.
Figure 4 - Article 87-9-5
ACTION: Do not fill engine oil to the "MAX" oil level line marked on the dipstick. The "MAX" line
represents a tolerance limit that is about 1/2 quart above the specified (normal) engine oil operating
level. A correctly filled engine should show an oil fill level reading in the crosshatched area of the
dipstick, Figure 4. During new vehicle delivery or right after an oil change, the oil fill reading should
be at the full mark on the new style dipstick and in the upper crosshatched area on the old style
dipstick. Refer to the following specification chart for proper fill requirements.
OTHER APPLICABLE ARTICLES: 87-5-20, 87-7-23 WARRANTY STATUS: "INFORMATION
ONLY"
1987 ENGINE OIL LEVEL SPECIFICATION CHART
Oil Fill With Filter
Engine Models Change
Car 1.9L N.A. EFI 4.0 Qts.
2.3L OHC N.A. EFI/TC 5.0 Qts.
2.3L/2.5L HSC/PENTA 4.5 Qts.
3.0L All 4.5 Qts.
3.8L All 5.0 Qts.
5.0L All 5.0 Qts.
5.8L All 5.0 Qts.
Truck 2.0L Ranger 5.0 Qts.
2.3L Ranger 5.0 Qts.
2.9L Ranger 5.0 Qts.
3.0L Aerostar 4.5 Qts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Technical Service Bulletins > Engine - Oil Dipstick May Not Be Read Correctly > Page
1566
4.9L All 6.0 Qts.
5.0L All 6.0 Qts.
5.8L All 6.0 Qts.
6.1L/7.0L All 9.0 Qts.
7.5L All 6.0 Qts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine - Correct Oil Fill Level Markings
Engine Oil: Technical Service Bulletins Engine - Correct Oil Fill Level Markings
Article No. OIL DIPSTICK - CORRECT ENGINE OIL FILL
87-9-5 LEVEL MARKINGS - GASOLINE ENGINES
FORD: 1987 ALL CAR LINES
LINCOLN-MERCURY: 1987 ALL CAR LINES
LIGHT TRUCK: 1987 ALL LIGHT TRUCK LINES
ISSUE: The "markings" on the engine oil level dipstick (indicator) are being read incorrectly. This
incorrect reading results in overfilling the engine with oil in newly delivered vehicles during the
"prep" procedure.
Figure 4 - Article 87-9-5
ACTION: Do not fill engine oil to the "MAX" oil level line marked on the dipstick. The "MAX" line
represents a tolerance limit that is about 1/2 quart above the specified (normal) engine oil operating
level. A correctly filled engine should show an oil fill level reading in the crosshatched area of the
dipstick, Figure 4. During new vehicle delivery or right after an oil change, the oil fill reading should
be at the full mark on the new style dipstick and in the upper crosshatched area on the old style
dipstick. Refer to the following specification chart for proper fill requirements.
OTHER APPLICABLE ARTICLES: 87-5-20, 87-7-23 WARRANTY STATUS: "INFORMATION
ONLY"
1987 ENGINE OIL LEVEL SPECIFICATION CHART
Oil Fill With Filter
Engine Models Change
Car 1.9L N.A. EFI 4.0 Qts.
2.3L OHC N.A. EFI/TC 5.0 Qts.
2.3L/2.5L HSC/PENTA 4.5 Qts.
3.0L All 4.5 Qts.
3.8L All 5.0 Qts.
5.0L All 5.0 Qts.
5.8L All 5.0 Qts.
Truck 2.0L Ranger 5.0 Qts.
2.3L Ranger 5.0 Qts.
2.9L Ranger 5.0 Qts.
3.0L Aerostar 4.5 Qts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine - Correct Oil Fill Level Markings > Page 1571
4.9L All 6.0 Qts.
5.0L All 6.0 Qts.
5.8L All 6.0 Qts.
6.1L/7.0L All 9.0 Qts.
7.5L All 6.0 Qts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine oil capacity ...............................................................................................................................
........................................................... 5.0 Qts.(4.7L)
Note: Add 1 Qt. with filter change.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 1574
Engine Oil: Fluid Type Specifications
BL Self-adjusting Brake Lubricant
EC Ethylene Glycol Coolant
Mix 50/50 with water to at least -20°F (-29°C) protection
EP Extreme Pressure Gear Lubricant
Ford Part No. D8DZ-19C547-A
FA Automatic Transmission Fluid, Type F
GL-5 Gear Oil, API Service GL-5
HBH Hydraulic Brake Fluid, Extra
Heavy-Duty
HP Hypoid Gear Oil
Ford Part No. E0AZ-19580-A
HP* Hypoid Gear Oil for Limited-Slip
or Traction-Lok Differential
LM Lithium Grease, with Polyethylene
LS Steering Gear Lubricant
MA MERCONAutomatic Transmission
Fluid
MH Manifold Heat Valve Solvent
SG Motor Oil, API Service SG
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Technical Service Bulletins > Oil Filter - Heavy Duty Motorcraft Filter Now Available
Oil Filter: Technical Service Bulletins Oil Filter - Heavy Duty Motorcraft Filter Now Available
Article No. 86-25-17
OIL FILTER - 7.5L ENGINE - HEAVY DUTY MOTORCRAFT FILTER NOW AVAILABLE
LIGHT TRUCK 1974-87 E-250/350, F-250/350
A heavy duty Motorcraft oil filter (FL-1 HP) is now available for use on the 7.5L engine. It is
recommended that vehicles subject to severe service, as outlined in the Owner Guide or off-road
driving, use Motorcraft Oil Filter (FL-1 HP) at all normal oil change intervals.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator >
Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov >
93 > Instrument Cluster Warning Lights - Dimly Lit
Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit
Article No. 93-24-10
11/24/93
^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG,
THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO
LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND
MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ
LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91
AEROSTAR 1991-93 EXPLORER
ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of
the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch.
ACTION:
If the vehicle displays the subject symptoms and meets the following conditions, replace the
ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for
1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks,
Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the
Parts Block in this article for correct parts usage.
CONDITIONS
^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring
schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator >
Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov >
93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1587
^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part
Number Chart.
NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL
HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN
IMPROVED TO CORRECT THE SUBJECT ISSUE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models
Except Lincolns. Major Component Warranty Coverage For Lincolns
OPERATION DESCRIPTION TIME
932410A Replace Ignition Switch - 0.5 Hr.
All Light and Compact Trucks
DEALER CODING
BASIC PART NO. CONDITION CODE
11572 X1
OASIS CODES: 201000, 201100, 206000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: >
932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit
Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit
Article No. 93-24-10
11/24/93
^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG,
THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO
LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND
MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ
LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91
AEROSTAR 1991-93 EXPLORER
ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of
the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch.
ACTION:
If the vehicle displays the subject symptoms and meets the following conditions, replace the
ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for
1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks,
Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the
Parts Block in this article for correct parts usage.
CONDITIONS
^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring
schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: >
932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1593
^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part
Number Chart.
NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL
HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN
IMPROVED TO CORRECT THE SUBJECT ISSUE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models
Except Lincolns. Major Component Warranty Coverage For Lincolns
OPERATION DESCRIPTION TIME
932410A Replace Ignition Switch - 0.5 Hr.
All Light and Compact Trucks
DEALER CODING
BASIC PART NO. CONDITION CODE
11572 X1
OASIS CODES: 201000, 201100, 206000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator >
Component Information > Technical Service Bulletins > Page 1594
Oil Level Warning Indicator: Description and Operation
This system is used to indicate a low engine oil level condition. The lamp will be illuminated during
engine starting. If oil level is sufficient, the lamp will go off when engine is operating. If oil level is
low the lamp will remain on until engine oil is added and the ignition switch is placed in the Off
position. The module may take a few minutes to reset. If the engine is started during this period,
the last recorded reading will be displayed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair
Oil Pan: Service and Repair
Engine oiling system. V8-460
V8-460
1. Remove engine cover, then disconnect battery ground cable and drain cooling system.
2. Remove air cleaner, then disconnect throttle and transmission linkages from carburetor.
3. Disconnect power brake vacuum line, if equipped.
4. Disconnect fuel line and choke lines, then remove air cleaner adapter from carburetor.
5. Disconnect upper and lower radiator hoses and transmission oil cooler lines (if equipped) from
radiator.
6. Remove fan shroud, fan and radiator.
7. On models equipped with power steering, unfasten steering pump and position aside.
8. On all models, remove front engine mount through bolts, then the engine oil dipstick tube.
9. On models equipped with A/C, move refrigerant lines from rear of compressor downward to clear
dash, or remove lines if necessary.
10. On all models, raise and support vehicle.
11. Drain engine oil and remove oil filter.
12. Remove muffler inlet pipe assembly, then disconnect manual and kickdown linkages from
transmission.
13. Remove driveshaft and coupling shaft assembly, then the transmission dipstick tube.
14. Remove dipstick and tube from oil pan, then position a suitable jack and a wooden block under
oil pan. Raise engine slightly until transmission contacts floor, then block engine in place at the
mounts. The engine assembly must be raised exactly four inches and remain centered in the
engine compartment to remove the oil pan.
15. Remove oil pan attaching bolts and lower the pan.
16. Remove oil pump and pickup tube assembly and lay in oil pan, then slide oil pan rearward and
remove from vehicle.
17. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component
Information > Testing and Inspection
Oil Pressure Gauge: Testing and Inspection
This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil
pressure gauge and a sending unit which are connected in series. The sending unit consists of a
diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm
actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil
pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge,
in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor
is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge
reading.
TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions
included with the tester.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations
Oil Pressure Sender: Locations
LH Side Of V8-460/7.
Top Center Rear Of Engine
Applicable to: 5L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning
Lamp/Indicator > Component Information > Testing and Inspection
Oil Pressure Warning Lamp/Indicator: Testing and Inspection
Many trucks utilize a warning light on the instrument panel in place of the conventional dash
indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is
wired in series with the ignition switch and the engine unit--which is an oil pressure switch. The oil
pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on,
the warning light circuit is energized and the circuit is completed through the closed contacts in the
pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm,
opening the contacts, thereby breaking the circuit and putting out the light.
TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If
it does not light, disconnect the wire from the engine unit and ground the wire to the frame or
cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the
bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the
engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight
and properly grounded, it should be removed and a new one installed. (The presence of sealing
compound on the threads of the engine unit will cause a poor ground). If the warning light remains
lit when it normally should be out, replace the engine unit before proceeding further to determine
the cause for a low pressure indication. The warning light will sometimes light up or flicker when the
engine is idling, even though the oil pressure is adequate. However, the light should go out when
the engine speed is increased.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component
Information > Specifications
Oil Pump: Specifications
Rotor Backlash 0.012 in
Note: Maximum inner and outer rotor tip clearance.
Rotor To Body Clearance 0.001-0.013 in
Rotor End Clearance 0.004 in
Note: Measured between pump cover mounting surface & end
of gear using suitable straightedge & feeler gauges.
Maximum
Maximum Cover Flatness Variation N/A
Note: Pump should be replaced if cover is damaged, scored
or worn.
Driveshaft To Pump Body Clearance 0.0015-0.0030 in
Relief Valve To Body Clearance 0.0015-0.0030 in
Relief Spring Pressure 20.6-22.6 lbf at 2.49 in
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component
Information > Service and Repair > Removal and Installation
Oil Pump: Service and Repair Removal and Installation
V8 ENGINES
On some models, the oil pump must be removed when removing the oil pan. These models are
indicated in the ``Oil Pan, Replace''
procedures.
1. Remove oil pan as previously described.
2. Remove oil pump attaching bolts and the oil pump.
3. To install, prime pump with engine oil and apply sealant to gasket.
4. Insert distributor intermediate shaft, making sure that it is properly seated, then install oil pump.
Do not force pump into place if it will not
readily seat, as the intermediate shaft may be misaligned with distributor shaft. To align, rotate
intermediate shaft until pump can be seated without applying force.
5. Install oil pan.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component
Information > Service and Repair > Removal and Installation > Page 1612
Oil Pump: Service and Repair Service
Fig. 42 Oil pump. 6-300
Fig. 43 Oil pump. V8-255, 302, 351W
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component
Information > Service and Repair > Removal and Installation > Page 1613
Fig. 44 Oil pump assembly. 351M & 400
ROTOR TYPE PUMP
1. To disassemble, Figs. 42, 43 and 44, remove cover, inner rotor and shaft assembly and outer
race. Remove staking marks at relief valve chamber cap. Insert a self-threading sheet metal screw
of proper diameter into oil pressure relief valve chamber cap and pull cap out of chamber. Then
remove spring and plunger.
2. To assemble, install pressure relief valve plunger, spring and a new cap. Stake cap in place.
Install outer race, inner rotor and shaft. Be sure identification dimple mark on outer race is facing
outward and on the same side as dimple on rotor. Inner rotor and shaft and outer race are
furnished only as a unit. One part should not be replaced without replacing the other.
3. Install pump cover.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Intake Manifold: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1618
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1619
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Page 1620
Intake Manifold: Specifications
Intake Manifold 22-32 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Page 1621
Intake Manifold: Service and Repair
Fig. 12 Intake manifold tightening sequence. V8-460
Fig. 20 Intake manifold installation. V8 engines
V8-460
1. Drain cooling system, then remove air cleaner and intake duct assembly.
2. Disconnect upper radiator hose from engine and the heater hose from intake manifold and water
pump and position aside.
3. Loosen water pump bypass hose clamp at intake manifold.
4. Disconnect PCV valve hose from right rocker arm cover.
5. Disconnect and tag all vacuum lines at rear of intake manifold.
6. Disconnect ignition wires from spark plugs and position aside.
7. Disconnect high tension lead from ignition coil, then remove distributor cap and wires as an
assembly.
8. Disconnect and tag all distributor vacuum lines at carburetor and vacuum control valve.
9. Disconnect accelerator linkage and transmission kickdown linkage (if equipped).
10. On models equipped with speed control, remove speed control linkage bracket from intake
manifold and disconnect it from carburetor.
11. On all models, remove accelerator linkage cable attaching bolts and position linkage aside.
12. Disconnect fuel inlet line from carburetor.
13. Disconnect electrical connector from ignition coil battery terminal.
14. Disconnect engine temperature and oil pressure sending unit electrical connectors and any
other connectors necessary for intake manifold removal.
15. Unfasten wiring harness from 3 retaining clips on left rocker arm cover and position harness
aside.
16. Remove ignition coil and bracket assembly.
17. Remove intake manifold attaching bolts and nuts, then the intake manifold and carburetor as an
assembly.
18. Reverse procedure to install. Apply sealer as shown in Fig. 20 Torque manifold attaching bolts
to 22-32 ft-lbs as shown in Fig. 12.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning
Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: >
932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit
Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit
Article No. 93-24-10
11/24/93
^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG,
THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO
LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND
MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ
LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91
AEROSTAR 1991-93 EXPLORER
ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of
the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch.
ACTION:
If the vehicle displays the subject symptoms and meets the following conditions, replace the
ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for
1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks,
Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the
Parts Block in this article for correct parts usage.
CONDITIONS
^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring
schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning
Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: >
932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1631
^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part
Number Chart.
NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL
HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN
IMPROVED TO CORRECT THE SUBJECT ISSUE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models
Except Lincolns. Major Component Warranty Coverage For Lincolns
OPERATION DESCRIPTION TIME
932410A Replace Ignition Switch - 0.5 Hr.
All Light and Compact Trucks
DEALER CODING
BASIC PART NO. CONDITION CODE
11572 X1
OASIS CODES: 201000, 201100, 206000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning
Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning
Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit
Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit
Article No. 93-24-10
11/24/93
^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG,
THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO
LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND
MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ
LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91
AEROSTAR 1991-93 EXPLORER
ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of
the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch.
ACTION:
If the vehicle displays the subject symptoms and meets the following conditions, replace the
ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for
1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks,
Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the
Parts Block in this article for correct parts usage.
CONDITIONS
^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring
schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning
Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning
Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1637
^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part
Number Chart.
NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL
HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN
IMPROVED TO CORRECT THE SUBJECT ISSUE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models
Except Lincolns. Major Component Warranty Coverage For Lincolns
OPERATION DESCRIPTION TIME
932410A Replace Ignition Switch - 0.5 Hr.
All Light and Compact Trucks
DEALER CODING
BASIC PART NO. CONDITION CODE
11572 X1
OASIS CODES: 201000, 201100, 206000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning
Indicator > Component Information > Technical Service Bulletins > Page 1638
Oil Level Warning Indicator: Description and Operation
This system is used to indicate a low engine oil level condition. The lamp will be illuminated during
engine starting. If oil level is sufficient, the lamp will go off when engine is operating. If oil level is
low the lamp will remain on until engine oil is added and the ignition switch is placed in the Off
position. The module may take a few minutes to reset. If the engine is started during this period,
the last recorded reading will be displayed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge >
Component Information > Testing and Inspection
Oil Pressure Gauge: Testing and Inspection
This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil
pressure gauge and a sending unit which are connected in series. The sending unit consists of a
diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm
actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil
pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge,
in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor
is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge
reading.
TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions
included with the tester.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning
Lamp/Indicator > Component Information > Testing and Inspection
Oil Pressure Warning Lamp/Indicator: Testing and Inspection
Many trucks utilize a warning light on the instrument panel in place of the conventional dash
indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is
wired in series with the ignition switch and the engine unit--which is an oil pressure switch. The oil
pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on,
the warning light circuit is energized and the circuit is completed through the closed contacts in the
pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm,
opening the contacts, thereby breaking the circuit and putting out the light.
TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If
it does not light, disconnect the wire from the engine unit and ground the wire to the frame or
cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the
bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the
engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight
and properly grounded, it should be removed and a new one installed. (The presence of sealing
compound on the threads of the engine unit will cause a poor ground). If the warning light remains
lit when it normally should be out, replace the engine unit before proceeding further to determine
the cause for a low pressure indication. The warning light will sometimes light up or flicker when the
engine is idling, even though the oil pressure is adequate. However, the light should go out when
the engine speed is increased.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Specifications
Crankshaft Main Bearing Seal: Specifications
Main Bearing Cap Bolt Torque
.................................................................................................................................................
129-142 Nm (95-105 ft-lbs)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Removal
Crankshaft Main Bearing Seal: Service and Repair Removal
A split lip-type crankshaft rear oil seal is provided for servicing these engines. 1. Remove the oil
pan and the oil pump, if required. 2. Loosen all the crankshaft main bearing cap bolts, thereby
lowering the crankshaft slightly but not to exceed 0.7938 mm (1/32 inch).
CAUTION: Use care to prevent scratching or damaging the crankshaft sealing surfaces.
3. Remove the rear crankshaft main bearing cap, and remove the crankshaft rear oil seal from the
rear crankshaft main bearing cap and cylinder
block. On the cylinder block half of the crankshaft rear oil seal use a seal removal tool, or install a
small metal screw in one end of the crankshaft rear oil seal, and PULL on the screw to remove the
crankshaft rear oil seal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Removal > Page 1651
Crankshaft Main Bearing Seal: Service and Repair Installation
1. Carefully clean the seal groove in the rear crankshaft main bearing cap and cylinder block with a
brush and solvent such as lacquer thinner, Extra
Strength Spot and Stain Remover. Also, clean the area where sealer is later to be applied. Dry the
area thoroughly, so that no solvent touches the crankshaft rear oil seal.
2. Dip the split lip-type seal halves in clean engine oil.
Crankshaft rear oil seal installation
CAUTION: Be sure no rubber has been shaved from the outside diameter of the crankshaft rear oil
seal by the bottom edge of the groove. Do not allow oil to get on the sealer area.
3. Carefully install the upper half of the crankshaft rear oil seal (cylinder block) into its groove with
undercut side of crankshaft rear oil seal toward
the FRONT of the engine, by ROTATING it on the seal journal of the crankshaft until approximately
9.525 mm (3/8 inch) protrudes below the parting surface.
4. Tighten the remaining crankshaft main bearing cap bolts to specifications. 5. Install the lower half
of the crankshaft rear oil seal in the rear crankshaft main bearing cap with undercut side of
crankshaft rear oil seal toward the
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Removal > Page 1652
FRONT of the engine. Allow the crankshaft rear oil seal to protrude approximately 9.525 mm (3/8
inch) above the parting surface to mate with the upper half of the crankshaft rear oil seal when the
rear crankshaft main bearing cap is installed.
6. Apply a continuous even 1.588 mm (1/16 inch) diameter bead of RTV Silicone Rubber Sealer or
equivalent to the areas shown in the image,
following the procedures given in the illustration.
NOTE: When applying rubber silicone always use the bead size specified and join the components
within 15 minutes of application. After this amount of time the sealant begins to "set-up" and its
sealing effectiveness may be reduced.
7. Install the rear crankshaft main bearing cap. Tighten the bolts to specifications. 8. Install the oil
pump and oil pan. Fill the crankcase with the proper amount and type of oil. 9. Operate the engine
and check for oil leaks.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Locations
Oil Pressure Sender: Locations
LH Side Of V8-460/7.
Top Center Rear Of Engine
Applicable to: 5L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair
Timing Chain: Service and Repair
Fig. 27 Valve timing alignment marks
Fig. 32 Timing marks aligned for correct valve timing. 1982 V6-232
V6-232, V8-255, 302, 351, 400 & 460 After removing the cover as outlined previously, remove the
crankshaft front oil slinger, if equipped. On V6-232 engines, remove camshaft thrust button and
spring from end of camshaft. Crank the engine until the timing marks are aligned as shown in Figs.
31 and 32. Remove camshaft sprocket retaining bolt, washer and fuel pump eccentric. Slide
sprockets and chain forward and remove them as an assembly. Reverse the order of the foregoing
procedure to install the chain and sprockets, being sure the timing marks are properly aligned.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Service and Repair
Timing Cover: Service and Repair
V8-460
1. Drain cooling system and engine oil.
2. Remove radiator shroud and fan, then disconnect radiator hoses from engine.
3. On models equipped with automatic transmission, disconnect oil cooler lines from radiator.
4. On all models, remove radiator upper support and radiator.
5. Loosen alternator mounting bolts and, on models equipped with A/C, the A/C compressor idler
pulley.
6. Remove air pump (if equipped), drive belts and water pump pulley.
7. On models equipped with A/C, remove A/C compressor support from water pump.
8. On all models, remove crankshaft pulley, then the vibration damper and woodruff key.
9. Loosen bypass hose, then disconnect heater return tube from water pump.
10. Disconnect fuel lines from fuel pump, then remove pump. Plug open lines to prevent
contamination.
11. Remove timing case cover attaching bolts, then the timing case cover and water pump as an
assembly.
12. Reverse procedure to install. Apply suitable sealant to cylinder block and timing case cover
gasket surfaces.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Technical Service Bulletins > By Symptom
Fuel Pressure: By Symptom
Technical Service Bulletin # 911211 Date: 910612
Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Technical Service Bulletins > By Symptom > Page 1669
temperatures. Refer to the following procedure for service details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Technical Service Bulletins > By Symptom > Page 1670
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Technical Service Bulletin # 911211 Date: 910612
Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Technical Service Bulletins > By Symptom > Page 1671
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Technical Service Bulletins > By Symptom > Page 1672
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 >
Jun > 91 > Engine - Lack of Power/No Start Diagnosis
Fuel Pressure: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 >
Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 1678
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 >
Jun > 91 > Engine - Lack of Power/No Start Diagnosis > Page 1679
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Technical Service Bulletins > Page 1680
Fuel Pressure: Specifications
Fuel Pressure 5-7 psi
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Technical Service Bulletins > Page 1681
Fuel Pressure: Testing and Inspection
1. Connect a suitable pressure gauge (0-15 psi) to the carburetor end of the fuel line (no "T" is
required). 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the
carburetor bowl) and read the pressure after 10 seconds. The fuel
pump pressure should read 6-8 psi at normal curb idle speed, with the transmission in NEUTRAL,
the engine at normal operating temperatures, and the fuel return line closed (if present). If pump
pressure is too low or too high install a new fuel pump.
3. Reconnect fuel line at filter and install air cleaner.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision
Technical Service Bulletin # 8912A26 Date: 890627
Idle Fuel Mixture - Manual Revision
ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1986-SECTION 4-IDLE FUEL
MIXTURE-PROPANE ENRICHMENT METHOD
ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1987-SECTION 4-IDLE FUEL
MIXTURE-PROPANE ENRICHMENT METHOD
Article No. 89-12A-26
FORD: 1986 ESCORT, LTD, MUSTANG 1986-87 TEMPO 1986 THUNDERBIRD
LINCOLN-MERCURY: 1986 CAPRI, COUGAR, MARQUIS 1986-87 TOPAZ
LIGHT TRUCK: 1986 AEROSTAR 1986-87 BRONCO, ECONOLINE, F-150, F-250, F-350,
RANGER
ISSUE: The tachometer reference "or equivalent" as shown in procedure I.-B in both 1986 and
1987 Engine Emissions Diagnosis Manuals is incorrect. This also applies to procedure I.-H in the
1986 Engine Emissions Diagnosis Manual.
ACTION: Refer to the pages following this TSB article for the revised Volume H pages which show
the correct tachometer designation as: "Connect an analog tachometer, Rotunda 059-000010 or an
equivalent analog tachometer." This information should be inserted in your 1986 Engine Emissions
Diagnosis Manual, pages 4-83, 4-87, 4-90, 4-93 and the 1987 Manual, pages 4-66 and 4-69.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
INFORMATION ONLY
OASIS CODES: 680000
Pages 4-83, 4-84
1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-83
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
Passenger Car. 1.9L w/740-2V, 2.3L OHC w/YFA-IV FB, 2.3L HSC w/1949-IV, 3.8L w/2150-A-2V
and 5.0L w/4180C-4V.
Truck, Under 8500 GVW: 5.8L w/4180C-4V.
NOTE: This procedure is applicable to the above engines only. If CO and HC are not within
specification, perform appropriate electrical diagnostic procedure in Section 15.
I. Vehicle Preparation: All Carburetors as noted above.
A. Apply the parking brake, and block the wheels. Disconnect the automatic brake release, if so
equipped, and plug the vacuum connection.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. If so equipped, insure that the hot idle compensator is in a closed position and remains so
throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to insure
that HIC valve is closed.
D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L
engines) and plug the connection. (Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger Car
engines).
E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple.
(Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger car engines).
F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
G. For vehicles equipped with thermactor systems, revise the dump valve vacuum hoses as
follows: (Not applicable to 1.9L engines).
1. For dump valves with two vacuum fittings, disconnect and plug the hose(s).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1686
2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at
the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake
manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB).
3. For 2.3L OHC engines:
a. Equipped with a dump valve with two vacuum fittings: Disconnect and plug the hoses.
b. Equipped with a combination dump valve and air diverter valve: Disconnect and plug the hoses
(2-port) from the dump valve portion.
c. Equipped with feedback carburetor: Disconnect electric lead wire from electric PVS.
4. On 3.8L engine Canadian 2150A-2V applications, do not make any thermactor system
modifications.
5. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve.
1986 4-84
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
H. For 1.9L ATX/MTX vehicles equipped with (Mechanical Vacuum) Idle Speed Control (ISC):
1. With engine off:
a. Disconnect and plug the vacuum hose at the MVISC.
b. Connect an alternate vacuum source (hand vacuum pump) capable of maintaining 22 inches Hg.
to the ISC diaphragm on carburetor, and apply vacuum (retracting ISC plunger clear of throttle
linkage).
2. With engine running and transmission in Drive (ATX) or Neutral (MTX):
^ Idle speed should be equal to the ISC retracted speed specified on the emission decal, if not
readjust throttle stop adjustment screw under choke housing to specification, (fan On, A/C Off).
I. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify that the timing is set to specification; reset if necessary, Section 15.
B. Check engine curb idle rpm or A/C-off rpm, and, if necessary, reset to specification, Section 4.
NOTE: Even If the vehicle has less than 160.9 km (100 miles) of operation, set the speed to the
normal engine specification.
NOTE: Remove PCV valve from grommet, and allow PCV valve to draw underhood air during idle
fuel mixture check. (PCV should remain in vertical position).
NOTE: Escort/Lynx, has an in-line fixed orifice crankcase vent, not a conventional PCV valve. The
fixed orifice is located in the crankcase vent hose located between the vacuum fitting on the intake
manifold and the plastic fitting attached to the air cleaner tray.
Locate the crankcase vent hose and disconnect at the air cleaner end, allowing the hose to vent to
underhood air during idle fuel/air mixture check.
C. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds
before each mixture check.
NOTE: On Escort/Lynx and Tempo/Topaz, run engine until electric fan comes On.
Pages 4-87 Thru 4-90
1986
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1687
Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-87
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
2.0L TRUCK UNDER 8600 GVW w/YFA-IV
NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane
specifications are not listed for these applications. If CO and HC are not within specification,
perform appropriate electrical diagnostic procedure, Section 15.
I. Vehicle Preparation
A. Apply the parking brake and block the wheels.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
D. Disconnect and plug the hose at the air bypass valve.
E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve.
F. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify engine timing is set to specification - reset if necessary, Section 15.
B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect
idle speed control (ISC) motor from wiring harness.
C. Place A/C-heat selector in the Off position and verify that lamps are Off.
NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at
the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle
fuel mixture check).
D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds
before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step.
1986 4-88
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
E. With the engine idling at normal operating temperature gradually open the propane tool valve
and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum
and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical
position).
NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary
repeat Steps D & E with a new propane cartridge gas supply.
F. Compare measured speed gain to specified speed gain.*
1. If the measured speed gain is within specification, proceed to Step H.
NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the
carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the
above feature.
NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture
according to the reset rpm specification.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1688
2. If the measured speed gain is higher than the speed gain specification:*
Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
3. If the measured speed gain is lower than the speed gain specification:*
Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following
speed drop test:
NOTE: Speed drop test information is specified with the artificial enrichment requirements
whenever the minimum speed gain specification is "0" rpm. *
a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop
in engine speed.
b. If the measured speed drop is greater "0" and less than or equal to 30 rpm, proceed to Step G.
c. If the measured speed drop is more than 30 rpm, return the mixture screw to the position before
adjustment. Proceed to Step G.
d. If the measured speed drop is still "0" rpm repeat steps a, b, and c.
G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see
Section III.
*Refer to the Special Specifications Issue TSB Publications.
1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-89
Idle Mixture Setting Procedures
H. Reinstall PCV valve in grommet. Reconnect air bypass valve, purge valve and crankcase
closure hose. Reconnect ISC motor to wiring harness.
I. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten
the air cleaner wing nut(s) to specification.
III. Removal and Installation for Tamper-Resistant Fuel Air Adjustment Feature:
A. See appropriate carburetor disassembly instructions in Shop Manual, Group 24.
1986 4-90
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
2.8L AEROSTAR w/2150A FB
NOTE: This procedure is for the 2.8L engine only. It is not for trucks over 8500 GVW.
I. Vehicle Preparation
A. Apply the parking brake and block the wheels.
B. Verify that timing is set to specification.
C. Remove the air cleaner assembly.
D. Disconnect wiring harness from carburetor feedback solenoid, located in the rear of carburetor.
E. Remove the PCV valve from the rocker cover grommet and move away from the crankcase
vapors.
F. Disconnect the fuel evaporating purge line (from the intake manifold spacer at the purge
solenoid).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1689
G. Install purge line tester (Tool T84T-9600-A) into the end of purge line that is still connected to
the intake manifold spacer.
H. Disconnect ISC motor from wiring harness as follows: Simultaneously: 1.
Connect tachometer, Rotunda Model 059-00001, 099-00001 or equivalent.
2. Start engine.
3. Manually hold throttle above 1000 rpm.
4. Push ISC plunger until it retracts fully.
5. After plunger retracts, release throttle and quickly unplug the connection.
NOTE: Before proceeding, verify that the throttle lever is resting on the speed screw and that the
engine idles at specification for anti-dieseling rpm (750 rpm in neutral).
I. Install air cleaner assembly, but do not connect the flexible fresh air tube to the air cleaner duct
and valve assembly. Using a propane enrichment Tool T75L-9600-A or equivalent, insert the tool
hose approximately 3/4 of the way into the duct and valve assembly. If necessary, secure the hose
with tape.
J. When the above Steps have been completed, proceed to Section II.
Pages 4-93 & 4-94
1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-93
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
4.9L TRUCK UNDER 8500 GVW w/YFA-IV FB
NOTE: This procedure is for the 4.9L engine only. It is not for trucks over 8600 GVW. Propane
specifications are not listed for these applications. If CO and HC are not within specification,
perform appropriate electrical diagnostic procedure, Section 15.
I. Vehicle Preparation
A. Apply the parking brake and block the wheels. Disconnect the automatic brake release (if so
equipped), and plug the vacuum connection.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. Disconnect the flexible fresh air tube from the air cleaner duct or adapter. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
D. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify engine timing is set to specification-reset if necessary, Section 15.
B. Place A/C-heat selector in the Off position and verify that all accessories (lamps, defrost, etc.)
are Off.
1986 4-94
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1690
Figure 1 - In-Line Base Timing Connector
NOTE: Remove PCV valve from grommet locate the crankcase closure hose and disconnect at the
air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel
mixture check).
C. Verify that the idle speed control motor and the single wire connector near the distributor
(sometimes called the In-Line Base timing connector, Figure 1) are connected electrically. With the
transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each
mixture check. If check is not completed within 60 seconds, repeat this cleanout Step.
D. Return engine to idle and disconnect idle speed control motor from wiring harness. Disconnect
single wire connector near the distributor (Fig. 1). With the engine idling at normal operating
temperature, place the transmission selector in the position specified for the idle fuel mixture check.
Gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When
the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain.
(Propane cartridge must be in vertical position).
NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary
repeat Steps C and D with a new propane cartridge gas supply.
E. Compare measured speed gain to specified speed gain.*
1. If the measured speed gain is within specification, proceed to Step G.
NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the
carburetor must be removed from the vehicle. Refer to Group 24, Powertrain Shop manual for
removal of the above feature.
NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture
according to the reset rpm specification.
2. If the measured speed gain is higher than the speed gain specification:*
Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps C and D until the
measured speed rise meets the reset rpm specification,* After final adjustment, proceed to Step F.
3. If the measured speed gain is lower than the speed gain specification:*
Turn the mixture screw clockwise (lean) and simultaneously repeat Steps C and D until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step F.
F. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled. Refer to
appropriate carburetor assembly instructions in Shop Manual, Group 24.
G. Reinstall PCV valve in grommet. Reconnect idle speed control motor and crankcase closure
system, and the single wire connector near the distributor.
H. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten
the air cleaner wing nut(s) to specification, *Specified speed gain is 10 to 70 rpm, specified reset is
30 rpm.
Pages 4-65 & 4-66
1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-65
Idle Mixture Setting Procedures
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1691
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
Propane Enrichment Procedures Are Not Applicable For The Following:
^ CFI Applications.
^ EFI Applications.
^ Truck Over 8500 GVW Applications.
^ 5.8L MCU Police and Trailer Tow Vehicles w/7200 Carburetors.
1987 4-66
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
Passenger Car. 2.3L HSC w/1949-IV
Truck, Under 8500 GVW: 5.8L w/418OC-4V. NOTE:
This procedure is applicable to the above engines only. If CO and HC are not within specificatlon,
perform appropriate electrical diagnostic procedure in Section 15.
I. Vehicle Preparation: All Carburetors as noted above.
A. Apply the parking brake, and block the wheels, Disconnect the automatic brake release, If so
equipped, and plug the vacuum connection.
B. Connect an analog tachometer, Rotunda 059-000010 or equivalent analog tachometer.
C. If so equipped, ensure that the hot idle compensator is in a closed position and remains so
throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to
ensure that HIC valve is closed.
D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L
engines) and plug the connection. (Not applicable to 5.8L Truck engines).
E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple.
(Not applicable 5.8L Truck engines.)
F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
G. For vehicles equipped with Thermactor systems, revise the dump valve vacuum hoses as
follows:
1. For dump valves with two vacuum fittings, disconnect and plug the hose(s).
2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at
the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake
manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB).
3. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve.
H. When the above Steps have been completed, proceed to Section II.
Pages 4-69 & 4-70
1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-69
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
2.0L TRUCK UNDER 8500 GVW w/Aisan Carburetor
NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane
specifications are not listed for these applications. If CO and HC are not within specification,
perform appropriate electrical diagnostic procedure, Section 15.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1692
I. Vehicle Preparation
A. Apply the parking brake and block the wheels.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
D. Disconnect and plug the hose at the air bypass valve.
E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve.
F. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify engine timing is set to specification-reset if necessary, Section 15.
B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect
idle speed control (ISC) motor from wiring harness.
C. Place A/C-heat selector in the Off position and verify that lamps are Off.
NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at
the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle
fuel mixture check).
D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds
before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step.
1987 4-70
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
E. With the engine idling at normal operating temperature gradually open the propane tool valve
and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum
and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical
position).
NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary
repeat Steps D & E with a new propane cartridge gas supply.
F. Compare measured speed gain to specified speed gain.*
1. If the measured speed gain is within specification, proceed to Step H.
NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the
carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the
above feature.
NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture
according to the reset rpm specification.
2. If the measured speed gain is higher than the speed gain specification:*
Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
3. If the measured speed gain is lower than the speed gain specification:*
Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Mixture > System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 1693
4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following
speed drop test:
NOTE: Speed drop test information is specified with the artificial enrichment requirements
whenever the minimum speed gain specification is "0" rpm.*
a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop
in engine speed.
b. If the measured speed drop is greater than "0" and less than or equal to 40 rpm, proceed to Step
G.
c. If the measured speed drop is more than 40 rpm, return the mixture screw to the position before
adjustment. Proceed to Step G.
d. If the measured speed drop is still "0" rpm repeat steps a, b, and c.
G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see
Section III.
*Refer to the Special Specifications Issue TSB Publications.
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Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 >
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 >
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1702
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 >
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1703
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 >
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1704
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 >
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1705
Figure 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 >
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1706
Figure 4
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 >
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1707
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 >
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1708
Figure 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 >
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1709
Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 >
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1710
Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 >
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1711
Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 >
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1712
Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 >
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1713
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1714
serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
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Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1716
For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1717
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1718
Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
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91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1724
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
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91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1725
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1726
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1727
Figure 3
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91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1728
Figure 4
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec >
91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1729
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1730
Figure 6
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
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91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1731
Figure 7
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91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1732
Figure 8
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Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
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Figure 10
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91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1735
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1738
For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec >
91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1739
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec >
91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1740
Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Idle Speed: By Symptom
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1742
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1743
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1744
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1745
Figure 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1746
Figure 4
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1747
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1748
Figure 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1749
Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1750
Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1751
Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1752
Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1753
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1754
serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1756
For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1757
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1758
Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
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^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
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The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
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Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1761
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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Figure 3
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Figure 4
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1764
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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Figure 6
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
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Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1767
Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1768
Figure 9
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1769
Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1770
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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Speed > System Information > Specifications > With Automatic Transmission
Idle Speed: Specifications With Automatic Transmission
Curb Idle Speed ...................................................................................................................................
................................................ 650 rpm (in DRIVE)
Fast Idle Speed ...................................................................................................................................
........................................... 1600 rpm (in PARK) [1]
[1] On kickdown step of fast idle cam.
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Idle Speed: Specifications With Manual Transmission
Curb Idle Speed ...................................................................................................................................
................................................................. 800 rpm
Fast Idle Speed ...................................................................................................................................
........................................................... 2200 rpm [1]
[1] On kickdown step of fast idle cam.
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Speed > System Information > Adjustments > Calibration 4-98S-R11
Idle Speed: Adjustments Calibration 4-98S-R11
1. Stabilize engine temperature.
2. Place truck in Park or Neutral, turn the A/C off, and set the parking brake.
3. Remove the air cleaner.
4. Disconnect and plug the decel throttle control kicker diaphragm vacuum hose. a.
Connect a slave vacuum hose from an engine manifold vacuum source to the decel throttle control
kicker.
b. Run engine at approximately 2500 rpm for 15 seconds, then return to idle.
c. If decel throttle control rpm is not within ±50 rpm of specification, adjust the kicker.
d. Disconnect the slave vacuum hose and allow engine to return to curb idle.
5. Adjust curb idle, if necessary, using the curb idle adjusting screw with transmission in Neutral
(M/T) or Drive (A/T).
6. Goose the throttle, then recheck curb idle speed and adjust as needed.
7. Reconnect the decel throttle control vacuum hose to the diaphragm.
8. Install the air cleaner.
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Idle Speed: Adjustments Calibrations 6-97J-R12, 6-97J-R18
1. Stabilize engine temperature.
2. Place truck in Park or Neutral, turn the A/C off, and set the parking brake.
3. Remove the air cleaner.
4. Adjust curb idle, if necessary, using the curb idle adjusting screw with transmission in Neutral
(M/T) or Drive (A/T).
5. Goose the throttle, then recheck curb idle speed and adjust as needed.
6. Check/adjust dashpot clearance by totally compressing the dashpot and adjusting for .100 inch
clearance between collapsed dashpot and throttle lever at the closed throttle position.
7. Install the air cleaner.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Engine - Lack of Power/No
Start Diagnosis
Air Filter Element: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
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NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Engine - Lack of Power/No
Start Diagnosis > Page 1788
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Component Information > Locations
Fuel Filter: Locations
Fuel Filter
The fuel filter is located on the frame rail between the frame mounted high pressure pump and
engine.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Component Information > Locations > Page 1792
Fuel Filter: Description and Operation
Clean fuel is extremely important in a fuel injection system because of the small orifice in the
injector tip through which fuel must pass. Most injection systems use three forms of filters. The first
is a fuel strainer or filter of woven plastic attached to the fuel pump inlet. This prevents
contamination from entering the fuel line and separates water from the fuel. The filter is
self-cleaning and requires no maintenance. If a fuel restriction occurs at this point, the tank
contains too much sediment or moisture and should be removed and cleaned. Additional filtration is
provided by a high capacity inline filter to remove contamination larger than 20 microns (0.0050
inch). This filter is designed to last the life of the vehicle. The final line of defense against fuel
contamination is in the fuel injector. Each injector contains its own inlet filter screen to prevent
contamination from reaching the tip.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Component Information > Locations > Page 1793
Fuel Filter: Service and Repair
Fuel Filter
REMOVAL
1. Shut engine off. De-pressurize fuel system. Use caution to prevent combustion from fuel
spillage.
2. Raise vehicle on hoist.
3. Loosen screw clamp so that filter slides rearward easily.
4. Remove push connect fittings at both ends of the filter. Install new retainer clips in each push
connect fitting.
5. Remove fuel filter from metal bracket by rotating the fuel line, being careful not to kink the fuel
line, and sliding the filter rearward.
Fuel Filter
INSTALLATION
1. Place filter into the bracket with flow arrow pointing toward tab of the bracket. Slide filter forward
until it rests against tab of the bracket.
2. Tighten retaining screw of the screw clamp to 1.3-2.1 ft. lb.
3. Install push-connect fittings onto filter ends.
4. Turn ignition switch from RUN/OFF position several times, without starting engine. Check for fuel
leaks.
5. Lower vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Ignition Timing Connector > Component Information > Description and Operation
Ignition Timing Connector: Description and Operation
Fig. 20 Ignition Timing Vacuum Switch
Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition
module to retard spark timing. The switch is closed above the vacuum setting and the ignition
module is in the non-retard spark timing mode. Calibration resistors inside the switch control the
amount of retard.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Ignition Timing Connector > Component Information > Description and Operation > Page 1801
Ignition Timing Connector: Testing and Inspection
Ignition Timing Vacuum Switch
Ignition Timing Vacuum Switch Test Chart
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less
than'' values in the Ignition Timing vacuum Switch Test chart.
3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured
across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart.
4. Replace switch if resistance is not within specifications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Timing Marks and Indicators > System Information > Diagrams
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Ignition Cable: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1809
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1810
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1811
Ignition Cable: Technical Service Bulletins Ignition System - Diagnostics Manual Correction
Article No. 89-5A-4
EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION
FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND
CROWN VICTORIA
LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ,
GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR
LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES
1986-88 AEROSTAR
ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989
Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service
information directs technicians to use a substitute coil instead of a resistance test.
ACTION: Refer to this TSB for revised ignition coil and secondary wire test information.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 680000
1989
Ignition Systems, Timing Procedures and Diagnostics 13-51
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1812
Ignition Coil and Secondary Wire
TFI-IV
And
TFI With CCD
Part 2
Test 7 1989 13-52
Ignition Systems, Timing Procedures and Diagnostics
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1813
EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2
Test 8
1989 Ignition Systems, Timing Procedures and Diagnostics
13-65
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1814
Ignition Coil And Secondary Wire
TFI-IV
Closed Bowl
Distributor
Part 2
Test 8 1989 13-66
Ignition Systems, Timing Procedures and Diagnostics
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1815
EEC-IV - Wiring TFI-IV
Closed Bowl
Distributor Part 2
Test 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Technical Service Bulletins > Page 1816
Ignition Cable: Testing and Inspection
Spark Plug Wire Resistance
*** UPDATED BY TSB #85-9-33
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Advance Unit > Component Information > Specifications
DISTRIBUTOR TIMING ADVANCE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark
Advance Mechanism
Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism
The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly
is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm
assembly used depends on the engine calibration.
Single Diaphragm Assembly
SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the
armature to stator relationship to give spark advance. The stator assembly position is changed by
means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm
assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance
spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached
to the stator assembly, makes the the stator assembly move with respect to the armature. This
changes the initial armature to stator relationship set during initial timing, causing spark advance.
The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly,
is attached to the distributor base.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark
Advance Mechanism > Page 1823
Dual Diaphragm Assembly
DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in
the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum
advance port causes the advance diaphragm and attached rod to move, otherwise the action is the
same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard
diaphragm to move, compressing the retard spring, which controls the rate of spark retard.
Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by
the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm
rod moves causing the attached stator assembly to change position with respect to the armature. In
this instance the direction of the stator assembly movement is opposite that occurring during
vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port
overrides any spark retard caused by vacuum being applied to the retard port.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark
Advance Mechanism > Page 1824
Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism
Distributor - Exploded view
The centrifugal advance mechanism varies the relationship of the armature to the stator assembly.
The armature is mounted to the sleeve and plate assembly which rotates in relation to the
distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine
RPM. The movement of the weights change the initial relationship of the armature to the stator
assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor
shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by
calibrated springs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Page 1825
Distributor Advance Unit: Service and Repair
1. Remove distributor cap and rotor.
2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup
assembly.
3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link.
4. Carefully remove unit from distributor.
5. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No
Start Diagnosis
Distributor Cap: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No
Start Diagnosis > Page 1830
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No
Start Diagnosis > Page 1831
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No
Start Diagnosis
Ignition Rotor: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No
Start Diagnosis > Page 1836
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No
Start Diagnosis > Page 1837
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Distributor, Ignition > Distributor Plate W/ Pick-up Sensor > Component Information > Service and Repair
Distributor Plate W/ Pick-up Sensor: Service and Repair
1. Remove distributor cap and rotor.
2. Remove vacuum advance unit and magnetic pickup assembly.
3. Remove attaching screws and lift base plate from distributor.
4. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Spark Plug: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1845
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 1846
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Technical Service Bulletins > Page 1847
Spark Plug: Specifications
Spark Plugs 5-10 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications
Valve Clearance: Specifications
ENGINE YEAR CLEARANCE
V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165
V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150
On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications > Page 1851
Valve Clearance: Locations
FRONT TO REAR 6-300 E-I-E-I-E-I-E-I-E-I-E-I V6-232 Right I-E-I-E-I-E V6-232 Left E-I-E-I-E-I
V8-255, 302 Left Bank E-I-E-I-E-I-E-I V8-255, 302 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Right
Bank I-E-I-E-I-E-I-E V8-351, 400 Left Bank E-I-E-I-E-I-E-I V8-460 Left Bank E-I-E-I-E-I-E-I V8-460
Right Bank I-E-I-E-I-E-I-E
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications > Page 1852
Valve Clearance: Adjustments
Fig. 2 Positioning crankshaft for valve clearance check
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications > Page 1853
Fig. 3 Checking collapsed tappet clearance
Valves, Adjust To provide a means to compensate for dimensional changes in the valve train and
provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve
clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance
is more than the maximum, the longer pushrod should be used. To check the valve clearance,
proceed as follows:
1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of
compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one
quarter turn clockwise (90°) from position No. 2, Fig. 2.
2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 3, and check the clearance on the following valves:
a. On V8-302 and 460 engines, check intake valve Nos. 1 , 7 and 8; exhaust valve Nos. 1, 4 and 5.
b. On V8-351, check intake valve Nos. 1, 4 and No. 8; exhaust valve Nos. 1, 3 and 7.
3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 3, and check the clearance on the following valves:
a. On V8-301 and 460 engines check intake valve Nos. 4 and 5; exhaust valve Nos. 2 and 6. b. On
V8-351 engines, check intake valve Nos. 3 and 7; exhaust valve Nos. 2 and 6.
4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or
equivalent and check the clearance on the following valves:
a. V8-302 and 460 engines check intake valve Nos. 2, 3 and 6; exhaust valve Nos. 3, 7 and 8. b.
On V8-351 engines, check intake valve Nos. 2, 5 and 6; exhaust valve Nos. 4, 5 and 8.
Valve Arrangement
Front to Rear
V8-302 Left Bank..................................................................................................................................
...........................................................E-I-E-I-E-I-E-I V8-302 Right Bank.............................................
..............................................................................................................................................I-E-I-E-IE-I-E V8-351 Right Bank......................................................................................................................
.....................................................................I-E-I-E-I-E-I-E V8-351 Left Bank......................................
.......................................................................................................................................................E-IE-I-E-I-E-I V8-460 Left Bank.................................................................................................................
............................................................................E-I-E-I-E-I-E-I V8-460 Right Bank............................
..............................................................................................................................................................
.I-E-I-E-I-E-I-E
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component
Information > Technical Service Bulletins > Customer Interest for Drive Pulley: > 87724 > Apr > 87 > Water Pump - Coolant
Leaks
Drive Pulley: Customer Interest Water Pump - Coolant Leaks
Article No. ^ WATER LEAKS - 7.5L - LEAKS ENGINE COOLANT
87-7-24
^ LEAKS - ENGINE COOLANT - 7.5L WATER PUMP
LIGHT TRUCK: 1984-87 E SERIES, F SERIES
ISSUE: Coolant leaks at the water pump caused by a pulled out bearing or a cracked water pump
housing may be due to excessive "RUN-OUT" of the water pump pulley.
ACTION: To correct this, install a new water pump and water pump pulley E5TZ- 8509-G
(two-groove) or E5TZ-8509-H (three-groove pulley).
NOTE: Water pump kit (E5TZ-8501-C) includes a water pump and a three-groove pulley which
may be used in place of the existing two-groove pulley application.
PART NUMBER PART NAME CLASS
E5TZ-8509-GWater Pump Pulley - C
Two-Groove
E5TZ-8509-H Water Pump Pulley - BM
Three-Groove
E5TZ-8501-C Water Pump Kit - B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: 8501A TIME:
Refer to the appropriate Service Labor Standards Manual for the reimbursement allowance
DLR. CODING: Basic Part No. 8501 - Code: 43
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Pulley: > 87724 > Apr > 87 > Water
Pump - Coolant Leaks
Drive Pulley: All Technical Service Bulletins Water Pump - Coolant Leaks
Article No. ^ WATER LEAKS - 7.5L - LEAKS ENGINE COOLANT
87-7-24
^ LEAKS - ENGINE COOLANT - 7.5L WATER PUMP
LIGHT TRUCK: 1984-87 E SERIES, F SERIES
ISSUE: Coolant leaks at the water pump caused by a pulled out bearing or a cracked water pump
housing may be due to excessive "RUN-OUT" of the water pump pulley.
ACTION: To correct this, install a new water pump and water pump pulley E5TZ- 8509-G
(two-groove) or E5TZ-8509-H (three-groove pulley).
NOTE: Water pump kit (E5TZ-8501-C) includes a water pump and a three-groove pulley which
may be used in place of the existing two-groove pulley application.
PART NUMBER PART NAME CLASS
E5TZ-8509-GWater Pump Pulley - C
Two-Groove
E5TZ-8509-H Water Pump Pulley - BM
Three-Groove
E5TZ-8501-C Water Pump Kit - B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: 8501A TIME:
Refer to the appropriate Service Labor Standards Manual for the reimbursement allowance
DLR. CODING: Basic Part No. 8501 - Code: 43
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement
Technical Service Bulletin # 88S99 Date: 880901
Recall - Heater/Engine Bypass Hose Replacement
At Dealers By Order as Req'd -0- % of Parts Direct Shipped to Dealers
At PDC By Now Temporary Maximum
Date in Owner Letter 9/2/88 Order Quantity of 2 Kits
RECALL NUMBER
88S99
Date: Sept., 1988
PLEASE GIVE COPIES OF THIS BULLETIN TO YOUR PARTS AND SERVICE MANAGERS
TO: All Ford and Heavy Truck Dealers
SUBJECT: Safety Recall 88S99 - Heater and Engine Bypass Hose Replacement and Muffler
Inspections/Replacement on Certain 1983 through 1987-model 5.8L-4V H.D. and 7.5L Engine
Equipped Ford Econoline-Based Ambulances
IN CARES/OASIS - YES
REFUND CLAIMING - USE FORM 1863
MODIFICATION CLAIMING - USE FORM 1864
VEHICLES AFFECTED:
Ford Motor Company is initiating a safety recall of certain 1983 through 1987-model Econoline
E250/E350- based ambulances equipped with 7.5 Liter engines as well as certain 1985 through
1987-model Econoline E250/E350-based ambulances equipped with 5.8L 4V H.D. engines. All
involved vehicles are rated over 8,500 lbs. GW.
REASONS FOR THIS RECALL:
Investigations of recent fires involving Econolinebased ambulances have disclosed a potential for
engine compartment heater or engine bypass hoses to wear-out prematurely and rupture, allowing
engine coolant to come in contact with hot engine exhaust manifolds and possibly ignite. Testing
has indicated that worn-out hoses are not able to withstand the prolonged periods of extreme
engine operating temperatures and higher engine cooling system pressures encountered during
EMS severe-duty cycles.
ACTION BY FORD: All ambulances returned for the service provided by this Safety Recall will be
modified as follows;
^ Replacement of existing engine compartment heater and bypass hoses with silicone/NOMEX
hoses.
^ Replacement of the radiator cap.
^ Replacement of the engine coolant with a 50/50 mix of water and antifreeze. This mixture of
coolant will provide freeze protection for most areas. Extreme cold-weather areas should be
provided with a 60/40 mixture of coolant and water.
^ Pressure test the cooling system.
^ Inspection and, if necessary, installation of aluminized stainless steel mufflers on 1985-87-model
7.5L dual-thermactor engine equipped vehicles.
^ High heat resistance aluminized stainless steel mufflers will be installed on those ambulances
equipped with 1985-1987 7.5L, dual thermactor air pump-equipped engines that did not have those
mufflers installed in connection with safety recall 87M53. A temporary shortage of aluminized
stainless steel mufflers last year required the use of substitute mufflers on ambulances that were
found in need of muffler replacement at that time.
^ Underbody inspection for loose, mispositioned or missing heat-shielding parts. Contact the
Special Toll-Free Econoline/Ambulance Hotline for authorization to perform modifications as a
result of this inspection.
This service will be performed at no cost. Owner/ operators win be provided with information about
replacement recommendations for engine coolant and heater and engine bypass hoses.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1877
REFUNDS: Owner/operators of 1985-87-model 7.5L dual-thermactor engine equipped vehicles will
be provided refunds for Ford-sourced aluminized stainless steel mufflers which may have been
installed at their expense under Safety Recall 87M53. DEALERS ARE INSTRUCTED TO
PROVIDE REFUNDS TO OWNERS WHO ADEQUATELY PROVE SUCH A PURCHASE AND TO
CLAIM FOR REFUNDS USING FORM 1863.
DEALER RESPONSIBILITIES:
Owners will be told that they may wish to inform the National Highway Traffic Safety Administration
if the recall is not performed without charge or within a reasonable time after the vehicle is brought
to their dealership for repair.
REPAIR CODES: REFER TO ATTACHMENT II, EXHIBIT 1 - THE "REPAIR CODES" SHOWN ON
THE REFERENCED ATTACHMENT HAVE BEEN DEVELOPED TO ASSIST YOU IN SELECTING
THE CORRECT EXHAUST SYSTEM MUFFLERS FOR SPECIFIC VEHICLES. THESE "REPAIR
CODES" WILL BE PRINTED ON THE OWNER LETTER AND THE CLAIM FORM 1864. USE THE
CODES TO DETERMINE REQUIRED MUFFLERS AND WHEN PREPARING CLAIM FORMS
AND SERVICE DOCUMENTS.
CARES/OASIS: Dealers are to check the CARES and OASIS programs todetermine if an affected
vehicle is involved in other recalls.
CLAIM FORMS: USE CLAIM FORM 1864 FOR THE MODIFICATIONS REQUIRED FOR THIS
RECALL. USE CLAIM FORM 1863 FOR REFUNDS TO OWNERS WHO PREVIOUSLY PAID FOR
INSTALLATION Of FORD-SOURCED ALUMINIZEDSTAINLESS STEEL MUFFLERS. Refer to
Attachment I for preparation instructions.
PARTS Refer to Attachment II.
REQUIREMENTS:
LABOR ALLOWANCE: Refer to Attachment II.
TECHNICAL INSTRUCTIONS:
Refer to Attachment III.
OWNER NOTIFICATION:
Owner/operators will be notified with the letter shown on Attachment IV.
FPSD ASSISTANCE: Contact your FPSD District Service Engineer with any problems you have
concerning this recall. Additionally, a special toll-free Econoline/Ambulance Technical Hotline is
available to assist in resolving unusual repair issues technicians may encounter.
Personnel are available daily from 7:30 A.M. to 6:00 P.M., Eastern Time to provide technical
assistance by calling 1-800-445-1571.
Administrative Instructions
SAFETY RECALL 88S99 ADMINISTRATIVE INSTRUCTIONS Attachment I VEHICLES
AFFECTED:
Certain 1983 through 1987-model Econoline E250/E350- based ambulances equipped with 7.5
Liter engines as well as certain 1985 through 1987-model Econoline E250/E330- based
ambulances equipped with 5.8 Liter 4V H.D. Engines. All affected vehicles are rated over 8,500 lbs.
GVW.
REPORTING COMPLETIONS: Only the Form 1864 will be accepted for reimbursement for
modifications performed under this recall. Upon completion of the required service, the Form 1864
must be completely filled out and signed by authorized dealer personnel. CLAIM SUBMISSION:
The claims must be entered through the Direct Warranty Entry (DWE) system. Dealers without
DWE capability must mail the second copy of the Form 1864 for reimbursement. Should your
dealership receive pre-printed Forms 1864 with a seven digit claim number, you must drop the first
digit and enter only the last six digits. You must sight verify the claim number for accuracy. It is
important that all claims be filed for all completed units so you will be reimbursed and our records
will show completion.
REFUNDS: Refund requests submitted under Safety Recall 88S99 are governed by the following
guidelines:
^ Owner/operators of 1985-87 model ambulances with 7.5L dual thermactor engines are eligible for
a refund if they paid for a muffler replacement under Safety Recall 87M53 and the replacement
muffler was the new ribbed design, aluminized stainless steel muffler (See Attachment II, Exhibit 2
for eligible muffler part numbers). Paid repair orders or invoices presented by the owner/operator
requesting a refund must show one of the eligible muffler part numbers.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1878
^ Refunds include return of any deductible amount owners may have paid.
^ A copy of the paid repair orders or parts purchase receipts must be retained in your service file
for at least one year following the date of Company notification of payment.
^ Owner refund requests must be submitted on separate Warranty Claim Form 1863. In addition to
the information shown for the special preparation of Owner Refund
claims (Reference: Warranty and Policy Manual - Subject 6.1, Page 18), please enter the
information shown below:
Causal Basic Part Number - 88S99
Condition Code - OB
Labor Operation - REFUND
Administrative Allowance - 0.2 Hr.
Program Code - 88S99
^ An administrative allowance of 0.2 hours will be allowed for processing each eligible owner
refund request. To claim the allowance, enter ALLOW in the Labor Operation No. column and 0.2
in the Scheduled Time column. Extend the 0.2 hours at your authorized warranty labor rate and
enter the result in the Amount column.
^ Please provide prompt refund to all eligible owners who respond to this recall with proper repair
documentation.
Labor and Parts Ordering Instructions
SAFETY RECALL 88S99 LABOR AND PARTS ORDERING INSTRUCTIONS
Attachment II
PARTS ORDERING: Service parts required for this recall may be ordered through normal
channels. Refer to the following material and Attachment II, Exhibits 1 and 2.
Coolant Ordering
^ Since most areas will require a 50/50 mixture of antifreeze and water, order and claim for the
amount of coolant required to service each ambulance using the following information:
- In extreme cold weather areas use a 60/40 mixture, order and claim appropriately.
- Order enough coolant (Ford Part Number E2FZ-19549-AA, or equivalent) to fill the entire engine
cooling system. In most cases, 3 gallons of antifreeze and 3 gallons of water should be adequate to
attain a 50/50 mix
Service Part Number
Description Class Dealer Price
E2FZ-19549-AA Coolant, Engine V $8.65/Gallon a/
E3UZ-18472-C Kit, Heater Hose BG $64.65
E8UZ-8597-A Hose, Engine Bypass (5.8L Engs.
CG $2.25
Only)
a/ Based on $51.90, Carton 6 Gallons, order this part number or use locally purchased equivalent.
Use dealer aquisition cost for locally purchased equivalent.
Scheduled Time
LABOR OPERATIONS: Basic Labor Operation (Hours)
Inspection of the Ambulance Underbody and Exhaust System, Installation of Heater and Engine
Bypass Hose Improvement
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1879
Modifications. . . . . . . . . . . . . 2.1 Insert in Box "B" of Form 1864
LABOR OPERATIONS: (Cont'd.)
Scheduled Time
Basic Labor Operation (Hours)
Supplemental Labor Operations (Additive to Above)
Replacement of the Exhaust System Muffler, and Attaching Parts (7.5L Dual-Thermactor Engine
Equipped Vehicles . . . . . . . .
0.8 Insert in Box "B" of Form 1864
Note: Use this supplemental time when replacing mufflers on 7.5L Dual-Thermactor Engine
equipped vehicles. This time may also be used when replacing mufflers performed at owners'
expense.)
Additional Time to Access Engine Bypass Hoses on 7.5L Engine Equipped Vehicles . . . . . . . . . . . .
.
0.4 Insert in Box "B" of Form 1864
Administrative Allowance (Additive to Above)
Administrative Allowance . . . . . 0.1 Hr.
The Supplemental Labor Operations and the 0.1 hour administrative allowance must be added
before inserting the total labor time in Box "B" of the Form 1864.
Repair Code Description
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1880
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1881
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Technical Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTIONS
Attachment III
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1882
TECHNICAL INSTRUCTIONS:
Inspections:
^ Underbody - All Vehicles
1. Inspect the underbody and exhaust system for missing, loose or mispositioned heat-shielding
parts (Refer to Safety Recall 87M53 instructions).
If you discover any conditions as a result of this inspection that requires modification, please
contact the Special Toll-Free Econoline/Ambulance Hotline, 1-800-445-1571, for authorization.
Contact your District Office if the Hotline is not available.
^ Mufflers - All Vehicles
2. Refer to Attachment III, Exhibit 1. Remove the exhaust system muffler heat shields.
3. Inspect the muffler per the instructions contained in Attachment III, Exhibit 1.
^ Replace unacceptable mufflers and attaching parts at the OWNERS EXPENSE ON:
i) 1983 through 1987-model 7.5L single-thermactor engine equipped vehicles; ii) 1985 through
1987-model, 5.8L 4V H.D. engine equipped vehicles.
^ Replace any mufflers that are not Ford-sourced aluminized stainless steel and attaching parts at
FORD EXPENSE on 1985 through 1987-model, 7.5L dual thermactor engine equipped vehicles.
^ Heater and Bypass Hose Replacement:
4. Refer to Attachment III, Exhibit 2. Replace the engine compartment heater and engine bypass
hoses as shown on the referenced attachment. Note: The 5.8L 4V H.D. engines require a formed
bypass hose. This is not in the heater hose/bypass parts kit. Order this hose separately.
5. Pressure test the cooling system and replace existing radiator cap.
NOTE: Owners will be instructed to retorque hose clamps to 2.5-3.0 N-m (22-26 in.lbs.) when
coolant leakage is observed.
MODIFICATION DECAL: Prepare an "Authorized Modifications" decal (Form FPS-8262) as shown
below. Affix the decal to a flat clean surface on
the radiator support. (Order the "Authorized Modifications" decal on your Weekly Stock Order Pad.)
Specific Technical Repair Code and Parts Ordering Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
Exhaust System-Ford Components-Correct Routing and Retention
1983-1985 7.5L MODELS (MODELS WITH SINGLE AIR PUMP) 1985-1/2-1987 5.8L MODELS
(OVER 8500 GVW WITH 4 BARREL CARBURETOR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1883
FIGURE 1
The Ford exhaust system as shown in Figure 1, provides the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheatng.
FIGURE 3
Inspect the exhaust system for leaks or ruptures. FOR 5.8L ONLY, it may be necessary to remove
the heat shields as shown in Figure 3. Inspect the muffler outer wrapper lock seam for separation.
If any such problems are found, notify the customer and request permission to repair the problem,
at the customer's expense. Note any such problems and the customer's reaction to your repair
request on your internal repair order form and retain in your records.
If a non-Ford exhaust system or exhaust components is noted on the unit, inform the customer of
the potential for durability reduction, exhaust flow restriction, or overheating as indicated above.
Note any such discrepancy and the customer's reaction on your internal repair order form and
retain in your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1884
FIGURE 1
ALL 5.8L AND ONLY CALIFORNIA CALIBRATION 7.5L: If the unit is not equiped with the all-steel
hangers shown in Figure 1, order and install the Ford Service Part as indicated in the attached
chart. SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
FIGURE 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1885
1985-1/2 - 1987 7.5L MODELS (MODELS WITH DUAL AIR PUMPS - SEE FIGURE 5)
FIGURE 2
The Ford exhaust system as shown in Figure 2, provdes the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheating.
FIGURE 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1886
FIGURE 4
Remove the heat shields covering the muffler by removing the retaining clamps securing the
shields as shown in Figure 3. If the muffler is a non-Ford design or is a non-ribbed design (Figure
4), remove the Muffler and Outlet Pipe Assembly and replace with the heavy duty ribbed muffler
assembly as indicated in the attached chart.
If the muffler is the heavy duty type (ribbed design - Figure 4), installed during the 1987 M53 recall,
inspect the entire surface of the muffler for cracks or openings. If any such openings are found,
replace the Muffler and Outet Pips Assembly with a new heavy duty ribbed muffler assembly.
Advise the Ambulance Technical Hot Line 1-800-445-1571, if you find a ribbed muffler with cracks
or openings.
FIGURE 2
If the unit is not equipped with the all-steel hangers as shown in Figure 2, order and install the Ford
Service Part as indicated in the attached chart. ATTACHMENT III EXHIBIT 1 PAGE 3 OF 3
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1887
KIT NUMBER E3UZ-18472-C HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED
AMBULANCES WITH 7.5L OR 5.8L 4V H.D. ENGINES SPECIAL NOTE: The following instructions
describe the installation procedure for the heater hose/bypass hose improvement package. It is
designed specially for Ford E-350 and E-250 (over 8500 pounds GVWR) based ambulances. The
original Ford heater hose system has probably been modified by the ambulance body builder. It is
not possible to identify all the designs and modifications used by these manufacturers. If you
encounter difficulties not anticipated in these instructions, contact the Ford Ambulance Recall
Hotline on 1-800-445-1571. PARTS LIST
Item Description Part Number Quantity
1 Silicons Hose - 5/8" I.D. *EST-M2D309-A 96"
2 Hose Clamp 388652-S2 20
3 "Y" Fitting D8UH-18663-AA 2
4 Tie Strap - 1/4" Wide 384213-S 10
5 Radiator Cap E5TH-8100-AA 1
*Engineering Specification Number
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1888
FIGURE 1
HEATER HOSE REMOVAL
1. Close the shutoff valves that connect the rear heater unit to the Ford installed heater hoses (See
Figure 1). Be sure to close both the supply and return hose valves. Failure to close these valves
could cause coolant fill problems later.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1889
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT.
2. Drain the coolant from the radiator by removing the radiator cap and carefully opening the drain
cock at the bottom of the radiator. After the coolant has drained from the radiator, close the drain
cock and discard the radiator cap.
3. Disconnect and remove any objects, such as thermactor pump filter/silencer or coolant overflow
bottle, obstructing access to the heater hoses.
4. Inspect the hoses for chaffing or cuts (See Figure 1). Note the position of any straps or clamps
for securing the new hoses at time of installation.
5. Disconnect the vacuum line from the water supply valve.
6. Disconnect the inlet and outlet hoses from the heater core, engine block, and rear heater shutoff
valves (See Figure 1). Loosen each clamp and cut the hose first to prevent core damage. DO NOT
twist hoses in the removal process. Disconnect the hoses from any locating clips. Discard all hose
clamps.
NOTE: DO NOT disconnect the hoses routed from the shutoff valves to the rear heater unit.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1890
FIGURE 1
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1891
FIGURE 2
HEATER HOSE INSTALLATION
1. Using hoses (Item 1), hose clamps (Item 2) and "Y" fittings (Item 3), assemble duplicate hose
layouts of the removed hose assemblies (Figure 1).
NOTE: The hoses leading from the "Y" fittings may have to be slightly longer than the original
hoses to avoid any kinks or bends. This is due to the replacement fittings having a different angle in
the "Y" than the original "Y" or "T" fittings. Silicone hoses require the special clamps Included in the
kit to prevent cutting the hose. DO NOT use any other type of clamp.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 1 OF 5
on 1-800-445-1571 if you have any questions.
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
2. Remove the vacuum operated water supply valve from the old hose assembly and install it into
the new hose assembly.
NOTE: Make sure that the flow arrow stamped on the valve is pointing toward the heater core.
3. Torque the clamps (Item 2) to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
4. Connect the hose assemblies with clamps (Item 2) to the engine block, heater core and rear shut
off valves.
5. Torque the clamps to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
6. Connect the vacuum line to the water supply valve.
7. Using tie straps (Item 4), secure the hoses to an adjacent engine component to prevent chaffing
or cutting during engine operation. The hoses may be secured in a manner similar to the original
method if the removed hoses were not damaged as noted earlier. If the original hoses were
damaged, route the hoses and secure them in a manner to prevent hose damage during engine
operation.
WATER BYPASS HOSE REMOVAL AND INSTALLATION FOR VEHICLES WITH 7.5L ENGINES
1. Remove the distributer vacuum hose to improve accessibility to the water bypass hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1892
FIGURE 2
2. Remove the water bypass hose and clamps (See Figure 2). Discard the clamps.
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
CAUTION: DO NOT ALTER (CUT OFF) THE INTAKE MANIFOLD AND/OR THE WATER PUMP
HOSE CONNECTIONS. ANY
DAMAGE SUCH AS SHARP EDGES, TO THESE CONNECTIONS WILL RESULT IN DAMAGE
TO THE NEW BYPASS HOSE DURING INSTALLATION.
4. Using the removed hose as a pattern, cut a piece of silicone hose (Item 1) to the proper length
and position it on the intake manifold bypass connection.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 3 OF 5
on 1-800-445-1571 if you have any questions
FIGURE 3
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D ENGINES
5. Position two (2) new hose clamps (Item 2) on the new hose, installed in Step 4, toward the
intake manifold. (See Figure 3.)
6. Bend (double over) the new bypass hose downward and slide the hose on to the water pump
bypass hose connection. (See Figure 3.)
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1893
FIGURE 4
FOR VEHICLES WITH 5.8L ENGINES
1. Remove the distributor vacuum hose to improve accessibility to the water bypass hose.
2. Remove the water bypass hose and clamps (See Figure 4). Discard the clamps.
Don't forget... ATTACHMENT III
call the Special Econline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 4 OF 5
on 1-800-445-1571 if you have any questions!
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
4. Position a new formed bypass hose (Part number E8UZ-8597-A) on the intake manifold bypass
connection.
5. Position two (2) new hose clamps (Item 2) on the new hose toward the intake manifold.
6. Bend and slide the hose on to the water pump bypass hose connection.
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to:) 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose, PRESSURE TEST COOLING SYSTEM
1. Reinstall all of the objects such as the thermactor pump filter/silencer or coolant overflow bottle,
that obstructed access to the heater hoses.
2. Fill the cooling system with a coolant mixture of 50/50 Ford Long Life Coolant E2FZ-19549-AA
(ESE-M97B44-A) or equivalent and water, to 38 mm (1.5 inches) below the cap seal.
3. Install radiator cap (Item 5)
WARNING: DO NOT STAND IN LINE WITH OR NEAR THE RADIATOR FAN WHEN THE
ENGINE IS RUNNING.
4. Start the engine, let it warm until the upper radiator hose is hot, shut off the engine. Allow the
engine to cool, remove the cap and check the coolant level. Fill as required.
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1894
5. Using the Rotunda Cooling System Pressurization Kit 021-00012, pressurize the cooling system
to 20 psi and check for leaks. Be sure to follow the instructions in the kit on the recommmended
method of connecting the tester to the radiator.
6. If any leaks are found, correct as needed.
7. Pressure test the cooling system until no leaks we found.
8. Rechock the coolant level in the radiator to make sure that it is 38 mm (1.5 inches ) below the
cap seal. If it is not, fill as required.
9. Reinstall the radiator cap and add coolant to the overflow bottle as required.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 5 OF 5
on 1-800-445-1571 if you have any questions!
Owner & Operator Letter Information
Attachment IV
September 2, 1988
Dear Owner/Operator:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
Ford Motor Company has determined that a defect which relates to Motor Vehicle Safety evists in
certain 1983-1987 Econoline-based ambulances equipped with 7.5 liter or 5.8 liter 4V H.D. V8
engines. Due to the prolonged periods of extreme engine operating temperatures and cooling
system pressures encountered during EMS severe-duty cycles, heater or engine bypass hoses
may wear-out prematurely and burst. Engine coolant ("antifreeze") from a burst hose may cause a
fire if it sprays onto an overheated engine exhaust manifold, especially if the coolant is
overconcentrated.
Ford Motor Company is now asking that you return your Econoline-based ambulance to your Ford
or Ford Heavy Truck Dealer for corrective action.
COOLING SYSTEM SERVICE
At no cost to you, your dealer will:
- replace certain "rubber" heater hoses installed by Ford Motor Company when the vehicle was
manufactured (ie., up to the auxiliary heater shut-off valves), with new "SILICONE/NOMEX" heater
hose;
- replace engine bypass hoses
- replace the engine coolant (with a proper 50/50 mixture);
- install a new radiator cap;
- pressure test the cooling system.
Most ambulances also have auxiliary heater systems. The ambulance body manufacturer typically
installs these heater systems. While these hoses are not part of this safety recall, we strongly
recommend that you consider replacing all non-silicone/Nomex @ auxiliary heater hoses also. THE
COST OF REPLACING THE AUXILIARY HEATER HOSES WILL BE AT YOUR EXPENSE. IF
LEAKS ARE FOUND IN OTHER COMPONENTS OF THE ENGINE COOLING SYSTEM, WHEN
THE SYSTEM IS PRESSURE TESTED SUCH AS THE RADIATOR OR RADIATOR HOSES, THE
COST OF REPAIRING THOSE COMPONENTS WILL BE AT YOUR EXPENSE.
FOR ALL HEATER SYSTEM HOSE REPLACEMENTS, FORD RECOMMENDS THAT YOU
SPECIFY HOSES MADE ONLY FROM THE "SILICONE/NOMEX" MATERIAL. SILICONE HOSES
ALSO REQUIRE SPECIAL HOSE CLAMPS TO PREVENT CUTTING THE HOSE. USE ONLY
THE HOSE CLAMPS RECOMMENDED BELOW WITH SILICONE HOSES.
When purchasing replacements, the following parts should be specified:
Ford Service Motorcraft Brand
Part Name Part Number Part Number
- SILICONE/NOMEX E8TZ-18472-H KH-15
Heater Hose - 25 foot lengths
- Formed Water Pump Bypass E8UZ-8597-A KMS-1776
Hose (for 5.8L 4V H.D. Engine)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1895
- Hose Clamps D9AZ-8287-C YF-842
It is important also that the proper torque be used when attaching the special hose clamps required
for SILICONE/NOMEX hoses. Your dealer will properly torque clamps when they install the heater
and engine bypass hoses on your ambulance. If you should notice coolant seepage, retorque the
clamps to 2.5 to 3.0 N-m (22-26 in.lbs.).
These parts are available through your Ford, Lincoln-Mercury or Ford Heavy Truck Dealer. They
are also available through any Motorcraft parts distributor.
Ford recommends that you always replace these SILICONE/NOMEX HEATER SYSTEM hoses
every 48,000 miles or 48 months, whichever comes first. Non-silicone hoses should be replaced
every 24,000 miles or 24 months, whichever comes first.
It is important that your ambulance cooling system have the proper anti-freeze coolant and water
mixture for adequate freeze protection. Please read and observe the recommendations on the
attachment, "The Importance of Proper Cooling System Anti-freeze Mixtures".
EXHAUST SYSTEM SERVICE
^ Certain 198-5-1987 Model Ambulances with 7.5 Liter/Dual Thermactor Engines
Ambulances with 7.5 Liter V8 engines and a dual-thermactor emission system will have a new
aluminized stainless steel muffler installed. Mufflers and installation will be free of charge.
Some of these ambulances may have already had new alumunized stainless steel mufflers
installed during the earlier recall. These vehicles will not need new mufflers.
^ Refunds for Certain Later Model Muffler Replacements
As noted above, some of these ambulances with 7.5 liter/dual thermactor engines may have
received the new aluminized stainless steel mufflers during the service for the earlier Safety Recall
87M53. If you paid to have these new aluminized stainless steel mufflers installed, you are entitled
to a refund for the costs of parts and labor. If you are entitled to this refund, please present your
paid receipt to any Ford or Ford Heavy Truck Dealer who will process a refund for you.
This receipt must show the date of repair, the part numbers for the new aluminized stainless steel
muffler and attaching parts as well as the parts and labor costs.
^ Other 7.5 Liter and 5.8 Liter 4V H.D. Engine Equipped Ambulances
Ambulances with 7.5 Liter V8 engines and a single thermactor emission system as well as all
1985-1987 model ambulances with 5.8 Liter 4V H.D. V8 engines will only have the muffler
inspected. Replacement of defective mufflers will be the owner's responsibility.
SCHEDULE SERVICE AT ANY FORD OR FORD HEAVY TRUCK DEALER NOW
Since the cooling system parts, mufflers and instructions are now available, we urge you to
schedule this service as quickly as possible.
NOTE: ANY FORD OR FORD HEAVY TRUCK DEALER CAN DO THE COOLING SYSTEM AND
MUFFLER SERVICE.
Before you return your vehicle for this service, we urge you to review the cooling system
information sent to you in June, 1988. Some cooling system maintenance may be needed now.
COMPUTER FORM
The computer form included with this letter may include a special part code. Your dealer will need
to know this code when you call to make an appointment. The code, located in the box labeled "Kit
Code", half way down the right side of the form, will be a single digit number from 1 through 8.
IMPORTANT NOTE
If your vehicle is not operated solely on propane and has not yet been modified to correct a fuel
system over-pressurization concern, announced in July, 1987 as Safety Recall 87M53, or has only
received the earlier (prior to late-October, 1987) Phase I fuel system modifications, you need to
have these modifications done as promptly as possible. You may want to have all of the required
services performed together.
NOTE: ONLY OUR SPECIALLY TRAINED DEALERS CAN WORK ON THE FUEL SYSTEM AND
SYSTEM MODIFICATIONS.
A listing of our specially trained dealers is enclosed.
THANK YOU FOR YOUR CONTINUED COOPERATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > 88S99 > Sep > 88 > Recall Heater/Engine Bypass Hose Replacement > Page 1896
We are sorry that we must inconvenience you again by asking you to return your Econoline-based
ambulance to your Ford or Ford Heavy Truck dealer. However we do wish to maintain your
confidence in our vehicle. Thank you for your continued cooperation in this matter of mutual
concern. THE IMPORTANCE OF PROPER COOLING SYSTEM ANTI-FREEZE MIXTURE
It is extremely important that the proper anti-freeze mixture be used in your ambulance cooling
system, and that it be maintained at recommended levels.
Ford recommends that a reasonably fresh 50% anti-freeze concentrate and 50% water mixture be
maintained in the cooling system of your ambulances at all times. This mixture provides adequate
freeze protection for most areas (50/50 mixtures provide protection to - 35~F). It also provides
optimum engine cooling and corrosion protection for the system.
Increasing the anti-freeze concentration above 50% will reduce engine cooling and result in hotter
engine operation. If you are in extremely cold area, it is permissible to use a 60% anti-freeze
concentrate and 40% water providing protection to approximately - 60~F, but only during the winter
months. (This is a revised coolant manufacturer recommendation from the information sent to you
in June, 1988, in a Motorcraft booklet "Cooling System Operation and Maintenance", dated April,
1979). The mixture should be returned to 50/50 at the end of your cold season. As the concentrate
percentage gets larger beyond 60% concentrate, the freeze protection is less. A 100% anti-freeze
concentration only protects your cooling system to - 8~F.
Decreasing the anti-freeze concentration below 40% reduces corrosion and freeze protection
(40/60 mixtures provides protection to - 10~F).
Remember:
^ Maintain cooling system mixtures at 50/50. Do not allow the mixture to be above 60/40.
^ Replace your cooling system mixture annually.
^ Replace lost coolant with a 50/50 mixture. Keep a pre-mixed supply of 50/50 mixture to refill the
system.
^ Do not refill your system with pure anti-freeze.
^ Regularly inspect and repair any cooling system leaks.
^ Replace cooling system hoses before they fail. Follow the Ford recommended replacement
intervals.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > Recalls for Thermostat Bypass Hose: > NHTSA88V133000 > Aug > 88 > Recall
88V133000: Cooling System Hose Replacement
Thermostat Bypass Hose: Recalls Recall 88V133000: Cooling System Hose Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement
Technical Service Bulletin # 88S99 Date: 880901
Recall - Heater/Engine Bypass Hose Replacement
At Dealers By Order as Req'd -0- % of Parts Direct Shipped to Dealers
At PDC By Now Temporary Maximum
Date in Owner Letter 9/2/88 Order Quantity of 2 Kits
RECALL NUMBER
88S99
Date: Sept., 1988
PLEASE GIVE COPIES OF THIS BULLETIN TO YOUR PARTS AND SERVICE MANAGERS
TO: All Ford and Heavy Truck Dealers
SUBJECT: Safety Recall 88S99 - Heater and Engine Bypass Hose Replacement and Muffler
Inspections/Replacement on Certain 1983 through 1987-model 5.8L-4V H.D. and 7.5L Engine
Equipped Ford Econoline-Based Ambulances
IN CARES/OASIS - YES
REFUND CLAIMING - USE FORM 1863
MODIFICATION CLAIMING - USE FORM 1864
VEHICLES AFFECTED:
Ford Motor Company is initiating a safety recall of certain 1983 through 1987-model Econoline
E250/E350- based ambulances equipped with 7.5 Liter engines as well as certain 1985 through
1987-model Econoline E250/E350-based ambulances equipped with 5.8L 4V H.D. engines. All
involved vehicles are rated over 8,500 lbs. GW.
REASONS FOR THIS RECALL:
Investigations of recent fires involving Econolinebased ambulances have disclosed a potential for
engine compartment heater or engine bypass hoses to wear-out prematurely and rupture, allowing
engine coolant to come in contact with hot engine exhaust manifolds and possibly ignite. Testing
has indicated that worn-out hoses are not able to withstand the prolonged periods of extreme
engine operating temperatures and higher engine cooling system pressures encountered during
EMS severe-duty cycles.
ACTION BY FORD: All ambulances returned for the service provided by this Safety Recall will be
modified as follows;
^ Replacement of existing engine compartment heater and bypass hoses with silicone/NOMEX
hoses.
^ Replacement of the radiator cap.
^ Replacement of the engine coolant with a 50/50 mix of water and antifreeze. This mixture of
coolant will provide freeze protection for most areas. Extreme cold-weather areas should be
provided with a 60/40 mixture of coolant and water.
^ Pressure test the cooling system.
^ Inspection and, if necessary, installation of aluminized stainless steel mufflers on 1985-87-model
7.5L dual-thermactor engine equipped vehicles.
^ High heat resistance aluminized stainless steel mufflers will be installed on those ambulances
equipped with 1985-1987 7.5L, dual thermactor air pump-equipped engines that did not have those
mufflers installed in connection with safety recall 87M53. A temporary shortage of aluminized
stainless steel mufflers last year required the use of substitute mufflers on ambulances that were
found in need of muffler replacement at that time.
^ Underbody inspection for loose, mispositioned or missing heat-shielding parts. Contact the
Special Toll-Free Econoline/Ambulance Hotline for authorization to perform modifications as a
result of this inspection.
This service will be performed at no cost. Owner/ operators win be provided with information about
replacement recommendations for engine coolant and heater and engine bypass hoses.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1906
REFUNDS: Owner/operators of 1985-87-model 7.5L dual-thermactor engine equipped vehicles will
be provided refunds for Ford-sourced aluminized stainless steel mufflers which may have been
installed at their expense under Safety Recall 87M53. DEALERS ARE INSTRUCTED TO
PROVIDE REFUNDS TO OWNERS WHO ADEQUATELY PROVE SUCH A PURCHASE AND TO
CLAIM FOR REFUNDS USING FORM 1863.
DEALER RESPONSIBILITIES:
Owners will be told that they may wish to inform the National Highway Traffic Safety Administration
if the recall is not performed without charge or within a reasonable time after the vehicle is brought
to their dealership for repair.
REPAIR CODES: REFER TO ATTACHMENT II, EXHIBIT 1 - THE "REPAIR CODES" SHOWN ON
THE REFERENCED ATTACHMENT HAVE BEEN DEVELOPED TO ASSIST YOU IN SELECTING
THE CORRECT EXHAUST SYSTEM MUFFLERS FOR SPECIFIC VEHICLES. THESE "REPAIR
CODES" WILL BE PRINTED ON THE OWNER LETTER AND THE CLAIM FORM 1864. USE THE
CODES TO DETERMINE REQUIRED MUFFLERS AND WHEN PREPARING CLAIM FORMS
AND SERVICE DOCUMENTS.
CARES/OASIS: Dealers are to check the CARES and OASIS programs todetermine if an affected
vehicle is involved in other recalls.
CLAIM FORMS: USE CLAIM FORM 1864 FOR THE MODIFICATIONS REQUIRED FOR THIS
RECALL. USE CLAIM FORM 1863 FOR REFUNDS TO OWNERS WHO PREVIOUSLY PAID FOR
INSTALLATION Of FORD-SOURCED ALUMINIZEDSTAINLESS STEEL MUFFLERS. Refer to
Attachment I for preparation instructions.
PARTS Refer to Attachment II.
REQUIREMENTS:
LABOR ALLOWANCE: Refer to Attachment II.
TECHNICAL INSTRUCTIONS:
Refer to Attachment III.
OWNER NOTIFICATION:
Owner/operators will be notified with the letter shown on Attachment IV.
FPSD ASSISTANCE: Contact your FPSD District Service Engineer with any problems you have
concerning this recall. Additionally, a special toll-free Econoline/Ambulance Technical Hotline is
available to assist in resolving unusual repair issues technicians may encounter.
Personnel are available daily from 7:30 A.M. to 6:00 P.M., Eastern Time to provide technical
assistance by calling 1-800-445-1571.
Administrative Instructions
SAFETY RECALL 88S99 ADMINISTRATIVE INSTRUCTIONS Attachment I VEHICLES
AFFECTED:
Certain 1983 through 1987-model Econoline E250/E350- based ambulances equipped with 7.5
Liter engines as well as certain 1985 through 1987-model Econoline E250/E330- based
ambulances equipped with 5.8 Liter 4V H.D. Engines. All affected vehicles are rated over 8,500 lbs.
GVW.
REPORTING COMPLETIONS: Only the Form 1864 will be accepted for reimbursement for
modifications performed under this recall. Upon completion of the required service, the Form 1864
must be completely filled out and signed by authorized dealer personnel. CLAIM SUBMISSION:
The claims must be entered through the Direct Warranty Entry (DWE) system. Dealers without
DWE capability must mail the second copy of the Form 1864 for reimbursement. Should your
dealership receive pre-printed Forms 1864 with a seven digit claim number, you must drop the first
digit and enter only the last six digits. You must sight verify the claim number for accuracy. It is
important that all claims be filed for all completed units so you will be reimbursed and our records
will show completion.
REFUNDS: Refund requests submitted under Safety Recall 88S99 are governed by the following
guidelines:
^ Owner/operators of 1985-87 model ambulances with 7.5L dual thermactor engines are eligible for
a refund if they paid for a muffler replacement under Safety Recall 87M53 and the replacement
muffler was the new ribbed design, aluminized stainless steel muffler (See Attachment II, Exhibit 2
for eligible muffler part numbers). Paid repair orders or invoices presented by the owner/operator
requesting a refund must show one of the eligible muffler part numbers.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1907
^ Refunds include return of any deductible amount owners may have paid.
^ A copy of the paid repair orders or parts purchase receipts must be retained in your service file
for at least one year following the date of Company notification of payment.
^ Owner refund requests must be submitted on separate Warranty Claim Form 1863. In addition to
the information shown for the special preparation of Owner Refund
claims (Reference: Warranty and Policy Manual - Subject 6.1, Page 18), please enter the
information shown below:
Causal Basic Part Number - 88S99
Condition Code - OB
Labor Operation - REFUND
Administrative Allowance - 0.2 Hr.
Program Code - 88S99
^ An administrative allowance of 0.2 hours will be allowed for processing each eligible owner
refund request. To claim the allowance, enter ALLOW in the Labor Operation No. column and 0.2
in the Scheduled Time column. Extend the 0.2 hours at your authorized warranty labor rate and
enter the result in the Amount column.
^ Please provide prompt refund to all eligible owners who respond to this recall with proper repair
documentation.
Labor and Parts Ordering Instructions
SAFETY RECALL 88S99 LABOR AND PARTS ORDERING INSTRUCTIONS
Attachment II
PARTS ORDERING: Service parts required for this recall may be ordered through normal
channels. Refer to the following material and Attachment II, Exhibits 1 and 2.
Coolant Ordering
^ Since most areas will require a 50/50 mixture of antifreeze and water, order and claim for the
amount of coolant required to service each ambulance using the following information:
- In extreme cold weather areas use a 60/40 mixture, order and claim appropriately.
- Order enough coolant (Ford Part Number E2FZ-19549-AA, or equivalent) to fill the entire engine
cooling system. In most cases, 3 gallons of antifreeze and 3 gallons of water should be adequate to
attain a 50/50 mix
Service Part Number
Description Class Dealer Price
E2FZ-19549-AA Coolant, Engine V $8.65/Gallon a/
E3UZ-18472-C Kit, Heater Hose BG $64.65
E8UZ-8597-A Hose, Engine Bypass (5.8L Engs.
CG $2.25
Only)
a/ Based on $51.90, Carton 6 Gallons, order this part number or use locally purchased equivalent.
Use dealer aquisition cost for locally purchased equivalent.
Scheduled Time
LABOR OPERATIONS: Basic Labor Operation (Hours)
Inspection of the Ambulance Underbody and Exhaust System, Installation of Heater and Engine
Bypass Hose Improvement
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1908
Modifications. . . . . . . . . . . . . 2.1 Insert in Box "B" of Form 1864
LABOR OPERATIONS: (Cont'd.)
Scheduled Time
Basic Labor Operation (Hours)
Supplemental Labor Operations (Additive to Above)
Replacement of the Exhaust System Muffler, and Attaching Parts (7.5L Dual-Thermactor Engine
Equipped Vehicles . . . . . . . .
0.8 Insert in Box "B" of Form 1864
Note: Use this supplemental time when replacing mufflers on 7.5L Dual-Thermactor Engine
equipped vehicles. This time may also be used when replacing mufflers performed at owners'
expense.)
Additional Time to Access Engine Bypass Hoses on 7.5L Engine Equipped Vehicles . . . . . . . . . . . .
.
0.4 Insert in Box "B" of Form 1864
Administrative Allowance (Additive to Above)
Administrative Allowance . . . . . 0.1 Hr.
The Supplemental Labor Operations and the 0.1 hour administrative allowance must be added
before inserting the total labor time in Box "B" of the Form 1864.
Repair Code Description
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1909
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1910
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Technical Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTIONS
Attachment III
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1911
TECHNICAL INSTRUCTIONS:
Inspections:
^ Underbody - All Vehicles
1. Inspect the underbody and exhaust system for missing, loose or mispositioned heat-shielding
parts (Refer to Safety Recall 87M53 instructions).
If you discover any conditions as a result of this inspection that requires modification, please
contact the Special Toll-Free Econoline/Ambulance Hotline, 1-800-445-1571, for authorization.
Contact your District Office if the Hotline is not available.
^ Mufflers - All Vehicles
2. Refer to Attachment III, Exhibit 1. Remove the exhaust system muffler heat shields.
3. Inspect the muffler per the instructions contained in Attachment III, Exhibit 1.
^ Replace unacceptable mufflers and attaching parts at the OWNERS EXPENSE ON:
i) 1983 through 1987-model 7.5L single-thermactor engine equipped vehicles; ii) 1985 through
1987-model, 5.8L 4V H.D. engine equipped vehicles.
^ Replace any mufflers that are not Ford-sourced aluminized stainless steel and attaching parts at
FORD EXPENSE on 1985 through 1987-model, 7.5L dual thermactor engine equipped vehicles.
^ Heater and Bypass Hose Replacement:
4. Refer to Attachment III, Exhibit 2. Replace the engine compartment heater and engine bypass
hoses as shown on the referenced attachment. Note: The 5.8L 4V H.D. engines require a formed
bypass hose. This is not in the heater hose/bypass parts kit. Order this hose separately.
5. Pressure test the cooling system and replace existing radiator cap.
NOTE: Owners will be instructed to retorque hose clamps to 2.5-3.0 N-m (22-26 in.lbs.) when
coolant leakage is observed.
MODIFICATION DECAL: Prepare an "Authorized Modifications" decal (Form FPS-8262) as shown
below. Affix the decal to a flat clean surface on
the radiator support. (Order the "Authorized Modifications" decal on your Weekly Stock Order Pad.)
Specific Technical Repair Code and Parts Ordering Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
Exhaust System-Ford Components-Correct Routing and Retention
1983-1985 7.5L MODELS (MODELS WITH SINGLE AIR PUMP) 1985-1/2-1987 5.8L MODELS
(OVER 8500 GVW WITH 4 BARREL CARBURETOR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1912
FIGURE 1
The Ford exhaust system as shown in Figure 1, provides the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheatng.
FIGURE 3
Inspect the exhaust system for leaks or ruptures. FOR 5.8L ONLY, it may be necessary to remove
the heat shields as shown in Figure 3. Inspect the muffler outer wrapper lock seam for separation.
If any such problems are found, notify the customer and request permission to repair the problem,
at the customer's expense. Note any such problems and the customer's reaction to your repair
request on your internal repair order form and retain in your records.
If a non-Ford exhaust system or exhaust components is noted on the unit, inform the customer of
the potential for durability reduction, exhaust flow restriction, or overheating as indicated above.
Note any such discrepancy and the customer's reaction on your internal repair order form and
retain in your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1913
FIGURE 1
ALL 5.8L AND ONLY CALIFORNIA CALIBRATION 7.5L: If the unit is not equiped with the all-steel
hangers shown in Figure 1, order and install the Ford Service Part as indicated in the attached
chart. SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
FIGURE 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1914
1985-1/2 - 1987 7.5L MODELS (MODELS WITH DUAL AIR PUMPS - SEE FIGURE 5)
FIGURE 2
The Ford exhaust system as shown in Figure 2, provdes the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheating.
FIGURE 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1915
FIGURE 4
Remove the heat shields covering the muffler by removing the retaining clamps securing the
shields as shown in Figure 3. If the muffler is a non-Ford design or is a non-ribbed design (Figure
4), remove the Muffler and Outlet Pipe Assembly and replace with the heavy duty ribbed muffler
assembly as indicated in the attached chart.
If the muffler is the heavy duty type (ribbed design - Figure 4), installed during the 1987 M53 recall,
inspect the entire surface of the muffler for cracks or openings. If any such openings are found,
replace the Muffler and Outet Pips Assembly with a new heavy duty ribbed muffler assembly.
Advise the Ambulance Technical Hot Line 1-800-445-1571, if you find a ribbed muffler with cracks
or openings.
FIGURE 2
If the unit is not equipped with the all-steel hangers as shown in Figure 2, order and install the Ford
Service Part as indicated in the attached chart. ATTACHMENT III EXHIBIT 1 PAGE 3 OF 3
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1916
KIT NUMBER E3UZ-18472-C HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED
AMBULANCES WITH 7.5L OR 5.8L 4V H.D. ENGINES SPECIAL NOTE: The following instructions
describe the installation procedure for the heater hose/bypass hose improvement package. It is
designed specially for Ford E-350 and E-250 (over 8500 pounds GVWR) based ambulances. The
original Ford heater hose system has probably been modified by the ambulance body builder. It is
not possible to identify all the designs and modifications used by these manufacturers. If you
encounter difficulties not anticipated in these instructions, contact the Ford Ambulance Recall
Hotline on 1-800-445-1571. PARTS LIST
Item Description Part Number Quantity
1 Silicons Hose - 5/8" I.D. *EST-M2D309-A 96"
2 Hose Clamp 388652-S2 20
3 "Y" Fitting D8UH-18663-AA 2
4 Tie Strap - 1/4" Wide 384213-S 10
5 Radiator Cap E5TH-8100-AA 1
*Engineering Specification Number
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1917
FIGURE 1
HEATER HOSE REMOVAL
1. Close the shutoff valves that connect the rear heater unit to the Ford installed heater hoses (See
Figure 1). Be sure to close both the supply and return hose valves. Failure to close these valves
could cause coolant fill problems later.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1918
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT.
2. Drain the coolant from the radiator by removing the radiator cap and carefully opening the drain
cock at the bottom of the radiator. After the coolant has drained from the radiator, close the drain
cock and discard the radiator cap.
3. Disconnect and remove any objects, such as thermactor pump filter/silencer or coolant overflow
bottle, obstructing access to the heater hoses.
4. Inspect the hoses for chaffing or cuts (See Figure 1). Note the position of any straps or clamps
for securing the new hoses at time of installation.
5. Disconnect the vacuum line from the water supply valve.
6. Disconnect the inlet and outlet hoses from the heater core, engine block, and rear heater shutoff
valves (See Figure 1). Loosen each clamp and cut the hose first to prevent core damage. DO NOT
twist hoses in the removal process. Disconnect the hoses from any locating clips. Discard all hose
clamps.
NOTE: DO NOT disconnect the hoses routed from the shutoff valves to the rear heater unit.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1919
FIGURE 1
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1920
FIGURE 2
HEATER HOSE INSTALLATION
1. Using hoses (Item 1), hose clamps (Item 2) and "Y" fittings (Item 3), assemble duplicate hose
layouts of the removed hose assemblies (Figure 1).
NOTE: The hoses leading from the "Y" fittings may have to be slightly longer than the original
hoses to avoid any kinks or bends. This is due to the replacement fittings having a different angle in
the "Y" than the original "Y" or "T" fittings. Silicone hoses require the special clamps Included in the
kit to prevent cutting the hose. DO NOT use any other type of clamp.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 1 OF 5
on 1-800-445-1571 if you have any questions.
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
2. Remove the vacuum operated water supply valve from the old hose assembly and install it into
the new hose assembly.
NOTE: Make sure that the flow arrow stamped on the valve is pointing toward the heater core.
3. Torque the clamps (Item 2) to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
4. Connect the hose assemblies with clamps (Item 2) to the engine block, heater core and rear shut
off valves.
5. Torque the clamps to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
6. Connect the vacuum line to the water supply valve.
7. Using tie straps (Item 4), secure the hoses to an adjacent engine component to prevent chaffing
or cutting during engine operation. The hoses may be secured in a manner similar to the original
method if the removed hoses were not damaged as noted earlier. If the original hoses were
damaged, route the hoses and secure them in a manner to prevent hose damage during engine
operation.
WATER BYPASS HOSE REMOVAL AND INSTALLATION FOR VEHICLES WITH 7.5L ENGINES
1. Remove the distributer vacuum hose to improve accessibility to the water bypass hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1921
FIGURE 2
2. Remove the water bypass hose and clamps (See Figure 2). Discard the clamps.
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
CAUTION: DO NOT ALTER (CUT OFF) THE INTAKE MANIFOLD AND/OR THE WATER PUMP
HOSE CONNECTIONS. ANY
DAMAGE SUCH AS SHARP EDGES, TO THESE CONNECTIONS WILL RESULT IN DAMAGE
TO THE NEW BYPASS HOSE DURING INSTALLATION.
4. Using the removed hose as a pattern, cut a piece of silicone hose (Item 1) to the proper length
and position it on the intake manifold bypass connection.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 3 OF 5
on 1-800-445-1571 if you have any questions
FIGURE 3
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D ENGINES
5. Position two (2) new hose clamps (Item 2) on the new hose, installed in Step 4, toward the
intake manifold. (See Figure 3.)
6. Bend (double over) the new bypass hose downward and slide the hose on to the water pump
bypass hose connection. (See Figure 3.)
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1922
FIGURE 4
FOR VEHICLES WITH 5.8L ENGINES
1. Remove the distributor vacuum hose to improve accessibility to the water bypass hose.
2. Remove the water bypass hose and clamps (See Figure 4). Discard the clamps.
Don't forget... ATTACHMENT III
call the Special Econline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 4 OF 5
on 1-800-445-1571 if you have any questions!
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
4. Position a new formed bypass hose (Part number E8UZ-8597-A) on the intake manifold bypass
connection.
5. Position two (2) new hose clamps (Item 2) on the new hose toward the intake manifold.
6. Bend and slide the hose on to the water pump bypass hose connection.
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to:) 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose, PRESSURE TEST COOLING SYSTEM
1. Reinstall all of the objects such as the thermactor pump filter/silencer or coolant overflow bottle,
that obstructed access to the heater hoses.
2. Fill the cooling system with a coolant mixture of 50/50 Ford Long Life Coolant E2FZ-19549-AA
(ESE-M97B44-A) or equivalent and water, to 38 mm (1.5 inches) below the cap seal.
3. Install radiator cap (Item 5)
WARNING: DO NOT STAND IN LINE WITH OR NEAR THE RADIATOR FAN WHEN THE
ENGINE IS RUNNING.
4. Start the engine, let it warm until the upper radiator hose is hot, shut off the engine. Allow the
engine to cool, remove the cap and check the coolant level. Fill as required.
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1923
5. Using the Rotunda Cooling System Pressurization Kit 021-00012, pressurize the cooling system
to 20 psi and check for leaks. Be sure to follow the instructions in the kit on the recommmended
method of connecting the tester to the radiator.
6. If any leaks are found, correct as needed.
7. Pressure test the cooling system until no leaks we found.
8. Rechock the coolant level in the radiator to make sure that it is 38 mm (1.5 inches ) below the
cap seal. If it is not, fill as required.
9. Reinstall the radiator cap and add coolant to the overflow bottle as required.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 5 OF 5
on 1-800-445-1571 if you have any questions!
Owner & Operator Letter Information
Attachment IV
September 2, 1988
Dear Owner/Operator:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
Ford Motor Company has determined that a defect which relates to Motor Vehicle Safety evists in
certain 1983-1987 Econoline-based ambulances equipped with 7.5 liter or 5.8 liter 4V H.D. V8
engines. Due to the prolonged periods of extreme engine operating temperatures and cooling
system pressures encountered during EMS severe-duty cycles, heater or engine bypass hoses
may wear-out prematurely and burst. Engine coolant ("antifreeze") from a burst hose may cause a
fire if it sprays onto an overheated engine exhaust manifold, especially if the coolant is
overconcentrated.
Ford Motor Company is now asking that you return your Econoline-based ambulance to your Ford
or Ford Heavy Truck Dealer for corrective action.
COOLING SYSTEM SERVICE
At no cost to you, your dealer will:
- replace certain "rubber" heater hoses installed by Ford Motor Company when the vehicle was
manufactured (ie., up to the auxiliary heater shut-off valves), with new "SILICONE/NOMEX" heater
hose;
- replace engine bypass hoses
- replace the engine coolant (with a proper 50/50 mixture);
- install a new radiator cap;
- pressure test the cooling system.
Most ambulances also have auxiliary heater systems. The ambulance body manufacturer typically
installs these heater systems. While these hoses are not part of this safety recall, we strongly
recommend that you consider replacing all non-silicone/Nomex @ auxiliary heater hoses also. THE
COST OF REPLACING THE AUXILIARY HEATER HOSES WILL BE AT YOUR EXPENSE. IF
LEAKS ARE FOUND IN OTHER COMPONENTS OF THE ENGINE COOLING SYSTEM, WHEN
THE SYSTEM IS PRESSURE TESTED SUCH AS THE RADIATOR OR RADIATOR HOSES, THE
COST OF REPAIRING THOSE COMPONENTS WILL BE AT YOUR EXPENSE.
FOR ALL HEATER SYSTEM HOSE REPLACEMENTS, FORD RECOMMENDS THAT YOU
SPECIFY HOSES MADE ONLY FROM THE "SILICONE/NOMEX" MATERIAL. SILICONE HOSES
ALSO REQUIRE SPECIAL HOSE CLAMPS TO PREVENT CUTTING THE HOSE. USE ONLY
THE HOSE CLAMPS RECOMMENDED BELOW WITH SILICONE HOSES.
When purchasing replacements, the following parts should be specified:
Ford Service Motorcraft Brand
Part Name Part Number Part Number
- SILICONE/NOMEX E8TZ-18472-H KH-15
Heater Hose - 25 foot lengths
- Formed Water Pump Bypass E8UZ-8597-A KMS-1776
Hose (for 5.8L 4V H.D. Engine)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1924
- Hose Clamps D9AZ-8287-C YF-842
It is important also that the proper torque be used when attaching the special hose clamps required
for SILICONE/NOMEX hoses. Your dealer will properly torque clamps when they install the heater
and engine bypass hoses on your ambulance. If you should notice coolant seepage, retorque the
clamps to 2.5 to 3.0 N-m (22-26 in.lbs.).
These parts are available through your Ford, Lincoln-Mercury or Ford Heavy Truck Dealer. They
are also available through any Motorcraft parts distributor.
Ford recommends that you always replace these SILICONE/NOMEX HEATER SYSTEM hoses
every 48,000 miles or 48 months, whichever comes first. Non-silicone hoses should be replaced
every 24,000 miles or 24 months, whichever comes first.
It is important that your ambulance cooling system have the proper anti-freeze coolant and water
mixture for adequate freeze protection. Please read and observe the recommendations on the
attachment, "The Importance of Proper Cooling System Anti-freeze Mixtures".
EXHAUST SYSTEM SERVICE
^ Certain 198-5-1987 Model Ambulances with 7.5 Liter/Dual Thermactor Engines
Ambulances with 7.5 Liter V8 engines and a dual-thermactor emission system will have a new
aluminized stainless steel muffler installed. Mufflers and installation will be free of charge.
Some of these ambulances may have already had new alumunized stainless steel mufflers
installed during the earlier recall. These vehicles will not need new mufflers.
^ Refunds for Certain Later Model Muffler Replacements
As noted above, some of these ambulances with 7.5 liter/dual thermactor engines may have
received the new aluminized stainless steel mufflers during the service for the earlier Safety Recall
87M53. If you paid to have these new aluminized stainless steel mufflers installed, you are entitled
to a refund for the costs of parts and labor. If you are entitled to this refund, please present your
paid receipt to any Ford or Ford Heavy Truck Dealer who will process a refund for you.
This receipt must show the date of repair, the part numbers for the new aluminized stainless steel
muffler and attaching parts as well as the parts and labor costs.
^ Other 7.5 Liter and 5.8 Liter 4V H.D. Engine Equipped Ambulances
Ambulances with 7.5 Liter V8 engines and a single thermactor emission system as well as all
1985-1987 model ambulances with 5.8 Liter 4V H.D. V8 engines will only have the muffler
inspected. Replacement of defective mufflers will be the owner's responsibility.
SCHEDULE SERVICE AT ANY FORD OR FORD HEAVY TRUCK DEALER NOW
Since the cooling system parts, mufflers and instructions are now available, we urge you to
schedule this service as quickly as possible.
NOTE: ANY FORD OR FORD HEAVY TRUCK DEALER CAN DO THE COOLING SYSTEM AND
MUFFLER SERVICE.
Before you return your vehicle for this service, we urge you to review the cooling system
information sent to you in June, 1988. Some cooling system maintenance may be needed now.
COMPUTER FORM
The computer form included with this letter may include a special part code. Your dealer will need
to know this code when you call to make an appointment. The code, located in the box labeled "Kit
Code", half way down the right side of the form, will be a single digit number from 1 through 8.
IMPORTANT NOTE
If your vehicle is not operated solely on propane and has not yet been modified to correct a fuel
system over-pressurization concern, announced in July, 1987 as Safety Recall 87M53, or has only
received the earlier (prior to late-October, 1987) Phase I fuel system modifications, you need to
have these modifications done as promptly as possible. You may want to have all of the required
services performed together.
NOTE: ONLY OUR SPECIALLY TRAINED DEALERS CAN WORK ON THE FUEL SYSTEM AND
SYSTEM MODIFICATIONS.
A listing of our specially trained dealers is enclosed.
THANK YOU FOR YOUR CONTINUED COOPERATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 1925
We are sorry that we must inconvenience you again by asking you to return your Econoline-based
ambulance to your Ford or Ford Heavy Truck dealer. However we do wish to maintain your
confidence in our vehicle. Thank you for your continued cooperation in this matter of mutual
concern. THE IMPORTANCE OF PROPER COOLING SYSTEM ANTI-FREEZE MIXTURE
It is extremely important that the proper anti-freeze mixture be used in your ambulance cooling
system, and that it be maintained at recommended levels.
Ford recommends that a reasonably fresh 50% anti-freeze concentrate and 50% water mixture be
maintained in the cooling system of your ambulances at all times. This mixture provides adequate
freeze protection for most areas (50/50 mixtures provide protection to - 35~F). It also provides
optimum engine cooling and corrosion protection for the system.
Increasing the anti-freeze concentration above 50% will reduce engine cooling and result in hotter
engine operation. If you are in extremely cold area, it is permissible to use a 60% anti-freeze
concentrate and 40% water providing protection to approximately - 60~F, but only during the winter
months. (This is a revised coolant manufacturer recommendation from the information sent to you
in June, 1988, in a Motorcraft booklet "Cooling System Operation and Maintenance", dated April,
1979). The mixture should be returned to 50/50 at the end of your cold season. As the concentrate
percentage gets larger beyond 60% concentrate, the freeze protection is less. A 100% anti-freeze
concentration only protects your cooling system to - 8~F.
Decreasing the anti-freeze concentration below 40% reduces corrosion and freeze protection
(40/60 mixtures provides protection to - 10~F).
Remember:
^ Maintain cooling system mixtures at 50/50. Do not allow the mixture to be above 60/40.
^ Replace your cooling system mixture annually.
^ Replace lost coolant with a 50/50 mixture. Keep a pre-mixed supply of 50/50 mixture to refill the
system.
^ Do not refill your system with pure anti-freeze.
^ Regularly inspect and repair any cooling system leaks.
^ Replace cooling system hoses before they fail. Follow the Ford recommended replacement
intervals.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Thermostat Bypass Hose: >
NHTSA88V133000 > Aug > 88 > Recall 88V133000: Cooling System Hose Replacement
Thermostat Bypass Hose: All Technical Service Bulletins Recall 88V133000: Cooling System Hose
Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Recycled Engine Coolant - Service Tips
Coolant: Technical Service Bulletins Recycled Engine Coolant - Service Tips
Article No. 95-18-2
09/11/95
^ COOLANT - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP
^ COOLING SYSTEM - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP
FORD: 1980 and after CROWN VICTORIA, MUSTANG, THUNDERBIRD 1981 and after ESCORT
1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE
1994 and after ASPIRE 1995 and after CONTOUR
LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN
CAR 1981-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE
1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 and
after MYSTIQUE
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after
BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and
after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after
WINDSTAR
This TSB is being republished in its entirety to include warranty information when using recycled
coolant
ISSUE: Ford Motor Company authorizes the use of recycled engine coolant that, when properly
processed and reinhibited, meets Ford specification ESE-M97B44-A. At this time, the Rotunda
Coolant Recycler (181-00003) process is the only approved coolant recycling method available
through Ford that is capable of producing recycled engine coolant that meets Ford specification
ESE-M97B44-A.
ACTION: Refer to the following Service Procedure for coolant processing and reinhibiting using
Rotunda Coolant Recycler (181-00003).
NOTE:
WHILE TESTING SHOWS THAT RECYCLED ENGINE COOLANT CAN PROVIDE ACCEPTABLE
PERFORMANCE, THE COOLANT PRODUCED FROM ROTUNDA EQUIPMENT IS INTENDED
FOR USE WITHIN DEALERSHIPS ON WARRANTY AND CUSTOMER PAY REPAIRS ONLY
AND NOT INTENDED FOR RETAIL SALE. THERE ARE REGULATORY, PACKAGING AND
LABELING CONCERNS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1934
ASSOCIATED WITH THE RETAIL SALE OF CHEMICAL PRODUCTS.
CAUTION:
THE REINHIBITOR CHEMICALS PROVIDED WITH THIS EQUIPMENT ARE NOT
APPROPRIATE FOR USE ON MEDIUM/HEAVY TRUCK APPLICATIONS.
WARNING:
ROTUNDA PREMIUM COOLANT REINHIBITORS # 1 AND # 2 HAVE BEEN SPECIFICALLY
FORMULATED TO WORK WITH ROTUNDA COOLANT RECYCLER (181-00003).
USE OF ANY OTHER CHEMICAL ADDITIVES WITH THIS SYSTEM WILL VOID ALL
WARRANTIES FOR THE EQUIPMENT AND FOR THE FINAL COOLANT PRODUCT.
SERVICE PROCEDURE
DIRECTIONS FOR PROCESSING USED ENGINE COOLANT WITH ROTUNDA COOLANT
RECYCLER
1. Close the drain valve on the unit.
2. Open the fill valve.
3. Pour used engine coolant into the funnel on the side of the unit.
NOTE:
MAXIMUM CAPACITY 15 25 GALLONS (95 L).
4. Insert the outlet hoses of the recycler into clean, properly labeled containers. One (1) container
is for the outlet process water and the other container is for distilled ethylene glycol.
5. Push the "ON" switch on the front to start the operation. The unit will process 1 gallon (3.8 L) per
hour of operation and will automatically shut off when cycle is complete.
6. Add reinhibitor following the directions in this article.
7. Open the drain valve to drain the residue from the distillation vessel. Dispose of residue in
accordance with all local. state and federal regulations.
ADDING REINHIBITOR CHEMICALS
1. Process the coolant according to the directions listed in this article
2. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 1 to each gallon of distilled ethylene glycol.
3. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 2 to each gallon of distilled ethylene glycol.
4. Mix well.
5. Check the pH level of the coolant. The pH level must be between 9 and 11.
6. Add enough water to the concentrated coolant to produce a 50/50 mixture of coolant and water.
NOTE:
THE CONCENTRATED COOLANT MUST BE MIXED WITH WATER TO MEET THE
NECESSARY ENGINE FREEZE PROTECTION.
7. Check the coolant freeze point of the 50% coolant solution. Freeze point should be -34°F
(-37°C).
Consult the Rotunda Coolant Recycler Manual for more detailed operating instructions. Call
1-800-ROTUNDA, 8 AM to 8 PM EST, for inquiries regarding the Rotunda Coolant Recycler and to
order the Reinhibitor (187-R0001).
PART NUMBER PART NAME
Rotunda # 187-R0001 Rotunda Premium Coolant Reinhibitor
WARRANTY CLAIMS: Dealer can claim recycled engine coolant by Ford approved process via a
warranty repair on an 1863 claim as follows:
Part Number: RECCOOL (not a valid part number, but it is recognized on an 1863 claim).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1935
Quantity: Indicate the number of QUARTS of recycled coolant used.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-16-6 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 402000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Recycled Engine Coolant - Service Tips > Page 1936
Coolant: Technical Service Bulletins Engine Coolant - Recycled Coolant Not Authorized
Article No. 90-4-10
COOLING SYSTEM - USE OF RECYCLED ENGINE COOLANT - SERVICE TIP
FORD: 1984-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90
TAURUS 1988-90 FESTIVA 1989-90 PROBE
LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX
1984-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90
SABLE 1987-90 TRACER
MERKUR: 1985-90 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1984-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1986-90 AEROSTAR
MEDIUM/HEAVY TRUCK: 1984-90 C SERIES, F & B SERIES, L SERIES 1986-90 CARGO
SERIES
ISSUE: Ford Motor Company does not authorize the use of recycled engine coolant nor do they
sanction the use of any machines or devices that recycle engine coolant.
Recycled engine coolant is not equivalent to the factory fill OEM coolant, the Ford premium cooling
system fluid (E2FZ-19549-AA) or the Ford heavy duty low silicate cooling fluid (E6HZ-19549-A).
The quality of engine coolant degenerates with use. Recycling used engine coolant is very difficult
to do without exposing the used coolant to additional foreign substances. Merely adding an additive
to the coolant will not restore it.
ACTION: Use new engine coolant that meets Ford Motor coolant specifications for the engine
being serviced.
Properly dispose of the used coolant.
WARNING: THE DISPOSAL OF ALL USED ENGINE COOLANT MUST ALWAYS BE DONE IN
ACCORDANCE WITH ALL APPLICABLE FEDERAL, STATE AND LOCAL LAWS AND
REGULATIONS.
PART NUMBER PART NAME CLASS
E2FZ-19549-AA Coolant System Fluid - Ford V
Premium
E6HZ-19549-A Coolant System Fluid - Ford V
Heavy Duty Low Silicate (For use in diesel powered med/hvy trucks)
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
4300
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Coolant Capacity 28 qts
..............................................................................................................................................................
..........................................
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications > Page 1939
Coolant: Fluid Type Specifications
COOLING SYSTEM FLUID, PREMIUM
Ford Part No.
U.S.A (Except Oregon)
............................................................................................................................................................
E2FZ-19549-AA or -B Canada ............................................................................................................
.............................................................................................. CXC-8-B Oregon ..................................
.............................................................................................................................................................
F5FZ-19549-CC
Ford Specification ................................................................................................................................
................................................... ESE-M97B44-A
COOLING SYSTEM FLUSH
Ford Part No. .......................................................................................................................................
................................................... F1AZ-19A503-A Ford Specification .................................................
..................................................................................................................................... ESR-M14P7-A
Coolant Mixture with Water .................................................................................................................
...................................................................... 50%
Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the
correct coolant type.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Indicator Lamp > Component
Information > Description and Operation
Coolant Level Indicator Lamp: Description and Operation
This lamp will be illuminated when engine coolant level in the radiator drops below a
pre-determined level. To turn lamp off, check cooling system, then add coolant to bring system to
proper level.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information >
Technical Service Bulletins > Recalls for Coolant Line/Hose: > NHTSA88V133000 > Aug > 88 > Recall 88V133000: Cooling
System Hose Replacement
Coolant Line/Hose: Recalls Recall 88V133000: Cooling System Hose Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > NHTSA88V133000 > Aug > 88 >
Recall 88V133000: Cooling System Hose Replacement
Coolant Line/Hose: All Technical Service Bulletins Recall 88V133000: Cooling System Hose
Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Motor > Component Information > Diagrams > Diagram Information and Instructions
Radiator Cooling Fan Motor: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1961
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 1962
Fig. 15 Cooling Fan Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Temperature Sensor / Switch > Component Information > Specifications
Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Technical Service Bulletins > Customer Interest for Fan Blade: > 921514 > Jul > 92 > Engine Cooling Concerns and/or Vibration
Fan Blade: Customer Interest Engine - Cooling Concerns and/or Vibration
Article No. 92-15-14
09/15/92
^ COOLING SYSTEM - OVERHEATING - ENGINE FAN CLUTCH NOT FUNCTIONING
PROPERLY
^ ENGINE COOLING FAN CLUTCH - DIAGNOSTIC PROCEDURE
^ VIBRATION - ENGINE FAN CLUTCH NOT FUNCTIONING PROPERLY
LIGHT TRUCK: 1987-92 BRONCO, ECONOLINE, F-150-350 SERIES 1988-92 F SUPER DUTY
ISSUE: A comprehensive diagnostic procedure has been developed for determining if the engine
cooling fan clutch is functioning properly. A fan clutch that is not functioning properly may cause
engine cooling concerns and/or vibration.
ACTION: Use the following diagnostic procedure to determine if the fan clutch is functioning
properly. A fan clutch that is not functioning properly should be replaced.
CAUTION: DO NOT ATTEMPT TO MODIFY THE BI-METALLIC COIL ON THE FACE OF THE
FAN CLUTCH.
DIAGNOSTIC PROCEDURE
NOTE: PROCEED ONLY AFTER COMPLETING THE ENGINE COOLING DIAGNOSIS
PROCEDURE IN SECTION 03-03 AND THE ACCESSORY DRIVE BELT TENSION
PROCEDURE IN SECTION 03-05 OF THE APPROPRIATE SERVICE MANUAL.
1. Turn off the air conditioner, heater-A/C fan and radio.
2. Check for viscous drag...
a. Before starting the engine, rotate the fan and clutch assembly by hand. It should have some
viscous drag, but it should turn smoothly during the full 360~ of rotation.
b. Replace the fan clutch if it does not turn smoothly or does not turn at all. Refer to the Dealer
Master Parts Catalog for correct parts usage. Refer to the appropriate Service Manual, Section
03-05, for service details.
c. Replace the fan if there are any cracks.
d. If this is not the concern, go to Step 3.
3. Check for lack of viscous drag...
a. If the fan clutch spins with no viscous drag when it is cold, and it has not been run for an hour or
more, it should be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage.
Refer to the appropriate Service Manual, Section 03-05, for service details.
b. If this is not the concern, go to Step 4.
4. Check for excessive fan clutch bearing clearance (cold fan clutch)...
a. Hold the tip of the fan blade between the thumb and forefinger.
b. Lightly pull toward the radiator, then push toward the engine.
c. Repeat the motion several times.
^ The total rocking movement at the end of the fan blade should be 2/10" (5.1 mm) or less when no
more than eight (8) ounces of force is applied.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Technical Service Bulletins > Customer Interest for Fan Blade: > 921514 > Jul > 92 > Engine Cooling Concerns and/or Vibration > Page 1974
^ A force greater than eight (8) ounces may deflect the fan blade with erroneous results.
d. Replace the fan clutch if more than 2/10" (5.1 mm) of movement is observed. Refer to the Dealer
Master Parts Catalog for correct parts usage. Refer to the appropriate Service Manual, Section
03-05, for service details.
e. If this is not the concern, go to Step 5.
5. Install a temporary engine tachometer if the vehicle is not equipped with a tachometer.
NOTE: DURING THE FOLLOWING TESTS, BE SURE TO MONITOR THE ENGINE COOLANT
TEMPERATURE BY THE TEMPERATURE GAUGE IN THE INSTRUMENT CLUSTER. SHUT
OFF THE ENGINE IF THE TEMPERATURE RISES ABOVE THE MAXIMUM RECOMMENDED
LIMIT FOR THE ENGINE OR IF COOLANT IS DISCHARGED OUTSIDE THE SYSTEM. THE
TESTS CAN BE RESUMED USING THE FOLLOWING PROCEDURES AFTER THE COOLANT
TEMPERATURE DROPS TO A NORMAL OPERATING LEVEL.
NOTE: IF THE HOOD IS LEFT OPEN, THE FAN NOISE MAY BE EASIER TO HEAR.
WARNING: DO NOT STAND IN LINE WITH THE FAN.
6. Start the engine.
7. Check for fan disengagement and be aware of the following operational characteristics.
^ The fan clutch may be engaged when the engine is first started. This will be apparent from the
noise level of the fan which has a distinctive roar.
^ The fan clutch engagement is due to the viscous silicone fluid draining back and filling the gap
between input and output components.
^ Running the engine at a constant speed of about 2000 rpm should pump the fluid back to its
reservoir, disengaging the fan clutch after no more than five minutes.
^ As the fan speed declines, the noise will drop off to a level inaudible to most observers.
a. Continuing the test, if the fan clutch does not reengage after five more minutes at 2000 rpm, the
fan clutch should be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage.
Refer to the appropriate Service Manual, Section 03-05, for service details.
b. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
c. If this is not the concern, go to Step 8.
8. Stop the engine.
a. Cut and install a piece of cardboard large enough to cover the front of the radiator with a six inch
diameter hole in line with the fan clutch.
b. If it is not possible to install the cardboard directly against the radiator, attach it to the A/C
condenser.
9. Start the engine.
a. With the gas engine at 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm, the vehicle
temperature gauge will rise steadily as the engine warms and then appear to level off for a short
time when the thermostat opens.
b. Make note of the temperature gauge position when the thermostat opens. The engine coolant
temperature will continue to rise until the fan clutch engages.
10. Check for fan engagement...
a. Continue to observe the coolant temperature gauge. As the fan clutch engages, the fan noise
will continue to increase and then level off at full engagement. The fan clutch may cycle off-and-on
a few times during the initial engagement.
b. If the fan clutch does not engage before the maximum indicated safe operating engine coolant
temperature is reached, it should be replaced. Refer to the Dealer Master Parts Catalog for correct
parts usage. Refer to the appropriate Service Manual, Section 03-05, for service details.
c. Repeat the test procedure after fan clutch replacement to verify the fix and to assure customer
satisfaction. The rate of rise of the coolant
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Technical Service Bulletins > Customer Interest for Fan Blade: > 921514 > Jul > 92 > Engine Cooling Concerns and/or Vibration > Page 1975
temperature will slow down after clutch engagement, but it will continue to rise as long as the
radiator remains covered.
d. If this is not the concern, go to Step 11.
11. Check for fan disengagement...
a. After completion of the above tests, shut off the engine.
b. Remove the cardboard cover from the front of the radiator.
c. Restart and return the gas engine to 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm,
continuing to watch the coolant temperature which will begin to decrease. The fan rpm will drop to
a reduced noise level where it was before the cycle began which indicates that the fan clutch has
disengaged.
d. If the fan clutch remains engaged and the coolant temperature has dropped below the
thermostat opening temperature (as noted in Step 9) for at least five minutes, the fan clutch should
be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage. Refer to the
appropriate Service Manual, Section 03-05, for service details.
e. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
WARRANTY STATUS AND OPERATION DESCRIPTION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Blade: > 921514 > Jul > 92 >
Engine - Cooling Concerns and/or Vibration
Fan Blade: All Technical Service Bulletins Engine - Cooling Concerns and/or Vibration
Article No. 92-15-14
09/15/92
^ COOLING SYSTEM - OVERHEATING - ENGINE FAN CLUTCH NOT FUNCTIONING
PROPERLY
^ ENGINE COOLING FAN CLUTCH - DIAGNOSTIC PROCEDURE
^ VIBRATION - ENGINE FAN CLUTCH NOT FUNCTIONING PROPERLY
LIGHT TRUCK: 1987-92 BRONCO, ECONOLINE, F-150-350 SERIES 1988-92 F SUPER DUTY
ISSUE: A comprehensive diagnostic procedure has been developed for determining if the engine
cooling fan clutch is functioning properly. A fan clutch that is not functioning properly may cause
engine cooling concerns and/or vibration.
ACTION: Use the following diagnostic procedure to determine if the fan clutch is functioning
properly. A fan clutch that is not functioning properly should be replaced.
CAUTION: DO NOT ATTEMPT TO MODIFY THE BI-METALLIC COIL ON THE FACE OF THE
FAN CLUTCH.
DIAGNOSTIC PROCEDURE
NOTE: PROCEED ONLY AFTER COMPLETING THE ENGINE COOLING DIAGNOSIS
PROCEDURE IN SECTION 03-03 AND THE ACCESSORY DRIVE BELT TENSION
PROCEDURE IN SECTION 03-05 OF THE APPROPRIATE SERVICE MANUAL.
1. Turn off the air conditioner, heater-A/C fan and radio.
2. Check for viscous drag...
a. Before starting the engine, rotate the fan and clutch assembly by hand. It should have some
viscous drag, but it should turn smoothly during the full 360~ of rotation.
b. Replace the fan clutch if it does not turn smoothly or does not turn at all. Refer to the Dealer
Master Parts Catalog for correct parts usage. Refer to the appropriate Service Manual, Section
03-05, for service details.
c. Replace the fan if there are any cracks.
d. If this is not the concern, go to Step 3.
3. Check for lack of viscous drag...
a. If the fan clutch spins with no viscous drag when it is cold, and it has not been run for an hour or
more, it should be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage.
Refer to the appropriate Service Manual, Section 03-05, for service details.
b. If this is not the concern, go to Step 4.
4. Check for excessive fan clutch bearing clearance (cold fan clutch)...
a. Hold the tip of the fan blade between the thumb and forefinger.
b. Lightly pull toward the radiator, then push toward the engine.
c. Repeat the motion several times.
^ The total rocking movement at the end of the fan blade should be 2/10" (5.1 mm) or less when no
more than eight (8) ounces of force is applied.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Blade: > 921514 > Jul > 92 >
Engine - Cooling Concerns and/or Vibration > Page 1981
^ A force greater than eight (8) ounces may deflect the fan blade with erroneous results.
d. Replace the fan clutch if more than 2/10" (5.1 mm) of movement is observed. Refer to the Dealer
Master Parts Catalog for correct parts usage. Refer to the appropriate Service Manual, Section
03-05, for service details.
e. If this is not the concern, go to Step 5.
5. Install a temporary engine tachometer if the vehicle is not equipped with a tachometer.
NOTE: DURING THE FOLLOWING TESTS, BE SURE TO MONITOR THE ENGINE COOLANT
TEMPERATURE BY THE TEMPERATURE GAUGE IN THE INSTRUMENT CLUSTER. SHUT
OFF THE ENGINE IF THE TEMPERATURE RISES ABOVE THE MAXIMUM RECOMMENDED
LIMIT FOR THE ENGINE OR IF COOLANT IS DISCHARGED OUTSIDE THE SYSTEM. THE
TESTS CAN BE RESUMED USING THE FOLLOWING PROCEDURES AFTER THE COOLANT
TEMPERATURE DROPS TO A NORMAL OPERATING LEVEL.
NOTE: IF THE HOOD IS LEFT OPEN, THE FAN NOISE MAY BE EASIER TO HEAR.
WARNING: DO NOT STAND IN LINE WITH THE FAN.
6. Start the engine.
7. Check for fan disengagement and be aware of the following operational characteristics.
^ The fan clutch may be engaged when the engine is first started. This will be apparent from the
noise level of the fan which has a distinctive roar.
^ The fan clutch engagement is due to the viscous silicone fluid draining back and filling the gap
between input and output components.
^ Running the engine at a constant speed of about 2000 rpm should pump the fluid back to its
reservoir, disengaging the fan clutch after no more than five minutes.
^ As the fan speed declines, the noise will drop off to a level inaudible to most observers.
a. Continuing the test, if the fan clutch does not reengage after five more minutes at 2000 rpm, the
fan clutch should be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage.
Refer to the appropriate Service Manual, Section 03-05, for service details.
b. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
c. If this is not the concern, go to Step 8.
8. Stop the engine.
a. Cut and install a piece of cardboard large enough to cover the front of the radiator with a six inch
diameter hole in line with the fan clutch.
b. If it is not possible to install the cardboard directly against the radiator, attach it to the A/C
condenser.
9. Start the engine.
a. With the gas engine at 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm, the vehicle
temperature gauge will rise steadily as the engine warms and then appear to level off for a short
time when the thermostat opens.
b. Make note of the temperature gauge position when the thermostat opens. The engine coolant
temperature will continue to rise until the fan clutch engages.
10. Check for fan engagement...
a. Continue to observe the coolant temperature gauge. As the fan clutch engages, the fan noise
will continue to increase and then level off at full engagement. The fan clutch may cycle off-and-on
a few times during the initial engagement.
b. If the fan clutch does not engage before the maximum indicated safe operating engine coolant
temperature is reached, it should be replaced. Refer to the Dealer Master Parts Catalog for correct
parts usage. Refer to the appropriate Service Manual, Section 03-05, for service details.
c. Repeat the test procedure after fan clutch replacement to verify the fix and to assure customer
satisfaction. The rate of rise of the coolant
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Blade: > 921514 > Jul > 92 >
Engine - Cooling Concerns and/or Vibration > Page 1982
temperature will slow down after clutch engagement, but it will continue to rise as long as the
radiator remains covered.
d. If this is not the concern, go to Step 11.
11. Check for fan disengagement...
a. After completion of the above tests, shut off the engine.
b. Remove the cardboard cover from the front of the radiator.
c. Restart and return the gas engine to 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm,
continuing to watch the coolant temperature which will begin to decrease. The fan rpm will drop to
a reduced noise level where it was before the cycle began which indicates that the fan clutch has
disengaged.
d. If the fan clutch remains engaged and the coolant temperature has dropped below the
thermostat opening temperature (as noted in Step 9) for at least five minutes, the fan clutch should
be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage. Refer to the
appropriate Service Manual, Section 03-05, for service details.
e. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
WARRANTY STATUS AND OPERATION DESCRIPTION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Testing and Inspection > Inspection
Fan Blade: Testing and Inspection Inspection
WARNING: Do not operate engine until fan has first been inspected for cracks and/or separations.
If a fan blade is found to be bent or damaged in any way, do not attempt to repair or reuse
damaged part. Proper balance is essential in fan assembly operation. Balance cannot be assured
once a fan assembly has been found to be bent or damaged and failure may occur during
operation, creating an extremely dangerous condition. Always replace damaged fan assembly.
Place fan on flat surface with leading edge facing down. If there is a clearance between fan blade
touching surface and opposite blade of more than .090 inch (2 mm), replace fan.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Testing and Inspection > Inspection > Page 1985
Fan Blade: Testing and Inspection Looseness
Lateral movement can be observed at the fan blade tip under various temperature conditions
because of the type bearing used. This movement should not exceed 1/4 inch (6.5 mm) as
measured at the fan tip. If this lateral movement does not exceed specifications, there is no cause
for replacement.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Technical Service Bulletins > Customer Interest for Fan Clutch: > 921514 > Jul > 92 > Engine Cooling Concerns and/or Vibration
Fan Clutch: Customer Interest Engine - Cooling Concerns and/or Vibration
Article No. 92-15-14
09/15/92
^ COOLING SYSTEM - OVERHEATING - ENGINE FAN CLUTCH NOT FUNCTIONING
PROPERLY
^ ENGINE COOLING FAN CLUTCH - DIAGNOSTIC PROCEDURE
^ VIBRATION - ENGINE FAN CLUTCH NOT FUNCTIONING PROPERLY
LIGHT TRUCK: 1987-92 BRONCO, ECONOLINE, F-150-350 SERIES 1988-92 F SUPER DUTY
ISSUE: A comprehensive diagnostic procedure has been developed for determining if the engine
cooling fan clutch is functioning properly. A fan clutch that is not functioning properly may cause
engine cooling concerns and/or vibration.
ACTION: Use the following diagnostic procedure to determine if the fan clutch is functioning
properly. A fan clutch that is not functioning properly should be replaced.
CAUTION: DO NOT ATTEMPT TO MODIFY THE BI-METALLIC COIL ON THE FACE OF THE
FAN CLUTCH.
DIAGNOSTIC PROCEDURE
NOTE: PROCEED ONLY AFTER COMPLETING THE ENGINE COOLING DIAGNOSIS
PROCEDURE IN SECTION 03-03 AND THE ACCESSORY DRIVE BELT TENSION
PROCEDURE IN SECTION 03-05 OF THE APPROPRIATE SERVICE MANUAL.
1. Turn off the air conditioner, heater-A/C fan and radio.
2. Check for viscous drag...
a. Before starting the engine, rotate the fan and clutch assembly by hand. It should have some
viscous drag, but it should turn smoothly during the full 360~ of rotation.
b. Replace the fan clutch if it does not turn smoothly or does not turn at all. Refer to the Dealer
Master Parts Catalog for correct parts usage. Refer to the appropriate Service Manual, Section
03-05, for service details.
c. Replace the fan if there are any cracks.
d. If this is not the concern, go to Step 3.
3. Check for lack of viscous drag...
a. If the fan clutch spins with no viscous drag when it is cold, and it has not been run for an hour or
more, it should be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage.
Refer to the appropriate Service Manual, Section 03-05, for service details.
b. If this is not the concern, go to Step 4.
4. Check for excessive fan clutch bearing clearance (cold fan clutch)...
a. Hold the tip of the fan blade between the thumb and forefinger.
b. Lightly pull toward the radiator, then push toward the engine.
c. Repeat the motion several times.
^ The total rocking movement at the end of the fan blade should be 2/10" (5.1 mm) or less when no
more than eight (8) ounces of force is applied.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Technical Service Bulletins > Customer Interest for Fan Clutch: > 921514 > Jul > 92 > Engine Cooling Concerns and/or Vibration > Page 1994
^ A force greater than eight (8) ounces may deflect the fan blade with erroneous results.
d. Replace the fan clutch if more than 2/10" (5.1 mm) of movement is observed. Refer to the Dealer
Master Parts Catalog for correct parts usage. Refer to the appropriate Service Manual, Section
03-05, for service details.
e. If this is not the concern, go to Step 5.
5. Install a temporary engine tachometer if the vehicle is not equipped with a tachometer.
NOTE: DURING THE FOLLOWING TESTS, BE SURE TO MONITOR THE ENGINE COOLANT
TEMPERATURE BY THE TEMPERATURE GAUGE IN THE INSTRUMENT CLUSTER. SHUT
OFF THE ENGINE IF THE TEMPERATURE RISES ABOVE THE MAXIMUM RECOMMENDED
LIMIT FOR THE ENGINE OR IF COOLANT IS DISCHARGED OUTSIDE THE SYSTEM. THE
TESTS CAN BE RESUMED USING THE FOLLOWING PROCEDURES AFTER THE COOLANT
TEMPERATURE DROPS TO A NORMAL OPERATING LEVEL.
NOTE: IF THE HOOD IS LEFT OPEN, THE FAN NOISE MAY BE EASIER TO HEAR.
WARNING: DO NOT STAND IN LINE WITH THE FAN.
6. Start the engine.
7. Check for fan disengagement and be aware of the following operational characteristics.
^ The fan clutch may be engaged when the engine is first started. This will be apparent from the
noise level of the fan which has a distinctive roar.
^ The fan clutch engagement is due to the viscous silicone fluid draining back and filling the gap
between input and output components.
^ Running the engine at a constant speed of about 2000 rpm should pump the fluid back to its
reservoir, disengaging the fan clutch after no more than five minutes.
^ As the fan speed declines, the noise will drop off to a level inaudible to most observers.
a. Continuing the test, if the fan clutch does not reengage after five more minutes at 2000 rpm, the
fan clutch should be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage.
Refer to the appropriate Service Manual, Section 03-05, for service details.
b. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
c. If this is not the concern, go to Step 8.
8. Stop the engine.
a. Cut and install a piece of cardboard large enough to cover the front of the radiator with a six inch
diameter hole in line with the fan clutch.
b. If it is not possible to install the cardboard directly against the radiator, attach it to the A/C
condenser.
9. Start the engine.
a. With the gas engine at 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm, the vehicle
temperature gauge will rise steadily as the engine warms and then appear to level off for a short
time when the thermostat opens.
b. Make note of the temperature gauge position when the thermostat opens. The engine coolant
temperature will continue to rise until the fan clutch engages.
10. Check for fan engagement...
a. Continue to observe the coolant temperature gauge. As the fan clutch engages, the fan noise
will continue to increase and then level off at full engagement. The fan clutch may cycle off-and-on
a few times during the initial engagement.
b. If the fan clutch does not engage before the maximum indicated safe operating engine coolant
temperature is reached, it should be replaced. Refer to the Dealer Master Parts Catalog for correct
parts usage. Refer to the appropriate Service Manual, Section 03-05, for service details.
c. Repeat the test procedure after fan clutch replacement to verify the fix and to assure customer
satisfaction. The rate of rise of the coolant
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Technical Service Bulletins > Customer Interest for Fan Clutch: > 921514 > Jul > 92 > Engine Cooling Concerns and/or Vibration > Page 1995
temperature will slow down after clutch engagement, but it will continue to rise as long as the
radiator remains covered.
d. If this is not the concern, go to Step 11.
11. Check for fan disengagement...
a. After completion of the above tests, shut off the engine.
b. Remove the cardboard cover from the front of the radiator.
c. Restart and return the gas engine to 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm,
continuing to watch the coolant temperature which will begin to decrease. The fan rpm will drop to
a reduced noise level where it was before the cycle began which indicates that the fan clutch has
disengaged.
d. If the fan clutch remains engaged and the coolant temperature has dropped below the
thermostat opening temperature (as noted in Step 9) for at least five minutes, the fan clutch should
be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage. Refer to the
appropriate Service Manual, Section 03-05, for service details.
e. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
WARRANTY STATUS AND OPERATION DESCRIPTION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Clutch: > 921514 > Jul > 92 >
Engine - Cooling Concerns and/or Vibration
Fan Clutch: All Technical Service Bulletins Engine - Cooling Concerns and/or Vibration
Article No. 92-15-14
09/15/92
^ COOLING SYSTEM - OVERHEATING - ENGINE FAN CLUTCH NOT FUNCTIONING
PROPERLY
^ ENGINE COOLING FAN CLUTCH - DIAGNOSTIC PROCEDURE
^ VIBRATION - ENGINE FAN CLUTCH NOT FUNCTIONING PROPERLY
LIGHT TRUCK: 1987-92 BRONCO, ECONOLINE, F-150-350 SERIES 1988-92 F SUPER DUTY
ISSUE: A comprehensive diagnostic procedure has been developed for determining if the engine
cooling fan clutch is functioning properly. A fan clutch that is not functioning properly may cause
engine cooling concerns and/or vibration.
ACTION: Use the following diagnostic procedure to determine if the fan clutch is functioning
properly. A fan clutch that is not functioning properly should be replaced.
CAUTION: DO NOT ATTEMPT TO MODIFY THE BI-METALLIC COIL ON THE FACE OF THE
FAN CLUTCH.
DIAGNOSTIC PROCEDURE
NOTE: PROCEED ONLY AFTER COMPLETING THE ENGINE COOLING DIAGNOSIS
PROCEDURE IN SECTION 03-03 AND THE ACCESSORY DRIVE BELT TENSION
PROCEDURE IN SECTION 03-05 OF THE APPROPRIATE SERVICE MANUAL.
1. Turn off the air conditioner, heater-A/C fan and radio.
2. Check for viscous drag...
a. Before starting the engine, rotate the fan and clutch assembly by hand. It should have some
viscous drag, but it should turn smoothly during the full 360~ of rotation.
b. Replace the fan clutch if it does not turn smoothly or does not turn at all. Refer to the Dealer
Master Parts Catalog for correct parts usage. Refer to the appropriate Service Manual, Section
03-05, for service details.
c. Replace the fan if there are any cracks.
d. If this is not the concern, go to Step 3.
3. Check for lack of viscous drag...
a. If the fan clutch spins with no viscous drag when it is cold, and it has not been run for an hour or
more, it should be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage.
Refer to the appropriate Service Manual, Section 03-05, for service details.
b. If this is not the concern, go to Step 4.
4. Check for excessive fan clutch bearing clearance (cold fan clutch)...
a. Hold the tip of the fan blade between the thumb and forefinger.
b. Lightly pull toward the radiator, then push toward the engine.
c. Repeat the motion several times.
^ The total rocking movement at the end of the fan blade should be 2/10" (5.1 mm) or less when no
more than eight (8) ounces of force is applied.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Clutch: > 921514 > Jul > 92 >
Engine - Cooling Concerns and/or Vibration > Page 2001
^ A force greater than eight (8) ounces may deflect the fan blade with erroneous results.
d. Replace the fan clutch if more than 2/10" (5.1 mm) of movement is observed. Refer to the Dealer
Master Parts Catalog for correct parts usage. Refer to the appropriate Service Manual, Section
03-05, for service details.
e. If this is not the concern, go to Step 5.
5. Install a temporary engine tachometer if the vehicle is not equipped with a tachometer.
NOTE: DURING THE FOLLOWING TESTS, BE SURE TO MONITOR THE ENGINE COOLANT
TEMPERATURE BY THE TEMPERATURE GAUGE IN THE INSTRUMENT CLUSTER. SHUT
OFF THE ENGINE IF THE TEMPERATURE RISES ABOVE THE MAXIMUM RECOMMENDED
LIMIT FOR THE ENGINE OR IF COOLANT IS DISCHARGED OUTSIDE THE SYSTEM. THE
TESTS CAN BE RESUMED USING THE FOLLOWING PROCEDURES AFTER THE COOLANT
TEMPERATURE DROPS TO A NORMAL OPERATING LEVEL.
NOTE: IF THE HOOD IS LEFT OPEN, THE FAN NOISE MAY BE EASIER TO HEAR.
WARNING: DO NOT STAND IN LINE WITH THE FAN.
6. Start the engine.
7. Check for fan disengagement and be aware of the following operational characteristics.
^ The fan clutch may be engaged when the engine is first started. This will be apparent from the
noise level of the fan which has a distinctive roar.
^ The fan clutch engagement is due to the viscous silicone fluid draining back and filling the gap
between input and output components.
^ Running the engine at a constant speed of about 2000 rpm should pump the fluid back to its
reservoir, disengaging the fan clutch after no more than five minutes.
^ As the fan speed declines, the noise will drop off to a level inaudible to most observers.
a. Continuing the test, if the fan clutch does not reengage after five more minutes at 2000 rpm, the
fan clutch should be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage.
Refer to the appropriate Service Manual, Section 03-05, for service details.
b. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
c. If this is not the concern, go to Step 8.
8. Stop the engine.
a. Cut and install a piece of cardboard large enough to cover the front of the radiator with a six inch
diameter hole in line with the fan clutch.
b. If it is not possible to install the cardboard directly against the radiator, attach it to the A/C
condenser.
9. Start the engine.
a. With the gas engine at 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm, the vehicle
temperature gauge will rise steadily as the engine warms and then appear to level off for a short
time when the thermostat opens.
b. Make note of the temperature gauge position when the thermostat opens. The engine coolant
temperature will continue to rise until the fan clutch engages.
10. Check for fan engagement...
a. Continue to observe the coolant temperature gauge. As the fan clutch engages, the fan noise
will continue to increase and then level off at full engagement. The fan clutch may cycle off-and-on
a few times during the initial engagement.
b. If the fan clutch does not engage before the maximum indicated safe operating engine coolant
temperature is reached, it should be replaced. Refer to the Dealer Master Parts Catalog for correct
parts usage. Refer to the appropriate Service Manual, Section 03-05, for service details.
c. Repeat the test procedure after fan clutch replacement to verify the fix and to assure customer
satisfaction. The rate of rise of the coolant
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fan Clutch: > 921514 > Jul > 92 >
Engine - Cooling Concerns and/or Vibration > Page 2002
temperature will slow down after clutch engagement, but it will continue to rise as long as the
radiator remains covered.
d. If this is not the concern, go to Step 11.
11. Check for fan disengagement...
a. After completion of the above tests, shut off the engine.
b. Remove the cardboard cover from the front of the radiator.
c. Restart and return the gas engine to 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm,
continuing to watch the coolant temperature which will begin to decrease. The fan rpm will drop to
a reduced noise level where it was before the cycle began which indicates that the fan clutch has
disengaged.
d. If the fan clutch remains engaged and the coolant temperature has dropped below the
thermostat opening temperature (as noted in Step 9) for at least five minutes, the fan clutch should
be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage. Refer to the
appropriate Service Manual, Section 03-05, for service details.
e. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
WARRANTY STATUS AND OPERATION DESCRIPTION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Testing and Inspection > Fan Clutch Fluid Leak
Fan Clutch: Testing and Inspection Fan Clutch Fluid Leak
Small fluid leaks do not generally affect the operation of the unit. These leaks generally occur
around the area of the bearing assembly, but if the leaks appear to be excessive, engine
overheating may occur. Check for clutch and fan free-wheeling by attempting to rotate fan and
clutch assembly by hand five times. If no drag is felt, replace clutch.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 2005
Fan Clutch: Testing and Inspection Fan Clutch Noise
Fan clutch noise can sometimes be noticed when clutch is engaged for maximum cooling. Clutch
noise is also noticeable within the first few minutes after starting engine while clutch is redistributing
the silicone fluid back to its normal, disengaged operating condition after settling for long periods of
time (over night). However, continuous fan noise or an excessive roar indicates the clutch
assembly is locked-up due to internal failure. This condition can be checked by attempting to
manually rotate fan. If fan cannot be rotated manually or there is a rough, abrasive feel as fan is
rotated, the clutch should be replaced.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 2006
Fan Clutch: Testing and Inspection Fan Clutch Operational Test
Do not operate the engine until the fan has been first checked for possible cracks and separations.
Run engine at a fast idle speed (1000 RPM) until normal operating temperature is reached. This
process can be done more quickly by blocking off the front of the radiator with cardboard.
Regardless of temperatures, unit must be operated for at least five minutes immediately before
being tested. Stop engine and using a glove or a cloth to protect the hand, immediately check the
effort required to turn the fan. If considerable effort is required, it can be assumed that coupling is
operating satisfactorily. If very little effort is required to turn the fan, it is an indication that the
coupling is not operating properly and should be replaced.
Bi-Metallic Coiled Spring Removal
The clutch fan may be tested while vehicle is being driven. To check, disconnect the bimetal spring,
Fig. 2, and rotate 90° counterclockwise. This disables the temperature-controlled, free-wheeling
feature and the clutch performs like a conventional fan. If this cures the overheating condition,
replace the clutch fan.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications
TEMPERATURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature
Sensor
Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor
Near Front Of Valve Cover
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature
Sensor > Page 2013
Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Switch (For
Computer)
RH Side Of V8-302/5.
Top Forward RH Side Of Engine, Under Water Outlet
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2014
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Fig. 7 Engine coolant temperature (ECT) sensor
The ECT, Fig. 7, sensor detects the temperature of engine coolant and supplies information to the
ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine
control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture.
On models with an electronic instrument cluster, the ECT output is used to control the coolant
temperature indicator.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications
Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Temperature Sensor (Gauge) > Component Information > Locations
Temperature Sensor (Gauge): Locations
LH Side Of V8-460/7.
LH Front Of Engine
Applicable to: 5L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component
Information > Locations
Heater Control Valve: Locations
Rear Of Engine Compartment
Above RH Rear Side Of Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary (Rear)
Heater Core: Service and Repair Auxiliary (Rear)
REMOVAL
1. Remove the first bench seat, if so equipped.
Fig. 5 - Auxiliary System Cover Removal And Installation.
2. Remove the auxiliary heater and/or air conditioning cover screws (Fig. 5), and remove the cover.
3. Remove the strap retaining the heater core in the auxiliary system case. 4. Remove the heater
hoses from the auxiliary heater core (2 clamps), and plug the hoses. 5. Disengage the wire
assembly from the heater core seal.
Fig. 12 - Heater Core And Resistor.
6. Slide the heater core and seal assembly out of the housing slot (Fig. 12).
INSTALLATION
1. Position the wire assembly to one side and slide the heater core and seal assembly into the
housing slot. 2. Install the heater hoses on the heater core tubes (2 clamps). 3. Fill the cooling
system and check for leaks.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary (Rear) > Page 2028
4. Install a new strap to retain the heater core in the case assembly. 5. Install the auxiliary heater
and/or air conditioner cover (Fig. 5). 6. Install the bench seat (if so equipped) and tighten the
retaining bolts to 34-61 Nm (25-45 ft lb).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary (Rear) > Page 2029
Heater Core: Service and Repair With A/C
REMOVAL
Fig. 19 - Manual A/C Heater System Heater Core Installation.
1. Disconnect electrical leads from resistor on front face of A/C blower scroll cover (Fig. 19.) 2.
Disconnect vacuum line from the outside-recirculated door vacuum motor. 3. Remove A/C blower
cover (five screws plus two screws attaching the blower scroll cover to plenum assembly).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary (Rear) > Page 2030
Fig. 15 - A/C Vacuum Motor Installation.
4. Remove pushnut, vacuum motor arm and washer from the outside-recirculated door shaft (Fig.
15, view X). 5. Remove control cable from bracket (one screw) and slide it over bracket. Remove
cable clip from blend door shaft. 6. Remove A/C blower motor housing (eleven screws). 7. Remove
the blend door. 8. Remove the heater hoses from the heater core and plug the hoses. 9. Remove
the two heater core retaining brackets (two screws).
10. Remove the heater core and seal assembly.
INSTALLATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary (Rear) > Page 2031
1. Position the heater core and seal assembly and install the core retaining brackets and screws. 2.
Install the heater hoses to the heater core (two clamps) and fill the cooling system. 3. Install the
blend door and frame assembly with seal in place between flanges. 4. Install the A/C blower motor
housing (eleven screws). 5. Position control cable clip to the blend door shaft. 6. Install control
cable to bracket attaching screw (one screw). 7. Install the washer, vacuum motor arm and pushnut
on the outside-recirculation doorshaft. 8. Install A/C blower cover (five screws plus two screws
attaching the blower scroll cover-to-plenum assembly). 9. Connect vacuum line to
outside-recirculated vacuum motor.
10. Connect the electrical leads to the resistor. 11. Adjust the control cable.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary (Rear) > Page 2032
Heater Core: Service and Repair Without A/C
REMOVAL
1. Disconnect the battery cables. 2. Remove the battery (on dual battery equipped vehicles,
passenger side battery).
Fig. 5 - Blower Motor And Wheel Assembly
3. Disconnect the resistor wiring harness. (Fig. 5.) 4. Disconnect the blower motor lead wire
(orange/black) at wiring harness (Fig. 5). 5. Remove ground wire (black) mounting screw from dash
panel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary (Rear) > Page 2033
Fig. 8a - Heater Hose Installation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary (Rear) > Page 2034
Fig. 8b - Heater Hose Installation.
6. Disconnect heater hoses from the core tube and plug the hoses. Remove plastic strap retaining
the heater hoses to the heater assembly (Fig. 8).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary (Rear) > Page 2035
Fig. 9 - Heater Core Installation.
Fig. 13 - Heater Assembly Installation.
7. Remove five heater mounting attachment nuts from inside of vehicle (Figs. 9 and 13.) 8. Remove
heater assembly. 9. Remove the case seal from the face of the case and remove retainer (two
screws) (Fig. 9).
10. Slide core and seal assembly out of case.
INSTALLATION
1. Slide the new heater core and seal assembly into the heater core case and install the retainer
with two attaching screws. 2. Install the case seal to the face of the case using care to correctly
align the seal over the five case bolts. 3. Install the heater assembly by reassembling the five
mounting attachment nuts from inside the vehicle. 4. Connect the heater hoses to the heater core
with new clamps and install the plastic strap. 5. Install the black ground wire to the dash panel (one
screw). 6. Connect the blower motor lead wire (orange/black) to the wiring harness. 7. Connect the
resistor wiring harness to the resistor.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Auxiliary (Rear) > Page 2036
8. Install the battery and connect the battery cable. 9. Add engine coolant and check heater
operation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > NHTSA89V139000 > Aug > 89 > Recall 89V139000: Heater Hose
Rerouting/Repair
Heater Hose: Recalls Recall 89V139000: Heater Hose Rerouting/Repair
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN UNDERHOOD FIRE. RE-ROUTE AND REPAIR HOSE, AS
NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: GAS CHASSIS - CUTAWAY AND VAN AMBULANCES.
1985 FORD TRUCK E350 1986 FORD TRUCK E350 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > NHTSA89V150000 > Aug > 89 > Recall 89V150000: Heater Hose
Rerouting
Heater Hose: Recalls Recall 89V150000: Heater Hose Rerouting
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN
UNDERHOOD FIRE. RE-ROUTE HOSE AS NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: AMBULANCES BUILT ON FORD E350 CHASSIS.
1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > NHTSA89V075000 > Apr > 89 > Recall 89V075000: Heater Hose
Rerouting
Heater Hose: Recalls Recall 89V075000: Heater Hose Rerouting
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN
UNDERHOOD FIRE. RE-ROUTE AND SPLICE HOSE AS NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: BUSES BUILT ON FORD E350 CHASSIS.
1986 FORD TRUCK E350
1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement
Technical Service Bulletin # 88S99 Date: 880901
Recall - Heater/Engine Bypass Hose Replacement
At Dealers By Order as Req'd -0- % of Parts Direct Shipped to Dealers
At PDC By Now Temporary Maximum
Date in Owner Letter 9/2/88 Order Quantity of 2 Kits
RECALL NUMBER
88S99
Date: Sept., 1988
PLEASE GIVE COPIES OF THIS BULLETIN TO YOUR PARTS AND SERVICE MANAGERS
TO: All Ford and Heavy Truck Dealers
SUBJECT: Safety Recall 88S99 - Heater and Engine Bypass Hose Replacement and Muffler
Inspections/Replacement on Certain 1983 through 1987-model 5.8L-4V H.D. and 7.5L Engine
Equipped Ford Econoline-Based Ambulances
IN CARES/OASIS - YES
REFUND CLAIMING - USE FORM 1863
MODIFICATION CLAIMING - USE FORM 1864
VEHICLES AFFECTED:
Ford Motor Company is initiating a safety recall of certain 1983 through 1987-model Econoline
E250/E350- based ambulances equipped with 7.5 Liter engines as well as certain 1985 through
1987-model Econoline E250/E350-based ambulances equipped with 5.8L 4V H.D. engines. All
involved vehicles are rated over 8,500 lbs. GW.
REASONS FOR THIS RECALL:
Investigations of recent fires involving Econolinebased ambulances have disclosed a potential for
engine compartment heater or engine bypass hoses to wear-out prematurely and rupture, allowing
engine coolant to come in contact with hot engine exhaust manifolds and possibly ignite. Testing
has indicated that worn-out hoses are not able to withstand the prolonged periods of extreme
engine operating temperatures and higher engine cooling system pressures encountered during
EMS severe-duty cycles.
ACTION BY FORD: All ambulances returned for the service provided by this Safety Recall will be
modified as follows;
^ Replacement of existing engine compartment heater and bypass hoses with silicone/NOMEX
hoses.
^ Replacement of the radiator cap.
^ Replacement of the engine coolant with a 50/50 mix of water and antifreeze. This mixture of
coolant will provide freeze protection for most areas. Extreme cold-weather areas should be
provided with a 60/40 mixture of coolant and water.
^ Pressure test the cooling system.
^ Inspection and, if necessary, installation of aluminized stainless steel mufflers on 1985-87-model
7.5L dual-thermactor engine equipped vehicles.
^ High heat resistance aluminized stainless steel mufflers will be installed on those ambulances
equipped with 1985-1987 7.5L, dual thermactor air pump-equipped engines that did not have those
mufflers installed in connection with safety recall 87M53. A temporary shortage of aluminized
stainless steel mufflers last year required the use of substitute mufflers on ambulances that were
found in need of muffler replacement at that time.
^ Underbody inspection for loose, mispositioned or missing heat-shielding parts. Contact the
Special Toll-Free Econoline/Ambulance Hotline for authorization to perform modifications as a
result of this inspection.
This service will be performed at no cost. Owner/ operators win be provided with information about
replacement recommendations for engine coolant and heater and engine bypass hoses.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2057
REFUNDS: Owner/operators of 1985-87-model 7.5L dual-thermactor engine equipped vehicles will
be provided refunds for Ford-sourced aluminized stainless steel mufflers which may have been
installed at their expense under Safety Recall 87M53. DEALERS ARE INSTRUCTED TO
PROVIDE REFUNDS TO OWNERS WHO ADEQUATELY PROVE SUCH A PURCHASE AND TO
CLAIM FOR REFUNDS USING FORM 1863.
DEALER RESPONSIBILITIES:
Owners will be told that they may wish to inform the National Highway Traffic Safety Administration
if the recall is not performed without charge or within a reasonable time after the vehicle is brought
to their dealership for repair.
REPAIR CODES: REFER TO ATTACHMENT II, EXHIBIT 1 - THE "REPAIR CODES" SHOWN ON
THE REFERENCED ATTACHMENT HAVE BEEN DEVELOPED TO ASSIST YOU IN SELECTING
THE CORRECT EXHAUST SYSTEM MUFFLERS FOR SPECIFIC VEHICLES. THESE "REPAIR
CODES" WILL BE PRINTED ON THE OWNER LETTER AND THE CLAIM FORM 1864. USE THE
CODES TO DETERMINE REQUIRED MUFFLERS AND WHEN PREPARING CLAIM FORMS
AND SERVICE DOCUMENTS.
CARES/OASIS: Dealers are to check the CARES and OASIS programs todetermine if an affected
vehicle is involved in other recalls.
CLAIM FORMS: USE CLAIM FORM 1864 FOR THE MODIFICATIONS REQUIRED FOR THIS
RECALL. USE CLAIM FORM 1863 FOR REFUNDS TO OWNERS WHO PREVIOUSLY PAID FOR
INSTALLATION Of FORD-SOURCED ALUMINIZEDSTAINLESS STEEL MUFFLERS. Refer to
Attachment I for preparation instructions.
PARTS Refer to Attachment II.
REQUIREMENTS:
LABOR ALLOWANCE: Refer to Attachment II.
TECHNICAL INSTRUCTIONS:
Refer to Attachment III.
OWNER NOTIFICATION:
Owner/operators will be notified with the letter shown on Attachment IV.
FPSD ASSISTANCE: Contact your FPSD District Service Engineer with any problems you have
concerning this recall. Additionally, a special toll-free Econoline/Ambulance Technical Hotline is
available to assist in resolving unusual repair issues technicians may encounter.
Personnel are available daily from 7:30 A.M. to 6:00 P.M., Eastern Time to provide technical
assistance by calling 1-800-445-1571.
Administrative Instructions
SAFETY RECALL 88S99 ADMINISTRATIVE INSTRUCTIONS Attachment I VEHICLES
AFFECTED:
Certain 1983 through 1987-model Econoline E250/E350- based ambulances equipped with 7.5
Liter engines as well as certain 1985 through 1987-model Econoline E250/E330- based
ambulances equipped with 5.8 Liter 4V H.D. Engines. All affected vehicles are rated over 8,500 lbs.
GVW.
REPORTING COMPLETIONS: Only the Form 1864 will be accepted for reimbursement for
modifications performed under this recall. Upon completion of the required service, the Form 1864
must be completely filled out and signed by authorized dealer personnel. CLAIM SUBMISSION:
The claims must be entered through the Direct Warranty Entry (DWE) system. Dealers without
DWE capability must mail the second copy of the Form 1864 for reimbursement. Should your
dealership receive pre-printed Forms 1864 with a seven digit claim number, you must drop the first
digit and enter only the last six digits. You must sight verify the claim number for accuracy. It is
important that all claims be filed for all completed units so you will be reimbursed and our records
will show completion.
REFUNDS: Refund requests submitted under Safety Recall 88S99 are governed by the following
guidelines:
^ Owner/operators of 1985-87 model ambulances with 7.5L dual thermactor engines are eligible for
a refund if they paid for a muffler replacement under Safety Recall 87M53 and the replacement
muffler was the new ribbed design, aluminized stainless steel muffler (See Attachment II, Exhibit 2
for eligible muffler part numbers). Paid repair orders or invoices presented by the owner/operator
requesting a refund must show one of the eligible muffler part numbers.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2058
^ Refunds include return of any deductible amount owners may have paid.
^ A copy of the paid repair orders or parts purchase receipts must be retained in your service file
for at least one year following the date of Company notification of payment.
^ Owner refund requests must be submitted on separate Warranty Claim Form 1863. In addition to
the information shown for the special preparation of Owner Refund
claims (Reference: Warranty and Policy Manual - Subject 6.1, Page 18), please enter the
information shown below:
Causal Basic Part Number - 88S99
Condition Code - OB
Labor Operation - REFUND
Administrative Allowance - 0.2 Hr.
Program Code - 88S99
^ An administrative allowance of 0.2 hours will be allowed for processing each eligible owner
refund request. To claim the allowance, enter ALLOW in the Labor Operation No. column and 0.2
in the Scheduled Time column. Extend the 0.2 hours at your authorized warranty labor rate and
enter the result in the Amount column.
^ Please provide prompt refund to all eligible owners who respond to this recall with proper repair
documentation.
Labor and Parts Ordering Instructions
SAFETY RECALL 88S99 LABOR AND PARTS ORDERING INSTRUCTIONS
Attachment II
PARTS ORDERING: Service parts required for this recall may be ordered through normal
channels. Refer to the following material and Attachment II, Exhibits 1 and 2.
Coolant Ordering
^ Since most areas will require a 50/50 mixture of antifreeze and water, order and claim for the
amount of coolant required to service each ambulance using the following information:
- In extreme cold weather areas use a 60/40 mixture, order and claim appropriately.
- Order enough coolant (Ford Part Number E2FZ-19549-AA, or equivalent) to fill the entire engine
cooling system. In most cases, 3 gallons of antifreeze and 3 gallons of water should be adequate to
attain a 50/50 mix
Service Part Number
Description Class Dealer Price
E2FZ-19549-AA Coolant, Engine V $8.65/Gallon a/
E3UZ-18472-C Kit, Heater Hose BG $64.65
E8UZ-8597-A Hose, Engine Bypass (5.8L Engs.
CG $2.25
Only)
a/ Based on $51.90, Carton 6 Gallons, order this part number or use locally purchased equivalent.
Use dealer aquisition cost for locally purchased equivalent.
Scheduled Time
LABOR OPERATIONS: Basic Labor Operation (Hours)
Inspection of the Ambulance Underbody and Exhaust System, Installation of Heater and Engine
Bypass Hose Improvement
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2059
Modifications. . . . . . . . . . . . . 2.1 Insert in Box "B" of Form 1864
LABOR OPERATIONS: (Cont'd.)
Scheduled Time
Basic Labor Operation (Hours)
Supplemental Labor Operations (Additive to Above)
Replacement of the Exhaust System Muffler, and Attaching Parts (7.5L Dual-Thermactor Engine
Equipped Vehicles . . . . . . . .
0.8 Insert in Box "B" of Form 1864
Note: Use this supplemental time when replacing mufflers on 7.5L Dual-Thermactor Engine
equipped vehicles. This time may also be used when replacing mufflers performed at owners'
expense.)
Additional Time to Access Engine Bypass Hoses on 7.5L Engine Equipped Vehicles . . . . . . . . . . . .
.
0.4 Insert in Box "B" of Form 1864
Administrative Allowance (Additive to Above)
Administrative Allowance . . . . . 0.1 Hr.
The Supplemental Labor Operations and the 0.1 hour administrative allowance must be added
before inserting the total labor time in Box "B" of the Form 1864.
Repair Code Description
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2060
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2061
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Technical Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTIONS
Attachment III
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2062
TECHNICAL INSTRUCTIONS:
Inspections:
^ Underbody - All Vehicles
1. Inspect the underbody and exhaust system for missing, loose or mispositioned heat-shielding
parts (Refer to Safety Recall 87M53 instructions).
If you discover any conditions as a result of this inspection that requires modification, please
contact the Special Toll-Free Econoline/Ambulance Hotline, 1-800-445-1571, for authorization.
Contact your District Office if the Hotline is not available.
^ Mufflers - All Vehicles
2. Refer to Attachment III, Exhibit 1. Remove the exhaust system muffler heat shields.
3. Inspect the muffler per the instructions contained in Attachment III, Exhibit 1.
^ Replace unacceptable mufflers and attaching parts at the OWNERS EXPENSE ON:
i) 1983 through 1987-model 7.5L single-thermactor engine equipped vehicles; ii) 1985 through
1987-model, 5.8L 4V H.D. engine equipped vehicles.
^ Replace any mufflers that are not Ford-sourced aluminized stainless steel and attaching parts at
FORD EXPENSE on 1985 through 1987-model, 7.5L dual thermactor engine equipped vehicles.
^ Heater and Bypass Hose Replacement:
4. Refer to Attachment III, Exhibit 2. Replace the engine compartment heater and engine bypass
hoses as shown on the referenced attachment. Note: The 5.8L 4V H.D. engines require a formed
bypass hose. This is not in the heater hose/bypass parts kit. Order this hose separately.
5. Pressure test the cooling system and replace existing radiator cap.
NOTE: Owners will be instructed to retorque hose clamps to 2.5-3.0 N-m (22-26 in.lbs.) when
coolant leakage is observed.
MODIFICATION DECAL: Prepare an "Authorized Modifications" decal (Form FPS-8262) as shown
below. Affix the decal to a flat clean surface on
the radiator support. (Order the "Authorized Modifications" decal on your Weekly Stock Order Pad.)
Specific Technical Repair Code and Parts Ordering Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
Exhaust System-Ford Components-Correct Routing and Retention
1983-1985 7.5L MODELS (MODELS WITH SINGLE AIR PUMP) 1985-1/2-1987 5.8L MODELS
(OVER 8500 GVW WITH 4 BARREL CARBURETOR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2063
FIGURE 1
The Ford exhaust system as shown in Figure 1, provides the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheatng.
FIGURE 3
Inspect the exhaust system for leaks or ruptures. FOR 5.8L ONLY, it may be necessary to remove
the heat shields as shown in Figure 3. Inspect the muffler outer wrapper lock seam for separation.
If any such problems are found, notify the customer and request permission to repair the problem,
at the customer's expense. Note any such problems and the customer's reaction to your repair
request on your internal repair order form and retain in your records.
If a non-Ford exhaust system or exhaust components is noted on the unit, inform the customer of
the potential for durability reduction, exhaust flow restriction, or overheating as indicated above.
Note any such discrepancy and the customer's reaction on your internal repair order form and
retain in your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2064
FIGURE 1
ALL 5.8L AND ONLY CALIFORNIA CALIBRATION 7.5L: If the unit is not equiped with the all-steel
hangers shown in Figure 1, order and install the Ford Service Part as indicated in the attached
chart. SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
FIGURE 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2065
1985-1/2 - 1987 7.5L MODELS (MODELS WITH DUAL AIR PUMPS - SEE FIGURE 5)
FIGURE 2
The Ford exhaust system as shown in Figure 2, provdes the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheating.
FIGURE 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2066
FIGURE 4
Remove the heat shields covering the muffler by removing the retaining clamps securing the
shields as shown in Figure 3. If the muffler is a non-Ford design or is a non-ribbed design (Figure
4), remove the Muffler and Outlet Pipe Assembly and replace with the heavy duty ribbed muffler
assembly as indicated in the attached chart.
If the muffler is the heavy duty type (ribbed design - Figure 4), installed during the 1987 M53 recall,
inspect the entire surface of the muffler for cracks or openings. If any such openings are found,
replace the Muffler and Outet Pips Assembly with a new heavy duty ribbed muffler assembly.
Advise the Ambulance Technical Hot Line 1-800-445-1571, if you find a ribbed muffler with cracks
or openings.
FIGURE 2
If the unit is not equipped with the all-steel hangers as shown in Figure 2, order and install the Ford
Service Part as indicated in the attached chart. ATTACHMENT III EXHIBIT 1 PAGE 3 OF 3
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2067
KIT NUMBER E3UZ-18472-C HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED
AMBULANCES WITH 7.5L OR 5.8L 4V H.D. ENGINES SPECIAL NOTE: The following instructions
describe the installation procedure for the heater hose/bypass hose improvement package. It is
designed specially for Ford E-350 and E-250 (over 8500 pounds GVWR) based ambulances. The
original Ford heater hose system has probably been modified by the ambulance body builder. It is
not possible to identify all the designs and modifications used by these manufacturers. If you
encounter difficulties not anticipated in these instructions, contact the Ford Ambulance Recall
Hotline on 1-800-445-1571. PARTS LIST
Item Description Part Number Quantity
1 Silicons Hose - 5/8" I.D. *EST-M2D309-A 96"
2 Hose Clamp 388652-S2 20
3 "Y" Fitting D8UH-18663-AA 2
4 Tie Strap - 1/4" Wide 384213-S 10
5 Radiator Cap E5TH-8100-AA 1
*Engineering Specification Number
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2068
FIGURE 1
HEATER HOSE REMOVAL
1. Close the shutoff valves that connect the rear heater unit to the Ford installed heater hoses (See
Figure 1). Be sure to close both the supply and return hose valves. Failure to close these valves
could cause coolant fill problems later.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2069
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT.
2. Drain the coolant from the radiator by removing the radiator cap and carefully opening the drain
cock at the bottom of the radiator. After the coolant has drained from the radiator, close the drain
cock and discard the radiator cap.
3. Disconnect and remove any objects, such as thermactor pump filter/silencer or coolant overflow
bottle, obstructing access to the heater hoses.
4. Inspect the hoses for chaffing or cuts (See Figure 1). Note the position of any straps or clamps
for securing the new hoses at time of installation.
5. Disconnect the vacuum line from the water supply valve.
6. Disconnect the inlet and outlet hoses from the heater core, engine block, and rear heater shutoff
valves (See Figure 1). Loosen each clamp and cut the hose first to prevent core damage. DO NOT
twist hoses in the removal process. Disconnect the hoses from any locating clips. Discard all hose
clamps.
NOTE: DO NOT disconnect the hoses routed from the shutoff valves to the rear heater unit.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2070
FIGURE 1
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2071
FIGURE 2
HEATER HOSE INSTALLATION
1. Using hoses (Item 1), hose clamps (Item 2) and "Y" fittings (Item 3), assemble duplicate hose
layouts of the removed hose assemblies (Figure 1).
NOTE: The hoses leading from the "Y" fittings may have to be slightly longer than the original
hoses to avoid any kinks or bends. This is due to the replacement fittings having a different angle in
the "Y" than the original "Y" or "T" fittings. Silicone hoses require the special clamps Included in the
kit to prevent cutting the hose. DO NOT use any other type of clamp.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 1 OF 5
on 1-800-445-1571 if you have any questions.
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
2. Remove the vacuum operated water supply valve from the old hose assembly and install it into
the new hose assembly.
NOTE: Make sure that the flow arrow stamped on the valve is pointing toward the heater core.
3. Torque the clamps (Item 2) to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
4. Connect the hose assemblies with clamps (Item 2) to the engine block, heater core and rear shut
off valves.
5. Torque the clamps to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
6. Connect the vacuum line to the water supply valve.
7. Using tie straps (Item 4), secure the hoses to an adjacent engine component to prevent chaffing
or cutting during engine operation. The hoses may be secured in a manner similar to the original
method if the removed hoses were not damaged as noted earlier. If the original hoses were
damaged, route the hoses and secure them in a manner to prevent hose damage during engine
operation.
WATER BYPASS HOSE REMOVAL AND INSTALLATION FOR VEHICLES WITH 7.5L ENGINES
1. Remove the distributer vacuum hose to improve accessibility to the water bypass hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2072
FIGURE 2
2. Remove the water bypass hose and clamps (See Figure 2). Discard the clamps.
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
CAUTION: DO NOT ALTER (CUT OFF) THE INTAKE MANIFOLD AND/OR THE WATER PUMP
HOSE CONNECTIONS. ANY
DAMAGE SUCH AS SHARP EDGES, TO THESE CONNECTIONS WILL RESULT IN DAMAGE
TO THE NEW BYPASS HOSE DURING INSTALLATION.
4. Using the removed hose as a pattern, cut a piece of silicone hose (Item 1) to the proper length
and position it on the intake manifold bypass connection.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 3 OF 5
on 1-800-445-1571 if you have any questions
FIGURE 3
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D ENGINES
5. Position two (2) new hose clamps (Item 2) on the new hose, installed in Step 4, toward the
intake manifold. (See Figure 3.)
6. Bend (double over) the new bypass hose downward and slide the hose on to the water pump
bypass hose connection. (See Figure 3.)
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2073
FIGURE 4
FOR VEHICLES WITH 5.8L ENGINES
1. Remove the distributor vacuum hose to improve accessibility to the water bypass hose.
2. Remove the water bypass hose and clamps (See Figure 4). Discard the clamps.
Don't forget... ATTACHMENT III
call the Special Econline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 4 OF 5
on 1-800-445-1571 if you have any questions!
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
4. Position a new formed bypass hose (Part number E8UZ-8597-A) on the intake manifold bypass
connection.
5. Position two (2) new hose clamps (Item 2) on the new hose toward the intake manifold.
6. Bend and slide the hose on to the water pump bypass hose connection.
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to:) 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose, PRESSURE TEST COOLING SYSTEM
1. Reinstall all of the objects such as the thermactor pump filter/silencer or coolant overflow bottle,
that obstructed access to the heater hoses.
2. Fill the cooling system with a coolant mixture of 50/50 Ford Long Life Coolant E2FZ-19549-AA
(ESE-M97B44-A) or equivalent and water, to 38 mm (1.5 inches) below the cap seal.
3. Install radiator cap (Item 5)
WARNING: DO NOT STAND IN LINE WITH OR NEAR THE RADIATOR FAN WHEN THE
ENGINE IS RUNNING.
4. Start the engine, let it warm until the upper radiator hose is hot, shut off the engine. Allow the
engine to cool, remove the cap and check the coolant level. Fill as required.
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2074
5. Using the Rotunda Cooling System Pressurization Kit 021-00012, pressurize the cooling system
to 20 psi and check for leaks. Be sure to follow the instructions in the kit on the recommmended
method of connecting the tester to the radiator.
6. If any leaks are found, correct as needed.
7. Pressure test the cooling system until no leaks we found.
8. Rechock the coolant level in the radiator to make sure that it is 38 mm (1.5 inches ) below the
cap seal. If it is not, fill as required.
9. Reinstall the radiator cap and add coolant to the overflow bottle as required.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 5 OF 5
on 1-800-445-1571 if you have any questions!
Owner & Operator Letter Information
Attachment IV
September 2, 1988
Dear Owner/Operator:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
Ford Motor Company has determined that a defect which relates to Motor Vehicle Safety evists in
certain 1983-1987 Econoline-based ambulances equipped with 7.5 liter or 5.8 liter 4V H.D. V8
engines. Due to the prolonged periods of extreme engine operating temperatures and cooling
system pressures encountered during EMS severe-duty cycles, heater or engine bypass hoses
may wear-out prematurely and burst. Engine coolant ("antifreeze") from a burst hose may cause a
fire if it sprays onto an overheated engine exhaust manifold, especially if the coolant is
overconcentrated.
Ford Motor Company is now asking that you return your Econoline-based ambulance to your Ford
or Ford Heavy Truck Dealer for corrective action.
COOLING SYSTEM SERVICE
At no cost to you, your dealer will:
- replace certain "rubber" heater hoses installed by Ford Motor Company when the vehicle was
manufactured (ie., up to the auxiliary heater shut-off valves), with new "SILICONE/NOMEX" heater
hose;
- replace engine bypass hoses
- replace the engine coolant (with a proper 50/50 mixture);
- install a new radiator cap;
- pressure test the cooling system.
Most ambulances also have auxiliary heater systems. The ambulance body manufacturer typically
installs these heater systems. While these hoses are not part of this safety recall, we strongly
recommend that you consider replacing all non-silicone/Nomex @ auxiliary heater hoses also. THE
COST OF REPLACING THE AUXILIARY HEATER HOSES WILL BE AT YOUR EXPENSE. IF
LEAKS ARE FOUND IN OTHER COMPONENTS OF THE ENGINE COOLING SYSTEM, WHEN
THE SYSTEM IS PRESSURE TESTED SUCH AS THE RADIATOR OR RADIATOR HOSES, THE
COST OF REPAIRING THOSE COMPONENTS WILL BE AT YOUR EXPENSE.
FOR ALL HEATER SYSTEM HOSE REPLACEMENTS, FORD RECOMMENDS THAT YOU
SPECIFY HOSES MADE ONLY FROM THE "SILICONE/NOMEX" MATERIAL. SILICONE HOSES
ALSO REQUIRE SPECIAL HOSE CLAMPS TO PREVENT CUTTING THE HOSE. USE ONLY
THE HOSE CLAMPS RECOMMENDED BELOW WITH SILICONE HOSES.
When purchasing replacements, the following parts should be specified:
Ford Service Motorcraft Brand
Part Name Part Number Part Number
- SILICONE/NOMEX E8TZ-18472-H KH-15
Heater Hose - 25 foot lengths
- Formed Water Pump Bypass E8UZ-8597-A KMS-1776
Hose (for 5.8L 4V H.D. Engine)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2075
- Hose Clamps D9AZ-8287-C YF-842
It is important also that the proper torque be used when attaching the special hose clamps required
for SILICONE/NOMEX hoses. Your dealer will properly torque clamps when they install the heater
and engine bypass hoses on your ambulance. If you should notice coolant seepage, retorque the
clamps to 2.5 to 3.0 N-m (22-26 in.lbs.).
These parts are available through your Ford, Lincoln-Mercury or Ford Heavy Truck Dealer. They
are also available through any Motorcraft parts distributor.
Ford recommends that you always replace these SILICONE/NOMEX HEATER SYSTEM hoses
every 48,000 miles or 48 months, whichever comes first. Non-silicone hoses should be replaced
every 24,000 miles or 24 months, whichever comes first.
It is important that your ambulance cooling system have the proper anti-freeze coolant and water
mixture for adequate freeze protection. Please read and observe the recommendations on the
attachment, "The Importance of Proper Cooling System Anti-freeze Mixtures".
EXHAUST SYSTEM SERVICE
^ Certain 198-5-1987 Model Ambulances with 7.5 Liter/Dual Thermactor Engines
Ambulances with 7.5 Liter V8 engines and a dual-thermactor emission system will have a new
aluminized stainless steel muffler installed. Mufflers and installation will be free of charge.
Some of these ambulances may have already had new alumunized stainless steel mufflers
installed during the earlier recall. These vehicles will not need new mufflers.
^ Refunds for Certain Later Model Muffler Replacements
As noted above, some of these ambulances with 7.5 liter/dual thermactor engines may have
received the new aluminized stainless steel mufflers during the service for the earlier Safety Recall
87M53. If you paid to have these new aluminized stainless steel mufflers installed, you are entitled
to a refund for the costs of parts and labor. If you are entitled to this refund, please present your
paid receipt to any Ford or Ford Heavy Truck Dealer who will process a refund for you.
This receipt must show the date of repair, the part numbers for the new aluminized stainless steel
muffler and attaching parts as well as the parts and labor costs.
^ Other 7.5 Liter and 5.8 Liter 4V H.D. Engine Equipped Ambulances
Ambulances with 7.5 Liter V8 engines and a single thermactor emission system as well as all
1985-1987 model ambulances with 5.8 Liter 4V H.D. V8 engines will only have the muffler
inspected. Replacement of defective mufflers will be the owner's responsibility.
SCHEDULE SERVICE AT ANY FORD OR FORD HEAVY TRUCK DEALER NOW
Since the cooling system parts, mufflers and instructions are now available, we urge you to
schedule this service as quickly as possible.
NOTE: ANY FORD OR FORD HEAVY TRUCK DEALER CAN DO THE COOLING SYSTEM AND
MUFFLER SERVICE.
Before you return your vehicle for this service, we urge you to review the cooling system
information sent to you in June, 1988. Some cooling system maintenance may be needed now.
COMPUTER FORM
The computer form included with this letter may include a special part code. Your dealer will need
to know this code when you call to make an appointment. The code, located in the box labeled "Kit
Code", half way down the right side of the form, will be a single digit number from 1 through 8.
IMPORTANT NOTE
If your vehicle is not operated solely on propane and has not yet been modified to correct a fuel
system over-pressurization concern, announced in July, 1987 as Safety Recall 87M53, or has only
received the earlier (prior to late-October, 1987) Phase I fuel system modifications, you need to
have these modifications done as promptly as possible. You may want to have all of the required
services performed together.
NOTE: ONLY OUR SPECIALLY TRAINED DEALERS CAN WORK ON THE FUEL SYSTEM AND
SYSTEM MODIFICATIONS.
A listing of our specially trained dealers is enclosed.
THANK YOU FOR YOUR CONTINUED COOPERATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose
Replacement > Page 2076
We are sorry that we must inconvenience you again by asking you to return your Econoline-based
ambulance to your Ford or Ford Heavy Truck dealer. However we do wish to maintain your
confidence in our vehicle. Thank you for your continued cooperation in this matter of mutual
concern. THE IMPORTANCE OF PROPER COOLING SYSTEM ANTI-FREEZE MIXTURE
It is extremely important that the proper anti-freeze mixture be used in your ambulance cooling
system, and that it be maintained at recommended levels.
Ford recommends that a reasonably fresh 50% anti-freeze concentrate and 50% water mixture be
maintained in the cooling system of your ambulances at all times. This mixture provides adequate
freeze protection for most areas (50/50 mixtures provide protection to - 35~F). It also provides
optimum engine cooling and corrosion protection for the system.
Increasing the anti-freeze concentration above 50% will reduce engine cooling and result in hotter
engine operation. If you are in extremely cold area, it is permissible to use a 60% anti-freeze
concentrate and 40% water providing protection to approximately - 60~F, but only during the winter
months. (This is a revised coolant manufacturer recommendation from the information sent to you
in June, 1988, in a Motorcraft booklet "Cooling System Operation and Maintenance", dated April,
1979). The mixture should be returned to 50/50 at the end of your cold season. As the concentrate
percentage gets larger beyond 60% concentrate, the freeze protection is less. A 100% anti-freeze
concentration only protects your cooling system to - 8~F.
Decreasing the anti-freeze concentration below 40% reduces corrosion and freeze protection
(40/60 mixtures provides protection to - 10~F).
Remember:
^ Maintain cooling system mixtures at 50/50. Do not allow the mixture to be above 60/40.
^ Replace your cooling system mixture annually.
^ Replace lost coolant with a 50/50 mixture. Keep a pre-mixed supply of 50/50 mixture to refill the
system.
^ Do not refill your system with pure anti-freeze.
^ Regularly inspect and repair any cooling system leaks.
^ Replace cooling system hoses before they fail. Follow the Ford recommended replacement
intervals.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Recalls for Heater Hose: > NHTSA88V133000 > Aug > 88 > Recall 88V133000: Cooling
System Hose Replacement
Heater Hose: Recalls Recall 88V133000: Cooling System Hose Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > NHTSA89V139000 > Aug > 89 > Recall
89V139000: Heater Hose Rerouting/Repair
Heater Hose: All Technical Service Bulletins Recall 89V139000: Heater Hose Rerouting/Repair
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN UNDERHOOD FIRE. RE-ROUTE AND REPAIR HOSE, AS
NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: GAS CHASSIS - CUTAWAY AND VAN AMBULANCES.
1985 FORD TRUCK E350 1986 FORD TRUCK E350 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > NHTSA89V150000 > Aug > 89 > Recall
89V150000: Heater Hose Rerouting
Heater Hose: All Technical Service Bulletins Recall 89V150000: Heater Hose Rerouting
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN
UNDERHOOD FIRE. RE-ROUTE HOSE AS NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: AMBULANCES BUILT ON FORD E350 CHASSIS.
1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > NHTSA89V075000 > Apr > 89 > Recall
89V075000: Heater Hose Rerouting
Heater Hose: All Technical Service Bulletins Recall 89V075000: Heater Hose Rerouting
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN
UNDERHOOD FIRE. RE-ROUTE AND SPLICE HOSE AS NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: BUSES BUILT ON FORD E350 CHASSIS.
1986 FORD TRUCK E350
1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement
Technical Service Bulletin # 88S99 Date: 880901
Recall - Heater/Engine Bypass Hose Replacement
At Dealers By Order as Req'd -0- % of Parts Direct Shipped to Dealers
At PDC By Now Temporary Maximum
Date in Owner Letter 9/2/88 Order Quantity of 2 Kits
RECALL NUMBER
88S99
Date: Sept., 1988
PLEASE GIVE COPIES OF THIS BULLETIN TO YOUR PARTS AND SERVICE MANAGERS
TO: All Ford and Heavy Truck Dealers
SUBJECT: Safety Recall 88S99 - Heater and Engine Bypass Hose Replacement and Muffler
Inspections/Replacement on Certain 1983 through 1987-model 5.8L-4V H.D. and 7.5L Engine
Equipped Ford Econoline-Based Ambulances
IN CARES/OASIS - YES
REFUND CLAIMING - USE FORM 1863
MODIFICATION CLAIMING - USE FORM 1864
VEHICLES AFFECTED:
Ford Motor Company is initiating a safety recall of certain 1983 through 1987-model Econoline
E250/E350- based ambulances equipped with 7.5 Liter engines as well as certain 1985 through
1987-model Econoline E250/E350-based ambulances equipped with 5.8L 4V H.D. engines. All
involved vehicles are rated over 8,500 lbs. GW.
REASONS FOR THIS RECALL:
Investigations of recent fires involving Econolinebased ambulances have disclosed a potential for
engine compartment heater or engine bypass hoses to wear-out prematurely and rupture, allowing
engine coolant to come in contact with hot engine exhaust manifolds and possibly ignite. Testing
has indicated that worn-out hoses are not able to withstand the prolonged periods of extreme
engine operating temperatures and higher engine cooling system pressures encountered during
EMS severe-duty cycles.
ACTION BY FORD: All ambulances returned for the service provided by this Safety Recall will be
modified as follows;
^ Replacement of existing engine compartment heater and bypass hoses with silicone/NOMEX
hoses.
^ Replacement of the radiator cap.
^ Replacement of the engine coolant with a 50/50 mix of water and antifreeze. This mixture of
coolant will provide freeze protection for most areas. Extreme cold-weather areas should be
provided with a 60/40 mixture of coolant and water.
^ Pressure test the cooling system.
^ Inspection and, if necessary, installation of aluminized stainless steel mufflers on 1985-87-model
7.5L dual-thermactor engine equipped vehicles.
^ High heat resistance aluminized stainless steel mufflers will be installed on those ambulances
equipped with 1985-1987 7.5L, dual thermactor air pump-equipped engines that did not have those
mufflers installed in connection with safety recall 87M53. A temporary shortage of aluminized
stainless steel mufflers last year required the use of substitute mufflers on ambulances that were
found in need of muffler replacement at that time.
^ Underbody inspection for loose, mispositioned or missing heat-shielding parts. Contact the
Special Toll-Free Econoline/Ambulance Hotline for authorization to perform modifications as a
result of this inspection.
This service will be performed at no cost. Owner/ operators win be provided with information about
replacement recommendations for engine coolant and heater and engine bypass hoses.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2098
REFUNDS: Owner/operators of 1985-87-model 7.5L dual-thermactor engine equipped vehicles will
be provided refunds for Ford-sourced aluminized stainless steel mufflers which may have been
installed at their expense under Safety Recall 87M53. DEALERS ARE INSTRUCTED TO
PROVIDE REFUNDS TO OWNERS WHO ADEQUATELY PROVE SUCH A PURCHASE AND TO
CLAIM FOR REFUNDS USING FORM 1863.
DEALER RESPONSIBILITIES:
Owners will be told that they may wish to inform the National Highway Traffic Safety Administration
if the recall is not performed without charge or within a reasonable time after the vehicle is brought
to their dealership for repair.
REPAIR CODES: REFER TO ATTACHMENT II, EXHIBIT 1 - THE "REPAIR CODES" SHOWN ON
THE REFERENCED ATTACHMENT HAVE BEEN DEVELOPED TO ASSIST YOU IN SELECTING
THE CORRECT EXHAUST SYSTEM MUFFLERS FOR SPECIFIC VEHICLES. THESE "REPAIR
CODES" WILL BE PRINTED ON THE OWNER LETTER AND THE CLAIM FORM 1864. USE THE
CODES TO DETERMINE REQUIRED MUFFLERS AND WHEN PREPARING CLAIM FORMS
AND SERVICE DOCUMENTS.
CARES/OASIS: Dealers are to check the CARES and OASIS programs todetermine if an affected
vehicle is involved in other recalls.
CLAIM FORMS: USE CLAIM FORM 1864 FOR THE MODIFICATIONS REQUIRED FOR THIS
RECALL. USE CLAIM FORM 1863 FOR REFUNDS TO OWNERS WHO PREVIOUSLY PAID FOR
INSTALLATION Of FORD-SOURCED ALUMINIZEDSTAINLESS STEEL MUFFLERS. Refer to
Attachment I for preparation instructions.
PARTS Refer to Attachment II.
REQUIREMENTS:
LABOR ALLOWANCE: Refer to Attachment II.
TECHNICAL INSTRUCTIONS:
Refer to Attachment III.
OWNER NOTIFICATION:
Owner/operators will be notified with the letter shown on Attachment IV.
FPSD ASSISTANCE: Contact your FPSD District Service Engineer with any problems you have
concerning this recall. Additionally, a special toll-free Econoline/Ambulance Technical Hotline is
available to assist in resolving unusual repair issues technicians may encounter.
Personnel are available daily from 7:30 A.M. to 6:00 P.M., Eastern Time to provide technical
assistance by calling 1-800-445-1571.
Administrative Instructions
SAFETY RECALL 88S99 ADMINISTRATIVE INSTRUCTIONS Attachment I VEHICLES
AFFECTED:
Certain 1983 through 1987-model Econoline E250/E350- based ambulances equipped with 7.5
Liter engines as well as certain 1985 through 1987-model Econoline E250/E330- based
ambulances equipped with 5.8 Liter 4V H.D. Engines. All affected vehicles are rated over 8,500 lbs.
GVW.
REPORTING COMPLETIONS: Only the Form 1864 will be accepted for reimbursement for
modifications performed under this recall. Upon completion of the required service, the Form 1864
must be completely filled out and signed by authorized dealer personnel. CLAIM SUBMISSION:
The claims must be entered through the Direct Warranty Entry (DWE) system. Dealers without
DWE capability must mail the second copy of the Form 1864 for reimbursement. Should your
dealership receive pre-printed Forms 1864 with a seven digit claim number, you must drop the first
digit and enter only the last six digits. You must sight verify the claim number for accuracy. It is
important that all claims be filed for all completed units so you will be reimbursed and our records
will show completion.
REFUNDS: Refund requests submitted under Safety Recall 88S99 are governed by the following
guidelines:
^ Owner/operators of 1985-87 model ambulances with 7.5L dual thermactor engines are eligible for
a refund if they paid for a muffler replacement under Safety Recall 87M53 and the replacement
muffler was the new ribbed design, aluminized stainless steel muffler (See Attachment II, Exhibit 2
for eligible muffler part numbers). Paid repair orders or invoices presented by the owner/operator
requesting a refund must show one of the eligible muffler part numbers.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2099
^ Refunds include return of any deductible amount owners may have paid.
^ A copy of the paid repair orders or parts purchase receipts must be retained in your service file
for at least one year following the date of Company notification of payment.
^ Owner refund requests must be submitted on separate Warranty Claim Form 1863. In addition to
the information shown for the special preparation of Owner Refund
claims (Reference: Warranty and Policy Manual - Subject 6.1, Page 18), please enter the
information shown below:
Causal Basic Part Number - 88S99
Condition Code - OB
Labor Operation - REFUND
Administrative Allowance - 0.2 Hr.
Program Code - 88S99
^ An administrative allowance of 0.2 hours will be allowed for processing each eligible owner
refund request. To claim the allowance, enter ALLOW in the Labor Operation No. column and 0.2
in the Scheduled Time column. Extend the 0.2 hours at your authorized warranty labor rate and
enter the result in the Amount column.
^ Please provide prompt refund to all eligible owners who respond to this recall with proper repair
documentation.
Labor and Parts Ordering Instructions
SAFETY RECALL 88S99 LABOR AND PARTS ORDERING INSTRUCTIONS
Attachment II
PARTS ORDERING: Service parts required for this recall may be ordered through normal
channels. Refer to the following material and Attachment II, Exhibits 1 and 2.
Coolant Ordering
^ Since most areas will require a 50/50 mixture of antifreeze and water, order and claim for the
amount of coolant required to service each ambulance using the following information:
- In extreme cold weather areas use a 60/40 mixture, order and claim appropriately.
- Order enough coolant (Ford Part Number E2FZ-19549-AA, or equivalent) to fill the entire engine
cooling system. In most cases, 3 gallons of antifreeze and 3 gallons of water should be adequate to
attain a 50/50 mix
Service Part Number
Description Class Dealer Price
E2FZ-19549-AA Coolant, Engine V $8.65/Gallon a/
E3UZ-18472-C Kit, Heater Hose BG $64.65
E8UZ-8597-A Hose, Engine Bypass (5.8L Engs.
CG $2.25
Only)
a/ Based on $51.90, Carton 6 Gallons, order this part number or use locally purchased equivalent.
Use dealer aquisition cost for locally purchased equivalent.
Scheduled Time
LABOR OPERATIONS: Basic Labor Operation (Hours)
Inspection of the Ambulance Underbody and Exhaust System, Installation of Heater and Engine
Bypass Hose Improvement
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2100
Modifications. . . . . . . . . . . . . 2.1 Insert in Box "B" of Form 1864
LABOR OPERATIONS: (Cont'd.)
Scheduled Time
Basic Labor Operation (Hours)
Supplemental Labor Operations (Additive to Above)
Replacement of the Exhaust System Muffler, and Attaching Parts (7.5L Dual-Thermactor Engine
Equipped Vehicles . . . . . . . .
0.8 Insert in Box "B" of Form 1864
Note: Use this supplemental time when replacing mufflers on 7.5L Dual-Thermactor Engine
equipped vehicles. This time may also be used when replacing mufflers performed at owners'
expense.)
Additional Time to Access Engine Bypass Hoses on 7.5L Engine Equipped Vehicles . . . . . . . . . . . .
.
0.4 Insert in Box "B" of Form 1864
Administrative Allowance (Additive to Above)
Administrative Allowance . . . . . 0.1 Hr.
The Supplemental Labor Operations and the 0.1 hour administrative allowance must be added
before inserting the total labor time in Box "B" of the Form 1864.
Repair Code Description
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2101
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2102
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Technical Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTIONS
Attachment III
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2103
TECHNICAL INSTRUCTIONS:
Inspections:
^ Underbody - All Vehicles
1. Inspect the underbody and exhaust system for missing, loose or mispositioned heat-shielding
parts (Refer to Safety Recall 87M53 instructions).
If you discover any conditions as a result of this inspection that requires modification, please
contact the Special Toll-Free Econoline/Ambulance Hotline, 1-800-445-1571, for authorization.
Contact your District Office if the Hotline is not available.
^ Mufflers - All Vehicles
2. Refer to Attachment III, Exhibit 1. Remove the exhaust system muffler heat shields.
3. Inspect the muffler per the instructions contained in Attachment III, Exhibit 1.
^ Replace unacceptable mufflers and attaching parts at the OWNERS EXPENSE ON:
i) 1983 through 1987-model 7.5L single-thermactor engine equipped vehicles; ii) 1985 through
1987-model, 5.8L 4V H.D. engine equipped vehicles.
^ Replace any mufflers that are not Ford-sourced aluminized stainless steel and attaching parts at
FORD EXPENSE on 1985 through 1987-model, 7.5L dual thermactor engine equipped vehicles.
^ Heater and Bypass Hose Replacement:
4. Refer to Attachment III, Exhibit 2. Replace the engine compartment heater and engine bypass
hoses as shown on the referenced attachment. Note: The 5.8L 4V H.D. engines require a formed
bypass hose. This is not in the heater hose/bypass parts kit. Order this hose separately.
5. Pressure test the cooling system and replace existing radiator cap.
NOTE: Owners will be instructed to retorque hose clamps to 2.5-3.0 N-m (22-26 in.lbs.) when
coolant leakage is observed.
MODIFICATION DECAL: Prepare an "Authorized Modifications" decal (Form FPS-8262) as shown
below. Affix the decal to a flat clean surface on
the radiator support. (Order the "Authorized Modifications" decal on your Weekly Stock Order Pad.)
Specific Technical Repair Code and Parts Ordering Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
Exhaust System-Ford Components-Correct Routing and Retention
1983-1985 7.5L MODELS (MODELS WITH SINGLE AIR PUMP) 1985-1/2-1987 5.8L MODELS
(OVER 8500 GVW WITH 4 BARREL CARBURETOR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2104
FIGURE 1
The Ford exhaust system as shown in Figure 1, provides the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheatng.
FIGURE 3
Inspect the exhaust system for leaks or ruptures. FOR 5.8L ONLY, it may be necessary to remove
the heat shields as shown in Figure 3. Inspect the muffler outer wrapper lock seam for separation.
If any such problems are found, notify the customer and request permission to repair the problem,
at the customer's expense. Note any such problems and the customer's reaction to your repair
request on your internal repair order form and retain in your records.
If a non-Ford exhaust system or exhaust components is noted on the unit, inform the customer of
the potential for durability reduction, exhaust flow restriction, or overheating as indicated above.
Note any such discrepancy and the customer's reaction on your internal repair order form and
retain in your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2105
FIGURE 1
ALL 5.8L AND ONLY CALIFORNIA CALIBRATION 7.5L: If the unit is not equiped with the all-steel
hangers shown in Figure 1, order and install the Ford Service Part as indicated in the attached
chart. SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
FIGURE 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2106
1985-1/2 - 1987 7.5L MODELS (MODELS WITH DUAL AIR PUMPS - SEE FIGURE 5)
FIGURE 2
The Ford exhaust system as shown in Figure 2, provdes the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheating.
FIGURE 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2107
FIGURE 4
Remove the heat shields covering the muffler by removing the retaining clamps securing the
shields as shown in Figure 3. If the muffler is a non-Ford design or is a non-ribbed design (Figure
4), remove the Muffler and Outlet Pipe Assembly and replace with the heavy duty ribbed muffler
assembly as indicated in the attached chart.
If the muffler is the heavy duty type (ribbed design - Figure 4), installed during the 1987 M53 recall,
inspect the entire surface of the muffler for cracks or openings. If any such openings are found,
replace the Muffler and Outet Pips Assembly with a new heavy duty ribbed muffler assembly.
Advise the Ambulance Technical Hot Line 1-800-445-1571, if you find a ribbed muffler with cracks
or openings.
FIGURE 2
If the unit is not equipped with the all-steel hangers as shown in Figure 2, order and install the Ford
Service Part as indicated in the attached chart. ATTACHMENT III EXHIBIT 1 PAGE 3 OF 3
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2108
KIT NUMBER E3UZ-18472-C HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED
AMBULANCES WITH 7.5L OR 5.8L 4V H.D. ENGINES SPECIAL NOTE: The following instructions
describe the installation procedure for the heater hose/bypass hose improvement package. It is
designed specially for Ford E-350 and E-250 (over 8500 pounds GVWR) based ambulances. The
original Ford heater hose system has probably been modified by the ambulance body builder. It is
not possible to identify all the designs and modifications used by these manufacturers. If you
encounter difficulties not anticipated in these instructions, contact the Ford Ambulance Recall
Hotline on 1-800-445-1571. PARTS LIST
Item Description Part Number Quantity
1 Silicons Hose - 5/8" I.D. *EST-M2D309-A 96"
2 Hose Clamp 388652-S2 20
3 "Y" Fitting D8UH-18663-AA 2
4 Tie Strap - 1/4" Wide 384213-S 10
5 Radiator Cap E5TH-8100-AA 1
*Engineering Specification Number
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2109
FIGURE 1
HEATER HOSE REMOVAL
1. Close the shutoff valves that connect the rear heater unit to the Ford installed heater hoses (See
Figure 1). Be sure to close both the supply and return hose valves. Failure to close these valves
could cause coolant fill problems later.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2110
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT.
2. Drain the coolant from the radiator by removing the radiator cap and carefully opening the drain
cock at the bottom of the radiator. After the coolant has drained from the radiator, close the drain
cock and discard the radiator cap.
3. Disconnect and remove any objects, such as thermactor pump filter/silencer or coolant overflow
bottle, obstructing access to the heater hoses.
4. Inspect the hoses for chaffing or cuts (See Figure 1). Note the position of any straps or clamps
for securing the new hoses at time of installation.
5. Disconnect the vacuum line from the water supply valve.
6. Disconnect the inlet and outlet hoses from the heater core, engine block, and rear heater shutoff
valves (See Figure 1). Loosen each clamp and cut the hose first to prevent core damage. DO NOT
twist hoses in the removal process. Disconnect the hoses from any locating clips. Discard all hose
clamps.
NOTE: DO NOT disconnect the hoses routed from the shutoff valves to the rear heater unit.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2111
FIGURE 1
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2112
FIGURE 2
HEATER HOSE INSTALLATION
1. Using hoses (Item 1), hose clamps (Item 2) and "Y" fittings (Item 3), assemble duplicate hose
layouts of the removed hose assemblies (Figure 1).
NOTE: The hoses leading from the "Y" fittings may have to be slightly longer than the original
hoses to avoid any kinks or bends. This is due to the replacement fittings having a different angle in
the "Y" than the original "Y" or "T" fittings. Silicone hoses require the special clamps Included in the
kit to prevent cutting the hose. DO NOT use any other type of clamp.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 1 OF 5
on 1-800-445-1571 if you have any questions.
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
2. Remove the vacuum operated water supply valve from the old hose assembly and install it into
the new hose assembly.
NOTE: Make sure that the flow arrow stamped on the valve is pointing toward the heater core.
3. Torque the clamps (Item 2) to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
4. Connect the hose assemblies with clamps (Item 2) to the engine block, heater core and rear shut
off valves.
5. Torque the clamps to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
6. Connect the vacuum line to the water supply valve.
7. Using tie straps (Item 4), secure the hoses to an adjacent engine component to prevent chaffing
or cutting during engine operation. The hoses may be secured in a manner similar to the original
method if the removed hoses were not damaged as noted earlier. If the original hoses were
damaged, route the hoses and secure them in a manner to prevent hose damage during engine
operation.
WATER BYPASS HOSE REMOVAL AND INSTALLATION FOR VEHICLES WITH 7.5L ENGINES
1. Remove the distributer vacuum hose to improve accessibility to the water bypass hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2113
FIGURE 2
2. Remove the water bypass hose and clamps (See Figure 2). Discard the clamps.
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
CAUTION: DO NOT ALTER (CUT OFF) THE INTAKE MANIFOLD AND/OR THE WATER PUMP
HOSE CONNECTIONS. ANY
DAMAGE SUCH AS SHARP EDGES, TO THESE CONNECTIONS WILL RESULT IN DAMAGE
TO THE NEW BYPASS HOSE DURING INSTALLATION.
4. Using the removed hose as a pattern, cut a piece of silicone hose (Item 1) to the proper length
and position it on the intake manifold bypass connection.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 3 OF 5
on 1-800-445-1571 if you have any questions
FIGURE 3
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D ENGINES
5. Position two (2) new hose clamps (Item 2) on the new hose, installed in Step 4, toward the
intake manifold. (See Figure 3.)
6. Bend (double over) the new bypass hose downward and slide the hose on to the water pump
bypass hose connection. (See Figure 3.)
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2114
FIGURE 4
FOR VEHICLES WITH 5.8L ENGINES
1. Remove the distributor vacuum hose to improve accessibility to the water bypass hose.
2. Remove the water bypass hose and clamps (See Figure 4). Discard the clamps.
Don't forget... ATTACHMENT III
call the Special Econline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 4 OF 5
on 1-800-445-1571 if you have any questions!
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
4. Position a new formed bypass hose (Part number E8UZ-8597-A) on the intake manifold bypass
connection.
5. Position two (2) new hose clamps (Item 2) on the new hose toward the intake manifold.
6. Bend and slide the hose on to the water pump bypass hose connection.
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to:) 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose, PRESSURE TEST COOLING SYSTEM
1. Reinstall all of the objects such as the thermactor pump filter/silencer or coolant overflow bottle,
that obstructed access to the heater hoses.
2. Fill the cooling system with a coolant mixture of 50/50 Ford Long Life Coolant E2FZ-19549-AA
(ESE-M97B44-A) or equivalent and water, to 38 mm (1.5 inches) below the cap seal.
3. Install radiator cap (Item 5)
WARNING: DO NOT STAND IN LINE WITH OR NEAR THE RADIATOR FAN WHEN THE
ENGINE IS RUNNING.
4. Start the engine, let it warm until the upper radiator hose is hot, shut off the engine. Allow the
engine to cool, remove the cap and check the coolant level. Fill as required.
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2115
5. Using the Rotunda Cooling System Pressurization Kit 021-00012, pressurize the cooling system
to 20 psi and check for leaks. Be sure to follow the instructions in the kit on the recommmended
method of connecting the tester to the radiator.
6. If any leaks are found, correct as needed.
7. Pressure test the cooling system until no leaks we found.
8. Rechock the coolant level in the radiator to make sure that it is 38 mm (1.5 inches ) below the
cap seal. If it is not, fill as required.
9. Reinstall the radiator cap and add coolant to the overflow bottle as required.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 5 OF 5
on 1-800-445-1571 if you have any questions!
Owner & Operator Letter Information
Attachment IV
September 2, 1988
Dear Owner/Operator:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
Ford Motor Company has determined that a defect which relates to Motor Vehicle Safety evists in
certain 1983-1987 Econoline-based ambulances equipped with 7.5 liter or 5.8 liter 4V H.D. V8
engines. Due to the prolonged periods of extreme engine operating temperatures and cooling
system pressures encountered during EMS severe-duty cycles, heater or engine bypass hoses
may wear-out prematurely and burst. Engine coolant ("antifreeze") from a burst hose may cause a
fire if it sprays onto an overheated engine exhaust manifold, especially if the coolant is
overconcentrated.
Ford Motor Company is now asking that you return your Econoline-based ambulance to your Ford
or Ford Heavy Truck Dealer for corrective action.
COOLING SYSTEM SERVICE
At no cost to you, your dealer will:
- replace certain "rubber" heater hoses installed by Ford Motor Company when the vehicle was
manufactured (ie., up to the auxiliary heater shut-off valves), with new "SILICONE/NOMEX" heater
hose;
- replace engine bypass hoses
- replace the engine coolant (with a proper 50/50 mixture);
- install a new radiator cap;
- pressure test the cooling system.
Most ambulances also have auxiliary heater systems. The ambulance body manufacturer typically
installs these heater systems. While these hoses are not part of this safety recall, we strongly
recommend that you consider replacing all non-silicone/Nomex @ auxiliary heater hoses also. THE
COST OF REPLACING THE AUXILIARY HEATER HOSES WILL BE AT YOUR EXPENSE. IF
LEAKS ARE FOUND IN OTHER COMPONENTS OF THE ENGINE COOLING SYSTEM, WHEN
THE SYSTEM IS PRESSURE TESTED SUCH AS THE RADIATOR OR RADIATOR HOSES, THE
COST OF REPAIRING THOSE COMPONENTS WILL BE AT YOUR EXPENSE.
FOR ALL HEATER SYSTEM HOSE REPLACEMENTS, FORD RECOMMENDS THAT YOU
SPECIFY HOSES MADE ONLY FROM THE "SILICONE/NOMEX" MATERIAL. SILICONE HOSES
ALSO REQUIRE SPECIAL HOSE CLAMPS TO PREVENT CUTTING THE HOSE. USE ONLY
THE HOSE CLAMPS RECOMMENDED BELOW WITH SILICONE HOSES.
When purchasing replacements, the following parts should be specified:
Ford Service Motorcraft Brand
Part Name Part Number Part Number
- SILICONE/NOMEX E8TZ-18472-H KH-15
Heater Hose - 25 foot lengths
- Formed Water Pump Bypass E8UZ-8597-A KMS-1776
Hose (for 5.8L 4V H.D. Engine)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2116
- Hose Clamps D9AZ-8287-C YF-842
It is important also that the proper torque be used when attaching the special hose clamps required
for SILICONE/NOMEX hoses. Your dealer will properly torque clamps when they install the heater
and engine bypass hoses on your ambulance. If you should notice coolant seepage, retorque the
clamps to 2.5 to 3.0 N-m (22-26 in.lbs.).
These parts are available through your Ford, Lincoln-Mercury or Ford Heavy Truck Dealer. They
are also available through any Motorcraft parts distributor.
Ford recommends that you always replace these SILICONE/NOMEX HEATER SYSTEM hoses
every 48,000 miles or 48 months, whichever comes first. Non-silicone hoses should be replaced
every 24,000 miles or 24 months, whichever comes first.
It is important that your ambulance cooling system have the proper anti-freeze coolant and water
mixture for adequate freeze protection. Please read and observe the recommendations on the
attachment, "The Importance of Proper Cooling System Anti-freeze Mixtures".
EXHAUST SYSTEM SERVICE
^ Certain 198-5-1987 Model Ambulances with 7.5 Liter/Dual Thermactor Engines
Ambulances with 7.5 Liter V8 engines and a dual-thermactor emission system will have a new
aluminized stainless steel muffler installed. Mufflers and installation will be free of charge.
Some of these ambulances may have already had new alumunized stainless steel mufflers
installed during the earlier recall. These vehicles will not need new mufflers.
^ Refunds for Certain Later Model Muffler Replacements
As noted above, some of these ambulances with 7.5 liter/dual thermactor engines may have
received the new aluminized stainless steel mufflers during the service for the earlier Safety Recall
87M53. If you paid to have these new aluminized stainless steel mufflers installed, you are entitled
to a refund for the costs of parts and labor. If you are entitled to this refund, please present your
paid receipt to any Ford or Ford Heavy Truck Dealer who will process a refund for you.
This receipt must show the date of repair, the part numbers for the new aluminized stainless steel
muffler and attaching parts as well as the parts and labor costs.
^ Other 7.5 Liter and 5.8 Liter 4V H.D. Engine Equipped Ambulances
Ambulances with 7.5 Liter V8 engines and a single thermactor emission system as well as all
1985-1987 model ambulances with 5.8 Liter 4V H.D. V8 engines will only have the muffler
inspected. Replacement of defective mufflers will be the owner's responsibility.
SCHEDULE SERVICE AT ANY FORD OR FORD HEAVY TRUCK DEALER NOW
Since the cooling system parts, mufflers and instructions are now available, we urge you to
schedule this service as quickly as possible.
NOTE: ANY FORD OR FORD HEAVY TRUCK DEALER CAN DO THE COOLING SYSTEM AND
MUFFLER SERVICE.
Before you return your vehicle for this service, we urge you to review the cooling system
information sent to you in June, 1988. Some cooling system maintenance may be needed now.
COMPUTER FORM
The computer form included with this letter may include a special part code. Your dealer will need
to know this code when you call to make an appointment. The code, located in the box labeled "Kit
Code", half way down the right side of the form, will be a single digit number from 1 through 8.
IMPORTANT NOTE
If your vehicle is not operated solely on propane and has not yet been modified to correct a fuel
system over-pressurization concern, announced in July, 1987 as Safety Recall 87M53, or has only
received the earlier (prior to late-October, 1987) Phase I fuel system modifications, you need to
have these modifications done as promptly as possible. You may want to have all of the required
services performed together.
NOTE: ONLY OUR SPECIALLY TRAINED DEALERS CAN WORK ON THE FUEL SYSTEM AND
SYSTEM MODIFICATIONS.
A listing of our specially trained dealers is enclosed.
THANK YOU FOR YOUR CONTINUED COOPERATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 88S99 > Sep > 88 > Recall - Heater/Engine
Bypass Hose Replacement > Page 2117
We are sorry that we must inconvenience you again by asking you to return your Econoline-based
ambulance to your Ford or Ford Heavy Truck dealer. However we do wish to maintain your
confidence in our vehicle. Thank you for your continued cooperation in this matter of mutual
concern. THE IMPORTANCE OF PROPER COOLING SYSTEM ANTI-FREEZE MIXTURE
It is extremely important that the proper anti-freeze mixture be used in your ambulance cooling
system, and that it be maintained at recommended levels.
Ford recommends that a reasonably fresh 50% anti-freeze concentrate and 50% water mixture be
maintained in the cooling system of your ambulances at all times. This mixture provides adequate
freeze protection for most areas (50/50 mixtures provide protection to - 35~F). It also provides
optimum engine cooling and corrosion protection for the system.
Increasing the anti-freeze concentration above 50% will reduce engine cooling and result in hotter
engine operation. If you are in extremely cold area, it is permissible to use a 60% anti-freeze
concentrate and 40% water providing protection to approximately - 60~F, but only during the winter
months. (This is a revised coolant manufacturer recommendation from the information sent to you
in June, 1988, in a Motorcraft booklet "Cooling System Operation and Maintenance", dated April,
1979). The mixture should be returned to 50/50 at the end of your cold season. As the concentrate
percentage gets larger beyond 60% concentrate, the freeze protection is less. A 100% anti-freeze
concentration only protects your cooling system to - 8~F.
Decreasing the anti-freeze concentration below 40% reduces corrosion and freeze protection
(40/60 mixtures provides protection to - 10~F).
Remember:
^ Maintain cooling system mixtures at 50/50. Do not allow the mixture to be above 60/40.
^ Replace your cooling system mixture annually.
^ Replace lost coolant with a 50/50 mixture. Keep a pre-mixed supply of 50/50 mixture to refill the
system.
^ Do not refill your system with pure anti-freeze.
^ Regularly inspect and repair any cooling system leaks.
^ Replace cooling system hoses before they fail. Follow the Ford recommended replacement
intervals.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > NHTSA88V133000 > Aug > 88 > Recall
88V133000: Cooling System Hose Replacement
Heater Hose: All Technical Service Bulletins Recall 88V133000: Cooling System Hose
Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Coolant Level Indicator Lamp > Component Information > Description and Operation
Coolant Level Indicator Lamp: Description and Operation
This lamp will be illuminated when engine coolant level in the radiator drops below a
pre-determined level. To turn lamp off, check cooling system, then add coolant to bring system to
proper level.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test
Temperature Gauge: Testing and Inspection Dash Gauge Test
Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble
should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by
clamps, check to see whether the insulation has been severed, thereby grounding the wire. In the
case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of
the tank unit. The Constant Voltage Regulator (CVR) type indicator is a bimetal-resistance type
system consisting of an Instrument Voltage Regulator (IVR), an indicator gauge, and a variable
resistance sending unit. Current to the system is applied to the gauge terminals by the IVR, which
maintains an average-pulsating value of 5 volts. The indicator gauge consists of a pointer which is
attached to a wire-wound bimetal strip. Current passing through the coil heats the bimetal strip,
causing the pointer to move. As more current passes through the coil, heat increases, moving the
pointer farther. The circuit is completed through a sending unit which contains a variable resistor.
When resistance is high, less current is allowed to pass through the gauge, and the pointer moves
very little. As resistance decreases due to changing conditions in system being monitored, more
current passes through gauge coil, causing pointer to move farther. Do not apply battery voltage to
system or ground output terminals of IVR, as damage to system components or wiring circuits may
result.
DASH GAUGE TEST
1. Disconnect battery ground cable and remove gauge from vehicle.
2. Connect ohmmeter between gauge terminals and read coil winding resistance.
3. An upward movement of ohmmeter needle from 10 ohms to 14 ohms is normal, as test current
of ohmmeter causes a temperature rise in gauge coil windings.
4. If ohmmeter reads below 10 ohms or above 14 ohms, gauge is defective.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test > Page 2130
Temperature Gauge: Testing and Inspection Electrical Temperature Gauges
This temperature indicating system consists of a sending unit, located on the cylinder head,
electrical temperature gauge and an instrument voltage regulator. As engine temperature increases
or decreases, the resistance of the sending unit changes, in turn controlling current flow to the
gauge. When engine temperature is low, the resistance of the sending unit is high, restricting
current flow to the gauge, in turn indicating low engine temperature. As engine temperature
increases, the resistance of the ending unit decreases, permitting an increased current flow to the
gauge, resulting in an increased temperature reading.
TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions
included with the tester.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Testing and Inspection
Temperature Warning Lamp/Indicator: Testing and Inspection
A bimetal temperature switch located in the cylinder head control the operation of a temperature
indicator light with a red lens. If the engine cooling system is not functioning properly and coolant
temperature exceeds a predetermined value, the warning light will illuminate.
TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a
burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when
the engine is running, check the wiring between light and switch for a ground, defective
temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is
functioning properly, a wire which is connected to the ground terminal of the ignition switch is
tapped into its circuit. When the ignition is in the ``Start'' (engine cranking) position, the ground
terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and
the ignition switch is in the ``On'' position, the test circuit is opened and the bulb is then controlled
by the temperature switch.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Specifications
Radiator Cap: Specifications
Release Pressure 13 psi
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information >
Technical Service Bulletins > Recalls for Radiator Hose: > NHTSA88V133000 > Aug > 88 > Recall 88V133000: Cooling
System Hose Replacement
Radiator Hose: Recalls Recall 88V133000: Cooling System Hose Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Radiator Hose: > NHTSA88V133000 > Aug > 88 > Recall
88V133000: Cooling System Hose Replacement
Radiator Hose: All Technical Service Bulletins Recall 88V133000: Cooling System Hose
Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
TEMPERATURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Coolant Temperature Sensor
Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor
Near Front Of Valve Cover
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Coolant Temperature Sensor > Page 2157
Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Switch (For
Computer)
RH Side Of V8-302/5.
Top Forward RH Side Of Engine, Under Water Outlet
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 2158
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Fig. 7 Engine coolant temperature (ECT) sensor
The ECT, Fig. 7, sensor detects the temperature of engine coolant and supplies information to the
ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine
control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture.
On models with an electronic instrument cluster, the ECT output is used to control the coolant
temperature indicator.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component
Information > Specifications
Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque
Switch Torque
Cooling Fan Switch 8-18 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations
Temperature Sensor (Gauge): Locations
LH Side Of V8-460/7.
LH Front Of Engine
Applicable to: 5L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information
> Testing and Inspection > Dash Gauge Test
Temperature Gauge: Testing and Inspection Dash Gauge Test
Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble
should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by
clamps, check to see whether the insulation has been severed, thereby grounding the wire. In the
case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of
the tank unit. The Constant Voltage Regulator (CVR) type indicator is a bimetal-resistance type
system consisting of an Instrument Voltage Regulator (IVR), an indicator gauge, and a variable
resistance sending unit. Current to the system is applied to the gauge terminals by the IVR, which
maintains an average-pulsating value of 5 volts. The indicator gauge consists of a pointer which is
attached to a wire-wound bimetal strip. Current passing through the coil heats the bimetal strip,
causing the pointer to move. As more current passes through the coil, heat increases, moving the
pointer farther. The circuit is completed through a sending unit which contains a variable resistor.
When resistance is high, less current is allowed to pass through the gauge, and the pointer moves
very little. As resistance decreases due to changing conditions in system being monitored, more
current passes through gauge coil, causing pointer to move farther. Do not apply battery voltage to
system or ground output terminals of IVR, as damage to system components or wiring circuits may
result.
DASH GAUGE TEST
1. Disconnect battery ground cable and remove gauge from vehicle.
2. Connect ohmmeter between gauge terminals and read coil winding resistance.
3. An upward movement of ohmmeter needle from 10 ohms to 14 ohms is normal, as test current
of ohmmeter causes a temperature rise in gauge coil windings.
4. If ohmmeter reads below 10 ohms or above 14 ohms, gauge is defective.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information
> Testing and Inspection > Dash Gauge Test > Page 2169
Temperature Gauge: Testing and Inspection Electrical Temperature Gauges
This temperature indicating system consists of a sending unit, located on the cylinder head,
electrical temperature gauge and an instrument voltage regulator. As engine temperature increases
or decreases, the resistance of the sending unit changes, in turn controlling current flow to the
gauge. When engine temperature is low, the resistance of the sending unit is high, restricting
current flow to the gauge, in turn indicating low engine temperature. As engine temperature
increases, the resistance of the ending unit decreases, permitting an increased current flow to the
gauge, resulting in an increased temperature reading.
TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions
included with the tester.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine
Cooling > Component Information > Testing and Inspection
Temperature Warning Lamp/Indicator: Testing and Inspection
A bimetal temperature switch located in the cylinder head control the operation of a temperature
indicator light with a red lens. If the engine cooling system is not functioning properly and coolant
temperature exceeds a predetermined value, the warning light will illuminate.
TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a
burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when
the engine is running, check the wiring between light and switch for a ground, defective
temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is
functioning properly, a wire which is connected to the ground terminal of the ignition switch is
tapped into its circuit. When the ignition is in the ``Start'' (engine cranking) position, the ground
terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and
the ignition switch is in the ``On'' position, the test circuit is opened and the bulb is then controlled
by the temperature switch.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Technical Service Bulletins > Cooling System - New System Diagnostics
Thermostat: Technical Service Bulletins Cooling System - New System Diagnostics
Article No. 93-24-8
11/24/93
^ HESITATION - ROUGH IDLE - ENGINE COOLANT DOES NOT REACH NORMAL OPERATING
TEMPERATURE - MEDIUM TRUCKS WITH 7.0L ENGINES
^ HESITATION/STALL DURING ACCELERATION OR DECELERATION
^ IDLE - ROUGH - ENGINE COOLANT DOES NOT REACH NORMAL OPERATING
TEMPERATURE
^ HEATER/DEFROSTER - POOR HEATER OUTPUT - THERMOSTAT STUCK OPEN
^ COOLING SYSTEM - NEW DIAGNOSTICS FOR ENGINES THAT DO NOT REACH NORMAL
OPERATING TEMPERATURE
FORD: 1983-94 ESCORT 1984-87 EXP 1984-94 CROWN VICTORIA, MUSTANG, TEMPO,
THUNDERBIRD 1986-94 TAURUS
LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-92 MARK VII 1984-94
CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89
TRACER 1991-94 CAPRI, TRACER
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1985-90
BRONCO II 1986-94 AEROSTAR 1988-94 F SUPER DUTY 1991-94 EXPLORER
This TSB article is being republished in its entirety to include 1994 model year vehicles.
ISSUE: Engine performance concerns such as hesitation or stall, rough idle, and/or poor fuel
economy may be caused by the thermostat stuck in an open position or opening at a temperature
lower than specified.
ACTION:
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Technical Service Bulletins > Cooling System - New System Diagnostics > Page 2177
Use the following "Cooling System Diagnosis" procedure to diagnose a cooling system that may
not be reaching normal operating temperature. Follow the "Thermostat Diagnosis" procedure to
determine if the thermostat may be at fault. Check the thermostat without removing it from the
vehicle by using Rotunda Service Coolant Temperature Monitor Harness 007-00064.
A new cooling system diagnosis procedure has been developed for engines that do not reach
normal operating temperature. A new thermostat diagnosis procedure also has been developed,
using a new service coolant temperature monitor harness.
NOTE: THIS PROCEDURE WILL DIAGNOSE ONLY COOLING SYSTEMS THAT MAY NOT BE
REACHING NORMAL OPERATING TEMPERATURE. IT WILL NOT DIAGNOSE A
THERMOSTAT THAT CAUSES AN ENGINE OVERHEAT CONDITION.
NOTE: THE ESCORT/TRACER SPECIFIC APPLICATION FOR THIS ARTICLE IS AS FOLLOWS:
^ 1983-1990 Escort 1.9L and 1.6L
^ 1991-1994 Escort 1.9L
^ 1991-1994 Tracer 1.9L Only
THERMOSTAT DIAGNOSIS
NOTE: DISCONNECTING THE POWERTRAIN CONTROL MODULE (PCM) TO ATTACH A
BREAKOUT BOX OR AN EEC IV MONITOR WILL ERASE THE ADAPTIVE LEARNING FROM
MEMORY AND MAY "HIDE" A DRIVE CONCERN TEMPORARILY UNTIL THE ADAPTIVE
LEARNING IS RE-LEARNED.
NOTE: THIS PROCEDURE IS MOST ACCURATE IF PERFORMED INDOORS AT LESS THAN
100~F (38~C) AMBIENT TEMPERATURE. THIS TEST MAY BE PERFORMED WITH OR
WITHOUT THE HOOD OPEN AND WITH THE ENGINE WARM OR COLD.
CAUTION: ALWAYS VENT THE EXHAUST TO THE OUTSIDE WHEN PERFORMING THIS
TEST.
1. Check the coolant level in the radiator and coolant recovery reservoir.
2. With the key in the "off" position, proceed as follows:
a. Remove the engine coolant temperature (ECT) sensor harness connector.
b. Attach Rotunda Service Coolant Temperature Monitor Harness 007-00064 as a jumper between
the PCM and the ECT.
c. Attach Rotunda 73 Digital Multimeter 105-00051 or equivalent to the thermostat monitor harness.
Voltage values (0-5vdc) may now be
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Technical Service Bulletins > Cooling System - New System Diagnostics > Page 2178
monitored while the sensor retains its connection to the wiring harness.
NOTE: A ROTUNDA NEW GENERATION STAR TESTER (NGS) 007-00500 OR THE ROTUNDA
SERVICE BAY DIAGNOSTIC SYSTEM (SBDS) 001-00001 MAY BE USED TO MONITOR THE
ECT ON VEHICLES EQUIPPED WITH DATA COMMUNICATIONS LINK (DCL). THE SBDS
SEQUENCE TO USE FOR THE SCREEN IS "TOOLBOX - ELECTRONIC ENGINE CONTROL
AND DCL - ITEM".
3. Vehicles equipped with electric engine cooling fan(s) must have a fan running during this test
(high or low speed may be used). Two methods may be used to turn the fan(s) on:
a. Disconnect the A/C compressor clutch power supply and turn the climate control to A/C "ON". Or
b. Disconnect the power supply to the cooling fan and supply 12 volts direct to the fan connector
from the battery.
NOTE: A GROUND MAY BE REQUIRED FOR SOME APPLICATIONS.
4. Place transmission in "park" or "neutral".
NOTE: RUNNING THIS TEST WITH THE VEHICLE IN GEAR OR WITH THE A/C COMPRESSOR
CLUTCH ENGAGED (RUNNING) WILL CAUSE IMPROPER DIAGNOSIS
5. Start the engine and allow to idle throughout this test:
a. Allow engine to run for 2 minutes, then record ECT voltage.
b. From now on, record ECT voltage every 60 seconds.
c. When the ECT voltage trend changes direction or changes only slightly (0.03 volts or less) from
the previous reading, record this as the thermostat opening voltage.
d. Use the "Voltage and Corresponding Temperature Chart" shown to obtain actual coolant
temperatures.
6. If the opening voltage is GREATER than 0.75 volts (less than 18~ F/ 82~ C), or 0.85 volts (170~
F/ 77~ C) for 2.3L HSC engine only, replace the thermostat. Refer to the dealer Master Parts
Catalog for correct thermostat usage.
7. If the thermostat opening voltage is LESS than 0.75 volts (greater than 180~ F/ 82~ C), or 0.85
volts (170~ F/ 77~ C) for 2.3L HSC engine only, the thermostat is good and should NOT be
replaced. The "Cooling System Diagnosis Chart" should be referenced for further instructions.
NOTE: The 10~ F opening temperature difference for the 2.3L HSC engine is due to the ECT
sensor location.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-14-4 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 208000, 208100, 402000, 608000, 608400, 609000,
609400, 611000, 611500, 622000, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump >
Component Information > Technical Service Bulletins > Customer Interest for Drive Pulley: > 87724 > Apr > 87 > Water
Pump - Coolant Leaks
Drive Pulley: Customer Interest Water Pump - Coolant Leaks
Article No. ^ WATER LEAKS - 7.5L - LEAKS ENGINE COOLANT
87-7-24
^ LEAKS - ENGINE COOLANT - 7.5L WATER PUMP
LIGHT TRUCK: 1984-87 E SERIES, F SERIES
ISSUE: Coolant leaks at the water pump caused by a pulled out bearing or a cracked water pump
housing may be due to excessive "RUN-OUT" of the water pump pulley.
ACTION: To correct this, install a new water pump and water pump pulley E5TZ- 8509-G
(two-groove) or E5TZ-8509-H (three-groove pulley).
NOTE: Water pump kit (E5TZ-8501-C) includes a water pump and a three-groove pulley which
may be used in place of the existing two-groove pulley application.
PART NUMBER PART NAME CLASS
E5TZ-8509-GWater Pump Pulley - C
Two-Groove
E5TZ-8509-H Water Pump Pulley - BM
Three-Groove
E5TZ-8501-C Water Pump Kit - B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: 8501A TIME:
Refer to the appropriate Service Labor Standards Manual for the reimbursement allowance
DLR. CODING: Basic Part No. 8501 - Code: 43
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Pulley: > 87724 > Apr > 87
> Water Pump - Coolant Leaks
Drive Pulley: All Technical Service Bulletins Water Pump - Coolant Leaks
Article No. ^ WATER LEAKS - 7.5L - LEAKS ENGINE COOLANT
87-7-24
^ LEAKS - ENGINE COOLANT - 7.5L WATER PUMP
LIGHT TRUCK: 1984-87 E SERIES, F SERIES
ISSUE: Coolant leaks at the water pump caused by a pulled out bearing or a cracked water pump
housing may be due to excessive "RUN-OUT" of the water pump pulley.
ACTION: To correct this, install a new water pump and water pump pulley E5TZ- 8509-G
(two-groove) or E5TZ-8509-H (three-groove pulley).
NOTE: Water pump kit (E5TZ-8501-C) includes a water pump and a three-groove pulley which
may be used in place of the existing two-groove pulley application.
PART NUMBER PART NAME CLASS
E5TZ-8509-GWater Pump Pulley - C
Two-Groove
E5TZ-8509-H Water Pump Pulley - BM
Three-Groove
E5TZ-8501-C Water Pump Kit - B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: 8501A TIME:
Refer to the appropriate Service Labor Standards Manual for the reimbursement allowance
DLR. CODING: Basic Part No. 8501 - Code: 43
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
Catalytic Converter: Customer Interest Engine - Lack of Power and/or No Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
> Page 2202
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
> Page 2203
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
> Page 2204
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
> Page 2205
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
> Page 2206
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
> Page 2207
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
> Page 2208
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No
Start Condition
Catalytic Converter: All Technical Service Bulletins Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No
Start Condition > Page 2214
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No
Start Condition > Page 2215
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No
Start Condition > Page 2216
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No
Start Condition > Page 2217
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No
Start Condition > Page 2218
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No
Start Condition > Page 2219
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power and/or No
Start Condition > Page 2220
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins: > 911211 > Jun > 91 > Engine - Lack of Power/No Start
Diagnosis
Catalytic Converter: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins: > 911211 > Jun > 91 > Engine - Lack of Power/No Start
Diagnosis > Page 2225
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Technical Service Bulletins: > 911211 > Jun > 91 > Engine - Lack of Power/No Start
Diagnosis > Page 2226
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 902317 > Nov > 90 > Driveline Vibration Cross Member Cracks
Subframe: All Technical Service Bulletins Driveline - Vibration Cross Member Cracks
^ VIBRATION - DRIVELINE - VEHICLES WITH C6 TRANSMISSION
^ DRIVELINE - VIBRATION - VEHICLES WITH C6 TRANSMISSION
Article No. 90-23-17 LIGHT TRUCK:
1987-88 E-350
ISSUE: A driveline vibration may be caused by a crack in the crossmember between the
transmission mounting bolts. This may occur on high GVW applications and trucks making multiple
stops and starts.
ACTION: Install a new # 2 transmission cross member if any cracks are found during the
inspection. Refer to the following procedure for service details. If no cracks are found, refer to the
NVH diagnostics in the 1987-88 Light Truck Shop Manual, Volume A, Section 18-01 for corrective
action.
Figure 1
1. Remove and throw away the cracked transmission cross member. Refer to the 1987-88 Light
Truck Shop Manual, Volume A, Section 17-01 for removal procedure.
2. Inspect the transmission insulator for damage.
a. If any damage is detected, replace the transmission insulator. Clean the threads with Ford Spot &
Stain Remover (B7A-19521-AA).
b. If the transmission insulator is not damaged, clean the bolt threads with a wire brush and Ford
Spot & Stain Remover (B7A-19521-AA).
3. Replace the insulator nuts and washers with new ones (N621945-S2).
4. Throw away the cross member to frame bolts and nuts. Replace them with new ones.
5. Apply Threadlocker 262 to all fasteners (Cross member-to-frame and cross member-to-insulator
nut). Be sure that all fastener surfaces are cleaned with Ford Spot & Stain Remover
(B7A-19521-AA).
6. Loosely install the new # 2 transmission cross member (E8UZ-6A023-A) to the frame side rails.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 902317 > Nov > 90 > Driveline Vibration Cross Member Cracks > Page 2232
Figure 2
7. Loosely install a fabricated reinforcement strap under the cross member.
a. Refer to Figure 2 for strap specifications and dimensions
b. Start nuts and run up to the point where they will hold the reinforcement strap in place.
8. Tighten the cross member-to-frame bolts and nuts to 65-70 lb.ft. (88-95 N-m).
9. Tighten the transmission insulator nuts to 75-80 lb.ft. (102-108 N-m).
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
902317A Install Cross member 1.1 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
6A023 01
OASIS CODES: 703000, 305000, 504000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 902317 > Nov > 90 > Driveline Vibration Cross Member Cracks > Page 2238
Figure 2
7. Loosely install a fabricated reinforcement strap under the cross member.
a. Refer to Figure 2 for strap specifications and dimensions
b. Start nuts and run up to the point where they will hold the reinforcement strap in place.
8. Tighten the cross member-to-frame bolts and nuts to 65-70 lb.ft. (88-95 N-m).
9. Tighten the transmission insulator nuts to 75-80 lb.ft. (102-108 N-m).
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
902317A Install Cross member 1.1 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
6A023 01
OASIS CODES: 703000, 305000, 504000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Dual Catalytic Converter
Catalytic Converter: Description and Operation Dual Catalytic Converter
Fig. 17 Dual catalytic converter
This converter consists of two catalytic converters in one shell, with a mixing chamber in between
the two, Fig. 17. Each converter is composed of a ceramic ``honey comb'' coated with a
rhodium/platinum catalyst designed to control oxides of nitrogen (NOx), unburned hydrocarbons
(HC) and carbon monoxide (CO), and is therefore called a ``three way catalyst'' (TWC). The rear
converter is coated with platinum catalyst and is called a ``conventional'' oxidation catalyst'' (COC)
converter. The platinum catalyst is also called a ``two way catalyst'' since it only acts on two of the
major pollutants, HC and CO.
The TWC converter acts on the exhaust gases from the engine. As the gases flow from the TWC to
the COC converter, they mix with air from the thermactor pump injected into the mixing chamber or
``mid-bed''. This air is required for proper oxidation of HC and CO in the COC converter.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Dual Catalytic Converter > Page 2241
Catalytic Converter: Description and Operation General Description
Fig. 4 Single type catalytic converter with single substrate catalyst
Fig. 5 Single type catalytic converter with dual substrate catalyst
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Dual Catalytic Converter > Page 2242
Fig. 6 Dual type catalytic converter
The catalytic converter used on some vehicles, serves two purposes: it permits a faster chemical
reaction to take place and although it enters into the chemical reaction, it remains unchanged,
ready to repeat the process. The catalytic converter combines hydrocarbons (HC) and carbon
monoxide (CO) with oxygen to form water (H2O) and carbon dioxide (CO2). The catalyst is
structured in the form of a honeycomb monolithic composition, Figs. 4,5 and 6 . The catalyst
consists of a porous substrate of an inert material, coated with platinum and other noble metals
(the catalytically active materials.) This device, located in the exhaust system between the exhaust
manifold and muffler, requires the use of heat shields, in some cases, due to its high operating
temperatures. The heat shields are necessary to protect chassis components, passenger
compartment and other areas from heat related damage. A small diameter fuel tank filler tube neck
is incorporated to prevent the larger service station pump nozzle, used for leaded fuels, being
inserted into the filler tube, thereby preventing system contamination. Since the use of leaded fuels
contaminates the catalysts, deteriorating its effectiveness, the use of unleaded fuels is mandatory
in vehicles equipped with catalytic converters. The catalytic converter can tolerate small amounts of
leaded fuels without permanently reducing the catalyst effectiveness. There are basically three
types of catalysts, the conventional oxidation catalyst (COC) containing Platinum (Pt) and
Palladium (Pd) which are effective for catalyzing the oxidation reactions of hydrocarbons (HC) and
carbon monoxide (CO) emissions. A three-way catalyst (TWC) containing Platinum (Pt) and
Rhodium (RH), is not only effective for catalyzing the oxidation reactions of HC and CO emissions,
but it also catalyzes the reduction of nitrogen oxides (NOx). A light off catalyst (LOC) is a single
bed converter. It is arranged in series with the main catalytic converter assembly of COC and/or
TWC as the aft member(s). This converter is designed to perform the very specialized function of
exhaust emission control during engine warm-up when the main converter(s) is not yet at the
temperature required for maximum efficiency. The LOC is designed to operate effectively in the
high environmental conditions that exist near the manifold flange. The LOC is designed with a
minimum heat sink effect and, provides minimum delay in warm-up of the main catalytic
converter(s). The oxidation catalyst requires the use of a secondary air source which is provided by
the pulse air or thermactor air injection systems.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 2243
Catalytic Converter: Testing and Inspection
Blocked or restricted exhaust system usually results in lack of power or popping through the intake
system. Verify that this condition is not caused by ignition timing problems, then proceed with
diagnosis.
Catalyst and Exhaust Systems
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 2244
Catalyst and Exhaust Systems
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Exhaust Manifold: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2249
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2250
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Technical Service Bulletins > Page 2251
Exhaust Manifold: Service and Repair
V8-460
1. Disconnect battery ground cable.
2. When removing right side exhaust manifold, remove air cleaner, intake duct assembly and heat
shroud.
3. Remove spark plug wires as necessary.
4. Disconnect exhaust pipe at exhaust manifold.
5. Remove attaching bolts and washers, then the exhaust manifold, lifting bracket and spark plug
wire heat shields.
6. Reverse procedure to install, torquing attaching bolts to specifications from centermost bolts
outward.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
Engine Control Module: Customer Interest Engine - Lack of Power and/or No Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2263
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2264
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2265
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2266
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2267
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2268
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2269
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition
Engine Control Module: All Technical Service Bulletins Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition > Page 2275
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition > Page 2276
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition > Page 2277
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition > Page 2278
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition > Page 2279
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition > Page 2280
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or
No Start Condition > Page 2281
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Engine Control Module: > 90116 > May > 90 > Body/Frame - Arc Welding
Precautions
Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions
Article No. 90-11-6
EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM
ARC WELDING
FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90
TAURUS
LINCOLN-MERCURY: 1985-86 CAPRI
1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90
SABLE
MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER
ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative
battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs
because the arc welding process can produce high electrical currents in the body of a vehicle when
the negative battery ground cable is left connected.
ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground
cable,
CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY
ELECTRIC WELDING EQUIPMENT
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Engine Control Module: > 90116 > May > 90 > Body/Frame - Arc Welding
Precautions
Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions
Article No. 90-11-6
EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM
ARC WELDING
FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90
TAURUS
LINCOLN-MERCURY: 1985-86 CAPRI
1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90
SABLE
MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER
ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative
battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs
because the arc welding process can produce high electrical currents in the body of a vehicle when
the negative battery ground cable is left connected.
ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground
cable,
CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY
ELECTRIC WELDING EQUIPMENT
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Page 2291
Engine Control Module: Locations
Under RH Side Of Dashboard
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation
> Electronic Control Assembly (ECA)
Engine Control Module: Description and Operation Electronic Control Assembly (ECA)
Fig. 6 Electronic control assembly
The ECA is the brain of the EEC-IV system and is comprised of a processor and calibration
assembly, Fig. 6. The processor receives input signals from the various sensors. The information
obtained is used by the processor to activate engine control systems to obtain optimum emission
control and performance. The calibration assembly is a permanent memory device that contains
information. The processor applies the sensor inputs to the stored information to determine when
and how long the various control systems should be applied.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation
> Electronic Control Assembly (ECA) > Page 2294
Engine Control Module: Description and Operation Failure Mode Effects Management
FMEM is an alternate system strategy in the ECA designed to allow improved vehicle drive should
one or more sensor inputs fail. When a sensor input is perceived to be out-of-limits by the ECA, an
alternative strategy will be initiated. The ECA will substitute a fixed in-limit sensor value and will
continue to monitor the faulty sensor input. If the faulty sensor operates within limits, the ECA will
return to the normal Engine Running mode (strategy). Code 98 will be displayed when FMEM is in
effect. The MIL ``Check Engine'' light will remain ON when the FMEM is in effect.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Under RH Side Of Dashboard
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 2298
Main Relay (Computer/Fuel System): Description and Operation
Fig. 12 EEC relay type, system application & relay locations
EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power
relays also provide reverse battery protection and increased load handling to improve ignition
switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine
applications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Emission Control Systems > EGR Control Module > Component Information > Locations
EGR Control Module: Locations
Behind LH Side Of Instrument Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Choke Relay > Component Information > Locations
Choke Relay: Locations
LH Fender Apron Near Dash
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins >
Customer Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down
Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down
^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY
CHARGE
^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF
Article No. 90-18-3 FORD:
1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD
1986-90 TAURUS
LINCOLN-MERCURY: 1983-87 LYNX
1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86
CAPRI, MARQUIS 1986-90 SABLE
LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1988-90 F SUPER DUTY
ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been
shut off. There may also be a no start condition or a discharged battery. These conditions are
caused by a sticking fuel pump relay.
ACTION: Install a new fuel pump relay. Refer to the following procedure for service details.
1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for
troubleshooting details.
2. Install a new fuel pump relay, if the old one is defective.
3. Check the vehicle for proper operation.
PART NUMBER PART NAME
F19Z-9345-A Fuel Pump Relay Assy.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901803A 1985-86 LTD/Marquis 0.6 Hr.
(includes pinpoint test)
901803A 1990 Town Car (includes 0.4 Hr.
pinpoint test)
901803A All Other Cars (includes 0.5 Hr.
pinpoint test)
901803A All Trucks (includes pinpoint 0.5 Hr.
test)
DEALER CODING
BASIC PART NO. CONDITION CODE
9345 09
OASIS CODES: 404000, 603300, 203000, 203100, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut
Down
Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut
Down
^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY
CHARGE
^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF
Article No. 90-18-3 FORD:
1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD
1986-90 TAURUS
LINCOLN-MERCURY: 1983-87 LYNX
1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86
CAPRI, MARQUIS 1986-90 SABLE
LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1988-90 F SUPER DUTY
ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been
shut off. There may also be a no start condition or a discharged battery. These conditions are
caused by a sticking fuel pump relay.
ACTION: Install a new fuel pump relay. Refer to the following procedure for service details.
1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for
troubleshooting details.
2. Install a new fuel pump relay, if the old one is defective.
3. Check the vehicle for proper operation.
PART NUMBER PART NAME
F19Z-9345-A Fuel Pump Relay Assy.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901803A 1985-86 LTD/Marquis 0.6 Hr.
(includes pinpoint test)
901803A 1990 Town Car (includes 0.4 Hr.
pinpoint test)
901803A All Other Cars (includes 0.5 Hr.
pinpoint test)
901803A All Trucks (includes pinpoint 0.5 Hr.
test)
DEALER CODING
BASIC PART NO. CONDITION CODE
9345 09
OASIS CODES: 404000, 603300, 203000, 203100, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Shut-off Solenoid Relay > Component Information > Locations
Fuel Shut-off Solenoid Relay: Locations
LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Under RH Side Of Dashboard
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 2326
Main Relay (Computer/Fuel System): Description and Operation
Fig. 12 EEC relay type, system application & relay locations
EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power
relays also provide reverse battery protection and increased load handling to improve ignition
switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine
applications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer
Interest: > 88209 > Sep > 88 > Engine - No Start or Hard Start Condition
Ignition Control Module: Customer Interest Engine - No Start or Hard Start Condition
^ NO START - ALL EEC IV WITH TFI
^ HARD START - ALL EEC IV WITH TFI
Article No. 88-20-9
FORD: 1987-88 ALL
LINCOLN-MERCURY: 1987-88 ALL
LIGHT TRUCK: 1987-88 ALL
ISSUE: A no start condition or hard start condition may be caused by a poor connection at the thick
film ignition (TFI) module mating connector on the wire harness.
ACTION: Inspect the TFI module to make sure a good connection is present. Refer to the following
procedure for service details.
1. Locate the TFI module. Check it and the mating connector on the wire harness to make sure
they are properly seated and latched.
2. With the engine running, pull on the wire harness at the base of the connector shell. The pull
should be hard enough to draw the wires straight and taut. If any of the above symptoms are
observed or the engine stops running, inspect the wire harness and connector terminals for
damage. Repair or replace the damaged components as necessary.
3. Grasp the connector shell and TFI module. Twist them back and forth. If any of above symptoms
are observed or the engine stops running, remove the TFI module and inspect for terminal blade
mislocation or bending. If the terminal blades are mislocated or bent, replace the TFI module.
4. Inspect the connector shell for the following items.
a. The red retainer clip should be present. If it is missing, install a new retainer clip.
b. The connector seal should be in place and seated to the connector at the latch base. If it is not
properly seated, install and fully seat a new seal.
NOTE: IF THE ABOVE SYMPTOMS ARE STILL PRESENT AFTER COMPLETING THE TSB,
REFER TO THE ENGINE/ EMISSIONS/DIAGNOSIS MANUAL.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty,
Emissions, and Major Component Coverage OPERATION: 882009A TIME: 0.4 Hr. - 1988
Continental, Thunderbird/ Cougar, Taurus/Sable with a 3.8L Engine
0.7 Hr. - 1987-88 Aerostar, Econoline 0.6 Hr. - All Other Vehicles
DLR. CODING: Basic Part No. 12A297 Condition Code: 44
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Customer
Interest: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition
Ignition Control Module: Customer Interest Engine - Stalling and/or A No Start Condition
^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No.
EEC IV VEHICLES 87-6-10
^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES
FORD 1984-87 ALL
LINCOLN-MERCURY 1984-87 ALL
MERKUR 1985-87 XR4Ti
LIGHT TRUCK 1984-87 ALL
ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may
be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI
module housing. This condition will result in a service code 14.
ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and
prevent further concerns.
NOTE: The distributor does not have to be removed to perform this repair.
1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior,
(mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures
and do not perform Steps 2 and 3.
2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper
towel.
3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A).
4. Clear service code 14 from memory.
PART NUMBER PART NAME CLASS
D7AZ-19A331-A Silicone Grease AM
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME:
1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code:
09
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 88209 > Sep > 88 > Engine - No Start or Hard Start Condition
Ignition Control Module: All Technical Service Bulletins Engine - No Start or Hard Start Condition
^ NO START - ALL EEC IV WITH TFI
^ HARD START - ALL EEC IV WITH TFI
Article No. 88-20-9
FORD: 1987-88 ALL
LINCOLN-MERCURY: 1987-88 ALL
LIGHT TRUCK: 1987-88 ALL
ISSUE: A no start condition or hard start condition may be caused by a poor connection at the thick
film ignition (TFI) module mating connector on the wire harness.
ACTION: Inspect the TFI module to make sure a good connection is present. Refer to the following
procedure for service details.
1. Locate the TFI module. Check it and the mating connector on the wire harness to make sure
they are properly seated and latched.
2. With the engine running, pull on the wire harness at the base of the connector shell. The pull
should be hard enough to draw the wires straight and taut. If any of the above symptoms are
observed or the engine stops running, inspect the wire harness and connector terminals for
damage. Repair or replace the damaged components as necessary.
3. Grasp the connector shell and TFI module. Twist them back and forth. If any of above symptoms
are observed or the engine stops running, remove the TFI module and inspect for terminal blade
mislocation or bending. If the terminal blades are mislocated or bent, replace the TFI module.
4. Inspect the connector shell for the following items.
a. The red retainer clip should be present. If it is missing, install a new retainer clip.
b. The connector seal should be in place and seated to the connector at the latch base. If it is not
properly seated, install and fully seat a new seal.
NOTE: IF THE ABOVE SYMPTOMS ARE STILL PRESENT AFTER COMPLETING THE TSB,
REFER TO THE ENGINE/ EMISSIONS/DIAGNOSIS MANUAL.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty,
Emissions, and Major Component Coverage OPERATION: 882009A TIME: 0.4 Hr. - 1988
Continental, Thunderbird/ Cougar, Taurus/Sable with a 3.8L Engine
0.7 Hr. - 1987-88 Aerostar, Econoline 0.6 Hr. - All Other Vehicles
DLR. CODING: Basic Part No. 12A297 Condition Code: 44
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure
Technical Service Bulletin # 872110 Date: 871021
TFI Module/PIP Sensor - New Diagnostic Procedure
EEC IV - TFI MODULE AND PIP SENSOR - Article No.
NEW DIAGNOSTIC PROCEDURE 87-21-10
FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88
TAURUS
LINCOLN-MERCURY: 1983 MARK VI
1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN
CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES
ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been
developed. This new procedure allows the technician to take a direct path when testing the TFI
module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003).
ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB.
Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose
or broken conditions.
^ Check that the TFI module is securely fastened to the distributor base.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00002.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to a shorting bar type connector used to set base
timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition, refer to Intermittent Diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2349
Functional Schematic
TFI-IV
The TFI-IV system electrical schematic is shown below. For detailed information, refer to the
vehicle wiring diagram.
Ignition Coil Secondary Voltage (Crank Mode)
TFI-IV Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2350
Ignition Coil Secondary Voltage
(Run Mode) TFI-IV Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2351
TFI-IV Part 2
Test 3
Stator - TFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2352
TFI-IV Part 2
Test 4 & 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2353
Stator - TFI-IV TFI-IV Part 2
Test 5
TFI Module
TFI-IV Part 2
Test 6
Ignition Coils - Secondary & Primary Resistance
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2354
Ignition Coil Primary Resistance TFI-IV Part 2
Test 7 & 8
Ignition Coil Secondary
Resistance
TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2355
Part 2
Test 8
EEC-IV - TFI-IV
TFI-IV Part 2
Test 9
Ignition Coil Supply Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2356
TFI-IV Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2357
TFI-IV Part 2
Test 11
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose,
or broken conditions.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2358
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00003.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to shorting bar type connector used to set base timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition refer to Intermittent Diagnosis.
Functional Schematic
TFI-IV
Closed Bowl
Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For
detailed information, refer to the vehicle wiring diagram.
Ignition Coil Secondary Voltage - Crank Mode
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2359
TFI-IV
Closed Bowl
Distributor Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2360
Ignition Coil Secondary
Voltage - Run Mode TFI-IV
Closed Bowl
Distributor Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2361
TFI-IV
Closed Bowl
Distributor Part 2
Test 3
Stator
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2362
TFI-IV
Closed Bowl
Distributor Part 2
Test 4, 5 & 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2363
Stator TFI-IV
Closed Bowl
Distributor Part 2
Test 5
Stator TFI-IV
Closed Bowl
Distributor Part 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2364
Test 6
TFI Module
TFI-IV
Closed Bowl
Distributor Part 2
Test 7
Ignition Coil, Primary & Secondary
Ignition Coil Primary Resistance TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2365
Closed Bowl
Distributor Part 2
Test 8
Ignition Coil Secondary
Resistance
TFI-IV
Closed Bowl
Distributor Part 2
Test 9
EEC IV - Wiring
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2366
TFI-IV
Closed Bowl
Distributor Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2367
TFI IV
Closed Bowl
Distributor Part 2
Test 11
Ignition Coil, TFI & Stator Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2368
Ignition Coil Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 12
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2369
TFI Supply Voltage TFI-IV
Closed Bowl
Distributor Part 2
Test 13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2370
Stator Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 14
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2371
TFI IV
Closed Bowl
Distributor Part 2
Test 15
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Control Module: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition
Ignition Control Module: All Technical Service Bulletins Engine - Stalling and/or A No Start
Condition
^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No.
EEC IV VEHICLES 87-6-10
^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES
FORD 1984-87 ALL
LINCOLN-MERCURY 1984-87 ALL
MERKUR 1985-87 XR4Ti
LIGHT TRUCK 1984-87 ALL
ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may
be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI
module housing. This condition will result in a service code 14.
ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and
prevent further concerns.
NOTE: The distributor does not have to be removed to perform this repair.
1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior,
(mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures
and do not perform Steps 2 and 3.
2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper
towel.
3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A).
4. Clear service code 14 from memory.
PART NUMBER PART NAME CLASS
D7AZ-19A331-A Silicone Grease AM
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME:
1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code:
09
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure
Technical Service Bulletin # 872110 Date: 871021
TFI Module/PIP Sensor - New Diagnostic Procedure
EEC IV - TFI MODULE AND PIP SENSOR - Article No.
NEW DIAGNOSTIC PROCEDURE 87-21-10
FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88
TAURUS
LINCOLN-MERCURY: 1983 MARK VI
1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN
CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES
ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been
developed. This new procedure allows the technician to take a direct path when testing the TFI
module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003).
ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB.
Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose
or broken conditions.
^ Check that the TFI module is securely fastened to the distributor base.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00002.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to a shorting bar type connector used to set base
timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition, refer to Intermittent Diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2381
Functional Schematic
TFI-IV
The TFI-IV system electrical schematic is shown below. For detailed information, refer to the
vehicle wiring diagram.
Ignition Coil Secondary Voltage (Crank Mode)
TFI-IV Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2382
Ignition Coil Secondary Voltage
(Run Mode) TFI-IV Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2383
TFI-IV Part 2
Test 3
Stator - TFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2384
TFI-IV Part 2
Test 4 & 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2385
Stator - TFI-IV TFI-IV Part 2
Test 5
TFI Module
TFI-IV Part 2
Test 6
Ignition Coils - Secondary & Primary Resistance
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2386
Ignition Coil Primary Resistance TFI-IV Part 2
Test 7 & 8
Ignition Coil Secondary
Resistance
TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2387
Part 2
Test 8
EEC-IV - TFI-IV
TFI-IV Part 2
Test 9
Ignition Coil Supply Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2388
TFI-IV Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2389
TFI-IV Part 2
Test 11
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose,
or broken conditions.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2390
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00003.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to shorting bar type connector used to set base timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition refer to Intermittent Diagnosis.
Functional Schematic
TFI-IV
Closed Bowl
Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For
detailed information, refer to the vehicle wiring diagram.
Ignition Coil Secondary Voltage - Crank Mode
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2391
TFI-IV
Closed Bowl
Distributor Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2392
Ignition Coil Secondary
Voltage - Run Mode TFI-IV
Closed Bowl
Distributor Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2393
TFI-IV
Closed Bowl
Distributor Part 2
Test 3
Stator
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2394
TFI-IV
Closed Bowl
Distributor Part 2
Test 4, 5 & 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2395
Stator TFI-IV
Closed Bowl
Distributor Part 2
Test 5
Stator TFI-IV
Closed Bowl
Distributor Part 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2396
Test 6
TFI Module
TFI-IV
Closed Bowl
Distributor Part 2
Test 7
Ignition Coil, Primary & Secondary
Ignition Coil Primary Resistance TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2397
Closed Bowl
Distributor Part 2
Test 8
Ignition Coil Secondary
Resistance
TFI-IV
Closed Bowl
Distributor Part 2
Test 9
EEC IV - Wiring
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2398
TFI-IV
Closed Bowl
Distributor Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2399
TFI IV
Closed Bowl
Distributor Part 2
Test 11
Ignition Coil, TFI & Stator Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2400
Ignition Coil Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 12
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2401
TFI Supply Voltage TFI-IV
Closed Bowl
Distributor Part 2
Test 13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2402
Stator Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 14
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure >
Page 2403
TFI IV
Closed Bowl
Distributor Part 2
Test 15
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2404
Ignition Control Module: Locations
The distributor is located on the top of the engine towards the front, The TFI ignition module is
attached to the distributor base.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2405
Ignition Control Module: Description and Operation
Typical Ignition System
The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic
pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short
period of time. High voltage is created each time the magnetic field is built up and collapsed. The
red ignition module wire provides operating voltage for the module's electronic components in the
Run mode. The white module wire and start bypass provide increased voltage for the module and
coil during Start mode.
Ignition Modules
Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control
signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the
Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this
second signal, the UIM provides additional spark timing control for certain operating conditions by
shutting off the ignition coil current flow at a different time than with just the distributor pick-up
signal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2406
Module Identification Chart
For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura
Spark II has 6 wire connector while Dura Spark III has a 5 wire connector.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2407
Ignition Control Module: Service and Repair
Open Bowl Distributor
1. Remove distributor cap and adapter. Position cap and wires aside.
2. Disconnect TFI wiring.
3. Remove distributor from engine using tool T82L-12270-A or equivalent to remove security-type
hold-down bolt, if equipped.
4. Place distributor on workbench and remove 2 TFI module screws, Fig. 2.
5. Pull right side of module down distributor mounting flange and then back up to disengage
module terminals from connector in distributor base. Module may then be pulled toward flange and
away from distributor. Do not attempt to lift module from mounting surface before moving entire TFI
module toward distributor flange, as pins at distributor/module connector will break otherwise.
6. Coat metal base plate of TFI ignition module with 1/32 inch thick layer of silicone grease
D7AZ-19A331-A, or equivalent.
7. Place TFI module on distributor base mounting flange. Carefully position TFI module assembly
toward distributor bowl and securely engage 3 distributor connector pins.
8. Install 2 TFI module mounting screws and torque to 9---35 inch lbs.
9. Install distributor on engine.
10. Install distributor cap and adapter.
11. Connect TFI wiring.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2408
12. Check and, if necessary adjust engine timing according to decal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation
Air Flow Meter/Sensor: Description and Operation
The vane air flow meter measures air flowing into the engine and is mounted between the air
cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a
potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and
potentiometer. The potentiometer relays vane position information to the EEC-IV module. The
EEC-IV module, then translates vane position information into the amount of air flowing into the
engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor
constantly monitors air temperature entering the engine and also transmits the information to the
EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature
information and adjusts the fuel flow to obtain the optimum air/fuel mixture required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service
Bulletins > MAP and BAP Sensor - Application Chart
Barometric Pressure Sensor: Technical Service Bulletins MAP and BAP Sensor - Application Chart
Article No. 89-1-12
^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART
^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS
FORD: 1984-87 ALL CARLINES
LINCOLN-MERCURY: 1984-89 ALL CARLINES
LIGHT TRUCK: 1984-89 ALL TRUCKLINES
This article is being republished in its entirety to include the MAP sensor application for the 2.3L
HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine.
ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L
HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP
and BAP sensor application chart has been assembled to assist technicians in making sure the
correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy,
erratic engine idle or hesitation on acceleration may result.
ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the
correct service part applications.
NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF
THE FORD PARTS CATALOG.
LIGHT TRUCK MAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE
1984-86 2.3L OHC All E6TZ-9F479-A MAP
1986-87 3.0L EFI All E6FZ-9F479-A MAP
1988-89 3.0L EFI All E7FZ-9F479-A MAP
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
4.9L EFI 5.0L EFI 7.5L EFI
1988-89 5.8L EFI All E7FZ-9F479-A MAP
PASSENGER CAR MAP AND BAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE
1984-89 1.6L EFI All E7FZ-12A644-A BAP
1.9L EFI 2.3L Turbo
1989 3.0 "SHO" All E7FZ-12A644-A BAP
1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP
(Mustang)
1989 5.0L Mass Air All E8FZ-12A644-A BAP
1984 2.3L HSC FBC All E6PZ-9F479-A MAP
1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP
2.5L HSC CFI
1984-85 3.8L CFI All E5SZ-9F479-A MAP
1984-85 5.0L CFI All E6TZ-9F479-A MAP
1986 2.3L OHC All E6FZ-9F479-A MAP
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service
Bulletins > MAP and BAP Sensor - Application Chart > Page 2418
3.0L EFI 3.8L CFI 5.0 SEFI
1984-85 2.3L OHC All E6FZ-9F479-A MAP
1987-89 1.9L CFI All E7DZ-9F479-A MAP
2.3L HSC CFI 2.5L HSC CFI
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI
PART NUMBER PART NAME CLASS
E7FZ-12A644-A BAP Sensor B
E8FZ-12A644-A BAP Sensor B
E6PZ-9F479-A MAP Sensor B
E5SZ-9F479-A MAP Sensor AM
E6TZ-9F479-A MAP Sensor BM
E6FZ-9F479-A MAP Sensor B
E7DZ-9F479-A MAP Sensor B
E7FZ-9F479-A MAP Sensor B
OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 620800, 631900, 640200
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service
Bulletins > Page 2419
MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service
Bulletins > Page 2420
Barometric Pressure Sensor: Locations
LH Side Of Dash Panel
Inside Of LH Front Fender, Near Ignition Module Or RH Fender Apron At Wheelwell
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and
Operation
Barometric Pressure Switch: Description and Operation
Fig. 19 Ignition barometric pressure switch. 1984-87
1984---87 This switch, Fig. 19, controls spark timing and/or other electrical devices according to
barometric pressure changes. Calibration resistors in the switch assembly cause the ignition
module to vary the spark timing. Spark timing is advanced for vehicle operation above a
predetermined altitude and retarded for vehicle operation below a predetermined altitude. Some
switch assemblies control both spark timing and another device while other switch assemblies
control only one or the other.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and
Inspection > Component Testing
Barometric Pressure Switch: Testing and Inspection Component Testing
Fig. 43 Ignition barometric pressure switch resistance chart. 1985---87
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values
in chart.
3. Replace switch if resistance is not within specifications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
TEMPERATURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Coolant Temperature Sensor
Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor
Near Front Of Valve Cover
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Coolant Temperature Sensor > Page 2431
Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Switch (For
Computer)
RH Side Of V8-302/5.
Top Forward RH Side Of Engine, Under Water Outlet
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Locations > Page 2432
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Fig. 7 Engine coolant temperature (ECT) sensor
The ECT, Fig. 7, sensor detects the temperature of engine coolant and supplies information to the
ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine
control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture.
On models with an electronic instrument cluster, the ECT output is used to control the coolant
temperature indicator.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision
Technical Service Bulletin # 8918A9 Date: 890915
EVP Sensor - Manual Revision
ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR
VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED
Article No. 89-18A-9
FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG,
TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE
LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS
1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89
SABLE 1987-89 TRACER
MERKUR: 1986-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER
1986-89 AEROSTAR
ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine
Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit
internal wear problems that can cause driveability symptoms and display a Continuous Self-Test
Code 32. This is not associated to correcting the problem using the existing diagnostic procedures.
ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
680000
1985 Pinpoint Tests - DM - EGR, EVP and EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2437
1985
EEC IV - Pinpoint Tests - All Vehicles 22-77
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test
1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2438
1985
22-78 EEC IV - Pinpoint Tests - All Vehicles
Neutral Drive Switch FA A/C Input PinpointTest
1986 (EGR) Systems Functional Diagnosis
1986
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2439
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1986 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2440
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1986 Quick Test: Continuous Self-Test 6.0
EEC IV - Quick Test - All Engines 18-13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2441
QUICK TEST: Continuous Self-Test 6.0
1986
18-14 EEC IV-Quick Test-All Engines
QUICK TEST: Continuous
Self-Test 6.0
Pinpoint Test - DN - EGR - EVP & EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2442
1986
EEC IV-Pinpoint Tests - All Vehicles 21-95
EGR Valve Position Sensor (EVP)
PinpointTest DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2443
21-96 1986 EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2444
EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2445
1986 21-97B
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR) Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2446
1986 EEC IV-Pinpoint Tests-All Vehicles
21-98
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
1987 (EGR) Systems - Functional Diagnosis
1987
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2447
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1987 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2448
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1987 Quick Test: Continuous Self-Test - 6.0
1987
EEC-IV Quick Test-All Engines 16-15
QUICK TEST: Continuous 6.0 Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2449
16-16 1987 EEC-IV Quick Test-All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
1987
EEC IV - Pinpoint Tests - All Vehicles 19-91
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2450
EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
19-92A 1987
EEC IV Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN
5.0L SEFI Passenger Car and 4.9L and 5.0L Truck
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Bulletins > EVP Sensor - Manual Revision > Page 2451
1987
EEC IV-Pinpoint Tests-All Vehicles 19-92B
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2452
1987 19-93-A
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2453
EEC IV-Pinpoint Tests-All Vehicles 1987 19-94
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1988
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2454
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise,
replace the EGR valve.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
replace the EGR valve.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12
1988 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 2-1/2 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Bulletins > EVP Sensor - Manual Revision > Page 2455
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
1988
EEC-IV - Quick Test - All Engines 16-15
QUICK TEST: Continuous
Self-Test 6.0
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Bulletins > EVP Sensor - Manual Revision > Page 2456
1988 16-16
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2457
EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2458
19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2459
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-102A
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2460
1988
19-103 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2461
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-104
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1989
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2462
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for
vacuum leak at EGR valve, replace the valve.
^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
check for contamination, clean the valve.
^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1989
6-12 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at
normal operating temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 1.0 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Bulletins > EVP Sensor - Manual Revision > Page 2463
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur:
^ Engine does not stall
^ Idle speed does not drop more than 100 rpm
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed
Then:
^ For vacuum leak at EGR valve, replace the valve.
^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or
equivalent.
^ Make sure there is no sand left in the valve.
^ Replace the EGR valve if necessary.
9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR
vacuum supply hose.
10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Bulletins > EVP Sensor - Manual Revision > Page 2464
1989 EEC-IV - Quick Test - All Engines
14-17
QUICK TEST: Continuous 6.0 Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Bulletins > EVP Sensor - Manual Revision > Page 2465
1989 14-18
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
1989
EEC-IV - Quick Test - All Engines 14-19
QUICK TEST: Continuous 6.0 Self-Test
Quick Test:Diagnostic By Symptom - 7.0
1989
14-20 EEC-IV - Quick Test - All Engines
QUICK TEST: Diagnostic By Symptom 7.0
A DIAGNOSTIC BY SYMPTOM
SPECIAL NOTES:
^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous
Self-Tests before continuing with this test.
^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By
Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2466
Pinpoint Test - DN - EGR - EVP & EVR
1989
EEC-IV - Pinpoint Tests-All Vehicles 17-133
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Bulletins > EVP Sensor - Manual Revision > Page 2467
1989
17-134 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2468
1989
EEC-IV-Pinpoint Tests - All Vehicles 17-134A
Pinpoint Test DN EGR Valve Position Sensor (EVP)
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2469
1989 17-135
EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > EVP Sensor - Manual Revision > Page 2470
1989
EEC-IV - Pinpoint Tests - All Vehicles 17-136A
EGR Valve Position Sensor (EVP)
04GPinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service
Bulletins > Page 2471
EGR Valve Position Sensor: Locations
At Center Rear Of Carburetor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications
TEMPERATURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications >
Page 2475
Intake Air Temperature Sensor: Locations
LH Side Of V8-302/5.
Near Front Of RH Valve Cover
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications >
Page 2476
Intake Air Temperature Sensor: Description and Operation
Fig. 2 Air charge temperature (ACT) sensor
This sensor, Fig. 2, provides the EFI system with air/fuel mixture temperature information. The air
charge temperature sensor is used both as a density corrector to air flow calculation and to
proportion the cold enrichment fuel flow. This sensor is similar in construction to the engine coolant
temperature sensor and is mounted on an intake manifold runner or on the air cleaner.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
LH Side Of V8-302/5.
Top Center Of Engine
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2480
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical
Service Bulletins > MAP and BAP Sensor - Application Chart
Manifold Pressure/Vacuum Sensor: Technical Service Bulletins MAP and BAP Sensor - Application
Chart
Article No. 89-1-12
^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART
^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS
FORD: 1984-87 ALL CARLINES
LINCOLN-MERCURY: 1984-89 ALL CARLINES
LIGHT TRUCK: 1984-89 ALL TRUCKLINES
This article is being republished in its entirety to include the MAP sensor application for the 2.3L
HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine.
ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L
HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP
and BAP sensor application chart has been assembled to assist technicians in making sure the
correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy,
erratic engine idle or hesitation on acceleration may result.
ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the
correct service part applications.
NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF
THE FORD PARTS CATALOG.
LIGHT TRUCK MAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE
1984-86 2.3L OHC All E6TZ-9F479-A MAP
1986-87 3.0L EFI All E6FZ-9F479-A MAP
1988-89 3.0L EFI All E7FZ-9F479-A MAP
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
4.9L EFI 5.0L EFI 7.5L EFI
1988-89 5.8L EFI All E7FZ-9F479-A MAP
PASSENGER CAR MAP AND BAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE
1984-89 1.6L EFI All E7FZ-12A644-A BAP
1.9L EFI 2.3L Turbo
1989 3.0 "SHO" All E7FZ-12A644-A BAP
1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP
(Mustang)
1989 5.0L Mass Air All E8FZ-12A644-A BAP
1984 2.3L HSC FBC All E6PZ-9F479-A MAP
1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP
2.5L HSC CFI
1984-85 3.8L CFI All E5SZ-9F479-A MAP
1984-85 5.0L CFI All E6TZ-9F479-A MAP
1986 2.3L OHC All E6FZ-9F479-A MAP
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical
Service Bulletins > MAP and BAP Sensor - Application Chart > Page 2485
3.0L EFI 3.8L CFI 5.0 SEFI
1984-85 2.3L OHC All E6FZ-9F479-A MAP
1987-89 1.9L CFI All E7DZ-9F479-A MAP
2.3L HSC CFI 2.5L HSC CFI
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI
PART NUMBER PART NAME CLASS
E7FZ-12A644-A BAP Sensor B
E8FZ-12A644-A BAP Sensor B
E6PZ-9F479-A MAP Sensor B
E5SZ-9F479-A MAP Sensor AM
E6TZ-9F479-A MAP Sensor BM
E6FZ-9F479-A MAP Sensor B
E7DZ-9F479-A MAP Sensor B
E7FZ-9F479-A MAP Sensor B
OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 620800, 631900, 640200
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical
Service Bulletins > Page 2486
MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical
Service Bulletins > Page 2487
Manifold Pressure/Vacuum Sensor: Locations
RH Fender Apron With EEC
RH Fender Well
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Engine - Lack of Power/No Start Diagnosis
Oxygen Sensor: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Engine - Lack of Power/No Start Diagnosis > Page 2492
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Engine - Lack of Power/No Start Diagnosis > Page 2493
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Engine - Lack of Power/No Start Diagnosis > Page 2494
Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination
Article No. 93-23-6
11/10/93
^ EGO SENSORS - SILICONE CONTAMINATION
^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED
^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO)
SENSORS
FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO,
THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE
LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94
CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89
TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE,
F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94
VILLAGER
This TSB article is being republished in its entirety to update model applicability and to revise the
part number of the Low Volatility Sealant.
ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the
engine. Volatile silicones can migrate throughout the system during the first one hundred hours of
service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These
products are commonly sold in tubes and caulking-type cartridges.
ACTION: When service is performed on the engine, only use new low volatility silicone sealant
(F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required.
CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN
LOW VOLATILITY SILICONE SEALANT IS SPECIFIED.
PART NUMBER PART NAME CLASS
F1AZ-19662-A Low Volatility RTV Sealant B
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Engine - Lack of Power/No Start Diagnosis > Page 2495
WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Page 2496
Oxygen Sensor: Locations
RH Side Of 6-300/4.
RH Rear Of Engine
Applicable to: 9L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins >
Page 2497
Oxygen Sensor: Description and Operation
Fig. 8 Exhaust gas oxygen (EGO) sensor
The exhaust gas oxygen sensor supplies the ECA with a signal which indicates either a rich or lean
condition during engine operation. The sensor is threaded into the center of the exhaust manifold
on 4-140 and 6-300 engines, threaded into the rear of left and right exhaust manifold assemblies
on V6-171 engine or threaded into the rear right exhaust manifold assembly on V8-302 and 351
engine, Fig. 8.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations
Power Steering Pressure Switch: Locations
Upper LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Throttle Position Sensor - Application Chart
Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart
EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP
Article No. 89-16-4
FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO,
THUNDERBIRD
LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII,
SABLE, TOPAZ, TOWN CAR
LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES
ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to
assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely.
ACTION: Refer to one of the following TPS service replacement charts to make sure that the
correct service part is installed.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Throttle Position Sensor - Application Chart > Page 2505
OASIS CODES: 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Throttle Position Sensor - Application Chart > Page 2506
Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove
THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP
Article No. 89-14-7
FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT
1986-89 TAURUS
LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII,
TOPAZ, TOWN CAR 1984-87 LYNX
MERKUR: 1985-89 ALL MERKUR LINES
LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES
ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The
"Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove
a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians
think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting
with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw.
ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws,
technicians should always use a # 2 "Pozidrive" screwdriver.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
INFORMATION ONLY
OASIS CODES: 4800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications >
Electrical Specifications
THROTTLE POSITION SENSOR SPECIFICATIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications >
Electrical Specifications > Page 2509
Throttle Position Sensor: Mechanical Specifications
IDLE SPEED Throttle Plate Stop Screw M/T.......................................................................................
......................................................................................625-675 rpm Throttle Plate Stop Screw A/T...
..............................................................................................................................................................
.............600-700 rpm
TORQUE VALUES
Air Bypass Valve To Lower Manifold....................................................................................................
...........................................70-100 in lb (8-11 N-m) Hose to Tank ......................................................
...................................................................................................................................25-35 in lb (3-4
N-m) Fuel Injector Manifold to Fuel Charging
Assembly...........................................................................................................................70-105 in lb
(8-12 N-m) Fuel Line Fittings................................................................................................................
................................................................10-15 ft lb (13-20 N-m) Fuel Pressure Regulator to Injector
Manifold......................................................................................................................................27-40
in lb (3-4.5 N-m) Retaining straps around Fuel Tank...........................................................................
..........................................................................22-30 in lb (30-41 N-m) Throttle Body to Upper
Intake Manifold.....................................................................................................................................
.......70-100 in lb (8-11 N-m) Throttle Position Sensor to Throttle
Body........................................................................................................................................11-16 in
lb (1.2-1.8 N-m) Upper Intake Manifold to Lower Intake Manifold
Bolts.....................................................................................................................12-18 ft lb (16-24
N-m)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page
2510
Throttle Position Sensor: Locations
RH Side Of V8-351/5.
At Front Of Carburetor
Applicable to: 8L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > EEC-IV
Using Breakout Box
Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box
Throttle Position Sensor
NOTE: This procedure can be used to check and adjust level "C" sensor only.
1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle.
2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive
lead into test socket 47 and the negative lead into socket 46 of the breakout box.
3. Turn the ignition ON, but DO NOT start the vehicle.
4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP)
sensor mounting screws and rotate the sensor until the voltage falls within this range.
5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m).
6. While observing the DVOM, move the throttle through the entire range of motion. The reading
should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt.
7. If the TP sensor cannot be adjusted, replace the sensor.
8. Perform an EEC-IV quick test on the vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > EEC-IV
Using Breakout Box > Page 2513
Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment
Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker,
as equipped. With engine not running, compare voltage reading against specifications and adjust
as needed.
Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and
connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust
TPS to specified value.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vacuum Switch > Component Information > Locations
Vacuum Switch: Locations
RH Fender Apron At Wheelwell
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications
VEHICLE SPEED SENSOR
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page
2520
Vehicle Speed Sensor: Locations
At LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection >
Speed Control/Speedometer
Vehicle Speed Sensor: Testing and Inspection Speed Control/Speedometer
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark
green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and
Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and
1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40
ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading
indicates an open coil.
2. Replace sensor if a correct reading has not been obtained.
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Page 2523
Vehicle Speed Sensor: Service and Repair
1. Separate electrical connector leading to the amplifier assembly.
2. Disconnect upper and lower speedometer cables at the speed sensor. Remove speed sensor.
3. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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> EVP Sensor - Manual Revision
Technical Service Bulletin # 8918A9 Date: 890915
EVP Sensor - Manual Revision
ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR
VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED
Article No. 89-18A-9
FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG,
TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE
LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS
1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89
SABLE 1987-89 TRACER
MERKUR: 1986-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER
1986-89 AEROSTAR
ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine
Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit
internal wear problems that can cause driveability symptoms and display a Continuous Self-Test
Code 32. This is not associated to correcting the problem using the existing diagnostic procedures.
ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
680000
1985 Pinpoint Tests - DM - EGR, EVP and EVR
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> EVP Sensor - Manual Revision > Page 2529
1985
EEC IV - Pinpoint Tests - All Vehicles 22-77
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test
1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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> EVP Sensor - Manual Revision > Page 2530
1985
22-78 EEC IV - Pinpoint Tests - All Vehicles
Neutral Drive Switch FA A/C Input PinpointTest
1986 (EGR) Systems Functional Diagnosis
1986
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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> EVP Sensor - Manual Revision > Page 2531
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1986 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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> EVP Sensor - Manual Revision > Page 2532
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1986 Quick Test: Continuous Self-Test 6.0
EEC IV - Quick Test - All Engines 18-13
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> EVP Sensor - Manual Revision > Page 2533
QUICK TEST: Continuous Self-Test 6.0
1986
18-14 EEC IV-Quick Test-All Engines
QUICK TEST: Continuous
Self-Test 6.0
Pinpoint Test - DN - EGR - EVP & EVR
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> EVP Sensor - Manual Revision > Page 2534
1986
EEC IV-Pinpoint Tests - All Vehicles 21-95
EGR Valve Position Sensor (EVP)
PinpointTest DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 2535
21-96 1986 EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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> EVP Sensor - Manual Revision > Page 2536
EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 2537
1986 21-97B
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR) Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 2538
1986 EEC IV-Pinpoint Tests-All Vehicles
21-98
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
1987 (EGR) Systems - Functional Diagnosis
1987
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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> EVP Sensor - Manual Revision > Page 2539
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1987 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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> EVP Sensor - Manual Revision > Page 2540
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1987 Quick Test: Continuous Self-Test - 6.0
1987
EEC-IV Quick Test-All Engines 16-15
QUICK TEST: Continuous 6.0 Self-Test
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> EVP Sensor - Manual Revision > Page 2541
16-16 1987 EEC-IV Quick Test-All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
1987
EEC IV - Pinpoint Tests - All Vehicles 19-91
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> EVP Sensor - Manual Revision > Page 2542
EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
19-92A 1987
EEC IV Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN
5.0L SEFI Passenger Car and 4.9L and 5.0L Truck
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> EVP Sensor - Manual Revision > Page 2543
1987
EEC IV-Pinpoint Tests-All Vehicles 19-92B
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 2544
1987 19-93-A
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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> EVP Sensor - Manual Revision > Page 2545
EEC IV-Pinpoint Tests-All Vehicles 1987 19-94
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1988
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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> EVP Sensor - Manual Revision > Page 2546
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise,
replace the EGR valve.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
replace the EGR valve.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12
1988 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 2-1/2 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
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> EVP Sensor - Manual Revision > Page 2547
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
1988
EEC-IV - Quick Test - All Engines 16-15
QUICK TEST: Continuous
Self-Test 6.0
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> EVP Sensor - Manual Revision > Page 2548
1988 16-16
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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> EVP Sensor - Manual Revision > Page 2549
EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 2550
19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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> EVP Sensor - Manual Revision > Page 2551
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-102A
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
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> EVP Sensor - Manual Revision > Page 2552
1988
19-103 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
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> EVP Sensor - Manual Revision > Page 2553
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-104
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1989
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
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> EVP Sensor - Manual Revision > Page 2554
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for
vacuum leak at EGR valve, replace the valve.
^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
check for contamination, clean the valve.
^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1989
6-12 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at
normal operating temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 1.0 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
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> EVP Sensor - Manual Revision > Page 2555
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur:
^ Engine does not stall
^ Idle speed does not drop more than 100 rpm
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed
Then:
^ For vacuum leak at EGR valve, replace the valve.
^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or
equivalent.
^ Make sure there is no sand left in the valve.
^ Replace the EGR valve if necessary.
9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR
vacuum supply hose.
10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 2556
1989 EEC-IV - Quick Test - All Engines
14-17
QUICK TEST: Continuous 6.0 Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 2557
1989 14-18
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
1989
EEC-IV - Quick Test - All Engines 14-19
QUICK TEST: Continuous 6.0 Self-Test
Quick Test:Diagnostic By Symptom - 7.0
1989
14-20 EEC-IV - Quick Test - All Engines
QUICK TEST: Diagnostic By Symptom 7.0
A DIAGNOSTIC BY SYMPTOM
SPECIAL NOTES:
^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous
Self-Tests before continuing with this test.
^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By
Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 2558
Pinpoint Test - DN - EGR - EVP & EVR
1989
EEC-IV - Pinpoint Tests-All Vehicles 17-133
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 2559
1989
17-134 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 2560
1989
EEC-IV-Pinpoint Tests - All Vehicles 17-134A
Pinpoint Test DN EGR Valve Position Sensor (EVP)
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 2561
1989 17-135
EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> EVP Sensor - Manual Revision > Page 2562
1989
EEC-IV - Pinpoint Tests - All Vehicles 17-136A
EGR Valve Position Sensor (EVP)
04GPinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins
> Page 2563
EGR Valve Position Sensor: Locations
At Center Rear Of Carburetor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Description and Operation
Air Flow Meter/Sensor: Description and Operation
The vane air flow meter measures air flowing into the engine and is mounted between the air
cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a
potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and
potentiometer. The potentiometer relays vane position information to the EEC-IV module. The
EEC-IV module, then translates vane position information into the amount of air flowing into the
engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor
constantly monitors air temperature entering the engine and also transmits the information to the
EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature
information and adjusts the fuel flow to obtain the optimum air/fuel mixture required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations
Fuel Tank Selector Switch: Locations
LH Side Of Instrument Panel Near Fuse Block
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions
Fuel Tank Selector Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 2573
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 2574
Fuel Tank Selector Switch: Electrical Diagrams
Fig. 28 Fuel Tank Selector Wiring Circuit. V8-351/5.8L Fuel Injected & V8-460/7.5L Non Hot Fuel
Handling
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 2575
Fig. 26 Fuel Tank Selector Wiring Circuit. V8-302/5.0L & V8-460/7.5L Hot Fuel Handling
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 2576
Fig. 29 Fuel Tank Selector Wiring Circuit. V8-460/7.5L Hot Fuel Cutaway
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Inertia Fuel Shutoff Switch: Locations
The inertia switch is located on the passenger side cowl panel, just forward of the right front door.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Throttle Position Sensor - Application Chart
Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart
EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP
Article No. 89-16-4
FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO,
THUNDERBIRD
LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII,
SABLE, TOPAZ, TOWN CAR
LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES
ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to
assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely.
ACTION: Refer to one of the following TPS service replacement charts to make sure that the
correct service part is installed.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Throttle Position Sensor - Application Chart > Page 2584
OASIS CODES: 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service
Bulletins > Throttle Position Sensor - Application Chart > Page 2585
Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove
THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP
Article No. 89-14-7
FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT
1986-89 TAURUS
LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII,
TOPAZ, TOWN CAR 1984-87 LYNX
MERKUR: 1985-89 ALL MERKUR LINES
LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES
ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The
"Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove
a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians
think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting
with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw.
ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws,
technicians should always use a # 2 "Pozidrive" screwdriver.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
INFORMATION ONLY
OASIS CODES: 4800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical
Specifications
THROTTLE POSITION SENSOR SPECIFICATIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical
Specifications > Page 2588
Throttle Position Sensor: Mechanical Specifications
IDLE SPEED Throttle Plate Stop Screw M/T.......................................................................................
......................................................................................625-675 rpm Throttle Plate Stop Screw A/T...
..............................................................................................................................................................
.............600-700 rpm
TORQUE VALUES
Air Bypass Valve To Lower Manifold....................................................................................................
...........................................70-100 in lb (8-11 N-m) Hose to Tank ......................................................
...................................................................................................................................25-35 in lb (3-4
N-m) Fuel Injector Manifold to Fuel Charging
Assembly...........................................................................................................................70-105 in lb
(8-12 N-m) Fuel Line Fittings................................................................................................................
................................................................10-15 ft lb (13-20 N-m) Fuel Pressure Regulator to Injector
Manifold......................................................................................................................................27-40
in lb (3-4.5 N-m) Retaining straps around Fuel Tank...........................................................................
..........................................................................22-30 in lb (30-41 N-m) Throttle Body to Upper
Intake Manifold.....................................................................................................................................
.......70-100 in lb (8-11 N-m) Throttle Position Sensor to Throttle
Body........................................................................................................................................11-16 in
lb (1.2-1.8 N-m) Upper Intake Manifold to Lower Intake Manifold
Bolts.....................................................................................................................12-18 ft lb (16-24
N-m)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page
2589
Throttle Position Sensor: Locations
RH Side Of V8-351/5.
At Front Of Carburetor
Applicable to: 8L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > EEC-IV
Using Breakout Box
Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box
Throttle Position Sensor
NOTE: This procedure can be used to check and adjust level "C" sensor only.
1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle.
2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive
lead into test socket 47 and the negative lead into socket 46 of the breakout box.
3. Turn the ignition ON, but DO NOT start the vehicle.
4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP)
sensor mounting screws and rotate the sensor until the voltage falls within this range.
5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m).
6. While observing the DVOM, move the throttle through the entire range of motion. The reading
should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt.
7. If the TP sensor cannot be adjusted, replace the sensor.
8. Perform an EEC-IV quick test on the vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > EEC-IV
Using Breakout Box > Page 2592
Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment
Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker,
as equipped. With engine not running, compare voltage reading against specifications and adjust
as needed.
Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and
connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust
TPS to specified value.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation
Hall Effect Sensor: Description and Operation
Profile Ignition Pickup
The PIP signal is created in the Hall Effect and Stator assembly and indicates crankshaft position
and engine RPM Fig. 21. The PIP signal is fed to both the TFI module and the ECA.
PIP Sensor
COMPONENTS The Hall Effect device is made up of a voltage regulator, a Hall voltage generator,
Darlington amplifier, Schmitt trigger, and an open collector output stage integrated in a single
monolithic silicon chip Fig. 22. A signal is produced when a ferrous material is passed through the
opening and the flux lines decrease. The Hall generator (Hall device) sends a sine wave signal to
the Darlington amplifier. The Darlington amplifier inverts the signal. When the signal is low the
output is high. When the signal is high the output is low. This output then goes to the Schmitt
trigger. The Schmitt trigger shapes the signal into a square wave (digital high) signal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page
2597
PIP Signal Operation
OPERATION The output signal to the Darlington amplifier is high when the window (on the
armature) allows the magnetic field to reach the Hall device (switch off) Fig. 23. When the TAB
shunts the magnetic field (closes) away from the Hall device the signal is low to the Darlington
amplifier (switch on).
Hall Effect Sensor
In other words when one of the windows or openings is in the gap between the Hall device and the
permanent magnet, the field stays strong and the voltage is high since the magnetic path is
complete from the magnet, through the Hall device, and back to the magnet. In this case the switch
is off and the Hall Effect does not send a signal. When the TAB enters the gap, the armature cuts
off the magnetic path to the Hall device and its voltage drops. In this case the switch is on and the
Hall Effect device sends a signal. The signal is switched On and Off as long as the armature is
rotating (distributor is turning) and opening and closing the magnetic path. This is the signal used
by the ECA to interpret crankshaft position and engine RPM. The signal can also be used by the
TFI module if the SPOUT signal from the ECA is lost.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page
2598
Signature PIP
SIGNATURE PIP Some Electronic Engine Control (EEC) vehicles are equipped with a signature
profile ignition pickup signal. The regular type armature used for the PIP signal has the same size
tabs and windows. In a signature PIP signal armature, one of the tabs is narrower than the others
Fig. 25. The narrower tab provides a different signal to the ECA when it passes through the Hall
Effect switch. When the ECA sees the narrow tab it knows when to properly pulse the fuel injectors.
This system is used on cars and trucks where the ECA needs to know when to pulse certain
injectors. For example, on sequential electronic fuel injection (SEFI) systems, each injector is
pulsed to coincide with its intake valve opening. With the signature PIP, the ECA knows when the
No. 1 cylinder needs to be supplied with fuel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation > Page
2599
Hall Effect Sensor: Service and Repair
Removal Do not attempt to replace stator without an arbor press.
1. Remove distributor. Remove rotor, then the TFI module.
2. If distributor uses push on type rotor, remove two retaining screws holding armature, then the
armature. Hold gear to loosen armature screws, do not hold armature.
3. Mark stator, armature, gear and collar with felt tip pen to aid in reassembly.
4. Remove and discard pins in gear and collar if equipped.
5. Invert distributor and place in Axle Bearing Seal Plate and press off gear using Bearing Removal
Tool.
6. Deburr and polish shaft with emery paper and wipe clean so that shaft slides out freely from
distributor base.
7. Remove shaft assembly, then the thrust washer from shaft. Next remove octane rod.
8. Remove stator assembly screws, then the stator assembly from top of bowl.
9. Inspect base bushing for wear of signs of excess heat concentration, replace distributor
assembly if damaged.
10. Inspect base O-ring for cuts or damage and replace as necessary.
11. Inspect base for cracks and wear, replace distributor assembly if damage is found.
Installation
1. Place stator assembly over bushing and press down to seat.
2. Place stator connector in position, tab should fit in notch on base with fastening eyelets aligned
with screw holes.
3. Install stator screws and Torque to 15-35 inch lbs. Next install octane rod.
4. Install thrust washer on top of bushing, then apply lubricant to distributor shaft below armature.
Do not over lubricate.
5. Insert shaft through base bushing, then place collar, if equipped, over shaft and line up mark on
armature and collar to aid alignment with original drill hole. Use a suitable drift punch to assure
proper alignment.
6. Drill holes through shaft and collar should align on both sides of shaft. If holes do not align, collar
may be 180 degrees out of alignment on shaft. Rotate collar on shaft one half rotation, then check.
7. Insert new roll pin through collar and shaft, pin should be flush with both sides of collar when
seated.
8. If distributor uses push on type rotor, place a 1/2 inch deep well socket over shaft, invert and
place on arbor plate.
9. If distributor uses screw down type rotor, invert and place on arbor plate.
10. Place distributor gear on shaft and line up marks on armature and gear. Hole in shaft and gear
must line up as accurately as possible to assure ease of roll pin insertion.
11. Place a 5/8 inch deep well socket over shaft and gear, then press gear to align with original drill
hole.
12. If gear holes do not align, gear must be removed and repressed on. Drift punch will not align
holes, as in collar, holes should align.
13. Insert new roll pin through gear and shaft, pin should extrude evenly on both sides.
14. Install armature, if removed, and Torque screws to 25-35 inch lbs.
15. Install TFI module, rotor, then distributor.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Doors and Ignition - Lock Service Tips
Ignition Switch Lock Cylinder: Technical Service Bulletins Doors and Ignition - Lock Service Tips
Article No. 87-24-2
12/04/87
LOCKS - DOORS AND IGNITION - GENERAL LOCK SERVICE TIPS
FORD: 1987-88 ESCORT/EXP, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, CROWN
VICTORIA
LINCOLN-MERCURY: 1987 LYNX 1987-88 TOPAZ, SABLE, COUGAR, GRAND MARQUIS,
MARK VII, CONTINENTAL, LINCOLN TOWN CAR
LIGHT TRUCK: 1987-88 AEROSTAR, RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO
ISSUE: Two types of key systems are used on Ford vehicles. The five (5) bit key system uses one
(1) key to operate the ignition lock and a second to operate the outside door locks. The ten (10) bit
key system uses one (1) key to operate the ignition lock and the outside door locks. The ten (10) bit
key system services the ignition lock as a separate service part so the door locks would not have to
be replaced in the event of an ignition lock failure.
ACTION: If service is required for the five (5) bit key system, the ignition and door locks are
serviced separately. Refer to the appropriate Shop Manual for removal and installation procedures.
If service is required for the ten (10) bit key system, a ten (10) bit ignition lock with partially cut keys
is available. Refer to the following service procedure.
NOTE:
Customers concerned with the heads of the new ten (10) bit ignition service keys not matching the
original keys may be resolved by ordering blank keys from Rotunda. Cut the two (2) blank keys
ordered from Rotunda on tumbler station numbers 1, 2, 3, 4, and 6 to match the new ten (10) bit
ignition service keys supplied with the new service ignition lock.
1. Remove the ignition lock cylinder. Refer to the appropriate Shop Manual.
FIGURE 2
2. Using the Ford Rotunda key code cutting package, tool number 011-00003, measure the depth
of the cut on the number six (6) tumbler station of the original key. Use this measurement to
determine the correct service ignition lock set. Refer to the chart in Figure 2.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Doors and Ignition - Lock Service Tips > Page 2605
3. Using the original ignition key, decode tumbler station numbers 5, 7, 8, 9, and 10.
4. Cut the new service key on tumbler station numbers 5, 7, 8, 9, and 10.
5. Check the operation of the new service key in the new ignition lock and outside door locks.
6. Install the new service ignition lock.
NOTE:
Retain both the original and new service key tabs for future key code identification.
OTHER APPLICABLE ARTICLES: 86-23-4
WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
LH Side Of V8-302/5.
Top Center Of Engine
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2609
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Technical Service Bulletins > By Symptom
Fuel Pressure: By Symptom
Technical Service Bulletin # 911211 Date: 910612
Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Technical Service Bulletins > By Symptom > Page 2615
temperatures. Refer to the following procedure for service details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Technical Service Bulletins > By Symptom > Page 2616
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Technical Service Bulletin # 911211 Date: 910612
Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Technical Service Bulletins > By Symptom > Page 2617
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Technical Service Bulletins > By Symptom > Page 2618
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine
- Lack of Power/No Start Diagnosis
Fuel Pressure: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine
- Lack of Power/No Start Diagnosis > Page 2624
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine
- Lack of Power/No Start Diagnosis > Page 2625
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Technical Service Bulletins > Page 2626
Fuel Pressure: Specifications
Fuel Pressure 5-7 psi
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System
Information > Technical Service Bulletins > Page 2627
Fuel Pressure: Testing and Inspection
1. Connect a suitable pressure gauge (0-15 psi) to the carburetor end of the fuel line (no "T" is
required). 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the
carburetor bowl) and read the pressure after 10 seconds. The fuel
pump pressure should read 6-8 psi at normal curb idle speed, with the transmission in NEUTRAL,
the engine at normal operating temperatures, and the fuel return line closed (if present). If pump
pressure is too low or too high install a new fuel pump.
3. Reconnect fuel line at filter and install air cleaner.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision
Technical Service Bulletin # 8912A26 Date: 890627
Idle Fuel Mixture - Manual Revision
ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1986-SECTION 4-IDLE FUEL
MIXTURE-PROPANE ENRICHMENT METHOD
ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1987-SECTION 4-IDLE FUEL
MIXTURE-PROPANE ENRICHMENT METHOD
Article No. 89-12A-26
FORD: 1986 ESCORT, LTD, MUSTANG 1986-87 TEMPO 1986 THUNDERBIRD
LINCOLN-MERCURY: 1986 CAPRI, COUGAR, MARQUIS 1986-87 TOPAZ
LIGHT TRUCK: 1986 AEROSTAR 1986-87 BRONCO, ECONOLINE, F-150, F-250, F-350,
RANGER
ISSUE: The tachometer reference "or equivalent" as shown in procedure I.-B in both 1986 and
1987 Engine Emissions Diagnosis Manuals is incorrect. This also applies to procedure I.-H in the
1986 Engine Emissions Diagnosis Manual.
ACTION: Refer to the pages following this TSB article for the revised Volume H pages which show
the correct tachometer designation as: "Connect an analog tachometer, Rotunda 059-000010 or an
equivalent analog tachometer." This information should be inserted in your 1986 Engine Emissions
Diagnosis Manual, pages 4-83, 4-87, 4-90, 4-93 and the 1987 Manual, pages 4-66 and 4-69.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
INFORMATION ONLY
OASIS CODES: 680000
Pages 4-83, 4-84
1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-83
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
Passenger Car. 1.9L w/740-2V, 2.3L OHC w/YFA-IV FB, 2.3L HSC w/1949-IV, 3.8L w/2150-A-2V
and 5.0L w/4180C-4V.
Truck, Under 8500 GVW: 5.8L w/4180C-4V.
NOTE: This procedure is applicable to the above engines only. If CO and HC are not within
specification, perform appropriate electrical diagnostic procedure in Section 15.
I. Vehicle Preparation: All Carburetors as noted above.
A. Apply the parking brake, and block the wheels. Disconnect the automatic brake release, if so
equipped, and plug the vacuum connection.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. If so equipped, insure that the hot idle compensator is in a closed position and remains so
throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to insure
that HIC valve is closed.
D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L
engines) and plug the connection. (Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger Car
engines).
E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple.
(Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger car engines).
F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
G. For vehicles equipped with thermactor systems, revise the dump valve vacuum hoses as
follows: (Not applicable to 1.9L engines).
1. For dump valves with two vacuum fittings, disconnect and plug the hose(s).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2632
2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at
the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake
manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB).
3. For 2.3L OHC engines:
a. Equipped with a dump valve with two vacuum fittings: Disconnect and plug the hoses.
b. Equipped with a combination dump valve and air diverter valve: Disconnect and plug the hoses
(2-port) from the dump valve portion.
c. Equipped with feedback carburetor: Disconnect electric lead wire from electric PVS.
4. On 3.8L engine Canadian 2150A-2V applications, do not make any thermactor system
modifications.
5. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve.
1986 4-84
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
H. For 1.9L ATX/MTX vehicles equipped with (Mechanical Vacuum) Idle Speed Control (ISC):
1. With engine off:
a. Disconnect and plug the vacuum hose at the MVISC.
b. Connect an alternate vacuum source (hand vacuum pump) capable of maintaining 22 inches Hg.
to the ISC diaphragm on carburetor, and apply vacuum (retracting ISC plunger clear of throttle
linkage).
2. With engine running and transmission in Drive (ATX) or Neutral (MTX):
^ Idle speed should be equal to the ISC retracted speed specified on the emission decal, if not
readjust throttle stop adjustment screw under choke housing to specification, (fan On, A/C Off).
I. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify that the timing is set to specification; reset if necessary, Section 15.
B. Check engine curb idle rpm or A/C-off rpm, and, if necessary, reset to specification, Section 4.
NOTE: Even If the vehicle has less than 160.9 km (100 miles) of operation, set the speed to the
normal engine specification.
NOTE: Remove PCV valve from grommet, and allow PCV valve to draw underhood air during idle
fuel mixture check. (PCV should remain in vertical position).
NOTE: Escort/Lynx, has an in-line fixed orifice crankcase vent, not a conventional PCV valve. The
fixed orifice is located in the crankcase vent hose located between the vacuum fitting on the intake
manifold and the plastic fitting attached to the air cleaner tray.
Locate the crankcase vent hose and disconnect at the air cleaner end, allowing the hose to vent to
underhood air during idle fuel/air mixture check.
C. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds
before each mixture check.
NOTE: On Escort/Lynx and Tempo/Topaz, run engine until electric fan comes On.
Pages 4-87 Thru 4-90
1986
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2633
Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-87
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
2.0L TRUCK UNDER 8600 GVW w/YFA-IV
NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane
specifications are not listed for these applications. If CO and HC are not within specification,
perform appropriate electrical diagnostic procedure, Section 15.
I. Vehicle Preparation
A. Apply the parking brake and block the wheels.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
D. Disconnect and plug the hose at the air bypass valve.
E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve.
F. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify engine timing is set to specification - reset if necessary, Section 15.
B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect
idle speed control (ISC) motor from wiring harness.
C. Place A/C-heat selector in the Off position and verify that lamps are Off.
NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at
the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle
fuel mixture check).
D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds
before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step.
1986 4-88
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
E. With the engine idling at normal operating temperature gradually open the propane tool valve
and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum
and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical
position).
NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary
repeat Steps D & E with a new propane cartridge gas supply.
F. Compare measured speed gain to specified speed gain.*
1. If the measured speed gain is within specification, proceed to Step H.
NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the
carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the
above feature.
NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture
according to the reset rpm specification.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2634
2. If the measured speed gain is higher than the speed gain specification:*
Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
3. If the measured speed gain is lower than the speed gain specification:*
Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following
speed drop test:
NOTE: Speed drop test information is specified with the artificial enrichment requirements
whenever the minimum speed gain specification is "0" rpm. *
a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop
in engine speed.
b. If the measured speed drop is greater "0" and less than or equal to 30 rpm, proceed to Step G.
c. If the measured speed drop is more than 30 rpm, return the mixture screw to the position before
adjustment. Proceed to Step G.
d. If the measured speed drop is still "0" rpm repeat steps a, b, and c.
G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see
Section III.
*Refer to the Special Specifications Issue TSB Publications.
1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-89
Idle Mixture Setting Procedures
H. Reinstall PCV valve in grommet. Reconnect air bypass valve, purge valve and crankcase
closure hose. Reconnect ISC motor to wiring harness.
I. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten
the air cleaner wing nut(s) to specification.
III. Removal and Installation for Tamper-Resistant Fuel Air Adjustment Feature:
A. See appropriate carburetor disassembly instructions in Shop Manual, Group 24.
1986 4-90
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
2.8L AEROSTAR w/2150A FB
NOTE: This procedure is for the 2.8L engine only. It is not for trucks over 8500 GVW.
I. Vehicle Preparation
A. Apply the parking brake and block the wheels.
B. Verify that timing is set to specification.
C. Remove the air cleaner assembly.
D. Disconnect wiring harness from carburetor feedback solenoid, located in the rear of carburetor.
E. Remove the PCV valve from the rocker cover grommet and move away from the crankcase
vapors.
F. Disconnect the fuel evaporating purge line (from the intake manifold spacer at the purge
solenoid).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2635
G. Install purge line tester (Tool T84T-9600-A) into the end of purge line that is still connected to
the intake manifold spacer.
H. Disconnect ISC motor from wiring harness as follows: Simultaneously: 1.
Connect tachometer, Rotunda Model 059-00001, 099-00001 or equivalent.
2. Start engine.
3. Manually hold throttle above 1000 rpm.
4. Push ISC plunger until it retracts fully.
5. After plunger retracts, release throttle and quickly unplug the connection.
NOTE: Before proceeding, verify that the throttle lever is resting on the speed screw and that the
engine idles at specification for anti-dieseling rpm (750 rpm in neutral).
I. Install air cleaner assembly, but do not connect the flexible fresh air tube to the air cleaner duct
and valve assembly. Using a propane enrichment Tool T75L-9600-A or equivalent, insert the tool
hose approximately 3/4 of the way into the duct and valve assembly. If necessary, secure the hose
with tape.
J. When the above Steps have been completed, proceed to Section II.
Pages 4-93 & 4-94
1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-93
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
4.9L TRUCK UNDER 8500 GVW w/YFA-IV FB
NOTE: This procedure is for the 4.9L engine only. It is not for trucks over 8600 GVW. Propane
specifications are not listed for these applications. If CO and HC are not within specification,
perform appropriate electrical diagnostic procedure, Section 15.
I. Vehicle Preparation
A. Apply the parking brake and block the wheels. Disconnect the automatic brake release (if so
equipped), and plug the vacuum connection.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. Disconnect the flexible fresh air tube from the air cleaner duct or adapter. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
D. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify engine timing is set to specification-reset if necessary, Section 15.
B. Place A/C-heat selector in the Off position and verify that all accessories (lamps, defrost, etc.)
are Off.
1986 4-94
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2636
Figure 1 - In-Line Base Timing Connector
NOTE: Remove PCV valve from grommet locate the crankcase closure hose and disconnect at the
air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel
mixture check).
C. Verify that the idle speed control motor and the single wire connector near the distributor
(sometimes called the In-Line Base timing connector, Figure 1) are connected electrically. With the
transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each
mixture check. If check is not completed within 60 seconds, repeat this cleanout Step.
D. Return engine to idle and disconnect idle speed control motor from wiring harness. Disconnect
single wire connector near the distributor (Fig. 1). With the engine idling at normal operating
temperature, place the transmission selector in the position specified for the idle fuel mixture check.
Gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When
the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain.
(Propane cartridge must be in vertical position).
NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary
repeat Steps C and D with a new propane cartridge gas supply.
E. Compare measured speed gain to specified speed gain.*
1. If the measured speed gain is within specification, proceed to Step G.
NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the
carburetor must be removed from the vehicle. Refer to Group 24, Powertrain Shop manual for
removal of the above feature.
NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture
according to the reset rpm specification.
2. If the measured speed gain is higher than the speed gain specification:*
Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps C and D until the
measured speed rise meets the reset rpm specification,* After final adjustment, proceed to Step F.
3. If the measured speed gain is lower than the speed gain specification:*
Turn the mixture screw clockwise (lean) and simultaneously repeat Steps C and D until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step F.
F. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled. Refer to
appropriate carburetor assembly instructions in Shop Manual, Group 24.
G. Reinstall PCV valve in grommet. Reconnect idle speed control motor and crankcase closure
system, and the single wire connector near the distributor.
H. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten
the air cleaner wing nut(s) to specification, *Specified speed gain is 10 to 70 rpm, specified reset is
30 rpm.
Pages 4-65 & 4-66
1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-65
Idle Mixture Setting Procedures
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2637
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
Propane Enrichment Procedures Are Not Applicable For The Following:
^ CFI Applications.
^ EFI Applications.
^ Truck Over 8500 GVW Applications.
^ 5.8L MCU Police and Trailer Tow Vehicles w/7200 Carburetors.
1987 4-66
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
Passenger Car. 2.3L HSC w/1949-IV
Truck, Under 8500 GVW: 5.8L w/418OC-4V. NOTE:
This procedure is applicable to the above engines only. If CO and HC are not within specificatlon,
perform appropriate electrical diagnostic procedure in Section 15.
I. Vehicle Preparation: All Carburetors as noted above.
A. Apply the parking brake, and block the wheels, Disconnect the automatic brake release, If so
equipped, and plug the vacuum connection.
B. Connect an analog tachometer, Rotunda 059-000010 or equivalent analog tachometer.
C. If so equipped, ensure that the hot idle compensator is in a closed position and remains so
throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to
ensure that HIC valve is closed.
D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L
engines) and plug the connection. (Not applicable to 5.8L Truck engines).
E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple.
(Not applicable 5.8L Truck engines.)
F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
G. For vehicles equipped with Thermactor systems, revise the dump valve vacuum hoses as
follows:
1. For dump valves with two vacuum fittings, disconnect and plug the hose(s).
2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at
the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake
manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB).
3. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve.
H. When the above Steps have been completed, proceed to Section II.
Pages 4-69 & 4-70
1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-69
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
2.0L TRUCK UNDER 8500 GVW w/Aisan Carburetor
NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane
specifications are not listed for these applications. If CO and HC are not within specification,
perform appropriate electrical diagnostic procedure, Section 15.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2638
I. Vehicle Preparation
A. Apply the parking brake and block the wheels.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
D. Disconnect and plug the hose at the air bypass valve.
E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve.
F. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify engine timing is set to specification-reset if necessary, Section 15.
B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect
idle speed control (ISC) motor from wiring harness.
C. Place A/C-heat selector in the Off position and verify that lamps are Off.
NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at
the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle
fuel mixture check).
D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds
before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step.
1987 4-70
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
E. With the engine idling at normal operating temperature gradually open the propane tool valve
and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum
and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical
position).
NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary
repeat Steps D & E with a new propane cartridge gas supply.
F. Compare measured speed gain to specified speed gain.*
1. If the measured speed gain is within specification, proceed to Step H.
NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the
carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the
above feature.
NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture
according to the reset rpm specification.
2. If the measured speed gain is higher than the speed gain specification:*
Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
3. If the measured speed gain is lower than the speed gain specification:*
Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 2639
4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following
speed drop test:
NOTE: Speed drop test information is specified with the artificial enrichment requirements
whenever the minimum speed gain specification is "0" rpm.*
a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop
in engine speed.
b. If the measured speed drop is greater than "0" and less than or equal to 40 rpm, proceed to Step
G.
c. If the measured speed drop is more than 40 rpm, return the mixture screw to the position before
adjustment. Proceed to Step G.
d. If the measured speed drop is still "0" rpm repeat steps a, b, and c.
G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see
Section III.
*Refer to the Special Specifications Issue TSB Publications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 2648
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 2649
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 2650
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 2651
Figure 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 2652
Figure 4
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 2653
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 2654
Figure 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 2655
Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 2656
Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 2657
Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 2658
Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 2659
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 2660
serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
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Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
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^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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Figure 3
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Figure 4
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Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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Figure 6
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Figure 7
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Figure 8
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Figure 9
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Figure 10
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Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2685
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2686
Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2687
Idle Speed: By Symptom
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2688
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2689
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2690
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2691
Figure 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2692
Figure 4
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2693
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2694
Figure 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2695
Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2696
Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2697
Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2698
Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2699
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2700
serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2702
For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2703
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2704
Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
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^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
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Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2706
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
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If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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Figure 3
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Figure 4
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Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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Figure 6
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Figure 7
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Figure 8
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Figure 9
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Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2715
Figure 10
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Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2716
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2720
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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Information > Specifications > With Automatic Transmission
Idle Speed: Specifications With Automatic Transmission
Curb Idle Speed ...................................................................................................................................
................................................ 650 rpm (in DRIVE)
Fast Idle Speed ...................................................................................................................................
........................................... 1600 rpm (in PARK) [1]
[1] On kickdown step of fast idle cam.
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Information > Specifications > With Automatic Transmission > Page 2724
Idle Speed: Specifications With Manual Transmission
Curb Idle Speed ...................................................................................................................................
................................................................. 800 rpm
Fast Idle Speed ...................................................................................................................................
........................................................... 2200 rpm [1]
[1] On kickdown step of fast idle cam.
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Information > Adjustments > Calibration 4-98S-R11
Idle Speed: Adjustments Calibration 4-98S-R11
1. Stabilize engine temperature.
2. Place truck in Park or Neutral, turn the A/C off, and set the parking brake.
3. Remove the air cleaner.
4. Disconnect and plug the decel throttle control kicker diaphragm vacuum hose. a.
Connect a slave vacuum hose from an engine manifold vacuum source to the decel throttle control
kicker.
b. Run engine at approximately 2500 rpm for 15 seconds, then return to idle.
c. If decel throttle control rpm is not within ±50 rpm of specification, adjust the kicker.
d. Disconnect the slave vacuum hose and allow engine to return to curb idle.
5. Adjust curb idle, if necessary, using the curb idle adjusting screw with transmission in Neutral
(M/T) or Drive (A/T).
6. Goose the throttle, then recheck curb idle speed and adjust as needed.
7. Reconnect the decel throttle control vacuum hose to the diaphragm.
8. Install the air cleaner.
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Information > Adjustments > Calibration 4-98S-R11 > Page 2727
Idle Speed: Adjustments Calibrations 6-97J-R12, 6-97J-R18
1. Stabilize engine temperature.
2. Place truck in Park or Neutral, turn the A/C off, and set the parking brake.
3. Remove the air cleaner.
4. Adjust curb idle, if necessary, using the curb idle adjusting screw with transmission in Neutral
(M/T) or Drive (A/T).
5. Goose the throttle, then recheck curb idle speed and adjust as needed.
6. Check/adjust dashpot clearance by totally compressing the dashpot and adjusting for .100 inch
clearance between collapsed dashpot and throttle lever at the closed throttle position.
7. Install the air cleaner.
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Air Filter Element > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Air Filter Element: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
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Air Filter Element > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis >
Page 2733
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis >
Page 2734
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Locations
Fuel Filter: Locations
Fuel Filter
The fuel filter is located on the frame rail between the frame mounted high pressure pump and
engine.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Locations > Page 2738
Fuel Filter: Description and Operation
Clean fuel is extremely important in a fuel injection system because of the small orifice in the
injector tip through which fuel must pass. Most injection systems use three forms of filters. The first
is a fuel strainer or filter of woven plastic attached to the fuel pump inlet. This prevents
contamination from entering the fuel line and separates water from the fuel. The filter is
self-cleaning and requires no maintenance. If a fuel restriction occurs at this point, the tank
contains too much sediment or moisture and should be removed and cleaned. Additional filtration is
provided by a high capacity inline filter to remove contamination larger than 20 microns (0.0050
inch). This filter is designed to last the life of the vehicle. The final line of defense against fuel
contamination is in the fuel injector. Each injector contains its own inlet filter screen to prevent
contamination from reaching the tip.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component
Information > Locations > Page 2739
Fuel Filter: Service and Repair
Fuel Filter
REMOVAL
1. Shut engine off. De-pressurize fuel system. Use caution to prevent combustion from fuel
spillage.
2. Raise vehicle on hoist.
3. Loosen screw clamp so that filter slides rearward easily.
4. Remove push connect fittings at both ends of the filter. Install new retainer clips in each push
connect fitting.
5. Remove fuel filter from metal bracket by rotating the fuel line, being careful not to kink the fuel
line, and sliding the filter rearward.
Fuel Filter
INSTALLATION
1. Place filter into the bracket with flow arrow pointing toward tab of the bracket. Slide filter forward
until it rests against tab of the bracket.
2. Tighten retaining screw of the screw clamp to 1.3-2.1 ft. lb.
3. Install push-connect fittings onto filter ends.
4. Turn ignition switch from RUN/OFF position several times, without starting engine. Check for fuel
leaks.
5. Lower vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition
Timing Connector > Component Information > Description and Operation
Ignition Timing Connector: Description and Operation
Fig. 20 Ignition Timing Vacuum Switch
Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition
module to retard spark timing. The switch is closed above the vacuum setting and the ignition
module is in the non-retard spark timing mode. Calibration resistors inside the switch control the
amount of retard.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition
Timing Connector > Component Information > Description and Operation > Page 2747
Ignition Timing Connector: Testing and Inspection
Ignition Timing Vacuum Switch
Ignition Timing Vacuum Switch Test Chart
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less
than'' values in the Ignition Timing vacuum Switch Test chart.
3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured
across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart.
4. Replace switch if resistance is not within specifications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing
Marks and Indicators > System Information > Diagrams
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Ignition Cable: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2755
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2756
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2757
Ignition Cable: Technical Service Bulletins Ignition System - Diagnostics Manual Correction
Article No. 89-5A-4
EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION
FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND
CROWN VICTORIA
LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ,
GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR
LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES
1986-88 AEROSTAR
ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989
Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service
information directs technicians to use a substitute coil instead of a resistance test.
ACTION: Refer to this TSB for revised ignition coil and secondary wire test information.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 680000
1989
Ignition Systems, Timing Procedures and Diagnostics 13-51
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2758
Ignition Coil and Secondary Wire
TFI-IV
And
TFI With CCD
Part 2
Test 7 1989 13-52
Ignition Systems, Timing Procedures and Diagnostics
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2759
EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2
Test 8
1989 Ignition Systems, Timing Procedures and Diagnostics
13-65
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2760
Ignition Coil And Secondary Wire
TFI-IV
Closed Bowl
Distributor
Part 2
Test 8 1989 13-66
Ignition Systems, Timing Procedures and Diagnostics
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2761
EEC-IV - Wiring TFI-IV
Closed Bowl
Distributor Part 2
Test 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Technical Service Bulletins > Page 2762
Ignition Cable: Testing and Inspection
Spark Plug Wire Resistance
*** UPDATED BY TSB #85-9-33
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Advance Unit > Component Information > Specifications
DISTRIBUTOR TIMING ADVANCE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism
Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism
The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly
is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm
assembly used depends on the engine calibration.
Single Diaphragm Assembly
SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the
armature to stator relationship to give spark advance. The stator assembly position is changed by
means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm
assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance
spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached
to the stator assembly, makes the the stator assembly move with respect to the armature. This
changes the initial armature to stator relationship set during initial timing, causing spark advance.
The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly,
is attached to the distributor base.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism >
Page 2769
Dual Diaphragm Assembly
DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in
the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum
advance port causes the advance diaphragm and attached rod to move, otherwise the action is the
same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard
diaphragm to move, compressing the retard spring, which controls the rate of spark retard.
Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by
the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm
rod moves causing the attached stator assembly to change position with respect to the armature. In
this instance the direction of the stator assembly movement is opposite that occurring during
vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port
overrides any spark retard caused by vacuum being applied to the retard port.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism >
Page 2770
Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism
Distributor - Exploded view
The centrifugal advance mechanism varies the relationship of the armature to the stator assembly.
The armature is mounted to the sleeve and plate assembly which rotates in relation to the
distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine
RPM. The movement of the weights change the initial relationship of the armature to the stator
assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor
shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by
calibrated springs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Advance Unit > Component Information > Description and Operation > Page 2771
Distributor Advance Unit: Service and Repair
1. Remove distributor cap and rotor.
2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup
assembly.
3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link.
4. Carefully remove unit from distributor.
5. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Distributor Cap: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis >
Page 2776
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Cap > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis >
Page 2777
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Ignition Rotor: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page
2782
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Ignition Rotor > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page
2783
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition >
Distributor Plate W/ Pick-up Sensor > Component Information > Service and Repair
Distributor Plate W/ Pick-up Sensor: Service and Repair
1. Remove distributor cap and rotor.
2. Remove vacuum advance unit and magnetic pickup assembly.
3. Remove attaching screws and lift base plate from distributor.
4. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Spark Plug: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2791
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 2792
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Technical Service Bulletins > Page 2793
Spark Plug: Specifications
Spark Plugs 5-10 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications
Valve Clearance: Specifications
ENGINE YEAR CLEARANCE
V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165
V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150
On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications > Page 2797
Valve Clearance: Locations
FRONT TO REAR 6-300 E-I-E-I-E-I-E-I-E-I-E-I V6-232 Right I-E-I-E-I-E V6-232 Left E-I-E-I-E-I
V8-255, 302 Left Bank E-I-E-I-E-I-E-I V8-255, 302 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Right
Bank I-E-I-E-I-E-I-E V8-351, 400 Left Bank E-I-E-I-E-I-E-I V8-460 Left Bank E-I-E-I-E-I-E-I V8-460
Right Bank I-E-I-E-I-E-I-E
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications > Page 2798
Valve Clearance: Adjustments
Fig. 2 Positioning crankshaft for valve clearance check
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications > Page 2799
Fig. 3 Checking collapsed tappet clearance
Valves, Adjust To provide a means to compensate for dimensional changes in the valve train and
provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve
clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance
is more than the maximum, the longer pushrod should be used. To check the valve clearance,
proceed as follows:
1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of
compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one
quarter turn clockwise (90°) from position No. 2, Fig. 2.
2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 3, and check the clearance on the following valves:
a. On V8-302 and 460 engines, check intake valve Nos. 1 , 7 and 8; exhaust valve Nos. 1, 4 and 5.
b. On V8-351, check intake valve Nos. 1, 4 and No. 8; exhaust valve Nos. 1, 3 and 7.
3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or
equivalent, Fig. 3, and check the clearance on the following valves:
a. On V8-301 and 460 engines check intake valve Nos. 4 and 5; exhaust valve Nos. 2 and 6. b. On
V8-351 engines, check intake valve Nos. 3 and 7; exhaust valve Nos. 2 and 6.
4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or
equivalent and check the clearance on the following valves:
a. V8-302 and 460 engines check intake valve Nos. 2, 3 and 6; exhaust valve Nos. 3, 7 and 8. b.
On V8-351 engines, check intake valve Nos. 2, 5 and 6; exhaust valve Nos. 4, 5 and 8.
Valve Arrangement
Front to Rear
V8-302 Left Bank..................................................................................................................................
...........................................................E-I-E-I-E-I-E-I V8-302 Right Bank.............................................
..............................................................................................................................................I-E-I-E-IE-I-E V8-351 Right Bank......................................................................................................................
.....................................................................I-E-I-E-I-E-I-E V8-351 Left Bank......................................
.......................................................................................................................................................E-IE-I-E-I-E-I V8-460 Left Bank.................................................................................................................
............................................................................E-I-E-I-E-I-E-I V8-460 Right Bank............................
..............................................................................................................................................................
.I-E-I-E-I-E-I-E
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor >
Component Information > Description and Operation
Air Flow Meter/Sensor: Description and Operation
The vane air flow meter measures air flowing into the engine and is mounted between the air
cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a
potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and
potentiometer. The potentiometer relays vane position information to the EEC-IV module. The
EEC-IV module, then translates vane position information into the amount of air flowing into the
engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor
constantly monitors air temperature entering the engine and also transmits the information to the
EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature
information and adjusts the fuel flow to obtain the optimum air/fuel mixture required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Specifications
TEMPERATURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Specifications > Page 2807
Intake Air Temperature Sensor: Locations
LH Side Of V8-302/5.
Near Front Of RH Valve Cover
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Specifications > Page 2808
Intake Air Temperature Sensor: Description and Operation
Fig. 2 Air charge temperature (ACT) sensor
This sensor, Fig. 2, provides the EFI system with air/fuel mixture temperature information. The air
charge temperature sensor is used both as a density corrector to air flow calculation and to
proportion the cold enrichment fuel flow. This sensor is similar in construction to the engine coolant
temperature sensor and is mounted on an intake manifold runner or on the air cleaner.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition
Auxiliary Air Valve (Idle Speed): Customer Interest Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2817
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2818
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2819
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2820
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2821
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2822
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 95711 >
Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2823
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Lack of Power and/or No
Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2829
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2830
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2831
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2832
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2833
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2834
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2835
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor >
Component Information > Technical Service Bulletins > MAP and BAP Sensor - Application Chart
Barometric Pressure Sensor: Technical Service Bulletins MAP and BAP Sensor - Application Chart
Article No. 89-1-12
^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART
^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS
FORD: 1984-87 ALL CARLINES
LINCOLN-MERCURY: 1984-89 ALL CARLINES
LIGHT TRUCK: 1984-89 ALL TRUCKLINES
This article is being republished in its entirety to include the MAP sensor application for the 2.3L
HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine.
ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L
HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP
and BAP sensor application chart has been assembled to assist technicians in making sure the
correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy,
erratic engine idle or hesitation on acceleration may result.
ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the
correct service part applications.
NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF
THE FORD PARTS CATALOG.
LIGHT TRUCK MAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE
1984-86 2.3L OHC All E6TZ-9F479-A MAP
1986-87 3.0L EFI All E6FZ-9F479-A MAP
1988-89 3.0L EFI All E7FZ-9F479-A MAP
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
4.9L EFI 5.0L EFI 7.5L EFI
1988-89 5.8L EFI All E7FZ-9F479-A MAP
PASSENGER CAR MAP AND BAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE
1984-89 1.6L EFI All E7FZ-12A644-A BAP
1.9L EFI 2.3L Turbo
1989 3.0 "SHO" All E7FZ-12A644-A BAP
1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP
(Mustang)
1989 5.0L Mass Air All E8FZ-12A644-A BAP
1984 2.3L HSC FBC All E6PZ-9F479-A MAP
1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP
2.5L HSC CFI
1984-85 3.8L CFI All E5SZ-9F479-A MAP
1984-85 5.0L CFI All E6TZ-9F479-A MAP
1986 2.3L OHC All E6FZ-9F479-A MAP
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor >
Component Information > Technical Service Bulletins > MAP and BAP Sensor - Application Chart > Page 2840
3.0L EFI 3.8L CFI 5.0 SEFI
1984-85 2.3L OHC All E6FZ-9F479-A MAP
1987-89 1.9L CFI All E7DZ-9F479-A MAP
2.3L HSC CFI 2.5L HSC CFI
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI
PART NUMBER PART NAME CLASS
E7FZ-12A644-A BAP Sensor B
E8FZ-12A644-A BAP Sensor B
E6PZ-9F479-A MAP Sensor B
E5SZ-9F479-A MAP Sensor AM
E6TZ-9F479-A MAP Sensor BM
E6FZ-9F479-A MAP Sensor B
E7DZ-9F479-A MAP Sensor B
E7FZ-9F479-A MAP Sensor B
OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 620800, 631900, 640200
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor >
Component Information > Technical Service Bulletins > Page 2841
MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor >
Component Information > Technical Service Bulletins > Page 2842
Barometric Pressure Sensor: Locations
LH Side Of Dash Panel
Inside Of LH Front Fender, Near Ignition Module Or RH Fender Apron At Wheelwell
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Switch >
Component Information > Description and Operation
Barometric Pressure Switch: Description and Operation
Fig. 19 Ignition barometric pressure switch. 1984-87
1984---87 This switch, Fig. 19, controls spark timing and/or other electrical devices according to
barometric pressure changes. Calibration resistors in the switch assembly cause the ignition
module to vary the spark timing. Spark timing is advanced for vehicle operation above a
predetermined altitude and retarded for vehicle operation below a predetermined altitude. Some
switch assemblies control both spark timing and another device while other switch assemblies
control only one or the other.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Switch >
Component Information > Testing and Inspection > Component Testing
Barometric Pressure Switch: Testing and Inspection Component Testing
Fig. 43 Ignition barometric pressure switch resistance chart. 1985---87
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values
in chart.
3. Replace switch if resistance is not within specifications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications
TEMPERATURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor
Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor
Near Front Of Valve Cover
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Coolant Temperature Sensor > Page 2853
Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Switch (For
Computer)
RH Side Of V8-302/5.
Top Forward RH Side Of Engine, Under Water Outlet
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Locations > Page 2854
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Fig. 7 Engine coolant temperature (ECT) sensor
The ECT, Fig. 7, sensor detects the temperature of engine coolant and supplies information to the
ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine
control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture.
On models with an electronic instrument cluster, the ECT output is used to control the coolant
temperature indicator.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision
Technical Service Bulletin # 8918A9 Date: 890915
EVP Sensor - Manual Revision
ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR
VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED
Article No. 89-18A-9
FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG,
TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE
LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS
1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89
SABLE 1987-89 TRACER
MERKUR: 1986-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER
1986-89 AEROSTAR
ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine
Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit
internal wear problems that can cause driveability symptoms and display a Continuous Self-Test
Code 32. This is not associated to correcting the problem using the existing diagnostic procedures.
ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
680000
1985 Pinpoint Tests - DM - EGR, EVP and EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2859
1985
EEC IV - Pinpoint Tests - All Vehicles 22-77
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test
1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2860
1985
22-78 EEC IV - Pinpoint Tests - All Vehicles
Neutral Drive Switch FA A/C Input PinpointTest
1986 (EGR) Systems Functional Diagnosis
1986
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2861
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1986 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2862
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1986 Quick Test: Continuous Self-Test 6.0
EEC IV - Quick Test - All Engines 18-13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2863
QUICK TEST: Continuous Self-Test 6.0
1986
18-14 EEC IV-Quick Test-All Engines
QUICK TEST: Continuous
Self-Test 6.0
Pinpoint Test - DN - EGR - EVP & EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2864
1986
EEC IV-Pinpoint Tests - All Vehicles 21-95
EGR Valve Position Sensor (EVP)
PinpointTest DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2865
21-96 1986 EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2866
EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2867
1986 21-97B
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR) Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2868
1986 EEC IV-Pinpoint Tests-All Vehicles
21-98
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
1987 (EGR) Systems - Functional Diagnosis
1987
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2869
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1987 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2870
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1987 Quick Test: Continuous Self-Test - 6.0
1987
EEC-IV Quick Test-All Engines 16-15
QUICK TEST: Continuous 6.0 Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2871
16-16 1987 EEC-IV Quick Test-All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
1987
EEC IV - Pinpoint Tests - All Vehicles 19-91
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2872
EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
19-92A 1987
EEC IV Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN
5.0L SEFI Passenger Car and 4.9L and 5.0L Truck
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2873
1987
EEC IV-Pinpoint Tests-All Vehicles 19-92B
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2874
1987 19-93-A
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2875
EEC IV-Pinpoint Tests-All Vehicles 1987 19-94
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1988
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2876
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise,
replace the EGR valve.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
replace the EGR valve.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12
1988 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 2-1/2 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2877
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
1988
EEC-IV - Quick Test - All Engines 16-15
QUICK TEST: Continuous
Self-Test 6.0
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2878
1988 16-16
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2879
EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2880
19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2881
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-102A
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2882
1988
19-103 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2883
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-104
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1989
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2884
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for
vacuum leak at EGR valve, replace the valve.
^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
check for contamination, clean the valve.
^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1989
6-12 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at
normal operating temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 1.0 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2885
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur:
^ Engine does not stall
^ Idle speed does not drop more than 100 rpm
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed
Then:
^ For vacuum leak at EGR valve, replace the valve.
^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or
equivalent.
^ Make sure there is no sand left in the valve.
^ Replace the EGR valve if necessary.
9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR
vacuum supply hose.
10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2886
1989 EEC-IV - Quick Test - All Engines
14-17
QUICK TEST: Continuous 6.0 Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2887
1989 14-18
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
1989
EEC-IV - Quick Test - All Engines 14-19
QUICK TEST: Continuous 6.0 Self-Test
Quick Test:Diagnostic By Symptom - 7.0
1989
14-20 EEC-IV - Quick Test - All Engines
QUICK TEST: Diagnostic By Symptom 7.0
A DIAGNOSTIC BY SYMPTOM
SPECIAL NOTES:
^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous
Self-Tests before continuing with this test.
^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By
Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2888
Pinpoint Test - DN - EGR - EVP & EVR
1989
EEC-IV - Pinpoint Tests-All Vehicles 17-133
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2889
1989
17-134 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2890
1989
EEC-IV-Pinpoint Tests - All Vehicles 17-134A
Pinpoint Test DN EGR Valve Position Sensor (EVP)
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2891
1989 17-135
EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2892
1989
EEC-IV - Pinpoint Tests - All Vehicles 17-136A
EGR Valve Position Sensor (EVP)
04GPinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor >
Component Information > Technical Service Bulletins > Page 2893
EGR Valve Position Sensor: Locations
At Center Rear Of Carburetor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition
Engine Control Module: Customer Interest Engine - Lack of Power and/or No Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 2902
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 2903
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 2904
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 2905
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 2906
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 2907
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 2908
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition
Engine Control Module: All Technical Service Bulletins Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2914
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2915
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2916
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2917
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2918
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2919
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 95711
> Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 2920
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 90116
> May > 90 > Body/Frame - Arc Welding Precautions
Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions
Article No. 90-11-6
EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM
ARC WELDING
FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90
TAURUS
LINCOLN-MERCURY: 1985-86 CAPRI
1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90
SABLE
MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER
ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative
battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs
because the arc welding process can produce high electrical currents in the body of a vehicle when
the negative battery ground cable is left connected.
ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground
cable,
CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY
ELECTRIC WELDING EQUIPMENT
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 90116 >
May > 90 > Body/Frame - Arc Welding Precautions
Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions
Article No. 90-11-6
EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM
ARC WELDING
FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90
TAURUS
LINCOLN-MERCURY: 1985-86 CAPRI
1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90
SABLE
MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER
ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative
battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs
because the arc welding process can produce high electrical currents in the body of a vehicle when
the negative battery ground cable is left connected.
ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground
cable,
CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY
ELECTRIC WELDING EQUIPMENT
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Page 2930
Engine Control Module: Locations
Under RH Side Of Dashboard
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Description and Operation > Electronic Control Assembly (ECA)
Engine Control Module: Description and Operation Electronic Control Assembly (ECA)
Fig. 6 Electronic control assembly
The ECA is the brain of the EEC-IV system and is comprised of a processor and calibration
assembly, Fig. 6. The processor receives input signals from the various sensors. The information
obtained is used by the processor to activate engine control systems to obtain optimum emission
control and performance. The calibration assembly is a permanent memory device that contains
information. The processor applies the sensor inputs to the stored information to determine when
and how long the various control systems should be applied.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Description and Operation > Electronic Control Assembly (ECA) > Page 2933
Engine Control Module: Description and Operation Failure Mode Effects Management
FMEM is an alternate system strategy in the ECA designed to allow improved vehicle drive should
one or more sensor inputs fail. When a sensor input is perceived to be out-of-limits by the ECA, an
alternative strategy will be initiated. The ECA will substitute a fixed in-limit sensor value and will
continue to monitor the faulty sensor input. If the faulty sensor operates within limits, the ECA will
return to the normal Engine Running mode (strategy). Code 98 will be displayed when FMEM is in
effect. The MIL ``Check Engine'' light will remain ON when the FMEM is in effect.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard
Cold Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard
Cold Starts/Hesitation/Stalls On Start-Up > Page 2942
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard
Cold Starts/Hesitation/Stalls On Start-Up > Page 2943
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard
Cold Starts/Hesitation/Stalls On Start-Up > Page 2944
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard
Cold Starts/Hesitation/Stalls On Start-Up > Page 2945
Figure 3
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard
Cold Starts/Hesitation/Stalls On Start-Up > Page 2946
Figure 4
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard
Cold Starts/Hesitation/Stalls On Start-Up > Page 2947
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard
Cold Starts/Hesitation/Stalls On Start-Up > Page 2948
Figure 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard
Cold Starts/Hesitation/Stalls On Start-Up > Page 2949
Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard
Cold Starts/Hesitation/Stalls On Start-Up > Page 2950
Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard
Cold Starts/Hesitation/Stalls On Start-Up > Page 2951
Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard
Cold Starts/Hesitation/Stalls On Start-Up > Page 2952
Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard
Cold Starts/Hesitation/Stalls On Start-Up > Page 2953
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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Cold Starts/Hesitation/Stalls On Start-Up > Page 2954
serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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Cold Starts/Hesitation/Stalls On Start-Up > Page 2955
17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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Cold Starts/Hesitation/Stalls On Start-Up > Page 2956
For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Cold Starts/Hesitation/Stalls On Start-Up > Page 2957
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Cold Starts/Hesitation/Stalls On Start-Up > Page 2958
Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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Idle Speed/Throttle Actuator - Electronic: Customer Interest Engine - Rough Idling Condition
^ FUEL SYSTEM-EFI ENGINES - AIR BY-PASS VALVE REPLACEMENT PART INOPERATIVE
^ IDLE - ROUGH-REPLACEMENT AIR BY-PASS VALVE INOPERATIVE
Article No. 89-24-4 FORD:
1983-88 ESCORT, EXP, THUNDERBIRD 1984-88 MUSTANG 1986-88 CROWN VICTORIA,
TAURUS 1988 TEMPO
LINCOLN-MERCURY: 1983 LN7 1983-86 LYNX 1983-88 COUGAR 1984-86 CAPRI 1986-88
CONTINENTAL, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR 1988 TOPAZ
MERKUR: 1985-88 XR4TI 1988 SCORPIO
LIGHT TRUCK: 1985-88 BRONCO, F-150, F-250, RANGER 1986-88 AEROSTAR, BRONCO II,
ECONOLINE 1987-88 F-350 1988 F SUPER DUTY
Figure 1
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ISSUE: A rough idle created when the air by-pass valve is replaced may be caused by a revision
made to the valve's wiring harness.
Vehicles built before the 1989 model year had a diode in the air by-pass valve wiring harness. The
new replacement valves have a 3D marking on the plastic portion of the solenoid, above the
connector cap, Figure 1. They have a diode in the air by-pass valve.
On the air by-pass valves used on vehicles built before the 1989 model year, the positive and
negative leads are not important to the operation of the valve. However, the polarity on the new
replacement air by-pass valve is important because if the wiring harness is reversed the air
by-pass valve will not work.
ACTION: Reverse the wires in the air by-pass valve connector and retest the valve. Refer to the
following EFI Engine Application Chart for engines using these air by-pass valves.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
620800
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> 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
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Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
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> 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2974
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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> 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2976
Figure 3
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> 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2977
Figure 4
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> 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2978
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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Figure 6
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> 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2980
Figure 7
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> 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2981
Figure 8
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> 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2982
Figure 9
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> 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2983
Figure 10
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> 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2984
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 98-5A-4 > Mar > 98 > Customer Interest for Idle Speed/Throttle Actuator - Electronic: > 89244 > Dec
> 89 > Engine - Rough Idling Condition
Idle Speed/Throttle Actuator - Electronic: Customer Interest Engine - Rough Idling Condition
^ FUEL SYSTEM-EFI ENGINES - AIR BY-PASS VALVE REPLACEMENT PART INOPERATIVE
^ IDLE - ROUGH-REPLACEMENT AIR BY-PASS VALVE INOPERATIVE
Article No. 89-24-4 FORD:
1983-88 ESCORT, EXP, THUNDERBIRD 1984-88 MUSTANG 1986-88 CROWN VICTORIA,
TAURUS 1988 TEMPO
LINCOLN-MERCURY: 1983 LN7 1983-86 LYNX 1983-88 COUGAR 1984-86 CAPRI 1986-88
CONTINENTAL, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR 1988 TOPAZ
MERKUR: 1985-88 XR4TI 1988 SCORPIO
LIGHT TRUCK: 1985-88 BRONCO, F-150, F-250, RANGER 1986-88 AEROSTAR, BRONCO II,
ECONOLINE 1987-88 F-350 1988 F SUPER DUTY
Figure 1
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 98-5A-4 > Mar > 98 > Customer Interest for Idle Speed/Throttle Actuator - Electronic: > 89244 > Dec
> 89 > Engine - Rough Idling Condition > Page 2994
ISSUE: A rough idle created when the air by-pass valve is replaced may be caused by a revision
made to the valve's wiring harness.
Vehicles built before the 1989 model year had a diode in the air by-pass valve wiring harness. The
new replacement valves have a 3D marking on the plastic portion of the solenoid, above the
connector cap, Figure 1. They have a diode in the air by-pass valve.
On the air by-pass valves used on vehicles built before the 1989 model year, the positive and
negative leads are not important to the operation of the valve. However, the polarity on the new
replacement air by-pass valve is important because if the wiring harness is reversed the air
by-pass valve will not work.
ACTION: Reverse the wires in the air by-pass valve connector and retest the valve. Refer to the
following EFI Engine Application Chart for engines using these air by-pass valves.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
620800
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > Customer Interest for
Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
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Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3005
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
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Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3006
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3007
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > Customer Interest for
Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3008
Figure 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > Customer Interest for
Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3009
Figure 4
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > Customer Interest for
Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3010
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3011
Figure 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > Customer Interest for
Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3012
Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > Customer Interest for
Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3013
Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > Customer Interest for
Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3014
Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > Customer Interest for
Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3015
Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > Customer Interest for
Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3016
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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Page 3017
serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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Page 3018
17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3019
For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3020
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up >
Page 3021
Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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Idle Speed/Throttle Actuator - Electronic: > 89244 > Dec > 89 > Engine - Rough Idling Condition
Idle Speed/Throttle Actuator - Electronic: Customer Interest Engine - Rough Idling Condition
^ FUEL SYSTEM-EFI ENGINES - AIR BY-PASS VALVE REPLACEMENT PART INOPERATIVE
^ IDLE - ROUGH-REPLACEMENT AIR BY-PASS VALVE INOPERATIVE
Article No. 89-24-4 FORD:
1983-88 ESCORT, EXP, THUNDERBIRD 1984-88 MUSTANG 1986-88 CROWN VICTORIA,
TAURUS 1988 TEMPO
LINCOLN-MERCURY: 1983 LN7 1983-86 LYNX 1983-88 COUGAR 1984-86 CAPRI 1986-88
CONTINENTAL, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR 1988 TOPAZ
MERKUR: 1985-88 XR4TI 1988 SCORPIO
LIGHT TRUCK: 1985-88 BRONCO, F-150, F-250, RANGER 1986-88 AEROSTAR, BRONCO II,
ECONOLINE 1987-88 F-350 1988 F SUPER DUTY
Figure 1
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Idle Speed/Throttle Actuator - Electronic: > 89244 > Dec > 89 > Engine - Rough Idling Condition > Page 3026
ISSUE: A rough idle created when the air by-pass valve is replaced may be caused by a revision
made to the valve's wiring harness.
Vehicles built before the 1989 model year had a diode in the air by-pass valve wiring harness. The
new replacement valves have a 3D marking on the plastic portion of the solenoid, above the
connector cap, Figure 1. They have a diode in the air by-pass valve.
On the air by-pass valves used on vehicles built before the 1989 model year, the positive and
negative leads are not important to the operation of the valve. However, the polarity on the new
replacement air by-pass valve is important because if the wiring harness is reversed the air
by-pass valve will not work.
ACTION: Reverse the wires in the air by-pass valve connector and retest the valve. Refer to the
following EFI Engine Application Chart for engines using these air by-pass valves.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
620800
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Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On
Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
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Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On
Start-Up > Page 3032
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
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Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On
Start-Up > Page 3033
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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Start-Up > Page 3034
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On
Start-Up > Page 3035
Figure 3
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On
Start-Up > Page 3036
Figure 4
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On
Start-Up > Page 3037
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On
Start-Up > Page 3038
Figure 6
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Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On
Start-Up > Page 3039
Figure 7
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On
Start-Up > Page 3040
Figure 8
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Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On
Start-Up > Page 3041
Figure 9
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Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On
Start-Up > Page 3042
Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On
Start-Up > Page 3043
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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Start-Up > Page 3044
serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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Start-Up > Page 3045
17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On
Start-Up > Page 3046
For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Start-Up > Page 3047
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Idle Speed/Throttle Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On
Start-Up > Page 3048
Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Idle Speed/Throttle Actuator - Electronic: > 89244 > Dec > 89 > Engine - Rough Idling Condition
Idle Speed/Throttle Actuator - Electronic: All Technical Service Bulletins Engine - Rough Idling
Condition
^ FUEL SYSTEM-EFI ENGINES - AIR BY-PASS VALVE REPLACEMENT PART INOPERATIVE
^ IDLE - ROUGH-REPLACEMENT AIR BY-PASS VALVE INOPERATIVE
Article No. 89-24-4 FORD:
1983-88 ESCORT, EXP, THUNDERBIRD 1984-88 MUSTANG 1986-88 CROWN VICTORIA,
TAURUS 1988 TEMPO
LINCOLN-MERCURY: 1983 LN7 1983-86 LYNX 1983-88 COUGAR 1984-86 CAPRI 1986-88
CONTINENTAL, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR 1988 TOPAZ
MERKUR: 1985-88 XR4TI 1988 SCORPIO
LIGHT TRUCK: 1985-88 BRONCO, F-150, F-250, RANGER 1986-88 AEROSTAR, BRONCO II,
ECONOLINE 1987-88 F-350 1988 F SUPER DUTY
Figure 1
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Idle Speed/Throttle Actuator - Electronic: > 89244 > Dec > 89 > Engine - Rough Idling Condition > Page 3053
ISSUE: A rough idle created when the air by-pass valve is replaced may be caused by a revision
made to the valve's wiring harness.
Vehicles built before the 1989 model year had a diode in the air by-pass valve wiring harness. The
new replacement valves have a 3D marking on the plastic portion of the solenoid, above the
connector cap, Figure 1. They have a diode in the air by-pass valve.
On the air by-pass valves used on vehicles built before the 1989 model year, the positive and
negative leads are not important to the operation of the valve. However, the polarity on the new
replacement air by-pass valve is important because if the wiring harness is reversed the air
by-pass valve will not work.
ACTION: Reverse the wires in the air by-pass valve connector and retest the valve. Refer to the
following EFI Engine Application Chart for engines using these air by-pass valves.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
620800
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 87721 > Apr > 87 > Component Information > Technical Service Bulletins > Page 3054
Idle Speed/Throttle Actuator - Electronic: Locations
Attached At Rear Of Carburetor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > Page 3055
Vacuum Brake Booster: Service and Repair
1. Disconnect battery ground cable.
2. Disconnect stop lamp switch electrical connectors.
3. Support underside of master cylinder, then remove power brake unit-to-master cylinder attaching
nuts.
4. Remove vacuum hose between manifold and power brake unit, or power brake unit check valve.
Remove check valve, if equipped.
5. Separate power brake unit and master cylinder, leaving master cylinder supported far enough
away to allow removal of power brake unit.
6. On models equipped with push rod mounted stop lamp switch, remove retaining pin, then slide
switch, push rod, spacers and bushing off brake pedal pin.
7. On models equipped with brake pedal mounted stop lamp switch, remove attaching bolt, nut and
plastic bushing, then disconnect power brake unit push rod from brake pedal.
8. Remove power brake unit attaching bolts and the power brake unit.
9. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Component Information > Description and Operation
Vacuum Brake Booster: Description and Operation
The single and tandem vacuum boosters are self contained vacuum hydraulic power braking units.
These are vacuum suspended units that use vacuum and atmospheric pressure for their power. On
gasoline engine vehicles, vacuum is supplied through a fitting in the intake manifold. On diesel
engine vehicles, vacuum is supplied through a vacuum pump. The three basic elements of the
booster are the vacuum power chamber, mechanically actuated booster check valve and a
hydraulic dual master cylinder which supplies hydraulic pressure to the brake system. The vacuum
power chamber consists of a front and rear shell, diaphragm, diaphragm plate, hydraulic pushrod
and vacuum diaphragm return spring. The mechanically actuated booster check valve controls the
degree of power brake application in accordance with foot pressure applied to the valve operating
rod through the brake pedal linkage. This valve is integral with the vacuum power diaphragm.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Component Information > Description and Operation > Page 3058
Vacuum Brake Booster: Service and Repair
1. Disconnect battery ground cable.
2. Disconnect stop lamp switch electrical connectors.
3. Support underside of master cylinder, then remove power brake unit-to-master cylinder attaching
nuts.
4. Remove vacuum hose between manifold and power brake unit, or power brake unit check valve.
Remove check valve, if equipped.
5. Separate power brake unit and master cylinder, leaving master cylinder supported far enough
away to allow removal of power brake unit.
6. On models equipped with push rod mounted stop lamp switch, remove retaining pin, then slide
switch, push rod, spacers and bushing off brake pedal pin.
7. On models equipped with brake pedal mounted stop lamp switch, remove attaching bolt, nut and
plastic bushing, then disconnect power brake unit push rod from brake pedal.
8. Remove power brake unit attaching bolts and the power brake unit.
9. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Mechanical > Idle Speed Vacuum Solenoid Valve > Component Information > Locations > Throttle Kicker Vacuum Valve
Idle Speed Vacuum Solenoid Valve: Locations Throttle Kicker Vacuum Valve
Top Of 8 Cyl, LH Side Of 6 Cyl. Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Mechanical > Idle Speed Vacuum Solenoid Valve > Component Information > Locations > Throttle Kicker Vacuum Valve >
Page 3064
Idle Speed Vacuum Solenoid Valve: Locations Throttle Kicker Solenoid
LH Side Of 6-300/4.
LH Side Of Engine, Above Distributor
Applicable to: 9L Engine With Heavy Duty Emissions
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations
Knock Sensor: Locations
LH Side Of V8-302/5.
Top Center Of Engine
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations > Page 3068
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Under RH Side Of Dashboard
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 3072
Main Relay (Computer/Fuel System): Description and Operation
Fig. 12 EEC relay type, system application & relay locations
EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power
relays also provide reverse battery protection and increased load handling to improve ignition
switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine
applications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Component Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
Fig. 1 Jumper wire connections for resetting Check Engine Lamp.
1985-90 Models w/EEC-IV
This lamp will be illuminated when the ignition switch is placed in the On position. After engine is
started the lamp should go off, unless a problem has been detected by the EEC-IV system. After
diagnosis and repair, the Check Engine/MIL lamp will automatically reset when stored codes are
cleared from the EEC-IV system memory. After diagnosis and repair, EEC-IV memory may be
cleared of stored codes as follows:
1. With ignition switch in the Off position, connect a jumper wire between Self Test and Self Test
Input (STI) connectors, Fig. 1.
On Aerostar, the Self Test and STI connectors are gray in color and are located on lefthand fender
apron, near the Electronic Engine Control (EEC) relay. On Bronco and F Series, the Self Test and
STI connectors are located in the area of the EEC system charcoal canister. On Bronco II and
Ranger, the Self Test connector and STI connector are red in color and they are both located on
the righthand fender apron near the Electronic Engine Control (EEC) relay. On E Series, the Self
Test and the STI connectors are located on the righthand fender apron in the area of the MAP
sensor and starter motor relay.
2. Position ignition switch in On position, then disconnect jumper wire from test connector
terminals. Disconnect jumper as soon as Check Engine lamp starts flashing.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Technical Service Bulletins > MAP and BAP Sensor - Application Chart
Manifold Pressure/Vacuum Sensor: Technical Service Bulletins MAP and BAP Sensor - Application
Chart
Article No. 89-1-12
^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART
^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS
FORD: 1984-87 ALL CARLINES
LINCOLN-MERCURY: 1984-89 ALL CARLINES
LIGHT TRUCK: 1984-89 ALL TRUCKLINES
This article is being republished in its entirety to include the MAP sensor application for the 2.3L
HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine.
ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L
HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP
and BAP sensor application chart has been assembled to assist technicians in making sure the
correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy,
erratic engine idle or hesitation on acceleration may result.
ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the
correct service part applications.
NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF
THE FORD PARTS CATALOG.
LIGHT TRUCK MAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE
1984-86 2.3L OHC All E6TZ-9F479-A MAP
1986-87 3.0L EFI All E6FZ-9F479-A MAP
1988-89 3.0L EFI All E7FZ-9F479-A MAP
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
4.9L EFI 5.0L EFI 7.5L EFI
1988-89 5.8L EFI All E7FZ-9F479-A MAP
PASSENGER CAR MAP AND BAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE
1984-89 1.6L EFI All E7FZ-12A644-A BAP
1.9L EFI 2.3L Turbo
1989 3.0 "SHO" All E7FZ-12A644-A BAP
1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP
(Mustang)
1989 5.0L Mass Air All E8FZ-12A644-A BAP
1984 2.3L HSC FBC All E6PZ-9F479-A MAP
1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP
2.5L HSC CFI
1984-85 3.8L CFI All E5SZ-9F479-A MAP
1984-85 5.0L CFI All E6TZ-9F479-A MAP
1986 2.3L OHC All E6FZ-9F479-A MAP
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Technical Service Bulletins > MAP and BAP Sensor - Application Chart > Page 3080
3.0L EFI 3.8L CFI 5.0 SEFI
1984-85 2.3L OHC All E6FZ-9F479-A MAP
1987-89 1.9L CFI All E7DZ-9F479-A MAP
2.3L HSC CFI 2.5L HSC CFI
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI
PART NUMBER PART NAME CLASS
E7FZ-12A644-A BAP Sensor B
E8FZ-12A644-A BAP Sensor B
E6PZ-9F479-A MAP Sensor B
E5SZ-9F479-A MAP Sensor AM
E6TZ-9F479-A MAP Sensor BM
E6FZ-9F479-A MAP Sensor B
E7DZ-9F479-A MAP Sensor B
E7FZ-9F479-A MAP Sensor B
OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 620800, 631900, 640200
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Technical Service Bulletins > Page 3081
MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Technical Service Bulletins > Page 3082
Manifold Pressure/Vacuum Sensor: Locations
RH Fender Apron With EEC
RH Fender Well
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Oxygen Sensor: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 3087
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 3088
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 3089
Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination
Article No. 93-23-6
11/10/93
^ EGO SENSORS - SILICONE CONTAMINATION
^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED
^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO)
SENSORS
FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO,
THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE
LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94
CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89
TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE,
F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94
VILLAGER
This TSB article is being republished in its entirety to update model applicability and to revise the
part number of the Low Volatility Sealant.
ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the
engine. Volatile silicones can migrate throughout the system during the first one hundred hours of
service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These
products are commonly sold in tubes and caulking-type cartridges.
ACTION: When service is performed on the engine, only use new low volatility silicone sealant
(F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required.
CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN
LOW VOLATILITY SILICONE SEALANT IS SPECIFIED.
PART NUMBER PART NAME CLASS
F1AZ-19662-A Low Volatility RTV Sealant B
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 3090
WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Technical Service Bulletins > Page 3091
Oxygen Sensor: Locations
RH Side Of 6-300/4.
RH Rear Of Engine
Applicable to: 9L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Technical Service Bulletins > Page 3092
Oxygen Sensor: Description and Operation
Fig. 8 Exhaust gas oxygen (EGO) sensor
The exhaust gas oxygen sensor supplies the ECA with a signal which indicates either a rich or lean
condition during engine operation. The sensor is threaded into the center of the exhaust manifold
on 4-140 and 6-300 engines, threaded into the rear of left and right exhaust manifold assemblies
on V6-171 engine or threaded into the rear right exhaust manifold assembly on V8-302 and 351
engine, Fig. 8.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch >
Component Information > Locations
Power Steering Pressure Switch: Locations
Upper LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
Engine Control Module: Customer Interest Engine - Lack of Power and/or No Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 3105
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 3106
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 3107
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 3108
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 3109
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 3110
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest:
> 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition > Page 3111
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition
Engine Control Module: All Technical Service Bulletins Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition >
Page 3117
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition >
Page 3118
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition >
Page 3119
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition >
Page 3120
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition >
Page 3121
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition >
Page 3122
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Engine Control Module: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start Condition >
Page 3123
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Engine Control Module: > 90116 > May > 90 > Body/Frame - Arc Welding Precautions
Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions
Article No. 90-11-6
EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM
ARC WELDING
FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90
TAURUS
LINCOLN-MERCURY: 1985-86 CAPRI
1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90
SABLE
MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER
ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative
battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs
because the arc welding process can produce high electrical currents in the body of a vehicle when
the negative battery ground cable is left connected.
ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground
cable,
CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY
ELECTRIC WELDING EQUIPMENT
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Engine Control Module: > 90116 > May > 90 > Body/Frame - Arc Welding Precautions
Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions
Article No. 90-11-6
EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM
ARC WELDING
FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90
TAURUS
LINCOLN-MERCURY: 1985-86 CAPRI
1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90
SABLE
MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER
ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative
battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs
because the arc welding process can produce high electrical currents in the body of a vehicle when
the negative battery ground cable is left connected.
ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground
cable,
CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY
ELECTRIC WELDING EQUIPMENT
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3133
Engine Control Module: Locations
Under RH Side Of Dashboard
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control
Assembly (ECA)
Engine Control Module: Description and Operation Electronic Control Assembly (ECA)
Fig. 6 Electronic control assembly
The ECA is the brain of the EEC-IV system and is comprised of a processor and calibration
assembly, Fig. 6. The processor receives input signals from the various sensors. The information
obtained is used by the processor to activate engine control systems to obtain optimum emission
control and performance. The calibration assembly is a permanent memory device that contains
information. The processor applies the sensor inputs to the stored information to determine when
and how long the various control systems should be applied.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control
Assembly (ECA) > Page 3136
Engine Control Module: Description and Operation Failure Mode Effects Management
FMEM is an alternate system strategy in the ECA designed to allow improved vehicle drive should
one or more sensor inputs fail. When a sensor input is perceived to be out-of-limits by the ECA, an
alternative strategy will be initiated. The ECA will substitute a fixed in-limit sensor value and will
continue to monitor the faulty sensor input. If the faulty sensor operates within limits, the ECA will
return to the normal Engine Running mode (strategy). Code 98 will be displayed when FMEM is in
effect. The MIL ``Check Engine'' light will remain ON when the FMEM is in effect.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Under RH Side Of Dashboard
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3140
Main Relay (Computer/Fuel System): Description and Operation
Fig. 12 EEC relay type, system application & relay locations
EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power
relays also provide reverse battery protection and increased load handling to improve ignition
switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine
applications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Description and Operation
Air Flow Meter/Sensor: Description and Operation
The vane air flow meter measures air flowing into the engine and is mounted between the air
cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a
potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and
potentiometer. The potentiometer relays vane position information to the EEC-IV module. The
EEC-IV module, then translates vane position information into the amount of air flowing into the
engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor
constantly monitors air temperature entering the engine and also transmits the information to the
EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature
information and adjusts the fuel flow to obtain the optimum air/fuel mixture required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins >
MAP and BAP Sensor - Application Chart
Barometric Pressure Sensor: Technical Service Bulletins MAP and BAP Sensor - Application Chart
Article No. 89-1-12
^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART
^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS
FORD: 1984-87 ALL CARLINES
LINCOLN-MERCURY: 1984-89 ALL CARLINES
LIGHT TRUCK: 1984-89 ALL TRUCKLINES
This article is being republished in its entirety to include the MAP sensor application for the 2.3L
HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine.
ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L
HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP
and BAP sensor application chart has been assembled to assist technicians in making sure the
correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy,
erratic engine idle or hesitation on acceleration may result.
ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the
correct service part applications.
NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF
THE FORD PARTS CATALOG.
LIGHT TRUCK MAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE
1984-86 2.3L OHC All E6TZ-9F479-A MAP
1986-87 3.0L EFI All E6FZ-9F479-A MAP
1988-89 3.0L EFI All E7FZ-9F479-A MAP
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
4.9L EFI 5.0L EFI 7.5L EFI
1988-89 5.8L EFI All E7FZ-9F479-A MAP
PASSENGER CAR MAP AND BAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE
1984-89 1.6L EFI All E7FZ-12A644-A BAP
1.9L EFI 2.3L Turbo
1989 3.0 "SHO" All E7FZ-12A644-A BAP
1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP
(Mustang)
1989 5.0L Mass Air All E8FZ-12A644-A BAP
1984 2.3L HSC FBC All E6PZ-9F479-A MAP
1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP
2.5L HSC CFI
1984-85 3.8L CFI All E5SZ-9F479-A MAP
1984-85 5.0L CFI All E6TZ-9F479-A MAP
1986 2.3L OHC All E6FZ-9F479-A MAP
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins >
MAP and BAP Sensor - Application Chart > Page 3149
3.0L EFI 3.8L CFI 5.0 SEFI
1984-85 2.3L OHC All E6FZ-9F479-A MAP
1987-89 1.9L CFI All E7DZ-9F479-A MAP
2.3L HSC CFI 2.5L HSC CFI
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI
PART NUMBER PART NAME CLASS
E7FZ-12A644-A BAP Sensor B
E8FZ-12A644-A BAP Sensor B
E6PZ-9F479-A MAP Sensor B
E5SZ-9F479-A MAP Sensor AM
E6TZ-9F479-A MAP Sensor BM
E6FZ-9F479-A MAP Sensor B
E7DZ-9F479-A MAP Sensor B
E7FZ-9F479-A MAP Sensor B
OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 620800, 631900, 640200
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins >
Page 3150
MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins >
Page 3151
Barometric Pressure Sensor: Locations
LH Side Of Dash Panel
Inside Of LH Front Fender, Near Ignition Module Or RH Fender Apron At Wheelwell
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and Operation
Barometric Pressure Switch: Description and Operation
Fig. 19 Ignition barometric pressure switch. 1984-87
1984---87 This switch, Fig. 19, controls spark timing and/or other electrical devices according to
barometric pressure changes. Calibration resistors in the switch assembly cause the ignition
module to vary the spark timing. Spark timing is advanced for vehicle operation above a
predetermined altitude and retarded for vehicle operation below a predetermined altitude. Some
switch assemblies control both spark timing and another device while other switch assemblies
control only one or the other.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection >
Component Testing
Barometric Pressure Switch: Testing and Inspection Component Testing
Fig. 43 Ignition barometric pressure switch resistance chart. 1985---87
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values
in chart.
3. Replace switch if resistance is not within specifications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications
TEMPERATURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Coolant Temperature Sensor
Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Sensor
Near Front Of Valve Cover
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Coolant Temperature Sensor > Page 3162
Coolant Temperature Sensor/Switch (For Computer): Locations Coolant Temperature Switch (For
Computer)
RH Side Of V8-302/5.
Top Forward RH Side Of Engine, Under Water Outlet
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Locations > Page 3163
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
Fig. 7 Engine coolant temperature (ECT) sensor
The ECT, Fig. 7, sensor detects the temperature of engine coolant and supplies information to the
ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine
control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture.
On models with an electronic instrument cluster, the ECT output is used to control the coolant
temperature indicator.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision
Technical Service Bulletin # 8918A9 Date: 890915
EVP Sensor - Manual Revision
ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR
VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED
Article No. 89-18A-9
FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG,
TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE
LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS
1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89
SABLE 1987-89 TRACER
MERKUR: 1986-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER
1986-89 AEROSTAR
ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine
Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit
internal wear problems that can cause driveability symptoms and display a Continuous Self-Test
Code 32. This is not associated to correcting the problem using the existing diagnostic procedures.
ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
680000
1985 Pinpoint Tests - DM - EGR, EVP and EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3168
1985
EEC IV - Pinpoint Tests - All Vehicles 22-77
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test
1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3169
1985
22-78 EEC IV - Pinpoint Tests - All Vehicles
Neutral Drive Switch FA A/C Input PinpointTest
1986 (EGR) Systems Functional Diagnosis
1986
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3170
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1986 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3171
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1986 Quick Test: Continuous Self-Test 6.0
EEC IV - Quick Test - All Engines 18-13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3172
QUICK TEST: Continuous Self-Test 6.0
1986
18-14 EEC IV-Quick Test-All Engines
QUICK TEST: Continuous
Self-Test 6.0
Pinpoint Test - DN - EGR - EVP & EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3173
1986
EEC IV-Pinpoint Tests - All Vehicles 21-95
EGR Valve Position Sensor (EVP)
PinpointTest DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3174
21-96 1986 EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3175
EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3176
1986 21-97B
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR) Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3177
1986 EEC IV-Pinpoint Tests-All Vehicles
21-98
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
1987 (EGR) Systems - Functional Diagnosis
1987
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3178
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1987 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3179
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1987 Quick Test: Continuous Self-Test - 6.0
1987
EEC-IV Quick Test-All Engines 16-15
QUICK TEST: Continuous 6.0 Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3180
16-16 1987 EEC-IV Quick Test-All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
1987
EEC IV - Pinpoint Tests - All Vehicles 19-91
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3181
EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
19-92A 1987
EEC IV Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN
5.0L SEFI Passenger Car and 4.9L and 5.0L Truck
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3182
1987
EEC IV-Pinpoint Tests-All Vehicles 19-92B
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3183
1987 19-93-A
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3184
EEC IV-Pinpoint Tests-All Vehicles 1987 19-94
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1988
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3185
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise,
replace the EGR valve.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
replace the EGR valve.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12
1988 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 2-1/2 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3186
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
1988
EEC-IV - Quick Test - All Engines 16-15
QUICK TEST: Continuous
Self-Test 6.0
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3187
1988 16-16
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3188
EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3189
19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3190
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-102A
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3191
1988
19-103 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3192
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-104
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1989
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3193
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for
vacuum leak at EGR valve, replace the valve.
^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
check for contamination, clean the valve.
^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1989
6-12 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at
normal operating temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 1.0 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3194
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur:
^ Engine does not stall
^ Idle speed does not drop more than 100 rpm
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed
Then:
^ For vacuum leak at EGR valve, replace the valve.
^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or
equivalent.
^ Make sure there is no sand left in the valve.
^ Replace the EGR valve if necessary.
9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR
vacuum supply hose.
10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3195
1989 EEC-IV - Quick Test - All Engines
14-17
QUICK TEST: Continuous 6.0 Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3196
1989 14-18
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
1989
EEC-IV - Quick Test - All Engines 14-19
QUICK TEST: Continuous 6.0 Self-Test
Quick Test:Diagnostic By Symptom - 7.0
1989
14-20 EEC-IV - Quick Test - All Engines
QUICK TEST: Diagnostic By Symptom 7.0
A DIAGNOSTIC BY SYMPTOM
SPECIAL NOTES:
^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous
Self-Tests before continuing with this test.
^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By
Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3197
Pinpoint Test - DN - EGR - EVP & EVR
1989
EEC-IV - Pinpoint Tests-All Vehicles 17-133
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3198
1989
17-134 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3199
1989
EEC-IV-Pinpoint Tests - All Vehicles 17-134A
Pinpoint Test DN EGR Valve Position Sensor (EVP)
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3200
1989 17-135
EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
EVP Sensor - Manual Revision > Page 3201
1989
EEC-IV - Pinpoint Tests - All Vehicles 17-136A
EGR Valve Position Sensor (EVP)
04GPinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins >
Page 3202
EGR Valve Position Sensor: Locations
At Center Rear Of Carburetor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications
TEMPERATURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3206
Intake Air Temperature Sensor: Locations
LH Side Of V8-302/5.
Near Front Of RH Valve Cover
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3207
Intake Air Temperature Sensor: Description and Operation
Fig. 2 Air charge temperature (ACT) sensor
This sensor, Fig. 2, provides the EFI system with air/fuel mixture temperature information. The air
charge temperature sensor is used both as a density corrector to air flow calculation and to
proportion the cold enrichment fuel flow. This sensor is similar in construction to the engine coolant
temperature sensor and is mounted on an intake manifold runner or on the air cleaner.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
LH Side Of V8-302/5.
Top Center Of Engine
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3211
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service
Bulletins > MAP and BAP Sensor - Application Chart
Manifold Pressure/Vacuum Sensor: Technical Service Bulletins MAP and BAP Sensor - Application
Chart
Article No. 89-1-12
^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART
^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS
FORD: 1984-87 ALL CARLINES
LINCOLN-MERCURY: 1984-89 ALL CARLINES
LIGHT TRUCK: 1984-89 ALL TRUCKLINES
This article is being republished in its entirety to include the MAP sensor application for the 2.3L
HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine.
ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L
HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP
and BAP sensor application chart has been assembled to assist technicians in making sure the
correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy,
erratic engine idle or hesitation on acceleration may result.
ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the
correct service part applications.
NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF
THE FORD PARTS CATALOG.
LIGHT TRUCK MAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE
1984-86 2.3L OHC All E6TZ-9F479-A MAP
1986-87 3.0L EFI All E6FZ-9F479-A MAP
1988-89 3.0L EFI All E7FZ-9F479-A MAP
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
4.9L EFI 5.0L EFI 7.5L EFI
1988-89 5.8L EFI All E7FZ-9F479-A MAP
PASSENGER CAR MAP AND BAP APPLICATION CHART
YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE
1984-89 1.6L EFI All E7FZ-12A644-A BAP
1.9L EFI 2.3L Turbo
1989 3.0 "SHO" All E7FZ-12A644-A BAP
1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP
(Mustang)
1989 5.0L Mass Air All E8FZ-12A644-A BAP
1984 2.3L HSC FBC All E6PZ-9F479-A MAP
1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP
2.5L HSC CFI
1984-85 3.8L CFI All E5SZ-9F479-A MAP
1984-85 5.0L CFI All E6TZ-9F479-A MAP
1986 2.3L OHC All E6FZ-9F479-A MAP
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service
Bulletins > MAP and BAP Sensor - Application Chart > Page 3216
3.0L EFI 3.8L CFI 5.0 SEFI
1984-85 2.3L OHC All E6FZ-9F479-A MAP
1987-89 1.9L CFI All E7DZ-9F479-A MAP
2.3L HSC CFI 2.5L HSC CFI
1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP
2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI
PART NUMBER PART NAME CLASS
E7FZ-12A644-A BAP Sensor B
E8FZ-12A644-A BAP Sensor B
E6PZ-9F479-A MAP Sensor B
E5SZ-9F479-A MAP Sensor AM
E6TZ-9F479-A MAP Sensor BM
E6FZ-9F479-A MAP Sensor B
E7DZ-9F479-A MAP Sensor B
E7FZ-9F479-A MAP Sensor B
OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 620800, 631900, 640200
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service
Bulletins > Page 3217
MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service
Bulletins > Page 3218
Manifold Pressure/Vacuum Sensor: Locations
RH Fender Apron With EEC
RH Fender Well
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack
of Power/No Start Diagnosis
Oxygen Sensor: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack
of Power/No Start Diagnosis > Page 3223
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack
of Power/No Start Diagnosis > Page 3224
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack
of Power/No Start Diagnosis > Page 3225
Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination
Article No. 93-23-6
11/10/93
^ EGO SENSORS - SILICONE CONTAMINATION
^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED
^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO)
SENSORS
FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO,
THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE
LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94
CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89
TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE,
F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94
VILLAGER
This TSB article is being republished in its entirety to update model applicability and to revise the
part number of the Low Volatility Sealant.
ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the
engine. Volatile silicones can migrate throughout the system during the first one hundred hours of
service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These
products are commonly sold in tubes and caulking-type cartridges.
ACTION: When service is performed on the engine, only use new low volatility silicone sealant
(F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required.
CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN
LOW VOLATILITY SILICONE SEALANT IS SPECIFIED.
PART NUMBER PART NAME CLASS
F1AZ-19662-A Low Volatility RTV Sealant B
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine - Lack
of Power/No Start Diagnosis > Page 3226
WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3227
Oxygen Sensor: Locations
RH Side Of 6-300/4.
RH Rear Of Engine
Applicable to: 9L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3228
Oxygen Sensor: Description and Operation
Fig. 8 Exhaust gas oxygen (EGO) sensor
The exhaust gas oxygen sensor supplies the ECA with a signal which indicates either a rich or lean
condition during engine operation. The sensor is threaded into the center of the exhaust manifold
on 4-140 and 6-300 engines, threaded into the rear of left and right exhaust manifold assemblies
on V6-171 engine or threaded into the rear right exhaust manifold assembly on V8-302 and 351
engine, Fig. 8.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations
Power Steering Pressure Switch: Locations
Upper LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins >
Throttle Position Sensor - Application Chart
Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart
EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP
Article No. 89-16-4
FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO,
THUNDERBIRD
LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII,
SABLE, TOPAZ, TOWN CAR
LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES
ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to
assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely.
ACTION: Refer to one of the following TPS service replacement charts to make sure that the
correct service part is installed.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins >
Throttle Position Sensor - Application Chart > Page 3236
OASIS CODES: 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins >
Throttle Position Sensor - Application Chart > Page 3237
Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove
THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP
Article No. 89-14-7
FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT
1986-89 TAURUS
LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII,
TOPAZ, TOWN CAR 1984-87 LYNX
MERKUR: 1985-89 ALL MERKUR LINES
LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES
ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The
"Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove
a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians
think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting
with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw.
ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws,
technicians should always use a # 2 "Pozidrive" screwdriver.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
INFORMATION ONLY
OASIS CODES: 4800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical
Specifications
THROTTLE POSITION SENSOR SPECIFICATIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical
Specifications > Page 3240
Throttle Position Sensor: Mechanical Specifications
IDLE SPEED Throttle Plate Stop Screw M/T.......................................................................................
......................................................................................625-675 rpm Throttle Plate Stop Screw A/T...
..............................................................................................................................................................
.............600-700 rpm
TORQUE VALUES
Air Bypass Valve To Lower Manifold....................................................................................................
...........................................70-100 in lb (8-11 N-m) Hose to Tank ......................................................
...................................................................................................................................25-35 in lb (3-4
N-m) Fuel Injector Manifold to Fuel Charging
Assembly...........................................................................................................................70-105 in lb
(8-12 N-m) Fuel Line Fittings................................................................................................................
................................................................10-15 ft lb (13-20 N-m) Fuel Pressure Regulator to Injector
Manifold......................................................................................................................................27-40
in lb (3-4.5 N-m) Retaining straps around Fuel Tank...........................................................................
..........................................................................22-30 in lb (30-41 N-m) Throttle Body to Upper
Intake Manifold.....................................................................................................................................
.......70-100 in lb (8-11 N-m) Throttle Position Sensor to Throttle
Body........................................................................................................................................11-16 in
lb (1.2-1.8 N-m) Upper Intake Manifold to Lower Intake Manifold
Bolts.....................................................................................................................12-18 ft lb (16-24
N-m)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3241
Throttle Position Sensor: Locations
RH Side Of V8-351/5.
At Front Of Carburetor
Applicable to: 8L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using
Breakout Box
Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box
Throttle Position Sensor
NOTE: This procedure can be used to check and adjust level "C" sensor only.
1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle.
2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive
lead into test socket 47 and the negative lead into socket 46 of the breakout box.
3. Turn the ignition ON, but DO NOT start the vehicle.
4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP)
sensor mounting screws and rotate the sensor until the voltage falls within this range.
5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m).
6. While observing the DVOM, move the throttle through the entire range of motion. The reading
should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt.
7. If the TP sensor cannot be adjusted, replace the sensor.
8. Perform an EEC-IV quick test on the vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using
Breakout Box > Page 3244
Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment
Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker,
as equipped. With engine not running, compare voltage reading against specifications and adjust
as needed.
Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and
connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust
TPS to specified value.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vacuum Switch > Component Information > Locations
Vacuum Switch: Locations
RH Fender Apron At Wheelwell
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications
VEHICLE SPEED SENSOR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 3251
Vehicle Speed Sensor: Locations
At LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed
Control/Speedometer
Vehicle Speed Sensor: Testing and Inspection Speed Control/Speedometer
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark
green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and
Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and
1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40
ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading
indicates an open coil.
2. Replace sensor if a correct reading has not been obtained.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 3254
Vehicle Speed Sensor: Service and Repair
1. Separate electrical connector leading to the amplifier assembly.
2. Disconnect upper and lower speedometer cables at the speed sensor. Remove speed sensor.
3. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Throttle Position Sensor - Application Chart
Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart
EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP
Article No. 89-16-4
FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO,
THUNDERBIRD
LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII,
SABLE, TOPAZ, TOWN CAR
LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES
ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to
assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely.
ACTION: Refer to one of the following TPS service replacement charts to make sure that the
correct service part is installed.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Throttle Position Sensor - Application Chart > Page 3259
OASIS CODES: 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Throttle Position Sensor - Application Chart > Page 3260
Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove
THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP
Article No. 89-14-7
FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT
1986-89 TAURUS
LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII,
TOPAZ, TOWN CAR 1984-87 LYNX
MERKUR: 1985-89 ALL MERKUR LINES
LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES
ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The
"Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove
a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians
think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting
with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw.
ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws,
technicians should always use a # 2 "Pozidrive" screwdriver.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
INFORMATION ONLY
OASIS CODES: 4800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Specifications > Electrical Specifications
THROTTLE POSITION SENSOR SPECIFICATIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Specifications > Electrical Specifications > Page 3263
Throttle Position Sensor: Mechanical Specifications
IDLE SPEED Throttle Plate Stop Screw M/T.......................................................................................
......................................................................................625-675 rpm Throttle Plate Stop Screw A/T...
..............................................................................................................................................................
.............600-700 rpm
TORQUE VALUES
Air Bypass Valve To Lower Manifold....................................................................................................
...........................................70-100 in lb (8-11 N-m) Hose to Tank ......................................................
...................................................................................................................................25-35 in lb (3-4
N-m) Fuel Injector Manifold to Fuel Charging
Assembly...........................................................................................................................70-105 in lb
(8-12 N-m) Fuel Line Fittings................................................................................................................
................................................................10-15 ft lb (13-20 N-m) Fuel Pressure Regulator to Injector
Manifold......................................................................................................................................27-40
in lb (3-4.5 N-m) Retaining straps around Fuel Tank...........................................................................
..........................................................................22-30 in lb (30-41 N-m) Throttle Body to Upper
Intake Manifold.....................................................................................................................................
.......70-100 in lb (8-11 N-m) Throttle Position Sensor to Throttle
Body........................................................................................................................................11-16 in
lb (1.2-1.8 N-m) Upper Intake Manifold to Lower Intake Manifold
Bolts.....................................................................................................................12-18 ft lb (16-24
N-m)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Specifications > Page 3264
Throttle Position Sensor: Locations
RH Side Of V8-351/5.
At Front Of Carburetor
Applicable to: 8L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Adjustments > EEC-IV Using Breakout Box
Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box
Throttle Position Sensor
NOTE: This procedure can be used to check and adjust level "C" sensor only.
1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle.
2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive
lead into test socket 47 and the negative lead into socket 46 of the breakout box.
3. Turn the ignition ON, but DO NOT start the vehicle.
4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP)
sensor mounting screws and rotate the sensor until the voltage falls within this range.
5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m).
6. While observing the DVOM, move the throttle through the entire range of motion. The reading
should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt.
7. If the TP sensor cannot be adjusted, replace the sensor.
8. Perform an EEC-IV quick test on the vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Adjustments > EEC-IV Using Breakout Box > Page 3267
Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment
Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker,
as equipped. With engine not running, compare voltage reading against specifications and adjust
as needed.
Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and
connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust
TPS to specified value.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Timer Unit > Component
Information > Locations
Timer Unit: Locations
The Combination IMS/EMW module is located at the bottom of the instrument panel left of the
steering column.
This article has been updated by Techincal Service Bulletin 89228 dated November 1989.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Timer Unit > Component
Information > Diagrams > Diagram Information and Instructions
Timer Unit: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Timer Unit > Component
Information > Diagrams > Diagram Information and Instructions > Page 3273
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Timer Unit > Component
Information > Diagrams > Diagram Information and Instructions > Page 3274
Fig. 23 Extended Useful Life Module Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Timer Unit > Component
Information > Diagrams > Page 3275
Timer Unit: Description and Operation
This article has been updated by Techincal Service Bulletin 89228 dated November 1989.
The Combination IMS/EMW module is located at the bottom of the instrument panel left of the
steering column.
There are three types of emission maintenance warning modules specified in the vehicles covered
by the Technical Service Bulletin:
The Emission Maintenance Warning "EMW" module operates a light that is located on the
instrument panel. For 1985-87 model year vehicles, the light will display the word "EMISSIONS".
- For 1988-89 model year vehicles, the light will display the words "CHECK ENGINE".
When the light is lit, it is indicating that the 60,000 mile emission maintenance should be
performed. After the maintenance is performed the EMW module must be reset to zero time. See:
Service and Repair
Another type of module is the "IMS" module. This module is not part of the light circuit and does not
require maintenance. At a predetermined time, the IMS module directs the EEC IV processor to
make a strategy change.
A third type of module is the "COMBO" module. This module combines the functions of the IMS
and the EMW modules.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Timer Unit > Component
Information > Diagrams > Page 3276
Timer Unit: Service and Repair
1. Turn ignition OFF.
2. On Bronco, and F-Series models, module is attached to instrument cluster to left of steering
column. On E-Series models, module is located under
lefthand side of instrument panel.
3. On all models, insert a suitable Phillips head screwdriver through 0.2 inch diameter hole located
on module near reset sticker, then press down
lightly and hold.
4. Turn ignition to RUN while still pressing down lightly on screwdriver. Emissions maintenance
lamp should remain lit for as long as screwdriver is
pressing down. Hold screwdriver in position for approximately five seconds.
5. Remove screwdriver. Lamp should go out after approximately two to five seconds, indicating
module has been reset. If lamp fails to go out,
repeat reset procedure. Turn ignition OFF.
6. Turn ignition to RUN and ensure emission maintenance lamp is lit for 2-5 seconds. Lamp should
turn off after approximately 2-5 seconds.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vacuum Switch > Component
Information > Locations
Vacuum Switch: Locations
RH Fender Apron At Wheelwell
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Specifications
VEHICLE SPEED SENSOR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Specifications > Page 3283
Vehicle Speed Sensor: Locations
At LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Testing and Inspection > Speed Control/Speedometer
Vehicle Speed Sensor: Testing and Inspection Speed Control/Speedometer
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark
green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and
Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and
1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40
ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading
indicates an open coil.
2. Replace sensor if a correct reading has not been obtained.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Testing and Inspection > Page 3286
Vehicle Speed Sensor: Service and Repair
1. Separate electrical connector leading to the amplifier assembly.
2. Disconnect upper and lower speedometer cables at the speed sensor. Remove speed sensor.
3. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Vacuum
Control Solenoid Valve > Component Information > Description and Operation
Air Injection Vacuum Control Solenoid Valve: Description and Operation
Solenoid Valve The dual thermactor air control solenoid valve assembly consists of two normally
closed solenoid vacuum valves (TAB and TAD), one controlling the thermactor air bypass valve
and the other controlling thermactor diverter valve. Both are vented when de-energized and is
sourced by the intake manifold vacuum reservoir and controlled by the EEC-IV system.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid >
Component Information > Locations > Thermactor Air Bypass (TAB) Solenoid
Air Diverter Solenoid: Locations Thermactor Air Bypass (TAB) Solenoid
RH Side 6-300/4.
LH Rear Of Engine
Applicable to: 9L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid >
Component Information > Locations > Thermactor Air Bypass (TAB) Solenoid > Page 3296
Air Diverter Solenoid: Locations Thermactor Air Diverter (TAD) Solenoid
RH Side 6-300/4.
LH Rear Of Engine
Applicable to: 9L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve >
Component Information > Description and Operation > Air Bypass Valves
Air Diverter Valve: Description and Operation Air Bypass Valves
Fig. 64 Normally closed air bypass valves
Fig. 65 Normally open air bypass valves with vacuum vents
Fig. 66 Normally open air bypass valves without vacuum vent
There are two general groups of bypass valves, normally open and normally closed. Both groups
are available in both remote and pump-mounted versions. Normally closed valves, Fig. 64, supply
air to the exhaust system with medium and high applied vacuum signals during normal modes
(engine operating at normal operating temperature), short idles, and some accelerations. With low
or no vacuum applied to pump, air is dumped through silencer ports of valve. Normally open valves
with a vacuum vent, Fig. 65, provide a timed air dump during decelerations and also dump when a
vacuum pressure difference is maintained between the signal port and the vent port. The signal
port must have 3 inches Hg more vacuum than the vent port to hold the dump. This mode is used
to protect the catalyst from overheating. Normally open valves without a vacuum vent, Fig. 66,
provide a timed dump of air for 1.1 or 2.8 seconds when a sudden high vacuum of about 20
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve >
Component Information > Description and Operation > Air Bypass Valves > Page 3301
inches Hg is applied to the signal port. This prevents backfire during deceleration.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve >
Component Information > Description and Operation > Air Bypass Valves > Page 3302
Air Diverter Valve: Description and Operation Air Divert/Control Valves
Fig. 67 Standard air control valve. 1983---87
These valves are used to direct air pump output to the exhaust manifold or downstream to the
catalyst system depending on the engine control modes. 1984---87 vehicles use the standard air
control valve, Fig. 67.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve
> Component Information > Testing and Inspection
Air Injection Bypass Valve: Testing and Inspection
Normally Closed
1. Disconnect air supply hose at valve outlet, then remove vacuum line and check if vacuum is
present at vacuum nipple.
2. Remove any restrictors or delay valves in vacuum line. Before proceeding to step 3, ensure
vacuum is present at vacuum nipple.
3. Reconnect vacuum line to nipple, then accelerate engine to 1500 RPM.
4. Air pump supply should be present at air bypass valve outlet. Disconnect vacuum line, air at
outlet should stop and air pump supply air should be present at silencer port.
5. If above step proves incorrect, check air pump, then bypass valve.
Normally Open With Vacuum Vents
1. Disconnect air pump supply line at outlet, then vacuum lines from vacuum nipple and vacuum
vent.
2. Accelerate engine to 1500 RPM, air pump supply air should be present at outlet.
3. Using suitable vacuum hose, connect vacuum nipple to intake manifold vacuum. No air should
be present at valve outlet, all air should bypass through silencer ports.
4. Using the same vacuum hose as above step, cap vacuum vent and accelerate engine to 2000
RPM. Air pump supply air should be interrupted when throttle is released.
5. If above steps prove incorrect, check air pump, then bypass valve.
Normally Open Without Vacuum Vent
1. Disconnect air supply line at valve outlet, then vacuum line at vacuum nipple.
2. Accelerate engine to 1500 RPM, air pump supply air should be present at outlet.
3. Using suitable vacuum hose, connect vacuum nipple to intake manifold vacuum. Air at outlet
should decrease or shut off.
4. Air pump supply air should be present at silencer ports.
5. If above steps prove incorrect, check air pump, then bypass valve.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve
> Component Information > Description and Operation > Air Check Valve
Air Injection Check Valve: Description and Operation Air Check Valve
This valve, used on some vehicles, allows thermactor air to enter exhaust port drillings, but
prevents reverse flow of exhaust gases in event of improper operation of system components. This
valve is located between bypass valve and exhaust port drillings, either on air manifold or engine.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve
> Component Information > Description and Operation > Air Check Valve > Page 3310
Air Injection Check Valve: Description and Operation Anti-Backfire Gulp Valve
Fig. 73 Anti-backfire gulp valve
The anti-backfire gulp valve, used on some vehicles, routes a portion of thermactor air to the intake
manifold and is activated by intake manifold vacuum signal, Fig. 73. This valve is located
downstream from the air bypass valve and functions only during periods of sudden decrease in
manifold pressure.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve
> Component Information > Testing and Inspection > Anti-Backfire Gulp Valve
Air Injection Check Valve: Testing and Inspection Anti-Backfire Gulp Valve
1. Disconnect supply hose from air pump side of valve.
2. Observe valve pintle by looking into valve through disconnected port.
3. Accelerate engine to 3000 RPM, then release throttle. Pintle should be open and then close.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve
> Component Information > Testing and Inspection > Anti-Backfire Gulp Valve > Page 3313
Air Injection Check Valve: Testing and Inspection Check Valves
1. Check valves should be inspected whenever the hose is disconnected from the valve or check
valve failure is suspected.
NOTE: Any indication of exhaust gases in the air pump indicates check valve failure.
2. Orally blow through the check valve (toward air manifold) then attempt to suck back. Flow should
be toward air manifold only.
3. When replacing a check valve, be careful not to bend or twist the air manifold.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Description and Operation > Combination Air Bypass/Air Control Valves
Air Injection Control Valve: Description and Operation Combination Air Bypass/Air Control Valves
Fig. 70 Normally open combination air bypass/air control valve less bleed
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Description and Operation > Combination Air Bypass/Air Control Valves > Page 3318
Fig. 71 Normally closed combination air bypass/air control valve less bleed
Fig. 72 Normally closed combination air bypass/air control valve with bleed
These valves, used on some 1982---87 vehicles, combine the function of the air bypass valve and
the air control valve.
Three types of valves are used, a normally open valve, Fig. 70, a normally closed valve without
bleed, Fig. 71, and a normally closed valve with bleed, Fig. 72.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Description and Operation > Combination Air Bypass/Air Control Valves > Page 3319
Air Injection Control Valve: Description and Operation Thermactor Vacuum Vent Valve
Fig. 76 Thermactor vacuum vent valve
Fig. 77 Thermactor vacuum vent valve schematic (typical)
This valve, Figs. 76 and 77, is used on some engines equipped with variable venturi carburetor. It
provides the air for the thermactor retard delay valve and air bypass valve during idle modes to
deactivate the thermactor system after a controlled period of time. Application of vacuum from the
carburetor to both ports of the thermactor vacuum vent causes the dump valve to seat and vacuum
to be applied to the rest of the system. Removal of
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Description and Operation > Combination Air Bypass/Air Control Valves > Page 3320
vacuum during idle modes results in unseating of the dump valve, opening of the vent and allowing
air to enter the system to reduce the vacuum previously applied to the retard delay valve.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Description and Operation > Combination Air Bypass/Air Control Valves > Page 3321
Air Injection Control Valve: Description and Operation Vacuum Differential Valve (VDV)
Fig. 78 Vacuum Differential Valve (VDV)
On some vehicles with the Thermactor system and catalytic converters, a VDV, Fig. 78, is used to
control the operation of the air bypass valve. Under normal operation, vacuum applied through the
VDV holds the valve upward, blocking the vent port and allowing Thermactor air flow. During
acceleration or deceleration or in case of system failure, the VDV momentarily cuts off vacuum flow
to the bypass valve, diverting the Thermactor air flow to atmosphere. In case of excessive pressure
or system restriction, the excess pressure will unseat the valve in the lower part of the bypass
valve, allowing a partial flow of air to atmosphere. At the same time, the valve in the upper part of
the valve remains unseated allowing a partial flow of air to the exhaust manifold.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Testing and Inspection > Air Control Valve
Air Injection Control Valve: Testing and Inspection Air Control Valve
Fig. 67 Standard air control valve. 1983---87
Standard Air Control Valve
1. Run engine at 1500 RPM and disconnect air supply hose at inlet, Fig. 67. There should be air
flow at hose. Reconnect air supply hose at valve inlet.
2. Disconnect air supply hoses at outlets A and B and the vacuum line at the vacuum nipple.
3. Run engine at 1500 RPM. There should be air flow at outlet B but little or no air flow at outlet A.
4. Run engine at 1500 RPM and connect a direct vacuum line from any manifold vacuum fitting to
air control valve vacuum nipple. There should be air flow at outlet A but little or no air flow at outlet
B.
5. Connect all vacuum hoses at original positions. If valve does not function correctly, replace
valve.
AIR CONTROL/SHUT-OFF VALVE
1. Start engine and run at idle, disconnect vacuum supply hose from vacuum nipple, and
disconnect inlet hose from valve. Suction should be felt at valve opening.
2. Apply manifold vacuum to vacuum nipple. No suction should be felt at valve inlet opening.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Testing and Inspection > Air Control Valve > Page 3324
Fig. 69 Air control & shut off valve with orifice. 1983
AIR CONTROL/SHUT-OFF VALVE WITH ORIFICE
1. Disconnect valve inlet supply hose and ensure that there is air flow to valve inlet, Fig. 69, then
reconnect air supply hose.
2. Run engine at 1500 RPM and disconnect air supply hose at valve outlet and the vacuum hose at
vacuum nipple. There should be air flow at valve outlet.
3. Connect a direct vacuum line from any manifold fitting to valve vacuum nipple. There should be
a noticeable increase in air flow at valve outlet.
4. Connect all vacuum hoses at original positions.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Testing and Inspection > Air Control Valve > Page 3325
Air Injection Control Valve: Testing and Inspection Combination Air Bypass/Air Control Valves
Fig. 71 Normally closed combination air bypass/air control valve less bleed
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve
> Component Information > Testing and Inspection > Air Control Valve > Page 3326
Fig. 72 Normally closed combination air bypass/air control valve with bleed
NORMALLY CLOSED VALVES
1. Disconnect hoses from outlets A and B, Figs. 71 and 72.
2. Disconnect and plug vacuum line to port D.
3. Run engine at 1500 RPM. There should be air flow at bypass vents.
4. Reconnect vacuum line to port D and disconnect and plug vacuum line to port S, then ensure
that vacuum is present in line to vacuum port D.
5. Run engine at 1500 RPM. There should be air flow at outlet B but no air flow at outlet A.
6. Apply 8---10 inches Hg vacuum to port S and run engine at 1500 RPM. There should be air flow
at outlet A.
7. On bleed type valve, some lesser amount of air will flow from outlet A or B and the main
discharge will change when vacuum is applied to port S. If there is a small air tap attached to the
inlet tube from the air pump, air flow should be present during engine operation.
Fig. 70 Normally open combination air bypass/air control valve less bleed
NORMALLY OPEN VALVES
1. Disconnect hoses from outlets A and B, Fig. 70.
2. Disconnect and plug vacuum lines to ports D and S.
3. Run engine at 1500 RPM. There should be air flow at outlet B.
4. Apply 8---10 inches Hg vacuum to port S and run engine at 1500 RPM. There should be air flow
at outlet A.
5. Reconnect vacuum line to port D and ensure that vacuum is present.
6. Run engine at 1500 RPM. Air should flow out of bypass vents.
7. Reconnect vacuum hoses to original positions.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Hose/Tube >
Component Information > Testing and Inspection
Air Injection Hose/Tube: Testing and Inspection
1. Inspect all hoses and tubes for deterioration or cracks.
2. Check hose and tube routing as interference may cause wear.
3. Check all hose and tube connections.
4. Check the pressure side of the system for leaks with a soapy water solution. With the pump
running, bubbles will form if a leak exists.
5. When replacing any hose or tube, note routing before removal. The hoses used with this system
are made of special material to withstand high temperature. No other type should be used.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump >
Component Information > Testing and Inspection
Air Injection Pump: Testing and Inspection
1. Remove air cleaner, then inspect all hoses and hose connections for leaks. Correct as
necessary. Check belt tension and correct as necessary.
2. With transmission in Park or Neutral and parking brake applied, start engine and allow it to reach
normal operating temperature.
3. Stop engine. Disconnect air supply hose(s) from air pump to air by-pass valve from pump.
4. Install suitable thermactor test gauge in end of hose disconnected from by-pass valve. Secure
hose with clamp to prevent it from blowing out. On side or cover mounted by-pass valves, install an
elbow and hose adapter, then install test gauge. Position air pump supply tester so that air blast
emitted will be harmlessly dissipated.
5. Connect tachometer to engine and start engine. Slowly increase engine speed to 1000 rpm while
observing pressure at gauge. Air pump pressure should be at least 2.25 psi. If thermactor test
gauge is not used, increase engine speed to 1500 rpm and place hand over open hose. Air flow
should be heard and felt.
6. If air pump output pressure is not at least 2.25 psi, or if air flow is not heard and felt, replace
pump and repeat test.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Pulsed Secondary Air
Injection > Component Information > Description and Operation
Pulsed Secondary Air Injection: Description and Operation
Fig. 79 Thermactor II system (typical)
Fig. 80 Thermactor II pulse air valve operation
Some engines are equipped with this type of exhaust air injection system, Fig. 79, which does not
have an air pump. The system uses the natural pulses of the exhaust system to draw air into the
exhaust manifold. The system is regulated by a pulse air valve. The valve, Fig. 80, is connected to
the air cleaner with a hose and to the exhaust manifold with a metal tube. Some pulse air valves
closely resemble the standard Thermactor check valves, but are not interchangeable with them.
When pressure inside the exhaust manifold is more than the pressure in the air cleaner, the reed in
the pulse air valve is closed. When pressure in the exhaust manifold is lower than in the air
cleaner, the reed opens and allows air to be drawn into the exhaust manifold.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve,
Air Injection > Component Information > Description and Operation > Temperature Vacuum Switch (TVS)
Thermal Vacuum Valve: Description and Operation Temperature Vacuum Switch (TVS)
Fig. 27 Temperature vacuum switch--TVS
This switch, Fig. 27, used on some vehicles, has a bimetal disc which locates itself in one of two
positions, depending on its temperature. One position allows free air flow in the vacuum line; and
the other blocks air flow by sealing itself against the O-ring. The switching temperature is below the
range of normal engine operating temperature.
The TVS may be used to control the vacuum signal to the thermactor dump valve, to reduce
emissions.
The normally open TVS may block the purge vacuum signal to provide satisfactory cold driveability
and reduce cold engine emissions. It may be also used to hold off EGR operation during cold
engine operation.
The normally closed TVS may allow cold spark advance to provide satisfactory cold engine
driveability.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve,
Air Injection > Component Information > Description and Operation > Temperature Vacuum Switch (TVS) > Page 3340
Thermal Vacuum Valve: Description and Operation Thermactor Idle Vacuum Valve (TIV)
Fig. 74 Typical Thermactor idle vacuum valve schematic
Fig. 75 Thermactor idle vacuum valve (TIV)
This valve, Fig. 74, used on some vehicles, operates in conjunction with a vacuum delay valve and
provides backfire control, full time idle air dump, cold temperature catalyst protection and cold EGR
lockout. This valve prevents excessive underbody temperature caused by the exhaust system by
diverting secondary air pump output during extended engine idle. EGR port vacuum at the
carburetor moves the power diaphragm which opens or closes vents to the atmosphere by moving
the valve membrane, Fig. 75. Vacuum at the EGR port switches off the thermactor at idle due to
the lack of vacuum at closed throttle conditions. The idle vacuum valve is open and dumps
thermactor air to the atmosphere during cold engine operation, extended idle periods and
deceleration. When the engine has reached normal operating temperature, the vacuum valve is
closed to the atmosphere to allow passage of thermactor air.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve,
AIR > Component Information > Description and Operation
Vacuum Check Valve: Description and Operation
Vacuum Check Valve
The vacuum check valve , Fig. 31, blocks air flow in one direction. It allows free air flow in the other
direction. The check side of this valve will hold the highest vacuum on the vacuum side.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve,
AIR > Component Information > Description and Operation > Page 3344
Vacuum Check Valve: Testing and Inspection
To check vacuum check valve, use a suitable hand held vacuum pump and apply 16 inches Hg
vacuum to the check portion of valve. Maintain vacuum. If vacuum applied remains above 15
inches Hg vacuum for approximately 10 seconds, the vacuum check valve is operating properly. If
not, replace vacuum check valve.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition
Catalytic Converter: Customer Interest Engine - Lack of Power and/or No Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3353
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3354
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3355
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3356
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3357
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3358
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power and/or No Start
Condition > Page 3359
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition
Catalytic Converter: All Technical Service Bulletins Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 3365
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 3366
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 3367
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 3368
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 3369
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 3370
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 3371
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 911211 > Jun > 91 > Engine - Lack of
Power/No Start Diagnosis
Catalytic Converter: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 911211 > Jun > 91 > Engine - Lack of
Power/No Start Diagnosis > Page 3376
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 911211 > Jun > 91 > Engine - Lack of
Power/No Start Diagnosis > Page 3377
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Catalytic Converter: > 90183 > Aug > 90 > Fuel
Pump - Buzzing/Humming After Engine Shut Down
Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut
Down
^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY
CHARGE
^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF
Article No. 90-18-3 FORD:
1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD
1986-90 TAURUS
LINCOLN-MERCURY: 1983-87 LYNX
1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86
CAPRI, MARQUIS 1986-90 SABLE
LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1988-90 F SUPER DUTY
ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been
shut off. There may also be a no start condition or a discharged battery. These conditions are
caused by a sticking fuel pump relay.
ACTION: Install a new fuel pump relay. Refer to the following procedure for service details.
1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for
troubleshooting details.
2. Install a new fuel pump relay, if the old one is defective.
3. Check the vehicle for proper operation.
PART NUMBER PART NAME
F19Z-9345-A Fuel Pump Relay Assy.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901803A 1985-86 LTD/Marquis 0.6 Hr.
(includes pinpoint test)
901803A 1990 Town Car (includes 0.4 Hr.
pinpoint test)
901803A All Other Cars (includes 0.5 Hr.
pinpoint test)
901803A All Trucks (includes pinpoint 0.5 Hr.
test)
DEALER CODING
BASIC PART NO. CONDITION CODE
9345 09
OASIS CODES: 404000, 603300, 203000, 203100, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Dual Catalytic Converter
Catalytic Converter: Description and Operation Dual Catalytic Converter
Fig. 17 Dual catalytic converter
This converter consists of two catalytic converters in one shell, with a mixing chamber in between
the two, Fig. 17. Each converter is composed of a ceramic ``honey comb'' coated with a
rhodium/platinum catalyst designed to control oxides of nitrogen (NOx), unburned hydrocarbons
(HC) and carbon monoxide (CO), and is therefore called a ``three way catalyst'' (TWC). The rear
converter is coated with platinum catalyst and is called a ``conventional'' oxidation catalyst'' (COC)
converter. The platinum catalyst is also called a ``two way catalyst'' since it only acts on two of the
major pollutants, HC and CO.
The TWC converter acts on the exhaust gases from the engine. As the gases flow from the TWC to
the COC converter, they mix with air from the thermactor pump injected into the mixing chamber or
``mid-bed''. This air is required for proper oxidation of HC and CO in the COC converter.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Dual Catalytic Converter > Page 3390
Catalytic Converter: Description and Operation General Description
Fig. 4 Single type catalytic converter with single substrate catalyst
Fig. 5 Single type catalytic converter with dual substrate catalyst
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Dual Catalytic Converter > Page 3391
Fig. 6 Dual type catalytic converter
The catalytic converter used on some vehicles, serves two purposes: it permits a faster chemical
reaction to take place and although it enters into the chemical reaction, it remains unchanged,
ready to repeat the process. The catalytic converter combines hydrocarbons (HC) and carbon
monoxide (CO) with oxygen to form water (H2O) and carbon dioxide (CO2). The catalyst is
structured in the form of a honeycomb monolithic composition, Figs. 4,5 and 6 . The catalyst
consists of a porous substrate of an inert material, coated with platinum and other noble metals
(the catalytically active materials.) This device, located in the exhaust system between the exhaust
manifold and muffler, requires the use of heat shields, in some cases, due to its high operating
temperatures. The heat shields are necessary to protect chassis components, passenger
compartment and other areas from heat related damage. A small diameter fuel tank filler tube neck
is incorporated to prevent the larger service station pump nozzle, used for leaded fuels, being
inserted into the filler tube, thereby preventing system contamination. Since the use of leaded fuels
contaminates the catalysts, deteriorating its effectiveness, the use of unleaded fuels is mandatory
in vehicles equipped with catalytic converters. The catalytic converter can tolerate small amounts of
leaded fuels without permanently reducing the catalyst effectiveness. There are basically three
types of catalysts, the conventional oxidation catalyst (COC) containing Platinum (Pt) and
Palladium (Pd) which are effective for catalyzing the oxidation reactions of hydrocarbons (HC) and
carbon monoxide (CO) emissions. A three-way catalyst (TWC) containing Platinum (Pt) and
Rhodium (RH), is not only effective for catalyzing the oxidation reactions of HC and CO emissions,
but it also catalyzes the reduction of nitrogen oxides (NOx). A light off catalyst (LOC) is a single
bed converter. It is arranged in series with the main catalytic converter assembly of COC and/or
TWC as the aft member(s). This converter is designed to perform the very specialized function of
exhaust emission control during engine warm-up when the main converter(s) is not yet at the
temperature required for maximum efficiency. The LOC is designed to operate effectively in the
high environmental conditions that exist near the manifold flange. The LOC is designed with a
minimum heat sink effect and, provides minimum delay in warm-up of the main catalytic
converter(s). The oxidation catalyst requires the use of a secondary air source which is provided by
the pulse air or thermactor air injection systems.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 3392
Catalytic Converter: Testing and Inspection
Blocked or restricted exhaust system usually results in lack of power or popping through the intake
system. Verify that this condition is not caused by ignition timing problems, then proceed with
diagnosis.
Catalyst and Exhaust Systems
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 3393
Catalyst and Exhaust Systems
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > EFE
Valve > Component Information > Specifications > Mechanical Specifications
EFE Valve: Mechanical Specifications
PVS Body Color Opening Temperature
Black 92-98 F
Blue 125-131 F
Purple 157-163 F
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > EFE
Valve > Component Information > Specifications > Mechanical Specifications > Page 3399
EFE Valve: Pressure, Vacuum and Temperature Specifications
PVS Body Color Opening Temperature
Black 92-98 F
Blue 125-131 F
Purple 157-163 F
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > EFE
Valve > Component Information > Specifications > Page 3400
EFE Valve: Description and Operation
Fig. 16 Exhaust heat control valve--HCV
Used on some V8 engines, this system, Fig. 16, provides quick induction system warm-up for
better cold engine fuel vaporization. A vacuum operated heat control valve mounted between the
exhaust manifold and pipe, directs a portion of the exhaust gases through the intake manifold
during engine warm-up. On cold starts, manifold vacuum is directed to the heat control valve (HCV)
through the top two ports in HCV PVS (ported vacuum switch), closing the HCV. When engine
coolant temperature reaches a predetermined value, the PVS closes off vacuum and vents the
PVS allowing the HCV to close under spring tension. The three PVS valves used may be identified
as follows:
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Emissions Maintenance Light >
Component Information > Technical Service Bulletins > Emission Maintenance Warning Module - Service
Emissions Maintenance Light: Technical Service Bulletins Emission Maintenance Warning Module
- Service
Article No. 89-22-8
^ EMISSION MAINTENANCE WARNING MODULE SERVICE INFORMATION
^ LAMP - "EMISSIONS/CHECK ENGINE" - EMISSION MAINTENANCE WARNING MODULE SERVICE INFORMATION
LIGHT TRUCK: 1985-89 BRONCO 1985-87 BRONCO II 1985-89 ECONOLINE, F-150, F-250,
F-350 1985-88 RANGER 1986-87 AEROSTAR
MEDIUM/HEAVY TRUCK: 1988-90 F & B SERIES
ISSUE: The Emission Maintenance Warning "EMW" module operates a light that is located on the
instrument panel. For 1985-87 model year vehicles, the light will display the word "EMISSIONS".
For 1988-89 model year vehicles, the light will display the words "CHECK ENGINE". When the light
is lit, it is indicating that the 60,000 mile emission maintenance should be performed. After the
maintenance is performed the EMW module must be reset to zero time. Another type of module is
the "IMS" module. This module is not part of the light circuit and does not require maintenance. At
a predetermined time, the IMS module directs the EEC IV processor to make a strategy change. A
third type of module is the "COMBO" module. This module combines the functions of the IMS and
the EMW modules.
ACTION: Refer to the following module application charts for the specific vehicle application and
location of the different types of modules.
NOTE: FOR APPLICATIONS NOT LOSTED IN THE FOLLOWING MODULE APPLICATION
CHARTS, THE "CHECK ENGINE" LIGHT IS CONTROLLED BY THE EEC IV PROCESSOR.
THESE VEHICLES DO NOT USE THE "EMW" MODULE.
1985 & 1986 MODULE APPLICATION CHART
1987 MODULE APPLICATION CHART
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Emissions Maintenance Light >
Component Information > Technical Service Bulletins > Emission Maintenance Warning Module - Service > Page 3405
1988 MODULE APPLICATION CHART
1989 MODULE APPLICATION CHART
1990 MODULE APPLICATION CHART PART NUMBER
PART NAME CLASS
E5TZ-12B514-C EMW Module - 1000 Hr BM
E5TZ-12B514-A EMW Module - 2000 Hr AM
E7TZ-12B514-A COMBO Module BM
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2300, 2500
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl
Vent Solenoid > Component Information > Locations
Bowl Vent Solenoid: Locations
RH Side 6-300/4.
At RH Front Of Carburetor
Applicable to: 9L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl
Vent Solenoid > Component Information > Locations > Page 3410
Bowl Vent Solenoid: Description and Operation
Fig. 9 Carburetor fuel bowl solenoid vent valve
This valve, Fig. 9, used on some vehicles, is a normally open valve located in the fuel bowl vent
line to the carbon canister. When the engine is running, the valve closes off the fuel bowl vent line.
When the engine is shut off, the vent line returns to the normally open condition.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl
Vent Solenoid > Component Information > Locations > Page 3411
Bowl Vent Solenoid: Testing and Inspection
1. Apply 12 volts to valve and ensure valve closes to block air passage.
2. Replace valve if it does not close when energized.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl
Vent Valve > Component Information > Description and Operation > Carburetor Fuel Bowl Thermal Vent Valve
Bowl Vent Valve: Description and Operation Carburetor Fuel Bowl Thermal Vent Valve
Fig. 10 Carburetor fuel bowl thermal vent valve
The thermal vent valve, Fig. 10, used on some vehicles, is a temperature actuated on/off valve,
that is inserted in the carburetor to carbon canister vent line. This valve is closed when the engine
compartment is cold, preventing fuel tank vapors, generated when the fuel tank heats up before the
engine compartment, from being vented through the carburetor bowl.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl
Vent Valve > Component Information > Description and Operation > Carburetor Fuel Bowl Thermal Vent Valve > Page 3416
Bowl Vent Valve: Description and Operation Solenoid Vent Valve
Fig. 57 Solenoid vent valve
The purpose of this valve, Fig. 57, is to close off the fuel bowl vent line when the engine is
operating. It is a normally open valve located in the fuel bowl vent to canister line. This valve is on
carburetors which do not have a built-in fuel bowl vent valve. When the ignition switch is turned on,
the coil energizes and the plunger is pulled against the valve seat to the closed position to prevent
purge vacuum from reaching the carburetor fuel bowl and upsetting the balanced air pressure.
When the ignition switch is turned off, the coil de-energizes and spring pressure unseats the
plunger to allow fuel vapors to flow to the carbon canister where they are stored until purged when
the engine is started. If vacuum from the purge control valve does reach the fuel bowl vent line, the
resultant low air pressure in the bowl will cause a lean fuel mixture condition. When diagnosing a
driveability problem associated with a lean fuel mixture, check the solenoid vent valve and/or the
built-in fuel bowl vent. The vent valves must be closed when the engine is operating.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl
Vent Valve > Component Information > Description and Operation > Carburetor Fuel Bowl Thermal Vent Valve > Page 3417
Bowl Vent Valve: Description and Operation Vacuum Bowl Vent Valve
Fig. 60 Vacuum bowl vent valve
This valve, Fig. 60, used on some vehicles, is a vacuum operated on/off valve. This valve controls
vapor flow from the carburetor bowl to the carbon canister. When the engine is running, manifold
vacuum closes the flow path from the carburetor bowl to the carbon canister.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl
Vent Valve > Component Information > Testing and Inspection > Solenoid Vent Valve
Bowl Vent Valve: Testing and Inspection Solenoid Vent Valve
Apply 9---14 volts DC to valve. If valve does not close, replace valve.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl
Vent Valve > Component Information > Testing and Inspection > Solenoid Vent Valve > Page 3420
Bowl Vent Valve: Testing and Inspection Thermal Vent Valve
1. With ambient temperature at or below 90° F, ensure that valve is fully closed.
2. With ambient temperature at or above 120° F, ensure that valve is fully open.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl
Vent Valve > Component Information > Testing and Inspection > Solenoid Vent Valve > Page 3421
Bowl Vent Valve: Testing and Inspection Vacuum Bowl Vent Valve
1. Ensure that air flows between carburetor port and canister port when no vacuum is applied to
vacuum signal nipple.
2. Apply vacuum to vacuum signal nipple and ensure that air does not flow between carburetor port
and canister port.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl
Vent Valve > Component Information > Testing and Inspection > Solenoid Vent Valve > Page 3422
Bowl Vent Valve: Testing and Inspection Vacuum/Thermostatic Bowl Vent Valve
1. With valve temperature at or above 120°F, ensure that air flows between carburetor port and
canister port when no vacuum is applied to vacuum signal nipple.
2. With valve temperature at or above 120°F, apply vacuum to vacuum signal nipple and ensure
that air does not flow between carburetor port and canister port.
3. With valve temperature at or below 90°F, ensure that there is no or very little air flow between
carburetor port and canister port, whether or not vacuum is applied to vacuum signal nipple.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Description and Operation > Canister Purge Regulator Valve
Canister Purge Control Valve: Description and Operation Canister Purge Regulator Valve
Fig. 56 Purge control valves
CANISTER MOUNTED PURGE CONTROL VALVE
The valve, Fig. 56, is installed on the carbon canister and controls the flow of fuel vapors during
various engine operating modes. The control is provided by a vacuum signal from either the spark
port, EGR port or intake manifold and opens or closes the valve accordingly. When the engine is
off, the vapors from the fuel tank and carburetor fuel bowl are routed through the purge control
valve and into the carbon canister for storage. During normal cruise conditions, spark port or EGR
vacuum is strong enough to open the orifice in the purge control valve to allow fuel vapors to flow
from the carburetor canister through the purge line to a connection in the PCV tube or into the
carburetor spacer. At the same time, the vapors from the fuel tank are also directed into the purge
line. At idle and low speed cruise conditions, spark port or EGR port vacuum is not strong enough
to open the orifice in the purge control valve so that the fuel vapors are then routed to the carbon
canister. On some vehicles fuel vapors are not purged during low engine speeds because the
additional fuel vapors will affect the fuel air mixture, resulting in a reduction of idle quality and an
increase in exhaust emissions. On vehicles not affected by this purging, manifold vacuum is used
to actuate the purge control valve and control the purging of fuel vapors since spark port or EGR
port vacuum is too weak.
IN-LINE MOUNTED PURGE CONTROL VALVE
The valve, Fig. 56, is installed in line with the carbon canister and controls the flow of fuel vapors
during various engine operating modes. The control is provided by a vacuum signal from either the
spark port, EGR port or intake manifold and opens or closes the valve accordingly. When the
engine is off, the vapors from the fuel tank and carburetor fuel bowl are routed through the purge
control valve and into the carbon canister for storage. During normal cruise conditions, spark port
or EGR vacuum is strong enough to open the orifice in the purge control valve to allow fuel vapors
to flow from the carburetor canister through the purge line to a connection in the PCV tube or into
the carburetor spacer. At the same time, the vapors from the fuel tank are also directed into the
purge line. At idle and low speed cruise conditions, spark port or EGR port vacuum is not strong
enough to open the orifice in the purge control valve so that the fuel vapors are then routed to the
carbon canister. On some vehicles fuel vapors are not purged during low engine speeds because
the additional fuel vapors will affect the fuel air mixture, resulting in a reduction of idle quality and
an increase in exhaust emissions. On vehicles not affected by this purging, manifold vacuum is
used to actuate the purge control valve and control the purging of fuel vapors since spark port or
EGR port vacuum is too weak.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Description and Operation > Canister Purge Regulator Valve >
Page 3427
Canister Purge Control Valve: Description and Operation PVS Valve
The PVS (ported vacuum switch) valve allows vacuum to open the purge control valve as the
engine warms up. The purge control valve closes as soon as the engine is turned off and vacuum
drops off. The evaporative emission system may be equipped with either a 2 or 4 port PVS. The 4
port PVS valve is actually two vacuum valves in one, and performs the same function as two 2 port
valves.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Description and Operation > Page 3428
Canister Purge Control Valve: Testing and Inspection
Fig. 56 Purge control valves
1. Apply vacuum to port B, Fig. 56. If there is vacuum flow, replace valve.
2. Apply and maintain 16 inches Hg vacuum to port A, then apply vacuum to port B. If air does not
flow, replace valve. Never apply vacuum to port(s) C.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations
Canister Purge Solenoid: Locations
RH Fender Apron At Wheelwell
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Page 3432
Canister Purge Solenoid: Description and Operation
Fig. 52 Canister purge solenoid
This valve, Fig. 52, used on some vehicles, controls the flow of vapors from the carbon canister to
the intake manifold during various engine operating modes. This is a normally closed valve that is
opened by a signal from the electronic engine control assembly to control carbon canister purging.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Locations
Evaporative Emission Control Canister: Locations
Figure 36 Typical 7.5L 49 States and Canada E-Series Heavy Duty Truck (Carbureted Only)Evaporative Emission System
Figure 38 Typical 7.5L California and Canada-E-250, E-350, Heavy Duty Truck (Carbureted Only)Evaporative Emission System
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Locations > Page 3436
Evaporative Emission Control Canister: Description and Operation
Fig. 53 Charcoal canister w/purge control valve
WITH PURGE CONTROL VALVE
The carbon canister stores fuel vapors from the fuel tank and carburetor until the engine is started.
Fuel vapors enter the top of the purge side of the canister, Fig. 53, and travel in a ``U'' shape
pattern to the fresh air vent side. Vapor flow to the engine is controlled by the purge control valve.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Locations > Page 3437
Fig. 54 Charcoal canister less purge control valve
WITHOUT PURGE CONTROL VALVE
The carbon canister, Fig. 54, stores fuel vapors from the fuel tank and carburetor bowl until the
engine is started. At this time, fuel vapors are purged from the canister into the engine for
combustion. Depending on application, either a 925ml or 1400ml canister is used.
On vehicles equipped with a dual canister system, two canisters are linked together and the
second canister is used for ``spill over'' fuel vapors.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Locations > Page 3438
Evaporative Emission Control Canister: Testing and Inspection
There are no moving parts or nothing to wear in the canister. Check for loose, missing, cracked, or
broken connections and parts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Fuel
Overflow Reservoir > Component Information > Description and Operation
Fuel Overflow Reservoir: Description and Operation
This system provides a vapor space above the gasoline surface in the fuel tank. This area is
enough to permit breathing space for the tank vapor valve assembly under all static and most
dynamic conditions. Horizontally mounted tanks accomplish this by a raised mounting section for
the valve assembly which is centrally located on the upper surface of the tank. Vertically mounted
tanks use a centrally mounted vapor valve assembly on the uppermost surface of the fuel tank.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Description and Operation
Liquid Vapor Separator: Description and Operation
Fig. 47 Fuel tank vapor valve
All fuel tank vapor valves, Fig. 55, use a small orifice which allows only vapor and not fuel to pass
into the line going to the vapor storage canister. This assembly is mounted on the fuel tank. Fuel
vapors trapped in the sealed fuel tank are vented through the vapor valve assembly. The vapors
leave the valve assembly through a single vapor line and continue to the charcoal canister for
storage, until they are purged into the engine. On vehicles equipped with fuel/vapor return lines,
vapors created in the fuel line is continuously vented back to the fuel tank. This prevents engine
surging from fuel enrichment.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Thermal Vacuum Valve - EVAP > Component Information > Description and Operation
Thermal Vacuum Valve - EVAP: Description and Operation
Fig. 22 Ported vacuum switches & vacuum control valves
Fig. 23 Electrical vacuum switch
These switches, Figs. 22 and 23, used on some vehicles, control vacuum to emission components
during engine warm-up.The 2-port and 4-port types open when coolant temperature reaches a
predetermined value. The 3-port type switches vacuum from the center to the top or bottom ports.
Electrical switches can be opened or closed until the PVS is fully cycled. All PVS units are
temperature-activated and have a specific opening and closing temperature.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Thermal Vacuum Valve - EVAP > Component Information > Description and Operation > Page 3448
Thermal Vacuum Valve - EVAP: Testing and Inspection
Fig. 22 Ported vacuum switches & vacuum control valves
Fig. 23 Electrical vacuum switch
VACUUM SWITCH TEST
1. With engine cold, turn ignition key to ``ON,'' connect vacuum gauge to port A, Figs. 22 and 23,
and a vacuum source to port B and then C. There should be no vacuum flow from A to B but there
should be vacuum from A to C.
2. Start engine and run until it reaches normal operating temperature, then apply vacuum to port B
and then port C. There should be vacuum from A to B but no vacuum from A to C. On 4-port valve,
check A1 to B1 and A2 to B2 separately.
3. If vacuum flow is not as described, replace valve.
ELECTRICAL SWITCH TEST
1. Using a suitable ohmmeter, measure resistance across switch terminals with engine cold and
note reading.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Thermal Vacuum Valve - EVAP > Component Information > Description and Operation > Page 3449
2. Start engine and allow to reach operating temperature, then measure resistance across switch
terminals.
3. A change in resistance should be noted at cold and warm engine temperature readings.
4. Check vacuum portion of switch as described above.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Vacuum Delay Valve, EVAP > Component Information > Description and Operation
Vacuum Delay Valve: Description and Operation
Fig. 32 Vacuum delay valve--VDV
This valve, Fig. 32, used on some vehicles, further reduces emissions by delaying the spark
advance during rapid acceleration and by cutting off advance immediately upon deceleration. This
is a one-way valve and will not operate if installed backwards.
On all systems which employ the dual diaphragm distributor, the line which has high vacuum at idle
(normal operating temperature) is connected to the secondary (retard) side of the distributor
vacuum advance unit. This is the connection closest to the distributor cap.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Vacuum Delay Valve, EVAP > Component Information > Testing and Inspection > Ported Vacuum Valves
Vacuum Delay Valve: Testing and Inspection Ported Vacuum Valves
Fig. 22 Ported vacuum switches & vacuum control valves
1. With engine cold, ensure that passage A to B is closed, and passage A to C is open, Fig. 22.
2. Start engine and run until it reaches normal operating temperature, then ensure that passage A
to B is open and passage A to C is closed. On 4-port valve, check A1 to B1 and A2 to B2
separately.
3. If valve does not operate as described, replace valve.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Vacuum Delay Valve, EVAP > Component Information > Testing and Inspection > Ported Vacuum Valves > Page 3455
Vacuum Delay Valve: Testing and Inspection Vacuum Delay Valve
Using a suitable hand held vacuum pump, apply vacuum to both sides of valve. On valve with one
side black or white and the other side a different color , vacuum should build up in one side but not
the other. On valve with both side the same color, vacuum should build up on both sides before
visibly decreasing. If valve does not function in this manner, it should be replaced.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Module > Component Information > Locations
EGR Control Module: Locations
Behind LH Side Of Instrument Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Solenoid > Component Information > Locations
EGR Control Solenoid: Locations
RH Side Of V8-302/5.
Top RH Side Of Engine
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Solenoid > Component Information > Locations > Page 3463
EGR Control Solenoid: Description and Operation
The dual EGR solenoid valve assembly consists of two dithering solenoid valves. The first is a
vacuum valve which supplies vacuum to the sonic EGR valve when energized. The second is a
vent valve which vents the EGR valve to the atmosphere when de-energized. Both solenoid valves
receive variable duty cycle signals from the ECA according to EGR requirements. A restrictor is
added in the vacuum valve inlet port to reduce its flow compared to that of the vent valve so that
when vacuum valve sticks open, the vent valve can immediately vent the vacuum valve flow
without affecting the devices being controlled.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Locations > EGR Vacuum Switch
EGR Electronic Vacuum Regulator Solenoid: Locations EGR Vacuum Switch
Attached To Bracket On LH Valve Cover
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Locations > EGR Vacuum Switch > Page 3468
EGR Electronic Vacuum Regulator Solenoid: Locations EGR Vent Solenoid
Attached To LH Valve Cover
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Maintenance Light > Component Information > Locations
EGR Maintenance Light: Locations
On Dash
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation
EGR Valve: Description and Operation
In this system the exhaust gases are reintroduced to the combustion cycle, therefore diluting the air
fuel mixture entering the combustion chambers. Dilution of the incoming mixture lowers peak flame
temperatures during combustion and thus limits the formation of nitrogen oxides (NOx).
Fig. 46 Spacer entry EGR connection
Some engines use the ``Spacer Entry'' EGR System which has the EGR valve mounted on the
carburetor spacer, Fig. 46. The exhaust gases are taken from a drilled passage in the exhaust
crossover of the intake manifold. The exhaust gas is then routed through a metered EGR valve to a
passage in the carburetor spacer and fed into the primary bore.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Page 3475
Fig. 47 Intake manifold mounted EGR connection
On some engines, the EGR system routes exhaust gas directly from the exhaust manifold, Fig. 47.
Two variables control the operation of the EGR system, 1) engine coolant temperature and 2)
engine or carburetor vacuum. When engine coolant temperature is below the specified level, the
EGR system is locked out by a temperature controlled vacuum switch. This vacuum switch is
installed in series with the EGR valve. This valve receives vacuum from a port in the carburetor
body. When the valve is closed due to lower coolant temperature, no vacuum is applied to the EGR
valve and no exhaust gas is fed to the air-fuel mixture. When the engine coolant temperature
reaches the specified level, the valve opens allowing vacuum to be applied to the EGR valve.
Exhaust gas is then fed to the air-fuel mixture. The second factor controlling EGR operation is
carburetor vacuum. The location of the EGR port in the carburetor determines at what point
vacuum is sent to the EGR valve. Vacuum should be fed to the EGR vacuum control valve when
the primary throttle plate reaches a position corresponding to a road speed of approximately 20
mph under light acceleration.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Page 3476
Fig. 48 Venturi vacuum amplifier
A Venturi Vacuum Amplifier, Fig. 48, uses a weak venturi vacuum signal to produce a strong intake
manifold vacuum to operate the EGR valve, thereby achieving an accurate, repeatable and almost
exact proportion between venturi airflow and EGR flow. This assists in controlling oxides of
nitrogen with minimal sacrifice in driveability.
There are four basic types of EGR valves: the ported type, the integral back pressure type, the
electronic-sonic type and the valve and transducer assembly type The electronic-sonic type valve
is used with the EEC system.
Fig. 6 EGR valve position sensor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Page 3477
This sensor, Fig. 6, is used to monitor the EGR valve pintle position. The computer applies a
reference voltage to the EVP sensor, and the resulting signal from the EVP sensor is proportional
to the amount of exhaust gases flowing through the EGR valve pintle into the intake manifold.
Depending on the input from this and other sensors, the computer can increase or decrease EGR
flow by activating or deactivating a pair of solenoid vacuum valves.
Fig. 49 Ported type EGR valves
Ported type valves, Fig. 49, may be of the poppet or tapered stem design and can have base or
side entry. The two passages connecting the exhaust system to intake manifold are blocked by a
valve which is opened by vacuum and closed by spring pressure.
Fig. 50 Integral back pressure transducer EGR valve
The integral back pressure transducer valve, Fig. 50, cannot be opened by vacuum until the bleed
hole is closed by exhaust back pressure. When open, the valve oscillates at a level dependent on
the exhaust back pressure flowing through the orifice. Valve opening increases as signal vacuum
and exhaust back pressure increases.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Page 3478
Fig. 51 EGR valve w/remote back pressure transducer
Some vehicles use an EGR valve with a remote back pressure transducer, Fig. 51. This assembly
operates the same as the EGR valve with integral back pressure transducer valve and is serviced
only as an assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Testing and Inspection > EGR Valve Tests, 1986-87
EGR Valve: Testing and Inspection EGR Valve Tests, 1986-87
PORTED EGR TYPE VALVE
Functional Test
1. Check to ensure all vacuum hoses are properly routed and not damaged.
2. With engine at operating temperature and idling, check to ensure that no vacuum is available at
EGR valve.
3. On EFI engines, disconnect electrical connector at idle air by-pass valve.
4. On all engines, disconnect and plug EGR vacuum supply hose.
5. Start engine and allow to reach operating temperature, check idle speed using a suitable
tachometer.
6. Connect a suitable hand held vacuum pump to EGR valve vacuum port and gradually apply 5 to
10 inches Hg. of vacuum.
7. When vacuum is applied to the EGR valve, idle speed should drop more than 100 RPM. In some
cases, the engine may stall when vacuum is applied to the EGR valve. When vacuum is removed
from the EGR valve, engine should return to within 25 RPM of the normal idle speed. If EGR valve
does not function in this manner, it should be replaced.
8. Connect EGR vacuum hose to EGR valve.
9. On EFI engines, connect idle air by-pass valve electrical connector.
INTEGRAL back pressure TRANSDUCER TYPE EGR VALVE
Functional Test
1. Check to ensure all vacuum hoses are properly routed and not damaged.
2. With engine at normal operating temperature and idling, check to ensure no vacuum is available
at EGR valve.
3. Install plug(s) in tail pipe(s), leaving a 1/2 inch diameter opening for exhaust gases to escape,to
increase exhaust system back pressure. Do not completely block tail pipe opening or operate
engine at speeds above idle for an extended period time with plug(s) installed.
4. Disconnect and plug EGR vacuum supply hose.
5. Start engine and allow to reach operating temperature, then check idle speed using a suitable
tachometer.
6. Connect a suitable hand held vacuum pump to EGR valve vacuum port and gradually apply 5 to
10 inches Hg. of vacuum.
7. When vacuum is applied to EGR valve idle speed should drop more than 100 RPM. In some
cases the engine may even stall when vacuum is applied. When vacuum is removed from EGR
valve, engine should return to within 25 RPM of normal idle speed. If EGR valve does not function
in this manner, it should be replaced.
8. Remove plug(s) from tail pipe(s) and reconnect EGR vacuum supply hose.
EGR VALVE & TRANSDUCER ASSEMBLY
Functional Test
1. Check to ensure all vacuum hose are properly routed and not damaged.
2. With engine at normal operating temperature and idling, check to ensure no vacuum is available
at EGR valve.
3. Install plug(s) into tail pipe(s), leaving a 1/2 inch diameter opening for exhaust gases to escape,
to increase exhaust system back pressure. Do not completely block tail pipe opening or operate
engine at speeds above idle for prolonged periods time with plug(s) installed.
4. Disconnect and plug vacuum supply hose from exhaust back pressure transducer. Do not
disconnect transducer to EGR valve hose.
5. Start engine and allow to reach operating temperature, then check idle speed using a suitable
tachometer.
6. Connect a suitable hand held vacuum pump to back pressure transducer vacuum port and
gradually apply 5 to 10 inches Hg. of vacuum.
7. When vacuum is applied to the back pressure transducer, idle speed should drop more than 100
RPM. In some cases the engine may even stall when vacuum is applied. When vacuum is removed
from the back pressure transducer, engine should return to within 25 RPM of normal idle speed. If
EGR valve and transducer assembly fail to operate in this manner, the assembly should be
replaced.
8. Remove plug(s) from tail pipe(s) and reconnect vacuum supply hose to back pressure
transducer.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Testing and Inspection > EGR Valve Tests, 1986-87 > Page 3481
EGR Valve: Testing and Inspection EGR Venturi Vacuum Amplifier
Idle must be set to specifications, engine must be at normal operating temperature and manifold
vacuum must be adequate for this test.
1. Connect a vacuum gauge hose at EGR valve. The gauge may read as high as 2 inches Hg at
idle.
2. Disconnect venturi hose at carburetor and increase engine speed to 2000 RPM (3000 on 2300
cc engines).
3. Connect venturi hose. Gauge should read 4 inches Hg.
4. Return engine to idle. Gauge should return to initial reading.
5. If operation is not as described previously, replace VVA.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision
Technical Service Bulletin # 8918A9 Date: 890915
EVP Sensor - Manual Revision
ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR
VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED
Article No. 89-18A-9
FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG,
TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE
LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS
1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89
SABLE 1987-89 TRACER
MERKUR: 1986-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER
1986-89 AEROSTAR
ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine
Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit
internal wear problems that can cause driveability symptoms and display a Continuous Self-Test
Code 32. This is not associated to correcting the problem using the existing diagnostic procedures.
ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
680000
1985 Pinpoint Tests - DM - EGR, EVP and EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3486
1985
EEC IV - Pinpoint Tests - All Vehicles 22-77
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test
1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3487
1985
22-78 EEC IV - Pinpoint Tests - All Vehicles
Neutral Drive Switch FA A/C Input PinpointTest
1986 (EGR) Systems Functional Diagnosis
1986
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3488
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1986 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3489
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1986 Quick Test: Continuous Self-Test 6.0
EEC IV - Quick Test - All Engines 18-13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3490
QUICK TEST: Continuous Self-Test 6.0
1986
18-14 EEC IV-Quick Test-All Engines
QUICK TEST: Continuous
Self-Test 6.0
Pinpoint Test - DN - EGR - EVP & EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3491
1986
EEC IV-Pinpoint Tests - All Vehicles 21-95
EGR Valve Position Sensor (EVP)
PinpointTest DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3492
21-96 1986 EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3493
EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3494
1986 21-97B
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR) Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3495
1986 EEC IV-Pinpoint Tests-All Vehicles
21-98
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
1987 (EGR) Systems - Functional Diagnosis
1987
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3496
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1987 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3497
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1987 Quick Test: Continuous Self-Test - 6.0
1987
EEC-IV Quick Test-All Engines 16-15
QUICK TEST: Continuous 6.0 Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3498
16-16 1987 EEC-IV Quick Test-All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
1987
EEC IV - Pinpoint Tests - All Vehicles 19-91
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3499
EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
19-92A 1987
EEC IV Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN
5.0L SEFI Passenger Car and 4.9L and 5.0L Truck
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3500
1987
EEC IV-Pinpoint Tests-All Vehicles 19-92B
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3501
1987 19-93-A
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3502
EEC IV-Pinpoint Tests-All Vehicles 1987 19-94
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1988
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3503
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise,
replace the EGR valve.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
replace the EGR valve.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12
1988 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 2-1/2 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3504
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
1988
EEC-IV - Quick Test - All Engines 16-15
QUICK TEST: Continuous
Self-Test 6.0
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3505
1988 16-16
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3506
EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3507
19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3508
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-102A
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3509
1988
19-103 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3510
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-104
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1989
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3511
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for
vacuum leak at EGR valve, replace the valve.
^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
check for contamination, clean the valve.
^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1989
6-12 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at
normal operating temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 1.0 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3512
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur:
^ Engine does not stall
^ Idle speed does not drop more than 100 rpm
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed
Then:
^ For vacuum leak at EGR valve, replace the valve.
^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or
equivalent.
^ Make sure there is no sand left in the valve.
^ Replace the EGR valve if necessary.
9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR
vacuum supply hose.
10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3513
1989 EEC-IV - Quick Test - All Engines
14-17
QUICK TEST: Continuous 6.0 Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3514
1989 14-18
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
1989
EEC-IV - Quick Test - All Engines 14-19
QUICK TEST: Continuous 6.0 Self-Test
Quick Test:Diagnostic By Symptom - 7.0
1989
14-20 EEC-IV - Quick Test - All Engines
QUICK TEST: Diagnostic By Symptom 7.0
A DIAGNOSTIC BY SYMPTOM
SPECIAL NOTES:
^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous
Self-Tests before continuing with this test.
^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By
Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3515
Pinpoint Test - DN - EGR - EVP & EVR
1989
EEC-IV - Pinpoint Tests-All Vehicles 17-133
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3516
1989
17-134 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3517
1989
EEC-IV-Pinpoint Tests - All Vehicles 17-134A
Pinpoint Test DN EGR Valve Position Sensor (EVP)
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3518
1989 17-135
EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3519
1989
EEC-IV - Pinpoint Tests - All Vehicles 17-136A
EGR Valve Position Sensor (EVP)
04GPinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
Position Sensor > Component Information > Technical Service Bulletins > Page 3520
EGR Valve Position Sensor: Locations
At Center Rear Of Carburetor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal
Vacuum Valve, EGR > Component Information > Description and Operation
Thermal Vacuum Valve: Description and Operation
Fig. 22 Ported vacuum switches & vacuum control valves
Fig. 23 Electrical vacuum switch
These switches, Figs. 22 and 23, used on some vehicles, control vacuum to emission components
during engine warm-up.The 2-port and 4-port types open when coolant temperature reaches a
predetermined value. The 3-port type switches vacuum from the center to the top or bottom ports.
Electrical switches can be opened or closed until the PVS is fully cycled. All PVS units are
temperature-activated and have a specific opening and closing temperature.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal
Vacuum Valve, EGR > Component Information > Description and Operation > Page 3524
Thermal Vacuum Valve: Testing and Inspection
Fig. 22 Ported vacuum switches & vacuum control valves
Fig. 23 Electrical vacuum switch
VACUUM SWITCH TEST
1. With engine cold, turn ignition key to ``ON,'' connect vacuum gauge to port A, Figs. 22 and 23,
and a vacuum source to port B and then C. There should be no vacuum flow from A to B but there
should be vacuum from A to C.
2. Start engine and run until it reaches normal operating temperature, then apply vacuum to port B
and then port C. There should be vacuum from A to B but no vacuum from A to C. On 4-port valve,
check A1 to B1 and A2 to B2 separately.
3. If vacuum flow is not as described, replace valve.
ELECTRICAL SWITCH TEST
1. Using a suitable ohmmeter, measure resistance across switch terminals with engine cold and
note reading.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal
Vacuum Valve, EGR > Component Information > Description and Operation > Page 3525
2. Start engine and allow to reach operating temperature, then measure resistance across switch
terminals.
3. A change in resistance should be noted at cold and warm engine temperature readings.
4. Check vacuum portion of switch as described above.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Hot Idle Compensator (Non Comp.
Controlled) > Component Information > Technical Service Bulletins > Customer Interest for Hot Idle Compensator (Non
Comp. Controlled): > 871913 > Sep > 87 > Engine - Hard Start After Hot Soak
Hot Idle Compensator (Non Comp. Controlled): Customer Interest Engine - Hard Start After Hot
Soak
HARD START AFTER HOT SOAK - Article No.
5.8L AND 7.5L ENGINE WITH HOLLEY 87-19-13
4V CARBURETOR - OVER 8500 LBS. GVW
LIGHT TRUCK: 1983-87 E SERIES, F SERIES
ISSUE: Hard starting at normal engine operating temperature after a 15 to 60 minute hot soak may
be caused by fuel vapor getting to the engine through the fuel bowl and evaporative emissions
system. The fuel vapor will cause an over-rich engine during restart. Volatility of gasoline may also
cause increased amounts of vapor when gasoline is warm. The affected vehicles are 1984-87 E
and F Series with a 5.8L engine and Holley 4V carburetor and 1983-87 E and F Series with a 7.5L
engine and Holley 4V carburetor.
ACTION: To correct this, install a Hot Idle Compensator (HIC) valve using the following service
procedure.
5.8L Engine
NOTE: Use original production PCV line.
Figure 10
1. Assemble HIC valve (E1TZ-9B532-A) and Tee (379507-S), Figure 10.
2. Install the HIC valve in the PCV line, Figure 10.
NOTE: Position the HIC valve in the PCV line over exhaust heat cross-over and under spark plug
wires.
7.5L Engine
1. Remove steel PCV line.
2. Install a new PCV line (E6HZ-6A664-A). The new PCV line fits from the PCV valve to the front of
the carburetor. PCV line must be routed along the right rocker arm cover under spark plug wires.
3. Assemble HIC valve (E1TZ-9B532-A) and Tee (379507-S), Figure 10.
4. Install HIC valve in the PCV line, Figure 10.
NOTE: Position the HIC valve in the PCV line over exhaust heat cross-over and under spark plug
wires.
PART NUMBER PART NAME CLASS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Hot Idle Compensator (Non Comp.
Controlled) > Component Information > Technical Service Bulletins > Customer Interest for Hot Idle Compensator (Non
Comp. Controlled): > 871913 > Sep > 87 > Engine - Hard Start After Hot Soak > Page 3534
E1TZ-9B532-A HIC Valve C
379507-S Tee RS
E6HZ-6A664-A PCV Line CQ
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: SP871913A TIME:
0.4 Hr. - F Series 0.6 Hr. - Econoline DLR. CODING: Basic Pan No. 9510 - Code: H5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Hot Idle Compensator (Non Comp.
Controlled) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hot Idle
Compensator (Non Comp. Controlled): > 871913 > Sep > 87 > Engine - Hard Start After Hot Soak
Hot Idle Compensator (Non Comp. Controlled): All Technical Service Bulletins Engine - Hard Start
After Hot Soak
HARD START AFTER HOT SOAK - Article No.
5.8L AND 7.5L ENGINE WITH HOLLEY 87-19-13
4V CARBURETOR - OVER 8500 LBS. GVW
LIGHT TRUCK: 1983-87 E SERIES, F SERIES
ISSUE: Hard starting at normal engine operating temperature after a 15 to 60 minute hot soak may
be caused by fuel vapor getting to the engine through the fuel bowl and evaporative emissions
system. The fuel vapor will cause an over-rich engine during restart. Volatility of gasoline may also
cause increased amounts of vapor when gasoline is warm. The affected vehicles are 1984-87 E
and F Series with a 5.8L engine and Holley 4V carburetor and 1983-87 E and F Series with a 7.5L
engine and Holley 4V carburetor.
ACTION: To correct this, install a Hot Idle Compensator (HIC) valve using the following service
procedure.
5.8L Engine
NOTE: Use original production PCV line.
Figure 10
1. Assemble HIC valve (E1TZ-9B532-A) and Tee (379507-S), Figure 10.
2. Install the HIC valve in the PCV line, Figure 10.
NOTE: Position the HIC valve in the PCV line over exhaust heat cross-over and under spark plug
wires.
7.5L Engine
1. Remove steel PCV line.
2. Install a new PCV line (E6HZ-6A664-A). The new PCV line fits from the PCV valve to the front of
the carburetor. PCV line must be routed along the right rocker arm cover under spark plug wires.
3. Assemble HIC valve (E1TZ-9B532-A) and Tee (379507-S), Figure 10.
4. Install HIC valve in the PCV line, Figure 10.
NOTE: Position the HIC valve in the PCV line over exhaust heat cross-over and under spark plug
wires.
PART NUMBER PART NAME CLASS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Hot Idle Compensator (Non Comp.
Controlled) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hot Idle
Compensator (Non Comp. Controlled): > 871913 > Sep > 87 > Engine - Hard Start After Hot Soak > Page 3540
E1TZ-9B532-A HIC Valve C
379507-S Tee RS
E6HZ-6A664-A PCV Line CQ
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: SP871913A TIME:
0.4 Hr. - F Series 0.6 Hr. - Econoline DLR. CODING: Basic Pan No. 9510 - Code: H5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Component Information > Description and Operation
Positive Crankcase Ventilation: Description and Operation
Fig. 62 Typical PCV system
Fig. 63 Typical PCV valve
All engines produce small amounts of blowby gases which seep past the piston rings and into the
crankcase. These blowby gases are the result of the high pressures developed within the
combustion chamber during the combustion process, and contain undesirable pollutants. To
prevent blow-by gases from entering atmosphere while allowing proper crankcase ventilation, all
engines use a PCV system, Fig. 62.
The PCV system prevents blowby gases from escaping by routing them through a vacuum
controlled ventilating valve and a hose into the intake manifold. The blowby gases mix with the
air/fuel mixture and are burned in the combustion chambers. When the engine is running, fresh air
is drawn into the crankcase through a tube or hose connected to the air cleaner housing.
The PCV valve, Fig. 63, consists of a needle valve, spring and housing. When the engine is off, the
spring holds the needle valve closed to stop vapors from entering the intake manifold. When the
engine is running, manifold vacuum unseats the valve allowing crankcase vapors to enter the
intake manifold. In case of a backfire in the intake manifold, the valve closes, stopping the backflow
and preventing ignition of fumes in the crankcase. During certain engine conditions, more blowby
gases are created than the ventilator valve can handle. The excess is returned through the air
intake tube to the air cleaner and carburetor where it is burned in the engine.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Component Information > Description and Operation > Page 3544
Positive Crankcase Ventilation: Testing and Inspection
1. Pull end of PCV valve out of valve cover. If valve rattles when shaken, proceed to step 2. If not,
replace valve.
2. Disconnect vacuum hose from air cleaner and feel for vacuum at hose with engine at idle. If
vacuum is felt, system is satisfactory. If no vacuum is felt, check for obstructions in PCV system or
a leaking evaporative valve.
3. Disconnect evaporative hose, then cap the tee fitting and retest. If vacuum is now felt, PCV
system is satisfactory. Check evaporative system. If no vacuum is felt, check for vacuum back
through the system and inspect rocker cover gasket for leaks. Repair or replace components as
necessary.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control
Systems > EGR Control Module > Component Information > Locations
EGR Control Module: Locations
Behind LH Side Of Instrument Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision
Technical Service Bulletin # 8918A9 Date: 890915
EVP Sensor - Manual Revision
ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR
VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED
Article No. 89-18A-9
FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG,
TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE
LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS
1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89
SABLE 1987-89 TRACER
MERKUR: 1986-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER
1986-89 AEROSTAR
ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine
Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit
internal wear problems that can cause driveability symptoms and display a Continuous Self-Test
Code 32. This is not associated to correcting the problem using the existing diagnostic procedures.
ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
680000
1985 Pinpoint Tests - DM - EGR, EVP and EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3554
1985
EEC IV - Pinpoint Tests - All Vehicles 22-77
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test
1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3555
1985
22-78 EEC IV - Pinpoint Tests - All Vehicles
Neutral Drive Switch FA A/C Input PinpointTest
1986 (EGR) Systems Functional Diagnosis
1986
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3556
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1986 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3557
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed to the emission decal specification.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1986 Quick Test: Continuous Self-Test 6.0
EEC IV - Quick Test - All Engines 18-13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3558
QUICK TEST: Continuous Self-Test 6.0
1986
18-14 EEC IV-Quick Test-All Engines
QUICK TEST: Continuous
Self-Test 6.0
Pinpoint Test - DN - EGR - EVP & EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3559
1986
EEC IV-Pinpoint Tests - All Vehicles 21-95
EGR Valve Position Sensor (EVP)
PinpointTest DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3560
21-96 1986 EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3561
EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3562
1986 21-97B
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR) Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3563
1986 EEC IV-Pinpoint Tests-All Vehicles
21-98
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
1987 (EGR) Systems - Functional Diagnosis
1987
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3564
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1987 6-12
Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve.
7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
10. Reconnect the idle air bypass valve electrical connector.
11. Unplug and reconnect the EGR vacuum supply hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3565
12. Reconnect the EVP sensor electrical connector.
13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
1987 Quick Test: Continuous Self-Test - 6.0
1987
EEC-IV Quick Test-All Engines 16-15
QUICK TEST: Continuous 6.0 Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3566
16-16 1987 EEC-IV Quick Test-All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
1987
EEC IV - Pinpoint Tests - All Vehicles 19-91
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3567
EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
19-92A 1987
EEC IV Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN
5.0L SEFI Passenger Car and 4.9L and 5.0L Truck
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3568
1987
EEC IV-Pinpoint Tests-All Vehicles 19-92B
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3569
1987 19-93-A
EEC IV-Pinpoint Tests-All Vehicles
EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI
Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3570
EEC IV-Pinpoint Tests-All Vehicles 1987 19-94
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1988
Exhaust Gas Recirculation (EGR) Systems 6-11
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3571
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise,
replace the EGR valve.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
replace the EGR valve.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12
1988 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 2-1/2 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve:
^ Engine does not stall.
^ Idle speed does not drop more than 100 rpm.
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3572
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
1988
EEC-IV - Quick Test - All Engines 16-15
QUICK TEST: Continuous
Self-Test 6.0
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3573
1988 16-16
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
Pinpoint Test - DN - EGR - EVP & EVR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3574
EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3575
19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3576
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-102A
EGR Valve Position Sensor (EVP)
EGR Valve Regulator (EVR)
Pinpoint Test DN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3577
1988
19-103 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3578
1988
EEC-IV - Pinpoint Tests - All Vehicles 19-104
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Valve Regulator (EVR)
(EGR) Systems - Functional Diagnosis
1989
6-11 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3579
PORTED EGR VALVE
1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace
cracked, crimped or broken hoses.
2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating
temperature.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is fully applied to the EGR valve:
^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for
vacuum leak at EGR valve, replace the valve.
^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner.
^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm),
check for contamination, clean the valve.
^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary.
9. Reconnect the idle air bypass valve electrical connector.
10. Unplug and reconnect the EGR vacuum supply hose.
11. The EGR system is OK, refer to the Diagnostic Routines in Section 2.
1989
6-12 Exhaust Gas Recirculation (EGR) Systems
Functional Diagnosis
ELECTRONIC EGR (EEGR) VALVE 1.
Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked,
crimped or broken hoses.
2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at
normal operating temperature.
NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This
signal should be less than 1.0 in-Hg at idle.
3. Install a tachometer, Rotunda 059-00010 or equivalent.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3580
4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only).
5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose.
6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If
necessary, adjust idle speed according to Section 4.
7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand
vacuum pump, Rotunda 021-00014 or equivalent.
8. When vacuum is applied to the EGR valve and any of the following occur:
^ Engine does not stall
^ Idle speed does not drop more than 100 rpm
^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed
Then:
^ For vacuum leak at EGR valve, replace the valve.
^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or
equivalent.
^ Make sure there is no sand left in the valve.
^ Replace the EGR valve if necessary.
9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR
vacuum supply hose.
10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the
Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2.
Quick Test:Continuous Self-Test - 6.0
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3581
1989 EEC-IV - Quick Test - All Engines
14-17
QUICK TEST: Continuous 6.0 Self-Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3582
1989 14-18
EEC-IV - Quick Test - All Engines
QUICK TEST: Continuous 6.0 Self-Test
1989
EEC-IV - Quick Test - All Engines 14-19
QUICK TEST: Continuous 6.0 Self-Test
Quick Test:Diagnostic By Symptom - 7.0
1989
14-20 EEC-IV - Quick Test - All Engines
QUICK TEST: Diagnostic By Symptom 7.0
A DIAGNOSTIC BY SYMPTOM
SPECIAL NOTES:
^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous
Self-Tests before continuing with this test.
^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By
Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3583
Pinpoint Test - DN - EGR - EVP & EVR
1989
EEC-IV - Pinpoint Tests-All Vehicles 17-133
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3584
1989
17-134 EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3585
1989
EEC-IV-Pinpoint Tests - All Vehicles 17-134A
Pinpoint Test DN EGR Valve Position Sensor (EVP)
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3586
1989 17-135
EEC-IV - Pinpoint Tests - All Vehicles
EGR Valve Position Sensor (EVP)
Pinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3587
1989
EEC-IV - Pinpoint Tests - All Vehicles 17-136A
EGR Valve Position Sensor (EVP)
04GPinpoint Test DN
EGR Vacuum Regulator Solenoid (EVR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 3588
EGR Valve Position Sensor: Locations
At Center Rear Of Carburetor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Thermostatic Air Cleaner > Thermostatic
Air Cleaner Vacuum Switch > Component Information > Description and Operation
Thermostatic Air Cleaner Vacuum Switch: Description and Operation
Fig. 1 Bi-metal switch
AIR TEMPERATURE CONTROL SENSOR
A vacuum operated duct valve with a thermostatic bi-metal switch, Fig. 1, is used. The valve in the
duct assembly is in an open position when the engine is not operating. When the engine is
operating at below 75° F, manifold vacuum is routed through the bi-metal switch to the vacuum
motor to close the duct valve allowing only heated air to enter the air cleaner. When the engine
reaches normal operating temperature, the bi-metal switch opens an air bleed which eliminates the
vacuum and the duct valve opens, allowing only cold air to enter the air cleaner. During periods of
acceleration the duct valve will open regardless of temperature due to the loss of manifold vacuum.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Thermostatic Air Cleaner > Thermostatic
Air Cleaner Vacuum Switch > Component Information > Description and Operation > Page 3593
Fig. 2 Cold weather modulator
COLD WEATHER MODULATOR
This modulator, Fig. 2, is used on some models to prevent the air cleaner door from opening when
outside air is below a predetermined temperature. At higher ambient temperatures, the modulator
is inoperative. During acceleration, with outside air below the preset temperature, the modulator will
close off vacuum to the motor and hold the duct open. The modulator is located in-line between the
air temperature control sensor and the vacuum duct motor.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Thermostatic Air Cleaner > Thermostatic
Air Cleaner Vacuum Switch > Component Information > Description and Operation > Page 3594
Thermostatic Air Cleaner Vacuum Switch: Testing and Inspection
AIR CLEANER TEMPERATURE SENSOR
1. With ambient temperature less than 75° F and engine cold, remove components necessary to
observe position of duct door.
2. Start engine and ensure that duct door is in full heat position.
3. Allow engine to warm up, ensuring that door begins to open for fresh air at specified temperature
for particular sensor. Brown sensor should begin to bleed off vacuum at approximately 75° F, black,
clear or pink sensor at approximately 90° F, and blue, green, or yellow sensor at approximately
105° F.
4. Install components removed in step 1.
Fig. 3 Cold weather modulator operating chart
COLD WEATHER MODULATOR
1. Apply 16 inches Hg vacuum to motor side of modulator.
2. Ensure that vacuum holds or leaks according to ambient temperature and temperature sensor
color, Fig. 3.
VACUUM MOTOR
Apply vacuum to vacuum motor and ensure that door stem pulls up and stays up until vacuum
source is eliminated.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Vacuum Restrictor > Component
Information > Description and Operation
Vacuum Restrictor: Description and Operation
Fig. 38 Vacuum restrictor
The orifice type flow restrictor, Fig. 38, is used on some systems to control the flow rate and or
timing characteristics to the following systems.
a. EGR valve timing (opening and closing). b. Part throttle spark advance. c. Purge system. d.
Thermactor system.
The flow rate through the restrictor is the same in both directions. If blocked, it should be replaced.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Technical Service Bulletins > By Symptom
Fuel Pressure: By Symptom
Technical Service Bulletin # 911211 Date: 910612
Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Technical Service Bulletins > By Symptom > Page 3603
temperatures. Refer to the following procedure for service details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Technical Service Bulletins > By Symptom > Page 3604
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Technical Service Bulletin # 911211 Date: 910612
Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Technical Service Bulletins > By Symptom > Page 3605
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Technical Service Bulletins > By Symptom > Page 3606
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of
Power/No Start Diagnosis
Fuel Pressure: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of
Power/No Start Diagnosis > Page 3612
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 > Engine - Lack of
Power/No Start Diagnosis > Page 3613
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Technical Service Bulletins > Page 3614
Fuel Pressure: Specifications
Fuel Pressure 5-7 psi
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information
> Technical Service Bulletins > Page 3615
Fuel Pressure: Testing and Inspection
1. Connect a suitable pressure gauge (0-15 psi) to the carburetor end of the fuel line (no "T" is
required). 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the
carburetor bowl) and read the pressure after 10 seconds. The fuel
pump pressure should read 6-8 psi at normal curb idle speed, with the transmission in NEUTRAL,
the engine at normal operating temperatures, and the fuel return line closed (if present). If pump
pressure is too low or too high install a new fuel pump.
3. Reconnect fuel line at filter and install air cleaner.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3624
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
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Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
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^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3626
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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Starts/Hesitation/Stalls On Start-Up > Page 3627
Figure 3
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3628
Figure 4
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3629
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3630
Figure 6
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3631
Figure 7
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3632
Figure 8
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3633
Figure 9
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3634
Figure 10
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3635
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
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For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3639
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3640
Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3646
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3647
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3648
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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Starts/Hesitation/Stalls On Start-Up > Page 3649
Figure 3
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3650
Figure 4
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3651
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3652
Figure 6
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3653
Figure 7
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold
Starts/Hesitation/Stalls On Start-Up > Page 3654
Figure 8
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Figure 9
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Figure 10
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Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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Idle Speed: By Symptom
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
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Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
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^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3666
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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Figure 3
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3668
Figure 4
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3669
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3670
Figure 6
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3671
Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3672
Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3673
Figure 9
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3674
Figure 10
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3675
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3678
For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3679
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3680
Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3681
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3682
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3683
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3684
Figure 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3685
Figure 4
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3686
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3687
Figure 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3688
Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3689
Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3690
Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3691
Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3692
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3693
serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3694
17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3695
For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3696
Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3697
Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Specifications > With Automatic Transmission
Idle Speed: Specifications With Automatic Transmission
Curb Idle Speed ...................................................................................................................................
................................................ 650 rpm (in DRIVE)
Fast Idle Speed ...................................................................................................................................
........................................... 1600 rpm (in PARK) [1]
[1] On kickdown step of fast idle cam.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Specifications > With Automatic Transmission > Page 3700
Idle Speed: Specifications With Manual Transmission
Curb Idle Speed ...................................................................................................................................
................................................................. 800 rpm
Fast Idle Speed ...................................................................................................................................
........................................................... 2200 rpm [1]
[1] On kickdown step of fast idle cam.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Adjustments > Calibration 4-98S-R11
Idle Speed: Adjustments Calibration 4-98S-R11
1. Stabilize engine temperature.
2. Place truck in Park or Neutral, turn the A/C off, and set the parking brake.
3. Remove the air cleaner.
4. Disconnect and plug the decel throttle control kicker diaphragm vacuum hose. a.
Connect a slave vacuum hose from an engine manifold vacuum source to the decel throttle control
kicker.
b. Run engine at approximately 2500 rpm for 15 seconds, then return to idle.
c. If decel throttle control rpm is not within ±50 rpm of specification, adjust the kicker.
d. Disconnect the slave vacuum hose and allow engine to return to curb idle.
5. Adjust curb idle, if necessary, using the curb idle adjusting screw with transmission in Neutral
(M/T) or Drive (A/T).
6. Goose the throttle, then recheck curb idle speed and adjust as needed.
7. Reconnect the decel throttle control vacuum hose to the diaphragm.
8. Install the air cleaner.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Adjustments > Calibration 4-98S-R11 > Page 3703
Idle Speed: Adjustments Calibrations 6-97J-R12, 6-97J-R18
1. Stabilize engine temperature.
2. Place truck in Park or Neutral, turn the A/C off, and set the parking brake.
3. Remove the air cleaner.
4. Adjust curb idle, if necessary, using the curb idle adjusting screw with transmission in Neutral
(M/T) or Drive (A/T).
5. Goose the throttle, then recheck curb idle speed and adjust as needed.
6. Check/adjust dashpot clearance by totally compressing the dashpot and adjusting for .100 inch
clearance between collapsed dashpot and throttle lever at the closed throttle position.
7. Install the air cleaner.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision
Technical Service Bulletin # 8912A26 Date: 890627
Idle Fuel Mixture - Manual Revision
ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1986-SECTION 4-IDLE FUEL
MIXTURE-PROPANE ENRICHMENT METHOD
ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1987-SECTION 4-IDLE FUEL
MIXTURE-PROPANE ENRICHMENT METHOD
Article No. 89-12A-26
FORD: 1986 ESCORT, LTD, MUSTANG 1986-87 TEMPO 1986 THUNDERBIRD
LINCOLN-MERCURY: 1986 CAPRI, COUGAR, MARQUIS 1986-87 TOPAZ
LIGHT TRUCK: 1986 AEROSTAR 1986-87 BRONCO, ECONOLINE, F-150, F-250, F-350,
RANGER
ISSUE: The tachometer reference "or equivalent" as shown in procedure I.-B in both 1986 and
1987 Engine Emissions Diagnosis Manuals is incorrect. This also applies to procedure I.-H in the
1986 Engine Emissions Diagnosis Manual.
ACTION: Refer to the pages following this TSB article for the revised Volume H pages which show
the correct tachometer designation as: "Connect an analog tachometer, Rotunda 059-000010 or an
equivalent analog tachometer." This information should be inserted in your 1986 Engine Emissions
Diagnosis Manual, pages 4-83, 4-87, 4-90, 4-93 and the 1987 Manual, pages 4-66 and 4-69.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
INFORMATION ONLY
OASIS CODES: 680000
Pages 4-83, 4-84
1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-83
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
Passenger Car. 1.9L w/740-2V, 2.3L OHC w/YFA-IV FB, 2.3L HSC w/1949-IV, 3.8L w/2150-A-2V
and 5.0L w/4180C-4V.
Truck, Under 8500 GVW: 5.8L w/4180C-4V.
NOTE: This procedure is applicable to the above engines only. If CO and HC are not within
specification, perform appropriate electrical diagnostic procedure in Section 15.
I. Vehicle Preparation: All Carburetors as noted above.
A. Apply the parking brake, and block the wheels. Disconnect the automatic brake release, if so
equipped, and plug the vacuum connection.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. If so equipped, insure that the hot idle compensator is in a closed position and remains so
throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to insure
that HIC valve is closed.
D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L
engines) and plug the connection. (Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger Car
engines).
E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple.
(Not applicable to 5.0L and 5.8L Truck and 5.0L Passenger car engines).
F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
G. For vehicles equipped with thermactor systems, revise the dump valve vacuum hoses as
follows: (Not applicable to 1.9L engines).
1. For dump valves with two vacuum fittings, disconnect and plug the hose(s).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3708
2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at
the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake
manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB).
3. For 2.3L OHC engines:
a. Equipped with a dump valve with two vacuum fittings: Disconnect and plug the hoses.
b. Equipped with a combination dump valve and air diverter valve: Disconnect and plug the hoses
(2-port) from the dump valve portion.
c. Equipped with feedback carburetor: Disconnect electric lead wire from electric PVS.
4. On 3.8L engine Canadian 2150A-2V applications, do not make any thermactor system
modifications.
5. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve.
1986 4-84
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
H. For 1.9L ATX/MTX vehicles equipped with (Mechanical Vacuum) Idle Speed Control (ISC):
1. With engine off:
a. Disconnect and plug the vacuum hose at the MVISC.
b. Connect an alternate vacuum source (hand vacuum pump) capable of maintaining 22 inches Hg.
to the ISC diaphragm on carburetor, and apply vacuum (retracting ISC plunger clear of throttle
linkage).
2. With engine running and transmission in Drive (ATX) or Neutral (MTX):
^ Idle speed should be equal to the ISC retracted speed specified on the emission decal, if not
readjust throttle stop adjustment screw under choke housing to specification, (fan On, A/C Off).
I. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify that the timing is set to specification; reset if necessary, Section 15.
B. Check engine curb idle rpm or A/C-off rpm, and, if necessary, reset to specification, Section 4.
NOTE: Even If the vehicle has less than 160.9 km (100 miles) of operation, set the speed to the
normal engine specification.
NOTE: Remove PCV valve from grommet, and allow PCV valve to draw underhood air during idle
fuel mixture check. (PCV should remain in vertical position).
NOTE: Escort/Lynx, has an in-line fixed orifice crankcase vent, not a conventional PCV valve. The
fixed orifice is located in the crankcase vent hose located between the vacuum fitting on the intake
manifold and the plastic fitting attached to the air cleaner tray.
Locate the crankcase vent hose and disconnect at the air cleaner end, allowing the hose to vent to
underhood air during idle fuel/air mixture check.
C. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds
before each mixture check.
NOTE: On Escort/Lynx and Tempo/Topaz, run engine until electric fan comes On.
Pages 4-87 Thru 4-90
1986
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3709
Carburetors, Fuel Charging Assemblies and Throttle Bodies 4-87
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
2.0L TRUCK UNDER 8600 GVW w/YFA-IV
NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane
specifications are not listed for these applications. If CO and HC are not within specification,
perform appropriate electrical diagnostic procedure, Section 15.
I. Vehicle Preparation
A. Apply the parking brake and block the wheels.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
D. Disconnect and plug the hose at the air bypass valve.
E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve.
F. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify engine timing is set to specification - reset if necessary, Section 15.
B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect
idle speed control (ISC) motor from wiring harness.
C. Place A/C-heat selector in the Off position and verify that lamps are Off.
NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at
the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle
fuel mixture check).
D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds
before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step.
1986 4-88
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
E. With the engine idling at normal operating temperature gradually open the propane tool valve
and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum
and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical
position).
NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary
repeat Steps D & E with a new propane cartridge gas supply.
F. Compare measured speed gain to specified speed gain.*
1. If the measured speed gain is within specification, proceed to Step H.
NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the
carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the
above feature.
NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture
according to the reset rpm specification.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3710
2. If the measured speed gain is higher than the speed gain specification:*
Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
3. If the measured speed gain is lower than the speed gain specification:*
Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following
speed drop test:
NOTE: Speed drop test information is specified with the artificial enrichment requirements
whenever the minimum speed gain specification is "0" rpm. *
a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop
in engine speed.
b. If the measured speed drop is greater "0" and less than or equal to 30 rpm, proceed to Step G.
c. If the measured speed drop is more than 30 rpm, return the mixture screw to the position before
adjustment. Proceed to Step G.
d. If the measured speed drop is still "0" rpm repeat steps a, b, and c.
G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see
Section III.
*Refer to the Special Specifications Issue TSB Publications.
1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-89
Idle Mixture Setting Procedures
H. Reinstall PCV valve in grommet. Reconnect air bypass valve, purge valve and crankcase
closure hose. Reconnect ISC motor to wiring harness.
I. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten
the air cleaner wing nut(s) to specification.
III. Removal and Installation for Tamper-Resistant Fuel Air Adjustment Feature:
A. See appropriate carburetor disassembly instructions in Shop Manual, Group 24.
1986 4-90
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
2.8L AEROSTAR w/2150A FB
NOTE: This procedure is for the 2.8L engine only. It is not for trucks over 8500 GVW.
I. Vehicle Preparation
A. Apply the parking brake and block the wheels.
B. Verify that timing is set to specification.
C. Remove the air cleaner assembly.
D. Disconnect wiring harness from carburetor feedback solenoid, located in the rear of carburetor.
E. Remove the PCV valve from the rocker cover grommet and move away from the crankcase
vapors.
F. Disconnect the fuel evaporating purge line (from the intake manifold spacer at the purge
solenoid).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3711
G. Install purge line tester (Tool T84T-9600-A) into the end of purge line that is still connected to
the intake manifold spacer.
H. Disconnect ISC motor from wiring harness as follows: Simultaneously: 1.
Connect tachometer, Rotunda Model 059-00001, 099-00001 or equivalent.
2. Start engine.
3. Manually hold throttle above 1000 rpm.
4. Push ISC plunger until it retracts fully.
5. After plunger retracts, release throttle and quickly unplug the connection.
NOTE: Before proceeding, verify that the throttle lever is resting on the speed screw and that the
engine idles at specification for anti-dieseling rpm (750 rpm in neutral).
I. Install air cleaner assembly, but do not connect the flexible fresh air tube to the air cleaner duct
and valve assembly. Using a propane enrichment Tool T75L-9600-A or equivalent, insert the tool
hose approximately 3/4 of the way into the duct and valve assembly. If necessary, secure the hose
with tape.
J. When the above Steps have been completed, proceed to Section II.
Pages 4-93 & 4-94
1986 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-93
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
4.9L TRUCK UNDER 8500 GVW w/YFA-IV FB
NOTE: This procedure is for the 4.9L engine only. It is not for trucks over 8600 GVW. Propane
specifications are not listed for these applications. If CO and HC are not within specification,
perform appropriate electrical diagnostic procedure, Section 15.
I. Vehicle Preparation
A. Apply the parking brake and block the wheels. Disconnect the automatic brake release (if so
equipped), and plug the vacuum connection.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. Disconnect the flexible fresh air tube from the air cleaner duct or adapter. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
D. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify engine timing is set to specification-reset if necessary, Section 15.
B. Place A/C-heat selector in the Off position and verify that all accessories (lamps, defrost, etc.)
are Off.
1986 4-94
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3712
Figure 1 - In-Line Base Timing Connector
NOTE: Remove PCV valve from grommet locate the crankcase closure hose and disconnect at the
air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle fuel
mixture check).
C. Verify that the idle speed control motor and the single wire connector near the distributor
(sometimes called the In-Line Base timing connector, Figure 1) are connected electrically. With the
transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds before each
mixture check. If check is not completed within 60 seconds, repeat this cleanout Step.
D. Return engine to idle and disconnect idle speed control motor from wiring harness. Disconnect
single wire connector near the distributor (Fig. 1). With the engine idling at normal operating
temperature, place the transmission selector in the position specified for the idle fuel mixture check.
Gradually open the propane tool valve and watch for engine speed gain, on the tachometer. When
the engine speed reaches a maximum and then begins to drop off, note the amount of speed gain.
(Propane cartridge must be in vertical position).
NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary
repeat Steps C and D with a new propane cartridge gas supply.
E. Compare measured speed gain to specified speed gain.*
1. If the measured speed gain is within specification, proceed to Step G.
NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the
carburetor must be removed from the vehicle. Refer to Group 24, Powertrain Shop manual for
removal of the above feature.
NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture
according to the reset rpm specification.
2. If the measured speed gain is higher than the speed gain specification:*
Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps C and D until the
measured speed rise meets the reset rpm specification,* After final adjustment, proceed to Step F.
3. If the measured speed gain is lower than the speed gain specification:*
Turn the mixture screw clockwise (lean) and simultaneously repeat Steps C and D until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step F.
F. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled. Refer to
appropriate carburetor assembly instructions in Shop Manual, Group 24.
G. Reinstall PCV valve in grommet. Reconnect idle speed control motor and crankcase closure
system, and the single wire connector near the distributor.
H. Remove all test equipment. Reconnect all system components, reinstall air cleaner, and tighten
the air cleaner wing nut(s) to specification, *Specified speed gain is 10 to 70 rpm, specified reset is
30 rpm.
Pages 4-65 & 4-66
1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-65
Idle Mixture Setting Procedures
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3713
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
Propane Enrichment Procedures Are Not Applicable For The Following:
^ CFI Applications.
^ EFI Applications.
^ Truck Over 8500 GVW Applications.
^ 5.8L MCU Police and Trailer Tow Vehicles w/7200 Carburetors.
1987 4-66
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
Passenger Car. 2.3L HSC w/1949-IV
Truck, Under 8500 GVW: 5.8L w/418OC-4V. NOTE:
This procedure is applicable to the above engines only. If CO and HC are not within specificatlon,
perform appropriate electrical diagnostic procedure in Section 15.
I. Vehicle Preparation: All Carburetors as noted above.
A. Apply the parking brake, and block the wheels, Disconnect the automatic brake release, If so
equipped, and plug the vacuum connection.
B. Connect an analog tachometer, Rotunda 059-000010 or equivalent analog tachometer.
C. If so equipped, ensure that the hot idle compensator is in a closed position and remains so
throughout the test. Idle vehicle on kickdown step of fast idle cam for three to five minutes to
ensure that HIC valve is closed.
D. If so equipped, disconnect the fuel evaporative purge hose at the engine or the carburetor, (1.9L
engines) and plug the connection. (Not applicable to 5.8L Truck engines).
E. If so equipped, disconnect the fuel evaporative purge hose at the air cleaner and plug the nipple.
(Not applicable 5.8L Truck engines.)
F. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
G. For vehicles equipped with Thermactor systems, revise the dump valve vacuum hoses as
follows:
1. For dump valves with two vacuum fittings, disconnect and plug the hose(s).
2. For dump valves with one fitting or combination air bypass/air control valve, remove the hose at
the dump valve and plug it. Connect a slave hose from the dump valve vacuum fitting to an intake
manifold vacuum fitting. (Not applicable to 5.0L and 5.8L Truck engines with 2150A-2VFB).
3. For 5.8L 4180C-4V Truck Disconnect and Plug Vacuum Hose to Dump Valve.
H. When the above Steps have been completed, proceed to Section II.
Pages 4-69 & 4-70
1987 Carburetors, Fuel Charging Assemblies and Throttle Bodies
4-69
Idle Mixture Setting Procedures
IDLE FUEL MIXTURE-PROPANE ENRICHMENT METHOD
2.0L TRUCK UNDER 8500 GVW w/Aisan Carburetor
NOTE: This procedure is for 2.0L Truck engines only, it is not for trucks over 8500 GVW. Propane
specifications are not listed for these applications. If CO and HC are not within specification,
perform appropriate electrical diagnostic procedure, Section 15.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3714
I. Vehicle Preparation
A. Apply the parking brake and block the wheels.
B. Connect an analog tachometer, Rotunda 059-000010 or an equivalent analog tachometer.
C. Disconnect the flexible fresh air tube from the air cleaner duct or adaptor. Using propane
enrichment Tool T75L-9600-A or equivalent, insert the tool hose approximately 3/4 of the way into
the duct or fresh air tube. If necessary, secure the hose with tape.
D. Disconnect and plug the hose at the air bypass valve.
E. Disconnect and plug the hose between the purge valve and the spacer at the purge valve.
F. When the above Steps have been completed, proceed to Section II.
II. Propane Enrichment Method (Except as Noted)
NOTE: Leave all vacuum signal hoses attached to the air cleaner assembly when relocating the
assembly to perform carburetor adjustments. The air cleaner assembly must be in place, however,
when measuring engine speeds.
CAUTION: Prolonged engine idling can result in catalyst overheating and excessive underbody
temperatures.
A. Verify engine timing is set to specification-reset if necessary, Section 15.
B. Verify that the curb idle speed is being controlled to specification. Then, electrically disconnect
idle speed control (ISC) motor from wiring harness.
C. Place A/C-heat selector in the Off position and verify that lamps are Off.
NOTE: Remove PCV valve from grommet, locate the crankcase closure hose and disconnect at
the air cleaner end (allowing the PCV valve and closure hose to vent to underhood air during idle
fuel mixture check).
D. With the transmission in Neutral, run the engine at approximately 2500 rpm for 15 seconds
before each mixture check. If check is not completed within 60 seconds, repeat this cleanout Step.
1987 4-70
Carburetors, Fuel Charging Assemblies and Throttle Bodies
Idle Mixture Setting Procedures
E. With the engine idling at normal operating temperature gradually open the propane tool valve
and watch for engine speed gain, on the tachometer. When the engine speed reaches a maximum
and then begins to drop off, note the amount of speed gain. (Propane cartridge must be in vertical
position).
NOTE: If the engine speed will not drop off check the propane cartridge gas supply. If necessary
repeat Steps D & E with a new propane cartridge gas supply.
F. Compare measured speed gain to specified speed gain.*
1. If the measured speed gain is within specification, proceed to Step H.
NOTE: The carburetor assembly is equipped with a tamper-resistant idle adjustment feature, the
carburetor must be removed from the vehicle. Refer to Shop Manual, Group 24 for removal of the
above feature.
NOTE: If it is determined that idle fuel mixture adjustment will be necessary, adjust the mixture
according to the reset rpm specification.
2. If the measured speed gain is higher than the speed gain specification:*
Turn the mixture screw counterclockwise (rich) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
3. If the measured speed gain is lower than the speed gain specification:*
Turn the mixture screw clockwise (lean) and simultaneously repeat Steps D and E until the
measured speed rise meets the reset rpm specification.* After final adjustment, proceed to Step G.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Information > Technical Service Bulletins > Idle Fuel Mixture - Manual Revision > Page 3715
4. If there is no rpm rise and the minimum speed gain specification is "0" rpm, perform the following
speed drop test:
NOTE: Speed drop test information is specified with the artificial enrichment requirements
whenever the minimum speed gain specification is "0" rpm.*
a. While watching the tachometer, adjust the mixture screw 1/4 turn clockwise (lean). Note the drop
in engine speed.
b. If the measured speed drop is greater than "0" and less than or equal to 40 rpm, proceed to Step
G.
c. If the measured speed drop is more than 40 rpm, return the mixture screw to the position before
adjustment. Proceed to Step G.
d. If the measured speed drop is still "0" rpm repeat steps a, b, and c.
G. The carburetor fuel air adjustment must have the tamper-resistant feature reinstalled, see
Section III.
*Refer to the Special Specifications Issue TSB Publications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Air Filter Element: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 3721
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 3722
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor >
Component Information > Description and Operation
Air Flow Meter/Sensor: Description and Operation
The vane air flow meter measures air flowing into the engine and is mounted between the air
cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a
potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and
potentiometer. The potentiometer relays vane position information to the EEC-IV module. The
EEC-IV module, then translates vane position information into the amount of air flowing into the
engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor
constantly monitors air temperature entering the engine and also transmits the information to the
EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature
information and adjusts the fuel flow to obtain the optimum air/fuel mixture required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition
Auxiliary Air Valve (Idle Speed): Customer Interest Engine - Lack of Power and/or No Start
Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 3734
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 3735
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 3736
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 3737
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 3738
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 3739
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 3740
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition
Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Lack of Power and/or No
Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 3746
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 3747
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 3748
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 3749
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 3750
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 3751
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95711 > Apr > 95 > Engine - Lack
of Power and/or No Start Condition > Page 3752
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): >
921514 > Jul > 92 > Engine - Cooling Concerns and/or Vibration
Fan Blade: All Technical Service Bulletins Engine - Cooling Concerns and/or Vibration
Article No. 92-15-14
09/15/92
^ COOLING SYSTEM - OVERHEATING - ENGINE FAN CLUTCH NOT FUNCTIONING
PROPERLY
^ ENGINE COOLING FAN CLUTCH - DIAGNOSTIC PROCEDURE
^ VIBRATION - ENGINE FAN CLUTCH NOT FUNCTIONING PROPERLY
LIGHT TRUCK: 1987-92 BRONCO, ECONOLINE, F-150-350 SERIES 1988-92 F SUPER DUTY
ISSUE: A comprehensive diagnostic procedure has been developed for determining if the engine
cooling fan clutch is functioning properly. A fan clutch that is not functioning properly may cause
engine cooling concerns and/or vibration.
ACTION: Use the following diagnostic procedure to determine if the fan clutch is functioning
properly. A fan clutch that is not functioning properly should be replaced.
CAUTION: DO NOT ATTEMPT TO MODIFY THE BI-METALLIC COIL ON THE FACE OF THE
FAN CLUTCH.
DIAGNOSTIC PROCEDURE
NOTE: PROCEED ONLY AFTER COMPLETING THE ENGINE COOLING DIAGNOSIS
PROCEDURE IN SECTION 03-03 AND THE ACCESSORY DRIVE BELT TENSION
PROCEDURE IN SECTION 03-05 OF THE APPROPRIATE SERVICE MANUAL.
1. Turn off the air conditioner, heater-A/C fan and radio.
2. Check for viscous drag...
a. Before starting the engine, rotate the fan and clutch assembly by hand. It should have some
viscous drag, but it should turn smoothly during the full 360~ of rotation.
b. Replace the fan clutch if it does not turn smoothly or does not turn at all. Refer to the Dealer
Master Parts Catalog for correct parts usage. Refer to the appropriate Service Manual, Section
03-05, for service details.
c. Replace the fan if there are any cracks.
d. If this is not the concern, go to Step 3.
3. Check for lack of viscous drag...
a. If the fan clutch spins with no viscous drag when it is cold, and it has not been run for an hour or
more, it should be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage.
Refer to the appropriate Service Manual, Section 03-05, for service details.
b. If this is not the concern, go to Step 4.
4. Check for excessive fan clutch bearing clearance (cold fan clutch)...
a. Hold the tip of the fan blade between the thumb and forefinger.
b. Lightly pull toward the radiator, then push toward the engine.
c. Repeat the motion several times.
^ The total rocking movement at the end of the fan blade should be 2/10" (5.1 mm) or less when no
more than eight (8) ounces of force is applied.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): >
921514 > Jul > 92 > Engine - Cooling Concerns and/or Vibration > Page 3758
^ A force greater than eight (8) ounces may deflect the fan blade with erroneous results.
d. Replace the fan clutch if more than 2/10" (5.1 mm) of movement is observed. Refer to the Dealer
Master Parts Catalog for correct parts usage. Refer to the appropriate Service Manual, Section
03-05, for service details.
e. If this is not the concern, go to Step 5.
5. Install a temporary engine tachometer if the vehicle is not equipped with a tachometer.
NOTE: DURING THE FOLLOWING TESTS, BE SURE TO MONITOR THE ENGINE COOLANT
TEMPERATURE BY THE TEMPERATURE GAUGE IN THE INSTRUMENT CLUSTER. SHUT
OFF THE ENGINE IF THE TEMPERATURE RISES ABOVE THE MAXIMUM RECOMMENDED
LIMIT FOR THE ENGINE OR IF COOLANT IS DISCHARGED OUTSIDE THE SYSTEM. THE
TESTS CAN BE RESUMED USING THE FOLLOWING PROCEDURES AFTER THE COOLANT
TEMPERATURE DROPS TO A NORMAL OPERATING LEVEL.
NOTE: IF THE HOOD IS LEFT OPEN, THE FAN NOISE MAY BE EASIER TO HEAR.
WARNING: DO NOT STAND IN LINE WITH THE FAN.
6. Start the engine.
7. Check for fan disengagement and be aware of the following operational characteristics.
^ The fan clutch may be engaged when the engine is first started. This will be apparent from the
noise level of the fan which has a distinctive roar.
^ The fan clutch engagement is due to the viscous silicone fluid draining back and filling the gap
between input and output components.
^ Running the engine at a constant speed of about 2000 rpm should pump the fluid back to its
reservoir, disengaging the fan clutch after no more than five minutes.
^ As the fan speed declines, the noise will drop off to a level inaudible to most observers.
a. Continuing the test, if the fan clutch does not reengage after five more minutes at 2000 rpm, the
fan clutch should be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage.
Refer to the appropriate Service Manual, Section 03-05, for service details.
b. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
c. If this is not the concern, go to Step 8.
8. Stop the engine.
a. Cut and install a piece of cardboard large enough to cover the front of the radiator with a six inch
diameter hole in line with the fan clutch.
b. If it is not possible to install the cardboard directly against the radiator, attach it to the A/C
condenser.
9. Start the engine.
a. With the gas engine at 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm, the vehicle
temperature gauge will rise steadily as the engine warms and then appear to level off for a short
time when the thermostat opens.
b. Make note of the temperature gauge position when the thermostat opens. The engine coolant
temperature will continue to rise until the fan clutch engages.
10. Check for fan engagement...
a. Continue to observe the coolant temperature gauge. As the fan clutch engages, the fan noise
will continue to increase and then level off at full engagement. The fan clutch may cycle off-and-on
a few times during the initial engagement.
b. If the fan clutch does not engage before the maximum indicated safe operating engine coolant
temperature is reached, it should be replaced. Refer to the Dealer Master Parts Catalog for correct
parts usage. Refer to the appropriate Service Manual, Section 03-05, for service details.
c. Repeat the test procedure after fan clutch replacement to verify the fix and to assure customer
satisfaction. The rate of rise of the coolant
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): >
921514 > Jul > 92 > Engine - Cooling Concerns and/or Vibration > Page 3759
temperature will slow down after clutch engagement, but it will continue to rise as long as the
radiator remains covered.
d. If this is not the concern, go to Step 11.
11. Check for fan disengagement...
a. After completion of the above tests, shut off the engine.
b. Remove the cardboard cover from the front of the radiator.
c. Restart and return the gas engine to 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm,
continuing to watch the coolant temperature which will begin to decrease. The fan rpm will drop to
a reduced noise level where it was before the cycle began which indicates that the fan clutch has
disengaged.
d. If the fan clutch remains engaged and the coolant temperature has dropped below the
thermostat opening temperature (as noted in Step 9) for at least five minutes, the fan clutch should
be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage. Refer to the
appropriate Service Manual, Section 03-05, for service details.
e. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
WARRANTY STATUS AND OPERATION DESCRIPTION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): >
921514 > Jul > 92 > Engine - Cooling Concerns and/or Vibration > Page 3765
^ A force greater than eight (8) ounces may deflect the fan blade with erroneous results.
d. Replace the fan clutch if more than 2/10" (5.1 mm) of movement is observed. Refer to the Dealer
Master Parts Catalog for correct parts usage. Refer to the appropriate Service Manual, Section
03-05, for service details.
e. If this is not the concern, go to Step 5.
5. Install a temporary engine tachometer if the vehicle is not equipped with a tachometer.
NOTE: DURING THE FOLLOWING TESTS, BE SURE TO MONITOR THE ENGINE COOLANT
TEMPERATURE BY THE TEMPERATURE GAUGE IN THE INSTRUMENT CLUSTER. SHUT
OFF THE ENGINE IF THE TEMPERATURE RISES ABOVE THE MAXIMUM RECOMMENDED
LIMIT FOR THE ENGINE OR IF COOLANT IS DISCHARGED OUTSIDE THE SYSTEM. THE
TESTS CAN BE RESUMED USING THE FOLLOWING PROCEDURES AFTER THE COOLANT
TEMPERATURE DROPS TO A NORMAL OPERATING LEVEL.
NOTE: IF THE HOOD IS LEFT OPEN, THE FAN NOISE MAY BE EASIER TO HEAR.
WARNING: DO NOT STAND IN LINE WITH THE FAN.
6. Start the engine.
7. Check for fan disengagement and be aware of the following operational characteristics.
^ The fan clutch may be engaged when the engine is first started. This will be apparent from the
noise level of the fan which has a distinctive roar.
^ The fan clutch engagement is due to the viscous silicone fluid draining back and filling the gap
between input and output components.
^ Running the engine at a constant speed of about 2000 rpm should pump the fluid back to its
reservoir, disengaging the fan clutch after no more than five minutes.
^ As the fan speed declines, the noise will drop off to a level inaudible to most observers.
a. Continuing the test, if the fan clutch does not reengage after five more minutes at 2000 rpm, the
fan clutch should be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage.
Refer to the appropriate Service Manual, Section 03-05, for service details.
b. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
c. If this is not the concern, go to Step 8.
8. Stop the engine.
a. Cut and install a piece of cardboard large enough to cover the front of the radiator with a six inch
diameter hole in line with the fan clutch.
b. If it is not possible to install the cardboard directly against the radiator, attach it to the A/C
condenser.
9. Start the engine.
a. With the gas engine at 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm, the vehicle
temperature gauge will rise steadily as the engine warms and then appear to level off for a short
time when the thermostat opens.
b. Make note of the temperature gauge position when the thermostat opens. The engine coolant
temperature will continue to rise until the fan clutch engages.
10. Check for fan engagement...
a. Continue to observe the coolant temperature gauge. As the fan clutch engages, the fan noise
will continue to increase and then level off at full engagement. The fan clutch may cycle off-and-on
a few times during the initial engagement.
b. If the fan clutch does not engage before the maximum indicated safe operating engine coolant
temperature is reached, it should be replaced. Refer to the Dealer Master Parts Catalog for correct
parts usage. Refer to the appropriate Service Manual, Section 03-05, for service details.
c. Repeat the test procedure after fan clutch replacement to verify the fix and to assure customer
satisfaction. The rate of rise of the coolant
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): >
921514 > Jul > 92 > Engine - Cooling Concerns and/or Vibration > Page 3766
temperature will slow down after clutch engagement, but it will continue to rise as long as the
radiator remains covered.
d. If this is not the concern, go to Step 11.
11. Check for fan disengagement...
a. After completion of the above tests, shut off the engine.
b. Remove the cardboard cover from the front of the radiator.
c. Restart and return the gas engine to 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm,
continuing to watch the coolant temperature which will begin to decrease. The fan rpm will drop to
a reduced noise level where it was before the cycle began which indicates that the fan clutch has
disengaged.
d. If the fan clutch remains engaged and the coolant temperature has dropped below the
thermostat opening temperature (as noted in Step 9) for at least five minutes, the fan clutch should
be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage. Refer to the
appropriate Service Manual, Section 03-05, for service details.
e. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
WARRANTY STATUS AND OPERATION DESCRIPTION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump >
Component Information > Description and Operation
Accelerator Pump: Description and Operation
Fig. 28 Temperature compensated accelerated pump. Motorcraft model 2150A carburetor
The temperature compensated accelerator pump, Fig. 28, is used on vehicles equipped with the
Motorcraft 2150A model carburetor, allows delivery of a large pump capacity to facilitate cold
engine requirements and a smaller pump capacity during warm engine operation. The amount of
fuel delivered during warm engine operation is a function of the rate at which the accelerator pedal
is applied (fast application/low capacity, slow application/high capacity). The design incorporates a
bypass bleed controlled by a vacuum operated valve. Normally, the input signal controlling the
valve position is manifold vacuum switched by a PVS located in the engine coolant system. The
valve is normally closed when no vacuum is applied, allowing full pump capacity during cold
operation. With vacuum applied, the pump functions as a rate sensitive valve controlling the
amount of fuel bypassed back to the carburetor fuel bowl and not delivered to the intake manifold
air stream.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump >
Component Information > Description and Operation > Page 3771
Accelerator Pump: Testing and Inspection
1. Allow engine coolant to stabilize to ambient temperature.
2. Start engine and immediately check for vacuum at the temperature compensated accelerator
pump valve.
3. When the engine is cold, no vacuum should be present.
4. Allow engine temperature to stabilize and check to ensure that a vacuum greater than 10 inches
Hg is present at the temperature compensated accelerator pump valve.
5. If the vacuum signal to the valve is incorrect in either hot or cold mode, check vacuum hoses,
connections and vacuum control valve. After a vacuum is verified, shut-off engine and connect a
six inch section of clear tubing (5/32 inch inside diameter) between the temperature compensated
accelerator pump valve. If no fuel is flowing, remove clear tubing and install vacuum hose to the
temperature compensated accelerator pump valve. Turn ignition switch to off position.
6. With ignition switch in off position, remove carburetor air horn and air horn gasket. If the engine
is warm, relieve pressure on fuel inlet needle by carefully depressing fuel bowl float.
7. Carefully remove float and needle assembly.
8. Remove enough fuel from the float bowl so that the temperature compensated accelerator pump
bleed hole is just at or above bowl level.
9. Remove vacuum hose from valve and actuate accelerator pedal at a moderate or fast rate, and
observe fuel discharge out of the temperature compensated accelerator pump bypass bleed. No
fuel discharge should be observed from the bypass bleed. If fuel does discharge, replace valve.
10. Using a hand operated vacuum pump, apply a vacuum greater than 10 inches Hg to the
temperature compensated accelerator pump valve. Actuate accelerator with a very quick action
from idle to wide open throttle, fuel should discharge from the bypass bleed. If fuel is not
discharged, replace temperature compensated accelerator pump valve. Install float and needle
assembly, air horn and a new air horn gasket. Tighten attaching screws securely.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump >
Component Information > Adjustments > Accelerator Pump Level
Accelerator Pump: Adjustments Accelerator Pump Level
Fig. 6 Checking accelerator pump lever clearance
1. Using a feeler gauge and with throttle plates wide open, there should be the specified clearance
(minimum) between pump operating lever adjustment screw and pump arm when pump arm is
depressed manually, Fig.6.
2. If adjustment is required, loosen lock nut and turn adjusting screw in to increase clearance and
out to decrease clearance. One-half turn of screw is equal to approximately .015 inch.
3. When proper adjustment has been made, hold screw in position with a wrench and tighten lock
nut.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump >
Component Information > Adjustments > Accelerator Pump Level > Page 3774
Accelerator Pump: Adjustments Accelerator Pump Stroke
To satisfy the requirements in various climates, the pump discharge can be adjusted. The bottom
hole (No. 2) in the pump cam and throttle lever provides the maximum pump discharge for extreme
cold weather, and the top hole (No. 1) provides the minimum pump discharge for warm weather
operation. If a change in the adjustment is required, make certain the proper hole in plastic pump
cam, located behind throttle lever, is properly indexed with the numbered hole in the throttle lever
before installing the retaining screw.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid >
Component Information > Locations
Bowl Vent Solenoid: Locations
RH Side 6-300/4.
At RH Front Of Carburetor
Applicable to: 9L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid >
Component Information > Locations > Page 3778
Bowl Vent Solenoid: Description and Operation
Fig. 9 Carburetor fuel bowl solenoid vent valve
This valve, Fig. 9, used on some vehicles, is a normally open valve located in the fuel bowl vent
line to the carbon canister. When the engine is running, the valve closes off the fuel bowl vent line.
When the engine is shut off, the vent line returns to the normally open condition.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid >
Component Information > Locations > Page 3779
Bowl Vent Solenoid: Testing and Inspection
1. Apply 12 volts to valve and ensure valve closes to block air passage.
2. Replace valve if it does not close when energized.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Float >
Component Information > Adjustments > Float Level (Dry)
Carburetor Float: Adjustments Float Level (Dry)
Fig. 4 Float adjustment
The dry float adjustment is a preliminary fuel level adjustment only. The final adjustment must be
performed after the carburetor is installed on the engine. With fuel bowl and float removed, adjust
the float so that it is parallel to the fuel bowl with the top of the fuel bowl inverted, Fig. 4. Adjust
both sides in the same manner.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Float >
Component Information > Adjustments > Float Level (Dry) > Page 3784
Carburetor Float: Adjustments Fuel Level (Wet)
Fig. 5 Fuel level adjustment
1. With vehicle resting on a flat surface, operate engine until normal operating temperature is
reached.
2. Remove air cleaner, then operate engine at approximately 1000 rpm for 30 seconds to stabilize
fuel level.
3. Stop engine, then remove sight plug from side of primary carburetor bowl.
4. Fuel level should be at bottom of sight plug hole. If fuel level is below sight plug hole, raise fuel
level. If fuel overflows when plug is removed, lower fuel level. Never loosen lock screw or nut or
attempt to adjust fuel level with sight plug removed or engine running, as this will create a potential
fire hazard.
5. Adjust fuel level as necessary by loosening lock screw, then turning adjusting nut clockwise to
lower fuel level or counterclockwise to raise fuel level, Fig. 5. Tighten lock screw and install sight
plug, using old gasket, then run engine at 1000 RPM for approximately 30 seconds to stabilize fuel
level. Each 1/8 turn of the adjusting nut will change fuel level approximately 1/32 inch.
6. Stop engine, remove sight plug and recheck fuel level. Repeat step 5 until fuel level is at bottom
of sight plug hole, then reinstall sight plug using a new gasket.
7. Perform steps 3 through 6 for secondary fuel bowl. To stabilize fuel level in the secondary fuel
bowl, the secondary throttle must be used.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Intake
Manifold Spacer > Component Information > Technical Service Bulletins > Customer Interest for Carburetor Intake Manifold
Spacer: > 882020 > Sep > 88 > Engine - Poor Performance/Spark Knock/Exhaust Backfire
Carburetor Intake Manifold Spacer: Customer Interest Engine - Poor Performance/Spark
Knock/Exhaust Backfire
Article No. 88-20-20
09/23/88
^ PERFORMANCE POOR - 6.1L, 7.0L AND 7.5L 4V ENGINES
^ SPARK KNOCK - 6.1L, 7.0L AND 7.5L 4V ENGINES
^ BACKFIRE - 6.1L, 7.0L AND 7.5L 4V ENGINES
LIGHT TRUCK: 1979-87 E AND F-SERIES
ISSUE: Poor performance, spark knock and exhaust backfire may be caused by a burned out or
blown out EGR spacer-to-intake manifold gasket. The damaged gasket causes exhaust gas and
intake manifold vacuum leaks which results in one or all of the above driveability conditions.
ACTION: Install a new EGR spacer-to-intake manifold gasket that has long life durability under high
heat conditions. Refer to the following procedure for service details.
1. Remove the air cleaner.
2. Remove the throttle rod from the throttle lever on 6.1L and 7.0L engines or the throttle cable on
7.5L engines.
3. Disconnect the choke control cable on 6.1L and 7.0L engines only.
4. Disconnect the hand ihrottle control cable on 6.1L and 7.0L engines only.
5. Disconnect and label the vacuum hoses for the distributor and EGR valve. Also disconnect the
vacuum hose at the governor on 6.1L and 7.0L engines only.
6. Disconnect the PCV hose.
7. Disconnect the carburetor fuel line.
8. Disconnect the governor electrical connector on 6.1L and 7.0L engines only.
9. Remove the carburetor retaining nuts and lock washers.
10. Remove the carburetor and EGR spacer from the intake manifold.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Intake
Manifold Spacer > Component Information > Technical Service Bulletins > Customer Interest for Carburetor Intake Manifold
Spacer: > 882020 > Sep > 88 > Engine - Poor Performance/Spark Knock/Exhaust Backfire > Page 3793
11. Remove the EGR spacer-to-intake manifold gasket and the carburetor-to-EGR spacer gasket
and throw them away, Figure 14.
12. Thoroughly clean gasket mating surfaces and install a new service EGR spacer-to-intake
manifold gasket, (E8TZ-9447-A) and carburetor-to-EGR spacer gasket, (E5HZ-9C477-B).
13. Reverse Steps 1 through 11 for assembly.
14. Adjust the engine idle speed.
15. Adjust the primary and secondary fuel levels and idle fuel mixture.
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible Under Emissions Warranty Coverage
OPERATION: 882020A
TIME: 1.1 Hrs. DLR. CODING: Basic Part No. 9447 Condition Code: 74
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Intake
Manifold Spacer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carburetor
Intake Manifold Spacer: > 882020 > Sep > 88 > Engine - Poor Performance/Spark Knock/Exhaust Backfire
Carburetor Intake Manifold Spacer: All Technical Service Bulletins Engine - Poor
Performance/Spark Knock/Exhaust Backfire
Article No. 88-20-20
09/23/88
^ PERFORMANCE POOR - 6.1L, 7.0L AND 7.5L 4V ENGINES
^ SPARK KNOCK - 6.1L, 7.0L AND 7.5L 4V ENGINES
^ BACKFIRE - 6.1L, 7.0L AND 7.5L 4V ENGINES
LIGHT TRUCK: 1979-87 E AND F-SERIES
ISSUE: Poor performance, spark knock and exhaust backfire may be caused by a burned out or
blown out EGR spacer-to-intake manifold gasket. The damaged gasket causes exhaust gas and
intake manifold vacuum leaks which results in one or all of the above driveability conditions.
ACTION: Install a new EGR spacer-to-intake manifold gasket that has long life durability under high
heat conditions. Refer to the following procedure for service details.
1. Remove the air cleaner.
2. Remove the throttle rod from the throttle lever on 6.1L and 7.0L engines or the throttle cable on
7.5L engines.
3. Disconnect the choke control cable on 6.1L and 7.0L engines only.
4. Disconnect the hand ihrottle control cable on 6.1L and 7.0L engines only.
5. Disconnect and label the vacuum hoses for the distributor and EGR valve. Also disconnect the
vacuum hose at the governor on 6.1L and 7.0L engines only.
6. Disconnect the PCV hose.
7. Disconnect the carburetor fuel line.
8. Disconnect the governor electrical connector on 6.1L and 7.0L engines only.
9. Remove the carburetor retaining nuts and lock washers.
10. Remove the carburetor and EGR spacer from the intake manifold.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Intake
Manifold Spacer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carburetor
Intake Manifold Spacer: > 882020 > Sep > 88 > Engine - Poor Performance/Spark Knock/Exhaust Backfire > Page 3799
11. Remove the EGR spacer-to-intake manifold gasket and the carburetor-to-EGR spacer gasket
and throw them away, Figure 14.
12. Thoroughly clean gasket mating surfaces and install a new service EGR spacer-to-intake
manifold gasket, (E8TZ-9447-A) and carburetor-to-EGR spacer gasket, (E5HZ-9C477-B).
13. Reverse Steps 1 through 11 for assembly.
14. Adjust the engine idle speed.
15. Adjust the primary and secondary fuel levels and idle fuel mixture.
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible Under Emissions Warranty Coverage
OPERATION: 882020A
TIME: 1.1 Hrs. DLR. CODING: Basic Part No. 9447 Condition Code: 74
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Pull-off >
Component Information > Adjustments
Choke Pull-off: Adjustments
Fig. 9 Choke plate pulldown vacuum passage. 1987 - 88 models w/electric choke
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Pull-off >
Component Information > Adjustments > Page 3803
Fig. 10 Removing choke pulldown diaphragm adjusting screw cover. 1987 - 88 models w/ electric
choke
1987 - 88 MODELS W/ELECTRIC CHOKE
1. Remove carburetor from vehicle and cover intake manifold.
2. Place carburetor on work stand suitable to allow access to pulldown diaphragm vacuum passage
on underside of throttle body, Fig. 9.
3. Scribe alignment marks on choke cap and choke housing, then remove choke cap, gasket and
retainer.
4. Temporarily install choke cap with standard choke cap gasket and align scribe marks, then
rotate cap 90° counterclockwise and secure with one screw.
5. Ensuring that choke plate is in fully closed position, actuate choke pulldown motor using an
outside vacuum source of at least 17 inches Hg.
6. Using drill gauge of specified size, check clearance between upper edge of choke plate and air
horn wall. Gauge should fit in such a manner that it contacts air horn and choke plate but does not
move plate.
7. If adjustment is necessary, carefully remove diaphragm adjustment screw cap using suitable
tool, Fig. 10.
8. Using 5/64 inch Allen wrench, turn adjustment screw clockwise to decrease setting or
counterclockwise to increase setting. Maintain a minimum of 17 inches Hg. to pulldown diaphragm
during adjustment. Cycle vacuum from 0 to 17 inches Hg. to verify setting.
9. Apply suitable sealant to adjustment screw cavity and check fast idle cam adjustment.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Relay >
Component Information > Locations
Choke Relay: Locations
LH Fender Apron Near Dash
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke
Thermostat/Heater > Component Information > Diagrams > Diagram Information and Instructions
Choke Thermostat/Heater: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke
Thermostat/Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 3811
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke
Thermostat/Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 3812
Choke Thermostat/Heater: Electrical Diagrams
Part 2 of 3 (With Integral Alternator Regulator)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke
Thermostat/Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 3813
Less Ammeter Part 1 of 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke
Thermostat/Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 3814
With Integral Alternator Regulator Part 1 of 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke
Thermostat/Heater > Component Information > Diagrams > Diagram Information and Instructions > Page 3815
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke
Thermostat/Heater > Component Information > Diagrams > Page 3816
Choke Thermostat/Heater: Description and Operation
Fig. 45 Typical electric assist choke installation
Most carbureted engine models are equipped with an electric assist choke. This device aids in
reducing emissions of hydrocarbons (HC) and carbon monoxide (CO) during starting and warm-up
(choke on) period. The electric assist choke is designed to give a more rapid choke opening at
temperatures of about 54° to 74° F, or higher. It also provides a slower choke opening at
temperatures below this point. The electric assist choke system does not change any carburetor
service procedures and cannot be adjusted. If system is found out of calibration the heater control
switch and/or choke unit must be replaced. The electric choke system, Fig. 45 consists of a choke
cap, thermostatic spring, a bimetal temperature sensing disc (switch), and a ceramic positive
temperature coefficient (PTC) heater. The choke is powered from terminal or tap of the alternator.
Current is constantly supplied to the ambient temperature switch. The system is grounded through
a ground strap connected to the carburetor body. At temperatures below approximately 60° F, the
switch opens and no current is supplied to the ceramic heater located within the thermostatic
spring. Normal thermostatic spring choking action then occurs. At temperatures above
approximately 54°---74° F the temperature sensing switch closes and current is supplied to the
ceramic heater. As the heater warms, it causes the thermostatic spring to pull the choke plates
open within 1 - 1.25 minutes.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke
Thermostat/Heater > Component Information > Diagrams > Page 3817
Choke Thermostat/Heater: Testing and Inspection
1. Disconnect stator lead at connector leading from choke cap and connect a test light in series
with stator lead and ground.
2. With engine running, test light should glow.
3. If light does not glow, repair or replace either the alternator or choke wire.
4. With engine running at normal operating temperature, place test light in series with choke
terminal and alternator lead. If light does not glow, replace choke cap assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke
Thermostat/Heater > Component Information > Diagrams > Page 3818
Choke Thermostat/Heater: Adjustments
1. Loosen thermostatic spring housing clamp retaining screws.
2. Rotate spring housing to align index mark on spring housing with center index mark on choke
housing.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Throttle Plate - Carb. >
Component Information > Adjustments
Throttle Plate - Carb.: Adjustments
Fig. 7 Secondary throttle plate adjustment
With secondary throttle plates closed, rotate secondary throttle shaft lever stop screw
counter-clockwise until the secondary throttle plates seat in the bores. Rotate adjusting screw
clockwise until it contacts the secondary lever, Fig. 7. Turn stop screw an additional 3/8 turn.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Dashpot > Component Information
> Locations
Dashpot: Locations
Attached To Bracket On LH Valve Cover
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Dashpot > Component Information
> Locations > Page 3825
Dashpot: Adjustments
1. With engine at normal operating temperature, apply 19 inches Hg vacuum to decel throttle
modulator.
2. Loosen decel throttle modulator lock nut and rotate modulator to achieve 1800 RPM.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Customer Interest: > 91813 > Apr > 91 > Engine - Rough Idle/Hesitation/Backfire/Stalling
Fuel: Customer Interest Engine - Rough Idle/Hesitation/Backfire/Stalling
Article No. 91-8-13
04/17/91
FUEL - USE OF UNLEADED GASOLINES - TIPS TO AVOID LEAN AIR - FUEL CONDITIONS
FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO,
THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE
LINCOLN-MERCURY: 1985-87 LYNX
1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR
1986-91 SABLE 1987-91 TRACER
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350
SERIES, RANGER 1989-91 F SUPER DUTY, F47, F53 1991 EXPLORER
ISSUE: Rough idle, hesitation, poor throttle response, induction backfire and stalls during cold
start/warm up may be caused by the poor volatility of some high octane premium grade unleaded
fuels (91 octane or higher (R+M)/2). When compared to regular grade unleaded fuel (87 octane
(R+M)/2), high octane premium grade unleaded fuel may cause long crank time.
ACTION: Use a regular grade unleaded fuel in all vehicles, except where a premium unleaded fuel
is recommended in the Owner Guide. If lean air-fuel type symptoms are experienced, determine
the grade and brand of fuel used and offer the following service tips.
^ Advise those using a higher octane grade fuel to switch to a regular grade unleaded fuel. For
those using a regular grade fuel, advise them to try another brand.
^ Do not advise using a higher octane unleaded fuel than is recommended for that specific engine.
Ford engines are designed to perform best using a high quality regular grade unleaded fuel.
^ Only advise using a higher octane unleaded fuel to avoid potentially damaging spark knock or
ping, but do so only after mechanical fixes are ineffective.
NOTE: ALL UNLEADED GASOLINES USED SHOULD CONTAIN DETERGENT ADDITIVES
THAT ARE ADVERTISED AS HAVING "KEEP CLEAN" OR "CLEAN UP" PERFORMANCE FOR
BOTH INTAKE VALVES AND FUEL INJECTORS.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
404000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 96107 > May > 96 > Fuel - California Reformulated Gasoline
Fuel: All Technical Service Bulletins Fuel - California Reformulated Gasoline
Article No. 96-10-7
05/06/96
FUEL - CALIFORNIA REFORMULATED GASOLINE (CARFG) - SERVICE TIP
FORD: 1983-86 LTD 1983-88 EXP 1983-96 CROWN VICTORIA, ESCORT, MUSTANG,
THUNDERBIRD 1985-94 TEMPO 1986-96 TAURUS 1989-96 PROBE 1995-96 CONTOUR
LINCOLN-MERCURY: 1980-83 MARK VI 1983-88 LN7 1983-96 COUGAR, GRAND MARQUIS,
TOWN CAR 1984-92 MARK VII 1985-94 TOPAZ 1986-96 SABLE 1991-96 TRACER 1993-96
CONTINENTAL, MARK VIII 1995-96 MYSTIQUE
LIGHT TRUCK: 1983-96 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1984-90
BRONCO II 1986-96 AEROSTAR 1987-96 F SUPER DUTY 1991-96 EXPLORER 1993-96
VILLAGER 1995-96 WINDSTAR
ISSUE: California introduced CaRFG around March 1, 1996 and statewide it must be available at
all service stations by June 1, 1996 to help reduce emissions and improve gasoline quality. It will
replace the traditional gasoline sold in Northern California and improve the reformulated gasoline
that has been sold in Southern California since January 1995. California Air Resources Board
(CARB) projects smog forming emissions from motor vehicles to be reduced by about 15 percent.
ACTION: The following text is provided to give some answers to some commonly asked questions
by our customers.
POSITION
Ford Motor Company recommends the use of CaRFG as a cost effective means of reducing
emissions to provide cleaner air. We have participated in vehicle and laboratory testing of CaRFG
to make sure it is acceptable for our customers' use. There are no unusual vehicle performance
concerns expected based upon these studies. The use of CaRFG will not affect Ford's new vehicle
and/or emissions warranty.
WHAT DOES CaRFG CONSIST OF?
CaRFG consists of the same basic components as other gasolines, but it reduces pollution
because of its cleaner burning components. Features are:
^ reduced aromatic hydrocarbons to form less smog emissions
^ added oxygenates to reduce emissions
^ decreases the amount of fuel evaporating from the vehicle
^ lowered sulfur content to provide more efficient operation of the vehicle's catalytic converter
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 96107 > May > 96 > Fuel - California Reformulated Gasoline
> Page 3839
^ reduced benzene by about one-half
IS CaRFG MORE HAZARDOUS THAN CONVENTIONAL GASOLINES?
CaRFG is a hazardous substance like conventional gasoline. Precautions should continue to be
taken to avoid exposure to vapors or liquid when it is pumped or handled. It should never be
siphoned or swallowed.
HOW WILL CaRFG AFFECT VEHICLE PERFORMANCE?
Properly blended CaRFG should have no adverse effect on vehicle performance or the durability of
engine and fuel system components. Its basic properties are not significantly different than other
cleaner burning gasolines that have been used in the U.S. for several years.
If the vehicle is a certified California calibration 1996 or later model year, it was designed to operate
on CaRFG gasoline. The vehicle will operate satisfactorily on gasolines in the other 49 states, but
emission control system performance may be affected. Using gasolines other than CaRFG have
substantially increased emissions from motor vehicles.
WILL THE USE OF CaRFG AFFECT CALIFORNIA VEHICLE WARRANTY?
No. The coverage of Ford's new vehicle warranty is not affected. In fact, Ford Owner Guides have
consistently approved the use of properly blended reformulated gasolines containing oxygenates.
Further information about properly fueling your vehicle is included in the Owner Guide.
WILL FUEL ECONOMY BE AFFECTED?
A very small reduction in fuel economy of less than one-half mile per gallon is possible if the
customer was using gasoline without oxygenates. This is attributed to the lower energy content of
oxygenates which have been in all Southern California gasolines since January of 1995 and in
some gasolines since the 1970's.
Many factors affect fuel economy like driving habits, vehicle maintenance, weather conditions, etc.
Fuel economy can vary by more than a mile per gallon from one fill-up to the next with the same
gasolines.
For further details see TSB Article 95-12-2 for customer expectations regarding fuel economy.
ARE SPECIAL ADDITIVES NECESSARY FOR CaRFG?
No. It is not necessary to add anything to the vehicle fuel tank after the gasoline is purchased from
the service station. California regulations require deposit control additives in CaRFG to minimize
port fuel injector and intake valve deposits.
WILL OLDER VEHICLES OPERATE SATISFACTORILY WITH THE NEW CaRFG?
Older vehicles are expected to operate satisfactorily on CaRFG because vehicles have been
operating on gasolines similar to CaRFG for a number of years. However, considerable testing
indicates that older, high mileage vehicles are more susceptible to fuel system problems due to age
and normal wear and tear regardless of whether they are operated on conventional or CaRFG
gasolines. Owners of these older vehicles are encouraged to follow their vehicle manufacturer's
recommendations regarding vehicle maintenance.
WILL THE SMELL BE DIFFERENT THAN CONVENTIONAL GASOLINE?
CaRFG is not expected to smell different than the gasoline most vehicles are currently using. If an
unusual odor is noticed, it would probably be from oxygenates. Most service stations use vapor
recovery systems to minimize the release of gasoline vapors while refueling.
The use of CaRFG should result in little or no "rotten egg" smell from the exhaust because CaRFG
has much lower sulfur than conventional gasoline.
WAS CaRFG TESTED BEFORE INTRODUCTION?
It was tested for over five million miles in more than 800 vehicles under the guidance of CARB
including experts representing automobile manufacturers, gasoline suppliers, fleet operations and
government. There was no increase in problems identified with the use of CaRFG.
DOES CaRFG COST MORE?
The price at the pump cannot be accurately predicted, although a modest increase is likely. The
price of CaRFG is subject to the competitive forces in the marketplace. Many factors including
production costs, supply and demand, weather, crude oil prices, and taxes affect gasoline prices.
WHERE CAN I GET MORE INFORMATION ON CaRFG?
Additional information within the state of California on CaRFG is available from the California Air
Resources Board toll-free at 1-800-922-7349 (within California only).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 96107 > May > 96 > Fuel - California Reformulated Gasoline
> Page 3840
OTHER APPLICABLE ARTICLES: 95-12-2
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 404000, 623000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 91813 > Apr > 91 > Engine - Rough
Idle/Hesitation/Backfire/Stalling
Fuel: All Technical Service Bulletins Engine - Rough Idle/Hesitation/Backfire/Stalling
Article No. 91-8-13
04/17/91
FUEL - USE OF UNLEADED GASOLINES - TIPS TO AVOID LEAN AIR - FUEL CONDITIONS
FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO,
THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE
LINCOLN-MERCURY: 1985-87 LYNX
1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR
1986-91 SABLE 1987-91 TRACER
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350
SERIES, RANGER 1989-91 F SUPER DUTY, F47, F53 1991 EXPLORER
ISSUE: Rough idle, hesitation, poor throttle response, induction backfire and stalls during cold
start/warm up may be caused by the poor volatility of some high octane premium grade unleaded
fuels (91 octane or higher (R+M)/2). When compared to regular grade unleaded fuel (87 octane
(R+M)/2), high octane premium grade unleaded fuel may cause long crank time.
ACTION: Use a regular grade unleaded fuel in all vehicles, except where a premium unleaded fuel
is recommended in the Owner Guide. If lean air-fuel type symptoms are experienced, determine
the grade and brand of fuel used and offer the following service tips.
^ Advise those using a higher octane grade fuel to switch to a regular grade unleaded fuel. For
those using a regular grade fuel, advise them to try another brand.
^ Do not advise using a higher octane unleaded fuel than is recommended for that specific engine.
Ford engines are designed to perform best using a high quality regular grade unleaded fuel.
^ Only advise using a higher octane unleaded fuel to avoid potentially damaging spark knock or
ping, but do so only after mechanical fixes are ineffective.
NOTE: ALL UNLEADED GASOLINES USED SHOULD CONTAIN DETERGENT ADDITIVES
THAT ARE ADVERTISED AS HAVING "KEEP CLEAN" OR "CLEAN UP" PERFORMANCE FOR
BOTH INTAKE VALVES AND FUEL INJECTORS.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
404000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 87239 > Nov > 87 > Rotunda Gas Chek Kit - Requires
Modification
Fuel: All Technical Service Bulletins Rotunda Gas Chek Kit - Requires Modification
Article No. FUEL SYSTEM - ROTUNDA "GAS-CHEK" KIT 87-23-9 TOOL MODIFICATION
FORD: 1988 And Prior ALL CAR LINES
LINCOLN-MERCURY: 1988 And Prior ALL CAR LINES
LIGHT TRUCK: 1988 And Prior ALL LIGHT TRUCK LINES
ISSUE: The Rotunda "Gas-Chek Kit" (Tool Number 113-00002) that you may have purchased prior
to October, 1987 requires modification. The necessary components and new operating instructions
will be shipped to you at no charge. This tool modification will provide greater accuracy when
performing high fuel vapor pressure testing of gasoline.
ACTION: To modify the Rotunda "Gas-Chek Kit", use the following service instructions.
NOTE: This modification MUST be done because it will seriously affect the volatility tests.
Figure 11
1. Remove adapter fitting attached to the 0-30 PSI gauge. CARE SHOULD BE TAKEN TO
PREVENT DAMAGE TO GAUGE ASSEMBLY WHEN REMOVING FITTING. Throw away the
adapter fitting, Figure 11.
2. Remove and throw away the aluminum vial, Figure 11.
3. Remove plastic thermos cup cap and throw away, Figure 11.
4. Remove the set of instructions from the lid of the Gas-Chek plastic storage box and throw them
away.
NOTE: USE ONLY THE NEW instruction booklet that is furnished in the modification kit.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Technical Service Bulletins: > 87239 > Nov > 87 > Rotunda Gas Chek Kit - Requires
Modification > Page 3849
Figure 12
5. Using thread sealer or teflon tape on the threads of the PSI gauge, install gauge and tighten into
new cover and air chamber, Figure
12. After installation is made, this assembly should not be disassembled.
6. Position small, plastic gasoline sample container and gas cup holder into gauge and vial cavity
of die-cut, foam material for storage, Figure 12.
7. Care should be taken when storing unit to prevent damage which could then cause bad readings
when checking gasoline vapor pressure.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuel: > 932514 > Dec > 93 > Full Float Rear Hub/Shaft Lubricant Leaks
Wheel Hub: All Technical Service Bulletins Full Float Rear Hub/Shaft - Lubricant Leaks
Article No. 93-25-14
12/08/93
^ AXLE - "DANA" FULL FLOAT REAR - NEW HUB/SHAFT BOLTS AND REVISED TORQUE
SPECIFICATIONS
^ AXLE - "DANA" FULL FLOAT REAR - SHAFT/HUB BOLTS LOOSEN AND LEAK AXLE LUBE SERVICE TIPS
^ LEAKS - AXLE LUBE - REAR AXLE SHAFT/HUB BOLTS LOOSEN - SERVICE TIPS
LIGHT TRUCK: 1980-94 E-350 1988-94 F SUPER DUTY
ISSUE: The rear axle shaft/hub bolts may loosen and leak axle lube. This loosening can occur due
to increased torques at the rear wheels.
ACTION: Install new higher strength flange head bolts and improved cellulose gaskets, which
clamp the joint together tighter. Refer to the following service tips and revised torque specifications.
^ Do not use higher torques specified for these bolts on previously specified hex head bolts.
^ Always replace the bolts and gaskets together rather than reusing them when servicing the wheel
end.
^ The new cellulose gaskets and new flanged head bolts are designed to be used together;
therefore, neither part should be used with older stock parts.
NOTE: WHEN REMOVING THE BOLTS, LOOSEN THEM BY HAND BEFORE USING AN
IMPACT WRENCH. THE SHOCK LOAD APPLIED BY A POWER TOOL MAY CAUSE THE BOLT
TO SNAP BEFORE IT RELEASES.
NOTE:
WHEN SERVICING THE REAR AXLE HUB OR SHAFT, REPLACE THE BOLTS AND GASKET
WITH THE NEW PARTS. USE THE NEW TORQUE SPECIFICATIONS.
NOTE: SPECIAL LUBRICANTS ARE REQUIRED FOR DANA FULL FLOAT REAR AXLES. USE
FORD HYPOID GEAR LUBE (C6AZ-19580-E OR EQUIVALENT), OR FOR EXTREME SERVICE
APPLICATIONS, USE FORD HIGH PERFORMANCE REAR AXLE LUBE (F1TZ-19580-B OR
EQUIVALENT). REFER TO TSB 92-3-11 FOR ADDITIONAL LUBRICANT INFORMATION.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuel: > 932514 > Dec > 93 > Full Float Rear Hub/Shaft Lubricant Leaks > Page 3855
OTHER APPLICABLE ARTICLES: 92-3-11 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage For 1992/94 Models, Basic Warranty Coverage For All
Other Models
OPERATION DESCRIPTION TIME
932514A Replace Axle Shaft/Hub 0.4 Hr.
Gaskets And Bolts (One Side)
932514B Replace Axle Shaft/Hub 0.6 Hr.
Gaskets And Bolts (Both Sides)
DEALER CODING
BASIC PART NO. CONDITION CODE
4A140 33
OASIS CODES: 509000, 590000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuel: > 932514 > Dec > 93 > Full Float Rear Hub/Shaft Lubricant Leaks > Page 3861
OTHER APPLICABLE ARTICLES: 92-3-11 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage For 1992/94 Models, Basic Warranty Coverage For All
Other Models
OPERATION DESCRIPTION TIME
932514A Replace Axle Shaft/Hub 0.4 Hr.
Gaskets And Bolts (One Side)
932514B Replace Axle Shaft/Hub 0.6 Hr.
Gaskets And Bolts (Both Sides)
DEALER CODING
BASIC PART NO. CONDITION CODE
4A140 33
OASIS CODES: 509000, 590000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Page 3862
Fuel: Testing and Inspection
A fuel sample should be drawn from the bottom of the fuel tank so that any water present in the
tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or
contaminated with water (as indicated by a layer at the bottom of the sample), this procedure
should not be used, and the fuel system should be cleaned.
1. Using a 100 ml cylinder with 1 ml graduation marks, fill to the 90 ml mark.
2. Add 10 ml of water to bring the total fluid volume to 100 ml and install a stopper.
3. Shake vigorously for 10 to 15 seconds.
4. Carefully loosen the stopper to release pressure.
5. Close the stopper and shake vigorously again for 10 to 15 seconds.
6. Put the graduated cylinder on a level surface for approximately 5 minutes to allow adequate
liquid separation.
If alcohol is present in the fuel, the volume of the lower layer (which would now contain both alcohol
and water) will be greater than 10 ml. For example, if the volume of the lower layer is increased to
15 ml, it will indicate at least 5 percent alcohol in the fuel. The actual amount of alcohol may be
somewhat greater because this procedure does not extract all of the alcohol from the fuel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Fuel Tank Filler Cap - New Design Available
Fuel Filler Cap: Technical Service Bulletins Fuel Tank Filler Cap - New Design Available
FUEL SYSTEM - HIGH FLOW "PRE-VENT" FULL TANK FILLER CAP Article No. 88-25-13 LIGHT
TRUCK:
1983-88 ECONOLINE 1983-86 F-SERIES
ISSUE: A new cam-lock high flow "Pre-vent" filler cap is available for service. The new filler cap
encourages slower loosening for more gradual venting of fuel tank pressure. The "Pre-vent" filler
cap has a black plastic cover. Trucks with exposed filler caps or trucks with filler caps covered by
fuel filler doors can use the new filler cap.
ACTION: Install a new high flow "Pre-vent" filler cap for service:
^ In areas that sell "winter grade" fuel in hot weather.
^ For owners who frequently overfill fuel tanks.
^ For owners concerned about normal venting of fuel tank pressure.
FIGURE 4
The new filler cap meets or exceeds the performance of all other filler caps released by Ford Motor
Company, Figure 4.
NOTE: USE THE NEW FILLER CAP TO REPLACE FILLER CAPS LISTED IN TSB 87-15-13.
PART NUMBER PART NAME CLASS
E8TZ-9030-C Cap Assembly C
ARTICLE SUPERSEDED: 87-15-13 WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODE: 4500
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information
> Locations
Fuel Filter: Locations
Fuel Filter
The fuel filter is located on the frame rail between the frame mounted high pressure pump and
engine.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information
> Locations > Page 3870
Fuel Filter: Description and Operation
Clean fuel is extremely important in a fuel injection system because of the small orifice in the
injector tip through which fuel must pass. Most injection systems use three forms of filters. The first
is a fuel strainer or filter of woven plastic attached to the fuel pump inlet. This prevents
contamination from entering the fuel line and separates water from the fuel. The filter is
self-cleaning and requires no maintenance. If a fuel restriction occurs at this point, the tank
contains too much sediment or moisture and should be removed and cleaned. Additional filtration is
provided by a high capacity inline filter to remove contamination larger than 20 microns (0.0050
inch). This filter is designed to last the life of the vehicle. The final line of defense against fuel
contamination is in the fuel injector. Each injector contains its own inlet filter screen to prevent
contamination from reaching the tip.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information
> Locations > Page 3871
Fuel Filter: Service and Repair
Fuel Filter
REMOVAL
1. Shut engine off. De-pressurize fuel system. Use caution to prevent combustion from fuel
spillage.
2. Raise vehicle on hoist.
3. Loosen screw clamp so that filter slides rearward easily.
4. Remove push connect fittings at both ends of the filter. Install new retainer clips in each push
connect fitting.
5. Remove fuel filter from metal bracket by rotating the fuel line, being careful not to kink the fuel
line, and sliding the filter rearward.
Fuel Filter
INSTALLATION
1. Place filter into the bracket with flow arrow pointing toward tab of the bracket. Slide filter forward
until it rests against tab of the bracket.
2. Tighten retaining screw of the screw clamp to 1.3-2.1 ft. lb.
3. Install push-connect fittings onto filter ends.
4. Turn ignition switch from RUN/OFF position several times, without starting engine. Check for fuel
leaks.
5. Lower vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Heater > Component
Information > Locations
Fuel Heater: Locations
RH Side Of V8-420/6.
RH Front Of Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Wiring Harness: >
87136 > Jul > 87 > Engine - Rough Idling
Fuel Injector Wiring Harness: Customer Interest Engine - Rough Idling
Article No. ^ WIRING - LOOSE FUEL INJECTOR ELECTRICAL
87-13-6 TERMINALS - VEHICLES EQUIPPED WITH EFI
^ IDLE - ROUGH - LOOSE FUEL INJECTOR ELECTRICAL TERMINALS - VEHICLES EQUIPPED
WITH EFI
FORD: 1987 ESCORT, EXP, MUSTANG, THUNDERBIRD, TAURUS, CROWN VICTORIA
LINCOLN-MERCURY: 1987 LYNX, COUGAR, SABLE, GRAND MARQUIS, MARK VII,
CONTINENTAL, LINCOLN TOWN CAR
LIGHT TRUCK: 1987 RANGER, BRONCO II, F SERIES, BRONCO, ECONOLINE, AEROSTAR
ISSUE: A rough idle on vehicles equipped with Electronic Fuel Injection (EFI) may be caused by
loose electrical terminals in the fuel injector hardshell connectors.
ACTION: To correct this, use the following diagnostic service procedure.
1. Check each connector for loose electrical terminals.
2. If you find that the electrical terminals are loose, remove each connector from the fuel injector
and push the electrical terminals into the hardshell connector until they are fully seated.
3. Reinstall the connector.
4. Pull on the wire with approximately ten (10) lbs. of force. If wire and electrical terminal pull out of
the connector, a new fuel injector wire harness assembly needs to be installed.
Use the appropriate 1987 Car or Light Truck Shop Manual for the fuel injector wire harness service
installation procedure.
NOTE: Refer to the following fuel injector wire harness application chart for the correct part
application.
FUEL INJECTOR WIRE HARNESS APPLICATION CHART
Vehicle Line Engine Part Number
Thunderbird/Cougar 5.0L E6SZ-9D930-A
Thunderbird 2.3L Turbo E7SZ-9D930-A
Crown Victoria/ Grand Marquis
5.0L E7AZ-9D930-A
Lincoln Town Car
Mustang 2.3L E7ZZ-9D930-C
Mustang 5.0L E6SZ-9D930-A
Escort/Lynx 1.9L E7FZ-9D930-B
Taurus/Sable 3.0L E7DZ-9D930-A
Mark VII, Continental 5.0L E6LY-9D930-A
F Series, Bronco 4.9L E7TZ-9D930-B
F Series, Bronco 5.0L E7TZ-9D930-A
F Series 7.5L E7TZ-9D930-C
Ranger, Bronco II 2.3L E5TZ-9D930-B
Ranger, Bronco II 2.9L E6TZ-9A451-A
Econoline 5.0L E7UZ-9D930-A
Econoline 7.5L E7UZ-9D930-B
Aerostar 2.3L E5TZ-9D930-B
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Technical Service Bulletins > Customer Interest for Fuel Injector Wiring Harness: >
87136 > Jul > 87 > Engine - Rough Idling > Page 3884
Aerostar 3.0L E7DZ-9D930-A
PART NUMBER PART NAME CLASS
E6SZ-9D930-A Fuel Injector Wire C
Harness
E7SZ-9D930-A Fuel Injector Wire C
Harness
E7AZ-9D930-A Fuel Injector Wire C
Harness
E7ZZ-9D930-C Fuel Injector Wire C
Harness
E7FZ-9D930-B Fuel Injector Wire C
Harness
E7DZ-9D930-A Fuel Injector Wire C
Harness
E6LY-9D930-A Fuel Injector Wire C
Harness
E7TZ-9D930-A Fuel Injector Wire C
Harness
E7TZ-9D930-B Fuel Injector Wire C
Harness
E7TZ-9D930-C Fuel Injector Wire C
Harness
E5TZ-9D930-B Fuel Injector Wire C
Harness
E6TZ-9A451 -A Fuel Injector Wire C
Harness
E7UZ-9D930-A Fuel Injector Wire C
Harness
E7UZ-9D930-B Fuel Injector Wire C
Harness
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP871306A - Time to check fuel
injector connector terminals for not being fully seated. TIME:
0.3 Hr. - May be used in conjunction with operations listed below.
OPERATION: SP871306B - Time to replace fuel injector wiring harness assembly. TIME: 1.3 Hrs. Mustang, Thunderbird/Cougar, Mark VII, Continental - 5.0L EFI
1.0 Hr. - Taurus/Sable - 3.0L EFI
1.2 Hrs. - Ford/Mercury, Lincoln Town Car, F Series, Bronco, Ranger, Bronco II, Aerostar - 2.9L
EFI, 3.0L EFI and 5.0L EFI
0.3 Hr. - Escort/Lynx, EXP, Mustang, Thunderbird, Aerostar, Ranger - 1.9L EFI, 2.3L EFI and 2.3L
EFI Turbo
1.7 Hrs. - Econoline - 4.9L EFI and 5.0L EFI
1.6 Hrs. - F Series, Bronco - 4.9L EFI
DLR. CODING: Basic Part No. 9D930 - Code: 44
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Wiring
Harness: > 87136 > Jul > 87 > Engine - Rough Idling
Fuel Injector Wiring Harness: All Technical Service Bulletins Engine - Rough Idling
Article No. ^ WIRING - LOOSE FUEL INJECTOR ELECTRICAL
87-13-6 TERMINALS - VEHICLES EQUIPPED WITH EFI
^ IDLE - ROUGH - LOOSE FUEL INJECTOR ELECTRICAL TERMINALS - VEHICLES EQUIPPED
WITH EFI
FORD: 1987 ESCORT, EXP, MUSTANG, THUNDERBIRD, TAURUS, CROWN VICTORIA
LINCOLN-MERCURY: 1987 LYNX, COUGAR, SABLE, GRAND MARQUIS, MARK VII,
CONTINENTAL, LINCOLN TOWN CAR
LIGHT TRUCK: 1987 RANGER, BRONCO II, F SERIES, BRONCO, ECONOLINE, AEROSTAR
ISSUE: A rough idle on vehicles equipped with Electronic Fuel Injection (EFI) may be caused by
loose electrical terminals in the fuel injector hardshell connectors.
ACTION: To correct this, use the following diagnostic service procedure.
1. Check each connector for loose electrical terminals.
2. If you find that the electrical terminals are loose, remove each connector from the fuel injector
and push the electrical terminals into the hardshell connector until they are fully seated.
3. Reinstall the connector.
4. Pull on the wire with approximately ten (10) lbs. of force. If wire and electrical terminal pull out of
the connector, a new fuel injector wire harness assembly needs to be installed.
Use the appropriate 1987 Car or Light Truck Shop Manual for the fuel injector wire harness service
installation procedure.
NOTE: Refer to the following fuel injector wire harness application chart for the correct part
application.
FUEL INJECTOR WIRE HARNESS APPLICATION CHART
Vehicle Line Engine Part Number
Thunderbird/Cougar 5.0L E6SZ-9D930-A
Thunderbird 2.3L Turbo E7SZ-9D930-A
Crown Victoria/ Grand Marquis
5.0L E7AZ-9D930-A
Lincoln Town Car
Mustang 2.3L E7ZZ-9D930-C
Mustang 5.0L E6SZ-9D930-A
Escort/Lynx 1.9L E7FZ-9D930-B
Taurus/Sable 3.0L E7DZ-9D930-A
Mark VII, Continental 5.0L E6LY-9D930-A
F Series, Bronco 4.9L E7TZ-9D930-B
F Series, Bronco 5.0L E7TZ-9D930-A
F Series 7.5L E7TZ-9D930-C
Ranger, Bronco II 2.3L E5TZ-9D930-B
Ranger, Bronco II 2.9L E6TZ-9A451-A
Econoline 5.0L E7UZ-9D930-A
Econoline 7.5L E7UZ-9D930-B
Aerostar 2.3L E5TZ-9D930-B
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Injector Wiring
Harness: > 87136 > Jul > 87 > Engine - Rough Idling > Page 3890
Aerostar 3.0L E7DZ-9D930-A
PART NUMBER PART NAME CLASS
E6SZ-9D930-A Fuel Injector Wire C
Harness
E7SZ-9D930-A Fuel Injector Wire C
Harness
E7AZ-9D930-A Fuel Injector Wire C
Harness
E7ZZ-9D930-C Fuel Injector Wire C
Harness
E7FZ-9D930-B Fuel Injector Wire C
Harness
E7DZ-9D930-A Fuel Injector Wire C
Harness
E6LY-9D930-A Fuel Injector Wire C
Harness
E7TZ-9D930-A Fuel Injector Wire C
Harness
E7TZ-9D930-B Fuel Injector Wire C
Harness
E7TZ-9D930-C Fuel Injector Wire C
Harness
E5TZ-9D930-B Fuel Injector Wire C
Harness
E6TZ-9A451 -A Fuel Injector Wire C
Harness
E7UZ-9D930-A Fuel Injector Wire C
Harness
E7UZ-9D930-B Fuel Injector Wire C
Harness
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP871306A - Time to check fuel
injector connector terminals for not being fully seated. TIME:
0.3 Hr. - May be used in conjunction with operations listed below.
OPERATION: SP871306B - Time to replace fuel injector wiring harness assembly. TIME: 1.3 Hrs. Mustang, Thunderbird/Cougar, Mark VII, Continental - 5.0L EFI
1.0 Hr. - Taurus/Sable - 3.0L EFI
1.2 Hrs. - Ford/Mercury, Lincoln Town Car, F Series, Bronco, Ranger, Bronco II, Aerostar - 2.9L
EFI, 3.0L EFI and 5.0L EFI
0.3 Hr. - Escort/Lynx, EXP, Mustang, Thunderbird, Aerostar, Ranger - 1.9L EFI, 2.3L EFI and 2.3L
EFI Turbo
1.7 Hrs. - Econoline - 4.9L EFI and 5.0L EFI
1.6 Hrs. - F Series, Bronco - 4.9L EFI
DLR. CODING: Basic Part No. 9D930 - Code: 44
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Technical Service Bulletins > Recalls for Fuel Line Coupler: > NHTSA87V139000 > Sep > 87 > Recall
87V139000: Fuel Line Coupling Retainer Clips
Fuel Line Coupler: Recalls Recall 87V139000: Fuel Line Coupling Retainer Clips
SPRING LOCK FUEL LINE COUPLING MAY NOT BE PROPERLY ENGAGED.
COUPLING COULD DISENGAGE DUE TO FUEL PRESSURE, VIBRATION, AND ENGINE
MOVEMENTS; THIS WOULD CAUSE LOSS OF FUEL WHICH, IN PRESENCE OF AN IGNITION
SOURCE, CREATES A FIRE RISK.
INSTALL RETAINER CLIPS OVER THE COUPLINGS TO PREVENT COUPLING SEPARATION
AND FUEL LEAKAGE.
SYSTEM: FUEL LINE COUPLING
VEHICLE DESCRIPTION: PASSENGER CARS AND LIGHT TRUCKS EQUIPPED WITH
FUELINJECTION.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Line Coupler: > NHTSA87V139000 >
Sep > 87 > Recall 87V139000: Fuel Line Coupling Retainer Clips
Fuel Line Coupler: All Technical Service Bulletins Recall 87V139000: Fuel Line Coupling Retainer
Clips
SPRING LOCK FUEL LINE COUPLING MAY NOT BE PROPERLY ENGAGED.
COUPLING COULD DISENGAGE DUE TO FUEL PRESSURE, VIBRATION, AND ENGINE
MOVEMENTS; THIS WOULD CAUSE LOSS OF FUEL WHICH, IN PRESENCE OF AN IGNITION
SOURCE, CREATES A FIRE RISK.
INSTALL RETAINER CLIPS OVER THE COUPLINGS TO PREVENT COUPLING SEPARATION
AND FUEL LEAKAGE.
SYSTEM: FUEL LINE COUPLING
VEHICLE DESCRIPTION: PASSENGER CARS AND LIGHT TRUCKS EQUIPPED WITH
FUELINJECTION.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Technical Service Bulletins > By Symptom
Fuel Pressure: By Symptom
Technical Service Bulletin # 911211 Date: 910612
Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Technical Service Bulletins > By Symptom > Page 3909
temperatures. Refer to the following procedure for service details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Technical Service Bulletins > By Symptom > Page 3910
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Technical Service Bulletin # 911211 Date: 910612
Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Technical Service Bulletins > By Symptom > Page 3911
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Technical Service Bulletins > By Symptom > Page 3912
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 >
Engine - Lack of Power/No Start Diagnosis
Fuel Pressure: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 >
Engine - Lack of Power/No Start Diagnosis > Page 3918
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure: > 911211 > Jun > 91 >
Engine - Lack of Power/No Start Diagnosis > Page 3919
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Technical Service Bulletins > Page 3920
Fuel Pressure: Specifications
Fuel Pressure 5-7 psi
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Technical Service Bulletins > Page 3921
Fuel Pressure: Testing and Inspection
1. Connect a suitable pressure gauge (0-15 psi) to the carburetor end of the fuel line (no "T" is
required). 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the
carburetor bowl) and read the pressure after 10 seconds. The fuel
pump pressure should read 6-8 psi at normal curb idle speed, with the transmission in NEUTRAL,
the engine at normal operating temperatures, and the fuel return line closed (if present). If pump
pressure is too low or too high install a new fuel pump.
3. Reconnect fuel line at filter and install air cleaner.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel
Pump - Buzzing/Humming After Engine Shut Down
Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down
^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY
CHARGE
^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF
Article No. 90-18-3 FORD:
1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD
1986-90 TAURUS
LINCOLN-MERCURY: 1983-87 LYNX
1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86
CAPRI, MARQUIS 1986-90 SABLE
LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1988-90 F SUPER DUTY
ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been
shut off. There may also be a no start condition or a discharged battery. These conditions are
caused by a sticking fuel pump relay.
ACTION: Install a new fuel pump relay. Refer to the following procedure for service details.
1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for
troubleshooting details.
2. Install a new fuel pump relay, if the old one is defective.
3. Check the vehicle for proper operation.
PART NUMBER PART NAME
F19Z-9345-A Fuel Pump Relay Assy.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901803A 1985-86 LTD/Marquis 0.6 Hr.
(includes pinpoint test)
901803A 1990 Town Car (includes 0.4 Hr.
pinpoint test)
901803A All Other Cars (includes 0.5 Hr.
pinpoint test)
901803A All Trucks (includes pinpoint 0.5 Hr.
test)
DEALER CODING
BASIC PART NO. CONDITION CODE
9345 09
OASIS CODES: 404000, 603300, 203000, 203100, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Relay: > 90183 > Aug
> 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down
Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut
Down
^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY
CHARGE
^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF
Article No. 90-18-3 FORD:
1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD
1986-90 TAURUS
LINCOLN-MERCURY: 1983-87 LYNX
1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86
CAPRI, MARQUIS 1986-90 SABLE
LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1988-90 F SUPER DUTY
ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been
shut off. There may also be a no start condition or a discharged battery. These conditions are
caused by a sticking fuel pump relay.
ACTION: Install a new fuel pump relay. Refer to the following procedure for service details.
1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for
troubleshooting details.
2. Install a new fuel pump relay, if the old one is defective.
3. Check the vehicle for proper operation.
PART NUMBER PART NAME
F19Z-9345-A Fuel Pump Relay Assy.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901803A 1985-86 LTD/Marquis 0.6 Hr.
(includes pinpoint test)
901803A 1990 Town Car (includes 0.4 Hr.
pinpoint test)
901803A All Other Cars (includes 0.5 Hr.
pinpoint test)
901803A All Trucks (includes pinpoint 0.5 Hr.
test)
DEALER CODING
BASIC PART NO. CONDITION CODE
9345 09
OASIS CODES: 404000, 603300, 203000, 203100, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures
Fuel Return Line: Technical Service Bulletins Fuel Line Spring Lock Coupling - Service Procedures
FUEL LINE SPRING LOCK COUPLING - SUMMARY Article No.
OF SERVICE PROCEDURES AND REVISED TOOLS 87-3-8
FORD 1986 LTD 1986-87 ESCORT, EXP, MUSTANG, TAURUS, THUNDERBIRD, FORD
LINCOLN-MERCURY 1986 MARQUIS, CAPRI 1986-87 LYNX, SABLE, COUGAR, MERCURY,
MARK VII, CONTINENTAL, LINCOLN TOWN CAR
LIGHT TRUCK 1985-87 RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO
ISSUE: This article summarizes the overall service procedure to be used for disconnecting and
connecting the fuel line spring lock coupling.
In addition, the service tools and service part O-rings have been recently revised. The service tools
(available March, 1987) D87L-9280-A (3/8") and D87L-9280-B (1/2") used to disconnect the spring
lock coupling will now fit around the rubber cover on the fuel line allowing an easier disconnect.
The O-ring part numbers were changed to specify color. The fuel resistant O-rings 390846-S96
(3/8") and 390847-S96 (1/2") will be BROWN in color while the A/C refrigerant Orings will continue
to be BLACK.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3939
Figure 5
ACTION: To properly disconnect and connect the fuel line spring coupling, use the illustrated
service procedure on page 44 of this TSB, Figure 5. This illustration should also be used in place of
the following 1985 through 1987 Car and Light Truck Shop Manual pages:
1985
Light Truck Shop Manual, Volume B, Section 24-05-16 / 24-05-17
1986
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3940
Car Shop Manual, Volume D, Section 24-50-11
Car Shop Manual, Volume E, Section 24-50-14
Taurus/Sable Shop Manual, Section 24-50-11
Ranger/Bronco II Shop Manual, Section 24-03-11
Aerostar Shop Maunal, Section 9-06-15 / 9-06-16
Light Truck Shop Manual, Volume B, Section 24-05-16 / 24-50-35
1987
Car Shop Manual, Volume D, Section 24-50-11
Car Shop Manual, Volume E, Section 24-50-17
Taurus/Sable Shop Manual, Section 24-50-12
Ranger/Bronco II Shop Manual, Section 24-03-10 / 24-05-10
Aerostar Shop Manual, Section 9-02-10 / 9-06-17 / 9-06-18
Light Truck Shop Manual, Volume B, Section 24-05-14 / 24-10-9 / 27-10-20 / 24-50-34
NOTE: The following items should be noted when service is required.
^ Use the specified tool or equivalent.
^ Inspect for missing or damaged O-rings.
^ Use the specified fuel resistant O-rings (BROWN).
^ Lubricate the O-ring with clean engine oil.
^ Check to make sure that the fitting is locked.
PART NUMBER PART NAME CLASS
390846-S96 O-Ring 3/8" (Brown) S
390847-S96 O-Ring 1/2" (Brown) S
OTHER APPLICABLE ARTICLES: Supersedes 86-12-17, 86-12-13 WARRANTY STATUS:
"INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3941
Fuel Return Line: Technical Service Bulletins Nylon Fuel Lines - Servicing Procedure
Article No. 92-12-16
DATE: 06-03-92
FUEL LINES-NYLON-SERVICING PROCEDURE
LIGHT TRUCK: 1985-92 F-150-350 SERIES 1986-90 BRONCO II 1986-92 AEROSTAR,
BRONCO, ECONOLINE, RANGER 1988-92 F SUPER DUTY 1991-92 EXPLORER
ISSUE: Metal fuel lines and connectors have been replaced with nylon lines and connectors on the
subject vehicles. A procedure has been developed for servicing damaged nylon fuel lines.
ACTION: If a nylon fuel line requires service, use the following procedure.
FUEL SYSTEM SERVICE PROCEDURE FOR NYLON FUEL TUBES AND PUSH CONNECT
FITTINGS
FUEL LINES AND HOSES
WARNING: FUEL SUPPLY LINES ON VEHICLES WITH FUEL INJECTED ENGINES WILL
REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUT DOWN WHICH
COULD RESULT IN PERSONAL INJURY. THE PRESSURE MUST BE RELIEVED, AS
OUTLINED PER THE FUEL SYSTEM PRESSURE RELIEF PROCEDURE, BEFORE SERVICING
THE FUEL SYSTEM. READ ALL CAUTIONARY NOTES PRIOR TO RELIEVING THE
PRESSURIZED FUEL SYSTEM.
FUEL TUBES - PLASTIC (NYLON)
CAUTION: FORD APPROVED NYLON FUEL TUBING IS MADE FROM MATERIAL WHICH HAS
BEEN TESTED AND PROVEN TO BE ACCEPTABLE FOR USE WITH COMMERCIALLY
AVAILABLE FUELS. IT IS ALSO RESISTANT TO MOST ENVIRONMENTAL CONDITIONS.
AVOID USING ALTERNATE TUBING MATERIALS. USE OF NON-APPROVED TUBING COULD
POSE A HAZARD IN SERVICE.
CAUTION: PLASTIC FUEL TUBES MUST NOT BE REPAIRED USING HOSE AND HOSE
CLAMPS. PUSH CONNECT FITTINGS CANNOT BE REPAIRED EXCEPT TO REPLACE THE
RETAINING CLIPS. IF THE PLASTIC TUBES OR PUSH CONNECT FITTINGS BECOME
DAMAGED AND LEAK, APPROVED SERVICE PARTS MUST BE USED TO SERVICE THE FUEL
LINES.
MAJOR SERVICE OPERATIONS - FUEL LINES
Vehicles equipped with nylon fuel tubes and push connect fittings have three (3) types of service
that can be performed to the fuel lines...
^ Replacing nylon tubing (splicing nylon to nylon)
^ Replacing push connector fittings
^ Replacing damaged push connect tube ends.
NOTE: FORMED SECTIONS (BENDS) OF NYLON FUEL LINES CANNOT BE REPAIRED USING
STRAIGHT TUBING. STRAIGHT SERVICE TUBING WILL KINK IF BENT. FORMED NYLON
FUEL LINE IS REOUIRED TO REPLACE THE DAMAGED SECTION.
SPLICING NYLON TO NYLON
1. Relieve the fuel system pressure as outlined in the Service Manual. Read the previously cited
Warning prior to relieving the pressurized fuel system.
2. Cut out the damaged section of tubing (straight non-formed sections only) and retain as a guide.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3942
3. Cut a section of nylon service tubing, type 11 or 12, of the same diameter and length as the
damaged section of tubing.
NOTE: TYPE 11 OR 12 NYLON SERVICE TUBING IS AVAILABLE IN 6.3MM (1/4"), 7.9MM
(5/16") AND 9.5MM (3/8") DIAMETER SIZES.
4. Select the proper nylon barbed connector(s) for completing the splice...
^ 7.9mm (5/16") - Part Number (N806120-S)
^ 9.5mm (3/8") - Part Number (N806119-S)
Two (2) in-line connectors are required for each splice.
NOTE: TO MAKE INSERTION OF THE BARB CONNECTORS INTO THE NYLON LINE EASIER,
THE TUBE END MAY BE SOAKED IN A CUP OF BOILING WATER FOR ONE (1) MINUTE
BEFORE PUSHING THE BARB CONNECTOR INTO THE NYLON. USE ROTUNDA TOOL
134-000001 OR EQUIVALENT TO ASSIST IN ASSEMBLY.
5. Set up Rotunda Tool 134-000001 for in-line splice as shown in Figure 1.
a. Select the proper inserts for the fuel line size and install into both sets of upper and lower block
cavities.
b. Connect the block cavity to the ratcheting rod of the Rotunda Tool with the slot in line with the
slot in the ratcheting tool barrel
c. Install both sets of upper and lower block cavities to the threaded rods of the ratcheting tool,
Figure 1.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3943
d. Install one fuel line into the lower block cavity closest to the ratcheting end of the tool so that the
extension of the fuel line is slightly greater than the barb length of the connector, Figure 2.
e. Route the fuel line through the slot in the tool, Figure 2.
f. Close the upper block cavity onto the lower block cavity and tighten the thumb screw securely.
g. Place the replacement tubing in the forward lower block cavity and repeat Steps d and e.
h. Place the barb connector between the ends of the lines to be spliced and ratchet the tool until
the nylon line has covered all three (3) barbs of the connector on both ends.
i. After completing the splice, unscrew the thumb screws and release the lines. Repeat Steps d
through h on the opposite line end to complete the splice.
6. The completed fuel line splice is shown in Figure 3.
7. Install any remaining clips which were removed for this service. Check to be sure the fuel lines
are secure in the original clips.
8. Start the engine and check for leaks.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3944
PART NUMBER PART NAME CLASS
N806119-S Connector - Hose Push CG
Connect (3/8")
N806120-S Connector - Hose Push CG
Connect (5/16")
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
404000, 490000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Shut-off Solenoid > Fuel
Shut-off Solenoid Relay > Component Information > Locations
Fuel Shut-off Solenoid Relay: Locations
LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures
Fuel Supply Line: Technical Service Bulletins Fuel Line Spring Lock Coupling - Service Procedures
FUEL LINE SPRING LOCK COUPLING - SUMMARY Article No.
OF SERVICE PROCEDURES AND REVISED TOOLS 87-3-8
FORD 1986 LTD 1986-87 ESCORT, EXP, MUSTANG, TAURUS, THUNDERBIRD, FORD
LINCOLN-MERCURY 1986 MARQUIS, CAPRI 1986-87 LYNX, SABLE, COUGAR, MERCURY,
MARK VII, CONTINENTAL, LINCOLN TOWN CAR
LIGHT TRUCK 1985-87 RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO
ISSUE: This article summarizes the overall service procedure to be used for disconnecting and
connecting the fuel line spring lock coupling.
In addition, the service tools and service part O-rings have been recently revised. The service tools
(available March, 1987) D87L-9280-A (3/8") and D87L-9280-B (1/2") used to disconnect the spring
lock coupling will now fit around the rubber cover on the fuel line allowing an easier disconnect.
The O-ring part numbers were changed to specify color. The fuel resistant O-rings 390846-S96
(3/8") and 390847-S96 (1/2") will be BROWN in color while the A/C refrigerant Orings will continue
to be BLACK.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3953
Figure 5
ACTION: To properly disconnect and connect the fuel line spring coupling, use the illustrated
service procedure on page 44 of this TSB, Figure 5. This illustration should also be used in place of
the following 1985 through 1987 Car and Light Truck Shop Manual pages:
1985
Light Truck Shop Manual, Volume B, Section 24-05-16 / 24-05-17
1986
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3954
Car Shop Manual, Volume D, Section 24-50-11
Car Shop Manual, Volume E, Section 24-50-14
Taurus/Sable Shop Manual, Section 24-50-11
Ranger/Bronco II Shop Manual, Section 24-03-11
Aerostar Shop Maunal, Section 9-06-15 / 9-06-16
Light Truck Shop Manual, Volume B, Section 24-05-16 / 24-50-35
1987
Car Shop Manual, Volume D, Section 24-50-11
Car Shop Manual, Volume E, Section 24-50-17
Taurus/Sable Shop Manual, Section 24-50-12
Ranger/Bronco II Shop Manual, Section 24-03-10 / 24-05-10
Aerostar Shop Manual, Section 9-02-10 / 9-06-17 / 9-06-18
Light Truck Shop Manual, Volume B, Section 24-05-14 / 24-10-9 / 27-10-20 / 24-50-34
NOTE: The following items should be noted when service is required.
^ Use the specified tool or equivalent.
^ Inspect for missing or damaged O-rings.
^ Use the specified fuel resistant O-rings (BROWN).
^ Lubricate the O-ring with clean engine oil.
^ Check to make sure that the fitting is locked.
PART NUMBER PART NAME CLASS
390846-S96 O-Ring 3/8" (Brown) S
390847-S96 O-Ring 1/2" (Brown) S
OTHER APPLICABLE ARTICLES: Supersedes 86-12-17, 86-12-13 WARRANTY STATUS:
"INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3955
Fuel Supply Line: Technical Service Bulletins Nylon Fuel Lines - Servicing Procedure
Article No. 92-12-16
DATE: 06-03-92
FUEL LINES-NYLON-SERVICING PROCEDURE
LIGHT TRUCK: 1985-92 F-150-350 SERIES 1986-90 BRONCO II 1986-92 AEROSTAR,
BRONCO, ECONOLINE, RANGER 1988-92 F SUPER DUTY 1991-92 EXPLORER
ISSUE: Metal fuel lines and connectors have been replaced with nylon lines and connectors on the
subject vehicles. A procedure has been developed for servicing damaged nylon fuel lines.
ACTION: If a nylon fuel line requires service, use the following procedure.
FUEL SYSTEM SERVICE PROCEDURE FOR NYLON FUEL TUBES AND PUSH CONNECT
FITTINGS
FUEL LINES AND HOSES
WARNING: FUEL SUPPLY LINES ON VEHICLES WITH FUEL INJECTED ENGINES WILL
REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUT DOWN WHICH
COULD RESULT IN PERSONAL INJURY. THE PRESSURE MUST BE RELIEVED, AS
OUTLINED PER THE FUEL SYSTEM PRESSURE RELIEF PROCEDURE, BEFORE SERVICING
THE FUEL SYSTEM. READ ALL CAUTIONARY NOTES PRIOR TO RELIEVING THE
PRESSURIZED FUEL SYSTEM.
FUEL TUBES - PLASTIC (NYLON)
CAUTION: FORD APPROVED NYLON FUEL TUBING IS MADE FROM MATERIAL WHICH HAS
BEEN TESTED AND PROVEN TO BE ACCEPTABLE FOR USE WITH COMMERCIALLY
AVAILABLE FUELS. IT IS ALSO RESISTANT TO MOST ENVIRONMENTAL CONDITIONS.
AVOID USING ALTERNATE TUBING MATERIALS. USE OF NON-APPROVED TUBING COULD
POSE A HAZARD IN SERVICE.
CAUTION: PLASTIC FUEL TUBES MUST NOT BE REPAIRED USING HOSE AND HOSE
CLAMPS. PUSH CONNECT FITTINGS CANNOT BE REPAIRED EXCEPT TO REPLACE THE
RETAINING CLIPS. IF THE PLASTIC TUBES OR PUSH CONNECT FITTINGS BECOME
DAMAGED AND LEAK, APPROVED SERVICE PARTS MUST BE USED TO SERVICE THE FUEL
LINES.
MAJOR SERVICE OPERATIONS - FUEL LINES
Vehicles equipped with nylon fuel tubes and push connect fittings have three (3) types of service
that can be performed to the fuel lines...
^ Replacing nylon tubing (splicing nylon to nylon)
^ Replacing push connector fittings
^ Replacing damaged push connect tube ends.
NOTE: FORMED SECTIONS (BENDS) OF NYLON FUEL LINES CANNOT BE REPAIRED USING
STRAIGHT TUBING. STRAIGHT SERVICE TUBING WILL KINK IF BENT. FORMED NYLON
FUEL LINE IS REOUIRED TO REPLACE THE DAMAGED SECTION.
SPLICING NYLON TO NYLON
1. Relieve the fuel system pressure as outlined in the Service Manual. Read the previously cited
Warning prior to relieving the pressurized fuel system.
2. Cut out the damaged section of tubing (straight non-formed sections only) and retain as a guide.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3956
3. Cut a section of nylon service tubing, type 11 or 12, of the same diameter and length as the
damaged section of tubing.
NOTE: TYPE 11 OR 12 NYLON SERVICE TUBING IS AVAILABLE IN 6.3MM (1/4"), 7.9MM
(5/16") AND 9.5MM (3/8") DIAMETER SIZES.
4. Select the proper nylon barbed connector(s) for completing the splice...
^ 7.9mm (5/16") - Part Number (N806120-S)
^ 9.5mm (3/8") - Part Number (N806119-S)
Two (2) in-line connectors are required for each splice.
NOTE: TO MAKE INSERTION OF THE BARB CONNECTORS INTO THE NYLON LINE EASIER,
THE TUBE END MAY BE SOAKED IN A CUP OF BOILING WATER FOR ONE (1) MINUTE
BEFORE PUSHING THE BARB CONNECTOR INTO THE NYLON. USE ROTUNDA TOOL
134-000001 OR EQUIVALENT TO ASSIST IN ASSEMBLY.
5. Set up Rotunda Tool 134-000001 for in-line splice as shown in Figure 1.
a. Select the proper inserts for the fuel line size and install into both sets of upper and lower block
cavities.
b. Connect the block cavity to the ratcheting rod of the Rotunda Tool with the slot in line with the
slot in the ratcheting tool barrel
c. Install both sets of upper and lower block cavities to the threaded rods of the ratcheting tool,
Figure 1.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3957
d. Install one fuel line into the lower block cavity closest to the ratcheting end of the tool so that the
extension of the fuel line is slightly greater than the barb length of the connector, Figure 2.
e. Route the fuel line through the slot in the tool, Figure 2.
f. Close the upper block cavity onto the lower block cavity and tighten the thumb screw securely.
g. Place the replacement tubing in the forward lower block cavity and repeat Steps d and e.
h. Place the barb connector between the ends of the lines to be spliced and ratchet the tool until
the nylon line has covered all three (3) barbs of the connector on both ends.
i. After completing the splice, unscrew the thumb screws and release the lines. Repeat Steps d
through h on the opposite line end to complete the splice.
6. The completed fuel line splice is shown in Figure 3.
7. Install any remaining clips which were removed for this service. Check to be sure the fuel lines
are secure in the original clips.
8. Start the engine and check for leaks.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Fuel Line Spring Lock Coupling - Service Procedures > Page 3958
PART NUMBER PART NAME CLASS
N806119-S Connector - Hose Push CG
Connect (3/8")
N806120-S Connector - Hose Push CG
Connect (5/16")
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
404000, 490000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Page 3959
Fuel Supply Line: Description and Operation
Hairpin Clip Connector
FUEL LINES AND CONNECTORS Fuel injection systems often use special kinds of fittings to
ensure leakproof connections. Some high-pressure fittings use O-ring seals instead of the
traditional flare connections. The O-rings are made of special materials that can withstand contact
with gasoline and alcohol-blend fuels. Whenever you replace one of these O-rings, you must use a
new part specifically designed for fuel system service. The O-rings used in air conditioning systems
are not satisfactory. Ford uses nylon fuel tubing with several unique push-connect fittings. Special
barbed connectors are required to join sections of nylon tubing together. Connectors that join nylon
to steel tubing also have barbed ends for the nylon lines, but they use O-rings to seal the steel line.
Ford uses two kinds of retainer clips on these connectors. Fittings for 5/16 and 3/8 inch lines have
hairpin clips. Fittings for 1/4 inch lines have duckbill clips.
Fuel Return
FUEL SUPPLY MANIFOLD
High pressure fuel is delivered from the vehicle fuel supply line to the eight fuel injectors by the fuel
supply manifold assembly. The assembly consists of two banks of tubular fuel rails connected by
two permanent crossover connections, a mounting flange to the fuel pressure regulator and
mounting attachments which locate the fuel manifold assembly, eight injector connectors, and
provide fuel injector retention. The fuel inlet and outlet connections have push connect fittings.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Page 3960
Fuel Filler System
FUEL TANK FILLER NECK
To prevent accidental filling with other than unleaded fuel, vehicles that require unleaded fuel have
a special filler tube. This filler tube has a restriction in it so that the only nozzles that can be
inserted are the smaller diameter nozzles of pumps dispensing unleaded fuel.
It is recommended that the amount of fuel put in the tank when filling be limited to the automatic
pump shutoff. Due to the expansion of fuel during temperature increases, or overfilling ("topping
off") can cause fuel overflow at the filler cap when the vehicle is standing or the cap is removed. If
the vehicle has two tanks, use fuel from both tanks after fill-up to reduce fuel levels.
Orifice Rollover Valve
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Page 3961
ORIFICE/ROLLOVER VALVE ASSEMBLY The orifice valve tends to meter the amount of fuel
vapor passing out of the tank. The fuel vapors trapped in the sealed fuel tank are vented through
the orifice fuel tank vapor valve assembly. The vapors then leave the valve assembly through a
single vapor line and continue to the carbon canister in the engine compartment for storage, until
they are purged to the engine.
VAPOR VENT In-tank venting provides a vapor space above the gasoline surface in the fuel tank.
This area is sufficient to permit adequate breathing space for the tank vapor valve assembly under
all static and most dynamic condition.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Page 3962
Fuel Supply Line: Service and Repair
Duckbill Clip Connector
DUCKBILL CLIP CONNECTOR
REMOVAL
To remove duckbill, use special tool shown, or pliers with thin jaws, to release the clip. Pull the
connector apart gently.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Page 3963
Replacement Garter Springs
PUSH CONNECT FITTINGS
REMOVAL
1. Inspect the push connect fittings for accumulation of dirt. If more than a light coating of dust is
present, clean the fitting before disassembly.
2. Some adhesion between the seals in the fitting and the tubing will occur with time. To separate,
twist the fitting on the tube, then push and pull the fitting until it moves freely on the tube.
3. Remove "hairpin" type clip from fitting by: a. Bend the shipping tab downward so that it will clear
the body. b. Spread the two clip legs approximately 3.2 mm (1/8 inch) each to disengage the body
and push the legs into the fitting. c. Lightly pull from the triangular end of the clip and work it clear
of the tube and fitting.
CAUTION: Do not use any tools.
4. Grasp the fitting and hose assembly and pull in an axial direction to remove the fitting from the
steel tube.
5. Once the fitting is removed from the tube end, inspect the fitting and tube for any internal parts
that may have been dislodged from the fitting.
INSTALLATION
1. It is recommended that the original clip not be reused. To install the new clip, insert clip into any
two adjacent openings with the triangular portion pointing away from the fitting opening. Install clip
to fully engage the body (legs of "hairpin" clip locked on outside of body.
2. Before installing fitting on the tube, wipe tube end clean with a cloth. Inspect the fitting to ensure
it is free of dirt and/or obstructions.
3. To install the fitting onto the tube, align the fitting and tube axially and push the fitting onto the
tube end. When the fitting is engaged, a definite click will be heard. Pull on fitting to ensure it is fully
engaged.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Page 3964
Replacing Push Connectors
REPLACING DAMAGED PUSH CONNECTORS
1. Relieve fuel system pressure.
NOTE: Damaged push connectors must be discarded and replaced with new push connectors. If
only the retaining clip is damaged, replace the clip.
2. Disconnect the damaged push connector. Be sure to bend the shipping tab to the side before
removing retaining clip.
3. Select the proper size replacement push connector and nylon tube assembly.
Replacing Push Connectors
4. Cut out a section of the original nylon tube to the same length as the nylon tube attached to the
new push connector.
5. Install proper barbed connector into the replacement nylon assembly.
NOTE: To make hand insertion of the barbed connectors into the nylon easier, the tube end must
be soaked in a cup of boiling water for one minute immediately before pushing the barbs into the
nylon. The 7.938 mm (5/16 inch) barbed connector is used for splicing 9.525 mm (3/8 inch), and
7.938 mm (5/16 inch) EFI tubing.
6. Complete the splice by connecting the barbed connector to the original nylon.
7. Connect the new connector assembly to the steel tube end.
8. Check that the underbody clips are properly securing the fuel tubes.
9. Start engine and check for fuel leaks.
SPLICING NYLON TO NYLON
1. Relieve fuel system pressure.
2. Cut out damaged section of tubing and retain as a guide.
3. Cut a section of service tubing (type 11 or 12 nylon available in 6.35 mm (1/4 inch), 9.525 mm
(3/8 inch) and 7.938 mm (5/16)) to the same length as the damaged section of tubing.
4. Select the proper 6.35 mm (1/4 inch), 9.525 mm (3/8 inch), and 7.938 mm (5/16 inch)) barbed
connectors for completing the splice. Two connectors are required for each splice.
NOTE: To make hard insertion of the barbed connectors into the nylon easier, the tube end must
be soaked in a cup of boiling water for one minute immediately before pushing the barbs into the
nylon. The 9.525 (3/8 inch) and 7.938 mm (5/16 inch) barbed connectors are used for splicing,
9.525 mm (3/8 inch) and 7.938 mm (5/16 inch) EFI tubing.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Technical Service Bulletins > Page 3965
5. Install the barbed connectors into each end of the replacement tubing using boiling water.
6. Install clips onto any tubes which might be difficult to access once the final splices are
completed.
7. Complete the splice of the replacement nylon to the original nylon tubing at both ends. (Use the
boiling water method mentioned to get the required number of barbs engaged.)
8. Install any remaining clips which were removed for this service and check that the tubes are
secure in the original clips.
9. Start engine and check for leaks.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Recalls for Fuel Filler Hose: > 5800 > Sep > 87 > Recall - Fuel Filler
Pipe Replacement
Fuel Filler Hose: Recalls Recall - Fuel Filler Pipe Replacement
TSB # 5800
DATE 09-01-87
KIT X PART NO. E3UZ-9000-E
FUEL FILLER PIPE 1983-1987 ECONOLINE VAN/CLUB WAGON W/5.8L-4V OR 7.5L ENGINE
SPECIAL NOTE:
Installation instructions for the following parts are contained in the master kits requiring them.
PARTS LIST ITEM
DESCRIPTION PART NUMBER QUANTITY
1 Filler Pipe E8UA-9034-BA 2
2 Screw N802826-S55M 6
3 Inspection Sheet 5801 1
4 Instruction Sheet 5800 1
IMPORTANT
TECHNICIAN:
If the new Ford filler pipes and gas caps supplied in this kit will not fit the owner's vehicle even after
use of the procedures provided in the recall program letter, give this sheet and the parts to the
customer and note on the inspection form that the new filler pipes could not be installed due to
final-stage manufacturer modifications.
CUSTOMER:
The dealership was unable to install the new filler pipes and gas caps supplied in the recall
program due to modifications made by the final-stage manufacturer of your vehicle. Please contact
the manufacturer of your vehicle to arrange for installation of filler pipes that will accept the new
screw-on type PREVENT (TM) gas caps supplied by Ford. If your vehicle's manufacturer is unable
to assist you, Ford will have a new PREVENT (TM) type gas cap available in January, 1988 that
will fit the old style FORD cam-lock filler pipes. To obtain these gas caps, fill in the tear-off section
below and mail to the indicated address. The gas caps will be mailed to you at no charge as soon
as they are available.
Refer to "The Importance of Sound Operating Practices" which was enclosed with your vehicle
recall letter for operating practices that will minimize the potential for excessive fuel pressures and
possible fuel expulsion.
PREVENT Trademark of Stant, Inc.
Mail to: PREVENT (TM) Gas Caps My vehicle has: [ ] One gas cap P.O. Box 7049 Lincoln Park, MI
48146
[ ] Two gas caps
Name:
Address:
City/State/Province:
Zip Code/Postal Code:
Vehicle Identification Number (VIN):
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 5800 > Sep >
87 > Recall - Fuel Filler Pipe Replacement
Fuel Filler Hose: All Technical Service Bulletins Recall - Fuel Filler Pipe Replacement
TSB # 5800
DATE 09-01-87
KIT X PART NO. E3UZ-9000-E
FUEL FILLER PIPE 1983-1987 ECONOLINE VAN/CLUB WAGON W/5.8L-4V OR 7.5L ENGINE
SPECIAL NOTE:
Installation instructions for the following parts are contained in the master kits requiring them.
PARTS LIST ITEM
DESCRIPTION PART NUMBER QUANTITY
1 Filler Pipe E8UA-9034-BA 2
2 Screw N802826-S55M 6
3 Inspection Sheet 5801 1
4 Instruction Sheet 5800 1
IMPORTANT
TECHNICIAN:
If the new Ford filler pipes and gas caps supplied in this kit will not fit the owner's vehicle even after
use of the procedures provided in the recall program letter, give this sheet and the parts to the
customer and note on the inspection form that the new filler pipes could not be installed due to
final-stage manufacturer modifications.
CUSTOMER:
The dealership was unable to install the new filler pipes and gas caps supplied in the recall
program due to modifications made by the final-stage manufacturer of your vehicle. Please contact
the manufacturer of your vehicle to arrange for installation of filler pipes that will accept the new
screw-on type PREVENT (TM) gas caps supplied by Ford. If your vehicle's manufacturer is unable
to assist you, Ford will have a new PREVENT (TM) type gas cap available in January, 1988 that
will fit the old style FORD cam-lock filler pipes. To obtain these gas caps, fill in the tear-off section
below and mail to the indicated address. The gas caps will be mailed to you at no charge as soon
as they are available.
Refer to "The Importance of Sound Operating Practices" which was enclosed with your vehicle
recall letter for operating practices that will minimize the potential for excessive fuel pressures and
possible fuel expulsion.
PREVENT Trademark of Stant, Inc.
Mail to: PREVENT (TM) Gas Caps My vehicle has: [ ] One gas cap P.O. Box 7049 Lincoln Park, MI
48146
[ ] Two gas caps
Name:
Address:
City/State/Province:
Zip Code/Postal Code:
Vehicle Identification Number (VIN):
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Fuel Tank Sending Unit - Connector Replacement
Fuel Gauge Sender: Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement
FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT
WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT
Article No. 89-14-6
FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO,
THUNDERBIRD 1986-89 TAURUS
LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX
1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE
LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER
Figure 1
ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire
harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire
harness and cutting off the connector.
ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the
following procedure for service details.
1. Disconnect the battery ground.
2. Cut the connector from the new harness.
3. Leave 6-8 inches of wiring lead on the connector.
4. Remove the old connector from the fuel tank sending unit.
5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector.
6. Match the wire colors.
7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1.
8. Using a heat gun, seal the splice.
CAUTION: DO NOT USE AN OPEN FLAME.
9. Connect the battery ground.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Fuel Tank Sending Unit - Connector Replacement > Page 3984
10. Check the operation of the fuel gauge.
PART NUMBER PART NAME CLASS
E9FZ-9A400-A Wire Harness - Fuel Pump C
OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2300, 2310, 2400, 2770, 4500
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Technical Service Bulletins > Fuel Tank Sending Unit - Connector Replacement > Page 3985
Fuel Gauge Sender: Technical Service Bulletins Fuel Sender - Auxiliary Port Rubber Cap
Replacement
Article No. FUEL SYSTEM - 5.8L/7.5L - FUEL SENDER
87-7-26 AUXILIARY PORT - SERVICE REPLACEMENT RUBBER PORT CAP
LIGHT TRUCK: 1983-87 E-350
ISSUE: Recreational vehicles with cut away chassis are equipped with an auxiliary fuel port on the
fuel gauge sending unit of the aft fuel tank. The port is provided as a fuel source for a generator set
or other gasoline-powered accessories. When the auxiliary port is not used, it is covered with a
rubber port cap and clamped.
ACTION: If the rubber port cap requires replacement, use a new type service part EOPZ-9G270-A
(color coded with red paint). Be sure cap is securely clamped.
PART NUMBER PART NAME CLASS
EOPZ-9G270-A Port Cap C
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Locations > Auxiliary Tank Fuel Gauge Sender
Fuel Gauge Sender: Locations Auxiliary Tank Fuel Gauge Sender
Attached To Rear Fuel Tank
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Locations > Auxiliary Tank Fuel Gauge Sender > Page 3988
Fuel Gauge Sender: Locations Fuel Gauge Sender
Attached To Main Or Front Fuel Tank
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector
Switch > Component Information > Locations
Fuel Tank Selector Switch: Locations
LH Side Of Instrument Panel Near Fuse Block
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector
Switch > Component Information > Diagrams > Diagram Information and Instructions
Fuel Tank Selector Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3994
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3995
Fuel Tank Selector Switch: Electrical Diagrams
Fig. 28 Fuel Tank Selector Wiring Circuit. V8-351/5.8L Fuel Injected & V8-460/7.5L Non Hot Fuel
Handling
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3996
Fig. 26 Fuel Tank Selector Wiring Circuit. V8-302/5.0L & V8-460/7.5L Hot Fuel Handling
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3997
Fig. 29 Fuel Tank Selector Wiring Circuit. V8-460/7.5L Hot Fuel Cutaway
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Locations
Fuel Tank Switching Valve: Locations
On LH Side Of Frame At No. 3 Crossmember
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Diagrams > Diagram Information and Instructions
Fuel Tank Switching Valve: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Diagrams > Diagram Information and Instructions > Page 4003
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Diagrams > Diagram Information and Instructions > Page 4004
Fuel Tank Switching Valve: Electrical Diagrams
Fig. 28 Fuel Tank Selector Wiring Circuit. V8-351/5.8L Fuel Injected & V8-460/7.5L Non Hot Fuel
Handling
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Diagrams > Diagram Information and Instructions > Page 4005
Fig. 26 Fuel Tank Selector Wiring Circuit. V8-302/5.0L & V8-460/7.5L Hot Fuel Handling
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Diagrams > Diagram Information and Instructions > Page 4006
Fig. 29 Fuel Tank Selector Wiring Circuit. V8-460/7.5L Hot Fuel Cutaway
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Diagrams > Page 4007
Fuel Tank Switching Valve: Description and Operation
Dual Function Reservoir
FUEL RESERVOIR An in-line reservoir has been included in the fuel system. Under normal
operating conditions, valving in the in-line reservoir allows the high-pressure pump and engine to
be supplied with fuel directly from the tank while return flow is routed directly back to the tank.
When the pick-up tube is exposed to air, the high pressure pump draws fuel from the reservoir.
When the pick-up is again submerged, normal operation resumes. There are two types of
reservoirs single function and dual function. A single function reservoir is used with single tank
vehicles. The dual function reservoir is used with dual tank vehicles. A dual function reservoir
combines the function of the reservoir with the function of a mechanically actuated selector valve.
FUEL SELECTOR VALVE/DUAL FUNCTION RESERVOIR
Vehicles with dual tanks have three electric fuel pumps. Two low pressure in-tank fuel pumps,
located in both the front and rear tanks, pump fuel into a reservoir. A high pressure in-line fuel
pump then takes the fuel from the reservoir to the fuel injectors. This system can draw fuel from
either the front or rear fuel tank unit. With the ignition switch in START or RUN, current flows
through a fuse link to the fuel pump relay. The dual function reservoir replaces the six port selector
valve on fuel injected dual tank vehicles. The dual function reservoir switches the tank from which
the engine draws fuel mechanically, instead of electrically. The dual function reservoir operates as
follows: Fuel pressure created by the selected in-tank fuel pump exerts force on a 3 inch
fluorosilicon diaphragm which is in turn connected to a T-bar and two shafts. This force moves the
valve shaft, simultaneously opening and closing supply and return ports. When the alternate fuel
tank is selected, pressure is exerted on the opposite side of the diaphragm, moving the valve
shafts to open the alternate fuel tank ports.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Testing and Inspection > Does Not Switch Tanks
Fuel Tank Switching Valve: Testing and Inspection Does Not Switch Tanks
Fuel Valve Does Not Switch Tanks - 3 Port Fuel Selector Valve
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Testing and Inspection > Does Not Switch Tanks > Page 4010
Engine Runs Rough Or Floods Out - One Tank Position Only - 6-Port Fuel Selector Valve With Or
Without Hot Fuel Handling
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Testing and Inspection > Does Not Switch Tanks > Page 4011
Fuel Tank Switching Valve: Testing and Inspection Does Not Operate - 6-Port (Hot Fuel Handling)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching
Valve > Component Information > Testing and Inspection > Does Not Switch Tanks > Page 4012
In Tank Fuel Pump(s) Do Not Operate - 6-Port Fuel Selector Valve With Hot Fuel Handling
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent >
Component Information > Technical Service Bulletins > Recalls for Fuel Tank Vent: > NHTSA87V113000 > Jul > 87 >
Recall 87V113000: EVAP System Modification
Fuel Tank Vent: Recalls Recall 87V113000: EVAP System Modification
EXPULSION OF FUEL DUE TO OVER PRESSURIZATION. FUEL OR FUEL VAPORS IN THE
PRESENCE OF AN IGNITION SOURCE CAN CAUSE A FIRE. MODIFICATION OF THE BASE
FUEL VENTING AND EMISSION CONTROL SYSTEM TO REDUCE OPERATING
TEMPERATURES AND FUEL SYSTEM PRESSURES.
SYSTEM: FUEL.
VEHICLE DESCRIPTION: AMBULANCE, FORD ECONOLINE E350 CUTAWAY CHASSIS AND
VANS,EQUIPPED WITH 7.5 LITER ENGINES.
1983 FORD TRUCK E350 1983 FORD TRUCK ECONOLINE 1984 FORD TRUCK E350 1984
FORD TRUCK ECONOLINE 1985 FORD TRUCK E350 1985 FORD TRUCK ECONOLINE 1986
FORD TRUCK E350 1986 FORD TRUCK ECONOLINE 1987 FORD TRUCK E350 1987 FORD
TRUCK ECONOLINE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent >
Component Information > Technical Service Bulletins > Recalls for Fuel Tank Vent: > NHTSA87V111000 > Jul > 87 >
Recall 87V111000: Vapor Valve Grommet Replacement
Fuel Tank Vent: Recalls Recall 87V111000: Vapor Valve Grommet Replacement
FUEL LEAK AT THE TOP OF THE FRONT FUEL TANK IN THE AREA OF THE VAPOR VALVE
GROMMET. GROMMET MAY SPLIT DUE TO COMPRESSIVE LOAD WHEN INSTALLED IN THE
FUEL TANK. FUEL MAY LEAK FROM VAPOR VALVE AND BECOME THE SOURCE OF FUEL
FOR A FIRE. INSTALLATION OF A NEWLY DESIGNED VAPOR VALVE GROMMET.
SYSTEM: FUEL/TANK VAPOR VALVE.
VEHICLE DESCRIPTION: AMBULANCE, ECONOLINE E350 VANS AND CUTAWAY CHASSIS
WITH 7.5 LITER ENGINES.
1984 FORD TRUCK E350 1984 FORD TRUCK ECONOLINE 1985 FORD TRUCK E350 1985
FORD TRUCK ECONOLINE 1986 FORD TRUCK E350 1986 FORD TRUCK ECONOLINE 1987
FORD TRUCK E350 1987 FORD TRUCK ECONOLINE
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: >
NHTSA87V113000 > Jul > 87 > Recall 87V113000: EVAP System Modification
Fuel Tank Vent: All Technical Service Bulletins Recall 87V113000: EVAP System Modification
EXPULSION OF FUEL DUE TO OVER PRESSURIZATION. FUEL OR FUEL VAPORS IN THE
PRESENCE OF AN IGNITION SOURCE CAN CAUSE A FIRE. MODIFICATION OF THE BASE
FUEL VENTING AND EMISSION CONTROL SYSTEM TO REDUCE OPERATING
TEMPERATURES AND FUEL SYSTEM PRESSURES.
SYSTEM: FUEL.
VEHICLE DESCRIPTION: AMBULANCE, FORD ECONOLINE E350 CUTAWAY CHASSIS AND
VANS,EQUIPPED WITH 7.5 LITER ENGINES.
1983 FORD TRUCK E350 1983 FORD TRUCK ECONOLINE 1984 FORD TRUCK E350 1984
FORD TRUCK ECONOLINE 1985 FORD TRUCK E350 1985 FORD TRUCK ECONOLINE 1986
FORD TRUCK E350 1986 FORD TRUCK ECONOLINE 1987 FORD TRUCK E350 1987 FORD
TRUCK ECONOLINE
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: >
NHTSA87V111000 > Jul > 87 > Recall 87V111000: Vapor Valve Grommet Replacement
Fuel Tank Vent: All Technical Service Bulletins Recall 87V111000: Vapor Valve Grommet
Replacement
FUEL LEAK AT THE TOP OF THE FRONT FUEL TANK IN THE AREA OF THE VAPOR VALVE
GROMMET. GROMMET MAY SPLIT DUE TO COMPRESSIVE LOAD WHEN INSTALLED IN THE
FUEL TANK. FUEL MAY LEAK FROM VAPOR VALVE AND BECOME THE SOURCE OF FUEL
FOR A FIRE. INSTALLATION OF A NEWLY DESIGNED VAPOR VALVE GROMMET.
SYSTEM: FUEL/TANK VAPOR VALVE.
VEHICLE DESCRIPTION: AMBULANCE, ECONOLINE E350 VANS AND CUTAWAY CHASSIS
WITH 7.5 LITER ENGINES.
1984 FORD TRUCK E350 1984 FORD TRUCK ECONOLINE 1985 FORD TRUCK E350 1985
FORD TRUCK ECONOLINE 1986 FORD TRUCK E350 1986 FORD TRUCK ECONOLINE 1987
FORD TRUCK E350 1987 FORD TRUCK ECONOLINE
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel/Water Separator > Component
Information > Locations
Fuel/Water Separator: Locations
LH Frame Rail
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
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Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
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^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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Figure 3
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4049
Figure 4
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4050
Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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Figure 6
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Figure 7
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Figure 8
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4054
Figure 9
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4055
Figure 10
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Customer Interest for Idle Speed/Throttle Actuator Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4056
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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Idle Speed/Throttle Actuator - Electronic: Customer Interest Engine - Rough Idling Condition
^ FUEL SYSTEM-EFI ENGINES - AIR BY-PASS VALVE REPLACEMENT PART INOPERATIVE
^ IDLE - ROUGH-REPLACEMENT AIR BY-PASS VALVE INOPERATIVE
Article No. 89-24-4 FORD:
1983-88 ESCORT, EXP, THUNDERBIRD 1984-88 MUSTANG 1986-88 CROWN VICTORIA,
TAURUS 1988 TEMPO
LINCOLN-MERCURY: 1983 LN7 1983-86 LYNX 1983-88 COUGAR 1984-86 CAPRI 1986-88
CONTINENTAL, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR 1988 TOPAZ
MERKUR: 1985-88 XR4TI 1988 SCORPIO
LIGHT TRUCK: 1985-88 BRONCO, F-150, F-250, RANGER 1986-88 AEROSTAR, BRONCO II,
ECONOLINE 1987-88 F-350 1988 F SUPER DUTY
Figure 1
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ISSUE: A rough idle created when the air by-pass valve is replaced may be caused by a revision
made to the valve's wiring harness.
Vehicles built before the 1989 model year had a diode in the air by-pass valve wiring harness. The
new replacement valves have a 3D marking on the plastic portion of the solenoid, above the
connector cap, Figure 1. They have a diode in the air by-pass valve.
On the air by-pass valves used on vehicles built before the 1989 model year, the positive and
negative leads are not important to the operation of the valve. However, the polarity on the new
replacement air by-pass valve is important because if the wiring harness is reversed the air
by-pass valve will not work.
ACTION: Reverse the wires in the air by-pass valve connector and retest the valve. Refer to the
following EFI Engine Application Chart for engines using these air by-pass valves.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
620800
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Actuator - Electronic: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
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Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
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^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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Figure 3
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Figure 4
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Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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Figure 6
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Figure 7
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Figure 8
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Figure 9
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Figure 10
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Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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Actuator - Electronic: > 89244 > Dec > 89 > Engine - Rough Idling Condition
Idle Speed/Throttle Actuator - Electronic: All Technical Service Bulletins Engine - Rough Idling
Condition
^ FUEL SYSTEM-EFI ENGINES - AIR BY-PASS VALVE REPLACEMENT PART INOPERATIVE
^ IDLE - ROUGH-REPLACEMENT AIR BY-PASS VALVE INOPERATIVE
Article No. 89-24-4 FORD:
1983-88 ESCORT, EXP, THUNDERBIRD 1984-88 MUSTANG 1986-88 CROWN VICTORIA,
TAURUS 1988 TEMPO
LINCOLN-MERCURY: 1983 LN7 1983-86 LYNX 1983-88 COUGAR 1984-86 CAPRI 1986-88
CONTINENTAL, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR 1988 TOPAZ
MERKUR: 1985-88 XR4TI 1988 SCORPIO
LIGHT TRUCK: 1985-88 BRONCO, F-150, F-250, RANGER 1986-88 AEROSTAR, BRONCO II,
ECONOLINE 1987-88 F-350 1988 F SUPER DUTY
Figure 1
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed/Throttle
Actuator - Electronic: > 89244 > Dec > 89 > Engine - Rough Idling Condition > Page 4093
ISSUE: A rough idle created when the air by-pass valve is replaced may be caused by a revision
made to the valve's wiring harness.
Vehicles built before the 1989 model year had a diode in the air by-pass valve wiring harness. The
new replacement valves have a 3D marking on the plastic portion of the solenoid, above the
connector cap, Figure 1. They have a diode in the air by-pass valve.
On the air by-pass valves used on vehicles built before the 1989 model year, the positive and
negative leads are not important to the operation of the valve. However, the polarity on the new
replacement air by-pass valve is important because if the wiring harness is reversed the air
by-pass valve will not work.
ACTION: Reverse the wires in the air by-pass valve connector and retest the valve. Refer to the
following EFI Engine Application Chart for engines using these air by-pass valves.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
620800
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Technical Service Bulletins > Page 4094
Idle Speed/Throttle Actuator - Electronic: Locations
Attached At Rear Of Carburetor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Mechanical > Idle Speed Vacuum Solenoid Valve > Component Information > Locations > Throttle Kicker Vacuum Valve
Idle Speed Vacuum Solenoid Valve: Locations Throttle Kicker Vacuum Valve
Top Of 8 Cyl, LH Side Of 6 Cyl. Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Mechanical > Idle Speed Vacuum Solenoid Valve > Component Information > Locations > Throttle Kicker Vacuum Valve >
Page 4100
Idle Speed Vacuum Solenoid Valve: Locations Throttle Kicker Solenoid
LH Side Of 6-300/4.
LH Side Of Engine, Above Distributor
Applicable to: 9L Engine With Heavy Duty Emissions
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non
Comp. Controlled) > Component Information > Description and Operation > Altitude Compensator
Idle/Altitude Compensator (Non Comp. Controlled): Description and Operation Altitude
Compensator
Fig. 7 Electrical type altitude compensator
ELECTRICAL The electrical type altitude compensator, Fig. 7, used on some vehicles, is mounted
on the ignition module. The compensator improves emissions and aids engine performance at
altitudes above 4000 ft. by advancing the timing and leaning the air/fuel mixture.
Fig. 8 Mechanical type altitude compensator
MECHANICAL The mechanical type altitude compensator, Fig. 8, is mounted on the bulkhead. The
compensator leans the air/fuel mixture at altitudes above 3000 ft. by supplying additional filtered air
to the carburetor.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non
Comp. Controlled) > Component Information > Description and Operation > Altitude Compensator > Page 4105
Idle/Altitude Compensator (Non Comp. Controlled): Description and Operation Hot Idle
Compensator
Fig. 17 Hot idle compensator
The hot idle compensator, Fig. 17, used on some vehicles, cools the engine during hot idle
operation. The compensator may be integral with the carburetor or mounted separately. When
open, the compensator bleeds air into the manifold, leaning out the air/fuel mixture at idle. This
increased air intake causes an increase in engine idle speed, resulting in cooling of the engine.
Temperature rise on the bi-metal sensor lifts the normally closed valve and opens the air passage.
A valve that does not fully close will cause high idle speed and excessive exhaust emission.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non
Comp. Controlled) > Component Information > Description and Operation > Page 4106
Idle/Altitude Compensator (Non Comp. Controlled): Testing and Inspection
ELECTRICAL
1. Check and record engine timing.
2. Disconnect compensator from ignition module and connect suitable jumper wire across module
connectors. Recheck engine timing.
3. At altitudes of 4000 ft. or lower, timing should be advanced 4° on V8-302 engine, or 6° on
V8-351 engine.
4. At altitudes of 4000 ft. or higher on 6-300 engine, or 4600 ft. or more on V8-302 and V8-351
engines, there should be no change in timing.
Fig. 8 Mechanical type altitude compensator
MECHANICAL
1. Connect a suitable vacuum gauge to air inlet nipple, Fig. 8, and check for vacuum with engine
running.
2. On 4-140 engine, there should be no vacuum at altitudes of 2500 ft. or lower and vacuum should
be present at altitudes of 3000 ft. or higher.
3. On V6-232 engines, there should be no vacuum at altitudes of 3500 ft. or lower and vacuum
should be present at altitudes of 4000 ft. or higher.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations
Inertia Fuel Shutoff Switch: Locations
The inertia switch is located on the passenger side cowl panel, just forward of the right front door.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Under RH Side Of Dashboard
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 4113
Main Relay (Computer/Fuel System): Description and Operation
Fig. 12 EEC relay type, system application & relay locations
EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power
relays also provide reverse battery protection and increased load handling to improve ignition
switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine
applications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Choke Relay > Component Information > Locations
Choke Relay: Locations
LH Fender Apron Near Dash
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest for Fuel
Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down
Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down
^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY
CHARGE
^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF
Article No. 90-18-3 FORD:
1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD
1986-90 TAURUS
LINCOLN-MERCURY: 1983-87 LYNX
1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86
CAPRI, MARQUIS 1986-90 SABLE
LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1988-90 F SUPER DUTY
ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been
shut off. There may also be a no start condition or a discharged battery. These conditions are
caused by a sticking fuel pump relay.
ACTION: Install a new fuel pump relay. Refer to the following procedure for service details.
1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for
troubleshooting details.
2. Install a new fuel pump relay, if the old one is defective.
3. Check the vehicle for proper operation.
PART NUMBER PART NAME
F19Z-9345-A Fuel Pump Relay Assy.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901803A 1985-86 LTD/Marquis 0.6 Hr.
(includes pinpoint test)
901803A 1990 Town Car (includes 0.4 Hr.
pinpoint test)
901803A All Other Cars (includes 0.5 Hr.
pinpoint test)
901803A All Trucks (includes pinpoint 0.5 Hr.
test)
DEALER CODING
BASIC PART NO. CONDITION CODE
9345 09
OASIS CODES: 404000, 603300, 203000, 203100, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down
Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut
Down
^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY
CHARGE
^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF
Article No. 90-18-3 FORD:
1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD
1986-90 TAURUS
LINCOLN-MERCURY: 1983-87 LYNX
1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86
CAPRI, MARQUIS 1986-90 SABLE
LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1988-90 F SUPER DUTY
ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been
shut off. There may also be a no start condition or a discharged battery. These conditions are
caused by a sticking fuel pump relay.
ACTION: Install a new fuel pump relay. Refer to the following procedure for service details.
1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for
troubleshooting details.
2. Install a new fuel pump relay, if the old one is defective.
3. Check the vehicle for proper operation.
PART NUMBER PART NAME
F19Z-9345-A Fuel Pump Relay Assy.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901803A 1985-86 LTD/Marquis 0.6 Hr.
(includes pinpoint test)
901803A 1990 Town Car (includes 0.4 Hr.
pinpoint test)
901803A All Other Cars (includes 0.5 Hr.
pinpoint test)
901803A All Trucks (includes pinpoint 0.5 Hr.
test)
DEALER CODING
BASIC PART NO. CONDITION CODE
9345 09
OASIS CODES: 404000, 603300, 203000, 203100, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Shut-off Solenoid Relay > Component Information > Locations
Fuel Shut-off Solenoid Relay: Locations
LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Under RH Side Of Dashboard
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4137
Main Relay (Computer/Fuel System): Description and Operation
Fig. 12 EEC relay type, system application & relay locations
EEC power relays are in parallel with ignition switch and provides power to the EEC module. Power
relays also provide reverse battery protection and increased load handling to improve ignition
switch reliability. Refer to Figs. 12 & 12a, for EEC-IV power relay type, location and model/engine
applications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank >
Component Information > Description and Operation
Rollover Valve: Description and Operation
Hairpin Clip Connector
FUEL LINES AND CONNECTORS Fuel injection systems often use special kinds of fittings to
ensure leakproof connections. Some high-pressure fittings use O-ring seals instead of the
traditional flare connections. The O-rings are made of special materials that can withstand contact
with gasoline and alcohol-blend fuels. Whenever you replace one of these O-rings, you must use a
new part specifically designed for fuel system service. The O-rings used in air conditioning systems
are not satisfactory. Ford uses nylon fuel tubing with several unique push-connect fittings. Special
barbed connectors are required to join sections of nylon tubing together. Connectors that join nylon
to steel tubing also have barbed ends for the nylon lines, but they use O-rings to seal the steel line.
Ford uses two kinds of retainer clips on these connectors. Fittings for 5/16 and 3/8 inch lines have
hairpin clips. Fittings for 1/4 inch lines have duckbill clips.
Fuel Return
FUEL SUPPLY MANIFOLD
High pressure fuel is delivered from the vehicle fuel supply line to the eight fuel injectors by the fuel
supply manifold assembly. The assembly consists of two banks of tubular fuel rails connected by
two permanent crossover connections, a mounting flange to the fuel pressure regulator and
mounting attachments which locate the fuel manifold assembly, eight injector connectors, and
provide fuel injector retention. The fuel inlet and outlet connections have push connect fittings.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank >
Component Information > Description and Operation > Page 4141
Fuel Filler System
FUEL TANK FILLER NECK
To prevent accidental filling with other than unleaded fuel, vehicles that require unleaded fuel have
a special filler tube. This filler tube has a restriction in it so that the only nozzles that can be
inserted are the smaller diameter nozzles of pumps dispensing unleaded fuel.
It is recommended that the amount of fuel put in the tank when filling be limited to the automatic
pump shutoff. Due to the expansion of fuel during temperature increases, or overfilling ("topping
off") can cause fuel overflow at the filler cap when the vehicle is standing or the cap is removed. If
the vehicle has two tanks, use fuel from both tanks after fill-up to reduce fuel levels.
Orifice Rollover Valve
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank >
Component Information > Description and Operation > Page 4142
ORIFICE/ROLLOVER VALVE ASSEMBLY The orifice valve tends to meter the amount of fuel
vapor passing out of the tank. The fuel vapors trapped in the sealed fuel tank are vented through
the orifice fuel tank vapor valve assembly. The vapors then leave the valve assembly through a
single vapor line and continue to the carbon canister in the engine compartment for storage, until
they are purged to the engine.
VAPOR VENT In-tank venting provides a vapor space above the gasoline surface in the fuel tank.
This area is sufficient to permit adequate breathing space for the tank vapor valve assembly under
all static and most dynamic condition.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Description and Operation
Air Flow Meter/Sensor: Description and Operation
The vane air flow meter measures air flowing into the engine and is mounted between the air
cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a
potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and
potentiometer. The potentiometer relays vane position information to the EEC-IV module. The
EEC-IV module, then translates vane position information into the amount of air flowing into the
engine. An air temperature sensor is incorporated within the vane air flow meter. This sensor
constantly monitors air temperature entering the engine and also transmits the information to the
EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature
information and adjusts the fuel flow to obtain the optimum air/fuel mixture required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations
Fuel Tank Selector Switch: Locations
LH Side Of Instrument Panel Near Fuse Block
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and
Instructions
Fuel Tank Selector Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and
Instructions > Page 4152
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and
Instructions > Page 4153
Fuel Tank Selector Switch: Electrical Diagrams
Fig. 28 Fuel Tank Selector Wiring Circuit. V8-351/5.8L Fuel Injected & V8-460/7.5L Non Hot Fuel
Handling
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and
Instructions > Page 4154
Fig. 26 Fuel Tank Selector Wiring Circuit. V8-302/5.0L & V8-460/7.5L Hot Fuel Handling
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Diagrams > Diagram Information and
Instructions > Page 4155
Fig. 29 Fuel Tank Selector Wiring Circuit. V8-460/7.5L Hot Fuel Cutaway
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Inertia Fuel Shutoff Switch: Locations
The inertia switch is located on the passenger side cowl panel, just forward of the right front door.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle
Position Sensor - Application Chart
Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart
EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP
Article No. 89-16-4
FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO,
THUNDERBIRD
LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII,
SABLE, TOPAZ, TOWN CAR
LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES
ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to
assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely.
ACTION: Refer to one of the following TPS service replacement charts to make sure that the
correct service part is installed.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle
Position Sensor - Application Chart > Page 4163
OASIS CODES: 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle
Position Sensor - Application Chart > Page 4164
Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove
THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP
Article No. 89-14-7
FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT
1986-89 TAURUS
LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII,
TOPAZ, TOWN CAR 1984-87 LYNX
MERKUR: 1985-89 ALL MERKUR LINES
LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES
ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The
"Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove
a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians
think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting
with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw.
ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws,
technicians should always use a # 2 "Pozidrive" screwdriver.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
INFORMATION ONLY
OASIS CODES: 4800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications
THROTTLE POSITION SENSOR SPECIFICATIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications >
Page 4167
Throttle Position Sensor: Mechanical Specifications
IDLE SPEED Throttle Plate Stop Screw M/T.......................................................................................
......................................................................................625-675 rpm Throttle Plate Stop Screw A/T...
..............................................................................................................................................................
.............600-700 rpm
TORQUE VALUES
Air Bypass Valve To Lower Manifold....................................................................................................
...........................................70-100 in lb (8-11 N-m) Hose to Tank ......................................................
...................................................................................................................................25-35 in lb (3-4
N-m) Fuel Injector Manifold to Fuel Charging
Assembly...........................................................................................................................70-105 in lb
(8-12 N-m) Fuel Line Fittings................................................................................................................
................................................................10-15 ft lb (13-20 N-m) Fuel Pressure Regulator to Injector
Manifold......................................................................................................................................27-40
in lb (3-4.5 N-m) Retaining straps around Fuel Tank...........................................................................
..........................................................................22-30 in lb (30-41 N-m) Throttle Body to Upper
Intake Manifold.....................................................................................................................................
.......70-100 in lb (8-11 N-m) Throttle Position Sensor to Throttle
Body........................................................................................................................................11-16 in
lb (1.2-1.8 N-m) Upper Intake Manifold to Lower Intake Manifold
Bolts.....................................................................................................................12-18 ft lb (16-24
N-m)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4168
Throttle Position Sensor: Locations
RH Side Of V8-351/5.
At Front Of Carburetor
Applicable to: 8L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Adjustments > EEC-IV Using Breakout
Box
Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box
Throttle Position Sensor
NOTE: This procedure can be used to check and adjust level "C" sensor only.
1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle.
2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive
lead into test socket 47 and the negative lead into socket 46 of the breakout box.
3. Turn the ignition ON, but DO NOT start the vehicle.
4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP)
sensor mounting screws and rotate the sensor until the voltage falls within this range.
5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m).
6. While observing the DVOM, move the throttle through the entire range of motion. The reading
should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt.
7. If the TP sensor cannot be adjusted, replace the sensor.
8. Perform an EEC-IV quick test on the vehicle.
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Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment
Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker,
as equipped. With engine not running, compare voltage reading against specifications and adjust
as needed.
Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and
connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust
TPS to specified value.
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Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
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Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
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^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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Figure 3
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Figure 4
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Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
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Starts/Hesitation/Stalls On Start-Up > Page 4186
Figure 6
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Starts/Hesitation/Stalls On Start-Up > Page 4187
Figure 7
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Figure 8
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Figure 9
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Figure 10
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Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
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Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up
Technical Service Bulletin # 91257 Date: 911213
Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up
Article No. 91-25-7
12/13/91
^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE
FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS
1986-91 CROWN VICTORIA 1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90
CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be
caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the
throttle body bore and plate or the idle air by-pass valve may cause one or more of the following
conditions.
^ Hard Cold Start
^ Stall On Initial Start-Up
^ Stall During Idle
^ Stall During Decel
^ Rough Idle
^ Rolling Idle
^ Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to
correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to
clean the majority of past model throttle body applications. Cleaning is not required on sludge
tolerant throttle body designs released for 1991 and newer model years.
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Figure 1
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent
correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet
included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port
fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
^ One (1) Idle Adjust Spacer
^ Two (2) Gaskets
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^ Two (2) Attaching Bolts
^ One (1) "Attention" Sticker
^ One (1) Instruction Sheet
Figure 2
Refer to Figure 2 for a pictorial of the kits components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED
UNDER 5/50 EMISSIONS WARRANTY,
UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW
THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body
sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic
adjustment of the throttle body is not required.
Procedures, Warranty and Labor
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the
service kit installation.
^ Contamination within the idle air by-pass solenoid
^ Lack of fuel system control (excessively rich or lean)
^ Ignition timing change
^ Incorrect or malfunctioning EGR system
^ Incorrect or malfunctioning cooling system
^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster
where applicable)
^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes
have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the
service kit installation.
Idle Speed Adjustment
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WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT
THE FOLLOWING ITEMS ARE TAKEN CARE
OF PROPERLY.
^ The transmission is in PARK or Neutral.
^ The parking brake is applied.
^ The wheels are properly blocked.
^ The engine is at operating temperature.
^ The heater, A/C, cooling fan and other accessories are OFF.
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Figure 3
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Figure 4
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Figure 5
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars
and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the
appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly,
after service kit installation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Figure 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4210
Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4211
Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4212
Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4213
Figure 11
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by
engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6
through 11. Refer to these charts to see if the service kit is to be installed and which service
cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures
6-11, for the vehicle/engine combination being
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serviced.
^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST
SPACER.
^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type
brush.
^ Use rubber gloves and eye protection.
^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
^ Do not run vehicles with air flow meters when the air duct is removed.
^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner
(D9AZ-19579-AA).
Procedure # 1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE
CLEANING PROCEDURE. IF THERE IS A
YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN,
OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE
PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
2. Remove the air duct to the throttle body inlet.
3. Disoonnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine. Do not start engines that have air flow meters.
6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet
the bore and throttle plate.
7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the
throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach
into the corners where the throttle shaft meets the bore wall.
11. Start the actuator and the start the engine. Do not start engines that have air flow meters.
12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away
residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow
meters and are not running.
13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of
the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on
engines that have air flow meters and are not running.
14. Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
15. Reinstall the air duct.
16. Start and run the engine for about one (1) minute to dry out the solvent residue.
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17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
18. Disconnect the actuator from the idle air by-pass valve.
19. Reattach the control signal lead to the air by-pass valve.
20. Check engine for normal operation. It may be necessary to reset the idle speed due to a
previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis
Service Manual, Throttle Body Section, for idle speed adjust procedure.)
Procedure # 2 Idle Air By-Pass Valve Cleaning Only
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT
THROTTLE BODIES WHICH ARE IDENTIFIED
WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT
(F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY
BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH
AIR FLOW METERS DURING CLEANING PROCEDURE.
1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or
equivalent.
2. Remove the air duct to the throttle body inlet.
3. Disconnect the idle air by-pass valve signal lead.
4. Attach the actuator harness plug to the idle air by-pass valve.
5. Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve
inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA.
7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
8. Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON
ENGINES THAT HAVE AIR FLOW METERS AND
ARE NOT RUNNING.
10. Stop actuator and stop engine if running.
11. Reinstall the air duct.
12. Start and run the engine for about one (1) minute to dry out the solvent residue.
13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
14. Disconnect the actuator from the idle air by-pass valve.
15. Reattach the control signal lead to the air by-pass valve.
16. Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE
IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
Warranty Coverage
Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992
model year that can be cleaned (as identified in the application charts) are covered under 5/50
Emissions Warranty Coverage.
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For those throttle bodies identified as having sludge tolerant designs or using service kit
(F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for
cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not
allowed. Service kit installation (single time) is covered under 5/50 emission warranty.
Labor Standards Operations
The labor operations shown in the following Operation/Description/Time columns are identified by
procedure number and vehicle line. Specific engines for various vehicles are identified in the
sludge cleaning procedure application charts. The throttle body cleaning operations with
combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals
under the following operation numbers.
^ 9926 B - Throttle body and idle air by-pass valve cleaning
^ 9926 B2 - Adjust idle speed
^ 9715 A - Air by-pass valve cleaning only
^ 9715 A1 - Adjust idle speed
PART NUMBER PART NAME CLASS
F2PZ-9F939-A Idle Air By-pass Service Kit B
D9AZ-19579-AA Carburstor Tune-Up Cleaner BG
OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES:
88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4
Operation Description
WARRANTY STATUS: Eligible Under Warranty
Coverage As Stated In The Text Of This Article
OPERATION DESCRIPTION TIME
912507A Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI.
912507B Idle Air By-Pass Valve 0.5 Hr.
Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI.
912507C Idle Air By Pass Valve 0.5 Hr.
Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C,
1987/92 Mustang 2.3L EFI.
912507D Idle By-Pass Valve Cleaning 0.6 Hr.
- 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI.
912507E Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI.
912507F Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI.
912507G Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI.
912507H Idle Air By-Pass Valve 0.7 Hr.
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Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI.
912507I Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L
S/C.
912507J Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI,
1990-92 Ranger 4.0L EFI.
912507K Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear
Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI.
912507L Idle Air By-Pass Valve 0.6 Hr.
Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn
- Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO.
912507M Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI.
912507N Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean
Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10,
1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00.
912507O Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1991/92 F And B Series, 7.0L EFI.
912507P Idle Air By-Pass Valve 0.7 Hr.
Cleaning - 1987-92 E-Series, F-Series 7.5L EFI.
912507Q Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI.
912507R Throttle Body And Idle Air 0.8 Hr.
By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI.
912507S Throttle Body And Idle Air 0.9 Hr.
By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI.
912507T Service Kit Install - All Cars 1.0 Hr.
And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application
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Charts, For Vehicle Application.
912507U Service Kit Install - 1.2 Hr.
Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application.
DEALER CODING
BASIC PART NO. CONDITION CODE
9E926 49
OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Throttle Position Sensor - Application Chart
Throttle Position Sensor: Technical Service Bulletins Throttle Position Sensor - Application Chart
EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP
Article No. 89-16-4
FORD: 1984-88 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TAURUS, TEMPO,
THUNDERBIRD
LINCOLN-MERCURY: 1984-88 COUGAR, GRAND MARQUIS, LYNX, MARK VI, MARK VII,
SABLE, TOPAZ, TOWN CAR
LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES
ISSUE: A quick reference throttle position sensor (TPS) application chart has been put together to
assist technicians in correct part useage. If the wrong TPS is installed, it could fail prematurely.
ACTION: Refer to one of the following TPS service replacement charts to make sure that the
correct service part is installed.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
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Component Information > Technical Service Bulletins > Throttle Position Sensor - Application Chart > Page 4223
OASIS CODES: 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Technical Service Bulletins > Throttle Position Sensor - Application Chart > Page 4224
Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove
THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP
Article No. 89-14-7
FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT
1986-89 TAURUS
LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII,
TOPAZ, TOWN CAR 1984-87 LYNX
MERKUR: 1985-89 ALL MERKUR LINES
LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES
ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The
"Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove
a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians
think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting
with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw.
ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws,
technicians should always use a # 2 "Pozidrive" screwdriver.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
INFORMATION ONLY
OASIS CODES: 4800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Specifications > Electrical Specifications
THROTTLE POSITION SENSOR SPECIFICATIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Specifications > Electrical Specifications > Page 4227
Throttle Position Sensor: Mechanical Specifications
IDLE SPEED Throttle Plate Stop Screw M/T.......................................................................................
......................................................................................625-675 rpm Throttle Plate Stop Screw A/T...
..............................................................................................................................................................
.............600-700 rpm
TORQUE VALUES
Air Bypass Valve To Lower Manifold....................................................................................................
...........................................70-100 in lb (8-11 N-m) Hose to Tank ......................................................
...................................................................................................................................25-35 in lb (3-4
N-m) Fuel Injector Manifold to Fuel Charging
Assembly...........................................................................................................................70-105 in lb
(8-12 N-m) Fuel Line Fittings................................................................................................................
................................................................10-15 ft lb (13-20 N-m) Fuel Pressure Regulator to Injector
Manifold......................................................................................................................................27-40
in lb (3-4.5 N-m) Retaining straps around Fuel Tank...........................................................................
..........................................................................22-30 in lb (30-41 N-m) Throttle Body to Upper
Intake Manifold.....................................................................................................................................
.......70-100 in lb (8-11 N-m) Throttle Position Sensor to Throttle
Body........................................................................................................................................11-16 in
lb (1.2-1.8 N-m) Upper Intake Manifold to Lower Intake Manifold
Bolts.....................................................................................................................12-18 ft lb (16-24
N-m)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Specifications > Page 4228
Throttle Position Sensor: Locations
RH Side Of V8-351/5.
At Front Of Carburetor
Applicable to: 8L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Adjustments > EEC-IV Using Breakout Box
Throttle Position Sensor: Adjustments EEC-IV Using Breakout Box
Throttle Position Sensor
NOTE: This procedure can be used to check and adjust level "C" sensor only.
1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle.
2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive
lead into test socket 47 and the negative lead into socket 46 of the breakout box.
3. Turn the ignition ON, but DO NOT start the vehicle.
4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP)
sensor mounting screws and rotate the sensor until the voltage falls within this range.
5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m).
6. While observing the DVOM, move the throttle through the entire range of motion. The reading
should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt.
7. If the TP sensor cannot be adjusted, replace the sensor.
8. Perform an EEC-IV quick test on the vehicle.
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Component Information > Adjustments > EEC-IV Using Breakout Box > Page 4231
Throttle Position Sensor: Adjustments Throttle Position Sensor Adjustment
Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker,
as equipped. With engine not running, compare voltage reading against specifications and adjust
as needed.
Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and
connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust
TPS to specified value.
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Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector >
Component Information > Description and Operation
Ignition Timing Connector: Description and Operation
Fig. 20 Ignition Timing Vacuum Switch
Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition
module to retard spark timing. The switch is closed above the vacuum setting and the ignition
module is in the non-retard spark timing mode. Calibration resistors inside the switch control the
amount of retard.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector >
Component Information > Description and Operation > Page 4240
Ignition Timing Connector: Testing and Inspection
Ignition Timing Vacuum Switch
Ignition Timing Vacuum Switch Test Chart
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less
than'' values in the Ignition Timing vacuum Switch Test chart.
3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured
across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart.
4. Replace switch if resistance is not within specifications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators >
System Information > Diagrams
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Ballast Resistor > Component Information
> Specifications > DS II
IGNITION RESISTOR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Ballast Resistor > Component Information
> Specifications > DS II > Page 4248
Ignition Ballast Resistor: Specifications TFI IV
BALLAST RESISTOR: Wire Type - Resistance: 1.1 Ohms + or - .05 Ohms
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Ballast Resistor > Component Information
> Specifications > Page 4249
Ignition Ballast Resistor: Locations
The Ballast Resistor is a wire type and is in-line with the ignition wiring harness located near the
steering column. NOTE: Verify vehicle has a ballast resistor by referencing wiring diagram.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Ballast Resistor > Component Information
> Specifications > Page 4250
Ignition Ballast Resistor: Description and Operation
The ballast resistor, (wire type), maintains a specific resistance between the positive (Batt.)
terminal of the ignition coil connector and the wiring harness connector. It is not in operation during
engine cranking enabling the coil to receive a hotter signal for starting. Once the engine is running,
the resistor is used to protect the coil from voltage overload.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Ballast Resistor > Component Information
> Specifications > Page 4251
Ignition Ballast Resistor: Testing and Inspection
1. Disconnect module connector with red and white wires then, ignition coil connector.
2. Using a suitable ohmmeter, measure resistance between Batt. terminal of ignition coil connector
and wiring harness connector wire that joins red wire in module connector.
3. If resistance is 0.8---1.6 ohms, ballast resistor is satisfactory. If resistance is less than 0.8 ohms
or greater than 1.6 ohms, replace ballast resistor.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit >
Component Information > Specifications
DISTRIBUTOR TIMING ADVANCE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit >
Component Information > Description and Operation > Vacuum Spark Advance Mechanism
Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism
The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly
is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm
assembly used depends on the engine calibration.
Single Diaphragm Assembly
SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the
armature to stator relationship to give spark advance. The stator assembly position is changed by
means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm
assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance
spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached
to the stator assembly, makes the the stator assembly move with respect to the armature. This
changes the initial armature to stator relationship set during initial timing, causing spark advance.
The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly,
is attached to the distributor base.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit >
Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 4258
Dual Diaphragm Assembly
DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in
the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum
advance port causes the advance diaphragm and attached rod to move, otherwise the action is the
same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard
diaphragm to move, compressing the retard spring, which controls the rate of spark retard.
Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by
the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm
rod moves causing the attached stator assembly to change position with respect to the armature. In
this instance the direction of the stator assembly movement is opposite that occurring during
vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port
overrides any spark retard caused by vacuum being applied to the retard port.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit >
Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 4259
Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism
Distributor - Exploded view
The centrifugal advance mechanism varies the relationship of the armature to the stator assembly.
The armature is mounted to the sleeve and plate assembly which rotates in relation to the
distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine
RPM. The movement of the weights change the initial relationship of the armature to the stator
assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor
shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by
calibrated springs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit >
Component Information > Description and Operation > Page 4260
Distributor Advance Unit: Service and Repair
1. Remove distributor cap and rotor.
2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup
assembly.
3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link.
4. Carefully remove unit from distributor.
5. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Distributor Cap: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4265
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Cap > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4266
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Ignition Rotor: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4271
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component
Information > Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4272
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Plate W/ Pick-up
Sensor > Component Information > Service and Repair
Distributor Plate W/ Pick-up Sensor: Service and Repair
1. Remove distributor cap and rotor.
2. Remove vacuum advance unit and magnetic pickup assembly.
3. Remove attaching screws and lift base plate from distributor.
4. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component
Information > Description and Operation
Hall Effect Sensor: Description and Operation
Profile Ignition Pickup
The PIP signal is created in the Hall Effect and Stator assembly and indicates crankshaft position
and engine RPM Fig. 21. The PIP signal is fed to both the TFI module and the ECA.
PIP Sensor
COMPONENTS The Hall Effect device is made up of a voltage regulator, a Hall voltage generator,
Darlington amplifier, Schmitt trigger, and an open collector output stage integrated in a single
monolithic silicon chip Fig. 22. A signal is produced when a ferrous material is passed through the
opening and the flux lines decrease. The Hall generator (Hall device) sends a sine wave signal to
the Darlington amplifier. The Darlington amplifier inverts the signal. When the signal is low the
output is high. When the signal is high the output is low. This output then goes to the Schmitt
trigger. The Schmitt trigger shapes the signal into a square wave (digital high) signal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component
Information > Description and Operation > Page 4279
PIP Signal Operation
OPERATION The output signal to the Darlington amplifier is high when the window (on the
armature) allows the magnetic field to reach the Hall device (switch off) Fig. 23. When the TAB
shunts the magnetic field (closes) away from the Hall device the signal is low to the Darlington
amplifier (switch on).
Hall Effect Sensor
In other words when one of the windows or openings is in the gap between the Hall device and the
permanent magnet, the field stays strong and the voltage is high since the magnetic path is
complete from the magnet, through the Hall device, and back to the magnet. In this case the switch
is off and the Hall Effect does not send a signal. When the TAB enters the gap, the armature cuts
off the magnetic path to the Hall device and its voltage drops. In this case the switch is on and the
Hall Effect device sends a signal. The signal is switched On and Off as long as the armature is
rotating (distributor is turning) and opening and closing the magnetic path. This is the signal used
by the ECA to interpret crankshaft position and engine RPM. The signal can also be used by the
TFI module if the SPOUT signal from the ECA is lost.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component
Information > Description and Operation > Page 4280
Signature PIP
SIGNATURE PIP Some Electronic Engine Control (EEC) vehicles are equipped with a signature
profile ignition pickup signal. The regular type armature used for the PIP signal has the same size
tabs and windows. In a signature PIP signal armature, one of the tabs is narrower than the others
Fig. 25. The narrower tab provides a different signal to the ECA when it passes through the Hall
Effect switch. When the ECA sees the narrow tab it knows when to properly pulse the fuel injectors.
This system is used on cars and trucks where the ECA needs to know when to pulse certain
injectors. For example, on sequential electronic fuel injection (SEFI) systems, each injector is
pulsed to coincide with its intake valve opening. With the signature PIP, the ECA knows when the
No. 1 cylinder needs to be supplied with fuel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component
Information > Description and Operation > Page 4281
Hall Effect Sensor: Service and Repair
Removal Do not attempt to replace stator without an arbor press.
1. Remove distributor. Remove rotor, then the TFI module.
2. If distributor uses push on type rotor, remove two retaining screws holding armature, then the
armature. Hold gear to loosen armature screws, do not hold armature.
3. Mark stator, armature, gear and collar with felt tip pen to aid in reassembly.
4. Remove and discard pins in gear and collar if equipped.
5. Invert distributor and place in Axle Bearing Seal Plate and press off gear using Bearing Removal
Tool.
6. Deburr and polish shaft with emery paper and wipe clean so that shaft slides out freely from
distributor base.
7. Remove shaft assembly, then the thrust washer from shaft. Next remove octane rod.
8. Remove stator assembly screws, then the stator assembly from top of bowl.
9. Inspect base bushing for wear of signs of excess heat concentration, replace distributor
assembly if damaged.
10. Inspect base O-ring for cuts or damage and replace as necessary.
11. Inspect base for cracks and wear, replace distributor assembly if damage is found.
Installation
1. Place stator assembly over bushing and press down to seat.
2. Place stator connector in position, tab should fit in notch on base with fastening eyelets aligned
with screw holes.
3. Install stator screws and Torque to 15-35 inch lbs. Next install octane rod.
4. Install thrust washer on top of bushing, then apply lubricant to distributor shaft below armature.
Do not over lubricate.
5. Insert shaft through base bushing, then place collar, if equipped, over shaft and line up mark on
armature and collar to aid alignment with original drill hole. Use a suitable drift punch to assure
proper alignment.
6. Drill holes through shaft and collar should align on both sides of shaft. If holes do not align, collar
may be 180 degrees out of alignment on shaft. Rotate collar on shaft one half rotation, then check.
7. Insert new roll pin through collar and shaft, pin should be flush with both sides of collar when
seated.
8. If distributor uses push on type rotor, place a 1/2 inch deep well socket over shaft, invert and
place on arbor plate.
9. If distributor uses screw down type rotor, invert and place on arbor plate.
10. Place distributor gear on shaft and line up marks on armature and gear. Hole in shaft and gear
must line up as accurately as possible to assure ease of roll pin insertion.
11. Place a 5/8 inch deep well socket over shaft and gear, then press gear to align with original drill
hole.
12. If gear holes do not align, gear must be removed and repressed on. Drift punch will not align
holes, as in collar, holes should align.
13. Insert new roll pin through gear and shaft, pin should extrude evenly on both sides.
14. Install armature, if removed, and Torque screws to 25-35 inch lbs.
15. Install TFI module, rotor, then distributor.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Ignition Cable: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4286
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4287
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4288
Ignition Cable: Technical Service Bulletins Ignition System - Diagnostics Manual Correction
Article No. 89-5A-4
EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION
FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND
CROWN VICTORIA
LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ,
GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR
LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES
1986-88 AEROSTAR
ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989
Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service
information directs technicians to use a substitute coil instead of a resistance test.
ACTION: Refer to this TSB for revised ignition coil and secondary wire test information.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 680000
1989
Ignition Systems, Timing Procedures and Diagnostics 13-51
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4289
Ignition Coil and Secondary Wire
TFI-IV
And
TFI With CCD
Part 2
Test 7 1989 13-52
Ignition Systems, Timing Procedures and Diagnostics
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4290
EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2
Test 8
1989 Ignition Systems, Timing Procedures and Diagnostics
13-65
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4291
Ignition Coil And Secondary Wire
TFI-IV
Closed Bowl
Distributor
Part 2
Test 8 1989 13-66
Ignition Systems, Timing Procedures and Diagnostics
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4292
EEC-IV - Wiring TFI-IV
Closed Bowl
Distributor Part 2
Test 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Technical Service Bulletins > Page 4293
Ignition Cable: Testing and Inspection
Spark Plug Wire Resistance
*** UPDATED BY TSB #85-9-33
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Customer Interest: > 872018 > Oct > 87 > Engine/Ignition - No Start Condition
Ignition Coil: Customer Interest Engine/Ignition - No Start Condition
NO START - EEC IV - "E" COIL Article No. 87-20-18 FORD:
1983-86 LTD 1983-87 ESCORT, EXP, MUSTANG, THUNDERBIRD, CROWN VICTORIA 1984-87
TEMPO 1986-87 TAURUS
LINCOLN-MERCURY: 1983 LN7 1983-86 MARQUIS 1983-87 LYNX, COUGAR, GRAND
MARQUIS, MARK VII, CONTINENTAL, LINCOLN TOWN CAR
1984-87 TOPAZ 1986-87 SABLE
LIGHT TRUCK: 1983-87 RANGER, E-SERIES, F-SERIES, BRONCO 1984-87 BRONCO II
1986-87 AEROSTAR
This article is being republished in its entirety to expand the model year coverage.
ISSUE: The primary winding of the E-core ignition coil may be damaged if the wire harness
containing the tachometer circuit has a short to ground.
ACTION: Before replacing the E-core ignition coil, perform the following diagnostic procedure.
1. Turn ignition to "ON" position.
2. Measure and record battery voltage.
Figure 50
3. Measure and record voltage between negative terminal and coil and battery ground post as
shown, Figure 50.
4. If the differencce in readings is greater than 1.0 volt, check tachometer circuit for a potential
short to ground.
5. If a short is present, make necessary wire harness repair.
6. Replace ignition coil as required.
OTHER APPLICABLE ARTICLES: Supersedes 84-14-18, 84-14-18-S, 85-16-13, 86-2-21
WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 911211 > Jun > 91 > Engine - Lack of Power/No Start
Diagnosis
Ignition Coil: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 911211 > Jun > 91 > Engine - Lack of Power/No Start
Diagnosis > Page 4307
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 911211 > Jun > 91 > Engine - Lack of Power/No Start
Diagnosis > Page 4308
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics
Manual Correction
Ignition Coil: All Technical Service Bulletins Ignition System - Diagnostics Manual Correction
Article No. 89-5A-4
EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION
FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND
CROWN VICTORIA
LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ,
GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR
LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES
1986-88 AEROSTAR
ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989
Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service
information directs technicians to use a substitute coil instead of a resistance test.
ACTION: Refer to this TSB for revised ignition coil and secondary wire test information.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 680000
1989
Ignition Systems, Timing Procedures and Diagnostics 13-51
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics
Manual Correction > Page 4313
Ignition Coil and Secondary Wire
TFI-IV
And
TFI With CCD
Part 2
Test 7 1989 13-52
Ignition Systems, Timing Procedures and Diagnostics
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics
Manual Correction > Page 4314
EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2
Test 8
1989 Ignition Systems, Timing Procedures and Diagnostics
13-65
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics
Manual Correction > Page 4315
Ignition Coil And Secondary Wire
TFI-IV
Closed Bowl
Distributor
Part 2
Test 8 1989 13-66
Ignition Systems, Timing Procedures and Diagnostics
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics
Manual Correction > Page 4316
EEC-IV - Wiring TFI-IV
Closed Bowl
Distributor Part 2
Test 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 872018 > Oct > 87 > Engine/Ignition - No Start
Condition
Ignition Coil: All Technical Service Bulletins Engine/Ignition - No Start Condition
NO START - EEC IV - "E" COIL Article No. 87-20-18 FORD:
1983-86 LTD 1983-87 ESCORT, EXP, MUSTANG, THUNDERBIRD, CROWN VICTORIA 1984-87
TEMPO 1986-87 TAURUS
LINCOLN-MERCURY: 1983 LN7 1983-86 MARQUIS 1983-87 LYNX, COUGAR, GRAND
MARQUIS, MARK VII, CONTINENTAL, LINCOLN TOWN CAR
1984-87 TOPAZ 1986-87 SABLE
LIGHT TRUCK: 1983-87 RANGER, E-SERIES, F-SERIES, BRONCO 1984-87 BRONCO II
1986-87 AEROSTAR
This article is being republished in its entirety to expand the model year coverage.
ISSUE: The primary winding of the E-core ignition coil may be damaged if the wire harness
containing the tachometer circuit has a short to ground.
ACTION: Before replacing the E-core ignition coil, perform the following diagnostic procedure.
1. Turn ignition to "ON" position.
2. Measure and record battery voltage.
Figure 50
3. Measure and record voltage between negative terminal and coil and battery ground post as
shown, Figure 50.
4. If the differencce in readings is greater than 1.0 volt, check tachometer circuit for a potential
short to ground.
5. If a short is present, make necessary wire harness repair.
6. Replace ignition coil as required.
OTHER APPLICABLE ARTICLES: Supersedes 84-14-18, 84-14-18-S, 85-16-13, 86-2-21
WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Ignition Coil: > 911211 > Jun > 91 > Engine - Lack of Power/No Start
Diagnosis
Ignition Coil: All Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Ignition Coil: > 911211 > Jun > 91 > Engine - Lack of Power/No Start
Diagnosis > Page 4326
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Ignition Coil: > 911211 > Jun > 91 > Engine - Lack of Power/No Start
Diagnosis > Page 4327
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual
Correction
Ignition Coil: All Technical Service Bulletins Ignition System - Diagnostics Manual Correction
Article No. 89-5A-4
EEC IV - TFI IV - IGNITION SYSTEM - REVISED TIMING PROCEDURES AND DIAGNOSTICS SHOP MANUAL CORRECTION
FORD: 1984-86 LTD 1984-88 EXP 1984-88 ESCORT THUNDERBIRD, MUSTANG, TEMPO, AND
CROWN VICTORIA
LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-88 COUGAR, TOPAZ,
GRAND MARQUIS, CONTINENTAL, MARK VII, AND LINCOLN TOWN CAR
LIGHT TRUCK: 1984-88 RANGER, BRONCO II, ECONOLINE, BRONCO, AND F-SERIES
1986-88 AEROSTAR
ISSUE: The Ignition Coil and Secondary Wire Test Steps on pages 13-51 and 13-65 of the 1989
Engine Emissions Diagnosis Shop Manual, Volume H, have been revised. The new service
information directs technicians to use a substitute coil instead of a resistance test.
ACTION: Refer to this TSB for revised ignition coil and secondary wire test information.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 680000
1989
Ignition Systems, Timing Procedures and Diagnostics 13-51
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual
Correction > Page 4332
Ignition Coil and Secondary Wire
TFI-IV
And
TFI With CCD
Part 2
Test 7 1989 13-52
Ignition Systems, Timing Procedures and Diagnostics
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual
Correction > Page 4333
EEC-IV - TFI-IV TFI-IV And TFI-IV With CCD Part 2
Test 8
1989 Ignition Systems, Timing Procedures and Diagnostics
13-65
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual
Correction > Page 4334
Ignition Coil And Secondary Wire
TFI-IV
Closed Bowl
Distributor
Part 2
Test 8 1989 13-66
Ignition Systems, Timing Procedures and Diagnostics
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Ignition Coil: > 895A4 > Mar > 89 > Ignition System - Diagnostics Manual
Correction > Page 4335
EEC-IV - Wiring TFI-IV
Closed Bowl
Distributor Part 2
Test 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Page 4336
Ignition Coil: Specifications
Winding Resistance (ohms at 75 degrees F or 24 degrees C)
1982-88 w/TFI (EEC IV): Primary, 0.3-1.0; Secondary, 8000-11,500.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical
Service Bulletins > Page 4337
Ignition Coil: Locations
Component Locations - RH Side of Engine Duraspark II
Component Locations - Top LH Side Of Engine TFI-IV Ignition
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > Customer Interest: > 88209 > Sep > 88 > Engine - No Start or Hard Start Condition
Ignition Control Module: Customer Interest Engine - No Start or Hard Start Condition
^ NO START - ALL EEC IV WITH TFI
^ HARD START - ALL EEC IV WITH TFI
Article No. 88-20-9
FORD: 1987-88 ALL
LINCOLN-MERCURY: 1987-88 ALL
LIGHT TRUCK: 1987-88 ALL
ISSUE: A no start condition or hard start condition may be caused by a poor connection at the thick
film ignition (TFI) module mating connector on the wire harness.
ACTION: Inspect the TFI module to make sure a good connection is present. Refer to the following
procedure for service details.
1. Locate the TFI module. Check it and the mating connector on the wire harness to make sure
they are properly seated and latched.
2. With the engine running, pull on the wire harness at the base of the connector shell. The pull
should be hard enough to draw the wires straight and taut. If any of the above symptoms are
observed or the engine stops running, inspect the wire harness and connector terminals for
damage. Repair or replace the damaged components as necessary.
3. Grasp the connector shell and TFI module. Twist them back and forth. If any of above symptoms
are observed or the engine stops running, remove the TFI module and inspect for terminal blade
mislocation or bending. If the terminal blades are mislocated or bent, replace the TFI module.
4. Inspect the connector shell for the following items.
a. The red retainer clip should be present. If it is missing, install a new retainer clip.
b. The connector seal should be in place and seated to the connector at the latch base. If it is not
properly seated, install and fully seat a new seal.
NOTE: IF THE ABOVE SYMPTOMS ARE STILL PRESENT AFTER COMPLETING THE TSB,
REFER TO THE ENGINE/ EMISSIONS/DIAGNOSIS MANUAL.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty,
Emissions, and Major Component Coverage OPERATION: 882009A TIME: 0.4 Hr. - 1988
Continental, Thunderbird/ Cougar, Taurus/Sable with a 3.8L Engine
0.7 Hr. - 1987-88 Aerostar, Econoline 0.6 Hr. - All Other Vehicles
DLR. CODING: Basic Part No. 12A297 Condition Code: 44
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > Customer Interest: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition
Ignition Control Module: Customer Interest Engine - Stalling and/or A No Start Condition
^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No.
EEC IV VEHICLES 87-6-10
^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES
FORD 1984-87 ALL
LINCOLN-MERCURY 1984-87 ALL
MERKUR 1985-87 XR4Ti
LIGHT TRUCK 1984-87 ALL
ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may
be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI
module housing. This condition will result in a service code 14.
ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and
prevent further concerns.
NOTE: The distributor does not have to be removed to perform this repair.
1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior,
(mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures
and do not perform Steps 2 and 3.
2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper
towel.
3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A).
4. Clear service code 14 from memory.
PART NUMBER PART NAME CLASS
D7AZ-19A331-A Silicone Grease AM
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME:
1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code:
09
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 88209 > Sep > 88 > Engine - No
Start or Hard Start Condition
Ignition Control Module: All Technical Service Bulletins Engine - No Start or Hard Start Condition
^ NO START - ALL EEC IV WITH TFI
^ HARD START - ALL EEC IV WITH TFI
Article No. 88-20-9
FORD: 1987-88 ALL
LINCOLN-MERCURY: 1987-88 ALL
LIGHT TRUCK: 1987-88 ALL
ISSUE: A no start condition or hard start condition may be caused by a poor connection at the thick
film ignition (TFI) module mating connector on the wire harness.
ACTION: Inspect the TFI module to make sure a good connection is present. Refer to the following
procedure for service details.
1. Locate the TFI module. Check it and the mating connector on the wire harness to make sure
they are properly seated and latched.
2. With the engine running, pull on the wire harness at the base of the connector shell. The pull
should be hard enough to draw the wires straight and taut. If any of the above symptoms are
observed or the engine stops running, inspect the wire harness and connector terminals for
damage. Repair or replace the damaged components as necessary.
3. Grasp the connector shell and TFI module. Twist them back and forth. If any of above symptoms
are observed or the engine stops running, remove the TFI module and inspect for terminal blade
mislocation or bending. If the terminal blades are mislocated or bent, replace the TFI module.
4. Inspect the connector shell for the following items.
a. The red retainer clip should be present. If it is missing, install a new retainer clip.
b. The connector seal should be in place and seated to the connector at the latch base. If it is not
properly seated, install and fully seat a new seal.
NOTE: IF THE ABOVE SYMPTOMS ARE STILL PRESENT AFTER COMPLETING THE TSB,
REFER TO THE ENGINE/ EMISSIONS/DIAGNOSIS MANUAL.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty,
Emissions, and Major Component Coverage OPERATION: 882009A TIME: 0.4 Hr. - 1988
Continental, Thunderbird/ Cougar, Taurus/Sable with a 3.8L Engine
0.7 Hr. - 1987-88 Aerostar, Econoline 0.6 Hr. - All Other Vehicles
DLR. CODING: Basic Part No. 12A297 Condition Code: 44
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure
Technical Service Bulletin # 872110 Date: 871021
TFI Module/PIP Sensor - New Diagnostic Procedure
EEC IV - TFI MODULE AND PIP SENSOR - Article No.
NEW DIAGNOSTIC PROCEDURE 87-21-10
FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88
TAURUS
LINCOLN-MERCURY: 1983 MARK VI
1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN
CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES
ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been
developed. This new procedure allows the technician to take a direct path when testing the TFI
module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003).
ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB.
Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose
or broken conditions.
^ Check that the TFI module is securely fastened to the distributor base.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00002.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to a shorting bar type connector used to set base
timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition, refer to Intermittent Diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4359
Functional Schematic
TFI-IV
The TFI-IV system electrical schematic is shown below. For detailed information, refer to the
vehicle wiring diagram.
Ignition Coil Secondary Voltage (Crank Mode)
TFI-IV Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4360
Ignition Coil Secondary Voltage
(Run Mode) TFI-IV Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4361
TFI-IV Part 2
Test 3
Stator - TFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4362
TFI-IV Part 2
Test 4 & 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4363
Stator - TFI-IV TFI-IV Part 2
Test 5
TFI Module
TFI-IV Part 2
Test 6
Ignition Coils - Secondary & Primary Resistance
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4364
Ignition Coil Primary Resistance TFI-IV Part 2
Test 7 & 8
Ignition Coil Secondary
Resistance
TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4365
Part 2
Test 8
EEC-IV - TFI-IV
TFI-IV Part 2
Test 9
Ignition Coil Supply Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4366
TFI-IV Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4367
TFI-IV Part 2
Test 11
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose,
or broken conditions.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4368
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00003.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to shorting bar type connector used to set base timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition refer to Intermittent Diagnosis.
Functional Schematic
TFI-IV
Closed Bowl
Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For
detailed information, refer to the vehicle wiring diagram.
Ignition Coil Secondary Voltage - Crank Mode
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4369
TFI-IV
Closed Bowl
Distributor Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4370
Ignition Coil Secondary
Voltage - Run Mode TFI-IV
Closed Bowl
Distributor Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4371
TFI-IV
Closed Bowl
Distributor Part 2
Test 3
Stator
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4372
TFI-IV
Closed Bowl
Distributor Part 2
Test 4, 5 & 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4373
Stator TFI-IV
Closed Bowl
Distributor Part 2
Test 5
Stator TFI-IV
Closed Bowl
Distributor Part 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4374
Test 6
TFI Module
TFI-IV
Closed Bowl
Distributor Part 2
Test 7
Ignition Coil, Primary & Secondary
Ignition Coil Primary Resistance TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4375
Closed Bowl
Distributor Part 2
Test 8
Ignition Coil Secondary
Resistance
TFI-IV
Closed Bowl
Distributor Part 2
Test 9
EEC IV - Wiring
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4376
TFI-IV
Closed Bowl
Distributor Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4377
TFI IV
Closed Bowl
Distributor Part 2
Test 11
Ignition Coil, TFI & Stator Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4378
Ignition Coil Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 12
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4379
TFI Supply Voltage TFI-IV
Closed Bowl
Distributor Part 2
Test 13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4380
Stator Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 14
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI
Module/PIP Sensor - New Diagnostic Procedure > Page 4381
TFI IV
Closed Bowl
Distributor Part 2
Test 15
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Control Module: > 87610 > Mar > 87 > Engine Stalling and/or A No Start Condition
Ignition Control Module: All Technical Service Bulletins Engine - Stalling and/or A No Start
Condition
^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No.
EEC IV VEHICLES 87-6-10
^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES
FORD 1984-87 ALL
LINCOLN-MERCURY 1984-87 ALL
MERKUR 1985-87 XR4Ti
LIGHT TRUCK 1984-87 ALL
ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may
be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI
module housing. This condition will result in a service code 14.
ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and
prevent further concerns.
NOTE: The distributor does not have to be removed to perform this repair.
1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior,
(mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures
and do not perform Steps 2 and 3.
2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper
towel.
3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A).
4. Clear service code 14 from memory.
PART NUMBER PART NAME CLASS
D7AZ-19A331-A Silicone Grease AM
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME:
1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code:
09
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure
Technical Service Bulletin # 872110 Date: 871021
TFI Module/PIP Sensor - New Diagnostic Procedure
EEC IV - TFI MODULE AND PIP SENSOR - Article No.
NEW DIAGNOSTIC PROCEDURE 87-21-10
FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88
TAURUS
LINCOLN-MERCURY: 1983 MARK VI
1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN
CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES
ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been
developed. This new procedure allows the technician to take a direct path when testing the TFI
module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003).
ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB.
Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose
or broken conditions.
^ Check that the TFI module is securely fastened to the distributor base.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00002.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to a shorting bar type connector used to set base
timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition, refer to Intermittent Diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4391
Functional Schematic
TFI-IV
The TFI-IV system electrical schematic is shown below. For detailed information, refer to the
vehicle wiring diagram.
Ignition Coil Secondary Voltage (Crank Mode)
TFI-IV Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4392
Ignition Coil Secondary Voltage
(Run Mode) TFI-IV Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4393
TFI-IV Part 2
Test 3
Stator - TFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4394
TFI-IV Part 2
Test 4 & 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4395
Stator - TFI-IV TFI-IV Part 2
Test 5
TFI Module
TFI-IV Part 2
Test 6
Ignition Coils - Secondary & Primary Resistance
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4396
Ignition Coil Primary Resistance TFI-IV Part 2
Test 7 & 8
Ignition Coil Secondary
Resistance
TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4397
Part 2
Test 8
EEC-IV - TFI-IV
TFI-IV Part 2
Test 9
Ignition Coil Supply Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4398
TFI-IV Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4399
TFI-IV Part 2
Test 11
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose,
or broken conditions.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4400
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00003.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to shorting bar type connector used to set base timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition refer to Intermittent Diagnosis.
Functional Schematic
TFI-IV
Closed Bowl
Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For
detailed information, refer to the vehicle wiring diagram.
Ignition Coil Secondary Voltage - Crank Mode
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4401
TFI-IV
Closed Bowl
Distributor Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4402
Ignition Coil Secondary
Voltage - Run Mode TFI-IV
Closed Bowl
Distributor Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4403
TFI-IV
Closed Bowl
Distributor Part 2
Test 3
Stator
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4404
TFI-IV
Closed Bowl
Distributor Part 2
Test 4, 5 & 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4405
Stator TFI-IV
Closed Bowl
Distributor Part 2
Test 5
Stator TFI-IV
Closed Bowl
Distributor Part 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4406
Test 6
TFI Module
TFI-IV
Closed Bowl
Distributor Part 2
Test 7
Ignition Coil, Primary & Secondary
Ignition Coil Primary Resistance TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4407
Closed Bowl
Distributor Part 2
Test 8
Ignition Coil Secondary
Resistance
TFI-IV
Closed Bowl
Distributor Part 2
Test 9
EEC IV - Wiring
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4408
TFI-IV
Closed Bowl
Distributor Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4409
TFI IV
Closed Bowl
Distributor Part 2
Test 11
Ignition Coil, TFI & Stator Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4410
Ignition Coil Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 12
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4411
TFI Supply Voltage TFI-IV
Closed Bowl
Distributor Part 2
Test 13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4412
Stator Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 14
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Ignition Control Module: > 872110 > Oct > 87 > TFI Module/PIP
Sensor - New Diagnostic Procedure > Page 4413
TFI IV
Closed Bowl
Distributor Part 2
Test 15
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > Page 4414
Ignition Control Module: Locations
The distributor is located on the top of the engine towards the front, The TFI ignition module is
attached to the distributor base.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > Page 4415
Ignition Control Module: Description and Operation
Typical Ignition System
The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic
pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short
period of time. High voltage is created each time the magnetic field is built up and collapsed. The
red ignition module wire provides operating voltage for the module's electronic components in the
Run mode. The white module wire and start bypass provide increased voltage for the module and
coil during Start mode.
Ignition Modules
Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control
signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the
Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this
second signal, the UIM provides additional spark timing control for certain operating conditions by
shutting off the ignition coil current flow at a different time than with just the distributor pick-up
signal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > Page 4416
Module Identification Chart
For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura
Spark II has 6 wire connector while Dura Spark III has a 5 wire connector.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > Page 4417
Ignition Control Module: Service and Repair
Open Bowl Distributor
1. Remove distributor cap and adapter. Position cap and wires aside.
2. Disconnect TFI wiring.
3. Remove distributor from engine using tool T82L-12270-A or equivalent to remove security-type
hold-down bolt, if equipped.
4. Place distributor on workbench and remove 2 TFI module screws, Fig. 2.
5. Pull right side of module down distributor mounting flange and then back up to disengage
module terminals from connector in distributor base. Module may then be pulled toward flange and
away from distributor. Do not attempt to lift module from mounting surface before moving entire TFI
module toward distributor flange, as pins at distributor/module connector will break otherwise.
6. Coat metal base plate of TFI ignition module with 1/32 inch thick layer of silicone grease
D7AZ-19A331-A, or equivalent.
7. Place TFI module on distributor base mounting flange. Carefully position TFI module assembly
toward distributor bowl and securely engage 3 distributor connector pins.
8. Install 2 TFI module mounting screws and torque to 9---35 inch lbs.
9. Install distributor on engine.
10. Install distributor cap and adapter.
11. Connect TFI wiring.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information >
Technical Service Bulletins > Page 4418
12. Check and, if necessary adjust engine timing according to decal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component
Information > Description and Operation
Ignition Timing Connector: Description and Operation
Fig. 20 Ignition Timing Vacuum Switch
Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition
module to retard spark timing. The switch is closed above the vacuum setting and the ignition
module is in the non-retard spark timing mode. Calibration resistors inside the switch control the
amount of retard.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component
Information > Description and Operation > Page 4422
Ignition Timing Connector: Testing and Inspection
Ignition Timing Vacuum Switch
Ignition Timing Vacuum Switch Test Chart
1. Disconnect switch from ignition module.
2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less
than'' values in the Ignition Timing vacuum Switch Test chart.
3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured
across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart.
4. Replace switch if resistance is not within specifications.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations
Knock Sensor: Locations
LH Side Of V8-302/5.
Top Center Of Engine
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 4426
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information >
Specifications > Electrical Specifications
DISTRIBUTOR PICKUP
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information >
Specifications > Electrical Specifications > Page 4431
DISTRIBUTOR PICKUP
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information >
Specifications > Page 4432
Pick-Up Coil: Testing and Inspection
Procedure
1. Disconnect distributor electrical connector. Inspect connections for dirt or corrosion. 2. Using a
suitable ohmmeter, measure resistance across orange and purple wires in distributor connector. 3.
If readings obtained are within 400---1000 ohms, circuit is satisfactory. If readings are less than 400
or more than 1000 ohms, replace stator
assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 88209 > Sep > 88 > Engine No Start or Hard Start Condition
Ignition Control Module: Customer Interest Engine - No Start or Hard Start Condition
^ NO START - ALL EEC IV WITH TFI
^ HARD START - ALL EEC IV WITH TFI
Article No. 88-20-9
FORD: 1987-88 ALL
LINCOLN-MERCURY: 1987-88 ALL
LIGHT TRUCK: 1987-88 ALL
ISSUE: A no start condition or hard start condition may be caused by a poor connection at the thick
film ignition (TFI) module mating connector on the wire harness.
ACTION: Inspect the TFI module to make sure a good connection is present. Refer to the following
procedure for service details.
1. Locate the TFI module. Check it and the mating connector on the wire harness to make sure
they are properly seated and latched.
2. With the engine running, pull on the wire harness at the base of the connector shell. The pull
should be hard enough to draw the wires straight and taut. If any of the above symptoms are
observed or the engine stops running, inspect the wire harness and connector terminals for
damage. Repair or replace the damaged components as necessary.
3. Grasp the connector shell and TFI module. Twist them back and forth. If any of above symptoms
are observed or the engine stops running, remove the TFI module and inspect for terminal blade
mislocation or bending. If the terminal blades are mislocated or bent, replace the TFI module.
4. Inspect the connector shell for the following items.
a. The red retainer clip should be present. If it is missing, install a new retainer clip.
b. The connector seal should be in place and seated to the connector at the latch base. If it is not
properly seated, install and fully seat a new seal.
NOTE: IF THE ABOVE SYMPTOMS ARE STILL PRESENT AFTER COMPLETING THE TSB,
REFER TO THE ENGINE/ EMISSIONS/DIAGNOSIS MANUAL.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty,
Emissions, and Major Component Coverage OPERATION: 882009A TIME: 0.4 Hr. - 1988
Continental, Thunderbird/ Cougar, Taurus/Sable with a 3.8L Engine
0.7 Hr. - 1987-88 Aerostar, Econoline 0.6 Hr. - All Other Vehicles
DLR. CODING: Basic Part No. 12A297 Condition Code: 44
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 87610 > Mar > 87 > Engine Stalling and/or A No Start Condition
Ignition Control Module: Customer Interest Engine - Stalling and/or A No Start Condition
^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No.
EEC IV VEHICLES 87-6-10
^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES
FORD 1984-87 ALL
LINCOLN-MERCURY 1984-87 ALL
MERKUR 1985-87 XR4Ti
LIGHT TRUCK 1984-87 ALL
ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may
be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI
module housing. This condition will result in a service code 14.
ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and
prevent further concerns.
NOTE: The distributor does not have to be removed to perform this repair.
1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior,
(mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures
and do not perform Steps 2 and 3.
2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper
towel.
3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A).
4. Clear service code 14 from memory.
PART NUMBER PART NAME CLASS
D7AZ-19A331-A Silicone Grease AM
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME:
1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code:
09
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 88209 > Sep > 88 > Engine - No Start or Hard Start Condition
Ignition Control Module: All Technical Service Bulletins Engine - No Start or Hard Start Condition
^ NO START - ALL EEC IV WITH TFI
^ HARD START - ALL EEC IV WITH TFI
Article No. 88-20-9
FORD: 1987-88 ALL
LINCOLN-MERCURY: 1987-88 ALL
LIGHT TRUCK: 1987-88 ALL
ISSUE: A no start condition or hard start condition may be caused by a poor connection at the thick
film ignition (TFI) module mating connector on the wire harness.
ACTION: Inspect the TFI module to make sure a good connection is present. Refer to the following
procedure for service details.
1. Locate the TFI module. Check it and the mating connector on the wire harness to make sure
they are properly seated and latched.
2. With the engine running, pull on the wire harness at the base of the connector shell. The pull
should be hard enough to draw the wires straight and taut. If any of the above symptoms are
observed or the engine stops running, inspect the wire harness and connector terminals for
damage. Repair or replace the damaged components as necessary.
3. Grasp the connector shell and TFI module. Twist them back and forth. If any of above symptoms
are observed or the engine stops running, remove the TFI module and inspect for terminal blade
mislocation or bending. If the terminal blades are mislocated or bent, replace the TFI module.
4. Inspect the connector shell for the following items.
a. The red retainer clip should be present. If it is missing, install a new retainer clip.
b. The connector seal should be in place and seated to the connector at the latch base. If it is not
properly seated, install and fully seat a new seal.
NOTE: IF THE ABOVE SYMPTOMS ARE STILL PRESENT AFTER COMPLETING THE TSB,
REFER TO THE ENGINE/ EMISSIONS/DIAGNOSIS MANUAL.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty,
Emissions, and Major Component Coverage OPERATION: 882009A TIME: 0.4 Hr. - 1988
Continental, Thunderbird/ Cougar, Taurus/Sable with a 3.8L Engine
0.7 Hr. - 1987-88 Aerostar, Econoline 0.6 Hr. - All Other Vehicles
DLR. CODING: Basic Part No. 12A297 Condition Code: 44
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure
Technical Service Bulletin # 872110 Date: 871021
TFI Module/PIP Sensor - New Diagnostic Procedure
EEC IV - TFI MODULE AND PIP SENSOR - Article No.
NEW DIAGNOSTIC PROCEDURE 87-21-10
FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88
TAURUS
LINCOLN-MERCURY: 1983 MARK VI
1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN
CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES
ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been
developed. This new procedure allows the technician to take a direct path when testing the TFI
module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003).
ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB.
Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose
or broken conditions.
^ Check that the TFI module is securely fastened to the distributor base.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00002.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to a shorting bar type connector used to set base
timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition, refer to Intermittent Diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4455
Functional Schematic
TFI-IV
The TFI-IV system electrical schematic is shown below. For detailed information, refer to the
vehicle wiring diagram.
Ignition Coil Secondary Voltage (Crank Mode)
TFI-IV Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4456
Ignition Coil Secondary Voltage
(Run Mode) TFI-IV Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4457
TFI-IV Part 2
Test 3
Stator - TFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4458
TFI-IV Part 2
Test 4 & 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4459
Stator - TFI-IV TFI-IV Part 2
Test 5
TFI Module
TFI-IV Part 2
Test 6
Ignition Coils - Secondary & Primary Resistance
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4460
Ignition Coil Primary Resistance TFI-IV Part 2
Test 7 & 8
Ignition Coil Secondary
Resistance
TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4461
Part 2
Test 8
EEC-IV - TFI-IV
TFI-IV Part 2
Test 9
Ignition Coil Supply Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4462
TFI-IV Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4463
TFI-IV Part 2
Test 11
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose,
or broken conditions.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4464
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00003.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to shorting bar type connector used to set base timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition refer to Intermittent Diagnosis.
Functional Schematic
TFI-IV
Closed Bowl
Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For
detailed information, refer to the vehicle wiring diagram.
Ignition Coil Secondary Voltage - Crank Mode
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4465
TFI-IV
Closed Bowl
Distributor Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4466
Ignition Coil Secondary
Voltage - Run Mode TFI-IV
Closed Bowl
Distributor Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4467
TFI-IV
Closed Bowl
Distributor Part 2
Test 3
Stator
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4468
TFI-IV
Closed Bowl
Distributor Part 2
Test 4, 5 & 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4469
Stator TFI-IV
Closed Bowl
Distributor Part 2
Test 5
Stator TFI-IV
Closed Bowl
Distributor Part 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4470
Test 6
TFI Module
TFI-IV
Closed Bowl
Distributor Part 2
Test 7
Ignition Coil, Primary & Secondary
Ignition Coil Primary Resistance TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4471
Closed Bowl
Distributor Part 2
Test 8
Ignition Coil Secondary
Resistance
TFI-IV
Closed Bowl
Distributor Part 2
Test 9
EEC IV - Wiring
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4472
TFI-IV
Closed Bowl
Distributor Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4473
TFI IV
Closed Bowl
Distributor Part 2
Test 11
Ignition Coil, TFI & Stator Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4474
Ignition Coil Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 12
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4475
TFI Supply Voltage TFI-IV
Closed Bowl
Distributor Part 2
Test 13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4476
Stator Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 14
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4477
TFI IV
Closed Bowl
Distributor Part 2
Test 15
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Control
Module: > 87610 > Mar > 87 > Engine - Stalling and/or A No Start Condition
Ignition Control Module: All Technical Service Bulletins Engine - Stalling and/or A No Start
Condition
^ STALL - THICK FILM IGNITION (TFI) MODULE - Article No.
EEC IV VEHICLES 87-6-10
^ STALL/NO START - THICK FILM IGNITION (TFI) MODULE - EEC IV VEHICLES
FORD 1984-87 ALL
LINCOLN-MERCURY 1984-87 ALL
MERKUR 1985-87 XR4Ti
LIGHT TRUCK 1984-87 ALL
ISSUE: Stalling and/or a no-start condition on vehicles with EEC IV and certain TFI modules may
be caused by moisture or salt splash entering at the upper right hand mounting hole of the TFI
module housing. This condition will result in a service code 14.
ACTION: To correct this, use the following diagnostic and service procedure to seal the hole and
prevent further concerns.
NOTE: The distributor does not have to be removed to perform this repair.
1. Check to see if the TFI-IV module part number suffix is A2A and the date code is 6K08 or prior,
(mounting hole was sealed after 6K08). If the suffix is not A2A, use normal diagnostic procedures
and do not perform Steps 2 and 3.
2. Thoroughly clean and dry upper right hand mounting hole of the TFI module with a clean paper
towel.
3. Fill the cleaned hole with silicone grease (D7AZ-19A331-A).
4. Clear service code 14 from memory.
PART NUMBER PART NAME CLASS
D7AZ-19A331-A Silicone Grease AM
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP870610A TIME:
1.0 Hr. DLR. CODING: Basic Part No. 12A297 - Code:
09
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure
Technical Service Bulletin # 872110 Date: 871021
TFI Module/PIP Sensor - New Diagnostic Procedure
EEC IV - TFI MODULE AND PIP SENSOR - Article No.
NEW DIAGNOSTIC PROCEDURE 87-21-10
FORD: 1983-88 ESCORT/EXP, MUSTANG, THUNDERBIRD, FORD 1984-88 TEMPO 1986-88
TAURUS
LINCOLN-MERCURY: 1983 MARK VI
1983-86 CAPRI 1983-87 LYNX 1983-88 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN
CAR 1984-88 TOPAZ, MARK VII 1986-88 SABLE
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1983-88 ALL LIGHT TRUCK LINES
ISSUE: A new diagnostic procedure for testing the TFI module and PIP sensor has been
developed. This new procedure allows the technician to take a direct path when testing the TFI
module and PIP sensor with the use of the new TFI IV diagnostic tester (Rotunda No. 105-00003).
ACTION: If service is required, use the diagnostic procedures on pages 29 through 60 of this TSB.
Insert these pages in the Engine/Emission Diagnosis Manual, Volume H, Section 15.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose
or broken conditions.
^ Check that the TFI module is securely fastened to the distributor base.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00002.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to a shorting bar type connector used to set base
timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition, refer to Intermittent Diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4487
Functional Schematic
TFI-IV
The TFI-IV system electrical schematic is shown below. For detailed information, refer to the
vehicle wiring diagram.
Ignition Coil Secondary Voltage (Crank Mode)
TFI-IV Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4488
Ignition Coil Secondary Voltage
(Run Mode) TFI-IV Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4489
TFI-IV Part 2
Test 3
Stator - TFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4490
TFI-IV Part 2
Test 4 & 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4491
Stator - TFI-IV TFI-IV Part 2
Test 5
TFI Module
TFI-IV Part 2
Test 6
Ignition Coils - Secondary & Primary Resistance
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4492
Ignition Coil Primary Resistance TFI-IV Part 2
Test 7 & 8
Ignition Coil Secondary
Resistance
TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4493
Part 2
Test 8
EEC-IV - TFI-IV
TFI-IV Part 2
Test 9
Ignition Coil Supply Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4494
TFI-IV Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4495
TFI-IV Part 2
Test 11
Preliminary Checkout, Equipment & Notes
CHECKOUT
^ Visually inspect the engine compartment to ensure all vacuum hoses and spark plug wires are
properly routed and securely connected.
^ Examine all wiring harnesses and connectors for insulation damage, burned, overheated, loose,
or broken conditions.
^ Be certain the battery is fully charged.
^ All accessories should be off during diagnosis.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4496
EQUIPMENT
Obtain the following test equipment or an equivalent:
^ Spark Tester, Special Service Tool D81P-6666-A. See note.
^ Volt/Ohm Meter Rotunda 014-00407.
^ 12 Volt Test Light.
^ Small straight pin.
^ Remote Starter Switch.
^ TFI Ignition Tester, Rotunda 105-00003.
NOTES
^ A spark plug with a broken side electrode is not sufficient to check for spark and may lead to
incorrect results.
^ When instructed to inspect a wiring harness, both a visual inspection and a continuity test should
be performed.
^ When making measurements on a wiring harness or connector, it is good practice to wiggle the
wires while measuring.
^ References to pin-in-line connector apply to shorting bar type connector used to set base timing.
^ This procedure is intended to identify faulty components or wiring while the fault is present. If the
complaint is of an intermittent condition refer to Intermittent Diagnosis.
Functional Schematic
TFI-IV
Closed Bowl
Distributor The TFI-IV Closed Bowl Distributor system electrical schematic is shown below. For
detailed information, refer to the vehicle wiring diagram.
Ignition Coil Secondary Voltage - Crank Mode
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4497
TFI-IV
Closed Bowl
Distributor Part 2
Test 1 & 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4498
Ignition Coil Secondary
Voltage - Run Mode TFI-IV
Closed Bowl
Distributor Part 2
Test 2
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4499
TFI-IV
Closed Bowl
Distributor Part 2
Test 3
Stator
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4500
TFI-IV
Closed Bowl
Distributor Part 2
Test 4, 5 & 6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4501
Stator TFI-IV
Closed Bowl
Distributor Part 2
Test 5
Stator TFI-IV
Closed Bowl
Distributor Part 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4502
Test 6
TFI Module
TFI-IV
Closed Bowl
Distributor Part 2
Test 7
Ignition Coil, Primary & Secondary
Ignition Coil Primary Resistance TFI-IV
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4503
Closed Bowl
Distributor Part 2
Test 8
Ignition Coil Secondary
Resistance
TFI-IV
Closed Bowl
Distributor Part 2
Test 9
EEC IV - Wiring
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4504
TFI-IV
Closed Bowl
Distributor Part 2
Test 10
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4505
TFI IV
Closed Bowl
Distributor Part 2
Test 11
Ignition Coil, TFI & Stator Voltage
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4506
Ignition Coil Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 12
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4507
TFI Supply Voltage TFI-IV
Closed Bowl
Distributor Part 2
Test 13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4508
Stator Supply Voltage TFI IV
Closed Bowl
Distributor Part 2
Test 14
Wiring Harness
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Control
Module: > 872110 > Oct > 87 > TFI Module/PIP Sensor - New Diagnostic Procedure > Page 4509
TFI IV
Closed Bowl
Distributor Part 2
Test 15
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > Page 4510
Ignition Control Module: Locations
The distributor is located on the top of the engine towards the front, The TFI ignition module is
attached to the distributor base.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > Page 4511
Ignition Control Module: Description and Operation
Typical Ignition System
The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic
pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short
period of time. High voltage is created each time the magnetic field is built up and collapsed. The
red ignition module wire provides operating voltage for the module's electronic components in the
Run mode. The white module wire and start bypass provide increased voltage for the module and
coil during Start mode.
Ignition Modules
Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control
signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the
Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this
second signal, the UIM provides additional spark timing control for certain operating conditions by
shutting off the ignition coil current flow at a different time than with just the distributor pick-up
signal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > Page 4512
Module Identification Chart
For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura
Spark II has 6 wire connector while Dura Spark III has a 5 wire connector.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > Page 4513
Ignition Control Module: Service and Repair
Open Bowl Distributor
1. Remove distributor cap and adapter. Position cap and wires aside.
2. Disconnect TFI wiring.
3. Remove distributor from engine using tool T82L-12270-A or equivalent to remove security-type
hold-down bolt, if equipped.
4. Place distributor on workbench and remove 2 TFI module screws, Fig. 2.
5. Pull right side of module down distributor mounting flange and then back up to disengage
module terminals from connector in distributor base. Module may then be pulled toward flange and
away from distributor. Do not attempt to lift module from mounting surface before moving entire TFI
module toward distributor flange, as pins at distributor/module connector will break otherwise.
6. Coat metal base plate of TFI ignition module with 1/32 inch thick layer of silicone grease
D7AZ-19A331-A, or equivalent.
7. Place TFI module on distributor base mounting flange. Carefully position TFI module assembly
toward distributor bowl and securely engage 3 distributor connector pins.
8. Install 2 TFI module mounting screws and torque to 9---35 inch lbs.
9. Install distributor on engine.
10. Install distributor cap and adapter.
11. Connect TFI wiring.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition
Control Module > Component Information > Technical Service Bulletins > Page 4514
12. Check and, if necessary adjust engine timing according to decal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall
Effect Sensor, Ignition > Component Information > Description and Operation
Hall Effect Sensor: Description and Operation
Profile Ignition Pickup
The PIP signal is created in the Hall Effect and Stator assembly and indicates crankshaft position
and engine RPM Fig. 21. The PIP signal is fed to both the TFI module and the ECA.
PIP Sensor
COMPONENTS The Hall Effect device is made up of a voltage regulator, a Hall voltage generator,
Darlington amplifier, Schmitt trigger, and an open collector output stage integrated in a single
monolithic silicon chip Fig. 22. A signal is produced when a ferrous material is passed through the
opening and the flux lines decrease. The Hall generator (Hall device) sends a sine wave signal to
the Darlington amplifier. The Darlington amplifier inverts the signal. When the signal is low the
output is high. When the signal is high the output is low. This output then goes to the Schmitt
trigger. The Schmitt trigger shapes the signal into a square wave (digital high) signal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall
Effect Sensor, Ignition > Component Information > Description and Operation > Page 4519
PIP Signal Operation
OPERATION The output signal to the Darlington amplifier is high when the window (on the
armature) allows the magnetic field to reach the Hall device (switch off) Fig. 23. When the TAB
shunts the magnetic field (closes) away from the Hall device the signal is low to the Darlington
amplifier (switch on).
Hall Effect Sensor
In other words when one of the windows or openings is in the gap between the Hall device and the
permanent magnet, the field stays strong and the voltage is high since the magnetic path is
complete from the magnet, through the Hall device, and back to the magnet. In this case the switch
is off and the Hall Effect does not send a signal. When the TAB enters the gap, the armature cuts
off the magnetic path to the Hall device and its voltage drops. In this case the switch is on and the
Hall Effect device sends a signal. The signal is switched On and Off as long as the armature is
rotating (distributor is turning) and opening and closing the magnetic path. This is the signal used
by the ECA to interpret crankshaft position and engine RPM. The signal can also be used by the
TFI module if the SPOUT signal from the ECA is lost.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall
Effect Sensor, Ignition > Component Information > Description and Operation > Page 4520
Signature PIP
SIGNATURE PIP Some Electronic Engine Control (EEC) vehicles are equipped with a signature
profile ignition pickup signal. The regular type armature used for the PIP signal has the same size
tabs and windows. In a signature PIP signal armature, one of the tabs is narrower than the others
Fig. 25. The narrower tab provides a different signal to the ECA when it passes through the Hall
Effect switch. When the ECA sees the narrow tab it knows when to properly pulse the fuel injectors.
This system is used on cars and trucks where the ECA needs to know when to pulse certain
injectors. For example, on sequential electronic fuel injection (SEFI) systems, each injector is
pulsed to coincide with its intake valve opening. With the signature PIP, the ECA knows when the
No. 1 cylinder needs to be supplied with fuel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall
Effect Sensor, Ignition > Component Information > Description and Operation > Page 4521
Hall Effect Sensor: Service and Repair
Removal Do not attempt to replace stator without an arbor press.
1. Remove distributor. Remove rotor, then the TFI module.
2. If distributor uses push on type rotor, remove two retaining screws holding armature, then the
armature. Hold gear to loosen armature screws, do not hold armature.
3. Mark stator, armature, gear and collar with felt tip pen to aid in reassembly.
4. Remove and discard pins in gear and collar if equipped.
5. Invert distributor and place in Axle Bearing Seal Plate and press off gear using Bearing Removal
Tool.
6. Deburr and polish shaft with emery paper and wipe clean so that shaft slides out freely from
distributor base.
7. Remove shaft assembly, then the thrust washer from shaft. Next remove octane rod.
8. Remove stator assembly screws, then the stator assembly from top of bowl.
9. Inspect base bushing for wear of signs of excess heat concentration, replace distributor
assembly if damaged.
10. Inspect base O-ring for cuts or damage and replace as necessary.
11. Inspect base for cracks and wear, replace distributor assembly if damage is found.
Installation
1. Place stator assembly over bushing and press down to seat.
2. Place stator connector in position, tab should fit in notch on base with fastening eyelets aligned
with screw holes.
3. Install stator screws and Torque to 15-35 inch lbs. Next install octane rod.
4. Install thrust washer on top of bushing, then apply lubricant to distributor shaft below armature.
Do not over lubricate.
5. Insert shaft through base bushing, then place collar, if equipped, over shaft and line up mark on
armature and collar to aid alignment with original drill hole. Use a suitable drift punch to assure
proper alignment.
6. Drill holes through shaft and collar should align on both sides of shaft. If holes do not align, collar
may be 180 degrees out of alignment on shaft. Rotate collar on shaft one half rotation, then check.
7. Insert new roll pin through collar and shaft, pin should be flush with both sides of collar when
seated.
8. If distributor uses push on type rotor, place a 1/2 inch deep well socket over shaft, invert and
place on arbor plate.
9. If distributor uses screw down type rotor, invert and place on arbor plate.
10. Place distributor gear on shaft and line up marks on armature and gear. Hole in shaft and gear
must line up as accurately as possible to assure ease of roll pin insertion.
11. Place a 5/8 inch deep well socket over shaft and gear, then press gear to align with original drill
hole.
12. If gear holes do not align, gear must be removed and repressed on. Drift punch will not align
holes, as in collar, holes should align.
13. Insert new roll pin through gear and shaft, pin should extrude evenly on both sides.
14. Install armature, if removed, and Torque screws to 25-35 inch lbs.
15. Install TFI module, rotor, then distributor.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Doors and Ignition - Lock
Service Tips
Ignition Switch Lock Cylinder: Technical Service Bulletins Doors and Ignition - Lock Service Tips
Article No. 87-24-2
12/04/87
LOCKS - DOORS AND IGNITION - GENERAL LOCK SERVICE TIPS
FORD: 1987-88 ESCORT/EXP, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, CROWN
VICTORIA
LINCOLN-MERCURY: 1987 LYNX 1987-88 TOPAZ, SABLE, COUGAR, GRAND MARQUIS,
MARK VII, CONTINENTAL, LINCOLN TOWN CAR
LIGHT TRUCK: 1987-88 AEROSTAR, RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO
ISSUE: Two types of key systems are used on Ford vehicles. The five (5) bit key system uses one
(1) key to operate the ignition lock and a second to operate the outside door locks. The ten (10) bit
key system uses one (1) key to operate the ignition lock and the outside door locks. The ten (10) bit
key system services the ignition lock as a separate service part so the door locks would not have to
be replaced in the event of an ignition lock failure.
ACTION: If service is required for the five (5) bit key system, the ignition and door locks are
serviced separately. Refer to the appropriate Shop Manual for removal and installation procedures.
If service is required for the ten (10) bit key system, a ten (10) bit ignition lock with partially cut keys
is available. Refer to the following service procedure.
NOTE:
Customers concerned with the heads of the new ten (10) bit ignition service keys not matching the
original keys may be resolved by ordering blank keys from Rotunda. Cut the two (2) blank keys
ordered from Rotunda on tumbler station numbers 1, 2, 3, 4, and 6 to match the new ten (10) bit
ignition service keys supplied with the new service ignition lock.
1. Remove the ignition lock cylinder. Refer to the appropriate Shop Manual.
FIGURE 2
2. Using the Ford Rotunda key code cutting package, tool number 011-00003, measure the depth
of the cut on the number six (6) tumbler station of the original key. Use this measurement to
determine the correct service ignition lock set. Refer to the chart in Figure 2.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Doors and Ignition - Lock
Service Tips > Page 4527
3. Using the original ignition key, decode tumbler station numbers 5, 7, 8, 9, and 10.
4. Cut the new service key on tumbler station numbers 5, 7, 8, 9, and 10.
5. Check the operation of the new service key in the new ignition lock and outside door locks.
6. Install the new service ignition lock.
NOTE:
Retain both the original and new service key tabs for future key code identification.
OTHER APPLICABLE ARTICLES: 86-23-4
WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations
Knock Sensor: Locations
LH Side Of V8-302/5.
Top Center Of Engine
Applicable to: 0L Engine With EFI
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 4531
Knock Sensor: Description and Operation
Knock Sensor
The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed
to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses
the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz).
This method allows relatively large signals to be achieved without electrical amplification. The
sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm.
Electrical connections are made through a two-pin integral connector.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Engine - Lack of Power/No Start Diagnosis
Spark Plug: Technical Service Bulletins Engine - Lack of Power/No Start Diagnosis
Article No. 91-12-11
06/12/91
LACK OF POWER 7.5L, 5.8L, 5.0L, 4.9L - CATALYTIC CONVERTER DIAGNOSTIC TIPS
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES 1988-91 F SUPER DUTY,
F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused
by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually
caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and
Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the
following procedures for service details.
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition,
which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any
codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182,
183 AND 565 ARE RECEIVED, CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
^ Ignition Coil
^ Distributor Cap
^ Distributor Rotor
^ Fouled Spark Plug
^ Spark Plug Wires
^ Air Filter
^ Stuck Open Injector
^ Fuel Contamination Engine OIL
^ Manifold Leaks Intake/ Exhaust
^ Fuel Pressure
^ Poor Power Ground
^ Engine Not At Normal Operating Temperature
^ HEGO Sensor
2. Spark timing that is retarded from specification may increase exhaust gas temperature and
shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the
specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20~ BTDC +/- 3~.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary
ignition misfire.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4536
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS
BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which
could cause higher than normal catalyst temperatures. Refer to the following procedure for service
details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures
between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to
40 PSI +/- 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER,
THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause
excessive catalyst temperatures during downhill grades. Refer to the following procedure for
service details.
a. Visually inspect the throttle body and linkage for:
^ Binding or sticking throttle linkage.
^ Tight speed control linkage or cable.
^ Vacuum line interference.
^ Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED
WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE
RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate
properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires
are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or
broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump
thermactor air to the atmosphere properly or at the correct time can cause high catalyst
temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on
following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform 0.5 Hrs.
KOEO And KOER Self Tests
911211B Timing - Check Or Adjust 0.5 Hrs.
Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine
Analyzer.
911211C Check - Fuel Pressure And 0.2 Hrs.
Inspect Vacuum Line For Raw Fuel.
911211D Inspect - Throttle Body And 0.1 Hrs.
Linkage.
911211E Inspect - Vacuum Hoses, 0.1 Hrs.
Electrical Harnesses,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Engine - Lack of Power/No Start Diagnosis > Page 4537
Connectors And Spark Plug Wires For Routing Damage.
911211F Thermactor System - 0.3 Hrs.
Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control
Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter.
911211G Thermostat - Check For 0.2 Hrs.
Proper Operation.
DEALER CODING
BASIC PART NO. CONDITION CODE
5E212 25
OASIS CODES: 403000, 603300, 614000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical
Service Bulletins > Page 4538
Spark Plug: Specifications
Spark Plugs 5-10 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Powertrain Management > Ignition System > Vacuum Restrictor > Component Information >
Description and Operation
Vacuum Restrictor: Description and Operation
Fig. 38 Vacuum restrictor
The orifice type flow restrictor, Fig. 38, is used on some systems to control the flow rate and or
timing characteristics to the following systems.
a. EGR valve timing (opening and closing). b. Part throttle spark advance. c. Purge system. d.
Thermactor system.
The flow rate through the restrictor is the same in both directions. If blocked, it should be replaced.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Technical Service Bulletins > A/T - AOD New Overdrive Band Anchor Pin
Band: Technical Service Bulletins A/T - AOD New Overdrive Band Anchor Pin
Article No. TRANSMISSION - AUTOMATIC OVERDRIVE
87-22-13 (AOD) - NEW OVERDRIVE BAND ANCHOR PIN - VEHICLES BUILT BEFORE 09/30/86
FORD: 1980-87 MUSTANG, THUNDERBIRD, FORD
LINCOLN-MERCURY: 1980-83 MARK VI 1980-87 COUGAR, MERCURY, CONTINENTAL,
LINCOLN TOWN CAR
LIGHT TRUCK: 1980-87 E SERIES, F SERIES, BRONCO
ISSUE: A new overdrive band anchor pin, with a stepped diameter, is available for service. The old
pin may have caused overdrive band wear or anchor pin leakage on vehicles built before 09/30/86.
NOTE: AOD transmissions built after 09/30/86 have the new design overdrive band anchor pin.
This pin is NOT serviceable on transmissions built after 09/30/86. If replacement is required, a new
transmission case must be installed.
Figure 10
ACTION: If service is required, use the appropriate Car or Light Truck Shop Manual, Section 17-20,
for installation of the new overdrive band anchor pin, Figure 10.
PART NUMBER PART NAME CLASS
E2AZ-7F295-A Anchor Pin C
E0AZ-19554-BA Ford Stud and B
Bearing Mount
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component
Information > Technical Service Bulletins > Page 4548
Band: Adjustments
INTERMEDIATE BAND ADJUSTMENT
NOTE: When making the intermediate band adjustment, the locknut must be discarded and a new
one installed each time the band is adjusted. Refer to service bulletins section for additional
information on this procedure.
1. Clean dirt from the band adjusting screw. Remove and discard locknut. 2. Install a new locknut
and tighten the adjusting screw to 14 Nm (10 ft lbs). 3. Back the screw off exactly 1.5 turns. 4. Hold
the adjusting screw from turning and torque the locknut to 48-61 Nm(35-40 ft lbs).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component
Information > Technical Service Bulletins > A/T - AOD Case Thread Update
Case: Technical Service Bulletins A/T - AOD Case Thread Update
TRANSMISSION - AOD - CASE BOLT HOLE SIZE CHANGE
Article No. 89-9-12
FORD: 1986-88 CROWN VICTORIA 1986 LTD 1986-88 MUSTANG, THUNDERBIRD
LINCOLN-MERCURY: 1986 CAPRI 1986-87 CONTINENTAL 1986-88 COUGAR, GRAND
MARQUIS, MARK VII 1986 MARQUIS 1986-88 TOWN CAR
LIGHT TRUCK: 1986-88 BRONCO, ECONOLINE, F-150, F-250, F-350
ISSUE: The 1989 model year "AOD" transmission case threads are different from prior model year
cases. Prior model year transmission cases use a 5/16"-18 thread. 1989 model year transmission
cases use a M10-1.5 thread. The larger M10-1.5 bolts will not pass through the prior model year
converter plate, transmission brace or engine cover plate.
FIGURE 1
ACTION: If a transmission case replacement is required on a past model vehicle, the bolt holes for
the car's transmission brace and converter cover plate will need to be enlarged with a 1/2" drill. On
light trucks, enlarge the converter cover plate and engine cover plate with a 1/2" drill. Refer to
Figure 1 for the bolt hole locations.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
5800
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > A/T - Mercon V ATF Usage
Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage
TSB 06-14-4
07/24/06
MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID.
FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993
Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996
Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996
Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004
Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650,
F-750
LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator
2002-2003 Blackwood
MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer
1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner
MERKUR: 1985-1989 XR4TI
This article supersedes TSB 01-15-7 to update the vehicle application chart.
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a
service fluid.
ACTION Beginning immediately all automatic transmission / transaxle applications requiring
MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission
Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R)
Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will
only continue for however long it takes to deplete what remains in inventory.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 4557
Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R)
Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V
For proper fluid application on current and past model vehicles equipped with automatic
transmissions I transaxles refer to the fluid usage chart. (Figure 1)
CAUTION
AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL
ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 4558
CAUTION
MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND
MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS
RECOMMENDING THAT PARTICULAR FLUID.
USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION
DAMAGE.
CAUTION
THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY
DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS).
USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE
TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE
FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE.
CAUTION
DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES,
TREATMENTS OR CLEANING AGENTS.
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 4559
Fluid - A/T: Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid
TRANSMISSION - AUTOMATIC/MANUAL - Article No.
NEW FLUID AND USAGE CHART 87-18-14
FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS,
THUNDERBIRD, FORD
LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior
TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II,
AEROSTAR
ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart),
(XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON"
transmission fluid, where specified, will improve cold weather shift effort and synchronized
operation.
ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic
transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles.
NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual
transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the
transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent.
PART NUMBER PART NAME CLASS
XT-2-QDX MERCON - Quart V
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 4560
XT-2-DDX MERCON - 55 Gallon V
Drum
E5RY-19C547-A Semi-Synthetic Oil B
OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS:
"INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Refill Capacity
Fluid - A/T: Specifications
TYPE MA
CAPACITY, Initial Refill*: C-6 5.0 qt (US)
With the engine at operating temperature, shift
transmission through all gears. Check fluid level in PARK
and add fluid as needed
Others 3.0 qt (US)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Refill Capacity > Page 4563
Fluid - A/T: Specifications
Fluid Capacity Note: C6 units, 11.8 qts.; automatic overdrive units, 12
qts. Approximate. Make final check with dipstick.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines
Technical Service Bulletin # 962612 Date: 961216
Torque Converter - Cleaning and Replacement Guidelines
Article No. 96-26-12
12/16/96
^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE
CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP
^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE
CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP
FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT,
MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97
ASPIRE 1995-97 CONTOUR
LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94
TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE
1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE
MERKUR: 1985-89 XR4TI 1988-90 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350
SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97
VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER
ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle)
cooling-system cleaning procedures are now available to reduce repeat repairs.
ACTION: Refer to the following guideline to properly diagnose and service torque converters and to
properly clean the torque converter and transmission cooling system using forward
flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year
Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page
4568
OASIS CODES: 501000, 502000, 503000, 504000
Diagnostic Procedure
Prior to torque converter replacement, all diagnostic procedures must be followed. This is to
prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic
evaluation can the decision be made to replace the torque converter.
The normal diagnostic procedure is as follows:
1. Preliminary inspection.
2. Know and understand the customers concern.
3. Verify the concern:
- Perform the Torque Converter Clutch Operation Test
4. Perform diagnostic procedures:
a. Run On-Board Diagnostics
- Repair all non-transmission-related Diagnostic
Trouble Codes (DTCs) first.
- Repair all transmission DTCs.
- Rerun On-Board Diagnostic to verify repair.
b. Perform Line Pressure Test
c. Perform Stall Speed Test
d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best
describes the symptom(s). The routine will list all possible components that may cause or
contribute to the symptom. Check each component listed, diagnose and service as required, before
servicing the torque converter.
Replacement
The torque converter must be replaced if one or more of the following statements are true:
^ A torque converter malfunction has been determined based on completed diagnostic procedures
^ A converter stud(s), impeller hub or bushing is damaged
^ If there is discoloration of the torque converter (due to overheating)
^ The torque converter is found to be out of specification when performing the following checks (as
applicable):
1. Torque Converter One-way Clutch Check
2. End Play Check
3. Stator-to-Turbine Interference Check
4. Converter Leakage Check
5. Stator-to-Impeller Interference Check
^ If there is evidence of transmission assembly or fluid contamination due to the following failure
modes:
Torque converter Replacement Policy Failure Modes Major metallic failure
Multiple clutches or clutch plate failures
Sufficient component wear which results in metallic contamination
Torque Converter & Transmission Cooling System Cleaning
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page
4569
When the torque converter is replaced, the following actions must take place:
1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual
procedure.
2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing
using Service Manual procedure.
3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using
Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV.
Replace CBV if damaged or plugged.
4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow
Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only
factory approved service parts.
If the torque converter is not being replaced, the following actions must take place:
1. The torque convener must be thoroughly cleaned:
a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner
Follow the instructions included with the equipment.
b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using
clean transmission fluid (as recommended for the particular transmission). Hand agitate the
converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission,
and reinstall.
2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual
procedure.
3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing
using Service Manual procedure.
4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using
Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV.
Replace CBV if damaged or plugged.
5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow
Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only
factory approved service parts.
Required Tools
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure
Torque Converter: Technical Service Bulletins A/T Torque Converter - Leak Test Procedure
Article No. 96-24-9
11/18/96
TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP
FORD: 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD
1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR
LINCOLN-MERCURY: 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR,
GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1991-94 CAPRI 1991-97 TRACER 1993-97
MARK VIII 1995-97 MYSTIQUE
LIGHT TRUCK: 1984-90 BRONCO II 1984-96 BRONCO 1984-97 ECONOLINE, F-150-350
SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97
VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER
ISSUE: A new torque converter leak test tool has been released. The current leak test tool has
been discontinued by the manufacturer. The new tool will be available to all dealers in 1997.
ACTION: When using the new leak test tool, a new procedure must be followed. Refer to the
following Service Procedure and/or the 1997 Service/Workshop Manuals when using the new leak
test tool.
NEW TOOL NUMBER
Description Tool Number
Torque converter Leak Test Tool and Gasket 014-R1075
SERVICE PROCEDURE
1. Clean the outside surface of the torque converter.
CAUTION:
BE CAREFUL NOT TO DAMAGE THE CONVERTER HUB FINISH WHEN INSTALLING THE
TOOL.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4574
2. Install the Torque Converter Leak Test Tool and Gasket (O14-R1075) into the converter hub.
Figure 1.
WARNING:
ALWAYS USE PROPER SAFETY PROCEDURES WHILE USING PRESS.
CAUTION:
DO NOT DAMAGE THE CONVERTER BY APPLYING EXCESSIVE FORCE FROM THE PRESS.
USE ONLY ENOUGH FORCE TO SEAL TOOL INTO THE CONVERTER.
3. Place the torque converter with the tool installed into press and apply enough force to seal tool
into the converter. Figure 2.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4575
4. Using clean, dry shop air only, apply air pressure of 552 kPa (80 psi) maximum to the valve on
the tool. Refer to Figure 3.
5. With air pressure applied to the valve, inspect for any air leaks at the studs, seams and pilot hub.
A soap bubble solution may be applied around those areas to aid in diagnosis. If any leaks are
present, replace the converter.
6. Disconnect the air line and release the air pressure from the tool by pulling on the release ring
and then slowly releasing the press. Refer to Figure 4.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4576
7. Turn the torque converter and tool upside down and reinstall into the press. Repeat Steps 2-6 to
check for leaks on the opposite side. Refer to Figure 5.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 501000, 502000, 504000, 510000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4577
Technical Service Bulletin # 962612 Date: 961216
Torque Converter - Cleaning and Replacement Guidelines
Article No. 96-26-12
12/16/96
^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE
CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP
^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE
CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP
FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT,
MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97
ASPIRE 1995-97 CONTOUR
LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94
TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE
1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE
MERKUR: 1985-89 XR4TI 1988-90 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350
SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97
VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER
ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle)
cooling-system cleaning procedures are now available to reduce repeat repairs.
ACTION: Refer to the following guideline to properly diagnose and service torque converters and to
properly clean the torque converter and transmission cooling system using forward
flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year
Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4578
OASIS CODES: 501000, 502000, 503000, 504000
Diagnostic Procedure
Prior to torque converter replacement, all diagnostic procedures must be followed. This is to
prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic
evaluation can the decision be made to replace the torque converter.
The normal diagnostic procedure is as follows:
1. Preliminary inspection.
2. Know and understand the customers concern.
3. Verify the concern:
- Perform the Torque Converter Clutch Operation Test
4. Perform diagnostic procedures:
a. Run On-Board Diagnostics
- Repair all non-transmission-related Diagnostic
Trouble Codes (DTCs) first.
- Repair all transmission DTCs.
- Rerun On-Board Diagnostic to verify repair.
b. Perform Line Pressure Test
c. Perform Stall Speed Test
d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best
describes the symptom(s). The routine will list all possible components that may cause or
contribute to the symptom. Check each component listed, diagnose and service as required, before
servicing the torque converter.
Replacement
The torque converter must be replaced if one or more of the following statements are true:
^ A torque converter malfunction has been determined based on completed diagnostic procedures
^ A converter stud(s), impeller hub or bushing is damaged
^ If there is discoloration of the torque converter (due to overheating)
^ The torque converter is found to be out of specification when performing the following checks (as
applicable):
1. Torque Converter One-way Clutch Check
2. End Play Check
3. Stator-to-Turbine Interference Check
4. Converter Leakage Check
5. Stator-to-Impeller Interference Check
^ If there is evidence of transmission assembly or fluid contamination due to the following failure
modes:
Torque converter Replacement Policy Failure Modes Major metallic failure
Multiple clutches or clutch plate failures
Sufficient component wear which results in metallic contamination
Torque Converter & Transmission Cooling System Cleaning
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4579
When the torque converter is replaced, the following actions must take place:
1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual
procedure.
2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing
using Service Manual procedure.
3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using
Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV.
Replace CBV if damaged or plugged.
4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow
Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only
factory approved service parts.
If the torque converter is not being replaced, the following actions must take place:
1. The torque convener must be thoroughly cleaned:
a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner
Follow the instructions included with the equipment.
b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using
clean transmission fluid (as recommended for the particular transmission). Hand agitate the
converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission,
and reinstall.
2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual
procedure.
3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing
using Service Manual procedure.
4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using
Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV.
Replace CBV if damaged or plugged.
5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow
Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only
factory approved service parts.
Required Tools
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines
Technical Service Bulletin # 962612 Date: 961216
Torque Converter - Cleaning and Replacement Guidelines
Article No. 96-26-12
12/16/96
^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE
CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP
^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE
CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP
FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT,
MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97
ASPIRE 1995-97 CONTOUR
LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94
TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE
1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE
MERKUR: 1985-89 XR4TI 1988-90 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350
SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97
VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER
ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle)
cooling-system cleaning procedures are now available to reduce repeat repairs.
ACTION: Refer to the following guideline to properly diagnose and service torque converters and to
properly clean the torque converter and transmission cooling system using forward
flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year
Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page
4584
OASIS CODES: 501000, 502000, 503000, 504000
Diagnostic Procedure
Prior to torque converter replacement, all diagnostic procedures must be followed. This is to
prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic
evaluation can the decision be made to replace the torque converter.
The normal diagnostic procedure is as follows:
1. Preliminary inspection.
2. Know and understand the customers concern.
3. Verify the concern:
- Perform the Torque Converter Clutch Operation Test
4. Perform diagnostic procedures:
a. Run On-Board Diagnostics
- Repair all non-transmission-related Diagnostic
Trouble Codes (DTCs) first.
- Repair all transmission DTCs.
- Rerun On-Board Diagnostic to verify repair.
b. Perform Line Pressure Test
c. Perform Stall Speed Test
d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best
describes the symptom(s). The routine will list all possible components that may cause or
contribute to the symptom. Check each component listed, diagnose and service as required, before
servicing the torque converter.
Replacement
The torque converter must be replaced if one or more of the following statements are true:
^ A torque converter malfunction has been determined based on completed diagnostic procedures
^ A converter stud(s), impeller hub or bushing is damaged
^ If there is discoloration of the torque converter (due to overheating)
^ The torque converter is found to be out of specification when performing the following checks (as
applicable):
1. Torque Converter One-way Clutch Check
2. End Play Check
3. Stator-to-Turbine Interference Check
4. Converter Leakage Check
5. Stator-to-Impeller Interference Check
^ If there is evidence of transmission assembly or fluid contamination due to the following failure
modes:
Torque converter Replacement Policy Failure Modes Major metallic failure
Multiple clutches or clutch plate failures
Sufficient component wear which results in metallic contamination
Torque Converter & Transmission Cooling System Cleaning
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page
4585
When the torque converter is replaced, the following actions must take place:
1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual
procedure.
2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing
using Service Manual procedure.
3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using
Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV.
Replace CBV if damaged or plugged.
4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow
Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only
factory approved service parts.
If the torque converter is not being replaced, the following actions must take place:
1. The torque convener must be thoroughly cleaned:
a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner
Follow the instructions included with the equipment.
b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using
clean transmission fluid (as recommended for the particular transmission). Hand agitate the
converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission,
and reinstall.
2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual
procedure.
3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing
using Service Manual procedure.
4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using
Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV.
Replace CBV if damaged or plugged.
5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow
Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only
factory approved service parts.
Required Tools
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T - AOD Separator Plate Gasket Changes
Valve Body: Technical Service Bulletins A/T - AOD Separator Plate Gasket Changes
TRANSMISSION - AOD - MAIN CONTROL GASKET CHANGES AFFECTING USAGE OF
SERVICE KITS Article No. 89-23-7 FORD:
1980-90 CROWN VICTORIA 1980-86 LTD 1980-90 THUNDERBIRD 1985-90 MUSTANG
LINCOLN-MERCURY: 1980-87 CONTINENTAL 1980-90 COUGAR, GRAND MARQUIS 1980-83
MARK VI 1980-90 TOWN CAR 1984-90 MARK VII 1985 CAPRI, MARQUIS
LIGHT TRUCK: 1981-90 BRONCO, ECONOLINE, F-150, F-250
ISSUE: The separator plate lower gasket from the current gasket service kit (7153) and overhaul
service kit (7C391) cannot be used on any 1990 model vehicles.
ACTION: When servicing 1990 AOD transmissions the separator plate lower gasket found in the
current kits must be thrown away and replaced with a new gasket (F0AZ-7D100-A). This new
gasket can only be used on 1990 vehicles.
CAUTION: USE OF THE SEPARATOR PLATE LOWER GASKET CONTAINED IN THE
CURRENT KITS ON 1990 VEHICLES COULD
CAUSE A REDUCTION IN THROTTLE VALVE PRESSURE. THIS CAN RESULT IN POSSIBLE
TRANSMISSION FAILURES.
In the near future, gasket and overhaul kits will no longer contain any main control gaskets. Two
main control lower separator plate gasket items will be available. Refer to the following gasket
application chart for correct service part usage.
PART NUMBER PART NAME CLASS
E9AZ-7D100-B Main Control Gasket Kit B
FOAZ-7D100-A Separator Plate Lower Gasket B
E9SZ-7C155-A Main Control Upper Separator B
Plate Gasket
OTHER APPLICABLE ARTICLES: none
SUPERSEDES: 88-13-6
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 5100, 5101, 5102, 5200, 5300, 5500, 5800
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > A/T - AOD Separator Plate Gasket Changes > Page 4590
Valve Body: Technical Service Bulletins Main Control Assembly - Special Attaching Bolts
TRANSMISSION - AOD - MAIN CONTROL Article No.
ASSEMBLY - SPECIAL ATTACHING BOLTS 87-10-14
SERVICE TIP
FORD: 1987 MUSTANG, THUNDERBIRD, FORD
LINCOLN-MERCURY: 1987 COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN
CAR
LIGHT TRUCK: 1987 E SERIES, F SERIES, BRONCO
Figure 15 - Article 87-10-14
ISSUE: Two (2) special shoulder bolts are used to align and attach the main control assembly
(valve body) to the transmission case.
ACTION: When servicing the main control assembly, the two (2) shoulder bolts must be reinstalled
ONLY at the same locations, Figure 15. Installing these bolts at other locations could damage the
main control assembly casting and/or cause a mis-alignment of the main control to transmission
case.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information >
Description and Operation
Clutch Disc: Description and Operation
DESCRIPTION AND OPERATION
The purpose of the clutch is to connect and disconnect a manually operated transmission and the
remainder of the power-transmission system from the engine. This permits starting and stopping
the vehicle, shifting and changing speeds that correspond to the engine speed through gear
reductions for both forward and reverse directions.
The clutch consists of a driven plate (clutch disc) splined for the input shaft of the transmission and
the clutch housing (pressure plate).
This forms a continuous system by which rotation of the engine is connected to the transmission by
solid member when engaged (clutch assembly). For power at the output shaft of the transmission
or rear wheel rotation (forward or reverse), the driven plate is a metal disc, faced on both sides with
woven friction materials. The pressure plate is a metal member bolted on the flywheel which
houses the driven plate held in position by the transmission input shaft. A clutch sleeve mounted
over the input shaft of the transmission carries a release bearing that is pressed against the fingers
of the clutch that pushes it away from the driven plate causing disengagement-breaking the
connection between the engine (flywheel) and the clutch. Reverse action or the release of the
bearing engages the clutch. The release lever is actuated by a hydraulic system. Other internal
clutch parts are a pilot bearing mounted in the crankshaft which supports the end of the input shaft.
Bearings are designed for long life and require no lubrication.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information >
Adjustments
Clutch Pedal Assembly: Adjustments
No clutch linkage or pedal travel adjustments are required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information >
Locations
Clutch Switch: Locations
LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information >
Locations > Page 4601
Clutch Switch: Testing and Inspection
Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized
tools near this switch.
1. If the switch is open when the clutch pedal is released, speed control will not operate. This must
be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher
when performing the clutch switch test.
2. Disconnect switch pigtail connector from speed control harness connector and connect an
ohmmeter to the two switch connector terminals.
3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With
clutch pedal fully depressed, the circuit should be open.
4. If switch does not function as described, remove and replace switch.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings >
Component Information > Testing and Inspection > Bearing Cups
Carrier Bearings: Testing and Inspection Bearing Cups
Check bearing cups for rings, spalling, galling or erratic wear patterns. The bearing cups must be
solidly seated. Check by attempting to insert .0015 inch feeler gauge between cups and bottoms of
bores.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings >
Component Information > Testing and Inspection > Bearing Cups > Page 4608
Carrier Bearings: Testing and Inspection Cone & Roller Assemblies
When operated in the cups, the cone and roller assemblies must turn without any roughness.
Examine roller ends for wear.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings >
Component Information > Testing and Inspection > Bearing Cups > Page 4609
Carrier Bearings: Testing and Inspection Differential Bearing Adjusters
Test fit of bearing adjusters in their threads with bearing caps installed. Ensure that bearing caps
are on sides that they were machined to fit. The faces of the adjusters that contact the bearing
cups must be smooth and square. Examine threads in carrier if their fit is not proper and replace
any adjuster with a damaged face or threads.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears >
Component Information > Testing and Inspection
Carrier Side Gears: Testing and Inspection
Examine drive pinion and ring gear teeth for scoring or signs of excessive wear. Worn gears cannot
be rebuilt to correct a noisy condition. Gear scoring and flaking are the result of excessive shock
loading or the use of improper lubricant. Scored gears cannot be reused.
Examine teeth and thrust surfaces of differential gears. Wear on hub of differential side gears may
cause a chucking noise known as chuckle, when the vehicle is operated at low speeds. Wear of
splines, thrust surfaces or thrust washers may contribute to excessive drive line backlash.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Testing and Inspection
Differential Case: Testing and Inspection
Ensure that hubs where bearings mount are smooth. Check fit of differential gears in the
counterbores. Carefully examine thrust washers, which may be damaged when bearings are
removed. If differential bearing assemblies do not seat firmly on hubs, failure is certain. Ensure that
mating surfaces of the two parts of case and the face of the ring gear attaching flange are smooth
and free from nicks and burrs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Testing and Inspection > Page 4616
Differential Case: Adjustments
1. Attach ring gear to the differential case using new bolts. Torque bolts alternately and evenly to
50---60 ft. lbs. on except model 60 monobeam axle or 100-120 ft. lbs on model 60 monobeam axle.
2. Clean trunnions on the differential and install the master differential bearings on to differential
case. Remove all burrs and nicks from hubs so master bearings rotate freely.
3. Place differential case into carrier (without pinion). The differential case should move freely in the
carrier assembly. Position a suitable dial indicator against differential case flanges. Locate tip of the
indicator on the flat surface of one ring gear bolt. Force the differential case toward the dial
indicator as far as possible and zero dial indicator with force still applied. Dial indicator should have
a minimum of .200 inch travel. Force differential case away from the dial indicator as far as it will
go. Repeat this procedure until the same reading is obtained. Record dial indicator reading. This
reading indicates the amount of shims needed behind the differential side bearings to take up total
clearance between the differential bearing and case. This reading will be used during pinion and
ring gear backlash adjustment.
4. Remove differential case from the carrier. Do not remove the master differential bearings at this
time.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Testing and Inspection > Page 4617
Differential Case: Service and Repair
For limited slip & locking differential assemblies, refer to ``Ford Drive Axle w/Integral Carrier''
section for assembly procedures. For adjustment procedures on these differentials, refer to step 9
in this procedure.
1. Install differential case in a vise, then apply suitable lubricant to side gear thrust washers and to
hubs and thrust face of the new side gears.
2. Assemble both side gears and apply suitable lubricant to the spherical washers and pinion mate
gears, then assemble pinion mate gears and washers.
3. Install both side gears and thrust washers, then the pinion mate gears and washers to hold side
gears in position.
4. Rotate side gears until holes of washers and pinion gears line up with holes of the case. If gears
cannot be rotated by hand, install one of the axle shafts into the side gear spline and use a pipe
wrench to turn shaft.
5. Line up gear holes with those of the differential case using a suitable drift, then install pinion
mate shaft. Ensure lock pin hole of shaft is lined up with lock pin hole of case.
6. Install lock pin, then peen metal of case over pin to lock in position. The semi-float shaft riding
bearing design uses a locking pin that is
installed using a suitable wrench. Use a new lock pin and assemble finger tight. This prevents
differential side gears and differential pinion mate gears from rotating in the case and dropping out
when servicing the carrier section. A new lock pin should be installed after assembling the axle
shafts.
7. Install ring gear to case, then the ring gear attaching screws. Torque ring gear attaching screws
alternately to approximately 115 ft. lbs. on except model 30 axle or 45---60 ft. lbs on model 30 axle.
8. Install differential bearings onto case using suitable tool.
9. Install differential case assembly into carrier, less pinion, then mount suitable dial indicator on
face of housing.
10. Locate tip of indicator on flat surface of one of the ring gear screw spot faces, then force
differential assembly as far as possible in the direction towards the indicator. With force still
applied, set indicator at zero.
11. Force differential assembly as far as it will go in the opposite direction. Repeat this step until
the same reading is obtained, then record this reading.
This reading will be the total amount of shims required, less preload, and will be calculated later
during assembly.
12. Remove indicator and differential assembly from housing. Do not remove bearings from
differential case at this time.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly
Differential Axle Housing: Service and Repair Dana/Spicer Integral - Rear Axle Assembly
1. Raise vehicle from floor and support with stand jacks under frame side rails.
2. Remove rear wheels.
3. Split rear universal joint.
4. Disconnect parking brake cable from equalizer rod and unfasten brake cable brackets from
frame crossmember.
5. Disconnect hydraulic brake line connection at rear axle housing.
6. Loosen and move shock absorbers out of the way.
7. While supporting axle housing with hydraulic jack, remove spring clips and lower axle assembly
to the floor.
8. Reverse the foregoing procedure to install the rear axle assembly, being sure to bleed the brake
system when the installation is completed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4622
Differential Axle Housing: Service and Repair Ford Integral Carrier
Axle Disassembly, Ford Integral Carrier
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4623
Fig. 1 Disassembled view of Ford 6 3/4 inch ring gear axle
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4624
Fig. 2 Disassembled view of Ford 7 1/2 inch ring gear axle
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4625
Fig. 3 Exploded view of 8.8 & 10.25 inch ring gear axles (except models w/anti-lock brakes). 8.8
inch ring gear axle shown, 10.25 inch ring gear axle similar
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4626
Fig. 4 Exploded view of 8.8 inch ring gear axles. Models w/anti-lock brakes
1. Remove axle cover, Figs. 1 through 4, then wipe lubricant from internal working parts and
visually inspect parts for wear or damage.
2. Rotate gears to check for any roughness, which indicates damaged bearings or gears.
3. Check ring gear teeth for signs of scoring, abnormal wear, nicks or chips.
4. On models with 8.8 or 10.25 inch ring gear, proceed as follows:
a. Using dial indicator, check ring gear backlash and ring gear back face runout. Backlash should
be .008---.015 inch and back face runout
should be under .004 inch.
b. Do not use contact pattern as a guide to check for noise. Check for proper gear set assembly
using pinion depth gauge tool to determine
correct pinion shim required to ensure acceptable running condition.
5. On models with 6 3/4 or 7 1/2 inch ring gear, test ring gear runout as follows:
a. Install suitable dial indicator and zero indicator, then rotate ring gear and record reading. b. If
reading exceeds .003 inch, check for improper torque of ring gear bolts or dirt between ring and
case.
6. If reading still exceeds .003 inch after step 5b, diagnose ring gear runout as follows:
a. Remove ring gear. 1987 Bronco II models with anti-lock brakes use an exciter ring located on
the ring gear assembly. Removal of the exciter
ring is not necessary when removing ring gear on this model.
b. On models with 6 3/4 inch ring gear, install left case on right and tap them together, then place
differential cups on differential bearing cone
and roller.
c. On all models, place differential assembly in carrier casting. On models with 6 3/4 inch ring gear,
two bolts and nuts must be installed to
hold case halves together.
d. Install .265 inch shim on left side as guide. e. Install left bearing cap and tighten bolts finger tight.
f.
Install progressively larger shims on right side until largest shim selected can be assembled with a
slight drag feel. Apply pressure toward left side to ensure that bearing cup is seated.
g. Install right side bearing cap and torque differential bearing cap bolts to 70---80 ft. lbs., then
rotate assembly to ensure free rotation. h. Check runout of differential case flange with dial
indicator. If runout is within .003 inch, install new ring and pinion gear. If runout exceeds
specifications, trouble is due to either a damaged case or worn bearings.
i. Remove differential case from carrier and the differential bearings from case.
j. Install new differential bearings on case hubs and install differential assembly in carrier less ring
gear.
k. Check case runout. If runout is within .003 inch, use new bearings for reassembly. If runout is
still excessive, case is damaged and must be
replaced.
7. Remove axle shafts.
8. Mark relationship of driveshaft end yoke and axle companion flange for proper assembly, then
disconnect driveshaft at rear axle universal joint.
9. Install inch pound torque wrench on pinion nut and record torque required to maintain rotation of
pinion through several turns.
10. Using suitable tools, hold companion flange and remove pinion nut.
11. Clean area around oil seal and place drain pan under seal.
12. Mark relationship of companion flange to pinion shaft for proper assembly, then, using suitable
puller, remove companion flange.
13. Using suitable tool, remove pinion oil seal.
14. Mark one differential bearing cap to ensure proper positioning of caps during assembly. Do not
interchange left and right bearing caps.
15. Loosen differential bearing cap bolts and bearing caps, noting direction of triangles on bearing
caps for proper assembly.
16. Pry differential case, bearing cups and shims out until they are loose in bearing caps, then
remove bearing caps and pry differential assembly from carrier. When using pry bar, place a wood
block between pry bar and axle housing to protect casting face from damage.
17. Using suitable mallet, drive pinion out of front bearing cone and remove through rear of carrier
casting.
18. Using suitable tools, remove pinion rear cone and roller bearing assembly, then, using
micrometer, measure and record thickness of shim found under bearing cone.
19. Remove damaged pinion bearing cups from carrier by tapping alternately with brass drift on
opposite sides of cups to prevent cups from cocking in casting.
Axle Housing, Replace, Ford Integral Carrier
1. Remove four backing plate nuts from each side of axle and wire backing plate aside.
2. Remove vent hose from vent and vent from brake junction block on rear axle housing.
3. Remove brake line from clips on axle housing and remove brake junction block. Do not open
brake lines when removing junction box.
4. Support rear axle housing on suitable jack and remove U-bolt nuts and plates.
5. Disconnect lower bolts on shock absorber mounting bracket and remove housing from vehicle.
6. Reverse procedure to install. Torque U-bolt nuts to 75-100 ft. lbs. on 1983 F-100-350 & Bronco;
75-105 ft. lbs. on 1983 E-100-150 and 1984-87 E-250; 75-115 ft. lbs. on 1984-87 models exc.
F-250 4 2 chassis cab and E series; 150-180 ft. lbs. on 1983 E-250 and 1983-87 E-350; and
150-210 ft. lbs. on 1983 and 1986-87 F-350 and 1984-87 F-250 4 2 chassis cab. Torque shock
absorber lower bolts to 40-60 ft. lbs. on Econoline models, and 40-64 ft. lbs. on all other models.
Torque backing brake attaching bolts to 20-40 ft. lbs. on F-100-150 models, and 50-70 ft. lbs. on
E-250 & F-250 models with 4050 lb. axle. No gaskets are required on brake backing plate.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component
Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 4627
Differential Axle Housing: Service and Repair Ford Removable Carrier
1. Raise and support vehicle.
2. Remove rear wheels and brake drums.
3. Remove rear wheel bearing retainer plate attaching nuts, then disconnect axle shafts from axle
housing.
4. Mark driveshaft end yoke and U-joint flange for assembly reference, then disconnect driveshaft
from flange. Mark position of cups to flange and remove driveshaft from transmission extension
housing. Install a suitable seal installation tool into housing to prevent leakage.
5. Unfasten brake lines from retaining clips and disconnect vent tube, if equipped, from axle
housing.
6. Remove brake backing plate assemblies from axle housing and wire aside.
7. Disconnect rear shock absorbers from lower mounts and position aside.
8. Lower axle slightly to reduce spring tension, then remove spring clips, U-bolt nuts and spring
seat caps from each rear spring and lower axle assembly from vehicle.
9. On all models, reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Technical Service Bulletins > Drivetrain - Lubricant Usage
Fluid - Differential: Technical Service Bulletins Drivetrain - Lubricant Usage
Article No. 89-8-16
^ DRIVETRAIN - LUBRICATION USAGE
^ TRANSMISSION - MANUAL - LUBRICATION USAGE
LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER
1984-89 BRONCO II 1986-89 AEROSTAR
ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain
lubrication usage chart for light trucks has been put together to assist technicians in the event
service is required.
FIGURE 1
FIGURE 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 4632
ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage.
Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage.
PART NUMBER PART NAME CLASS
D8DZ-19C547-A Standard Transmission BG
Lubricant - 5 gallons C1AZ-19590-BA
Long Life Lubricant B
(molybdenum disulfide) - 14.5 ounces
DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B
tube
D7AZ-19584-AA Multi-Purpose Grease - 15 B
ounce aerosol can
XT-2-QDX Transmission Fluid (Mercon) - V
quart can (pkg. of 12)
C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG
C8AZ-19B546-A Additive Friction Modifier - 4 AM
ounce bottle
D7AZ-19590-A Disc Brake Caliper Slide AM
Grease - 4 ounce tube
E8TZ-19590-A Grease - 14.5 ounces B
E1TZ-19590-A Automatic Hublock Grease - 5 B
ounce tube
E5RY-19C547-A Merkur Synthetic Manual B
Transmission Fluid
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 5970
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
TYPE: Standard 90 HP
Limited-Slip 90 HP*
8.8" & 10 1/4" has removable cover, 9.0" does not
CAPACITY, Refill: Front: Dana 44 3.8 pt (US)
LIMITED-SLIP OR TRACTION-LOK IDENTIFICATION: Label on door
lock pillar shows letter and number
Dana 50 4.0 pt (US)
Dana 60 5.8 pt (US)
Rear: Ford w/8.8" ring gear* 5.5 pt (US)
10 1/4 ring gear* 6.5 pt (US)
Dana 60 & 61 6.0 pt (US)
Dana 70 HD 7.4 pt (US)
Dana 70 6.5 pt (US)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications > Page 4635
Fluid - Differential: Fluid Type Specifications
BL Self-adjusting Brake Lubricant
EC Ethylene Glycol Coolant
Mix 50/50 with water to at least -20°F (-29°C) protection
EP Extreme Pressure Gear Lubricant
Ford Part No. D8DZ-19C547-A
FA Automatic Transmission Fluid, Type F
GL-5 Gear Oil, API Service GL-5
HBH Hydraulic Brake Fluid, Extra
Heavy-Duty
HP Hypoid Gear Oil
Ford Part No. E0AZ-19580-A
HP* Hypoid Gear Oil for Limited-Slip
or Traction-Lok Differential
LM Lithium Grease, with Polyethylene
LS Steering Gear Lubricant
MA MERCONAutomatic Transmission
Fluid
MH Manifold Heat Valve Solvent
SG Motor Oil, API Service SG
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Testing and Inspection > Bearing Cups
Pinion Bearing: Testing and Inspection Bearing Cups
Check bearing cups for rings, galling or erratic wear patterns. The bearing cups must be solidly
seated. Check by attempting to insert .0015 inch feeler gauge between cups and bottoms of bores.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Testing and Inspection > Bearing Cups > Page 4640
Pinion Bearing: Testing and Inspection Companion Flange
Be sure that flat machined surfaces and the bearing cup sockets of the flange have not been
damaged in removing driveshaft or in removing flange from axle. The edge of the flange that
contacts the oil slinger or pinion front bearing must be smooth. Roughness aggravates backlash
noises and causes wear on the slinger with a resultant loss in drive pinion bearing preload. The
seal surface should be perfectly smooth or leakage will result.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Testing and Inspection > Bearing Cups > Page 4641
Pinion Bearing: Testing and Inspection Cone & Roller Assemblies
When operated in the cups, the cone and roller assemblies must turn without any roughness.
Examine roller ends for wear.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Testing and Inspection > Bearing Cups > Page 4642
Pinion Bearing: Testing and Inspection Differential Bearing Adjusters
Test fit of bearing adjusters in their threads with bearing caps installed. Ensure that bearing caps
are on sides that they were machined to fit. The faces of the adjusters that contact the bearing
cups must be smooth and square. Examine threads in carrier if their fit is not proper and replace
any adjuster with a damaged face or threads.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Testing and Inspection > Bearing Cups > Page 4643
Pinion Bearing: Testing and Inspection Pinion Retainer
Inspect visually for damage. Ensure that pinion bearing cups are seated. Ensure that there are no
chips or burrs on mounting flange. Clean all lubricant passages. If pinion bearing cups were
removed, examine bores in retainer carefully. Any nicks or burrs in these bores must be removed
to permit proper seating of cups.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Testing and Inspection > Page 4644
Pinion Bearing: Adjustments
Fig. 4 Shim replacement for preload adjustment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Testing and Inspection > Page 4645
Fig. 5 Final pinion depth check
1. Install preload shims and slinger, if equipped, onto the pinion.
2. Install bearing cone assembly using suitable tool.
3. Install end yoke, washer and new pinion nut. Torque nut to approximately 250 ft. lbs. on except
model 30 axle or 200---220 ft. lbs. on model 30 axle.
4. Rotate pinion using a suitable torque wrench. Rotating torque should be 20---40 inch lbs. To
increase preload, remove shims from drive pinion. To decrease preload, add shims to pinion, Fig.
4.
5. Install suitable gauge tube in housing, then the bearing caps and cap attaching bolts, Fig. 5.
Torque cap attaching bolts to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs. on model 30
axle.
6. Insert proper final check gauge block on top of pinion face under the gauge tube, Fig. 5. Place
thumb on gauge block to ensure block is level.
7. Insert feeler gauge or shims between gauge tube and final check gauge block until slight drag is
felt.
8. The reading in step 7 should be .020 inch added to the drive pinion etching, which could be plus
(+) or minus ( - ) with a tolerance of .002 inch. If the distance must be increased, remove shims
from beneath the inner pinion bearing cup. If the distance must be decreased, add shims beneath
the inner pinion bearing cup.
9. With drive pinion at the correct depth, remove the yoke, nut and washer using a suitable tool.
10. Apply suitable lubricant to oil seal, then install drive pinion oil seal using a suitable installer.
Ensure seal spring is properly installed after seal installation.
11. Install yoke using suitable tool, then the washer and nut. Torque nut to approximately 250 ft.
lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle
Pinion Bearing: Service and Repair Dana/Spicer, Rear Axle
Pinion Bearing Cup Installation, DANA/SPICER, REAR AXLE
1. Place inner and outer bearing cups into carrier bore.
2. Install suitable inner bearing cup replacer tool on the inner bearing cup.
3. Install suitable outer bearing cup replacer tool on the outer bearing cup.
4. Install suitable threaded draw bar into the replacer tools, then tighten the draw bar to install cups
into carrier bore.
Pinion Bearing Preload & Final Depth Check, REAR AXLE
Fig. 4 Shim replacement for preload adjustment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4648
Fig. 5 Final pinion depth check
1. Install preload shims and slinger, if equipped, onto the pinion.
2. Install bearing cone assembly using suitable tool.
3. Install end yoke, washer and new pinion nut. Torque nut to approximately 250 ft. lbs. on except
model 30 axle or 200---220 ft. lbs. on model 30 axle.
4. Rotate pinion using a suitable torque wrench. Rotating torque should be 20---40 inch lbs. To
increase preload, remove shims from drive pinion. To decrease preload, add shims to pinion, Fig.
4.
5. Install suitable gauge tube in housing, then the bearing caps and cap attaching bolts, Fig. 5.
Torque cap attaching bolts to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs. on model 30
axle.
6. Insert proper final check gauge block on top of pinion face under the gauge tube, Fig. 5. Place
thumb on gauge block to ensure block is level.
7. Insert feeler gauge or shims between gauge tube and final check gauge block until slight drag is
felt.
8. The reading in step 7 should be .020 inch added to the drive pinion etching, which could be plus
(+) or minus ( - ) with a tolerance of .002 inch. If the distance must be increased, remove shims
from beneath the inner pinion bearing cup. If the distance must be decreased, add shims beneath
the inner pinion bearing cup.
9. With drive pinion at the correct depth, remove the yoke, nut and washer using a suitable tool.
10. Apply suitable lubricant to oil seal, then install drive pinion oil seal using a suitable installer.
Ensure seal spring is properly installed after seal installation.
11. Install yoke using suitable tool, then the washer and nut. Torque nut to approximately 250 ft.
lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4649
Pinion Bearing: Service and Repair Ford Removable
Backlash & Differential Bearing Preload Adjustment
1. Remove adjusting nut locks and loosen differential bearing cap bolts, then torque cap bolts to
approximately 20 ft. lbs. Left adjusting nut is on ring gear side of carrier and right adjusting nut is on
pinion side.
2. Loosen right nut until it is away from cup and tighten left nut until ring gear is just forced into
position with zero backlash, then rotate pinion several revolutions to ensure that no binding is
evident.
3. Check right nut to ensure that it is still loose, then install dial indicator.
4. Tighten right nut until it just contacts bearing cup, then set dial indicator to zero and apply
pressure to bearings by tightening right nut until indicator reads .008---.012 inch.
5. Turn pinion gear several times in each direction to seat bearings in cups and ensure that no
binding is evident, then torque bearing caps to 70---80 ft. lbs.
6. Measure backlash on several teeth around ring gear.
7. If backlash varies by more than .004 inch between any two teeth, loosen one adjusting nut and
tighten opposite nut an equal amount to move ring gear away from or toward pinion. Tightening left
nut moves ring gear into pinion to decrease backlash while tightening right nut moves ring gear
away. When moving adjusting nuts, final movement should always be made in a tightening
direction. Assuming left nut had to be loosened one notch, loosen nut two notches, then tighten
one notch.
8. Ensure that case spread remains within specifications as previously described.
9. Perform teeth pattern check as described under ``General Axle Service.'' If backlash is correct
and gross pattern error results, recheck pinion shim selection.
Drive Pinion & Bearing Retainer, FORD, REMOVABLE CARRIER,
Fig. 7 Installing Pinion And Retainer Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4650
Fig. 8 Installing Companion Flange
Fig. 9 Checking Pinion Bearing Preload
A new ring gear and drive pinion should always be installed as a matched set. Ensure that
identifying numbers on ring gear and head of drive pinion are identical.
1. Using suitable tool, install pinion rear bearing cone on pinion shaft, then position new spacer on
pinion shaft.
2. Place bearing retainer on drive pinion shaft and install front bearing cone and roller, then, using
tool T57L-4621-B or equivalent, press bearing cone and roller into position, being careful not to
crush collapsible spacer.
3. Lubricate O-ring with suitable lubricant, install into groove in pinion retainer, and snap into place.
Then lubricate front and rear pinion bearings.
4. Position selected shim on carrier housing and install pinion and retainer assembly, being careful
not to pinch O-ring, Fig. 7.
5. Install pinion retainer attaching bolts, torquing to 30---40 ft. lbs., then install oil slinger, if
equipped.
6. Using suitable tool, install new pinion oil seal in bearing retainer.
7. Install companion flange, Fig. 8.
8. Apply small amount of suitable lubricant to flange side of new pinion nut and start nut on drive
pinion shaft.
9. Hold flange with suitable tool and tighten flange nut.
10. Check pinion bearing preload, Fig. 9. Correct preload is obtained when torque required to
rotate pinion in retainer is 8---14 inch lbs. for original bearing or 16---29 inch lbs. for new bearing. If
torque required to rotate pinion is less than specified, tighten pinion shaft nut a little at a time until
proper preload is obtained. Do not over tighten nut. If excessive preload is obtained as a result of
over tightening, replace collapsible bearing spacer. Do not back off pinion shaft nut to establish
pinion bearing preload.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4651
Pinion Bearing Cups, Replace, FORD REMOVABLE CARRIER
Do not remove drive pinion bearing cups from the retainer unless cups are worn or damaged.
1. Using suitable puller, remove bearing cups.
2. Using tool T71P-4616-A or equivalent, install new bearing cups.
3. Check seating of cups by attempting to insert a .0015 inch feeler gauge between cup and bottom
of bore. Cone and roller assemblies should be replaced whenever cups are replaced.
Selecting Correct Pinion Shim, FORD REMOVABLE CARRIER
Fig. 5 Removable carrier 9 inch ring gear axle pinion depth tool gauge
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4652
Fig. 6 Using pinion depth gauge tool
When the ring gear and drive pinion or pinion bearings are replaced, the correct pinion shim
thickness must be determined using tool T79P-4020-A or equivalent.
1. Select proper rear pinion bearing aligning adapter and gauge disc and slide these adapters over
screw or threaded shaft, Fig. 5.
2. Install gauge block on threaded shaft and tighten securely, Fig. 6 (1).
3. Place assembly and rear drive pinion bearing into pinion bearing retainer assembly, then install
front pinion bearing and screw handle onto threaded shaft, tapered end into front pinion bearing,
Fig. 6 (1) and (2). Flat end of handle has 3/8 inch hole cut in it so that an inch pound torque wrench
may be used to obtain proper pinion bearing preload.
4. Install pinion bearing retainer assembly into carrier, less shim, torquing attaching bolts to 30---40
ft. lbs.
5. Rotate gauge block so that it rests against pilot boss, Fig. 6 (3).
6. Using feeler gauge, measure distance between gauge block and gauge tube, Fig. 6 (4). Insert
blade directly along gauge block top to ensure a correct reading. Fit should be a slight drag-type
feeling.
7. Select proper shim according to feeler gauge reading, Fig. 6.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4653
Pinion Bearing: Service and Repair Ford, Removable Carrier, Disassembly
Fig. 3 Removing Pinion Shaft Nut
Fig. 4 Removing Companion Flange
1. Remove drive pinion shaft nut, Fig. 3.
2. Remove companion flange from drive pinion shaft, Fig. 4.
3. Using suitable puller, remove pinion seal.
4. Remove the pinion, bearing, and retainer assembly from carrier housing. Extreme care must be
taken not to damage mounting surfaces of retainer and carrier.
5. Place protective sleeve on pinion pilot bearing surface and press drive pinion shaft out of pinion
retainer.
6. Using tool T71P-4621-B or equivalent, press pinion shaft out of pinion rear bearing cone.
7. Clean and inspect all parts as described in ``General Axle Service.''
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4654
Pinion Bearing: Service and Repair Pinion Bearing Cup Installation
1. Place inner and outer bearing cups into carrier bore.
2. Install suitable inner bearing cup replacer tool on the inner bearing cup.
3. Install suitable outer bearing cup replacer tool on the outer bearing cup.
4. Install suitable threaded draw bar into the replacer tools, then tighten the draw bar to install cups
into carrier bore.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Testing and Inspection
Pinion Gear: Testing and Inspection
Examine drive pinion and ring gear teeth for scoring or signs of excessive wear. Worn gears cannot
be rebuilt to correct a noisy condition. Gear scoring and flaking are the result of excessive shock
loading or the use of improper lubricant. Scored gears cannot be reused.
Examine teeth and thrust surfaces of differential gears. Wear on hub of differential side gears may
cause a chucking noise known as chuckle, when the vehicle is operated at low speeds. Wear of
splines, thrust surfaces or thrust washers may contribute to excessive drive line backlash.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Adjustments > Depth Gauge Check
Pinion Gear: Adjustments Depth Gauge Check
If any of the gauge surfaces become nicked, the high spots should be removed using an oil stone.
1. Install a new rear pinion bearing over a suitable aligning adapter, then position into the pinion
bearing retainer assembly.
2. Place front of pinion bearing into the bearing cup, then assemble the handle onto the screw and
hand tighten. The square drive in the handle of the tool is to be used for obtaining the proper pinion
bearing preload. Set preload to 20---40 inch lbs.
3. Center suitable gauge tube into the differential bearing bore, then install the differential bearing
caps.
4. Using a feeler gauge tool or shims, select the thickest shim that will enter between the gauge
tube and gauge block. Insert feeler gauge directly along the gauge block to ensure a correct
reading. If the service pinion gear is marked with a plus (+) reading, this amount should be
subtracted from the thickness dimension obtained in step 4. If the service pinion gear is marked
with a minus ( - ) reading, this amount should be added to the thickness dimension obtained in step
4.
5. Remove inner pinion bearing cup and install the correct number of shims in the carrier bore.
6. Install bearing cup and oil slinger, if equipped, on the pinion, then press on bearing using a
suitable tool. If a baffle or slinger is used, replace with a new one during assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Adjustments > Depth Gauge Check > Page 4660
Pinion Gear: Adjustments Drive Pinion Depth of Mesh Setting
Fig. 3 Shim setting chart
Ring gears and pinions are supplied in matched sets only. Matched numbers on both the pinion
and ring gear are etched for verification. On the face of each pinion there is etched either a plus or
a minus number, or ``0,'' which indicates the best running position for each particular gear set. This
dimension is controlled by shimming behind the inner pinion bearing cup. A pinion etched with a +3
would require .003 inch less shims that a pinion etched ``0.'' A pinion etched - 3 would require .003
inch more shims than a pinion etched ``0.'' If the etched figure is ``0'' the shim pack will remain the
same. Refer to chart, Fig. 3. Shims are available in thicknesses of .003 inch, .005 inch, .010 inch
and .030 inch.
If old ring and pinion set is to be reused, measure the old shim pack and build a new shim pack to
the same dimension. If a baffle is used in the axle assembly, it is considered a part of the shim
pack. Measure each shim separately with a micrometer and add together to get the total shim pack
thickness from the original build up.
If a new gear set is being used, notice the (+) or ( - ) etching on both the new and old pinion and
adjust thickness of new shim pack to compensate for the difference of these two figures. For
example, if the old pinion reads +2 and the new pinion is - 2, add .004 inch shims to the original
shim pack.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Adjustments > Depth Gauge Check > Page 4661
Pinion Gear: Adjustments Pinion Bearing Preload & Final Depth Check
Fig. 4 Shim replacement for preload adjustment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Adjustments > Depth Gauge Check > Page 4662
Fig. 5 Final pinion depth check
1. Install preload shims and slinger, if equipped, onto the pinion.
2. Install bearing cone assembly using suitable tool.
3. Install end yoke, washer and new pinion nut. Torque nut to approximately 250 ft. lbs. on except
model 30 axle or 200---220 ft. lbs. on model 30 axle.
4. Rotate pinion using a suitable torque wrench. Rotating torque should be 20---40 inch lbs. To
increase preload, remove shims from drive pinion. To decrease preload, add shims to pinion, Fig.
4.
5. Install suitable gauge tube in housing, then the bearing caps and cap attaching bolts, Fig. 5.
Torque cap attaching bolts to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs. on model 30
axle.
6. Insert proper final check gauge block on top of pinion face under the gauge tube, Fig. 5. Place
thumb on gauge block to ensure block is level.
7. Insert feeler gauge or shims between gauge tube and final check gauge block until slight drag is
felt.
8. The reading in step 7 should be .020 inch added to the drive pinion etching, which could be plus
(+) or minus ( - ) with a tolerance of .002 inch. If the distance must be increased, remove shims
from beneath the inner pinion bearing cup. If the distance must be decreased, add shims beneath
the inner pinion bearing cup.
9. With drive pinion at the correct depth, remove the yoke, nut and washer using a suitable tool.
10. Apply suitable lubricant to oil seal, then install drive pinion oil seal using a suitable installer.
Ensure seal spring is properly installed after seal installation.
11. Install yoke using suitable tool, then the washer and nut. Torque nut to approximately 250 ft.
lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle
Pinion Gear: Service and Repair Dana/Spicer, Rear Axle
Depth Gauge Check, Dana/Spicer, Rear Axle
If any of the gauge surfaces become nicked, the high spots should be removed using an oil stone.
1. Install a new rear pinion bearing over a suitable aligning adapter, then position into the pinion
bearing retainer assembly.
2. Place front of pinion bearing into the bearing cup, then assemble the handle onto the screw and
hand tighten. The square drive in the handle of the tool is to be used for obtaining the proper pinion
bearing preload. Set preload to 20---40 inch lbs.
3. Center suitable gauge tube into the differential bearing bore, then install the differential bearing
caps.
4. Using a feeler gauge tool or shims, select the thickest shim that will enter between the gauge
tube and gauge block. Insert feeler gauge directly along the gauge block to ensure a correct
reading. If the service pinion gear is marked with a plus (+) reading, this amount should be
subtracted from the thickness dimension obtained in step 4. If the service pinion gear is marked
with a minus ( - ) reading, this amount should be added to the thickness dimension obtained in step
4.
5. Remove inner pinion bearing cup and install the correct number of shims in the carrier bore.
6. Install bearing cup and oil slinger, if equipped, on the pinion, then press on bearing using a
suitable tool. If a baffle or slinger is used, replace with a new one during assembly.
Drive Pinion Depth of Mesh Setting, Dana/Spicer, Rear Axle
Fig. 3 Shim setting chart
Ring gears and pinions are supplied in matched sets only. Matched numbers on both the pinion
and ring gear are etched for verification. On the face of each pinion there is etched either a plus or
a minus number, or ``0,'' which indicates the best running position for each particular gear set. This
dimension is controlled by shimming behind the inner pinion bearing cup. A pinion etched with a +3
would require .003 inch less shims that a pinion etched ``0.'' A pinion etched - 3 would require .003
inch more shims than a pinion etched ``0.'' If the etched figure is ``0'' the shim pack will remain the
same. Refer to chart, Fig. 3. Shims are available in thicknesses of .003 inch, .005 inch, .010 inch
and .030 inch.
If old ring and pinion set is to be reused, measure the old shim pack and build a new shim pack to
the same dimension. If a baffle is used in the axle assembly, it is considered a part of the shim
pack. Measure each shim separately with a micrometer and add together to get the total shim pack
thickness from the original build up.
If a new gear set is being used, notice the (+) or ( - ) etching on both the new and old pinion and
adjust thickness of new shim pack to compensate for the difference of these two figures. For
example, if the old pinion reads +2 and the new pinion is - 2, add .004 inch shims to the original
shim pack.
Pinion Bearing Preload & Final Depth Check, Rear Axle
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4665
Fig. 4 Shim replacement for preload adjustment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4666
Fig. 5 Final pinion depth check
1. Install preload shims and slinger, if equipped, onto the pinion.
2. Install bearing cone assembly using suitable tool.
3. Install end yoke, washer and new pinion nut. Torque nut to approximately 250 ft. lbs. on except
model 30 axle or 200---220 ft. lbs. on model 30 axle.
4. Rotate pinion using a suitable torque wrench. Rotating torque should be 20---40 inch lbs. To
increase preload, remove shims from drive pinion. To decrease preload, add shims to pinion, Fig.
4.
5. Install suitable gauge tube in housing, then the bearing caps and cap attaching bolts, Fig. 5.
Torque cap attaching bolts to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs. on model 30
axle.
6. Insert proper final check gauge block on top of pinion face under the gauge tube, Fig. 5. Place
thumb on gauge block to ensure block is level.
7. Insert feeler gauge or shims between gauge tube and final check gauge block until slight drag is
felt.
8. The reading in step 7 should be .020 inch added to the drive pinion etching, which could be plus
(+) or minus ( - ) with a tolerance of .002 inch. If the distance must be increased, remove shims
from beneath the inner pinion bearing cup. If the distance must be decreased, add shims beneath
the inner pinion bearing cup.
9. With drive pinion at the correct depth, remove the yoke, nut and washer using a suitable tool.
10. Apply suitable lubricant to oil seal, then install drive pinion oil seal using a suitable installer.
Ensure seal spring is properly installed after seal installation.
11. Install yoke using suitable tool, then the washer and nut. Torque nut to approximately 250 ft.
lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4667
Pinion Gear: Service and Repair Ford Drive Axle W/ Removable Carrier
Backlash & Differential Bearing Preload Adjustment
1. Remove adjusting nut locks and loosen differential bearing cap bolts, then torque cap bolts to
approximately 20 ft. lbs. Left adjusting nut is on ring gear side of carrier and right adjusting nut is on
pinion side.
2. Loosen right nut until it is away from cup and tighten left nut until ring gear is just forced into
position with zero backlash, then rotate pinion several revolutions to ensure that no binding is
evident.
3. Check right nut to ensure that it is still loose, then install dial indicator.
4. Tighten right nut until it just contacts bearing cup, then set dial indicator to zero and apply
pressure to bearings by tightening right nut until indicator reads .008---.012 inch.
5. Turn pinion gear several times in each direction to seat bearings in cups and ensure that no
binding is evident, then torque bearing caps to 70---80 ft. lbs.
6. Measure backlash on several teeth around ring gear.
7. If backlash varies by more than .004 inch between any two teeth, loosen one adjusting nut and
tighten opposite nut an equal amount to move ring gear away from or toward pinion. Tightening left
nut moves ring gear into pinion to decrease backlash while tightening right nut moves ring gear
away. When moving adjusting nuts, final movement should always be made in a tightening
direction. Assuming left nut had to be loosened one notch, loosen nut two notches, then tighten
one notch.
8. Ensure that case spread remains within specifications as previously described.
9. Perform teeth pattern check as described under ``General Axle Service.'' If backlash is correct
and gross pattern error results, recheck pinion shim selection.
Drive Pinion & Bearing Retainer, Disassembly
Fig. 3 Removing Pinion Shaft Nut
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4668
Fig. 4 Removing Companion Flange
1. Remove drive pinion shaft nut, Fig. 3.
2. Remove companion flange from drive pinion shaft, Fig. 4.
3. Using suitable puller, remove pinion seal.
4. Remove the pinion, bearing, and retainer assembly from carrier housing. Extreme care must be
taken not to damage mounting surfaces of retainer and carrier.
5. Place protective sleeve on pinion pilot bearing surface and press drive pinion shaft out of pinion
retainer.
6. Using tool T71P-4621-B or equivalent, press pinion shaft out of pinion rear bearing cone.
7. Clean and inspect all parts as described in ``General Axle Service.''
Drive Pinion & Bearing Retainer, Ford, Removable Carrier,
Fig. 7 Installing Pinion And Retainer Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4669
Fig. 8 Installing Companion Flange
Fig. 9 Checking Pinion Bearing Preload
A new ring gear and drive pinion should always be installed as a matched set. Ensure that
identifying numbers on ring gear and head of drive pinion are identical.
1. Using suitable tool, install pinion rear bearing cone on pinion shaft, then position new spacer on
pinion shaft.
2. Place bearing retainer on drive pinion shaft and install front bearing cone and roller, then, using
tool T57L-4621-B or equivalent, press bearing cone and roller into position, being careful not to
crush collapsible spacer.
3. Lubricate O-ring with suitable lubricant, install into groove in pinion retainer, and snap into place.
Then lubricate front and rear pinion bearings.
4. Position selected shim on carrier housing and install pinion and retainer assembly, being careful
not to pinch O-ring, Fig. 7.
5. Install pinion retainer attaching bolts, torquing to 30---40 ft. lbs., then install oil slinger, if
equipped.
6. Using suitable tool, install new pinion oil seal in bearing retainer.
7. Install companion flange, Fig. 8.
8. Apply small amount of suitable lubricant to flange side of new pinion nut and start nut on drive
pinion shaft.
9. Hold flange with suitable tool and tighten flange nut.
10. Check pinion bearing preload, Fig. 9. Correct preload is obtained when torque required to
rotate pinion in retainer is 8---14 inch lbs. for original bearing or 16---29 inch lbs. for new bearing. If
torque required to rotate pinion is less than specified, tighten pinion shaft nut a little at a time until
proper preload is obtained. Do not over tighten nut. If excessive preload is obtained as a result of
over tightening, replace collapsible bearing spacer. Do not back off pinion shaft nut to establish
pinion bearing preload.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4670
Selecting Correct Pinion Shim, Ford Removable Carrier
Fig. 5 Removable carrier 9 inch ring gear axle pinion depth tool gauge
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Dana/Spicer, Rear Axle > Page 4671
Fig. 6 Using pinion depth gauge tool
When the ring gear and drive pinion or pinion bearings are replaced, the correct pinion shim
thickness must be determined using tool T79P-4020-A or equivalent.
1. Select proper rear pinion bearing aligning adapter and gauge disc and slide these adapters over
screw or threaded shaft, Fig. 5.
2. Install gauge block on threaded shaft and tighten securely, Fig. 6 (1).
3. Place assembly and rear drive pinion bearing into pinion bearing retainer assembly, then install
front pinion bearing and screw handle onto threaded shaft, tapered end into front pinion bearing,
Fig. 6 (1) and (2). Flat end of handle has 3/8 inch hole cut in it so that an inch pound torque wrench
may be used to obtain proper pinion bearing preload.
4. Install pinion bearing retainer assembly into carrier, less shim, torquing attaching bolts to 30---40
ft. lbs.
5. Rotate gauge block so that it rests against pilot boss, Fig. 6 (3).
6. Using feeler gauge, measure distance between gauge block and gauge tube, Fig. 6 (4). Insert
blade directly along gauge block top to ensure a correct reading. Fit should be a slight drag-type
feeling.
7. Select proper shim according to feeler gauge reading, Fig. 6.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Testing and Inspection > Gears
Ring Gear: Testing and Inspection Gears
Examine drive pinion and ring gear teeth for scoring or signs of excessive wear. Worn gears cannot
be rebuilt to correct a noisy condition. Gear scoring and flaking are the result of excessive shock
loading or the use of improper lubricant. Scored gears cannot be reused.
Examine teeth and thrust surfaces of differential gears. Wear on hub of differential side gears may
cause a chucking noise known as chuckle, when the vehicle is operated at low speeds. Wear of
splines, thrust surfaces or thrust washers may contribute to excessive drive line backlash.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Testing and Inspection > Gears > Page 4676
Ring Gear: Testing and Inspection Runout
1987 models equipped with anti-lock brakes incorporate a multi-tooth exciter ring which is pressed
on the differential case located behind the ring gear assembly. Do not remove exciter ring to
measure ring gear runout. A space is provided between the exciter ring and ring gear to measure
ring gear runout.
If ring gear runout during disassembly exceeded specifications, the condition may be caused by a
warped gear, or distorted or damaged case or foreign matter trapped between differential case
halves or under ring gears.
To determine cause of excessive runout, assemble differential case without ring gear, then check
as described below.
Install case in differential carrier without ring gear attached. Install bearing caps and adjuster nuts
and tighten cap bolts to specifications. Tighten adjuster nuts to center differential side bearing.
Mount a dial indicator and check runout of case flange and ring gear pilot. If runout at either point is
excessive, install a new differential case. If runout is within specification, the ring gear is out of
specification. When performing this check on a locking differential case the four compression
springs within the case should be temporarily removed. This will prevent a false runout reading due
to distortion caused by the springs forcing the case apart.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Adjustments > Assembly of Differential Into Housing
Ring Gear: Adjustments Assembly of Differential Into Housing
Ring Gear & Pinion Backlash
1. Position differential assembly, with pinion installed, into housing. Ensure master bearings are still
assembled in case.
2. Install dial indicator on carrier housing in same location as when spreading case.
3. Force ring gear into mesh with pinion, then set dial indicator to ``0'' while maintaining force on
differential case.
4. Force ring gear away from pinion gear and note dial reading. Repeat sequence until same
indicator reading is obtained. This measurement indicates amount of shims needed between
differential case and bearings on the ring gear side.
5. Remove dial indicator and differential case from carrier, then the master bearings from
differential case.
6. Place shims determined in step 4 on ring gear hub of differential case.
7. Install bearing cone on ring gear side of differential case, then drive bearing into place.
8. To determine thickness of shims required on hub of drive pinion side of differential case, subtract
thickness of shims installed in step 6 from total differential case endplay as measured in
``Differential Case Assembly'' procedure. To this figure, add .015 inch.
9. Place shims determined in step 8 on hub of drive pinion side of differential case.
10. Install bearing cone on hub of drive pinion side of differential case.
11. Position suitable step plate on ring gear side bearing to protect bearing.
12. Place bearing on drive pinion side hub and drive it into position.
13. Install spreader tool and dial indicator as previously described. Do not spread case more than
.015 inch.
14. Assemble differential bearing cups to bearing cones, then install differential assembly into
carrier.
15. Tap differential assembly into position in carrier using a soft-faced hammer, then remove
spreader tool from case.
16. Install bearing caps in proper position, then torque cap screws to 80---90 ft. lbs. on except
model 30 axle or 35---50 ft. lbs on model 30 axle.
17. Measure ring gear and pinion backlash at three equidistant points using a dial indicator.
Backlash must measure .004---.009 inch on except model 30 axle or .005---.009 inch on model 30
axle and cannot vary more than .003 inch on except model 30 axle or .002 inch on model 30 axle
between points checked. Backlash may be brought within specifications by switching shims from
one side of differential case to the other. Move ring gear closer to pinion to correct high backlash,
or further away from pinion to correct low backlash.
18. On except model 30 axle having a cover plate without a flat mounting surface, install cover
plate, using a new gasket, and torque attaching bolts alternately and evenly to 30---40 ft. lbs. On
model 30 axle, torque cover attaching bolts to 15---25 ft. lbs.
19. On units having a cover plate with a flat mounting surface, install cover as follows:
a. Clean flat surface of cover plate and carrier mating surface. b. Apply suitable sealant to cover
plate surface, ensuring bead of sealant is laid on inside of cover screw holes. c. Install two
attaching bolts into cover at 2 o'clock and 8 o'clock positions. d. Position cover on carrier, then
install remaining attaching bolts. e. Torque all attaching bolts alternately and evenly to 30---40 ft.
lbs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Adjustments > Assembly of Differential Into Housing > Page 4679
Ring Gear: Adjustments Backlash & Differential Bearing Preload Adjustment
FORD REMOVABLE CARRIER
1. Remove adjusting nut locks and loosen differential bearing cap bolts, then torque cap bolts to
approximately 20 ft. lbs. Left adjusting nut is on ring gear side of carrier and right adjusting nut is on
pinion side.
2. Loosen right nut until it is away from cup and tighten left nut until ring gear is just forced into
position with zero backlash, then rotate pinion several revolutions to ensure that no binding is
evident.
3. Check right nut to ensure that it is still loose, then install dial indicator.
4. Tighten right nut until it just contacts bearing cup, then set dial indicator to zero and apply
pressure to bearings by tightening right nut until indicator reads .008---.012 inch.
5. Turn pinion gear several times in each direction to seat bearings in cups and ensure that no
binding is evident, then torque bearing caps to 70---80 ft. lbs.
6. Measure backlash on several teeth around ring gear.
7. If backlash varies by more than .004 inch between any two teeth, loosen one adjusting nut and
tighten opposite nut an equal amount to move ring gear away from or toward pinion. Tightening left
nut moves ring gear into pinion to decrease backlash while tightening right nut moves ring gear
away. When moving adjusting nuts, final movement should always be made in a tightening
direction. Assuming left nut had to be loosened one notch, loosen nut two notches, then tighten
one notch.
8. Ensure that case spread remains within specifications as previously described.
9. Perform teeth pattern check as described under ``General Axle Service.'' If backlash is correct
and gross pattern error results, recheck pinion shim selection.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component
Information > Service and Repair > Dana/Spicer Integral Housing Type
Axle Bearing: Service and Repair Dana/Spicer Integral Housing Type
Full-Floating Axle
1. Set parking brake and loosen axle shaft bolts.
2. Raise and support rear of vehicle so that axle is parallel with floor.
3. Remove axle shaft bolts.
4. Remove axle shaft and discard gasket.
5. Pry out locking wedge with screwdriver.
6. Raise wheel until weight is removed from wheel bearing.
7. Remove wheel bearing adjustment nut.
8. Remove outer bearing cone and pull wheel assembly from axle.
9. Drive inner bearing cone and seal out of wheel hub with brass drift.
10. Inspect bearings and races and replace if worn or damaged. Drive races from wheel hub with
brass drift.
11. Lubricate bearing cone and roller assemblies and place inner assemblies into wheel hub. Install
new hub inner seal.
12. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and
remove tape.
13. Install outer wheel bearing and start adjuster nut. Lower wheel to ground.
14. While rotating wheel, torque adjusting nut to 120-140 ft. lbs. Back off the nut to obtain
0.001---0.010 inch endplay (1/8-3/8 turn). If nut or locking wedge are damaged or do not allow for
proper endplay they should be replaced.
15. Position locking wedge in key way slot, making sure it is not bottomed against the shoulder of
adjusting nut.
16. Install axle shaft and new flange gasket, then install retaining bolts and torque locking bolts to
40---50 ft. lbs.
17. Adjust brakes.
18. Remove supports and lower vehicle.
Semi-Floating Axle
1. Raise and support vehicle.
2. Remove wheel and brake drum.
3. Remove cover plate and discard gasket.
4. Remove differential pinion shaft lock screw and the shaft.
5. Remove C-clip from button end of shaft by pushing inward on other end.
6. Pull shaft from axle tube. Do not rotate differential side gears.
7. Remove and discard oil seal from axle tube.
8. Pull bearing from axle tube.
9. Lubricate new bearing and install in axle tube.
10. Lubricate and install new oil seal.
11. Insert shaft into axle tube, making sure splines engage side gears, then install C-clip and pull
shaft outward until the clip locks.
12. Install pinion mate shaft, aligning lock pin holes, and pinion gear side washers.
13. Install new lock screw and torque to 8 ft. lbs. on 1980---81 models, or 20---25 ft. lbs. on
1982---87 models.
14. Install cover plate and gasket. Torque bolts to 30---40 ft. lbs.
15. Install wheel and drum assembly.
16. Remove supports and lower vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component
Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 4685
Axle Bearing: Service and Repair Ford Integral Carrier Type Axle
1. Remove axle shaft as outlined in ``Axle Shaft, Replace''.
2. Insert tool T83T-1226-A for models with 8.8 inch ring gear, or tool T85T-1225-AH for models with
10.25 inch ring gear, and tool T50T-100-A into axle bore so tangs on tool engage bearing outer
race. Remove bearing and seal as an assembly.
3. Install new bearing using tool T83T-1225-B on models with 8.8 inch ring gear, or tool
T80T-4000-W on models with 10.25 inch ring gear, and new seal using tool T83T-1175-A on
models with 8.8 inch ring gear, or tool T80T-4000-Y on models with 10.25 inch ring gear. Pack lips
of seal with C1AZ-19590-B or equivalent.
4. Reinstall axle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component
Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 4686
Axle Bearing: Service and Repair Ford Removable Carrier Type
Removal, Units w/Ball Bearing
1. Remove wheel assembly.
2. Remove brake drum from flange.
3. Working through hole provided in axle shaft flange, remove nuts that secure wheel bearing
retainer.
4. Pull axle shaft out of housing. If bearing is a tight fit in axle housing, use a slide hammer type
puller.
5. Remove brake backing plate and secure to frame rail.
6. If the axle shaft bearing is to be replaced, loosen the inner retainer by nicking it deeply with a
chisel in several places. The bearing will then slide off easily.
7. Press bearing from axle shaft.
8. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing
action of the oil seal. Carefully remove any burrs or rough spots.
Installation
1. Press new bearing on shaft until it seats firmly against shoulder on shaft.
2. Press inner bearing retainer on shaft until it seats firmly against bearing.
3. If oil seal is to be replaced, use a hook-type tool to pull it out of housing. Wipe a small amount of
oil resistant sealer on outer edge of seal before it is installed.
Removal, Units W/Roller Bearing
1. Remove wheel assembly.
2. Remove brake drum from flange.
3. Working through hole provided in axle flange, remove nuts securing wheel bearing retainer.
4. Pull axle shaft carefully from housing to prevent damage to outer seal rubber. Use a slide
hammer type puller to remove tapered bearing cup from housing. Remove brake backing plate and
secure to frame rail.
5. If the axle shaft bearing or seal is to be replaced, split the inner bearing retainer.
6. Press bearing from axle shaft.
7. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing
action of the oil seal. Carefully remove any burrs or rough spots.
8. Install outer retainer plate on axle shaft. Press lubricated seal and bearing onto shaft until firmly
seated. Oil seal for rear drum brake equipped vehicles is different than that used on vehicles with
rear disc brakes. Seals used with drum brakes have a gray metal colored outer rim, while seals
used with disc brakes have a black or orange color.
9. Press new bearing retainer onto shaft until seated.
Installation
1. On 1980---84 models, place a new gasket on each side of brake carrier plate, and slide axle
shaft into housing. On models with roller bearing, ensure outer seal is fully seated on bearing.
2. Start splines into differential side gear and push shaft in until bearing bottoms in housing.
3. Torque bearing retainer nuts to 20---40 ft. lbs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 932514 > Dec > 93 >
Full Float Rear Hub/Shaft - Lubricant Leaks
Axle Shaft: Customer Interest Full Float Rear Hub/Shaft - Lubricant Leaks
Article No. 93-25-14
12/08/93
^ AXLE - "DANA" FULL FLOAT REAR - NEW HUB/SHAFT BOLTS AND REVISED TORQUE
SPECIFICATIONS
^ AXLE - "DANA" FULL FLOAT REAR - SHAFT/HUB BOLTS LOOSEN AND LEAK AXLE LUBE SERVICE TIPS
^ LEAKS - AXLE LUBE - REAR AXLE SHAFT/HUB BOLTS LOOSEN - SERVICE TIPS
LIGHT TRUCK: 1980-94 E-350 1988-94 F SUPER DUTY
ISSUE: The rear axle shaft/hub bolts may loosen and leak axle lube. This loosening can occur due
to increased torques at the rear wheels.
ACTION: Install new higher strength flange head bolts and improved cellulose gaskets, which
clamp the joint together tighter. Refer to the following service tips and revised torque specifications.
^ Do not use higher torques specified for these bolts on previously specified hex head bolts.
^ Always replace the bolts and gaskets together rather than reusing them when servicing the wheel
end.
^ The new cellulose gaskets and new flanged head bolts are designed to be used together;
therefore, neither part should be used with older stock parts.
NOTE: WHEN REMOVING THE BOLTS, LOOSEN THEM BY HAND BEFORE USING AN
IMPACT WRENCH. THE SHOCK LOAD APPLIED BY A POWER TOOL MAY CAUSE THE BOLT
TO SNAP BEFORE IT RELEASES.
NOTE:
WHEN SERVICING THE REAR AXLE HUB OR SHAFT, REPLACE THE BOLTS AND GASKET
WITH THE NEW PARTS. USE THE NEW TORQUE SPECIFICATIONS.
NOTE: SPECIAL LUBRICANTS ARE REQUIRED FOR DANA FULL FLOAT REAR AXLES. USE
FORD HYPOID GEAR LUBE (C6AZ-19580-E OR EQUIVALENT), OR FOR EXTREME SERVICE
APPLICATIONS, USE FORD HIGH PERFORMANCE REAR AXLE LUBE (F1TZ-19580-B OR
EQUIVALENT). REFER TO TSB 92-3-11 FOR ADDITIONAL LUBRICANT INFORMATION.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Technical Service Bulletins > Customer Interest for Axle Shaft: > 932514 > Dec > 93 >
Full Float Rear Hub/Shaft - Lubricant Leaks > Page 4696
OTHER APPLICABLE ARTICLES: 92-3-11 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage For 1992/94 Models, Basic Warranty Coverage For All
Other Models
OPERATION DESCRIPTION TIME
932514A Replace Axle Shaft/Hub 0.4 Hr.
Gaskets And Bolts (One Side)
932514B Replace Axle Shaft/Hub 0.6 Hr.
Gaskets And Bolts (Both Sides)
DEALER CODING
BASIC PART NO. CONDITION CODE
4A140 33
OASIS CODES: 509000, 590000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 932514 >
Dec > 93 > Full Float Rear Hub/Shaft - Lubricant Leaks
Axle Shaft: All Technical Service Bulletins Full Float Rear Hub/Shaft - Lubricant Leaks
Article No. 93-25-14
12/08/93
^ AXLE - "DANA" FULL FLOAT REAR - NEW HUB/SHAFT BOLTS AND REVISED TORQUE
SPECIFICATIONS
^ AXLE - "DANA" FULL FLOAT REAR - SHAFT/HUB BOLTS LOOSEN AND LEAK AXLE LUBE SERVICE TIPS
^ LEAKS - AXLE LUBE - REAR AXLE SHAFT/HUB BOLTS LOOSEN - SERVICE TIPS
LIGHT TRUCK: 1980-94 E-350 1988-94 F SUPER DUTY
ISSUE: The rear axle shaft/hub bolts may loosen and leak axle lube. This loosening can occur due
to increased torques at the rear wheels.
ACTION: Install new higher strength flange head bolts and improved cellulose gaskets, which
clamp the joint together tighter. Refer to the following service tips and revised torque specifications.
^ Do not use higher torques specified for these bolts on previously specified hex head bolts.
^ Always replace the bolts and gaskets together rather than reusing them when servicing the wheel
end.
^ The new cellulose gaskets and new flanged head bolts are designed to be used together;
therefore, neither part should be used with older stock parts.
NOTE: WHEN REMOVING THE BOLTS, LOOSEN THEM BY HAND BEFORE USING AN
IMPACT WRENCH. THE SHOCK LOAD APPLIED BY A POWER TOOL MAY CAUSE THE BOLT
TO SNAP BEFORE IT RELEASES.
NOTE:
WHEN SERVICING THE REAR AXLE HUB OR SHAFT, REPLACE THE BOLTS AND GASKET
WITH THE NEW PARTS. USE THE NEW TORQUE SPECIFICATIONS.
NOTE: SPECIAL LUBRICANTS ARE REQUIRED FOR DANA FULL FLOAT REAR AXLES. USE
FORD HYPOID GEAR LUBE (C6AZ-19580-E OR EQUIVALENT), OR FOR EXTREME SERVICE
APPLICATIONS, USE FORD HIGH PERFORMANCE REAR AXLE LUBE (F1TZ-19580-B OR
EQUIVALENT). REFER TO TSB 92-3-11 FOR ADDITIONAL LUBRICANT INFORMATION.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Shaft: > 932514 >
Dec > 93 > Full Float Rear Hub/Shaft - Lubricant Leaks > Page 4702
OTHER APPLICABLE ARTICLES: 92-3-11 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage For 1992/94 Models, Basic Warranty Coverage For All
Other Models
OPERATION DESCRIPTION TIME
932514A Replace Axle Shaft/Hub 0.4 Hr.
Gaskets And Bolts (One Side)
932514B Replace Axle Shaft/Hub 0.6 Hr.
Gaskets And Bolts (Both Sides)
DEALER CODING
BASIC PART NO. CONDITION CODE
4A140 33
OASIS CODES: 509000, 590000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Dana/Spicer Integral Housing Type
Axle Shaft: Service and Repair Dana/Spicer Integral Housing Type
Full-Floating Axle
1. Set parking brake and loosen axle shaft bolts.
2. Raise and support rear of vehicle so that axle is parallel with floor.
3. Remove axle shaft bolts.
4. Remove axle shaft and discard gasket.
5. Pry out locking wedge with screwdriver.
6. Raise wheel until weight is removed from wheel bearing.
7. Remove wheel bearing adjustment nut.
8. Remove outer bearing cone and pull wheel assembly from axle.
9. Drive inner bearing cone and seal out of wheel hub with brass drift.
10. Inspect bearings and races and replace if worn or damaged. Drive races from wheel hub with
brass drift.
11. Lubricate bearing cone and roller assemblies and place inner assemblies into wheel hub. Install
new hub inner seal.
12. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and
remove tape.
13. Install outer wheel bearing and start adjuster nut. Lower wheel to ground.
14. While rotating wheel, torque adjusting nut to 120-140 ft. lbs. Back off the nut to obtain
0.001---0.010 inch endplay (1/8-3/8 turn). If nut or locking wedge are damaged or do not allow for
proper endplay they should be replaced.
15. Position locking wedge in key way slot, making sure it is not bottomed against the shoulder of
adjusting nut.
16. Install axle shaft and new flange gasket, then install retaining bolts and torque locking bolts to
40---50 ft. lbs.
17. Adjust brakes.
18. Remove supports and lower vehicle.
Semi-Floating Axle
1. Raise and support vehicle.
2. Remove wheel and brake drum.
3. Remove cover plate and discard gasket.
4. Remove differential pinion shaft lock screw and the shaft.
5. Remove C-clip from button end of shaft by pushing inward on other end.
6. Pull shaft from axle tube. Do not rotate differential side gears.
7. Remove and discard oil seal from axle tube.
8. Pull bearing from axle tube.
9. Lubricate new bearing and install in axle tube.
10. Lubricate and install new oil seal.
11. Insert shaft into axle tube, making sure splines engage side gears, then install C-clip and pull
shaft outward until the clip locks.
12. Install pinion mate shaft, aligning lock pin holes, and pinion gear side washers.
13. Install new lock screw and torque to 8 ft. lbs. on 1980---81 models, or 20---25 ft. lbs. on
1982---87 models.
14. Install cover plate and gasket. Torque bolts to 30---40 ft. lbs.
15. Install wheel and drum assembly.
16. Remove supports and lower vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 4705
Axle Shaft: Service and Repair Ford Integral Carrier Type Axle
1. Raise and support vehicle, then remove rear wheel and brake drum.
2. Loosen rear housing cover screws and allow lubricant to drain, then remove cover.
3. Remove differential pinion shaft lock bolt and differential pinion shaft.
4. Move flanged end of axle shaft inward and remove C-lock from end of shaft.
5. Remove axle shaft from housing by pulling outward.
6. Reverse procedure to install. Apply Loctite EOAZ-19554-B to pinion shaft lock bolt threads, then
torque lock bolt to 15-30 ft. lbs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 4706
Axle Shaft: Service and Repair Ford Removable Carrier Type
Removal, Units w/Ball Bearing
1. Remove wheel assembly.
2. Remove brake drum from flange.
3. Working through hole provided in axle shaft flange, remove nuts that secure wheel bearing
retainer.
4. Pull axle shaft out of housing. If bearing is a tight fit in axle housing, use a slide hammer type
puller.
5. Remove brake backing plate and secure to frame rail.
6. If the axle shaft bearing is to be replaced, loosen the inner retainer by nicking it deeply with a
chisel in several places. The bearing will then slide off easily.
7. Press bearing from axle shaft.
8. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing
action of the oil seal. Carefully remove any burrs or rough spots.
Installation
1. Press new bearing on shaft until it seats firmly against shoulder on shaft.
2. Press inner bearing retainer on shaft until it seats firmly against bearing.
3. If oil seal is to be replaced, use a hook-type tool to pull it out of housing. Wipe a small amount of
oil resistant sealer on outer edge of seal before it is installed.
Removal, Units W/Roller Bearing
1. Remove wheel assembly.
2. Remove brake drum from flange.
3. Working through hole provided in axle flange, remove nuts securing wheel bearing retainer.
4. Pull axle shaft carefully from housing to prevent damage to outer seal rubber. Use a slide
hammer type puller to remove tapered bearing cup from housing. Remove brake backing plate and
secure to frame rail.
5. If the axle shaft bearing or seal is to be replaced, split the inner bearing retainer.
6. Press bearing from axle shaft.
7. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing
action of the oil seal. Carefully remove any burrs or rough spots.
8. Install outer retainer plate on axle shaft. Press lubricated seal and bearing onto shaft until firmly
seated. Oil seal for rear drum brake equipped vehicles is different than that used on vehicles with
rear disc brakes. Seals used with drum brakes have a gray metal colored outer rim, while seals
used with disc brakes have a black or orange color.
9. Press new bearing retainer onto shaft until seated.
Installation
1. On 1980---84 models, place a new gasket on each side of brake carrier plate, and slide axle
shaft into housing. On models with roller bearing, ensure outer seal is fully seated on bearing.
2. Start splines into differential side gear and push shaft in until bearing bottoms in housing.
3. Torque bearing retainer nuts to 20---40 ft. lbs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Service and Repair
Seals and Gaskets: Service and Repair
Removal, Units w/Ball Bearing
1. Remove wheel assembly.
2. Remove brake drum from flange.
3. Working through hole provided in axle shaft flange, remove nuts that secure wheel bearing
retainer.
4. Pull axle shaft out of housing. If bearing is a tight fit in axle housing, use a slide hammer type
puller.
5. Remove brake backing plate and secure to frame rail.
6. If the axle shaft bearing is to be replaced, loosen the inner retainer by nicking it deeply with a
chisel in several places. The bearing will then slide off easily.
7. Press bearing from axle shaft.
8. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing
action of the oil seal. Carefully remove any burrs or rough spots.
Installation
1. Press new bearing on shaft until it seats firmly against shoulder on shaft.
2. Press inner bearing retainer on shaft until it seats firmly against bearing.
3. If oil seal is to be replaced, use a hook-type tool to pull it out of housing. Wipe a small amount of
oil resistant sealer on outer edge of seal before it is installed.
Removal, Units W/Roller Bearing
1. Remove wheel assembly.
2. Remove brake drum from flange.
3. Working through hole provided in axle flange, remove nuts securing wheel bearing retainer.
4. Pull axle shaft carefully from housing to prevent damage to outer seal rubber. Use a slide
hammer type puller to remove tapered bearing cup from housing. Remove brake backing plate and
secure to frame rail.
5. If the axle shaft bearing or seal is to be replaced, split the inner bearing retainer.
6. Press bearing from axle shaft.
7. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing
action of the oil seal. Carefully remove any burrs or rough spots.
8. Install outer retainer plate on axle shaft. Press lubricated seal and bearing onto shaft until firmly
seated. Oil seal for rear drum brake equipped vehicles is different than that used on vehicles with
rear disc brakes. Seals used with drum brakes have a gray metal colored outer rim, while seals
used with disc brakes have a black or orange color.
9. Press new bearing retainer onto shaft until seated.
Installation
1. On 1980---84 models, place a new gasket on each side of brake carrier plate, and slide axle
shaft into housing. On models with roller bearing, ensure outer seal is fully seated on bearing.
2. Start splines into differential side gear and push shaft in until bearing bottoms in housing.
3. Torque bearing retainer nuts to 20---40 ft. lbs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Wheel Bearing Torque Specification - Manual Correction
Wheel Bearing: Technical Service Bulletins Wheel Bearing Torque Specification - Manual
Correction
WHEEL BEARING - FRONT - ADJUSTING NUT TORQUE SPECIFICATION - SHOP MANUAL
CORRECTION
Article No. 88-4-15
LIGHT TRUCK: 1987-88 E-SERIES
ISSUE: The front wheel bearing adjusting nut torque specification as published in the 1987 and
1988 Light Truck Shop Manual, Volume A, Section 12-24-3, Figures 2 and 3 is incorrect.
ACTION: If service is required, torque the front wheel bearing adjusting nut to 22-25 ft.lbs. (30-33
N-m) and then back the adjusting nut off 1/8 turn as described in the Light Truck Shop Manual,
Volume A, Section 11-10-1.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Page 4714
Wheel Bearing: Specifications
Wheel Adjusting Nut [1] .......................................................................................................................
........................................... 30-33 Nm (22-25 ft lbs)
Bearing End Play
..............................................................................................................................................................
0.025-0.254mm (0.001-0.010 in)
[1] Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional
movement of the adjusting nut.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Page 4715
Wheel Bearing: Adjustments
1. Raise the vehicle until the tire clears the floor and install safety stands.
2. Remove the wheel cover.
3. Remove the grease cap from the hub. Wipe the excess grease from the end of the spindle.
Remove the cotter pin and locknut.
4. Loosen the adjusting nut three turns. Attempt to obtain running clearance between the rotor
brake surface and the disc pads by rocking the wheel,
hub and rotor assembly in and out several times to push the pads away from the rotor. If running
clearance cannot be maintained throughout bearing adjustment in Steps 5 and 6, the caliper must
be removed.
NOTE: Do not pry on the phenolic caliper piston.
5. Tighten the wheel adjusting nut to 30-33 Nm (22-25 ft lbs) while rotating the disc brake rotor in
the opposite direction.
6. Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional
movement of the adjusting nut. Bearing end play
should be 0.025-0.254mm (0.001-0.010 in). Bend the ends of the cotter pin around the castellated
flange of the locknut.
7. Check front wheel rotation. If the wheel rotates properly, reinstall the grease cap and wheel
cover. If rotation is noisy or rough, remove and inspect
the bearings. Service as required.
WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake
pedal travel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Page 4716
Wheel Bearing: Service and Repair
Wheel bearing lubricant is a lithium-base grease. Sodium-base grease is not compatible with
lithium-base grease and should not be intermixed. Therefore, do not lubricate front and/or rear
wheel bearings without first identifying the type of original wheel bearing lubricant. Usage of
incompatible bearing lubricants may result in premature lubricant breakdown.
REMOVAL
Front Hub And Rotor Assembly
1. Raise the vehicle until the tire clears the floor and remove the wheel and tire assembly.
2. Remove the brake caliper and secure to the underbody to prevent damage to the brake hose. It
is not necessary to disconnect the hose from the
caliper. Do not let the caliper hang with its weight on the brake hose or the hose may become
stretched, twisted or ruptured. See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair
3. Remove the grease cap, cotter pin, retainer adjusting nut and washer.
4. Remove the outer bearing cone and roller.
5. Pull the hub and rotor off the spindle and remove and discard the grease seal.
6. Remove the inner bearing cone and roller from the hub. Remove all traces of old lubricant from
bearings, hub and axle spindle.
7. Inspect the cups for scratches, pits or cracks. If the cups are worn or damaged, remove them
with a drift. Clean the inner and outer bearing cones
and rollers with solvent and dry thoroughly.
CAUTION: Do not spin the bearings dry with compressed air.
8. Inspect the cones and rollers for cracks, nicks, brinelling, or seized rollers. Inspect the grease
retainer and replace it if it is cracked, nicked, dented
or worn.
9. Cover the spindle with a clean cloth. A water dampened cloth or water based solution should be
used to remove and dust or loose dirt from the
brake assembly. Remove the cloth from the spindle carefully to prevent dirt from falling on the
spindle.
NOTE: Do not use compressed air.
INSTALLATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Page 4717
Installing Bearing Cups (Typical)
1. If inner or outer bearing cups were removed, install replacement inner and outer bearing cups in
the hub with the appropriate bearing cup replacer
tool. Be sure to seat the cups properly in the hub. The cups will be properly seated when they are
fully bottomed. Replace grease retainers. Polish grease retainer journal on spindle with 400 grit
sandpaper. Clean with clean cloth.
2. Pack the inside of the hub with lithium-base grease or equivalent. Fill the hub until the grease is
flush with the inside diameters of both bearing
cups. Pack the bearing cones and rollers with wheel bearing grease. Use a bearing packer for this
operation. If a packer is not available, work as much lubricant as possible between the rollers and
cages. Lubricate the cone surfaces with grease.
Installing Grease Seal (Typical)
3. Place the inner bearing cone and roller in the inner cup and install the new grease seal. Be sure
that the seal is fully seated.
4. Install the hub and rotor on the wheel spindle. Keep the hub centered on the spindle to prevent
damage to the grease retainer or the spindle threads.
5. Install the outer bearing cone and roller and the flat washer on the spindle, then install the
adjusting nut, and adjust the wheel bearing.
6. Install the retainer, new cotter pin, and grease cap.
7. Install the caliper.
8. Install the wheel and tire assembly.
9. Lower vehicle and torque the lug nuts to specification. Re-install the wheel cover or hub cap.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Technical Service Bulletins > Page 4718
WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake
pedal travel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Technical Service Bulletins > Customer Interest for Wheel Hub: > 932514 > Dec > 93 > Full Float Rear
Hub/Shaft - Lubricant Leaks
Wheel Hub: Customer Interest Full Float Rear Hub/Shaft - Lubricant Leaks
Article No. 93-25-14
12/08/93
^ AXLE - "DANA" FULL FLOAT REAR - NEW HUB/SHAFT BOLTS AND REVISED TORQUE
SPECIFICATIONS
^ AXLE - "DANA" FULL FLOAT REAR - SHAFT/HUB BOLTS LOOSEN AND LEAK AXLE LUBE SERVICE TIPS
^ LEAKS - AXLE LUBE - REAR AXLE SHAFT/HUB BOLTS LOOSEN - SERVICE TIPS
LIGHT TRUCK: 1980-94 E-350 1988-94 F SUPER DUTY
ISSUE: The rear axle shaft/hub bolts may loosen and leak axle lube. This loosening can occur due
to increased torques at the rear wheels.
ACTION: Install new higher strength flange head bolts and improved cellulose gaskets, which
clamp the joint together tighter. Refer to the following service tips and revised torque specifications.
^ Do not use higher torques specified for these bolts on previously specified hex head bolts.
^ Always replace the bolts and gaskets together rather than reusing them when servicing the wheel
end.
^ The new cellulose gaskets and new flanged head bolts are designed to be used together;
therefore, neither part should be used with older stock parts.
NOTE: WHEN REMOVING THE BOLTS, LOOSEN THEM BY HAND BEFORE USING AN
IMPACT WRENCH. THE SHOCK LOAD APPLIED BY A POWER TOOL MAY CAUSE THE BOLT
TO SNAP BEFORE IT RELEASES.
NOTE:
WHEN SERVICING THE REAR AXLE HUB OR SHAFT, REPLACE THE BOLTS AND GASKET
WITH THE NEW PARTS. USE THE NEW TORQUE SPECIFICATIONS.
NOTE: SPECIAL LUBRICANTS ARE REQUIRED FOR DANA FULL FLOAT REAR AXLES. USE
FORD HYPOID GEAR LUBE (C6AZ-19580-E OR EQUIVALENT), OR FOR EXTREME SERVICE
APPLICATIONS, USE FORD HIGH PERFORMANCE REAR AXLE LUBE (F1TZ-19580-B OR
EQUIVALENT). REFER TO TSB 92-3-11 FOR ADDITIONAL LUBRICANT INFORMATION.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Technical Service Bulletins > Customer Interest for Wheel Hub: > 932514 > Dec > 93 > Full Float Rear
Hub/Shaft - Lubricant Leaks > Page 4727
OTHER APPLICABLE ARTICLES: 92-3-11 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage For 1992/94 Models, Basic Warranty Coverage For All
Other Models
OPERATION DESCRIPTION TIME
932514A Replace Axle Shaft/Hub 0.4 Hr.
Gaskets And Bolts (One Side)
932514B Replace Axle Shaft/Hub 0.6 Hr.
Gaskets And Bolts (Both Sides)
DEALER CODING
BASIC PART NO. CONDITION CODE
4A140 33
OASIS CODES: 509000, 590000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 932514 > Dec > 93 > Full Float
Rear Hub/Shaft - Lubricant Leaks
Wheel Hub: All Technical Service Bulletins Full Float Rear Hub/Shaft - Lubricant Leaks
Article No. 93-25-14
12/08/93
^ AXLE - "DANA" FULL FLOAT REAR - NEW HUB/SHAFT BOLTS AND REVISED TORQUE
SPECIFICATIONS
^ AXLE - "DANA" FULL FLOAT REAR - SHAFT/HUB BOLTS LOOSEN AND LEAK AXLE LUBE SERVICE TIPS
^ LEAKS - AXLE LUBE - REAR AXLE SHAFT/HUB BOLTS LOOSEN - SERVICE TIPS
LIGHT TRUCK: 1980-94 E-350 1988-94 F SUPER DUTY
ISSUE: The rear axle shaft/hub bolts may loosen and leak axle lube. This loosening can occur due
to increased torques at the rear wheels.
ACTION: Install new higher strength flange head bolts and improved cellulose gaskets, which
clamp the joint together tighter. Refer to the following service tips and revised torque specifications.
^ Do not use higher torques specified for these bolts on previously specified hex head bolts.
^ Always replace the bolts and gaskets together rather than reusing them when servicing the wheel
end.
^ The new cellulose gaskets and new flanged head bolts are designed to be used together;
therefore, neither part should be used with older stock parts.
NOTE: WHEN REMOVING THE BOLTS, LOOSEN THEM BY HAND BEFORE USING AN
IMPACT WRENCH. THE SHOCK LOAD APPLIED BY A POWER TOOL MAY CAUSE THE BOLT
TO SNAP BEFORE IT RELEASES.
NOTE:
WHEN SERVICING THE REAR AXLE HUB OR SHAFT, REPLACE THE BOLTS AND GASKET
WITH THE NEW PARTS. USE THE NEW TORQUE SPECIFICATIONS.
NOTE: SPECIAL LUBRICANTS ARE REQUIRED FOR DANA FULL FLOAT REAR AXLES. USE
FORD HYPOID GEAR LUBE (C6AZ-19580-E OR EQUIVALENT), OR FOR EXTREME SERVICE
APPLICATIONS, USE FORD HIGH PERFORMANCE REAR AXLE LUBE (F1TZ-19580-B OR
EQUIVALENT). REFER TO TSB 92-3-11 FOR ADDITIONAL LUBRICANT INFORMATION.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 932514 > Dec > 93 > Full Float
Rear Hub/Shaft - Lubricant Leaks > Page 4733
OTHER APPLICABLE ARTICLES: 92-3-11 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage For 1992/94 Models, Basic Warranty Coverage For All
Other Models
OPERATION DESCRIPTION TIME
932514A Replace Axle Shaft/Hub 0.4 Hr.
Gaskets And Bolts (One Side)
932514B Replace Axle Shaft/Hub 0.6 Hr.
Gaskets And Bolts (Both Sides)
DEALER CODING
BASIC PART NO. CONDITION CODE
4A140 33
OASIS CODES: 509000, 590000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 88621 > Mar
> 88 > Driveshaft - Clicking/Popping Noise
Drive/Propeller Shaft: Customer Interest Driveshaft - Clicking/Popping Noise
^ DRIVELINE - ALUMINUM DRIVESHAFT - Article No.
"CLICKING" OR "POPPING" NOISE 88-6-21
^ NOISE - "CLICKING" OR "POPPING" - ALUMINUM DRIVESHAFT
LIGHT TRUCK: 1986-88 AEROSTAR 1987-88 E-SERIES, F-SERIES
ISSUE: A "clicking" or "popping" noise from the driveshaft during transmission engagement or
when accelerating from a stop may be caused by inadequate tubeto-yoke bonding on the
aluminum driveshaft.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 88621 > Mar
> 88 > Driveshaft - Clicking/Popping Noise > Page 4743
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 88621 > Mar
> 88 > Driveshaft - Clicking/Popping Noise > Page 4744
ACTION: To correct this, install a new aluminum driveshaft with an improved tube-to-yoke bond.
Refer to the appropriate model year Shop Manual for driveshaft removal and installation
procedures. Refer to the driveshaft application charts on pages 38 and 39 of this TSB for the
correct part numbers.
PART NUMBER PART NAME CLASS
E8TZ-4602-W Aluminum Driveshaft C
E8TZ-4602-Y Aluminum Driveshaft C
E8TZ-4602-Z Aluminum Driveshaft C
E8TZ-4602-AB Aluminum Driveshaft C
E8UZ-4602-C Aluminum Driveshaft C
E8UZ-4602-D Aluminum Driveshaft C
E8UZ-4602-E Aluminum Driveshaft C
E8UZ-4602-F Aluminum Driveshaft C
E89Z-4602-B Aluminum Driveshaft C
E89Z-4602-C Aluminum Driveshaft C
E79Z-4602-A Aluminum Driveshaft C
OTHER APPLICABLE ARTICLES: Supersedes 86-23-20 WARRANTY STATUS: Eligible Under
Powertrain Warranty Coverage OPERATION: 880621A - One-piece driveshaft TIME:
0.4 Hr. - Aerostar 0.3 Hr. - E-Series, F-Series
OPERATION: 880621B - Two-piece driveshaft TIME:
0.5 Hr. - E-Series, F-Series
DLR. CODING: Basic Part No. 4602 - Code: 61
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 872218 > Nov
> 87 > Driveline - Clunk/Grunt Noise On Start Up
Drive/Propeller Shaft: Customer Interest Driveline - Clunk/Grunt Noise On Start Up
Article No. 87-22-18
^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND
STOPPING
^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING
LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87
AEROSTAR
This article is being republished in its entirety to clarify the slip yoke application chart.
ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive
modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the
transmission output shaft splines. During the same drive modes, rear suspension wrap-up
overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which
results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6
transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission;
1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2)
and 1986-87 Aerostar.
ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for
smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke
removal and installation procedures. Also, refer to the slip yoke application chart below for the
correct service part number.
PART NUMBER PART NAME CLASS
E6TZ-4841-D Slip Yoke C
E6TZ-4841-E Slip Yoke C
E6TZ-4841-F Slip Yoke C
E4TZ-4841-G Slip Yoke B
E1TZ-4841-D Slip Yoke B
D5UZ-4841-C Slip Yoke B
OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible
Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part
No. 4841 - Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 87536 > Mar
> 87 > Driveshafts - Vibration
Drive/Propeller Shaft: Customer Interest Driveshafts - Vibration
^ VIBRATION/NVH - DRIVESHAFTS Article No. 87-5-36
^ DRIVESHAFTS - VIBRATION/NVH Supersedes 87-2-28
LIGHT TRUCK 1987 E-150/350, F-150/350 ISSUE:
Several driveline changes have occurred at or shortly after Job #1, 1987. The following is a list of
the changes.
^ All two (2) piece steel driveshafts are system balanced. These driveshafts may be identified by an
engineering base part number 4K145 or a service base part number 4R602.
^ 4" aluminum one (1) piece driveshafts replaced two (2) piece steel driveshafts where possible
(production incorporation delayed on some applications).
^ 8.8" high torque rear axles replaced the 9" rear axles.
NOTE: Refer to TSB 86-15-14 and 86-15-15 for 9" rear axle driveshaft vibration concerns.
ACTION: When vibration complaints caused by the driveshaft are encountered, refer to the
following steps for the appropriate service action.
^ Vehicles with one (1) piece driveshafts
- Balance the driveshaft on the vehicle.
- If balancing is unsuccessful, replace the driveshaft.
^ Vehicles with two (2) piece steel driveshafts
- Replace two (2) piece driveshaft with a one
(1) piece aluminum driveshaft if instructed to by a technical service bulletin.
- Replace two (2) piece driveshaft with a system balanced two (2) piece service driveshaft (4R602)
if a one (1) piece driveshaft is applicable.
Refer to the following service procedure to install the new design aluminum driveshaft. The
driveshaft application chart on page 2 of this TSB should be used to obtain the correct aluminum
driveshaft service part number.
NOTE: Some vehicles will continue to use twopiece drivelines for structural reasons. These
assemblies are system balanced.
CAUTION: Never replace a two-piece steel driveshaft with a one-piece steel driveshaft.
1. Remove the existing two-piece driveshaft.
2. Remove the two-piece driveshaft center bearing support plate. Rivets are to be removed by
chiseling off the heads. Drilling or the use of cutting torch may result in damage to the
crossmember.
NOTE: The support plate must be removed to prevent interference with the new one-piece
aluminum driveshaft.
3. Install the new one-piece aluminum driveshaft. Make sure the yellow dot on the driveshaft and
axle flange are aligned.
NOTE: If the yellow dot on the axle flange is not visible, the vehicle will have to be test driven to
determine the best location.
4. Tighten U-bolt nuts to 8-15 ft.lbs. (11-20 N-m). On circular flange equipped driveshaft, tighten the
bolts to 61-87 ft.lbs. (73-118 N-m).
NOTE: The circular flange type attachment allows 45~ intervals for improved NVH tuning.
PART NUMBER PART NAME CLASS
E7UZ-4602-M Aluminum Driveshaft C
E7UZ-4602-N Aluminum Driveshaft C
E7UZ-4602-P Aluminum Driveshaft C
E7UZ-4602-T Aluminum Driveshaft C
E7TZ-4602-U Aluminum Driveshaft C
E7TZ-4602-V Aluminum Driveshaft C
E7TZ-4602-W Aluminum Driveshaft C
E7TZ-4602-X Aluminum Driveshaft C
E7TZ-4602-Y Aluminum Driveshaft C
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > Customer Interest for Drive/Propeller Shaft: > 87536 > Mar
> 87 > Driveshafts - Vibration > Page 4753
E7TZ-4602-Z Aluminum Driveshaft C
OTHER APPLICABLE ARTICLES: 86-15-14 86-15-15, Supersedes 87-2-28 WARRANTY
STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION:
SP870536A - Install one-piece driveshaft TIME:
0.8 Hr.
OPERATION: SP870536S1 - Extra time to re-index driveshaft TIME:
0.4 Hr. DLR. CODING: Basic Part No. 4602 - Code: 67
DRIVESHAFT APPLICATION CHART
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
88621 > Mar > 88 > Driveshaft - Clicking/Popping Noise
Drive/Propeller Shaft: All Technical Service Bulletins Driveshaft - Clicking/Popping Noise
^ DRIVELINE - ALUMINUM DRIVESHAFT - Article No.
"CLICKING" OR "POPPING" NOISE 88-6-21
^ NOISE - "CLICKING" OR "POPPING" - ALUMINUM DRIVESHAFT
LIGHT TRUCK: 1986-88 AEROSTAR 1987-88 E-SERIES, F-SERIES
ISSUE: A "clicking" or "popping" noise from the driveshaft during transmission engagement or
when accelerating from a stop may be caused by inadequate tubeto-yoke bonding on the
aluminum driveshaft.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
88621 > Mar > 88 > Driveshaft - Clicking/Popping Noise > Page 4759
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
88621 > Mar > 88 > Driveshaft - Clicking/Popping Noise > Page 4760
ACTION: To correct this, install a new aluminum driveshaft with an improved tube-to-yoke bond.
Refer to the appropriate model year Shop Manual for driveshaft removal and installation
procedures. Refer to the driveshaft application charts on pages 38 and 39 of this TSB for the
correct part numbers.
PART NUMBER PART NAME CLASS
E8TZ-4602-W Aluminum Driveshaft C
E8TZ-4602-Y Aluminum Driveshaft C
E8TZ-4602-Z Aluminum Driveshaft C
E8TZ-4602-AB Aluminum Driveshaft C
E8UZ-4602-C Aluminum Driveshaft C
E8UZ-4602-D Aluminum Driveshaft C
E8UZ-4602-E Aluminum Driveshaft C
E8UZ-4602-F Aluminum Driveshaft C
E89Z-4602-B Aluminum Driveshaft C
E89Z-4602-C Aluminum Driveshaft C
E79Z-4602-A Aluminum Driveshaft C
OTHER APPLICABLE ARTICLES: Supersedes 86-23-20 WARRANTY STATUS: Eligible Under
Powertrain Warranty Coverage OPERATION: 880621A - One-piece driveshaft TIME:
0.4 Hr. - Aerostar 0.3 Hr. - E-Series, F-Series
OPERATION: 880621B - Two-piece driveshaft TIME:
0.5 Hr. - E-Series, F-Series
DLR. CODING: Basic Part No. 4602 - Code: 61
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
872218 > Nov > 87 > Driveline - Clunk/Grunt Noise On Start Up
Drive/Propeller Shaft: All Technical Service Bulletins Driveline - Clunk/Grunt Noise On Start Up
Article No. 87-22-18
^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND
STOPPING
^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING
LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87
AEROSTAR
This article is being republished in its entirety to clarify the slip yoke application chart.
ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive
modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the
transmission output shaft splines. During the same drive modes, rear suspension wrap-up
overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which
results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6
transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission;
1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2)
and 1986-87 Aerostar.
ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for
smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke
removal and installation procedures. Also, refer to the slip yoke application chart below for the
correct service part number.
PART NUMBER PART NAME CLASS
E6TZ-4841-D Slip Yoke C
E6TZ-4841-E Slip Yoke C
E6TZ-4841-F Slip Yoke C
E4TZ-4841-G Slip Yoke B
E1TZ-4841-D Slip Yoke B
D5UZ-4841-C Slip Yoke B
OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible
Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part
No. 4841 - Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
87536 > Mar > 87 > Driveshafts - Vibration
Drive/Propeller Shaft: All Technical Service Bulletins Driveshafts - Vibration
^ VIBRATION/NVH - DRIVESHAFTS Article No. 87-5-36
^ DRIVESHAFTS - VIBRATION/NVH Supersedes 87-2-28
LIGHT TRUCK 1987 E-150/350, F-150/350 ISSUE:
Several driveline changes have occurred at or shortly after Job #1, 1987. The following is a list of
the changes.
^ All two (2) piece steel driveshafts are system balanced. These driveshafts may be identified by an
engineering base part number 4K145 or a service base part number 4R602.
^ 4" aluminum one (1) piece driveshafts replaced two (2) piece steel driveshafts where possible
(production incorporation delayed on some applications).
^ 8.8" high torque rear axles replaced the 9" rear axles.
NOTE: Refer to TSB 86-15-14 and 86-15-15 for 9" rear axle driveshaft vibration concerns.
ACTION: When vibration complaints caused by the driveshaft are encountered, refer to the
following steps for the appropriate service action.
^ Vehicles with one (1) piece driveshafts
- Balance the driveshaft on the vehicle.
- If balancing is unsuccessful, replace the driveshaft.
^ Vehicles with two (2) piece steel driveshafts
- Replace two (2) piece driveshaft with a one
(1) piece aluminum driveshaft if instructed to by a technical service bulletin.
- Replace two (2) piece driveshaft with a system balanced two (2) piece service driveshaft (4R602)
if a one (1) piece driveshaft is applicable.
Refer to the following service procedure to install the new design aluminum driveshaft. The
driveshaft application chart on page 2 of this TSB should be used to obtain the correct aluminum
driveshaft service part number.
NOTE: Some vehicles will continue to use twopiece drivelines for structural reasons. These
assemblies are system balanced.
CAUTION: Never replace a two-piece steel driveshaft with a one-piece steel driveshaft.
1. Remove the existing two-piece driveshaft.
2. Remove the two-piece driveshaft center bearing support plate. Rivets are to be removed by
chiseling off the heads. Drilling or the use of cutting torch may result in damage to the
crossmember.
NOTE: The support plate must be removed to prevent interference with the new one-piece
aluminum driveshaft.
3. Install the new one-piece aluminum driveshaft. Make sure the yellow dot on the driveshaft and
axle flange are aligned.
NOTE: If the yellow dot on the axle flange is not visible, the vehicle will have to be test driven to
determine the best location.
4. Tighten U-bolt nuts to 8-15 ft.lbs. (11-20 N-m). On circular flange equipped driveshaft, tighten the
bolts to 61-87 ft.lbs. (73-118 N-m).
NOTE: The circular flange type attachment allows 45~ intervals for improved NVH tuning.
PART NUMBER PART NAME CLASS
E7UZ-4602-M Aluminum Driveshaft C
E7UZ-4602-N Aluminum Driveshaft C
E7UZ-4602-P Aluminum Driveshaft C
E7UZ-4602-T Aluminum Driveshaft C
E7TZ-4602-U Aluminum Driveshaft C
E7TZ-4602-V Aluminum Driveshaft C
E7TZ-4602-W Aluminum Driveshaft C
E7TZ-4602-X Aluminum Driveshaft C
E7TZ-4602-Y Aluminum Driveshaft C
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive/Propeller Shaft: >
87536 > Mar > 87 > Driveshafts - Vibration > Page 4769
E7TZ-4602-Z Aluminum Driveshaft C
OTHER APPLICABLE ARTICLES: 86-15-14 86-15-15, Supersedes 87-2-28 WARRANTY
STATUS: Reimbursable within the provisions of the Warranty and Policy Manual OPERATION:
SP870536A - Install one-piece driveshaft TIME:
0.8 Hr.
OPERATION: SP870536S1 - Extra time to re-index driveshaft TIME:
0.4 Hr. DLR. CODING: Basic Part No. 4602 - Code: 67
DRIVESHAFT APPLICATION CHART
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke >
Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 872218 > Nov > 87 > Driveline Clunk/Grunt Noise On Start Up
Slip Yoke: Customer Interest Driveline - Clunk/Grunt Noise On Start Up
Article No. 87-22-18
^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND
STOPPING
^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING
LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87
AEROSTAR
This article is being republished in its entirety to clarify the slip yoke application chart.
ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive
modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the
transmission output shaft splines. During the same drive modes, rear suspension wrap-up
overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which
results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6
transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission;
1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2)
and 1986-87 Aerostar.
ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for
smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke
removal and installation procedures. Also, refer to the slip yoke application chart below for the
correct service part number.
PART NUMBER PART NAME CLASS
E6TZ-4841-D Slip Yoke C
E6TZ-4841-E Slip Yoke C
E6TZ-4841-F Slip Yoke C
E4TZ-4841-G Slip Yoke B
E1TZ-4841-D Slip Yoke B
D5UZ-4841-C Slip Yoke B
OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible
Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part
No. 4841 - Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 872218 > Nov > 87 >
Driveline - Clunk/Grunt Noise On Start Up
Slip Yoke: All Technical Service Bulletins Driveline - Clunk/Grunt Noise On Start Up
Article No. 87-22-18
^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND
STOPPING
^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING
LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87
AEROSTAR
This article is being republished in its entirety to clarify the slip yoke application chart.
ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive
modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the
transmission output shaft splines. During the same drive modes, rear suspension wrap-up
overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which
results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6
transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission;
1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2)
and 1986-87 Aerostar.
ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for
smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke
removal and installation procedures. Also, refer to the slip yoke application chart below for the
correct service part number.
PART NUMBER PART NAME CLASS
E6TZ-4841-D Slip Yoke C
E6TZ-4841-E Slip Yoke C
E6TZ-4841-F Slip Yoke C
E4TZ-4841-G Slip Yoke B
E1TZ-4841-D Slip Yoke B
D5UZ-4841-C Slip Yoke B
OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible
Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part
No. 4841 - Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Description and Operation
Universal Joint: Description and Operation
Fig. 3 Cross & roller type universal joints
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Description and Operation > Page 4786
Fig. 4 Cross & roller type universal joints & propeller shaft
Figs. 3 and 4 illustrate typical examples of universal joints of this type. They all operate on the
same principle and similar service and replacement procedures may be applied to all.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool
Universal Joint: Service and Repair Servicing Using Universal Joint Replacement Tool
Fig. 7 Removing bearing caps using tool & adapter
Fig. 8 Removing bearing cap by holding cap in vise & striking center yoke with hammer
Disassembly
1. Place driveshaft in a vise using care to avoid damaging it.
2. Remove bearing retaining snap rings. Some universal joints use injected nylon retainers in place
of snap rings. During servicing, the snap rings supplied with the replacement universal joint
assembly must be used.
3. Position tool on shaft and press bearing out of yoke, Fig. 7. If bearing cannot be pressed all the
way out, remove it using vise grips or channel lock pliers or position driveshaft as shown and strike
center yoke with hammer, Fig. 8. Mark yoke and shaft to make sure they will be reassembled in
their same relative positions.
4. Reposition tool so that it presses on the spider in order to press other bearing from opposite side
of flange.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool >
Page 4789
5. If used, remove flange from spider.
Assembly
1. Start new bearing into yoke, then position spider into yoke and press bearing until it is 1/4 inch
below surface.
2. Remove tool and install a new snap ring.
3. Start new bearing in opposite side of yoke, then install tool and press on bearing until opposite
bearing contacts snap ring.
4. Remove tool and install remaining snap ring.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool >
Page 4790
Universal Joint: Service and Repair Servicing Without Universal Joint Replacement Tool
Fig. 5 Removing bearings from yoke using a small socket as a driver & large socket as a receiver
Disassembly
1. Remove snap rings (or retainer plates) that retain bearings in yoke and drive shaft.
2. Place U-joint in a vise.
3. Select a wrench socket with an outside diameter slightly smaller than the U-joint bearings. Select
another wrench socket with an inside diameter slightly larger than the U-joint bearings.
4. Place the sockets at opposite bearings in the yoke so that the smaller socket becomes a bearing
pusher and the larger socket becomes a bearing receiver when the vise jaws come together, Fig.
5. Close vise jaws until both bearings are free of yoke and remove bearings from the cross or
spider.
5. If bearings will not come all the way out, close vise until bearing in receiver socket protrudes
from yoke as much as possible without using excessive force. Then remove from vise and place
that portion of bearing which protrudes from yoke between vise jaws. Tighten vise to hold bearing
and drive yoke off with a soft hammer.
6. To remove opposite bearing from yoke, replace in vise with pusher socket on exposed cross
journal with receiver socket over bearing cup. Then tighten vise jaws to press bearing back through
yoke into receiving socket.
7. Remove yoke from drive shaft and again place protruding portion of bearing between vise jaws.
Then tighten vise to hold bearing while driving yoke off bearing with soft hammer.
8. Turn spider or cross 1/4 turn and use the same procedure to press bearings out of drive shaft.
Fig. 6 Installing bearings into driveshaft yoke
Assembly
1. If old parts are to be reassembled, pack bearing cups with universal joint grease. Do not fill cups
completely or use excessive amounts as
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool >
Page 4791
over-lubrication may damage seals during reassembly. Use new seals.
2. If new parts are being installed, check new bearings for adequate grease before assembling.
3. With the pusher (smaller) socket, press one bearing part way into drive shaft. Position spider into
the partially installed bearing. Place second bearing into drive shaft. Fasten drive shaft in vise so
that bearings are in contact with faces of vise jaws, Fig. 6. Some spiders are provided with locating
lugs which must face toward drive shaft when installed.
4. Press bearings all the way into position and install snap rings or retainer plates.
5. Install bearings in yoke in same manner. When installation is completed, check U-joint for
binding or roughness. If free movement is impeded, correct the condition before installation in
vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications
Flywheel: Specifications
Flywheel To Crankshaft Bolts 75-85 ft.lb
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > Drivetrain - Lubricant Usage
Fluid - M/T: Technical Service Bulletins Drivetrain - Lubricant Usage
Article No. 89-8-16
^ DRIVETRAIN - LUBRICATION USAGE
^ TRANSMISSION - MANUAL - LUBRICATION USAGE
LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER
1984-89 BRONCO II 1986-89 AEROSTAR
ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain
lubrication usage chart for light trucks has been put together to assist technicians in the event
service is required.
FIGURE 1
FIGURE 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 4800
ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage.
Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage.
PART NUMBER PART NAME CLASS
D8DZ-19C547-A Standard Transmission BG
Lubricant - 5 gallons C1AZ-19590-BA
Long Life Lubricant B
(molybdenum disulfide) - 14.5 ounces
DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B
tube
D7AZ-19584-AA Multi-Purpose Grease - 15 B
ounce aerosol can
XT-2-QDX Transmission Fluid (Mercon) - V
quart can (pkg. of 12)
C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG
C8AZ-19B546-A Additive Friction Modifier - 4 AM
ounce bottle
D7AZ-19590-A Disc Brake Caliper Slide AM
Grease - 4 ounce tube
E8TZ-19590-A Grease - 14.5 ounces B
E1TZ-19590-A Automatic Hublock Grease - 5 B
ounce tube
E5RY-19C547-A Merkur Synthetic Manual B
Transmission Fluid
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 5970
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 4801
Fluid - M/T: Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid
TRANSMISSION - AUTOMATIC/MANUAL - Article No.
NEW FLUID AND USAGE CHART 87-18-14
FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS,
THUNDERBIRD, FORD
LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior
TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II,
AEROSTAR
ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart),
(XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON"
transmission fluid, where specified, will improve cold weather shift effort and synchronized
operation.
ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic
transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles.
NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual
transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the
transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent.
PART NUMBER PART NAME CLASS
XT-2-QDX MERCON - Quart V
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 4802
XT-2-DDX MERCON - 55 Gallon V
Drum
E5RY-19C547-A Semi-Synthetic Oil B
OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS:
"INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > Page 4803
Fluid - M/T: Specifications
Type 1987 5-speed Mercon(R) Automatic Transmission Fluid
All others 80W EP
CAPACITY, Refill: 3-speed 3.5 pt (US)
4-speed ex. OD 7.0 pt (US)
W/OD 4.5 pt (US)
5-speed 7.4 pt (US)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Technical Service Bulletins > Drivetrain - Lubricant Usage
Fluid - Transfer Case: Technical Service Bulletins Drivetrain - Lubricant Usage
Article No. 89-8-16
^ DRIVETRAIN - LUBRICATION USAGE
^ TRANSMISSION - MANUAL - LUBRICATION USAGE
LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER
1984-89 BRONCO II 1986-89 AEROSTAR
ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain
lubrication usage chart for light trucks has been put together to assist technicians in the event
service is required.
FIGURE 1
FIGURE 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 4809
ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage.
Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage.
PART NUMBER PART NAME CLASS
D8DZ-19C547-A Standard Transmission BG
Lubricant - 5 gallons C1AZ-19590-BA
Long Life Lubricant B
(molybdenum disulfide) - 14.5 ounces
DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B
tube
D7AZ-19584-AA Multi-Purpose Grease - 15 B
ounce aerosol can
XT-2-QDX Transmission Fluid (Mercon) - V
quart can (pkg. of 12)
C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG
C8AZ-19B546-A Additive Friction Modifier - 4 AM
ounce bottle
D7AZ-19590-A Disc Brake Caliper Slide AM
Grease - 4 ounce tube
E8TZ-19590-A Grease - 14.5 ounces B
E1TZ-19590-A Automatic Hublock Grease - 5 B
ounce tube
E5RY-19C547-A Merkur Synthetic Manual B
Transmission Fluid
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 5970
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
TYPE MERCON(R) Automatic Transmission Fluid
CAPACITY, Refill: NP208 9.0 pt (US)
Warner 1345 6.5 pt (US)
Warner 1356 4.0 pt (US)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Capacity Specifications > Page 4812
Fluid - Transfer Case: Fluid Type Specifications
BL Self-adjusting Brake Lubricant
EC Ethylene Glycol Coolant
Mix 50/50 with water to at least -20°F (-29°C) protection
EP Extreme Pressure Gear Lubricant
Ford Part No. D8DZ-19C547-A
FA Automatic Transmission Fluid, Type F
GL-5 Gear Oil, API Service GL-5
HBH Hydraulic Brake Fluid, Extra
Heavy-Duty
HP Hypoid Gear Oil
Ford Part No. E0AZ-19580-A
HP* Hypoid Gear Oil for Limited-Slip
or Traction-Lok Differential
LM Lithium Grease, with Polyethylene
LS Steering Gear Lubricant
MA MERCONAutomatic Transmission
Fluid
MH Manifold Heat Valve Solvent
SG Motor Oil, API Service SG
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic
Connector - ABS > Component Information > Locations
RABS Connector View
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations
Wheel Speed Sensor: Locations
At Rear Axle
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Manual Bleeding
Brake Bleeding: Service and Repair Manual Bleeding
NOTE: Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first
on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that
has been drained from hydraulic system.
1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to
absorb escaping brake fluid.
2. Depress brake pedal slowly by hand to floor of cab, forcing air trapped in master cylinder out at
fitting.
3. Hold pedal down and tighten fittings, then release brake pedal.
NOTE: Releasing brake pedal before fittings are tightened will allow air to enter the master
cylinder.
4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm.
5. Bleed rear brakes as follows:
RR, LR, RF, LF
WARNING: Do not bleed the brakes with the drums removed. The wheel-cylinders will over-extend
and eject the pistons.
a. Pump pedal several times, then hold pedal down firmly.
WARNING: Do not Full Stroke the brake pedal, this may damage the master cylinder. Place a 2
inch block of wood under the brake pedal to prevent Full Stroking.
b. With pedal firmly depressed, open bleeder screw on one rear brake until pedal fades to floor,
then close bleeder valve.
NOTE: Do not release the brake pedal until the bleeder valve is fully shut.
c. Repeat procedure until a continuous flow of brake fluid is released from bleeder valve.
d. Repeat steps 5a through 5c on other rear brake.
6. Bleed front brakes using same procedure as for rear brakes.
7. Fill master cylinder reservoirs to 1/4 inch from top of reservoirs.
9. Check brake operation and ensure pedal is firm, road test vehicle.
For additional information see Bleeding Notes.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Manual Bleeding > Page 4825
Brake Bleeding: Service and Repair Master Cylinder Bleeding
1. Support the master cylinder body in a vise, and fill both fluid reservoirs with heavy duty DOT 3
brake fluid. 2. Install plugs in the front and rear brake outlet ports. Bleed the front brake outlet
system first. 3. Loosen the plug in the front brake outlet port. Depress the secondary piston slowly
to force the air out of the master cylinder. Tighten plug while
piston is depressed or air will enter the master cylinder.
4. Repeat this procedure until air ceases to exit at the outlet port. 5. Repeat steps 3 and 4 for the
rear brake outlet port with the front brake outlet plugged. 6. Tighten the plugs and try to depress the
piston. Depressing the piston should be harder after all air is expelled. 7. Install the plastic cap. 8.
Install the master cylinder in the vehicle and bleed the hydraulic system.
For additional information see Bench Bleeding.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Manual Bleeding > Page 4826
Brake Bleeding: Service and Repair Pressure Bleeding
Be sure the bleeder tank contains enough of the specified brake fluid to complete the bleeding
operation. Charge the tank with approximately 69-206 kPa (10-30 psi). Never exceed 345 kPa (50
psi). Never use brake fluid that has been drained from the hydraulic system. Bleed the longest lines
first
1. Clean all dirt from the master cylinder reservoir cap.
2. Remove the master cylinder reservoir cap and fill the master cylinder reservoir with the specified
brake fluid. Install the pressure bleeder adapter
tool on the master cylinder, and attach the bleeder tank hose to the fitting on the adapter.
NOTE: Master cylinder pressure bleeder adapter tools are available from the manufacturers of
pressure bleeding equipment. Follow the manufacturer's instructions when installing the adapter.
3. Place a 3/8 inch box wrench on the bleeder fitting on the right rear brake wheel cylinder. Attach a
bleeder tube snugly to the bleeder fitting.
4. Open the valve on the bleeder tank and admit pressurized brake fluid to the master cylinder
reservoir.
5. Submerge the free end of the tube in a container partially filled with clean brake fluid, and loosen
the bleeder fitting.
6. When air bubbles no longer appear in the fluid at the submerged end of the bleeder tube, close
the bleeder fitting and remove the tube.
7. Repeat Steps 3 through 6 at the opposite wheel cylinder. On front brakes, bleed the right front
caliper first.
8. When the bleeding operation is completed, close the bleeder tank valve and remove the tank
hose from the adapter fitting.
9. Remove the pressure bleeder adapter tool. Fill the master cylinder reservoirs with the specified
brake fluid to within 3 mm (1/8 in) from the top of
the filler neck. Install the master cylinder cover.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams >
Diagram Information and Instructions
Brake Warning Indicator: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams >
Diagram Information and Instructions > Page 4831
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams >
Diagram Information and Instructions > Page 4832
Fig. 57 Warning Indicators Wiring Circuit. Gasoline Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear
Brake Caliper: Customer Interest Brakes - Soft Pedal Feel/Pull/Irregular Wear
Article No. 98-5A-29
03/18/98
^ BRAKES - "SOFT" PEDAL FEEL
^ BRAKES - IRREGULAR BRAKE WEAR AND/OR BRAKE PULL - SERVICE TIPS
LIGHT TRUCK: 1980-91 E-250, E-350 1980-94 F-250, F-350
ISSUE: Some vehicles may exhibit any one or more of the following conditions:
^ Excessive brake pedal travel
^ Irregular front lining wear
^ Brake pull
This may be caused by the inner brake pad binding and/or the outer pad being installed out of
position.
ACTION: Refer to the following Service Tips when servicing a vehicle for any of the concerns listed
above.
SERVICE TIPS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4842
1. Before servicing brakes, inspect the caliper for correctly positioned pads and equal lining wear.
Refer to Figure 1.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4843
2. An incorrectly positioned outer pad could become bent after the first brake application. Refer to
Figure 2.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4844
3. Remove the pads. Hold the inner pad and outer pad against each other as shown in Figure 3.
Check to see if the wear surfaces are parallel to the pad back surfaces. If the pads have an angled
wear, this may indicate that a pad was mispositioned and/or was not sliding properly on the caliper
rail.
NOTE:
PADS WITH AN ANGLED WEAR PATTERN REQUIRE EXCESSIVE CALIPER MOVEMENT TO
SEAT THE PADS TO THE ROTOR. THIS EXTRA MOVEMENT REQUIRES EXTRA FLUID
VOLUME, RESULTING IN ADDITIONAL PEDAL TRAVEL, SIMILAR TO MISADJUSTED REAR
BRAKES.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4845
4. Inspect the inner pad for binding. Inner pads could become stuck to the slide surface due to
contamination, burrs, or corrosion. Refer to Figure 4.
NOTE:
REFER TO TSB 98-5A-13 FOR FURTHER INFORMATION ON THE USE OF SILICONE BRAKE
CALIPER GREASE AND DIELECTRIC COMPOUND.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4846
5. Reinstall the caliper. During reassembly, inspect the pads and clean the caliper slide surfaces of
corrosion, contamination, or burrs. Polish with a crocus cloth and lubricate with Silicone Brake
Caliper Grease and Dielectric Compound (D7AZ-19A331-A). Refer to Figure 5.
NOTE:
ON 1988-91 F-250/350 TRUCKS THAT WERE INVOLVED IN RECALL 92S44, BE SURE TO
REASSEMBLE USING ALL COMPONENTS OF THE BRAKE CALIPER PISTON INSULATOR KIT
UNLESS PHENOLIC PISTONS HAVE BEEN INSTALLED.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4847
6. Reinstall the pads. During pad installation, be careful not to dislodge the outer pad from its slide
position. Refer to Figure 6. An incorrect installation will cause a bent outer pad. Refer to Figure 2.
7. Once the calipers have been reinstalled and servicing is complete, but before installing the
wheels, apply the brakes and confirm the outer pad position remains correct.
PART NUMBER PART NAME
D7AZ-19A331-A Silicone Caliper Grease And Compound
OTHER APPLICABLE ARTICLES: 98-5A-13 SUPERSEDES: 97-15-17 WARRANTY STATUS:
INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4848
OASIS CODES: 301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-38 > Mar > 98 > Front Brake Caliper - Piston
Boots Damaged
Brake Caliper: Customer Interest Front Brake Caliper - Piston Boots Damaged
Article No. 98-5A-38
03/18/98
BRAKES - CALIPERS - FRONT CALIPER PISTON BOOTS DAMAGED
LIGHT TRUCK: 1986-91 E-250, E-35O 1986-94 F-250, F-350
ISSUE: Some vehicles may have experienced deterioration of the front brake caliper piston boots
resulting from exposure to high operating temperatures during severe service.
ACTION: Replace the caliper piston boots with a new, more robust service caliper piston boot. The
new silicone rubber boot can withstand higher operating temperatures without damage. The new
boot is completely interchangeable with the prior design and will become the only service boot
available.
The heat damaged boots should be replaced with the new Boot (E7TZ.2207-A). Refer to the
appropriate Service Manual for removal and installation procedures.
PART NUMBER PART NAME
E7TZ-2207-A Caliper Piston Boot
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-24-11 WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year
Vehicles, Basic Warranty Coverage For All Other Model Years
OPERATION DESCRIPTION TIME
985A38AT Overhaul Front Calipers - 1.5 Hrs.
Both
985A38A Overhaul Front Caliper - 1.2 Hrs.
One
DEALER CODING
CONDITION
BASIC PART NO. CODE
2207 42
OASIS CODES: 301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 93117 > May > 93 > Brakes Sticking/Binding/Grabbing
Brake Caliper: Customer Interest Brakes - Sticking/Binding/Grabbing
Article No. 93-11-7
05/26/93
BRAKES - STICK/BIND/GRAB - FRONT CALIPER PINS CORRODED
LIGHT TRUCK: 1987-90 BRONCO II 1987-92 AEROSTAR, BRONCO, ECONOLINE, F-150-350
SERIES, RANGER 1988-92 F SUPER DUTY 1991-92 EXPLORER
This TSB article is being republished in its entirety to include F Super Duty vehicles.
ISSUE: Sticking, binding or grabbing of the brakes may be caused by brake caliper slide pins that
are corroded. The corrosion does not allow the brake caliper assembly to move freely.
ACTION: Install the new improved caliper pins that are corrosion resistant. Refer to the following
Service Procedure for service details.
SERVICE PROCEDURE
1. Remove the caliper and pins. Refer to the applicable Light Truck Service Manual for service
details.
NOTE: IF PADS ARE DAMAGED OR WORN, PAD REPLACEMENT IS REQUIRED.
2. Clean the upper and lower knuckle pin grooves, upper and lower knuckle inner pad grooves, and
the upper and lower caliper pin grooves with a wire brush or portable wire wheel.
WARNING: USE SAFETY GLASSES AND AN AIR RESPIRATOR WHEN CLEANING THE
GROOVES.
3. Apply a light coat of lubricant (D7AZ-19590-A) to the upper and lower knuckle inner pad grooves
and upper and lower caliper pin grooves.
CAUTION: LUBRICANT SHOULD NOT BE USED ON ROTORS, LININGS OR CALIPER PISTON
BOOTS.
4. Re-assemble the caliper using the new pins, (F2TZ-2C150-A) for all vehicles except F Super
Duty. Use new pins (F2TZ-2C150-B) for F Super Duty vehicles.
NOTE: NORMAL BRAKE MAINTENANCE REQUIREMENTS LISTED IN THE OWNER MANUAL
SHOULD BE PERFORMED EVERY 15,000 MILES.
PART NUMBER PART NAME CLASS
D7AZ-19590-A Lubricant-Disc Brake AM
F2TZ-2C150-A Pin-Brake Caliper B
F2TZ-2C150-B Pin-Brake Caliper (F Super B
Duty)
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 92-12-14
WARRANTY STATUS: Eligible Under Bumper To Bumper For 1992 Models And Basic Warranty
Coverage For All Other Model Years
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 93117 > May > 93 > Brakes Sticking/Binding/Grabbing > Page 4857
OPERATION DESCRIPTION TIME
931107A Aerostar/Ranger/Bronco II, 0.8 Hr.
(Through 1990), Explorer (Starting 1991), F-Series Under 8500 GVW, Bronco And Econoline
Under 8500
931107B F-Series Over 8500 GVW 0.9 Hr.
And Econoline Over 8500 GVW Through 1991
931107C F Super Duty Front 1.2 Hr.
931107D F Super Duty Rear 1.2 Hr.
931107E F Super Duty Front And 2.1 Hr.
Rear
DEALER CODING
BASIC PART NO. CONDITION CODE
2C150 41
OASIS CODES: 301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling Noise
Brake Caliper: Customer Interest Brake Caliper - Rattling Noise
BRAKE - CALIPER "RATTLING" NOISE - VEHICLES BUILT BEFORE 3/01/88
BRAKE - CALIPER PINS - SERVICE REMOVAL TOOL
NOISE - "RATTLE" FROM BRAKE CALIPER - VEHICLES BUILT BEFORE 3/01 /88
Article No. 88-13-7
LIGHT TRUCK: 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR, BRONCO, E
SERIES, F SERIES 1988 F-SUPER DUTY
ISSUE: A "rattling" noise may be heard coming from the front disc brake calipers. The caliper pins
may eventually take a set under certain load conditions allowing the disc brake caliper to "rattle".
The "rattling" noise is more likely to develop on units that are driven off-road or operated on rough
roads.
ACTION: To correct this, install new design caliper pins. A new caliper pin removal tool can be
made to aid in removal of the pins. Refer to the caliper pin application chart on this page for the
correct service part number.
FIGURE 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling Noise >
Page 4862
FIGURE 9
FIGURE 10
FIGURE 11
The caliper pin removal tool is recommended for use on all the above listed vehicles, including
1988 Super Duty, Figures 8 through 11. This caliper pin tool can be made from a 1/2 inch diameter
rod 7 inches long. Simply grind or cut a "V" notch in one (1) end. The "V" notch is used to
compress the pin retention tabs while the tool is also used to drive the pin out of the caliper slide
groove. This tool replaces a pair of pliers and screwdriver as outlined in the Shop Manual service
procedure.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling Noise >
Page 4863
The idea for this tool was submitted for the Best Idea Contest by Joseph L. Kaiser, Bauer Ford Inc.,
Brookville, Indiana. See "Service Life", Winter 1987 issue for featured article.
CALIPER PIN APPLICATION CHART
Part Number Part Name Vehicle Usage
E8TZ-2C150-A Caliper Pin Super Duty
E8TZ-2C150-B Caliper Pin Ranger, Bronco II, Aerostar, Bronco, E Series, F Series
PART NUMBER PART NAME CLASS
E8TZ-2C150-A Caliper Pin B
E8TZ-2C150-B Caliper Pin B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: 881307A - Both sides TIME: 0.5 Hr. DLR. CODING: Basic Part No. 2C150
Condition Code: 33
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear
Brake Caliper: All Technical Service Bulletins Brakes - Soft Pedal Feel/Pull/Irregular Wear
Article No. 98-5A-29
03/18/98
^ BRAKES - "SOFT" PEDAL FEEL
^ BRAKES - IRREGULAR BRAKE WEAR AND/OR BRAKE PULL - SERVICE TIPS
LIGHT TRUCK: 1980-91 E-250, E-350 1980-94 F-250, F-350
ISSUE: Some vehicles may exhibit any one or more of the following conditions:
^ Excessive brake pedal travel
^ Irregular front lining wear
^ Brake pull
This may be caused by the inner brake pad binding and/or the outer pad being installed out of
position.
ACTION: Refer to the following Service Tips when servicing a vehicle for any of the concerns listed
above.
SERVICE TIPS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4869
1. Before servicing brakes, inspect the caliper for correctly positioned pads and equal lining wear.
Refer to Figure 1.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4870
2. An incorrectly positioned outer pad could become bent after the first brake application. Refer to
Figure 2.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4871
3. Remove the pads. Hold the inner pad and outer pad against each other as shown in Figure 3.
Check to see if the wear surfaces are parallel to the pad back surfaces. If the pads have an angled
wear, this may indicate that a pad was mispositioned and/or was not sliding properly on the caliper
rail.
NOTE:
PADS WITH AN ANGLED WEAR PATTERN REQUIRE EXCESSIVE CALIPER MOVEMENT TO
SEAT THE PADS TO THE ROTOR. THIS EXTRA MOVEMENT REQUIRES EXTRA FLUID
VOLUME, RESULTING IN ADDITIONAL PEDAL TRAVEL, SIMILAR TO MISADJUSTED REAR
BRAKES.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4872
4. Inspect the inner pad for binding. Inner pads could become stuck to the slide surface due to
contamination, burrs, or corrosion. Refer to Figure 4.
NOTE:
REFER TO TSB 98-5A-13 FOR FURTHER INFORMATION ON THE USE OF SILICONE BRAKE
CALIPER GREASE AND DIELECTRIC COMPOUND.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4873
5. Reinstall the caliper. During reassembly, inspect the pads and clean the caliper slide surfaces of
corrosion, contamination, or burrs. Polish with a crocus cloth and lubricate with Silicone Brake
Caliper Grease and Dielectric Compound (D7AZ-19A331-A). Refer to Figure 5.
NOTE:
ON 1988-91 F-250/350 TRUCKS THAT WERE INVOLVED IN RECALL 92S44, BE SURE TO
REASSEMBLE USING ALL COMPONENTS OF THE BRAKE CALIPER PISTON INSULATOR KIT
UNLESS PHENOLIC PISTONS HAVE BEEN INSTALLED.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4874
6. Reinstall the pads. During pad installation, be careful not to dislodge the outer pad from its slide
position. Refer to Figure 6. An incorrect installation will cause a bent outer pad. Refer to Figure 2.
7. Once the calipers have been reinstalled and servicing is complete, but before installing the
wheels, apply the brakes and confirm the outer pad position remains correct.
PART NUMBER PART NAME
D7AZ-19A331-A Silicone Caliper Grease And Compound
OTHER APPLICABLE ARTICLES: 98-5A-13 SUPERSEDES: 97-15-17 WARRANTY STATUS:
INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4875
OASIS CODES: 301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-38 > Mar > 98 > Front Brake Caliper
- Piston Boots Damaged
Brake Caliper: All Technical Service Bulletins Front Brake Caliper - Piston Boots Damaged
Article No. 98-5A-38
03/18/98
BRAKES - CALIPERS - FRONT CALIPER PISTON BOOTS DAMAGED
LIGHT TRUCK: 1986-91 E-250, E-35O 1986-94 F-250, F-350
ISSUE: Some vehicles may have experienced deterioration of the front brake caliper piston boots
resulting from exposure to high operating temperatures during severe service.
ACTION: Replace the caliper piston boots with a new, more robust service caliper piston boot. The
new silicone rubber boot can withstand higher operating temperatures without damage. The new
boot is completely interchangeable with the prior design and will become the only service boot
available.
The heat damaged boots should be replaced with the new Boot (E7TZ.2207-A). Refer to the
appropriate Service Manual for removal and installation procedures.
PART NUMBER PART NAME
E7TZ-2207-A Caliper Piston Boot
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-24-11 WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year
Vehicles, Basic Warranty Coverage For All Other Model Years
OPERATION DESCRIPTION TIME
985A38AT Overhaul Front Calipers - 1.5 Hrs.
Both
985A38A Overhaul Front Caliper - 1.2 Hrs.
One
DEALER CODING
CONDITION
BASIC PART NO. CODE
2207 42
OASIS CODES: 301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 93117 > May > 93 > Brakes Sticking/Binding/Grabbing
Brake Caliper: All Technical Service Bulletins Brakes - Sticking/Binding/Grabbing
Article No. 93-11-7
05/26/93
BRAKES - STICK/BIND/GRAB - FRONT CALIPER PINS CORRODED
LIGHT TRUCK: 1987-90 BRONCO II 1987-92 AEROSTAR, BRONCO, ECONOLINE, F-150-350
SERIES, RANGER 1988-92 F SUPER DUTY 1991-92 EXPLORER
This TSB article is being republished in its entirety to include F Super Duty vehicles.
ISSUE: Sticking, binding or grabbing of the brakes may be caused by brake caliper slide pins that
are corroded. The corrosion does not allow the brake caliper assembly to move freely.
ACTION: Install the new improved caliper pins that are corrosion resistant. Refer to the following
Service Procedure for service details.
SERVICE PROCEDURE
1. Remove the caliper and pins. Refer to the applicable Light Truck Service Manual for service
details.
NOTE: IF PADS ARE DAMAGED OR WORN, PAD REPLACEMENT IS REQUIRED.
2. Clean the upper and lower knuckle pin grooves, upper and lower knuckle inner pad grooves, and
the upper and lower caliper pin grooves with a wire brush or portable wire wheel.
WARNING: USE SAFETY GLASSES AND AN AIR RESPIRATOR WHEN CLEANING THE
GROOVES.
3. Apply a light coat of lubricant (D7AZ-19590-A) to the upper and lower knuckle inner pad grooves
and upper and lower caliper pin grooves.
CAUTION: LUBRICANT SHOULD NOT BE USED ON ROTORS, LININGS OR CALIPER PISTON
BOOTS.
4. Re-assemble the caliper using the new pins, (F2TZ-2C150-A) for all vehicles except F Super
Duty. Use new pins (F2TZ-2C150-B) for F Super Duty vehicles.
NOTE: NORMAL BRAKE MAINTENANCE REQUIREMENTS LISTED IN THE OWNER MANUAL
SHOULD BE PERFORMED EVERY 15,000 MILES.
PART NUMBER PART NAME CLASS
D7AZ-19590-A Lubricant-Disc Brake AM
F2TZ-2C150-A Pin-Brake Caliper B
F2TZ-2C150-B Pin-Brake Caliper (F Super B
Duty)
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 92-12-14
WARRANTY STATUS: Eligible Under Bumper To Bumper For 1992 Models And Basic Warranty
Coverage For All Other Model Years
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 93117 > May > 93 > Brakes Sticking/Binding/Grabbing > Page 4884
OPERATION DESCRIPTION TIME
931107A Aerostar/Ranger/Bronco II, 0.8 Hr.
(Through 1990), Explorer (Starting 1991), F-Series Under 8500 GVW, Bronco And Econoline
Under 8500
931107B F-Series Over 8500 GVW 0.9 Hr.
And Econoline Over 8500 GVW Through 1991
931107C F Super Duty Front 1.2 Hr.
931107D F Super Duty Rear 1.2 Hr.
931107E F Super Duty Front And 2.1 Hr.
Rear
DEALER CODING
BASIC PART NO. CONDITION CODE
2C150 41
OASIS CODES: 301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling
Noise
Brake Caliper: All Technical Service Bulletins Brake Caliper - Rattling Noise
BRAKE - CALIPER "RATTLING" NOISE - VEHICLES BUILT BEFORE 3/01/88
BRAKE - CALIPER PINS - SERVICE REMOVAL TOOL
NOISE - "RATTLE" FROM BRAKE CALIPER - VEHICLES BUILT BEFORE 3/01 /88
Article No. 88-13-7
LIGHT TRUCK: 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR, BRONCO, E
SERIES, F SERIES 1988 F-SUPER DUTY
ISSUE: A "rattling" noise may be heard coming from the front disc brake calipers. The caliper pins
may eventually take a set under certain load conditions allowing the disc brake caliper to "rattle".
The "rattling" noise is more likely to develop on units that are driven off-road or operated on rough
roads.
ACTION: To correct this, install new design caliper pins. A new caliper pin removal tool can be
made to aid in removal of the pins. Refer to the caliper pin application chart on this page for the
correct service part number.
FIGURE 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling
Noise > Page 4889
FIGURE 9
FIGURE 10
FIGURE 11
The caliper pin removal tool is recommended for use on all the above listed vehicles, including
1988 Super Duty, Figures 8 through 11. This caliper pin tool can be made from a 1/2 inch diameter
rod 7 inches long. Simply grind or cut a "V" notch in one (1) end. The "V" notch is used to
compress the pin retention tabs while the tool is also used to drive the pin out of the caliper slide
groove. This tool replaces a pair of pliers and screwdriver as outlined in the Shop Manual service
procedure.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper - Rattling
Noise > Page 4890
The idea for this tool was submitted for the Best Idea Contest by Joseph L. Kaiser, Bauer Ford Inc.,
Brookville, Indiana. See "Service Life", Winter 1987 issue for featured article.
CALIPER PIN APPLICATION CHART
Part Number Part Name Vehicle Usage
E8TZ-2C150-A Caliper Pin Super Duty
E8TZ-2C150-B Caliper Pin Ranger, Bronco II, Aerostar, Bronco, E Series, F Series
PART NUMBER PART NAME CLASS
E8TZ-2C150-A Caliper Pin B
E8TZ-2C150-B Caliper Pin B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: 881307A - Both sides TIME: 0.5 Hr. DLR. CODING: Basic Part No. 2C150
Condition Code: 33
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Page 4891
Brake Caliper: Description and Operation
Disc Brake Caliper Disassembled
These models use the HD (Heavy Duty) pin rail sliding caliper type system, in which the dual piston
caliper slides on two pins attaching the caliper to the spindle assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Inspection
Brake Caliper: Service and Repair Inspection
For additional information see Installation Notes. See: Fundamentals and Basics
1. Install new inner and outer pad. Install anti-rattle spring.
NOTE:
- Always replace all pad and lining assemblies on an axle. Never service one wheel only.
- There is a raised section at one end of each pad so that installation can be made in one direction
only.
2. Install the caliper on the spindle, making sure the mounting surfaces are free of dirt and lubricate
the caliper grooves with disc brake caliper
grease.
3. Position pin with the pin retention tabs oriented adjacent to the spindle groove.
4. Tap the pin on the outboard end with a hammer. Continue tapping the pin inward until the
retention tabs on the sides of the pin contact the spindle
face. Repeat procedure for the lower pin.
Correct Caliper Pin Installation
CAUTION: During the installation procedure do not allow the tabs of the caliper pin to be tapped
too far into the spindle groove. If this happens
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Inspection > Page 4894
it will be necessary to tap the other end of the caliper pin until the tabs snap into place. The tabs on
each end of the caliper pin must be free to catch on the spindle flanks.
5. If removed, install the brake hose to the caliper and perform brake bleeding procedures.
Caliper Inlet Block
6. Install the wheel and tire assembly.
7. Lower the vehicle, check the brake fluid level and fill as necessary. Check brakes for proper
operation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Inspection > Page 4895
Brake Caliper: Service and Repair Rebuild
DISASSEMBLY
Disc Brake Caliper Disassembled
1. Drain the fluid from the cylinders.
2. Secure the caliper assembly in a vise.
Removing Caliper Piston
3. Place a block of wood between the caliper bridge and the cylinders, and apply low pressure air
to the brake hose inlet. The pistons will be forced
out to the wood block.
4. Remove the wood block, and remove the pistons.
5. Remove and discard the piston seals and boots.
6. If the caliper assembly is leaking, replace the piston assemblies. If the cylinder bores are scored,
corroded or excessively worn, replace the caliper.
Do not hone the cylinder bores. Piston assemblies are not available for oversize bores.
CLEANING and INSPECTION
Clean all metal parts with isopropyl alcohol. Clean out and dry the grooves and passageways with
compressed air. Make sure that caliper bore and component parts are thoroughly clean.
Use a wire brush to remove any rust or corrosion from the machined surfaces of the caliper
housing.
NOTE: Do not use a wire brush in the cylinder bore.
Check the cylinder bore and piston for damage or excessive wear. Replace the piston if it is pitted,
scored or worn. Do not replace phenolic pistons for cosmetic surface irregularities or small chips
between the piston groove and pad face.
Use a wire brush to clean corrosion from the boot groove and the machined surfaces of the spindle
assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Inspection > Page 4896
Replace the anti-rattle clip, piston seal and dust boot with new components.
ASSEMBLY
NOTE: Never re-use piston seals and dust boots. Install a new set each time the caliper is
assembled.
1. Lubricate new piston seals with clean brake fluid. Install them in the seal grooves in the cylinder
bores.
2. Apply a film of clean brake fluid to the cylinder bores.
3. Lubricate retaining lips of the dust boots with clean brake fluid and install them in the boot
retaining grooves in the cylinder bores.
4. Apply a film of clean brake fluid to the pistons.
5. Insert the pistons into the dust boots and start them into the cylinders by hand until they are
beyond the piston seals. Be careful not to damage or
dislodge the piston seal.
6. Place a wood block over one piston and press the piston into the cylinder being careful not to
cock the piston in the cylinder. Install the second
piston in the same manner. Make certain that boots are correctly seated.
7. Install the pad and lining assemblies and anti-rattle spring in the caliper assembly. Place the
caliper assembly on the support and install the caliper
pins.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Inspection > Page 4897
Brake Caliper: Service and Repair Removal
For additional information see Removal Notes. See: Fundamentals and Basics
1. To avoid overflow when the caliper pistons are compressed into the caliper pistons bores,
remove a portion of brake fluid from master cylinder
disc brake reservoir. Properly dispose the removed fluid.
2. Raise and support vehicle. Remove wheel and tire assembly.
Bottoming Caliper Piston
3. Install an appropriate size C-clamp on caliper. Tighten clamp to bottom caliper pistons in cylinder
bores. Remove the clamp.
NOTE: Do not use screwdriver or other edged tool to pry pistons from rotor.
4. Clean excess dirt from area around pin tabs.
5. Tap upper caliper pin towards inboard side until pin tabs touch the spindle face.
6. Insert a screwdriver into the slot provided behind the pin tabs on the inboard side of the pin.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Inspection > Page 4898
Compressing Spring Tabs
7. Use needle nose pliers to compress the outboard end of the pin while prying at the same time
with the screwdriver, until tabs slip into the spindle
groove.
8. Place one end of a punch (approximately 7/16 inch diameter) against the end of the caliper pin
and drive the caliper pin out of the caliper slide
groove.
9. Repeat removal procedure for lower pin.
10. Remove the caliper from the rotor. If the caliper is to be removed for service, remove the brake
hose from the caliper. If the caliper is not going to
be removed, secure it to the vehicle to avoid damage to the brake hose.
11. Remove the outer brake pad. Remove the anti-rattle clips and the inner brake pad.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Fundamentals and Basics > Removal Notes
Brake Caliper: Fundamentals and Basics Removal Notes
When Removing the Caliper, Remember...
- Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir
is only 1/3 full.
- Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender
covers to protect the vehicle's finish and electrical system.
- Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining
thickness between wheels on the same axle will result in a strong steering pull when the brakes are
applied.
- Work on one side at a time. If you forget how to reassemble the parts you can always use the
other side as a model.
- When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other
deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is
forced back into the caliper, these deposits will be forced back through the brake lines and into the
master-cylinder.
When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake fluid
will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to "shoot"
brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose and a
glass or plastic jar to catch the expelled fluid.
- Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses
can be damaged easily by this practice. These hoses are double walled, damage to the interior
pressure hose will not be visible.
- Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will
be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not
attempt to insert the piston back into the caliper.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Fundamentals and Basics > Removal Notes > Page 4901
Brake Caliper: Fundamentals and Basics Installation Notes
WHEN INSTALLING CALIPERS AND PADS, REMEMBER...
- Clean and lubricate caliper slide joint/pins with high temperature silicone grease:
Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake
pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted
movement of the caliper slide assemblies to release the brakes.
If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon
the release of the brake pedal. This will result in overheated brakes and premature brake wear.
Disc Brake Mechanical Force Diagram
NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating
or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel
forces the inner pad against the rotor, then further travel forces the movable part of the caliper to
pull the outer pad against the rotor.
High temperature silicone lubricant must be used. Low temperature grease can melt and
contaminate the pads and rotors, or can bake into a very hard substance which binds the slides.
Petroleum based grease can cause the slide boots to soften and swell.
Work on one side at a time. If you forget how to reassemble the parts you can always use the other
side as a model.
Anti-squeal Coating
- Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an
insulator to dampen high frequency vibrations that are generated during normal braking. These
compounds are highly effective in preventing brake squeal.
- Many professional repair shops recommend always rebuilding or replacing the calipers when
replacing the brake linings, because:
When the pistons are forced back into the calipers, the piston seals are dragged across any
corrosion or abrasives that may be deposited on the inside of the caliper.
Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston
is gradually withdrawn from the caliper.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Fundamentals and Basics > Removal Notes > Page 4902
This results in the piston seals again being dragged across the layer of corrosion and deposits.
Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking.
- Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck
bleeder screw is much easier with the caliper removed from the vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal Feel/Pull/Irregular Wear
Brake Pad: Customer Interest Brakes - Soft Pedal Feel/Pull/Irregular Wear
Article No. 98-5A-29
03/18/98
^ BRAKES - "SOFT" PEDAL FEEL
^ BRAKES - IRREGULAR BRAKE WEAR AND/OR BRAKE PULL - SERVICE TIPS
LIGHT TRUCK: 1980-91 E-250, E-350 1980-94 F-250, F-350
ISSUE: Some vehicles may exhibit any one or more of the following conditions:
^ Excessive brake pedal travel
^ Irregular front lining wear
^ Brake pull
This may be caused by the inner brake pad binding and/or the outer pad being installed out of
position.
ACTION: Refer to the following Service Tips when servicing a vehicle for any of the concerns listed
above.
SERVICE TIPS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal Feel/Pull/Irregular Wear >
Page 4911
1. Before servicing brakes, inspect the caliper for correctly positioned pads and equal lining wear.
Refer to Figure 1.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal Feel/Pull/Irregular Wear >
Page 4912
2. An incorrectly positioned outer pad could become bent after the first brake application. Refer to
Figure 2.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal Feel/Pull/Irregular Wear >
Page 4913
3. Remove the pads. Hold the inner pad and outer pad against each other as shown in Figure 3.
Check to see if the wear surfaces are parallel to the pad back surfaces. If the pads have an angled
wear, this may indicate that a pad was mispositioned and/or was not sliding properly on the caliper
rail.
NOTE:
PADS WITH AN ANGLED WEAR PATTERN REQUIRE EXCESSIVE CALIPER MOVEMENT TO
SEAT THE PADS TO THE ROTOR. THIS EXTRA MOVEMENT REQUIRES EXTRA FLUID
VOLUME, RESULTING IN ADDITIONAL PEDAL TRAVEL, SIMILAR TO MISADJUSTED REAR
BRAKES.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal Feel/Pull/Irregular Wear >
Page 4914
4. Inspect the inner pad for binding. Inner pads could become stuck to the slide surface due to
contamination, burrs, or corrosion. Refer to Figure 4.
NOTE:
REFER TO TSB 98-5A-13 FOR FURTHER INFORMATION ON THE USE OF SILICONE BRAKE
CALIPER GREASE AND DIELECTRIC COMPOUND.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal Feel/Pull/Irregular Wear >
Page 4915
5. Reinstall the caliper. During reassembly, inspect the pads and clean the caliper slide surfaces of
corrosion, contamination, or burrs. Polish with a crocus cloth and lubricate with Silicone Brake
Caliper Grease and Dielectric Compound (D7AZ-19A331-A). Refer to Figure 5.
NOTE:
ON 1988-91 F-250/350 TRUCKS THAT WERE INVOLVED IN RECALL 92S44, BE SURE TO
REASSEMBLE USING ALL COMPONENTS OF THE BRAKE CALIPER PISTON INSULATOR KIT
UNLESS PHENOLIC PISTONS HAVE BEEN INSTALLED.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal Feel/Pull/Irregular Wear >
Page 4916
6. Reinstall the pads. During pad installation, be careful not to dislodge the outer pad from its slide
position. Refer to Figure 6. An incorrect installation will cause a bent outer pad. Refer to Figure 2.
7. Once the calipers have been reinstalled and servicing is complete, but before installing the
wheels, apply the brakes and confirm the outer pad position remains correct.
PART NUMBER PART NAME
D7AZ-19A331-A Silicone Caliper Grease And Compound
OTHER APPLICABLE ARTICLES: 98-5A-13 SUPERSEDES: 97-15-17 WARRANTY STATUS:
INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal Feel/Pull/Irregular Wear >
Page 4917
OASIS CODES: 301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal
Brake Pad: Customer Interest Front Brakes - Premature Lining Wear/Hard Pedal
Article No. 89-25-16
^ BRAKES - FRONT - PREMATURE LINING WEAR
^ BRAKES - REAR HEIGHT SENSING PROPORTIONING VALVE - INOPERATIVE DUE TO
SUSPENSION MODIFICATION
LIGHT TRUCK: 1985-86 F-250, F-350 1985-89 E-250, E-350
ISSUE: High brake pedal efforts or increased front brake lining wear may be caused by aftermarket
suspension modifications. The modified suspension may affect the performance of the height
sensing proportioning valve.
Figure 2
Figure 3
ACTION: Inspect the truck to determine if the suspension has been modified. Compare the rear
suspension (springs) to the suspension specifications
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal
> Page 4922
shown in the Light Truck Facts Book and the spring codes listed on the vehicle certification label,
Figure 2 and 3. If the suspension has been modified or will be modified, use the following
procedure. If the suspension has not been modified, replace the height sensing proportioning valve
as outlined in TSB 88-12-20.
Figure 1
1. Remove the nut from the valve shaft and remove the leading arm of the linkage assembly,
Figure 1. Save the nut.
2. Remove the two (2) nuts from the differential housing bolts and remove the linkage bracket,
Figure 1.
3. Return the linkage to the customer.
Figure 4
4. Rotate the valve shaft one (1) full turn in either direction. Position the shaft with the flat at the
bottom and parallel with the ground, Figure 3.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal
> Page 4923
Figure 5
5. Rotate the valve shaft counter-clockwise 90~ so that the flat of the shaft is vertical, Figure 5.
Figure 6
6. Place the valve shaft positioner, (E9TZ-2W125-A) over the valve shaft as shown in Figure 6.
Make sure the shaft flat fits into the "D"-slot of the positioner and that the shroud is fully seated
over the valve casting.
7. Re-install the nut saved in Step 1 on the valve shaft. Hold the shaft positioner and tighten the nut
to a torque of 8-10 lb.ft. (11-14 N-m).
8. Install an "Authorized Modification" decal on the brake booster listing the modification as follows:
"HSPV REAR BRAKE OPERATION MODIFIED".
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal
> Page 4924
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
alterations performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME CLASS
E9TZ-2W125-A Valve Shaft Positioner C
OTHER APPLICABLE ARTICLES: 88-12-20 WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION
DESCRIPTION TIME
892516A Modify Height Sensing 0.6 Hr.
Valve
DEALER CODING BASIC PART NO. CONDITION CODE
2B547 53
OASIS CODES: 3050, 3051
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear
Brake Pad: All Technical Service Bulletins Brakes - Soft Pedal Feel/Pull/Irregular Wear
Article No. 98-5A-29
03/18/98
^ BRAKES - "SOFT" PEDAL FEEL
^ BRAKES - IRREGULAR BRAKE WEAR AND/OR BRAKE PULL - SERVICE TIPS
LIGHT TRUCK: 1980-91 E-250, E-350 1980-94 F-250, F-350
ISSUE: Some vehicles may exhibit any one or more of the following conditions:
^ Excessive brake pedal travel
^ Irregular front lining wear
^ Brake pull
This may be caused by the inner brake pad binding and/or the outer pad being installed out of
position.
ACTION: Refer to the following Service Tips when servicing a vehicle for any of the concerns listed
above.
SERVICE TIPS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4930
1. Before servicing brakes, inspect the caliper for correctly positioned pads and equal lining wear.
Refer to Figure 1.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4931
2. An incorrectly positioned outer pad could become bent after the first brake application. Refer to
Figure 2.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4932
3. Remove the pads. Hold the inner pad and outer pad against each other as shown in Figure 3.
Check to see if the wear surfaces are parallel to the pad back surfaces. If the pads have an angled
wear, this may indicate that a pad was mispositioned and/or was not sliding properly on the caliper
rail.
NOTE:
PADS WITH AN ANGLED WEAR PATTERN REQUIRE EXCESSIVE CALIPER MOVEMENT TO
SEAT THE PADS TO THE ROTOR. THIS EXTRA MOVEMENT REQUIRES EXTRA FLUID
VOLUME, RESULTING IN ADDITIONAL PEDAL TRAVEL, SIMILAR TO MISADJUSTED REAR
BRAKES.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4933
4. Inspect the inner pad for binding. Inner pads could become stuck to the slide surface due to
contamination, burrs, or corrosion. Refer to Figure 4.
NOTE:
REFER TO TSB 98-5A-13 FOR FURTHER INFORMATION ON THE USE OF SILICONE BRAKE
CALIPER GREASE AND DIELECTRIC COMPOUND.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4934
5. Reinstall the caliper. During reassembly, inspect the pads and clean the caliper slide surfaces of
corrosion, contamination, or burrs. Polish with a crocus cloth and lubricate with Silicone Brake
Caliper Grease and Dielectric Compound (D7AZ-19A331-A). Refer to Figure 5.
NOTE:
ON 1988-91 F-250/350 TRUCKS THAT WERE INVOLVED IN RECALL 92S44, BE SURE TO
REASSEMBLE USING ALL COMPONENTS OF THE BRAKE CALIPER PISTON INSULATOR KIT
UNLESS PHENOLIC PISTONS HAVE BEEN INSTALLED.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4935
6. Reinstall the pads. During pad installation, be careful not to dislodge the outer pad from its slide
position. Refer to Figure 6. An incorrect installation will cause a bent outer pad. Refer to Figure 2.
7. Once the calipers have been reinstalled and servicing is complete, but before installing the
wheels, apply the brakes and confirm the outer pad position remains correct.
PART NUMBER PART NAME
D7AZ-19A331-A Silicone Caliper Grease And Compound
OTHER APPLICABLE ARTICLES: 98-5A-13 SUPERSEDES: 97-15-17 WARRANTY STATUS:
INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 98-5A-29 > Mar > 98 > Brakes - Soft Pedal
Feel/Pull/Irregular Wear > Page 4936
OASIS CODES: 301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 90226 > Oct > 90 > Brakes - Intermittent
Brake Squeal
Brake Pad: All Technical Service Bulletins Brakes - Intermittent Brake Squeal
Article No. 90-22-6
^ BRAKES - OCCASIONAL OR INTERMITTENT "SQUEAL"
^ NOISE - BRAKES - OCCASIONAL OR INTERMITTENT SQUEAL"
FORD: 1985-86 LTD 1985-88 EXP
1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS
LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS
1985-87 LYNX
1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91
SABLE 1987-91 TRACER 1991 CAPRI
MERKUR: 1985-89 XR4TI
LIGHT TRUCK: 1985-90 BRONCO II
1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F
SUPER DUTY 1991 EXPLORER
This TSB article is being republished in its entirety to expand the model and model year coverage.
ISSUE: Occasional or intermittent brake squeal may be cause by the brake friction material
generating noise and heat in order to dissipate energy. This occasional or intermittent squeal may
be a normal condition and requires no corrective action.
ACTION: If a customer is concerned about occasional or intermittent brake squeal, it should be
explained that brake friction materials inherently generate noise and heat in order to dissipate
energy. As a result, an occasional squeal condition may be normal, and could be affected by cold,
heat, wetness, snow, salt, mud etc.
NOTE: THIS OCCASIONAL OR INTERMITTENT SQUEAL IS NOT A FUNCTIONAL PROBLEM
AND DOES NOT INDICATE ANY LOSS OF BRAKE EFFECTIVENESS.
OTHER APPLICABLE ARTICLES: None SUPERSEDES:
87-16-7
WARRANTY STATUS: INFORMATION ONLY OASIS CODES:
301000, 702000, 702100
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 892516 > Dec > 89 > Front Brakes Premature Lining Wear/Hard Pedal
Brake Pad: All Technical Service Bulletins Front Brakes - Premature Lining Wear/Hard Pedal
Article No. 89-25-16
^ BRAKES - FRONT - PREMATURE LINING WEAR
^ BRAKES - REAR HEIGHT SENSING PROPORTIONING VALVE - INOPERATIVE DUE TO
SUSPENSION MODIFICATION
LIGHT TRUCK: 1985-86 F-250, F-350 1985-89 E-250, E-350
ISSUE: High brake pedal efforts or increased front brake lining wear may be caused by aftermarket
suspension modifications. The modified suspension may affect the performance of the height
sensing proportioning valve.
Figure 2
Figure 3
ACTION: Inspect the truck to determine if the suspension has been modified. Compare the rear
suspension (springs) to the suspension specifications
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 892516 > Dec > 89 > Front Brakes Premature Lining Wear/Hard Pedal > Page 4945
shown in the Light Truck Facts Book and the spring codes listed on the vehicle certification label,
Figure 2 and 3. If the suspension has been modified or will be modified, use the following
procedure. If the suspension has not been modified, replace the height sensing proportioning valve
as outlined in TSB 88-12-20.
Figure 1
1. Remove the nut from the valve shaft and remove the leading arm of the linkage assembly,
Figure 1. Save the nut.
2. Remove the two (2) nuts from the differential housing bolts and remove the linkage bracket,
Figure 1.
3. Return the linkage to the customer.
Figure 4
4. Rotate the valve shaft one (1) full turn in either direction. Position the shaft with the flat at the
bottom and parallel with the ground, Figure 3.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 892516 > Dec > 89 > Front Brakes Premature Lining Wear/Hard Pedal > Page 4946
Figure 5
5. Rotate the valve shaft counter-clockwise 90~ so that the flat of the shaft is vertical, Figure 5.
Figure 6
6. Place the valve shaft positioner, (E9TZ-2W125-A) over the valve shaft as shown in Figure 6.
Make sure the shaft flat fits into the "D"-slot of the positioner and that the shroud is fully seated
over the valve casting.
7. Re-install the nut saved in Step 1 on the valve shaft. Hold the shaft positioner and tighten the nut
to a torque of 8-10 lb.ft. (11-14 N-m).
8. Install an "Authorized Modification" decal on the brake booster listing the modification as follows:
"HSPV REAR BRAKE OPERATION MODIFIED".
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 892516 > Dec > 89 > Front Brakes Premature Lining Wear/Hard Pedal > Page 4947
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
alterations performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME CLASS
E9TZ-2W125-A Valve Shaft Positioner C
OTHER APPLICABLE ARTICLES: 88-12-20 WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION
DESCRIPTION TIME
892516A Modify Height Sensing 0.6 Hr.
Valve
DEALER CODING BASIC PART NO. CONDITION CODE
2B547 53
OASIS CODES: 3050, 3051
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Brake Pad: > 90226 > Oct > 90 > Brakes - Intermittent Brake
Squeal
Brake Pad: All Technical Service Bulletins Brakes - Intermittent Brake Squeal
Article No. 90-22-6
^ BRAKES - OCCASIONAL OR INTERMITTENT "SQUEAL"
^ NOISE - BRAKES - OCCASIONAL OR INTERMITTENT SQUEAL"
FORD: 1985-86 LTD 1985-88 EXP
1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS
LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS
1985-87 LYNX
1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91
SABLE 1987-91 TRACER 1991 CAPRI
MERKUR: 1985-89 XR4TI
LIGHT TRUCK: 1985-90 BRONCO II
1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F
SUPER DUTY 1991 EXPLORER
This TSB article is being republished in its entirety to expand the model and model year coverage.
ISSUE: Occasional or intermittent brake squeal may be cause by the brake friction material
generating noise and heat in order to dissipate energy. This occasional or intermittent squeal may
be a normal condition and requires no corrective action.
ACTION: If a customer is concerned about occasional or intermittent brake squeal, it should be
explained that brake friction materials inherently generate noise and heat in order to dissipate
energy. As a result, an occasional squeal condition may be normal, and could be affected by cold,
heat, wetness, snow, salt, mud etc.
NOTE: THIS OCCASIONAL OR INTERMITTENT SQUEAL IS NOT A FUNCTIONAL PROBLEM
AND DOES NOT INDICATE ANY LOSS OF BRAKE EFFECTIVENESS.
OTHER APPLICABLE ARTICLES: None SUPERSEDES:
87-16-7
WARRANTY STATUS: INFORMATION ONLY OASIS CODES:
301000, 702000, 702100
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Installation
Brake Pad: Service and Repair Installation
1. Install new inner and outer pad. Install anti-rattle spring.
NOTE:
- Always replace all pad and lining assemblies on an axle. Never service one wheel only.
- There is a raised section at one end of each pad so that installation can be made in one direction
only.
2. Install the caliper on the spindle, making sure the mounting surfaces are free of dirt and lubricate
the caliper grooves with disc brake caliper
grease.
3. Position pin with the pin retention tabs oriented adjacent to the spindle groove.
4. Tap the pin on the outboard end with a hammer. Continue tapping the pin inward until the
retention tabs on the sides of the pin contact the spindle
face. Repeat procedure for the lower pin.
CAUTION: During the installation procedure do not allow the tabs of the caliper pin to be tapped
too far into the spindle groove. If this happens it will be necessary to tap the other end of the caliper
pin until the tabs snap into place. The tabs on each end of the caliper pin must be free to catch on
the spindle flanks.
5. If removed, install the brake hose to the caliper and perform brake bleeding procedures.
6. Install the wheel and tire assembly.
7. Lower the vehicle, check the brake fluid level and fill as necessary. Check brakes for proper
operation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Installation > Page 4955
Brake Pad: Service and Repair Removal
1. To avoid overflow when the caliper pistons are compressed into the caliper pistons bores,
remove a portion of brake fluid from master cylinder
disc brake reservoir. Properly dispose the removed fluid.
2. Raise and support vehicle. Remove wheel and tire assembly.
Bottoming Caliper Piston
3. Install an appropriate size C-clamp on caliper. Tighten clamp to bottom caliper pistons in cylinder
bores. Remove the clamp.
NOTE: Do not use screwdriver or other edged tool to pry pistons from rotor.
4. Clean excess dirt from area around pin tabs.
5. Tap upper caliper pin towards inboard side until pin tabs touch the spindle face.
6. Insert a screwdriver into the slot provided behind the pin tabs on the inboard side of the pin.
Compressing Spring Tabs
7. Use needle nose pliers to compress the outboard end of the pin while prying at the same time
with the screwdriver, until tabs slip into the spindle
groove.
8. Place one end of a punch (approximately 7/16 inch diameter) against the end of the caliper pin
and drive the caliper pin out of the caliper slide
groove.
9. Repeat removal procedure for lower pin.
10. Remove the caliper from the rotor. If the caliper is to be removed for service, remove the brake
hose from the caliper. If the caliper is not going to
be removed, secure it to the vehicle to avoid damage to the brake hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Installation > Page 4956
11. Remove the outer brake pad. Remove the anti-rattle clips and the inner brake pad.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 872414 > Dec > 87 > Brakes - Shudder and
Vibration On Application
Brake Rotor/Disc: Customer Interest Brakes - Shudder and Vibration On Application
Article No. 87-24-14
BRAKE - ROTORS - SHUDDER AND VIBRATION DURING APPLICATION - CRACKED ROTOR
ASSEMBLY
VIBRATION AND SHUDDER - DURING BRAKE APPLICATION - CRACKED ROTOR
LIGHT TRUCK: 1980-87 E-250/350, F-250/350
ISSUE: Shudder and vibration during brake application may be caused by cracks in the braking
surface of the front disc brake rotors. Units that may be affected are 1980-87 E-250/350 and 4 x 2
F-250/350 vehicles with single rear wheels (SRW) and 1980-87 E-350 and 4 x 2 F-350 vehicles
with dual rear wheels (DRW).
ACTION: To correct this, install new design heavy-duty brake rotors. Refer to the Application Chart
below for the correct service part numbers.
PART NUMBER PART NAME CLASS
E0TZ-1102-J Disc Brake Rotor B
E0TZ-1102-K Disc Brake Rotor B
E0TZ-1102-L Disc Brake Rotor B
E7TZ-1102-C Disc Brake Rotor B
E7TZ-1102-D Disc Brake Rotor B
OTHER APPLICABLE ARTICLES: Supersedes 87-16-16 WARRANTY STATUS: Eligible Under
Basic Warranty Coverage OPERATION: SP872414A TIME:
1.0 Hr. DLR. CODING: Basic Part No. 1102 - Code: 01
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 872414 > Dec > 87 > Brakes Shudder and Vibration On Application
Brake Rotor/Disc: All Technical Service Bulletins Brakes - Shudder and Vibration On Application
Article No. 87-24-14
BRAKE - ROTORS - SHUDDER AND VIBRATION DURING APPLICATION - CRACKED ROTOR
ASSEMBLY
VIBRATION AND SHUDDER - DURING BRAKE APPLICATION - CRACKED ROTOR
LIGHT TRUCK: 1980-87 E-250/350, F-250/350
ISSUE: Shudder and vibration during brake application may be caused by cracks in the braking
surface of the front disc brake rotors. Units that may be affected are 1980-87 E-250/350 and 4 x 2
F-250/350 vehicles with single rear wheels (SRW) and 1980-87 E-350 and 4 x 2 F-350 vehicles
with dual rear wheels (DRW).
ACTION: To correct this, install new design heavy-duty brake rotors. Refer to the Application Chart
below for the correct service part numbers.
PART NUMBER PART NAME CLASS
E0TZ-1102-J Disc Brake Rotor B
E0TZ-1102-K Disc Brake Rotor B
E0TZ-1102-L Disc Brake Rotor B
E7TZ-1102-C Disc Brake Rotor B
E7TZ-1102-D Disc Brake Rotor B
OTHER APPLICABLE ARTICLES: Supersedes 87-16-16 WARRANTY STATUS: Eligible Under
Basic Warranty Coverage OPERATION: SP872414A TIME:
1.0 Hr. DLR. CODING: Basic Part No. 1102 - Code: 01
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > Page 4970
Brake Rotor/Disc: Specifications
Nominal Thickness 1.250 in
Minimum Allowable Thickness 1.180 in
Maximum Variation (Parallelism) Integral 0.0007 in
Two Piece 0.0010 in
Lateral Runout Integral 0.003 in
Two Piece 0.005 in
Rotor Surface Finish 15 To 80 in
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > Page 4971
Brake Rotor/Disc: Testing and Inspection
PURPOSE
In the manufacturing of the brake rotor all the tolerances regarding surface finish, parallelism, and
lateral runout are held very closely. The maintenance of these tolerances provide the surface
necessary to prevent brake roughness.
Light scoring of the rotor surface not in excess of 0.38 mm (0.015-inch) in depth is normal. This
condition does not affect the brake operation.
Some discoloration or wear of the disc surface is normal and does not require re-surfacing when
linings are replaced.
SPECIFICATIONS - See: Specifications
LATERAL RUNOUT
Lateral runout is the movement of the rotor from side to side as it rotates on the spindle. This could
also be referred to as "rotor wobble".
This movement causes the brake pad and piston to be knocked back into it's bore. This results in
additional pedal travel and a vibration during braking.
Checking Lateral Runout 1. Tighten the wheel bearings to eliminate all freeplay.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > Page 4972
2. Attach a dial indicator to a solid non-rotating portion of the hub assembly or suspension.
- The point of the styles must contact the rotor face about 25 mm (1-inch) from the rotor edge.
3. Move the rotor one complete rotation and observe the dial indicator.
4. Rotate the bezel on the dial indicator such that "0" is at the low deflection point. 5. Again rotate
the rotor at least one complete turn and observe the needle deflection. Total needle deflection will
equal lateral runout. 6. Readjust the wheel bearings.
MINIMUM THICKNESS
The thickness of a rotor is important for two reasons: 1. Rotors which are too thin are not able to
properly absorb and release heat during heavy braking. This results in reduced braking capacity
and
brake fade.
2. Rotors worn below minimum thickness in combination with worn pads/linings can result in the
caliper piston extending too far becoming
cocked or jammed.
Rotor thickness should be measured at the thinnest point on the rotor. Any rotor which is worn
below its minimum thickness should be replaced.
For accurate measurements, it is best to remove the caliper to allow for complete access to the
inboard side of the rotor. For more information on how to use a disc brake micrometer see
Fundamentals and Basics.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > Page 4973
PARALLELISM
Parallelism is the measurement of the thickness of the rotor at 12 or more points around the
circumference of the rotor. All measurements must be made at the same distance in from the edge
of the rotor.
Lack Of Parallelism
Lack Of Parallelism
MACHINING
Since accurate control of the rotor tolerances is necessary for proper performance of the disc
brakes, machining of the rotor should be done only with precision equipment.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Technical Service Bulletins > Page 4974
All brake rotors have a minimum thickness dimension cast into them. This dimension is the
minimum wear dimension and not a refinish dimension. Do not use a brake rotor that will not meet
the specifications, after refinishing. Replace with a new brake rotor.
NOTE: 1 inch = 25.4mm, so if your micrometer measures in inches and the specified thickness on
the disc is in millimeters, convert millimeters to inches by dividing the specified number of
millimeters by 25.4.
Example: Specification on disc is 17.8 mm. Dividing 17.8mm by 25.4mm/in = 17.8/25.4 = 0.70
inches.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Installation
Brake Rotor/Disc: Service and Repair Installation
Front Hub And Rotor Assembly
Wheel bearing lubricant is a lithium-base grease. Sodium-base grease is not compatible with
lithium-base grease and should not be intermixed. Therefore, do not lubricate front and/or rear
wheel bearings without first identifying the type of original wheel bearing lubricant. Usage of
incompatible bearing lubricants may result in premature lubricant breakdown.
1. If a new hub and rotor will be installed, remove the protective coating, any dirt or grease deposits
with brake parts cleaner or degreaser. 2. Pack the inside of the hub with lithium-base grease or
equivalent. Fill the hub until the grease is flush with the inside diameters of both bearing
cups. Pack the bearing cones and rollers with wheel bearing grease. Use a bearing packer for this
operation. If a packer is not available, work as much lubricant as possible between the rollers and
cages. Lubricate the cone surfaces with grease.
Installing Grease Seal (Typical)
3. Place the inner bearing cone and roller in the inner cup and install the new grease seal. Be sure
that the seal is fully seated. 4. Install the hub and rotor on the wheel spindle. Keep the hub
centered on the spindle to prevent damage to the grease retainer or the spindle threads. 5. Install
the outer bearing cone and roller and the flat washer on the spindle, then install the adjusting nut,
and adjust the wheel bearing. 6. Install the retainer, new cotter pin, and grease cap. 7. Install the
caliper.
For additional information see Installation Notes.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Installation > Page 4977
Brake Rotor/Disc: Service and Repair Removal
1. Raise the vehicle until the tire clears the floor and remove the wheel and tire assembly.
2. Remove the brake caliper and secure to the underbody to prevent damage to the brake hose. It
is not necessary to disconnect the hose from the
caliper. Do not let the caliper hang with its weight on the brake hose or the hose may become
stretched, twisted or ruptured.
Front Hub And Rotor Assembly
3. Remove the grease cap, cotter pin, retainer adjusting nut and washer.
4. Remove the outer bearing cone and roller.
5. Pull the hub and rotor off the spindle and remove and discard the grease seal.
6. Remove the inner bearing cone and roller from the hub. Remove all traces of old lubricant from
bearings, hub and axle spindle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Installation > Page 4978
Brake Rotor/Disc: Service and Repair Servicing
Each time the brakes are serviced, the disc brake rotor should be checked for scoring, runout,
parallelism and thickness.
ROTOR MACHINING
Do not machine, cut or true up new front disc brake hub and rotors prior to installation on vehicle.
Making a light cut on a new front disc brake hub and rotor may cause excessive runout and result
in brake shudder several thousand miles later. It is best to clean oil film off new front disc brake hub
and rotor with Brake Cleaner or equivalent install it on vehicle.
Never use a brake lathe that cuts only one face of the front disc brake hub and rotor at a time. It
must be a simultaneous straddle cut. All front disc brake hub and rotor refinishing must adhere to
the rule that equal amounts of front disc brake hub and rotor stock are removed from each braking
surface each time a front disc brake hub and rotor is refinished.
On-vehicle brake lathes, machine the front disc brake hub and rotor while it is on the hub and is
turning on the same axis as the hub. This procedure reduces front disc brake hub and rotor lateral
runout to near zero by cutting the front disc brake hub and rotor perpendicular to the axis of the
hub, therefore cancelling the affect of stacked tolerance of the front disc brake hub and rotor and
front wheel spindle. Follow the on-vehicle brake lathe manufacturer's instructions on machining
procedures.
A bench-mounted disc brake lathe machines the disc brake hub and rotor to the axis of the lathe
arbor and will not reduce total lateral runout associated with stacked tolerances of the front disc
brake hub and rotor and front wheel spindle. Follow manufacturer's instructions on machining
procedures.
With both types of brake lathes, set cutting tool to just contact the high spots on the front disc brake
hub and rotor then adjust cutting tool to the minimum depth required to clean up the front disc
brake hub and rotor face. The total material removed (combination of both sides) must not exceed
the minimum discard thickness that is marked on the inside of the front disc brake hub and rotor.
To improve initial brake pedal feel and surface finish on a machined front disc brake hub and rotor,
lightly sand rotor surface with 120 grit paper prior to road testing.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information >
Service and Repair
Backing Plate: Service and Repair
REMOVAL
1. Remove the wheel and brake drum. Disconnect the brake tube from the wheel cylinder and plug
the end of the brake tube to prevent air from
entering the system.
2. Remove brake linings and wheel cylinder.
3. Disconnect the parking brake lever from the cable. Remove the cable from the backing plate.
4. Remove the brake backing plate after the axle shaft has been removed.
INSTALLATION
1. Position the brake backing plate on the retaining bolts on the axle housing flange.
2. Install the parking brake cable from the backing plate. Connect the parking brake lever to the
cable.
3. Install the wheel cylinder and brake linings.
4. Connect the brake tube to the wheel cylinder and remove the air from the system by brake
bleeding.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Specifications
Brake Drum: Specifications
Nominal Inside Diameter And Width 12.00 X 3.0 In
Maximum Refinish Diameter 12.060 in
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Specifications > Page 4986
Brake Drum: Testing and Inspection
VISUAL INSPECTION
Inspect the drum for cracks. If any large, through-the-drum cracks are located the drum must be
replaced.
NOTE: Cracks in drums are often difficult to locate. To quickly determine if a drum is cracked lightly
drop the drum (from a height of 4-5 inches) onto a flat hard surface. A cracked drum will make a
dull thud sound while a good drum will make a ringing sound.
Inspect for signs of overheating. An overheated drum will often be discolored (blue/gold), warped,
or heat checked. Heat checks are small cracks in the drum friction surface. Heat checks can be
removed by resurfacing.
NOTE: The cause of the overheating should be determined prior to replacing the shoes/linings or
drums.
Inspect for scoring. Any grooves or scores in excess of 0.008 inches should be resurfaced.
SPECIFICATIONS - See: Specifications
MAXIMUM DIAMETER
Purpose
The thickness of the drum friction surface is directly proportional to the drums ability to absorb and
release heat during braking. As the drum becomes thinner due to normal wear and resurfacing it
looses its ability to absorb and release heat and is more prone to brake fade, distortion, and
cracking.
As the drum wears the inside diameter of the drum increases. The amount of drum thickness lost to
wear is equal to 1/2 the increase in diameter.
There are two specifications related to drum thickness.
Discard Diameter - This is the maximum diameter at which it becomes unsafe to operate. A drum
which has reached this thickness should not be machined and should be discarded.
Maximum Refinish - This is the maximum diameter to which a drum may be machined or
resurfaced to. This diameter is smaller (thicker) than the Discard diameter because it assumes the
drum will need to have a sufficient thickness left, after machining, to allow for further wear from a
new set of shoes/linings.
Which One Should Be Used?
If you install a new pair of shoes with the drum diameter at or less than the "Maximum Refinish"
specification the drums should have a sufficient thickness to last the normal life of the new
shoes/linings.
The "Discard Diameter" should be used to determine if a drum needs to be replaced at the present
time of inspection.
If you install a new pair of shoes with the drums machined at or near "Discard Diameter", within a
short time the drums will be too thin
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Specifications > Page 4987
(unsafe) and the new shoes/linings will be subject to overheating and brake fade.
How To Measure
NOTE: For additional information on how to use a drum micrometer see Fundamentals and Basics.
- A drum micrometer is used to measure the drum diameter.
- The micrometer scale should be initially set to the original (new) thickness of the drum.
- The base of the micrometer should be placed in the deepest groove in the drum and held steady
while the measuring point is swiveled to find the maximum diameter.
- The base and measuring point should be kept at the same depth in the drum.
Drum Micrometer
- The measurement should be repeated at 3 or more places around the circumference of the drum
to determine if the drum is out of round. If the measurements differ by more than 0.004 inches the
drum should be resurfaced.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Specifications > Page 4988
NOTE: A drum which is out of round will cause a pedal pulsation to be felt upon braking.
- The measurement should also be repeated at various depths of the drum to check for a bellmouth
condition. If the measurements differ by more than .010 inches the drum should be resurfaced.
NOTE: 1 inch = 25.4mm, so if your micrometer measures in inches and the specified thickness on
the disc is in millimeters, convert millimeters to inches by dividing the specified number of
millimeters by 25.4.
Example: Specification on disc is 17.8 mm. Dividing 17.8mm by 25.4mm/in = 17.8/25.4 = 0.70
inches.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Service and Repair > Removal and Installation
Brake Drum: Service and Repair Removal and Installation
For additional information see Notes, Warnings, and Hints.
REMOVAL
1. Raise the vehicle so the wheel is clear of the floor. Install safety stands under the axle.
CAUTION: Use of a drum puller or a torch Is not recommended. Drum distortion may result.
2. Remove the wheel and tire assembly. Remove the spring retaining nuts and remove the brake
drum.
3. If the brake drum is rusted to the axle shaft pilot diameter, use coarse sandpaper to remove the
rust build-up, then remove the brake drum.
4. Check the surface of the brake drum. If worn or if brake drum is suspected of having excessive
runout, the brake drum should be machined. After
machining, check maximum diameter (stamped on the outside of the brake drum). Brake drum
must be replaced if diameter is outside maximum limit.
Retracting Brake Shoes
If the brake drum will not come off, insert a narrow screwdriver through the brake adjusting hole in
the brake backing plate, and disengage the brake shoe adjusting lever from the brake adjuster
screw. While holding the brake shoe adjusting lever away from the brake adjuster screw, loosen
the brake adjuster screw with the brake adjusting tool. Loosen the brake adjuster screw only if the
brake drum cannot be removed. Do not burr, chip, or damage the notches in the brake adjuster
screw or the self-adjusting mechanism will not function properly.
If the brake adjuster screw was loosened, check to be sure the brake shoe adjusting lever is still
properly seated In the shoe web.
INSTALLATION
1. Remove the protective coating from a new brake drum with brake parts cleaner.
2. Adjust the brakes.
3. Install the brake drum onto the axle shaft flange or rear hub.
4. Install the retaining clips securely. Install the wheel on the axle shaft flange or rear hub studs
against the brake drum, and tighten to specification.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Service and Repair > Removal and Installation > Page 4991
Brake Drum: Service and Repair Servicing
Minor scores should be removed with sandpaper. Grooves and large scores can only be removed
by machining with special equipment, as long as the braking surface is within specifications
stamped on brake drum outer surface. Any brake drum sufficiently out of round to cause vehicle
vibration or noise while braking, or showing taper should also be machined, removing only enough
stock to true up the brake drum.
After a brake drum is machined, wipe braking surface diameter with a cloth soaked in denatured
alcohol. If one brake drum is machined, the other should also be machined to the same diameter to
maintain equal braking forces.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Intermittent Brake Squeal
Brake Shoe: Technical Service Bulletins Brakes - Intermittent Brake Squeal
Article No. 90-22-6
^ BRAKES - OCCASIONAL OR INTERMITTENT "SQUEAL"
^ NOISE - BRAKES - OCCASIONAL OR INTERMITTENT SQUEAL"
FORD: 1985-86 LTD 1985-88 EXP
1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS
LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS
1985-87 LYNX
1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91
SABLE 1987-91 TRACER 1991 CAPRI
MERKUR: 1985-89 XR4TI
LIGHT TRUCK: 1985-90 BRONCO II
1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F
SUPER DUTY 1991 EXPLORER
This TSB article is being republished in its entirety to expand the model and model year coverage.
ISSUE: Occasional or intermittent brake squeal may be cause by the brake friction material
generating noise and heat in order to dissipate energy. This occasional or intermittent squeal may
be a normal condition and requires no corrective action.
ACTION: If a customer is concerned about occasional or intermittent brake squeal, it should be
explained that brake friction materials inherently generate noise and heat in order to dissipate
energy. As a result, an occasional squeal condition may be normal, and could be affected by cold,
heat, wetness, snow, salt, mud etc.
NOTE: THIS OCCASIONAL OR INTERMITTENT SQUEAL IS NOT A FUNCTIONAL PROBLEM
AND DOES NOT INDICATE ANY LOSS OF BRAKE EFFECTIVENESS.
OTHER APPLICABLE ARTICLES: None SUPERSEDES:
87-16-7
WARRANTY STATUS: INFORMATION ONLY OASIS CODES:
301000, 702000, 702100
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Page 4996
Brake Shoe: Adjustments
Fig. 1 Drum Brake Assembly
Fig. 3 Left Rear 10 Inch Drum
The rear brake shoes, Figs. 2 and 3, adjust automatically when the vehicle is driven forward or
reverse and the brakes are applied sharply several times. Manual adjustment is required only when
brake shoes are replaced. When adjusting rear brakes, ensure that parking brake is properly
adjusted and that equalizer is operating freely.
With Drums Removed
1. With drums removed, clean areas where shoes contact backing plate, then apply suitable
lubricant to these contact areas, ensuring that lubricant does not contaminate linings.
2. Using suitable brake shoe adjusting gauge, adjust gauge to inside diameter of brake drum.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Page 4997
Fig. 4 Checking Brake Lining Clearance
3. Reverse tool and adjust shoes until they contact gauge, ensuring that gauge is parallel to vehicle
and at centerline of axle, Fig. 4. Holding automatic adjusting lever aside, rotate adjusting screw as
necessary.
4. Install drums, wheels and retaining nuts, then complete adjustment by applying brakes several
times while driving vehicle in reverse.
5. Check brake operation by making several stops in forward gear. Repeat step 4, if necessary.
With Drums Installed
1. Raise and support rear of vehicle.
2. Remove cover from adjusting hole located at bottom of backing plate.
Fig. 5 Adjusting Rear Drum Brakes
3. Using a small screwdriver to hold adjusting lever away from star wheel, rotate adjusting screw
star wheel until brake shoes are locked against drum, Fig. 5.
4. Back-off brake adjusting screw approximately 10 to 12 notches so that brake drum rotates freely
without drag. If brake drum does not rotate freely, remove drum and clean and inspect drum brake
components.
5. After adjusting both drum brakes lower vehicle and apply brakes several times to position brake
shoes.
6. Road test vehicle to ensure brakes operate properly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Installation
Brake Shoe: Service and Repair Installation
Exploded View
Assembled View
1. Clean ledge pads on backing plate, sanding lightly to bare metal. 2. Apply suitable lubricant to
retracting and hold-down spring contacts on brake shoes and backing plate. 3. Apply suitable
lubricant to threads and socket end of adjusting screw. 4. Install upper retracting spring on primary
and secondary shoes and position shoe assembly on backing plate with wheel cylinder pushrods in
shoe
slots. For additional information see Brake Spring Removal and Installation Notes.
5. Install brake shoe hold-down springs. 6. Install brake shoe adjustment screw assembly with the
slot in the head of adjustment screw facing primary shoe, lower retracting spring, adjusting
lever, and lever spring assembly. Connect adjusting cable to adjusting lever. Socket end of each
adjusting screw is stamped ``R'' or ``L'' to indicate use on right or left side of vehicle. Adjusting pivot
nuts can be identified by number of lines machined around body of nut. Two lines indicate
righthand nut and one line indicates lefthand nut.
7. Position cable in cable guide and install cable anchor fitting on the anchor pin. 8. Install parking
brake assembly in anchor pin and secure with retaining nut behind backing plate. 9. On vehicles
with full-floating axles, install brake drums as follows:
a. Place brake drum on hub and install attaching screws, bolts, or bolts and nuts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Installation > Page 5000
b. Place hub and drum as an assembly on axle and start adjusting nut. c. Adjust wheel bearing nut
and install wheel bearing lock washer and lock nut. See Rear Axle for procedure. d. Install new
gasket and the bolts and lock washers. e. Install wheel and tire assembly. f.
Adjust brakes.
For additional information see Notes, Warnings, and Hints.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Installation > Page 5001
Brake Shoe: Service and Repair Removal
Exploded View
Assembled View
1. Raise and support vehicle. 2. Remove wheel and tire assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Installation > Page 5002
Retracting Brake Shoes
3. If necessary, retract brake shoes. 4. On vehicles with full-floating axles, remove brake drums as
follows:
a. Loosen rear brake shoe adjustment screw. b. Remove rear axle retaining bolts and lock
washers, axle shaft, and gasket. c. Remove wheel bearing locknut, lock washer, and adjusting nut.
d. Remove hub and drum from axle. e. Remove brake drum-to-hub retaining screws, bolts, or bolts
and nuts, then remove brake drum from hub.
5. On vehicles with semi-floating axles, remove brake drums as follows:
a. Remove brake drum retaining nuts. b. Remove brake drum. If brake lining is dragging on brake
drum, back off brake adjustment by rotating adjusting screw.
6. Remove parking brake lever assembly retaining nut from behind backing plate and remove
parking brake lever assembly. 7. Remove adjusting cable assembly from anchor pin, cable guide,
and adjusting lever. 8. Remove brake shoe retracting springs. For additional information see Brake
Spring Removal and Installation Notes. 9. Remove brake shoe hold-down springs.
10. Remove brake shoes and adjusting screw assembly. 11. Disassemble adjusting screw
assembly.
For additional information see Notes, Warnings, and Hints.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information
> Service and Repair > Removal
Wheel Cylinder: Service and Repair Removal
1. Raise vehicle on hoist and position suitable safety stands under vehicle. 2. Remove wheel and
tire assembly. 3. Remove the brake drum. Remove brake linings. Remove the wheel cylinder brake
shoe links. 4. Disconnect the rear brake tube from the wheel cylinder. 5. Remove the brake cylinder
retaining bolts and lockwashers. Remove the wheel cylinder from the backing plate.
For additional information see Notes, Warnings, and Hints.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information
> Service and Repair > Removal > Page 5007
Wheel Cylinder: Service and Repair Rebuild
For additional information see Notes, Warnings, and Hints.
Rear Wheel Cylinder
DISASSEMBLY
1. Remove the rubber boots from the ends of the brake cylinder. 2. Remove the pistons, cups and
piston cup spring. 3. Remove the wheel cylinder bleeder screw. Ensure the bleeder screw is not
plugged.
ASSEMBLY
1. Coat all wheel cylinder parts with clean brake fluid or brake assembly lube. 2. Install the bleeder
screw into the wheel cylinder. 3. Place the wheel cylinder piston cup spring, cups and pistons into
the wheel cylinder. 4. Install a boot and wheel cylinder brake shoe link over each end of the wheel
cylinder.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information
> Service and Repair > Removal > Page 5008
Wheel Cylinder: Service and Repair Installation
1. Place wheel cylinder on the brake backing plate. Install the retaining bolts and lockwashers. 2.
Connect the brake tube to the wheel cylinder. 3. Install wheel cylinder brake shoe links and brake
linings. Install the brake drum and wheel and tire assembly. 4. Adjust the brakes. See: Brake
Shoe/Adjustments 5. Perform system brake bleeding procedures.
Check pedal operation before moving the vehicle.
For additional information see Notes, Warnings, and Hints.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Manual Bleeding
Brake Bleeding: Service and Repair Manual Bleeding
NOTE: Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first
on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that
has been drained from hydraulic system.
1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to
absorb escaping brake fluid.
2. Depress brake pedal slowly by hand to floor of cab, forcing air trapped in master cylinder out at
fitting.
3. Hold pedal down and tighten fittings, then release brake pedal.
NOTE: Releasing brake pedal before fittings are tightened will allow air to enter the master
cylinder.
4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm.
5. Bleed rear brakes as follows:
RR, LR, RF, LF
WARNING: Do not bleed the brakes with the drums removed. The wheel-cylinders will over-extend
and eject the pistons.
a. Pump pedal several times, then hold pedal down firmly.
WARNING: Do not Full Stroke the brake pedal, this may damage the master cylinder. Place a 2
inch block of wood under the brake pedal to prevent Full Stroking.
b. With pedal firmly depressed, open bleeder screw on one rear brake until pedal fades to floor,
then close bleeder valve.
NOTE: Do not release the brake pedal until the bleeder valve is fully shut.
c. Repeat procedure until a continuous flow of brake fluid is released from bleeder valve.
d. Repeat steps 5a through 5c on other rear brake.
6. Bleed front brakes using same procedure as for rear brakes.
7. Fill master cylinder reservoirs to 1/4 inch from top of reservoirs.
9. Check brake operation and ensure pedal is firm, road test vehicle.
For additional information see Bleeding Notes.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Manual Bleeding > Page 5014
Brake Bleeding: Service and Repair Master Cylinder Bleeding
1. Support the master cylinder body in a vise, and fill both fluid reservoirs with heavy duty DOT 3
brake fluid. 2. Install plugs in the front and rear brake outlet ports. Bleed the front brake outlet
system first. 3. Loosen the plug in the front brake outlet port. Depress the secondary piston slowly
to force the air out of the master cylinder. Tighten plug while
piston is depressed or air will enter the master cylinder.
4. Repeat this procedure until air ceases to exit at the outlet port. 5. Repeat steps 3 and 4 for the
rear brake outlet port with the front brake outlet plugged. 6. Tighten the plugs and try to depress the
piston. Depressing the piston should be harder after all air is expelled. 7. Install the plastic cap. 8.
Install the master cylinder in the vehicle and bleed the hydraulic system.
For additional information see Bench Bleeding.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Manual Bleeding > Page 5015
Brake Bleeding: Service and Repair Pressure Bleeding
Be sure the bleeder tank contains enough of the specified brake fluid to complete the bleeding
operation. Charge the tank with approximately 69-206 kPa (10-30 psi). Never exceed 345 kPa (50
psi). Never use brake fluid that has been drained from the hydraulic system. Bleed the longest lines
first
1. Clean all dirt from the master cylinder reservoir cap.
2. Remove the master cylinder reservoir cap and fill the master cylinder reservoir with the specified
brake fluid. Install the pressure bleeder adapter
tool on the master cylinder, and attach the bleeder tank hose to the fitting on the adapter.
NOTE: Master cylinder pressure bleeder adapter tools are available from the manufacturers of
pressure bleeding equipment. Follow the manufacturer's instructions when installing the adapter.
3. Place a 3/8 inch box wrench on the bleeder fitting on the right rear brake wheel cylinder. Attach a
bleeder tube snugly to the bleeder fitting.
4. Open the valve on the bleeder tank and admit pressurized brake fluid to the master cylinder
reservoir.
5. Submerge the free end of the tube in a container partially filled with clean brake fluid, and loosen
the bleeder fitting.
6. When air bubbles no longer appear in the fluid at the submerged end of the bleeder tube, close
the bleeder fitting and remove the tube.
7. Repeat Steps 3 through 6 at the opposite wheel cylinder. On front brakes, bleed the right front
caliper first.
8. When the bleeding operation is completed, close the bleeder tank valve and remove the tank
hose from the adapter fitting.
9. Remove the pressure bleeder adapter tool. Fill the master cylinder reservoirs with the specified
brake fluid to within 3 mm (1/8 in) from the top of
the filler neck. Install the master cylinder cover.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear
Brake Caliper: Customer Interest Brakes - Soft Pedal Feel/Pull/Irregular Wear
Article No. 98-5A-29
03/18/98
^ BRAKES - "SOFT" PEDAL FEEL
^ BRAKES - IRREGULAR BRAKE WEAR AND/OR BRAKE PULL - SERVICE TIPS
LIGHT TRUCK: 1980-91 E-250, E-350 1980-94 F-250, F-350
ISSUE: Some vehicles may exhibit any one or more of the following conditions:
^ Excessive brake pedal travel
^ Irregular front lining wear
^ Brake pull
This may be caused by the inner brake pad binding and/or the outer pad being installed out of
position.
ACTION: Refer to the following Service Tips when servicing a vehicle for any of the concerns listed
above.
SERVICE TIPS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear > Page 5024
1. Before servicing brakes, inspect the caliper for correctly positioned pads and equal lining wear.
Refer to Figure 1.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear > Page 5025
2. An incorrectly positioned outer pad could become bent after the first brake application. Refer to
Figure 2.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear > Page 5026
3. Remove the pads. Hold the inner pad and outer pad against each other as shown in Figure 3.
Check to see if the wear surfaces are parallel to the pad back surfaces. If the pads have an angled
wear, this may indicate that a pad was mispositioned and/or was not sliding properly on the caliper
rail.
NOTE:
PADS WITH AN ANGLED WEAR PATTERN REQUIRE EXCESSIVE CALIPER MOVEMENT TO
SEAT THE PADS TO THE ROTOR. THIS EXTRA MOVEMENT REQUIRES EXTRA FLUID
VOLUME, RESULTING IN ADDITIONAL PEDAL TRAVEL, SIMILAR TO MISADJUSTED REAR
BRAKES.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear > Page 5027
4. Inspect the inner pad for binding. Inner pads could become stuck to the slide surface due to
contamination, burrs, or corrosion. Refer to Figure 4.
NOTE:
REFER TO TSB 98-5A-13 FOR FURTHER INFORMATION ON THE USE OF SILICONE BRAKE
CALIPER GREASE AND DIELECTRIC COMPOUND.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear > Page 5028
5. Reinstall the caliper. During reassembly, inspect the pads and clean the caliper slide surfaces of
corrosion, contamination, or burrs. Polish with a crocus cloth and lubricate with Silicone Brake
Caliper Grease and Dielectric Compound (D7AZ-19A331-A). Refer to Figure 5.
NOTE:
ON 1988-91 F-250/350 TRUCKS THAT WERE INVOLVED IN RECALL 92S44, BE SURE TO
REASSEMBLE USING ALL COMPONENTS OF THE BRAKE CALIPER PISTON INSULATOR KIT
UNLESS PHENOLIC PISTONS HAVE BEEN INSTALLED.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear > Page 5029
6. Reinstall the pads. During pad installation, be careful not to dislodge the outer pad from its slide
position. Refer to Figure 6. An incorrect installation will cause a bent outer pad. Refer to Figure 2.
7. Once the calipers have been reinstalled and servicing is complete, but before installing the
wheels, apply the brakes and confirm the outer pad position remains correct.
PART NUMBER PART NAME
D7AZ-19A331-A Silicone Caliper Grease And Compound
OTHER APPLICABLE ARTICLES: 98-5A-13 SUPERSEDES: 97-15-17 WARRANTY STATUS:
INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-29 > Mar > 98 > Brakes - Soft
Pedal Feel/Pull/Irregular Wear > Page 5030
OASIS CODES: 301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 98-5A-38 > Mar > 98 > Front Brake
Caliper - Piston Boots Damaged
Brake Caliper: Customer Interest Front Brake Caliper - Piston Boots Damaged
Article No. 98-5A-38
03/18/98
BRAKES - CALIPERS - FRONT CALIPER PISTON BOOTS DAMAGED
LIGHT TRUCK: 1986-91 E-250, E-35O 1986-94 F-250, F-350
ISSUE: Some vehicles may have experienced deterioration of the front brake caliper piston boots
resulting from exposure to high operating temperatures during severe service.
ACTION: Replace the caliper piston boots with a new, more robust service caliper piston boot. The
new silicone rubber boot can withstand higher operating temperatures without damage. The new
boot is completely interchangeable with the prior design and will become the only service boot
available.
The heat damaged boots should be replaced with the new Boot (E7TZ.2207-A). Refer to the
appropriate Service Manual for removal and installation procedures.
PART NUMBER PART NAME
E7TZ-2207-A Caliper Piston Boot
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-24-11 WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year
Vehicles, Basic Warranty Coverage For All Other Model Years
OPERATION DESCRIPTION TIME
985A38AT Overhaul Front Calipers - 1.5 Hrs.
Both
985A38A Overhaul Front Caliper - 1.2 Hrs.
One
DEALER CODING
CONDITION
BASIC PART NO. CODE
2207 42
OASIS CODES: 301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 93117 > May > 93 > Brakes Sticking/Binding/Grabbing
Brake Caliper: Customer Interest Brakes - Sticking/Binding/Grabbing
Article No. 93-11-7
05/26/93
BRAKES - STICK/BIND/GRAB - FRONT CALIPER PINS CORRODED
LIGHT TRUCK: 1987-90 BRONCO II 1987-92 AEROSTAR, BRONCO, ECONOLINE, F-150-350
SERIES, RANGER 1988-92 F SUPER DUTY 1991-92 EXPLORER
This TSB article is being republished in its entirety to include F Super Duty vehicles.
ISSUE: Sticking, binding or grabbing of the brakes may be caused by brake caliper slide pins that
are corroded. The corrosion does not allow the brake caliper assembly to move freely.
ACTION: Install the new improved caliper pins that are corrosion resistant. Refer to the following
Service Procedure for service details.
SERVICE PROCEDURE
1. Remove the caliper and pins. Refer to the applicable Light Truck Service Manual for service
details.
NOTE: IF PADS ARE DAMAGED OR WORN, PAD REPLACEMENT IS REQUIRED.
2. Clean the upper and lower knuckle pin grooves, upper and lower knuckle inner pad grooves, and
the upper and lower caliper pin grooves with a wire brush or portable wire wheel.
WARNING: USE SAFETY GLASSES AND AN AIR RESPIRATOR WHEN CLEANING THE
GROOVES.
3. Apply a light coat of lubricant (D7AZ-19590-A) to the upper and lower knuckle inner pad grooves
and upper and lower caliper pin grooves.
CAUTION: LUBRICANT SHOULD NOT BE USED ON ROTORS, LININGS OR CALIPER PISTON
BOOTS.
4. Re-assemble the caliper using the new pins, (F2TZ-2C150-A) for all vehicles except F Super
Duty. Use new pins (F2TZ-2C150-B) for F Super Duty vehicles.
NOTE: NORMAL BRAKE MAINTENANCE REQUIREMENTS LISTED IN THE OWNER MANUAL
SHOULD BE PERFORMED EVERY 15,000 MILES.
PART NUMBER PART NAME CLASS
D7AZ-19590-A Lubricant-Disc Brake AM
F2TZ-2C150-A Pin-Brake Caliper B
F2TZ-2C150-B Pin-Brake Caliper (F Super B
Duty)
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 92-12-14
WARRANTY STATUS: Eligible Under Bumper To Bumper For 1992 Models And Basic Warranty
Coverage For All Other Model Years
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 93117 > May > 93 > Brakes Sticking/Binding/Grabbing > Page 5039
OPERATION DESCRIPTION TIME
931107A Aerostar/Ranger/Bronco II, 0.8 Hr.
(Through 1990), Explorer (Starting 1991), F-Series Under 8500 GVW, Bronco And Econoline
Under 8500
931107B F-Series Over 8500 GVW 0.9 Hr.
And Econoline Over 8500 GVW Through 1991
931107C F Super Duty Front 1.2 Hr.
931107D F Super Duty Rear 1.2 Hr.
931107E F Super Duty Front And 2.1 Hr.
Rear
DEALER CODING
BASIC PART NO. CONDITION CODE
2C150 41
OASIS CODES: 301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper Rattling Noise
Brake Caliper: Customer Interest Brake Caliper - Rattling Noise
BRAKE - CALIPER "RATTLING" NOISE - VEHICLES BUILT BEFORE 3/01/88
BRAKE - CALIPER PINS - SERVICE REMOVAL TOOL
NOISE - "RATTLE" FROM BRAKE CALIPER - VEHICLES BUILT BEFORE 3/01 /88
Article No. 88-13-7
LIGHT TRUCK: 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR, BRONCO, E
SERIES, F SERIES 1988 F-SUPER DUTY
ISSUE: A "rattling" noise may be heard coming from the front disc brake calipers. The caliper pins
may eventually take a set under certain load conditions allowing the disc brake caliper to "rattle".
The "rattling" noise is more likely to develop on units that are driven off-road or operated on rough
roads.
ACTION: To correct this, install new design caliper pins. A new caliper pin removal tool can be
made to aid in removal of the pins. Refer to the caliper pin application chart on this page for the
correct service part number.
FIGURE 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper Rattling Noise > Page 5044
FIGURE 9
FIGURE 10
FIGURE 11
The caliper pin removal tool is recommended for use on all the above listed vehicles, including
1988 Super Duty, Figures 8 through 11. This caliper pin tool can be made from a 1/2 inch diameter
rod 7 inches long. Simply grind or cut a "V" notch in one (1) end. The "V" notch is used to
compress the pin retention tabs while the tool is also used to drive the pin out of the caliper slide
groove. This tool replaces a pair of pliers and screwdriver as outlined in the Shop Manual service
procedure.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 88137 > Jun > 88 > Brake Caliper Rattling Noise > Page 5045
The idea for this tool was submitted for the Best Idea Contest by Joseph L. Kaiser, Bauer Ford Inc.,
Brookville, Indiana. See "Service Life", Winter 1987 issue for featured article.
CALIPER PIN APPLICATION CHART
Part Number Part Name Vehicle Usage
E8TZ-2C150-A Caliper Pin Super Duty
E8TZ-2C150-B Caliper Pin Ranger, Bronco II, Aerostar, Bronco, E Series, F Series
PART NUMBER PART NAME CLASS
E8TZ-2C150-A Caliper Pin B
E8TZ-2C150-B Caliper Pin B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: 881307A - Both sides TIME: 0.5 Hr. DLR. CODING: Basic Part No. 2C150
Condition Code: 33
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear
Brake Caliper: All Technical Service Bulletins Brakes - Soft Pedal Feel/Pull/Irregular Wear
Article No. 98-5A-29
03/18/98
^ BRAKES - "SOFT" PEDAL FEEL
^ BRAKES - IRREGULAR BRAKE WEAR AND/OR BRAKE PULL - SERVICE TIPS
LIGHT TRUCK: 1980-91 E-250, E-350 1980-94 F-250, F-350
ISSUE: Some vehicles may exhibit any one or more of the following conditions:
^ Excessive brake pedal travel
^ Irregular front lining wear
^ Brake pull
This may be caused by the inner brake pad binding and/or the outer pad being installed out of
position.
ACTION: Refer to the following Service Tips when servicing a vehicle for any of the concerns listed
above.
SERVICE TIPS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear > Page 5051
1. Before servicing brakes, inspect the caliper for correctly positioned pads and equal lining wear.
Refer to Figure 1.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear > Page 5052
2. An incorrectly positioned outer pad could become bent after the first brake application. Refer to
Figure 2.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear > Page 5053
3. Remove the pads. Hold the inner pad and outer pad against each other as shown in Figure 3.
Check to see if the wear surfaces are parallel to the pad back surfaces. If the pads have an angled
wear, this may indicate that a pad was mispositioned and/or was not sliding properly on the caliper
rail.
NOTE:
PADS WITH AN ANGLED WEAR PATTERN REQUIRE EXCESSIVE CALIPER MOVEMENT TO
SEAT THE PADS TO THE ROTOR. THIS EXTRA MOVEMENT REQUIRES EXTRA FLUID
VOLUME, RESULTING IN ADDITIONAL PEDAL TRAVEL, SIMILAR TO MISADJUSTED REAR
BRAKES.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear > Page 5054
4. Inspect the inner pad for binding. Inner pads could become stuck to the slide surface due to
contamination, burrs, or corrosion. Refer to Figure 4.
NOTE:
REFER TO TSB 98-5A-13 FOR FURTHER INFORMATION ON THE USE OF SILICONE BRAKE
CALIPER GREASE AND DIELECTRIC COMPOUND.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear > Page 5055
5. Reinstall the caliper. During reassembly, inspect the pads and clean the caliper slide surfaces of
corrosion, contamination, or burrs. Polish with a crocus cloth and lubricate with Silicone Brake
Caliper Grease and Dielectric Compound (D7AZ-19A331-A). Refer to Figure 5.
NOTE:
ON 1988-91 F-250/350 TRUCKS THAT WERE INVOLVED IN RECALL 92S44, BE SURE TO
REASSEMBLE USING ALL COMPONENTS OF THE BRAKE CALIPER PISTON INSULATOR KIT
UNLESS PHENOLIC PISTONS HAVE BEEN INSTALLED.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear > Page 5056
6. Reinstall the pads. During pad installation, be careful not to dislodge the outer pad from its slide
position. Refer to Figure 6. An incorrect installation will cause a bent outer pad. Refer to Figure 2.
7. Once the calipers have been reinstalled and servicing is complete, but before installing the
wheels, apply the brakes and confirm the outer pad position remains correct.
PART NUMBER PART NAME
D7AZ-19A331-A Silicone Caliper Grease And Compound
OTHER APPLICABLE ARTICLES: 98-5A-13 SUPERSEDES: 97-15-17 WARRANTY STATUS:
INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-29 > Mar > 98 >
Brakes - Soft Pedal Feel/Pull/Irregular Wear > Page 5057
OASIS CODES: 301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 98-5A-38 > Mar > 98 > Front
Brake Caliper - Piston Boots Damaged
Brake Caliper: All Technical Service Bulletins Front Brake Caliper - Piston Boots Damaged
Article No. 98-5A-38
03/18/98
BRAKES - CALIPERS - FRONT CALIPER PISTON BOOTS DAMAGED
LIGHT TRUCK: 1986-91 E-250, E-35O 1986-94 F-250, F-350
ISSUE: Some vehicles may have experienced deterioration of the front brake caliper piston boots
resulting from exposure to high operating temperatures during severe service.
ACTION: Replace the caliper piston boots with a new, more robust service caliper piston boot. The
new silicone rubber boot can withstand higher operating temperatures without damage. The new
boot is completely interchangeable with the prior design and will become the only service boot
available.
The heat damaged boots should be replaced with the new Boot (E7TZ.2207-A). Refer to the
appropriate Service Manual for removal and installation procedures.
PART NUMBER PART NAME
E7TZ-2207-A Caliper Piston Boot
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-24-11 WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year
Vehicles, Basic Warranty Coverage For All Other Model Years
OPERATION DESCRIPTION TIME
985A38AT Overhaul Front Calipers - 1.5 Hrs.
Both
985A38A Overhaul Front Caliper - 1.2 Hrs.
One
DEALER CODING
CONDITION
BASIC PART NO. CODE
2207 42
OASIS CODES: 301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 93117 > May > 93 > Brakes Sticking/Binding/Grabbing
Brake Caliper: All Technical Service Bulletins Brakes - Sticking/Binding/Grabbing
Article No. 93-11-7
05/26/93
BRAKES - STICK/BIND/GRAB - FRONT CALIPER PINS CORRODED
LIGHT TRUCK: 1987-90 BRONCO II 1987-92 AEROSTAR, BRONCO, ECONOLINE, F-150-350
SERIES, RANGER 1988-92 F SUPER DUTY 1991-92 EXPLORER
This TSB article is being republished in its entirety to include F Super Duty vehicles.
ISSUE: Sticking, binding or grabbing of the brakes may be caused by brake caliper slide pins that
are corroded. The corrosion does not allow the brake caliper assembly to move freely.
ACTION: Install the new improved caliper pins that are corrosion resistant. Refer to the following
Service Procedure for service details.
SERVICE PROCEDURE
1. Remove the caliper and pins. Refer to the applicable Light Truck Service Manual for service
details.
NOTE: IF PADS ARE DAMAGED OR WORN, PAD REPLACEMENT IS REQUIRED.
2. Clean the upper and lower knuckle pin grooves, upper and lower knuckle inner pad grooves, and
the upper and lower caliper pin grooves with a wire brush or portable wire wheel.
WARNING: USE SAFETY GLASSES AND AN AIR RESPIRATOR WHEN CLEANING THE
GROOVES.
3. Apply a light coat of lubricant (D7AZ-19590-A) to the upper and lower knuckle inner pad grooves
and upper and lower caliper pin grooves.
CAUTION: LUBRICANT SHOULD NOT BE USED ON ROTORS, LININGS OR CALIPER PISTON
BOOTS.
4. Re-assemble the caliper using the new pins, (F2TZ-2C150-A) for all vehicles except F Super
Duty. Use new pins (F2TZ-2C150-B) for F Super Duty vehicles.
NOTE: NORMAL BRAKE MAINTENANCE REQUIREMENTS LISTED IN THE OWNER MANUAL
SHOULD BE PERFORMED EVERY 15,000 MILES.
PART NUMBER PART NAME CLASS
D7AZ-19590-A Lubricant-Disc Brake AM
F2TZ-2C150-A Pin-Brake Caliper B
F2TZ-2C150-B Pin-Brake Caliper (F Super B
Duty)
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 92-12-14
WARRANTY STATUS: Eligible Under Bumper To Bumper For 1992 Models And Basic Warranty
Coverage For All Other Model Years
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 93117 > May > 93 > Brakes Sticking/Binding/Grabbing > Page 5066
OPERATION DESCRIPTION TIME
931107A Aerostar/Ranger/Bronco II, 0.8 Hr.
(Through 1990), Explorer (Starting 1991), F-Series Under 8500 GVW, Bronco And Econoline
Under 8500
931107B F-Series Over 8500 GVW 0.9 Hr.
And Econoline Over 8500 GVW Through 1991
931107C F Super Duty Front 1.2 Hr.
931107D F Super Duty Rear 1.2 Hr.
931107E F Super Duty Front And 2.1 Hr.
Rear
DEALER CODING
BASIC PART NO. CONDITION CODE
2C150 41
OASIS CODES: 301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 88137 > Jun > 88 > Brake
Caliper - Rattling Noise
Brake Caliper: All Technical Service Bulletins Brake Caliper - Rattling Noise
BRAKE - CALIPER "RATTLING" NOISE - VEHICLES BUILT BEFORE 3/01/88
BRAKE - CALIPER PINS - SERVICE REMOVAL TOOL
NOISE - "RATTLE" FROM BRAKE CALIPER - VEHICLES BUILT BEFORE 3/01 /88
Article No. 88-13-7
LIGHT TRUCK: 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR, BRONCO, E
SERIES, F SERIES 1988 F-SUPER DUTY
ISSUE: A "rattling" noise may be heard coming from the front disc brake calipers. The caliper pins
may eventually take a set under certain load conditions allowing the disc brake caliper to "rattle".
The "rattling" noise is more likely to develop on units that are driven off-road or operated on rough
roads.
ACTION: To correct this, install new design caliper pins. A new caliper pin removal tool can be
made to aid in removal of the pins. Refer to the caliper pin application chart on this page for the
correct service part number.
FIGURE 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 88137 > Jun > 88 > Brake
Caliper - Rattling Noise > Page 5071
FIGURE 9
FIGURE 10
FIGURE 11
The caliper pin removal tool is recommended for use on all the above listed vehicles, including
1988 Super Duty, Figures 8 through 11. This caliper pin tool can be made from a 1/2 inch diameter
rod 7 inches long. Simply grind or cut a "V" notch in one (1) end. The "V" notch is used to
compress the pin retention tabs while the tool is also used to drive the pin out of the caliper slide
groove. This tool replaces a pair of pliers and screwdriver as outlined in the Shop Manual service
procedure.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 88137 > Jun > 88 > Brake
Caliper - Rattling Noise > Page 5072
The idea for this tool was submitted for the Best Idea Contest by Joseph L. Kaiser, Bauer Ford Inc.,
Brookville, Indiana. See "Service Life", Winter 1987 issue for featured article.
CALIPER PIN APPLICATION CHART
Part Number Part Name Vehicle Usage
E8TZ-2C150-A Caliper Pin Super Duty
E8TZ-2C150-B Caliper Pin Ranger, Bronco II, Aerostar, Bronco, E Series, F Series
PART NUMBER PART NAME CLASS
E8TZ-2C150-A Caliper Pin B
E8TZ-2C150-B Caliper Pin B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: 881307A - Both sides TIME: 0.5 Hr. DLR. CODING: Basic Part No. 2C150
Condition Code: 33
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Page 5073
Brake Caliper: Description and Operation
Disc Brake Caliper Disassembled
These models use the HD (Heavy Duty) pin rail sliding caliper type system, in which the dual piston
caliper slides on two pins attaching the caliper to the spindle assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Inspection
Brake Caliper: Service and Repair Inspection
For additional information see Installation Notes. See: Fundamentals and Basics
1. Install new inner and outer pad. Install anti-rattle spring.
NOTE:
- Always replace all pad and lining assemblies on an axle. Never service one wheel only.
- There is a raised section at one end of each pad so that installation can be made in one direction
only.
2. Install the caliper on the spindle, making sure the mounting surfaces are free of dirt and lubricate
the caliper grooves with disc brake caliper
grease.
3. Position pin with the pin retention tabs oriented adjacent to the spindle groove.
4. Tap the pin on the outboard end with a hammer. Continue tapping the pin inward until the
retention tabs on the sides of the pin contact the spindle
face. Repeat procedure for the lower pin.
Correct Caliper Pin Installation
CAUTION: During the installation procedure do not allow the tabs of the caliper pin to be tapped
too far into the spindle groove. If this happens
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Inspection > Page 5076
it will be necessary to tap the other end of the caliper pin until the tabs snap into place. The tabs on
each end of the caliper pin must be free to catch on the spindle flanks.
5. If removed, install the brake hose to the caliper and perform brake bleeding procedures.
Caliper Inlet Block
6. Install the wheel and tire assembly.
7. Lower the vehicle, check the brake fluid level and fill as necessary. Check brakes for proper
operation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Inspection > Page 5077
Brake Caliper: Service and Repair Rebuild
DISASSEMBLY
Disc Brake Caliper Disassembled
1. Drain the fluid from the cylinders.
2. Secure the caliper assembly in a vise.
Removing Caliper Piston
3. Place a block of wood between the caliper bridge and the cylinders, and apply low pressure air
to the brake hose inlet. The pistons will be forced
out to the wood block.
4. Remove the wood block, and remove the pistons.
5. Remove and discard the piston seals and boots.
6. If the caliper assembly is leaking, replace the piston assemblies. If the cylinder bores are scored,
corroded or excessively worn, replace the caliper.
Do not hone the cylinder bores. Piston assemblies are not available for oversize bores.
CLEANING and INSPECTION
Clean all metal parts with isopropyl alcohol. Clean out and dry the grooves and passageways with
compressed air. Make sure that caliper bore and component parts are thoroughly clean.
Use a wire brush to remove any rust or corrosion from the machined surfaces of the caliper
housing.
NOTE: Do not use a wire brush in the cylinder bore.
Check the cylinder bore and piston for damage or excessive wear. Replace the piston if it is pitted,
scored or worn. Do not replace phenolic pistons for cosmetic surface irregularities or small chips
between the piston groove and pad face.
Use a wire brush to clean corrosion from the boot groove and the machined surfaces of the spindle
assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Inspection > Page 5078
Replace the anti-rattle clip, piston seal and dust boot with new components.
ASSEMBLY
NOTE: Never re-use piston seals and dust boots. Install a new set each time the caliper is
assembled.
1. Lubricate new piston seals with clean brake fluid. Install them in the seal grooves in the cylinder
bores.
2. Apply a film of clean brake fluid to the cylinder bores.
3. Lubricate retaining lips of the dust boots with clean brake fluid and install them in the boot
retaining grooves in the cylinder bores.
4. Apply a film of clean brake fluid to the pistons.
5. Insert the pistons into the dust boots and start them into the cylinders by hand until they are
beyond the piston seals. Be careful not to damage or
dislodge the piston seal.
6. Place a wood block over one piston and press the piston into the cylinder being careful not to
cock the piston in the cylinder. Install the second
piston in the same manner. Make certain that boots are correctly seated.
7. Install the pad and lining assemblies and anti-rattle spring in the caliper assembly. Place the
caliper assembly on the support and install the caliper
pins.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Inspection > Page 5079
Brake Caliper: Service and Repair Removal
For additional information see Removal Notes. See: Fundamentals and Basics
1. To avoid overflow when the caliper pistons are compressed into the caliper pistons bores,
remove a portion of brake fluid from master cylinder
disc brake reservoir. Properly dispose the removed fluid.
2. Raise and support vehicle. Remove wheel and tire assembly.
Bottoming Caliper Piston
3. Install an appropriate size C-clamp on caliper. Tighten clamp to bottom caliper pistons in cylinder
bores. Remove the clamp.
NOTE: Do not use screwdriver or other edged tool to pry pistons from rotor.
4. Clean excess dirt from area around pin tabs.
5. Tap upper caliper pin towards inboard side until pin tabs touch the spindle face.
6. Insert a screwdriver into the slot provided behind the pin tabs on the inboard side of the pin.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Inspection > Page 5080
Compressing Spring Tabs
7. Use needle nose pliers to compress the outboard end of the pin while prying at the same time
with the screwdriver, until tabs slip into the spindle
groove.
8. Place one end of a punch (approximately 7/16 inch diameter) against the end of the caliper pin
and drive the caliper pin out of the caliper slide
groove.
9. Repeat removal procedure for lower pin.
10. Remove the caliper from the rotor. If the caliper is to be removed for service, remove the brake
hose from the caliper. If the caliper is not going to
be removed, secure it to the vehicle to avoid damage to the brake hose.
11. Remove the outer brake pad. Remove the anti-rattle clips and the inner brake pad.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Fundamentals and Basics > Removal Notes
Brake Caliper: Fundamentals and Basics Removal Notes
When Removing the Caliper, Remember...
- Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir
is only 1/3 full.
- Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender
covers to protect the vehicle's finish and electrical system.
- Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining
thickness between wheels on the same axle will result in a strong steering pull when the brakes are
applied.
- Work on one side at a time. If you forget how to reassemble the parts you can always use the
other side as a model.
- When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other
deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is
forced back into the caliper, these deposits will be forced back through the brake lines and into the
master-cylinder.
When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake fluid
will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to "shoot"
brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose and a
glass or plastic jar to catch the expelled fluid.
- Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses
can be damaged easily by this practice. These hoses are double walled, damage to the interior
pressure hose will not be visible.
- Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will
be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not
attempt to insert the piston back into the caliper.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Fundamentals and Basics > Removal Notes > Page 5083
Brake Caliper: Fundamentals and Basics Installation Notes
WHEN INSTALLING CALIPERS AND PADS, REMEMBER...
- Clean and lubricate caliper slide joint/pins with high temperature silicone grease:
Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake
pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted
movement of the caliper slide assemblies to release the brakes.
If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon
the release of the brake pedal. This will result in overheated brakes and premature brake wear.
Disc Brake Mechanical Force Diagram
NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating
or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel
forces the inner pad against the rotor, then further travel forces the movable part of the caliper to
pull the outer pad against the rotor.
High temperature silicone lubricant must be used. Low temperature grease can melt and
contaminate the pads and rotors, or can bake into a very hard substance which binds the slides.
Petroleum based grease can cause the slide boots to soften and swell.
Work on one side at a time. If you forget how to reassemble the parts you can always use the other
side as a model.
Anti-squeal Coating
- Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an
insulator to dampen high frequency vibrations that are generated during normal braking. These
compounds are highly effective in preventing brake squeal.
- Many professional repair shops recommend always rebuilding or replacing the calipers when
replacing the brake linings, because:
When the pistons are forced back into the calipers, the piston seals are dragged across any
corrosion or abrasives that may be deposited on the inside of the caliper.
Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston
is gradually withdrawn from the caliper.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Fundamentals and Basics > Removal Notes > Page 5084
This results in the piston seals again being dragged across the layer of corrosion and deposits.
Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking.
- Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck
bleeder screw is much easier with the caliper removed from the vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch
> Component Information > Locations
Brake Fluid Pressure Sensor/Switch: Locations
On LH Frame At No. 2 Crossmember
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Technical Service Bulletins > Customer Interest: > WAGNER24 > Nov > 89 > Brakes - False or Dropping
Pedal
Brake Hose/Line: Customer Interest Brakes - False or Dropping Pedal
WAGNER BRAKE CENTER
BRAKE FAX
TECHNICAL TIPS
Bulletin No. 24
Date November, 1989
Vehicle Make/Model
DODGE FORD and GENERAL MOTORS TRUCKS 87-90 BRONCO BRONCO II/RANGER F,E
Equipped with Rear Anti-Lock Brake System Ford:
RABS (Rear Anti-Lock Brake System) GM & Dodge: RWAL (Rear Wheel Anti-Lock) Topic
False or Dropping Pedal
Some of the above-mentioned vehicles may experience a "false" or dropping pedal condition that
may feel very similer to a master cylinder with an excessive amount of by-pass. Upon installation of
the replacement master cylinder, there is little or no improvement in pedal feel or height. This
condition may be caused by the dump valve in the E-H (Electro Hydraulic) valve being held slightly
open by a small particle of foreign material. This allows fluid to flow into the accumulator and create
the low or dropping brake pedal. To determine if this is the cause of the dropping pedal, begin by
disconnecting the steal line at the master cylinder that serves the rear brakes. Install a solid tubing
plug into the outlet that serves the rear brakes. Note: When installing the plug, have an assistant
depress the pedal about one inch to purge any air from this outlet. Tighten the plug while the
assistant holds the pedal in this position. After, tightening the plug, continue to apply pressure to
the pedal. This will prevent damage to the primary cup in the master cylinder as the cup moves
across the vent port. If the pedal no longer drops as it did with the rear brakes connected, this
would indicate that the problem is in the rear brakes and not the master cylinder. The next step
would be to block off the outlet port of the E-H valve and retest the brake pedal as done previously.
If the dropping pedal reappears, the problem is in the E-H valve and most likely caused by fluid
leaking into the accumulator of the E-H valve. If this is the case, it will be necessary to change the
valve. The E-H valve, including the accumulator and valving, is not serviceable.
Note that brake fluid over a period of time absorbs contaminants, therefore, annual flushing and
replacement with clean, fresh brake fluid will help to prevent this condition from occurring.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > 91189 > Sep > 91 > Brake
Hoses - Wet Appearance
Brake Hose/Line: All Technical Service Bulletins Brake Hoses - Wet Appearance
Article No. 91-18-9 09/05/91
^ BRAKES-HYDRAULIC-RUBBER BRAKE HOSES ARE WET FROM SWEATING
^ BRAKES-HYDRAULIC-RUBBER HOSES-FLUID LEAK TESTING PROCEDURE
LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150, F-250, F-350,
RANGER 1986-92 AEROSTAR 1988-92 F SUPER DUTY, F-47, F-63, F-59 1991-92 EXPLORER
This TSB article is being republished in its entirety to include 1992 model vehicles.
ISSUE: The wet appearance of the outer cover of rubber brake hoses is called "sweating." This is a
normal condition for neoprene rayon braid hose. The "sweating" condition is not evidence of a
brake fluid leak and will not result in a loss of pressure in the system.
ACTION: No action is required for a normal "sweating" brake hose. However, to test for a hydraulic
fluid leak, proceed as follows:
1. Check the brake fluid level in the master cylinder. If necessary, add brake fluid.
2. Wipe off the hose(s) in question with a clean cloth and an all purpose cleaner, then dry.
3. With the engine running, fully depress the brake twice and hold for two (2) minutes. ^
If the pedal goes down, check all of the connections for leaks and repair as required.
^ If the pedal goes down and no visible leaks are seen, then the master cylinder is leaking
internally and must be replaced or rebuilt. Refer to the appropriate Light Truck or Medium/Heavy
Truck Shop Manual, Section 6 or 12 (Light Truck) and Section 12 (Med./Hvy Truck) for service
details.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:
90-11-9
WARRANTY STATUS: INFORMATION ONLY OASIS CODES:
301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Hose/Line: > WAGNER24 > Nov > 89 >
Brakes - False or Dropping Pedal
Brake Hose/Line: All Technical Service Bulletins Brakes - False or Dropping Pedal
WAGNER BRAKE CENTER
BRAKE FAX
TECHNICAL TIPS
Bulletin No. 24
Date November, 1989
Vehicle Make/Model
DODGE FORD and GENERAL MOTORS TRUCKS 87-90 BRONCO BRONCO II/RANGER F,E
Equipped with Rear Anti-Lock Brake System Ford:
RABS (Rear Anti-Lock Brake System) GM & Dodge: RWAL (Rear Wheel Anti-Lock) Topic
False or Dropping Pedal
Some of the above-mentioned vehicles may experience a "false" or dropping pedal condition that
may feel very similer to a master cylinder with an excessive amount of by-pass. Upon installation of
the replacement master cylinder, there is little or no improvement in pedal feel or height. This
condition may be caused by the dump valve in the E-H (Electro Hydraulic) valve being held slightly
open by a small particle of foreign material. This allows fluid to flow into the accumulator and create
the low or dropping brake pedal. To determine if this is the cause of the dropping pedal, begin by
disconnecting the steal line at the master cylinder that serves the rear brakes. Install a solid tubing
plug into the outlet that serves the rear brakes. Note: When installing the plug, have an assistant
depress the pedal about one inch to purge any air from this outlet. Tighten the plug while the
assistant holds the pedal in this position. After, tightening the plug, continue to apply pressure to
the pedal. This will prevent damage to the primary cup in the master cylinder as the cup moves
across the vent port. If the pedal no longer drops as it did with the rear brakes connected, this
would indicate that the problem is in the rear brakes and not the master cylinder. The next step
would be to block off the outlet port of the E-H valve and retest the brake pedal as done previously.
If the dropping pedal reappears, the problem is in the E-H valve and most likely caused by fluid
leaking into the accumulator of the E-H valve. If this is the case, it will be necessary to change the
valve. The E-H valve, including the accumulator and valving, is not serviceable.
Note that brake fluid over a period of time absorbs contaminants, therefore, annual flushing and
replacement with clean, fresh brake fluid will help to prevent this condition from occurring.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Brake Hose/Line: > 91189 > Sep > 91 > Brake
Hoses - Wet Appearance
Brake Hose/Line: All Technical Service Bulletins Brake Hoses - Wet Appearance
Article No. 91-18-9 09/05/91
^ BRAKES-HYDRAULIC-RUBBER BRAKE HOSES ARE WET FROM SWEATING
^ BRAKES-HYDRAULIC-RUBBER HOSES-FLUID LEAK TESTING PROCEDURE
LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150, F-250, F-350,
RANGER 1986-92 AEROSTAR 1988-92 F SUPER DUTY, F-47, F-63, F-59 1991-92 EXPLORER
This TSB article is being republished in its entirety to include 1992 model vehicles.
ISSUE: The wet appearance of the outer cover of rubber brake hoses is called "sweating." This is a
normal condition for neoprene rayon braid hose. The "sweating" condition is not evidence of a
brake fluid leak and will not result in a loss of pressure in the system.
ACTION: No action is required for a normal "sweating" brake hose. However, to test for a hydraulic
fluid leak, proceed as follows:
1. Check the brake fluid level in the master cylinder. If necessary, add brake fluid.
2. Wipe off the hose(s) in question with a clean cloth and an all purpose cleaner, then dry.
3. With the engine running, fully depress the brake twice and hold for two (2) minutes. ^
If the pedal goes down, check all of the connections for leaks and repair as required.
^ If the pedal goes down and no visible leaks are seen, then the master cylinder is leaking
internally and must be replaced or rebuilt. Refer to the appropriate Light Truck or Medium/Heavy
Truck Shop Manual, Section 6 or 12 (Light Truck) and Section 12 (Med./Hvy Truck) for service
details.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:
90-11-9
WARRANTY STATUS: INFORMATION ONLY OASIS CODES:
301000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes Premature Lining Wear/Hard Pedal
Brake Proportioning/Combination Valve: Customer Interest Front Brakes - Premature Lining
Wear/Hard Pedal
Article No. 89-25-16
^ BRAKES - FRONT - PREMATURE LINING WEAR
^ BRAKES - REAR HEIGHT SENSING PROPORTIONING VALVE - INOPERATIVE DUE TO
SUSPENSION MODIFICATION
LIGHT TRUCK: 1985-86 F-250, F-350 1985-89 E-250, E-350
ISSUE: High brake pedal efforts or increased front brake lining wear may be caused by aftermarket
suspension modifications. The modified suspension may affect the performance of the height
sensing proportioning valve.
Figure 2
Figure 3
ACTION: Inspect the truck to determine if the suspension has been modified. Compare the rear
suspension (springs) to the suspension specifications
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes Premature Lining Wear/Hard Pedal > Page 5118
shown in the Light Truck Facts Book and the spring codes listed on the vehicle certification label,
Figure 2 and 3. If the suspension has been modified or will be modified, use the following
procedure. If the suspension has not been modified, replace the height sensing proportioning valve
as outlined in TSB 88-12-20.
Figure 1
1. Remove the nut from the valve shaft and remove the leading arm of the linkage assembly,
Figure 1. Save the nut.
2. Remove the two (2) nuts from the differential housing bolts and remove the linkage bracket,
Figure 1.
3. Return the linkage to the customer.
Figure 4
4. Rotate the valve shaft one (1) full turn in either direction. Position the shaft with the flat at the
bottom and parallel with the ground, Figure 3.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes Premature Lining Wear/Hard Pedal > Page 5119
Figure 5
5. Rotate the valve shaft counter-clockwise 90~ so that the flat of the shaft is vertical, Figure 5.
Figure 6
6. Place the valve shaft positioner, (E9TZ-2W125-A) over the valve shaft as shown in Figure 6.
Make sure the shaft flat fits into the "D"-slot of the positioner and that the shroud is fully seated
over the valve casting.
7. Re-install the nut saved in Step 1 on the valve shaft. Hold the shaft positioner and tighten the nut
to a torque of 8-10 lb.ft. (11-14 N-m).
8. Install an "Authorized Modification" decal on the brake booster listing the modification as follows:
"HSPV REAR BRAKE OPERATION MODIFIED".
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Technical Service Bulletins > Customer Interest: > 892516 > Dec > 89 > Front Brakes Premature Lining Wear/Hard Pedal > Page 5120
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
alterations performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME CLASS
E9TZ-2W125-A Valve Shaft Positioner C
OTHER APPLICABLE ARTICLES: 88-12-20 WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION
DESCRIPTION TIME
892516A Modify Height Sensing 0.6 Hr.
Valve
DEALER CODING BASIC PART NO. CONDITION CODE
2B547 53
OASIS CODES: 3050, 3051
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake
Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal
Brake Proportioning/Combination Valve: All Technical Service Bulletins Front Brakes - Premature
Lining Wear/Hard Pedal
Article No. 89-25-16
^ BRAKES - FRONT - PREMATURE LINING WEAR
^ BRAKES - REAR HEIGHT SENSING PROPORTIONING VALVE - INOPERATIVE DUE TO
SUSPENSION MODIFICATION
LIGHT TRUCK: 1985-86 F-250, F-350 1985-89 E-250, E-350
ISSUE: High brake pedal efforts or increased front brake lining wear may be caused by aftermarket
suspension modifications. The modified suspension may affect the performance of the height
sensing proportioning valve.
Figure 2
Figure 3
ACTION: Inspect the truck to determine if the suspension has been modified. Compare the rear
suspension (springs) to the suspension specifications
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake
Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 5126
shown in the Light Truck Facts Book and the spring codes listed on the vehicle certification label,
Figure 2 and 3. If the suspension has been modified or will be modified, use the following
procedure. If the suspension has not been modified, replace the height sensing proportioning valve
as outlined in TSB 88-12-20.
Figure 1
1. Remove the nut from the valve shaft and remove the leading arm of the linkage assembly,
Figure 1. Save the nut.
2. Remove the two (2) nuts from the differential housing bolts and remove the linkage bracket,
Figure 1.
3. Return the linkage to the customer.
Figure 4
4. Rotate the valve shaft one (1) full turn in either direction. Position the shaft with the flat at the
bottom and parallel with the ground, Figure 3.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake
Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 5127
Figure 5
5. Rotate the valve shaft counter-clockwise 90~ so that the flat of the shaft is vertical, Figure 5.
Figure 6
6. Place the valve shaft positioner, (E9TZ-2W125-A) over the valve shaft as shown in Figure 6.
Make sure the shaft flat fits into the "D"-slot of the positioner and that the shroud is fully seated
over the valve casting.
7. Re-install the nut saved in Step 1 on the valve shaft. Hold the shaft positioner and tighten the nut
to a torque of 8-10 lb.ft. (11-14 N-m).
8. Install an "Authorized Modification" decal on the brake booster listing the modification as follows:
"HSPV REAR BRAKE OPERATION MODIFIED".
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake
Proportioning/Combination Valve: > 892516 > Dec > 89 > Front Brakes - Premature Lining Wear/Hard Pedal > Page 5128
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
alterations performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
PART NUMBER PART NAME CLASS
E9TZ-2W125-A Valve Shaft Positioner C
OTHER APPLICABLE ARTICLES: 88-12-20 WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION
DESCRIPTION TIME
892516A Modify Height Sensing 0.6 Hr.
Valve
DEALER CODING BASIC PART NO. CONDITION CODE
2B547 53
OASIS CODES: 3050, 3051
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake
Proportioning/Combination Valve: > 881220 > Jun > 88 > Height Sensing Proportioning Valve - Manual Correction
Brake Proportioning/Combination Valve: All Technical Service Bulletins Height Sensing
Proportioning Valve - Manual Correction
Article No 88-12-20
BRAKES - REAR HEIGHT SENSING PROPORTIONING VALVE - REMOVAL AND
INSTALLATION PROCEDURE - SHOP MANUAL CORRECTION
LIGHT TRUCK: 1985-88 E-250/350 1985-86 F-250/350
ISSUE: The rear height sensing brake proportioning valve removal and installation procedure as
published in the 1988 Light Truck Shop Manual, Volume A, Section 12-30-5 and 12-30-6, is
incorrect. Valve misadjustment may cause improper rear brake performance.
ACTION: If service is required, refer to the following removal and installation procedure. This
information should be inserted in the 1988 Light Truck Shop Manual, Volume A, Section 12-30-5
and 12-30-6.
NOTE: THIS PROCEDURE DOES NOT APPLY TO THE 1988 F-SUPER DUTY. A TSB ARTICLE
WILL BE FORTHCOMING.
NOTE: THE REAR TIRES AND WHEELS MUST BE REMOVED TO ALLOW THE REAR
SUSPENSION TO SETTLE AT THE PREDETERMINED HEIGHT FOR PROPER
LINKAGE-VALVE INDEXING.
If the linkage is disconnected from the height sensing valve, the proper indexing will be lost and a
new sensing valve must be installed. The new sensing valve assembly will have the shaft preset
and secured internally. If the valve shaft of the valve turns freely - DO NOT USE. The height/load
sensing brake proportioning valve is not to be repaired or disassembled. It must be replaced as a
complete assembly. If the linkage is damaged or broken and requires replacement, a new sensing
valve must also be installed. Removal
1. Raise the rear of the vehicle so that the rear suspension hangs freely.
2. Remove the rear tires and wheels. (The suspension is now in the correct position for installing
the pre-indexed height sensing valve).
3. Remove the nut holding the linkage arm to the height sensing valve and disconnect the linkage
arm.
4. Remove the flow bolt holding the flexible brake hose to the valve.
5. Disconnect the brake line from the valve.
6. Remove the two (2) bolts securing the height sensing valve to its mounting bracket, and remove
the valve.
Installation
1. Place the height sensing valve on its mounting bracket. Install the two (2) mounting bolts and
tighten to 12-18 ft.lbs. (17-24 N-m).
2. Install the flexible brake hose using new copper gaskets. Tighten the flow bolt to 17-28 ft.lbs.
(23-34 N-m).
3. Install the brake line to the lower port on the valve and tighten securely.
4. Position the linkage arm on the height sensing valve and tighten the retaining nut to 8-10 ft.lbs.
(11-14 N-m).
5. Bleed the brakes as described in the Light Truck Shop Manual, Volume A, Section 12-01,
"General Hydraulic Brake Service". Check for proper brake operation.
6. Install tires and wheels.
When servicing other rear suspension components, (axle assembly, rear springs, fuel tank, etc.),
remove the two (2) nuts attaching the sensing valve linkage to the rear axle cover plate. This will
eliminate the need to replace the brake valve.
NOTE: ANY CHANGE TO THE VEHICLE REAR SUSPENSION WHICH WILL ALTER THE
"CURB" RIDE HEIGHT OR SPRING DEFLECTION RATE, (INCREASED CAPACITY LEAF
SPRINGS, ADDITION OF SPACERS, ETC.), MAY CHANGE THE FUNCTION OF THE HEIGHT
SENSING VALVE AND ALTER THE SYSTEM BRAKING PERFORMANCE.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
"INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake
Proportioning/Combination Valve: > 881220 > Jun > 88 > Height Sensing Proportioning Valve - Manual Correction
Brake Proportioning/Combination Valve: All Technical Service Bulletins Height Sensing
Proportioning Valve - Manual Correction
Article No 88-12-20
BRAKES - REAR HEIGHT SENSING PROPORTIONING VALVE - REMOVAL AND
INSTALLATION PROCEDURE - SHOP MANUAL CORRECTION
LIGHT TRUCK: 1985-88 E-250/350 1985-86 F-250/350
ISSUE: The rear height sensing brake proportioning valve removal and installation procedure as
published in the 1988 Light Truck Shop Manual, Volume A, Section 12-30-5 and 12-30-6, is
incorrect. Valve misadjustment may cause improper rear brake performance.
ACTION: If service is required, refer to the following removal and installation procedure. This
information should be inserted in the 1988 Light Truck Shop Manual, Volume A, Section 12-30-5
and 12-30-6.
NOTE: THIS PROCEDURE DOES NOT APPLY TO THE 1988 F-SUPER DUTY. A TSB ARTICLE
WILL BE FORTHCOMING.
NOTE: THE REAR TIRES AND WHEELS MUST BE REMOVED TO ALLOW THE REAR
SUSPENSION TO SETTLE AT THE PREDETERMINED HEIGHT FOR PROPER
LINKAGE-VALVE INDEXING.
If the linkage is disconnected from the height sensing valve, the proper indexing will be lost and a
new sensing valve must be installed. The new sensing valve assembly will have the shaft preset
and secured internally. If the valve shaft of the valve turns freely - DO NOT USE. The height/load
sensing brake proportioning valve is not to be repaired or disassembled. It must be replaced as a
complete assembly. If the linkage is damaged or broken and requires replacement, a new sensing
valve must also be installed. Removal
1. Raise the rear of the vehicle so that the rear suspension hangs freely.
2. Remove the rear tires and wheels. (The suspension is now in the correct position for installing
the pre-indexed height sensing valve).
3. Remove the nut holding the linkage arm to the height sensing valve and disconnect the linkage
arm.
4. Remove the flow bolt holding the flexible brake hose to the valve.
5. Disconnect the brake line from the valve.
6. Remove the two (2) bolts securing the height sensing valve to its mounting bracket, and remove
the valve.
Installation
1. Place the height sensing valve on its mounting bracket. Install the two (2) mounting bolts and
tighten to 12-18 ft.lbs. (17-24 N-m).
2. Install the flexible brake hose using new copper gaskets. Tighten the flow bolt to 17-28 ft.lbs.
(23-34 N-m).
3. Install the brake line to the lower port on the valve and tighten securely.
4. Position the linkage arm on the height sensing valve and tighten the retaining nut to 8-10 ft.lbs.
(11-14 N-m).
5. Bleed the brakes as described in the Light Truck Shop Manual, Volume A, Section 12-01,
"General Hydraulic Brake Service". Check for proper brake operation.
6. Install tires and wheels.
When servicing other rear suspension components, (axle assembly, rear springs, fuel tank, etc.),
remove the two (2) nuts attaching the sensing valve linkage to the rear axle cover plate. This will
eliminate the need to replace the brake valve.
NOTE: ANY CHANGE TO THE VEHICLE REAR SUSPENSION WHICH WILL ALTER THE
"CURB" RIDE HEIGHT OR SPRING DEFLECTION RATE, (INCREASED CAPACITY LEAF
SPRINGS, ADDITION OF SPACERS, ETC.), MAY CHANGE THE FUNCTION OF THE HEIGHT
SENSING VALVE AND ALTER THE SYSTEM BRAKING PERFORMANCE.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
"INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Technical Service Bulletins > Page 5138
Brake Proportioning/Combination Valve: Description and Operation
EXCEPT AEROSTAR, BRONCO II & 1983---87 RANGER These vehicles use a pressure
differential valve, a metering valve (1980---84) and a proportioning valve which are combined in a
single unit. These valves sense unbalanced pressure between front and rear brakes. Loss of
pressure in either the primary or secondary brake system causes pressure differential valve to
move off center and illuminate brake warning light. After system is replaced and brakes are bled,
the valve centers itself, turning off warning light. The brake warning light switch is mounted on top of
the valve body casting above the pressure differential valve tapered shoulder groove. When the
valve is centered, spring loaded switch plunger fits into the tapered shoulder groove. The switch
contacts are open, interrupting electrical continuity to the brake warning light on the instrument
panel. The metering valve is located in the front end of the control valve housing between the front
brake system inlet port and the right and left front brake outlet ports. This valve regulates hydraulic
fluid pressure to the front disc brakes. The proportioning valve used on some models is located at
the bottom of the housing between the rear brake system inlet and outlet ports. This valve regulates
rear brake system hydraulic pressure. A plug and tube seat is pressed into the rear end of the
central bore. A hole through the center of the plug and tube seal directs hydraulic fluid from the
valve to the rear brake system outlet port.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications
Brake Master Cylinder: Specifications
Master Cylinder Attaching Nuts
.......................................................................................................................................................
24-34 Nm (18-25 ft lbs)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications > Page 5142
Brake Master Cylinder: Description and Operation
Master Cylinder
OPERATION
The dual master cylinder performs in the following manner: Rear wheel brakes - are connected to
the secondary outlet port and are actuated by the secondary piston assembly.
Front wheel brakes - are connected to the primary outlet port (nearest the dash panel) and are
actuated by the primary piston assembly.
NOTE: Both primary and secondary pistons function together.
The dual master cylinder contains a plastic "seethru" fluid reservoir with a Fluid Level Indicator
(FLI) and primary and secondary hydraulic pistons and an integral proportioning valve.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications > Page 5143
Brake Master Cylinder: Testing and Inspection
INSPECTION
Inspect for Leakage
NOTE: The master cylinder should be cleaned thoroughly prior to inspection (several days
preferably). Spilled brake fluid can be easily confused with leakage.
Piston Seals Leakage around the piston seals will seep out from the end of the cylinder and leak down the
outside of the brake booster.
- Inspect for signs of seepage or bubbled paint on the brake booster.
- If any leakage is detected the master cylinder should be replaced or overhauled
Brake Line Fittings While someone is applying pressure to the brake pedal, inspect the brake line fittings on the master
cylinder for leakage.
- If the fittings are leaking they should be disassembled and inspected.
Reservoir to Cylinder Gasket Inspect the gasket for signs of leakage or hardening and cracking.
- Overhaul or replace the master cylinder if any leakage is indicated.
Inspect for Oil Contamination.
- Inspect the rubber gasket on the inside of the master cylinder lid. If the gasket is swollen or
bloated, the brake fluid is contaminated with oil.
- Siphon or scoop a small amount of brake fluid out of the master cylinder and place into a
styrofoam cup filled 2/3 of the way with water. Brake fluid will mix with the water while oil
contaminants will float on the surface and dissolve the styrofoam.
NOTE: If any oil contamination is present ALL brake components containing rubber seals will need
to be replaced or overhauled. This includes the master cylinder, both front brake calipers, both rear
wheel-cylinders, and all flexible brake hoses.
Verify Hold-Down Bolts Are Tight
While someone is applying and releasing pressure to the brake pedal, verify the the master
cylinder is tightly secured to the brake booster.
- Retighten hold-down bolts if necessary.
Functional Checks
WARNING: Always bleed the entire brake system and verify the rear brakes are properly adjusted
prior to diagnosing a master cylinder as defective. For additional information see Master-Cylinder /
Brake Pedal Relationship.
Check Related Systems -
Check for proper brake booster operation 1. With the engine "OFF", depress and release the brake
pedal 4-5 times (this bleeds off the vacuum reserve in the booster). 2. Depress the brake pedal
firmly and start the engine.
If the pedal goes down slightly the brake booster is assisting in brake operation. If the pedal does
not go down slightly the brake booster is not assisting in brake operation and should be diagnosed
for problems.
- Check and adjust rear brakes.
- Check all brake lines and brake assemblies for leakage.
Repair all deficiencies with related systems prior to diagnosing the master cylinder as defective.
Check Brake Pedal Travel (Non-Antilock Brake Systems Only) Fully depress the brake pedal and check for the following: The pedal should have a 75% reserve.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications > Page 5144
Pedal Reserve Checks
- The pedal should be firm and not leak down.
Replace the master cylinder if all of the following conditions exist: The brake pedal is not firm with a 75% reserve and - There were no problems with any of the related systems and - The entire brake system has been bled and - The rear brakes are properly adjusted.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications > Page 5145
Brake Master Cylinder: Adjustments
Fig.1 Checking Master Cylinder Pushrod Length
Check the distance from the outer end of the booster assembly push rod to the front face of the
brake booster assembly. Turn the push rod adjusting screw in or out as required to obtain the
specified length.
For additional information see Fundamentals and Basics.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Brake Fluid Reservoir
Brake Master Cylinder: Service and Repair Brake Fluid Reservoir
REMOVAL
1. Disconnect the brake warning lamp indicator wire from the plastic reservoir fluid level indicator
socket. Drain the brake fluid from the master
cylinder assembly.
Reservoir Removal
2. Using a large screwdriver, pry between the reservoir and the master cylinder body and remove
the reservoir.
INSTALLATION
1. Lubricate the two grommets included in service kit with heavy duty DOT 3 brake fluid. Insert the
grommets into the master cylinder body.
NOTE: Whenever the master cylinder plastic reservoir is replaced, the grommets must also be
replaced.
2. Press the plastic reservoir into the grommets with the fluid level indicator socket facing outboard.
The reservoir should snap in place, indicating
that it is secure.
3. Connect the brake warning lamp indicator wire to the fluid level indicator socket. 4. Fill the
reservoir with heavy duty DOT 3 brake fluid. Bleed the system. See: Brake Bleeding
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Brake Fluid Reservoir > Page 5148
Brake Master Cylinder: Service and Repair Master Cylinder, Brakes
Removal
1. With the engine turned off, push the brake pedal down to expel vacuum from the brake booster
system. 2. Disconnect fluid level indicator switch connector from the master cylinder. 3. Disconnect
the hydraulic lines from the brake master cylinder. 4. Remove the brake booster-to-master cylinder
retaining nuts. Remove the master cylinder from the brake booster.
For additional information see Notes, Warnings, and Hints.
Installation
Bendix Booster Push Rod Gauge Dimensions and Adjustment
1. Before installing the master cylinder, check the distance from the outer end of the booster
assembly push rod, to the front face of the brake booster
assembly. Turn the push rod adjusting screw in or out as required to obtain the specified length.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Brake Fluid Reservoir > Page 5149
2. Position the master cylinder assembly over the booster push rod and onto the two studs on the
booster assembly. Install the attaching nuts and
tighten to 24-34 Nm (18-25 ft lbs).
3. Connect the hydraulic brake system lines to the master cylinder. 4. Connect fluid level indicator
switch. 5. Bleed the master cylinder. Fill the reservoir of the master cylinder with heavy duty DOT 3
brake fluid to the fluid fill line. Install gasket and bleed
the system. Refer to Brake Bleeding.
For additional information see Fundamentals and Basics.
Rebuild
Master Cylinder
DISASSEMBLY
1. Clean outside of the master cylinder. Remove the plastic cap and gasket. Drain and discard any
brake fluid that remains in the cylinder.
2. Remove the proportioning valve from the master cylinder.
3. Remove stop-bolt from the bottom of the master cylinder assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Brake Fluid Reservoir > Page 5150
Removing Snap Ring
4. Depress the secondary piston and remove snap ring from retaining groove at the rear of the
master cylinder bore.
5. Remove secondary piston assembly from the master cylinder bore and inspect for seal damage
or twisting. Record condition of piston assembly on
repair order and discard assembly.
6. Remove the primary piston assembly by directing compressed air into the outlet port at the blind
end of the bore while plugging the other outlet
port. Inspect for seal damage or twisting. Record condition of piston assembly on repair order and
discard assembly.
7. Inspect the master cylinder bore for signs of etching, pitting, scoring or other damage.
a. If bore is damaged, discard and replace with new master cylinder assembly. Do not attempt to
hone bore.
b. If bore is not damaged, rebuild master cylinder assembly using the proper repair kit and the
procedure outlined below.
ASSEMBLY
1. Clean the master cylinder body with clean isopropyl alcohol or brake parts cleaner to remove
any contamination.
2. Dip the repair kit piston assemblies in clean heavy duty DOT 3 brake fluid to lubricate seals.
3. Carefully insert the complete primary piston assembly in the master cylinder bore.
4. Carefully insert the secondary piston assembly in the master cylinder bore.
5. Depress the secondary piston and install the snap ring in the cylinder bore groove.
6. Install the stop-bolt into the bottom of the master cylinder.
7. Install the proportioning valve assembly into the master cylinder.
8. Install the plastic cap on the master cylinder.
For additional information see Fundamentals and Basics.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Page 5151
Brake Master Cylinder: Tools and Equipment
BASIC SERVICE (Removal and Installation)
- Fender cover (servicing and bleeding a master-cylinder can be a messy process)
CAUTION: DOT 3 or 4 brake fluid is very corrosive to the vehicles finish and electrical connections.
- Drip pan. - Complete set of combination wrenches or sockets. - Brake bleeding device:
- Pressure bleeder or
- Vacuum bleeder or
- One-man brake bleeder kit or
- Length of clear plastic hose (3/16 inch ID) and a glass jar.
Brake Bleeding Setup
- Small ruler or depth gauge (for adjusting the pushrod) - Brake adjusting tool (rear brake
adjustment should be checked) - Clean shop towels.
OPTIONAL
- Master Cylinder brake bleeding kit (contains plastic fittings and hoses used for bleeding master
cylinders) - Suction bulb (for removing brake fluid from reservoir)
IF MASTER-CYLINDER IS OVERHAULED
- Snap-ring pliers - Small pry bar (for separating the reservoir from the cylinder) - Cylinder hone
(cast iron cylinders only) - Feeler gauges (for checking piston to cylinder clearance).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Removal
Wheel Cylinder: Service and Repair Removal
1. Raise vehicle on hoist and position suitable safety stands under vehicle. 2. Remove wheel and
tire assembly. 3. Remove the brake drum. Remove brake linings. Remove the wheel cylinder brake
shoe links. 4. Disconnect the rear brake tube from the wheel cylinder. 5. Remove the brake cylinder
retaining bolts and lockwashers. Remove the wheel cylinder from the backing plate.
For additional information see Notes, Warnings, and Hints.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Removal > Page 5156
Wheel Cylinder: Service and Repair Rebuild
For additional information see Notes, Warnings, and Hints.
Rear Wheel Cylinder
DISASSEMBLY
1. Remove the rubber boots from the ends of the brake cylinder. 2. Remove the pistons, cups and
piston cup spring. 3. Remove the wheel cylinder bleeder screw. Ensure the bleeder screw is not
plugged.
ASSEMBLY
1. Coat all wheel cylinder parts with clean brake fluid or brake assembly lube. 2. Install the bleeder
screw into the wheel cylinder. 3. Place the wheel cylinder piston cup spring, cups and pistons into
the wheel cylinder. 4. Install a boot and wheel cylinder brake shoe link over each end of the wheel
cylinder.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Removal > Page 5157
Wheel Cylinder: Service and Repair Installation
1. Place wheel cylinder on the brake backing plate. Install the retaining bolts and lockwashers. 2.
Connect the brake tube to the wheel cylinder. 3. Install wheel cylinder brake shoe links and brake
linings. Install the brake drum and wheel and tire assembly. 4. Adjust the brakes. See: Drum Brake
System/Brake Shoe/Adjustments 5. Perform system brake bleeding procedures.
Check pedal operation before moving the vehicle.
For additional information see Notes, Warnings, and Hints.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Information > Adjustments
Parking Brake Lever: Adjustments
1985---87 E-350 W/ORSCHEIN PARKING BRAKE LEVER
1. Place parking brake handle in ON position.
2. Grip tension limiter housing to prevent it from turning and tighten equalizer nut until front cable
tension is 350 lbs.
3. Release, then reapply parking brake system and ensure front cable tension is at least 310 lbs.
4. Release parking brake and check for rear wheel drive.
5. If rear wheel drag is noted after adjustment, the rear drums must be removed after the service
and parking brakes have been adjusted. Check clearance between parking brake lever and cam
plate. If clearance is not .015 inch with brakes fully released, readjust parking brake cable.
6. Place parking brake in fully released position, then check slack in parking brake two rear cables.
The cables should be tight enough to provide full application of the rear brake shoes when the
parking brake lever or foot pedal is placed in the fully applied position, yet loose enough to ensure
complete release of the brake shoes when the lever is in released position.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component
Information > Adjustments
Parking Brake Pedal: Adjustments
Parking Brake Assembly
Adjust the drum brakes before adjusting the parking brake cables. See: Drum Brake System/Brake
Shoe/Adjustments
Initial Adjustment Procedure (Use this procedure when a new tension limiter is installed).
Cable Tension Limiter Assembly
1. Depress the parking brake pedal fully to the last detent position.
2. Grip the Tension Limiter housing to prevent it from spinning and tighten the equalizer nut
63.50mm +\- 3.175mm (2 1/2 inch +\- 1/8 inch) up the
rod.
3. Check to make sure cinch strap has slipped (less than 34.925mm or 1 3/8 inch remaining).
Field Adjustment (Use this procedure to correct a slack system if new tension limiter is not
installed)
1. Make sure brake drums are cold for correct adjustment.
2. Release the parking brake control.
3. Grip the tension limiter housing to prevent it from spinning and tighten the equalizer nut 6 full
turns past its original position on the threaded rod.
4. Fully depress pedal to the last detent position and check for proper rear cable tension of 1556 N
or (350 lbs). If tension is low repeat steps 2 and 3.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component
Information > Adjustments > Page 5165
5. Release parking brake and check for rear wheel drag.
Parking Brake Lever Clearance
6. If rear wheel brake drag is noted after adjustment the rear drums must be removed after the
service and parking brakes have been adjusted. Check
the clearance between the parking brake lever and the cam plate. The clearance should be
0.38mm (0.015 inch) with the brakes fully released. If the clearance is not within specifications,
readjust the parking brake cable.
NOTE: The tension limiter will reset the parking brake tension anytime the system is disconnected
provided the distance between the bracket and the cinch strap hook is reduced during adjustment.
When the cinch strap hook contacts the bracket, the system tension will increase significantly and
over tensioning may result. If all available adjustment travel has been used, the tension limiter must
be replaced.
7. Place the parking brake pedal in the fully released position, then check the slack in the parking
brake two rear cables.
The cables should be tight enough to provide full application of the rear brake shoes, when the
parking brake lever or foot pedal is placed in the fully applied position, yet loose enough to ensure
complete release of the brake shoes when the lever is in the released position.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component Information > Locations
Parking Brake Warning Switch: Locations
Top Of Parking Brake Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Description and Operation
Vacuum Brake Booster: Description and Operation
The single and tandem vacuum boosters are self contained vacuum hydraulic power braking units.
These are vacuum suspended units that use vacuum and atmospheric pressure for their power. On
gasoline engine vehicles, vacuum is supplied through a fitting in the intake manifold. On diesel
engine vehicles, vacuum is supplied through a vacuum pump. The three basic elements of the
booster are the vacuum power chamber, mechanically actuated booster check valve and a
hydraulic dual master cylinder which supplies hydraulic pressure to the brake system. The vacuum
power chamber consists of a front and rear shell, diaphragm, diaphragm plate, hydraulic pushrod
and vacuum diaphragm return spring. The mechanically actuated booster check valve controls the
degree of power brake application in accordance with foot pressure applied to the valve operating
rod through the brake pedal linkage. This valve is integral with the vacuum power diaphragm.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Description and Operation > Page 5173
Vacuum Brake Booster: Service and Repair
1. Disconnect battery ground cable.
2. Disconnect stop lamp switch electrical connectors.
3. Support underside of master cylinder, then remove power brake unit-to-master cylinder attaching
nuts.
4. Remove vacuum hose between manifold and power brake unit, or power brake unit check valve.
Remove check valve, if equipped.
5. Separate power brake unit and master cylinder, leaving master cylinder supported far enough
away to allow removal of power brake unit.
6. On models equipped with push rod mounted stop lamp switch, remove retaining pin, then slide
switch, push rod, spacers and bushing off brake pedal pin.
7. On models equipped with brake pedal mounted stop lamp switch, remove attaching bolt, nut and
plastic bushing, then disconnect power brake unit push rod from brake pedal.
8. Remove power brake unit attaching bolts and the power brake unit.
9. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Pressure Sensor/Switch > Component Information > Locations
Brake Fluid Pressure Sensor/Switch: Locations
On LH Frame At No. 2 Crossmember
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
Top Of Parking Brake Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations
Wheel Speed Sensor: Locations
At Rear Axle
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Locations
Clutch Switch: Locations
LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Locations > Page 5189
Clutch Switch: Testing and Inspection
Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized
tools near this switch.
1. If the switch is open when the clutch pedal is released, speed control will not operate. This must
be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher
when performing the clutch switch test.
2. Disconnect switch pigtail connector from speed control harness connector and connect an
ohmmeter to the two switch connector terminals.
3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With
clutch pedal fully depressed, the circuit should be open.
4. If switch does not function as described, remove and replace switch.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Doors and Ignition - Lock Service
Tips
Ignition Switch Lock Cylinder: Technical Service Bulletins Doors and Ignition - Lock Service Tips
Article No. 87-24-2
12/04/87
LOCKS - DOORS AND IGNITION - GENERAL LOCK SERVICE TIPS
FORD: 1987-88 ESCORT/EXP, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, CROWN
VICTORIA
LINCOLN-MERCURY: 1987 LYNX 1987-88 TOPAZ, SABLE, COUGAR, GRAND MARQUIS,
MARK VII, CONTINENTAL, LINCOLN TOWN CAR
LIGHT TRUCK: 1987-88 AEROSTAR, RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO
ISSUE: Two types of key systems are used on Ford vehicles. The five (5) bit key system uses one
(1) key to operate the ignition lock and a second to operate the outside door locks. The ten (10) bit
key system uses one (1) key to operate the ignition lock and the outside door locks. The ten (10) bit
key system services the ignition lock as a separate service part so the door locks would not have to
be replaced in the event of an ignition lock failure.
ACTION: If service is required for the five (5) bit key system, the ignition and door locks are
serviced separately. Refer to the appropriate Shop Manual for removal and installation procedures.
If service is required for the ten (10) bit key system, a ten (10) bit ignition lock with partially cut keys
is available. Refer to the following service procedure.
NOTE:
Customers concerned with the heads of the new ten (10) bit ignition service keys not matching the
original keys may be resolved by ordering blank keys from Rotunda. Cut the two (2) blank keys
ordered from Rotunda on tumbler station numbers 1, 2, 3, 4, and 6 to match the new ten (10) bit
ignition service keys supplied with the new service ignition lock.
1. Remove the ignition lock cylinder. Refer to the appropriate Shop Manual.
FIGURE 2
2. Using the Ford Rotunda key code cutting package, tool number 011-00003, measure the depth
of the cut on the number six (6) tumbler station of the original key. Use this measurement to
determine the correct service ignition lock set. Refer to the chart in Figure 2.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Doors and Ignition - Lock Service
Tips > Page 5195
3. Using the original ignition key, decode tumbler station numbers 5, 7, 8, 9, and 10.
4. Cut the new service key on tumbler station numbers 5, 7, 8, 9, and 10.
5. Check the operation of the new service key in the new ignition lock and outside door locks.
6. Install the new service ignition lock.
NOTE:
Retain both the original and new service key tabs for future key code identification.
OTHER APPLICABLE ARTICLES: 86-23-4
WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
Location For C6 Transmission
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 5199
Neutral Safety Switch: Service and Repair
Fig. 8 Neutral safety switch replacement. Exc. automatic overdrive transmission
EXC. AUTOMATIC OVERDRIVE TRANSMISSION
1. Disconnect battery ground cable.
2. Remove downshift linkage rod return spring from low-reverse servo cover.
3. Apply penetrating oil to outer lever attaching nut, then remove transmission downshift outer lever
attaching nut and lever.
4. Remove neutral safety switch attaching bolts, then disconnect electrical connectors and remove
switch from vehicle.
5. To install, position switch on transmission and secure with attaching bolts. Do not tighten bolts at
this time.
6. Place transmission manual lever in neutral position, then insert a .091 inch gauge pin through
gauge pin holes, Fig. 8.
7. Tighten switch attaching bolts, then remove gauge pin.
8. Install outer downshift lever and retaining nut.
9. Install downshift linkage rod return spring between lever and retaining clip on low-reverse servo
cover.
10. Reconnect electrical connectors, then check operation of switch.
W/AUTOMATIC OVERDRIVE TRANSMISSION
1. Disconnect battery ground cable.
2. Raise and support vehicle.
3. Disconnect electrical connector at neutral safety switch, lifting connector straight up.
4. Using suitable socket, remove neutral safety switch and O-ring seal.
5. Reverse procedure to install, installing new O-ring seal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
RH Fender Apron
On RH Front Fender Or Radiator Support
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service
Bulletins > Body/Frame - Arc Welding Precautions
Battery Cable: Technical Service Bulletins Body/Frame - Arc Welding Precautions
Article No. 90-11-6
EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM
ARC WELDING
FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90
TAURUS
LINCOLN-MERCURY: 1985-86 CAPRI
1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90
SABLE
MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER
ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative
battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs
because the arc welding process can produce high electrical currents in the body of a vehicle when
the negative battery ground cable is left connected.
ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground
cable,
CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY
ELECTRIC WELDING EQUIPMENT
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2800, 680000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Diode Trio, Alternator > Component
Information > Testing and Inspection
Diode Trio: Testing and Inspection
Fig. 9 Regulator plug. Jumper wire connection
Test Procedure
1. Disconnect electric choke, if equipped.
2. Disconnect voltage regulator wiring connector.
3. Connect a jumper wire between the ``A'' and ``F'' terminals of the voltage regulator wiring
connector, Fig. 9.
4. Connect voltmeter to battery clamps. Then, start and idle engine.
5. Observe and note voltmeter reading.
6. Move the voltmeter positive lead to the alternator ``S'' terminal and note voltage reading.
Test Results
1. If voltmeter reading is within {1/2} of battery voltage, the diodes are satisfactory.
2. If voltmeter reading is approximately 1.5 volts, the alternator has a shorted negative diode or a
grounded stator winding.
3. If voltmeter reading is approximately 1.5 volts less than battery voltage, the alternator has a
shorted positive diode.
4. If voltage reading is approximately 1 to 1.5 volts less than {1/2} battery voltage, the alternator
has an open positive diode.
5. If voltage reading is 1 to 1.5 volts above {1/2} battery voltage, the alternator has an open
negative diode.
6. Reconnect electric choke into circuit after tests are completed, if equipped.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator >
Component Information > Testing and Inspection
Rectifier Diode / Bridge: Testing and Inspection
Fig. 13 Testing diode trio
Fig. 14 Alternator w/integral regulator rectifier short or grounded & stator grounded test
RECTIFIER SHORT OR GROUNDED & STATOR GROUNDED TEST Using a suitable ohmmeter,
connect one probe to the alternator BAT terminal, Figs. 13 and 14, and the other probe to the STA
terminal (rear blade terminal). Then, reverse the ohmmeter probes and repeat the test. A reading of
about 6.5 ohms should be obtained in one direction and no needle movement with the probes
reversed. A reading in both directions indicates a bad positive diode, a grounded positive diode
plate or a grounded BAT terminal. Perform the same test using the STA and GND (ground)
terminals of the alternator. A reading in both directions indicates either a bad negative diode, a
grounded stator winding, a grounded stator terminal, a grounded positive diode plate, or a
grounded BAT terminal. Infinite readings (no needle movement) in all four probe positions in the
preceding tests indicates an open STA terminal lead connection inside the alternator.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator >
Component Information > Testing and Inspection > Page 5217
Fig. 15 Testing rectifier bridge diodes
FIELD OPEN OR SHORT CIRCUIT TEST Exc. Alternators W/Integral Regulators Using a suitable
ohmmeter, connect the alternator field terminal with one probe and the ground terminal with the
other probe, Fig. 15. Then, spin the alternator pulley. The ohmmeter reading should be between
2.4 and 25 ohms on 1980 units, 2.4 and 100 ohms on all 1981-85 units and 1986-87 models less
IAR system, and should fluctuate while the pulley is turning. An infinite reading (no meter
movement) indicates an open brush lead, worn or stuck brushes, or a bad rotor assembly. An
ohmmeter reading of less than 2.4 ohms indicates a grounded brush assembly, a grounded field
terminal or a bad rotor.
Fig. 16 Alternator w/integral regulator field open or short circuit test
Alternators W/Integral Regulators
1. Using a suitable ohmmeter, connect regulator A blade terminal with one probe and the regulator
``F'' screw head with the other probe, Fig. 16.
2. Spin the alternator pulley and note meter reading, then reverse probes and repeat step 1. In one
probe direction ohmmeter reading should be between 2.2 and 100 ohms and may fluctuate while
pulley is turning. In the other direction, reading should fluctuate between 2.2 and approximately 9
ohms.
3. An infinite reading (no meter movement) in one direction and approximately 9 ohms in the other,
indicates an open brush lead, worn or stuck brushes, defective rotor or a loose regulator to brush
holder attaching screw.
4. An ohmmeter reading less than 2.2 ohms in both directions indicates a shorted or defective
regulator.
5. An ohmmeter reading significantly over 9 ohms in both directions indicates a defective regulator
or loose ``F'' terminal screw.
6. Connect alternator rear housing with one ohmmeter probe and touch the other probe to the
regulator ``F'' terminal. Reverse probes and repeat test. Ohmmeter reading should be infinite in
one probe direction and approximately 9 ohms in the other.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator >
Component Information > Testing and Inspection > Page 5218
7. If ohmmeter reads less than infinite at either point, a grounded brush lead, grounded rotor or
defective regulator is indicated.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Stator, Alternator > Component
Information > Testing and Inspection
Stator: Testing and Inspection
Fig. 13 Testing diode trio
Fig. 14 Alternator w/integral regulator rectifier short or grounded & stator grounded test
RECTIFIER SHORT OR GROUNDED & STATOR GROUNDED TEST Using a suitable ohmmeter,
connect one probe to the alternator BAT terminal, Figs. 13 and 14, and the other probe to the STA
terminal (rear blade terminal). Then, reverse the ohmmeter probes and repeat the test. A reading of
about 6.5 ohms should be obtained in one direction and no needle movement with the probes
reversed. A reading in both directions indicates a bad positive diode, a grounded positive diode
plate or a grounded BAT terminal. Perform the same test using the STA and GND (ground)
terminals of the alternator. A reading in both directions indicates either a bad negative diode, a
grounded stator winding, a grounded stator terminal, a grounded positive diode plate, or a
grounded BAT terminal. Infinite readings (no needle movement) in all four probe positions in the
preceding tests indicates an open STA terminal lead connection inside the alternator.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Stator, Alternator > Component
Information > Testing and Inspection > Page 5222
Fig. 15 Testing rectifier bridge diodes
FIELD OPEN OR SHORT CIRCUIT TEST Exc. Alternators W/Integral Regulators Using a suitable
ohmmeter, connect the alternator field terminal with one probe and the ground terminal with the
other probe, Fig. 15. Then, spin the alternator pulley. The ohmmeter reading should be between
2.4 and 25 ohms on 1980 units, 2.4 and 100 ohms on all 1981-85 units and 1986-87 models less
IAR system, and should fluctuate while the pulley is turning. An infinite reading (no meter
movement) indicates an open brush lead, worn or stuck brushes, or a bad rotor assembly. An
ohmmeter reading of less than 2.4 ohms indicates a grounded brush assembly, a grounded field
terminal or a bad rotor.
Fig. 16 Alternator w/integral regulator field open or short circuit test
Alternators W/Integral Regulators
1. Using a suitable ohmmeter, connect regulator A blade terminal with one probe and the regulator
``F'' screw head with the other probe, Fig. 16.
2. Spin the alternator pulley and note meter reading, then reverse probes and repeat step 1. In one
probe direction ohmmeter reading should be between 2.2 and 100 ohms and may fluctuate while
pulley is turning. In the other direction, reading should fluctuate between 2.2 and approximately 9
ohms.
3. An infinite reading (no meter movement) in one direction and approximately 9 ohms in the other,
indicates an open brush lead, worn or stuck brushes, defective rotor or a loose regulator to brush
holder attaching screw.
4. An ohmmeter reading less than 2.2 ohms in both directions indicates a shorted or defective
regulator.
5. An ohmmeter reading significantly over 9 ohms in both directions indicates a defective regulator
or loose ``F'' terminal screw.
6. Connect alternator rear housing with one ohmmeter probe and touch the other probe to the
regulator ``F'' terminal. Reverse probes and repeat test. Ohmmeter reading should be infinite in
one probe direction and approximately 9 ohms in the other.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Stator, Alternator > Component
Information > Testing and Inspection > Page 5223
7. If ohmmeter reads less than infinite at either point, a grounded brush lead, grounded rotor or
defective regulator is indicated.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information >
Specifications
Voltage Regulator: Specifications
Measure battery voltage and record figure. With engine operating off idle and all secondary
electrical systems turned off, regulated voltage should be no greater than 2 volts above recorded
figure. Turn on headlights and set heater blower to high. Regulated voltage off idle should be no
less than 0.5 volts above recorded figure.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information >
Specifications > Page 5227
Voltage Regulator: Locations
RH Fender Apron
RH Radiator Support
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations
Clutch Switch: Locations
LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations
> Page 5232
Clutch Switch: Testing and Inspection
Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized
tools near this switch.
1. If the switch is open when the clutch pedal is released, speed control will not operate. This must
be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher
when performing the clutch switch test.
2. Disconnect switch pigtail connector from speed control harness connector and connect an
ohmmeter to the two switch connector terminals.
3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With
clutch pedal fully depressed, the circuit should be open.
4. If switch does not function as described, remove and replace switch.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Ballast Resistor > Component Information >
Specifications > DS II
IGNITION RESISTOR
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Ballast Resistor > Component Information >
Specifications > DS II > Page 5237
Ignition Ballast Resistor: Specifications TFI IV
BALLAST RESISTOR: Wire Type - Resistance: 1.1 Ohms + or - .05 Ohms
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Ballast Resistor > Component Information >
Specifications > Page 5238
Ignition Ballast Resistor: Locations
The Ballast Resistor is a wire type and is in-line with the ignition wiring harness located near the
steering column. NOTE: Verify vehicle has a ballast resistor by referencing wiring diagram.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Ballast Resistor > Component Information >
Specifications > Page 5239
Ignition Ballast Resistor: Description and Operation
The ballast resistor, (wire type), maintains a specific resistance between the positive (Batt.)
terminal of the ignition coil connector and the wiring harness connector. It is not in operation during
engine cranking enabling the coil to receive a hotter signal for starting. Once the engine is running,
the resistor is used to protect the coil from voltage overload.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Ballast Resistor > Component Information >
Specifications > Page 5240
Ignition Ballast Resistor: Testing and Inspection
1. Disconnect module connector with red and white wires then, ignition coil connector.
2. Using a suitable ohmmeter, measure resistance between Batt. terminal of ignition coil connector
and wiring harness connector wire that joins red wire in module connector.
3. If resistance is 0.8---1.6 ohms, ballast resistor is satisfactory. If resistance is less than 0.8 ohms
or greater than 1.6 ohms, replace ballast resistor.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams >
Diagram Information and Instructions
Ignition Lock: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams >
Diagram Information and Instructions > Page 5245
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams >
Diagram Information and Instructions > Page 5246
Ignition Lock: Connector Views
For Connector Views, please refer to: Ignition Switch/Diagrams,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams >
Diagram Information and Instructions > Page 5247
Ignition Lock: Electrical Diagrams
For Wiring Diagrams, please refer to: Starting System/Diagrams,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and
Repair > Ignition Lock Cylinder Assembly (With Key)
Ignition Lock: Service and Repair Ignition Lock Cylinder Assembly (With Key)
Ignition Lock Cylinder Assembly (With Key)
Removal
1. Disconnect the battery ground cable.
2. Remove the steering wheel trim pad and the steering wheel for Non-Tilt Steering Columns only.
3. Place the gear shift in PARK (with automatic transmission) and turn the lock cylinder with the
ignition key to ON position.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and
Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5250
4. Place 3.17mm (1/8 inch) diameter wire pin or small drift punch and depress the retaining pin
while pulling out on the lock cylinder to remove
it from the column housing. The pin is located inside the column near.the base of the lock cylinder
on Non- Tilt Steering Column. On Tilt-Steering Columns the pin is located adjacent to the Hazard
Warning Button.
Installation
1. Lubricate the lock cylinder with grease.
2. To install the lock cylinder, turn the lock cylinder to the ON position and depress the retaining
pin, then insert the lock cylinder into its housing
in the flange casting. Assure that the cylinder is fully seated and aligned into the interlocking
washer before turning the key to the OFF position. This action will permit the cylinder retaining pin
to extend into the cylinder casting housing hole.
3. Using the ignition key, rotate the lock cylinder to insure correct mechanical operation in all
positions.
4. Install the steering wheel and trim pads on Non-Tilt Steering Columns only.
5. Connect the battery ground cable.
6. Check for proper start in Park or Neutral. Also check to make certain that the start circuit cannot
be actuated in the Drive and Reverse
positions.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and
Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5251
Ignition Lock: Service and Repair Ignition Lock Cylinder Assembly (Without Key)
Ignition Lock Cylinder (Without Key)
NOTE: The following procedure applies to vehicles where the ignition lock is inoperative and the
lock cylinder cannot be rotated due to a lost or broken ignition key and the key number not known
or the lock cylinder cap is damaged and/or broken to the extent that the lock cylinder cannot be
rotated.
Removal
1. Disconnect the battery ground cable.
2. Remove the steering wheel and pad assembly.
3. Remove the turn signal lever from the steering column.
4. To gain access to the ignition switch remove the steering column trim shrouds from the steering
column. Detach and lower the steering column
assembly from the brake pedal support bracket.
5. Remove the ignition switch and key warning buzzer terminal and pin it in the LOCK position.
6. Remove the turn signal switch from the column assembly.
7. Remove the upper bearing snap ring and the (2) T-bolt retaining nuts that secure the flange
casting to the outer tube. Remove the entire flange
casting assembly, the upper shaft bearing, the lock cylinder assembly, the ignition switch actuator
and the ignition switch actuator rod by pulling the assembly over the end of the steering column
shaft.
8. Remove the lock actuator insert, the T-bolts, and the PRND21 insert on automatic transmissions
or the key release lever assembly on 4-speed
transmissions.
9. Replace the above assembly with a new assembly consisting of:
(1) Flange (1) Lock Cylinder Assembly (1) Lock Gear, Steering Column Lock (1) Bearing, Steering
Column Lock (1) Retainer, Steering Column Upper Bearing
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and
Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5252
(1) Actuator Assembly, Steering Column Lock
10. Install the key release lever assembly on 4-speed equipped vehicles and the PRND21 insert on
vehicles with automatic transmission. Install the
T-bolts and lock actuator insert.
NOTE: Retain the ignition switch actuating rod from the removed casting assembly and use it with
the new flange casting assembly.
Installation
1. Reassemble the above parts, install a new upper shaft bearing and set the actuator to drive
gear.
2. Install the turn signal-hazard warning switch and key warning buzzer.
3. Install the ignition switch, check and/or adjust for proper function.
4. Install the steering column assembly to the brake pedal support bracket.
5. Install the steering column trim shrouds, steering wheel and pad assembly.
6. Install the turn signal lever.
7. Using the ignition key, rotate the lock cylinder to insure correct mechanical operation in all
positions.
8. Connect the battery ground cable.
9. Check for proper start in Park and Neutral. Also check to make certain that the start circuit
cannot be actuated in the Drive and Reverse
positions.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and
Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5253
Ignition Lock: Service and Repair Ignition Lock Cylinder - Tilt Steering Column
Ignition Lock Cylinder-Tilt Steering Column
Removal
1. Disconnect the battery ground cable. Remove the steering column trim shrouds.
2. Tape the gap between the steering wheel hub and the cover casting. Cover the entire
circumference of the casting. Also cover the adjacent seat
and floor area with a suitable covering to protect the surrounding interior upholstery. Pull out the
hazard flasher switch and tape it down toward the floor to provide clearance for drilling out the lock
cylinder retainer pin.
3. The tilt column lock cylinder retaining pin is located on the outside of the steering column cover
casting adjacent to the hazard flasher button.
4. Tilt the steering column to the full up position and prepunch the lock cylinder retaining pin with a
prick punch. Using a 3.17mm (1/8 inch)
diameter drill with a right angle drive, drill out the retaining pin, going no deeper than 12.7mm (1 /2
inch).
NOTE: When drilling out the retaining pin, take care not to damage the cover cast housing or the
hazard flasher switch.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and
Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5254
5. Tilt the steering column to the full down position. Place a chisel at the base of the ignition lock
cylinder cap, and, using a hammer, strike the
chisel with sharp blows to break the cap away from the lock cylinder.
6. Using a 9.8mm (3/8 inch) diameter drill, drill down the middle of the ignition lock key slot
approximately 45mm (1-3/4 inch) until the lock
cylinder breaks loose from the steering column cover casting. Remove the lock cylinder, and the
drill shavings from the base of the cover cast housing.
7. Remove the steering wheel and pad.
8. Remove the turn signal lever from the column and then remove the two attaching screws from
the turn signal switch and one attaching screw
from the key warning buzzer terminal. Lift the turn signal switch up and over the end of the steering
shaft but do not disconnect it from the wiring harness.
9. Remove the four attaching screws from the cover casting and lift the casting over the end of the
steering shaft allowing the turn signal switch to
pass through the cover casting. The removal of the cover casting will expose the upper actuator.
Remove the upper actuator.
10. Remove the drive gear, snap ring and washer from the cover casting along with the upper
actuator mentioned above. Thoroughly clean the
components in an acceptable cleaning solution. Carefully inspect all components for any damage
resulting from the drilling operation. If any of the components show signs of damage, they must be
replaced. Clean the removed cover casting with compressed air to remove any drill shavings or
foreign particles and carefully inspect it for damage. If the cover casting is damaged, replace it with
a new one primed and painted to match the existing column.
Installation
1. Lubricate the tang of the lock cylinder with grease.
2. Attach the upper actuator to the lower actuator and lubricate the upper actuator. Reassemble the
cover casting, upper actuator, turn signal
switch and lever, lock drive gear, lock cylinder, steering wheel and pad, and the steering column
trim shrouds.
3. Using the ignition key, rotate the lock cylinder to insure correct mechanical operation in all
positions
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and
Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5255
4. Connect the battery ground cable.
5. Check for proper start in Park or Neutral. Also check to make certain that the start circuit cannot
be actuated in the Drive and Reverse
positions.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and
Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5256
Ignition Lock: Service and Repair Ignition Lock Drive Gear
Ignition Lock Drive Gear
Removal
1. Remove the lock cylinder assembly.
2. Insert a flat-bladed screwdriver in the recess of the drive gear at the bottom of the lock cylinder
housing. Turn the lock drive gear
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and
Repair > Ignition Lock Cylinder Assembly (With Key) > Page 5257
counterclockwise three notches.
3. Remove the snap ring, washer and lock drive gear from the lock cylinder housing. Note the
position of the drive gear to the rack teeth.
Installation
1. Install the lock drive gear in the housing in the same position as noted during removal.
Installation is correct if the last tooth on the drive gear
is meshed with the last tooth on the rack. Install the washer and snap ring.
2. Using the screwdriver blade, turn the drive gear clockwise three notches.
3. Install the lock cylinder.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Doors and Ignition - Lock Service Tips
Ignition Switch Lock Cylinder: Technical Service Bulletins Doors and Ignition - Lock Service Tips
Article No. 87-24-2
12/04/87
LOCKS - DOORS AND IGNITION - GENERAL LOCK SERVICE TIPS
FORD: 1987-88 ESCORT/EXP, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, CROWN
VICTORIA
LINCOLN-MERCURY: 1987 LYNX 1987-88 TOPAZ, SABLE, COUGAR, GRAND MARQUIS,
MARK VII, CONTINENTAL, LINCOLN TOWN CAR
LIGHT TRUCK: 1987-88 AEROSTAR, RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO
ISSUE: Two types of key systems are used on Ford vehicles. The five (5) bit key system uses one
(1) key to operate the ignition lock and a second to operate the outside door locks. The ten (10) bit
key system uses one (1) key to operate the ignition lock and the outside door locks. The ten (10) bit
key system services the ignition lock as a separate service part so the door locks would not have to
be replaced in the event of an ignition lock failure.
ACTION: If service is required for the five (5) bit key system, the ignition and door locks are
serviced separately. Refer to the appropriate Shop Manual for removal and installation procedures.
If service is required for the ten (10) bit key system, a ten (10) bit ignition lock with partially cut keys
is available. Refer to the following service procedure.
NOTE:
Customers concerned with the heads of the new ten (10) bit ignition service keys not matching the
original keys may be resolved by ordering blank keys from Rotunda. Cut the two (2) blank keys
ordered from Rotunda on tumbler station numbers 1, 2, 3, 4, and 6 to match the new ten (10) bit
ignition service keys supplied with the new service ignition lock.
1. Remove the ignition lock cylinder. Refer to the appropriate Shop Manual.
FIGURE 2
2. Using the Ford Rotunda key code cutting package, tool number 011-00003, measure the depth
of the cut on the number six (6) tumbler station of the original key. Use this measurement to
determine the correct service ignition lock set. Refer to the chart in Figure 2.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Doors and Ignition - Lock Service Tips > Page 5263
3. Using the original ignition key, decode tumbler station numbers 5, 7, 8, 9, and 10.
4. Cut the new service key on tumbler station numbers 5, 7, 8, 9, and 10.
5. Check the operation of the new service key in the new ignition lock and outside door locks.
6. Install the new service ignition lock.
NOTE:
Retain both the original and new service key tabs for future key code identification.
OTHER APPLICABLE ARTICLES: 86-23-4
WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations
Location For C6 Transmission
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations > Page 5267
Neutral Safety Switch: Service and Repair
Fig. 8 Neutral safety switch replacement. Exc. automatic overdrive transmission
EXC. AUTOMATIC OVERDRIVE TRANSMISSION
1. Disconnect battery ground cable.
2. Remove downshift linkage rod return spring from low-reverse servo cover.
3. Apply penetrating oil to outer lever attaching nut, then remove transmission downshift outer lever
attaching nut and lever.
4. Remove neutral safety switch attaching bolts, then disconnect electrical connectors and remove
switch from vehicle.
5. To install, position switch on transmission and secure with attaching bolts. Do not tighten bolts at
this time.
6. Place transmission manual lever in neutral position, then insert a .091 inch gauge pin through
gauge pin holes, Fig. 8.
7. Tighten switch attaching bolts, then remove gauge pin.
8. Install outer downshift lever and retaining nut.
9. Install downshift linkage rod return spring between lever and retaining clip on low-reverse servo
cover.
10. Reconnect electrical connectors, then check operation of switch.
W/AUTOMATIC OVERDRIVE TRANSMISSION
1. Disconnect battery ground cable.
2. Raise and support vehicle.
3. Disconnect electrical connector at neutral safety switch, lifting connector straight up.
4. Using suitable socket, remove neutral safety switch and O-ring seal.
5. Reverse procedure to install, installing new O-ring seal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Armature > Component
Information > Testing and Inspection > Armature & Field Grounded Circuit Test
Starter Armature: Testing and Inspection Armature & Field Grounded Circuit Test
Fig. 4 Field grounded circuit test connections
1. Connect jumper lead to positive battery terminal.
2. Connect negative voltmeter lead to negative battery terminal.
3. Touch positive voltmeter lead to commutator and jumper wire to armature.
4. If voltmeter indicates voltage, armature windings are grounded.
5. Make connections as shown, Fig. 4. If voltmeter indicates voltage, field windings are grounded.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Armature > Component
Information > Testing and Inspection > Armature & Field Grounded Circuit Test > Page 5273
Starter Armature: Testing and Inspection Armature Open Circuit Test
An open circuit in the armature can sometimes be detected by examining commutator for signs of
burning. A spot burned on the commutator is caused by an arc formed every time a commutator
segment connected to the open circuit winding passes under a brush.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision
Technical Service Bulletin # 9211B1 Date: 920605
Starter Motor Brushes - Replacement Revision
Article No. 92-11B-1
06/05/92
^ SHOP MANUAL - 1982 THROUGH 1991 AS APPLICABLE - STARTER - POSITIVE
ENGAGEMENT - STARTER MOTOR BRUSHES REPLACEMENT PROCEDURE FOR 4-INCH
STARTERS REVISED/ADDED
^ SHOP MANUAL - 1990 AND 1991 AS APPLICABLE - STARTER - POSITIVE ENGAGEMENT STARTER SIZE SPECFICATION REVISED
FORD: 1989 CROWN VICTORIA, ESCORT, TEMPO 1989-90 THUNDERBIRD 1989-91
MUSTANG, TAURUS
LINCOLN-MERCURY: 1989 CONTINENTAL, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR
1989-90 COUGAR 1989-91 SABLE
LIGHT TRUCK: 1982-91 BRONCO, ECONOLINE, F-150-350 SERIES 1983-91 RANGER 1984-90
BRONCO II 1986-91 AEROSTAR 1988-91 F SUPER DUTY
ISSUE: The procedure for Starter Motor Brushes Replacement applicable to vehicles with 4-inch
starters only is missing or incorrect in the "Starter-Positive Engagement" section of certain Shop
Manuals. Additionally, the 1990 and 1991 Light Truck Shop Manuals incorrectly show a 3-inch
starter in the Specifications Chart; the correct size is 4-inch. The following Shop Manuals are
affected in the Sections indicated:
^ 1989 Domestic Car Lines: Section 28-02
^ 1990 Mustang, Taurus/Sable, Thunderbird/Cougar: Section 28-02
^ 1991 Mustang, Taurus/Sable: Section 28-02
^ 1986 through 1988 Aerostar: Section 11-02
^ 1989 Aerostar, Ranger, Bronco II: Section 03-06
^ 1990 and 1991 Aerostar, Ranger, Bronco II: Section 03-06A
^ 1983 Ranger/1984 Bronco II (Reprint), 1984 through 1988 Ranger/Bronco II, 1982 through 1990
Light Truck-Engine: Section 28-02
^ 1991 Light Truck-Engine: Section 03-06A
ACTION: Refer to Disassembly and Assembly in this TSB article for the additional information.
NOTE: THIS TSB ARTICLE INCLUDES REVISED PAGES FROM THE 1989, 1990 AND 1991
CAR SHOP MANUALS LISTED ABOVE, THE 1991 COMPACT TRUCK SHOP MANUAL AND
THE 1990 AND 1991 LIGHT TRUCK SHOP MANUALS. ALTHOUGH NOT SHOWN, THE
REVISIONS APPLY TO ALL LIGHT TRUCK AND COMPACT TRUCK MANUALS LISTED ABOVE.
NOTE: THE PROCEDURE IN THIS TSB ARTICLE APPLIES TO VEHICLES WITH 4-INCH
STARTERS ONLY.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5278
290000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5279
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5280
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5281
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5282
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5283
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5284
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5285
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5286
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5287
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5288
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5289
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5290
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5291
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5292
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5293
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5294
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5295
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5296
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5297
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component
Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5298
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
Starter Relay: Locations
RH Fender Apron
On RH Front Fender Or Radiator Support
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Locations > Component Locations
Circuit Breaker: Component Locations
LH Side Of Dash Panel At Junction Block
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component
Information > Locations > Component Locations > Page 5307
Circuit Breaker: Fuse and Fusible Link Locations
Circuit Location Amp Windshield Wiper.....................Fuse Panel................7.5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information >
Technical Service Bulletins > Electrical Diode - Identification and Replacement
Diode: Technical Service Bulletins Electrical Diode - Identification and Replacement
Article No. 96-24-6
11/18/96
WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS
FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT,
MUSTANG, THUNDERBIRD 1986-97 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-97
CONTOUR
LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ
1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89
TRACER 1991-94 CAPRI 1991-97 TRACER 1995-97 MYSTIQUE
MERKUR: 1985-89 XR4TI 1988-90 SCORPIO
LIGHT TRUCK: 1983-97 RANGER 1984-90 BRONCO II 1984-97 ECONOLINE, F-150-350
SERIES 1986-97 AEROSTAR 1991-97 EXPLORER 1995-97 WINDSTAR
MEDIUM/HEAVY TRUCK: 1984-91 C SERIES, CL-CLT-9000 SERIES 1984-97 F & B SERIES, L
SERIES 1986-97 CARGO SERIES 1996-97 AEROMAX, LOUISVILLE
This TSB article is being republished in its entirety to update the applicable model years.
ISSUE: Electrical system concerns that are due to diode failure may be serviced with an approved
Ford service diode. Some electrical diodes used in early production vehicles are color coded for the
purpose of size identification while others are stamped with a manufacture number. All Ford service
diodes and current production diodes are identified by manufacture number.
ACTION: If service is required, refer to the appropriate model/year Electrical and Vacuum
Troubleshooting Manual (EVTM) to determine the size and location of the diode(s). Refer to the
following Electrical Diode Application Chart for the correct service part number.
NOTE:
IF THE DIODE REQUIRING REPLACEMENT DOES NOT HAVE THE SAME RATING AS LISTED
IN THE APPLICATION CHART, USE THE NEXT HIGHER RATED DIODE.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information >
Technical Service Bulletins > Electrical Diode - Identification and Replacement > Page 5312
ELECTRICAL DIODE APPLICATION CHART
PART NUMBER PART NAME
E8DZ-10C912-A Diode - 1.0 Amp - 400V
E8DZ-10C912-B Diode - 6.0 Amp - 400V
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 89-2-8
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 203000, 203200, 2770
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations
Fuse: Locations
LH Shroud, Near Access Hole
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations
Fuse Block: Locations
Under LH Side Of Instrument Panel, To Right Of Parking Brake.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5321
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 5322
Fig. 1 Fuse Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information
> Locations > Fuse Link F
Fusible Link: Locations Fuse Link F
RH Fender Apron With EEC
At Starter Relay
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information
> Locations > Fuse Link F > Page 5327
Fusible Link: Locations Fuse Link L
LH Fender Apron
Connected To Choke Heater Or Near Auxiliary Blower Relay
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Locations
Multiple Junction Connector: Locations
LH Fender Or LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Protection Relay > Component
Information > Locations
Power Protection Relay: Locations
Trailer Tow With Auxiliary Battery Above LH Headlight
LH Front Fender
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Protection Relay > Component Information > Locations
Power Protection Relay: Locations
Trailer Tow With Auxiliary Battery Above LH Headlight
LH Front Fender
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations >
Component Locations
Circuit Breaker: Component Locations
LH Side Of Dash Panel At Junction Block
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations >
Component Locations > Page 5343
Circuit Breaker: Fuse and Fusible Link Locations
Circuit Location Amp Windshield Wiper.....................Fuse Panel................7.5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins
> Electrical Diode - Identification and Replacement
Diode: Technical Service Bulletins Electrical Diode - Identification and Replacement
Article No. 96-24-6
11/18/96
WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS
FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT,
MUSTANG, THUNDERBIRD 1986-97 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-97
CONTOUR
LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ
1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89
TRACER 1991-94 CAPRI 1991-97 TRACER 1995-97 MYSTIQUE
MERKUR: 1985-89 XR4TI 1988-90 SCORPIO
LIGHT TRUCK: 1983-97 RANGER 1984-90 BRONCO II 1984-97 ECONOLINE, F-150-350
SERIES 1986-97 AEROSTAR 1991-97 EXPLORER 1995-97 WINDSTAR
MEDIUM/HEAVY TRUCK: 1984-91 C SERIES, CL-CLT-9000 SERIES 1984-97 F & B SERIES, L
SERIES 1986-97 CARGO SERIES 1996-97 AEROMAX, LOUISVILLE
This TSB article is being republished in its entirety to update the applicable model years.
ISSUE: Electrical system concerns that are due to diode failure may be serviced with an approved
Ford service diode. Some electrical diodes used in early production vehicles are color coded for the
purpose of size identification while others are stamped with a manufacture number. All Ford service
diodes and current production diodes are identified by manufacture number.
ACTION: If service is required, refer to the appropriate model/year Electrical and Vacuum
Troubleshooting Manual (EVTM) to determine the size and location of the diode(s). Refer to the
following Electrical Diode Application Chart for the correct service part number.
NOTE:
IF THE DIODE REQUIRING REPLACEMENT DOES NOT HAVE THE SAME RATING AS LISTED
IN THE APPLICATION CHART, USE THE NEXT HIGHER RATED DIODE.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins
> Electrical Diode - Identification and Replacement > Page 5348
ELECTRICAL DIODE APPLICATION CHART
PART NUMBER PART NAME
E8DZ-10C912-A Diode - 1.0 Amp - 400V
E8DZ-10C912-B Diode - 6.0 Amp - 400V
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 89-2-8
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 203000, 203200, 2770
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations
Fuse: Locations
LH Shroud, Near Access Hole
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations
Fuse Block: Locations
Under LH Side Of Instrument Panel, To Right Of Parking Brake.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions
Fuse Block: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5357
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 5358
Fig. 1 Fuse Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link
F
Fusible Link: Locations Fuse Link F
RH Fender Apron With EEC
At Starter Relay
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link
F > Page 5363
Fusible Link: Locations Fuse Link L
LH Fender Apron
Connected To Choke Heater Or Near Auxiliary Blower Relay
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Locations
Multiple Junction Connector: Locations
LH Fender Or LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Power and Ground Distribution > Power Protection Relay > Component Information > Locations
Power Protection Relay: Locations
Trailer Tow With Auxiliary Battery Above LH Headlight
LH Front Fender
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Protection Relay > Component Information > Locations
Power Protection Relay: Locations
Trailer Tow With Auxiliary Battery Above LH Headlight
LH Front Fender
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Tire
Wear - Toe Set Prior Vehicle Service
Alignment: Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service
Article No. 86-24-28
TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES
LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE
Certain model vehicles have a significant weight change on the front axle between manufacture by
Ford and placement into service. This occurs when incomplete vehicles are completed by a body
company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.).
This weight change can affect toe setting so these vehicles require that toe be reset.
Figure 25
The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the
intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE
ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Tire
Wear - Toe Set Prior Vehicle Service > Page 5379
Alignment: Technical Service Bulletins Front Tires - Irregular Wear Pattern
Article No. 86-24-27
TIRE WEAR - FRONT - IRREGULAR PATTERN
LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS
Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel
and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire
tread/ carcass/compound design.
Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and
set to Shop Manual preferred settings for toe.
In cases of severe wear, obtain the complete alignment readings and tire information. Contact both
your Ford Representative and Tire Manufacturer's Representative for their assistance and
participation in resolving the customer's concern. Contacting the "local" tire store may not obtain
the assistance which may be available from the tire manufacturer.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Camber
Alignment: Specifications Camber
Fig.1 Ride Height
Fig.2 Ride Height
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Camber > Page
5382
Camber Specifications
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Camber > Page
5383
Alignment: Specifications Caster
Fig.1 Ride Height
Caster Angle Specifications
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Camber > Page
5384
Alignment: Specifications Toe
Toe In ..................................................................................................................................................
........................................................................ 1/32 in
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5385
Alignment: Service and Repair
Fig. 1 Measuring Ride Height
Fig. 7 Measuring riding height. 1980---85 F-100---350 & Bronco
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 5386
Fig. 8 Measuring Riding Height
Prior to checking caster and camber, ensure vehicle front ride height is within {1/8} inch side to side
1980-87 E-100-350. On 1980-87 F-100-350 models, the left side ride height should be within
0-{3/8} inch higher than the right side ride height. On 1980-87 F-150-350 (4x4) and Bronco, the
front ride heights should be within {3/16} inch side to side. Refer to Figs. 6, 7 and 8. If the vehicle
ride heights are not within specifications, redistribute load on loaded vehicles or slightly load empty
vehicles on one side. If the ride heights cannot be brought within specifications, verify correct
spring installation. The ride height variations stated, are for checking purposes only. The vehicle
does not have to operate within these specifications. Check and correct as necessary all tire
inflation pressures, then check front tires for the same size, ply rating and load range. Check front
wheel bearings and adjust as necessary. If all the above checks have been made, check wheel
alignment with suitable alignment equipment. Using the ride heights obtained earlier, compare
caster and camber readings to those listed in the ``Wheel Alignment Specifications Chart''. If the
caster and camber angles exceed the specifications, inspect front end for damaged suspension
components. Replace as necessary. Alignment equipment indicates a true reading only when the
vehicle's frame is horizontal. Therefore, if the frame is not level (due to tire, spring or load
differences), the caster angle reading must be modified to compensate for the frame angles. If the
front is higher than the rear, subtract the amount of angle from the reading. If the front is lower than
the rear, add the angle. To check frame angle, use a spirit protractor, and take the frame angle
measurement on the lower frame flange at the flat area immediately adjacent to the rear spring
front hanger.
TOE-IN, ADJUST Check the steering wheel spoke position when the front wheels are in the
straight ahead position. If the spokes are not in the normal position, they can be adjusted while
toe-in is being adjusted.
1. Loosen clamp bolts on each tie rod end sleeve.
2. Adjust toe-in. If steering wheel spokes are in their normal position, lengthen or shorten both rods
equally to obtain correct toe-in. If spokes are not in normal position, make necessary rod
adjustments to obtain correct toe-in and steering wheel spoke alignment.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Power Steering Pressure Switch > Component Information > Locations
Power Steering Pressure Switch: Locations
Upper LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical
Service Bulletins > Customer Interest for Center Link: > 881414 > Jul > 88 > Steering - Unequal Left and Right Turn Angles
Center Link: Customer Interest Steering - Unequal Left and Right Turn Angles
^ STEERING - UNEQUAL LEFT AND RIGHT TURN ANGLES - VEHICLES BUILT BEFORE
2/22/88
^ STEERING - OFF CENTER STEERING GEAR AND WIDE CENTER FEEL - VEHICLES BUILT
BEFORE 2/22/88
Article No. 88-14-14
LIGHT TRUCK: 1975-88 E SERIES
ISSUE: Unequal left hand and right hand turn angles, wide center steering wheel feel and a
variance in steering wheel rotation from the straight-ahead position to full right turn versus the
straight-ahead position to full left turn may be caused by tolerance stack-ups and only one (1)
adjusting sleeve for toe-in setting which allows the steering maximum travel to be regulated by
steering gear travel rather than the axle spindle steering stops.
ACTION: To correct this, install a new design drag link with an adjusting sleeve. Refer to the
following service procedure. Refer to the steering drag link application chart on page 32 of this TSB
for the correct service parts.
FIGURE 12
1. Remove cotter pin and nut from both drag link ball studs and the tie rod stud at the drag link.
Refer to Figure 12.
2. Remove the tie rod ball stud from the drag link using a tie rod end remover.
3. Remove both drag link ball studs from the pitman arm and right hand spindle.
4. Remove the steering wheel from the tapered section of the steering column shaft, Refer to the
Light Truck Shop Manual, Volume A, Section 13-06 for detailed service procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical
Service Bulletins > Customer Interest for Center Link: > 881414 > Jul > 88 > Steering - Unequal Left and Right Turn Angles
> Page 5401
5. Place the wheel loosely on the shaft so that it can be easily removed by hand later.
6. Turn the steering wheel to the right stop.
7. Turn the steering wheel to the left stop while counting the number of turns.
8. Turn the wheel to the right one-half of the number of turns counted in Step 7. The steering gear
is now centered.
9. Without rotating the steering column, remove the steering wheel from the column and reinstall it
so that the clear vision is set at 0 degrees.
NOTE: THE STEERING COLUMN MUST NOT MOVE DURING THIS OPERATION OR THE
STEERING GEAR WILL BE OFF CENTER.
10. Repeat Steps 6, 7 and 8 to make sure the steering gear is centered.
11. Tighten steering wheel retaining to the torque specification listed in the Light Truck Shop
Manual, Volume A, Section 13-06.
12. Assemble the new drag link, tie rod end and adjusting sleeve.
13. Adjust the length of the drag link assembly so that it is about the same as the length of the old
drag link.
14. Install the new drag link. Refer to the Light Truck Shop Manual, Volume A, Section 13-24 for
service details.
NOTE: THE WHEELS MUST BE IN THE STRAIGHT-AHEAD POSITION AND THE STUDS
SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS SO THAT THE RUBBER
BALL SOCKETS WILL NOT BE PRELOADED AND CAUSE A DRIFT CONDITION.
15. Check and adjust toe. Refer to the Light Truck Shop Manual, Volume A, Section 14-01 for front
end alignment specifications and procedures.
NOTE: USE THE F SERIES PROCEDURE SINCE THE SYSTEM NOW HAS TWO (2)
ADJUSTING SLEEVES.
16. After toe is set, be sure to position the two (2) clamp bolts on the drag link adjusting sleeve
BELOW the linkage.
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible Under Basic
OPERATION: 881414A Warranty Coverage TIME:
1.2 Hrs.
DLR. CODING: Basic Part No. 3A131 Condition Code: 37
PART NUMBER PART NAME CLASS
E8UZ-3A131-A Socket - Steering Drag B
Link Arm
E8UZ-3A131-B Socket - Steering Drag C
Link Arm
E8UZ-3304-A Socket - Steering Drag B
Link Pitman Arm
E8UZ-3304-B Socket - Steering Drag C
Link Pitman Arm
D2TZ-3281-A Tube - Adjuster AG
E7TZ-3281-A Tube - Adjuster C
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Center Link: > 881414 > Jul > 88 > Steering - Unequal Left and Right
Turn Angles
Center Link: All Technical Service Bulletins Steering - Unequal Left and Right Turn Angles
^ STEERING - UNEQUAL LEFT AND RIGHT TURN ANGLES - VEHICLES BUILT BEFORE
2/22/88
^ STEERING - OFF CENTER STEERING GEAR AND WIDE CENTER FEEL - VEHICLES BUILT
BEFORE 2/22/88
Article No. 88-14-14
LIGHT TRUCK: 1975-88 E SERIES
ISSUE: Unequal left hand and right hand turn angles, wide center steering wheel feel and a
variance in steering wheel rotation from the straight-ahead position to full right turn versus the
straight-ahead position to full left turn may be caused by tolerance stack-ups and only one (1)
adjusting sleeve for toe-in setting which allows the steering maximum travel to be regulated by
steering gear travel rather than the axle spindle steering stops.
ACTION: To correct this, install a new design drag link with an adjusting sleeve. Refer to the
following service procedure. Refer to the steering drag link application chart on page 32 of this TSB
for the correct service parts.
FIGURE 12
1. Remove cotter pin and nut from both drag link ball studs and the tie rod stud at the drag link.
Refer to Figure 12.
2. Remove the tie rod ball stud from the drag link using a tie rod end remover.
3. Remove both drag link ball studs from the pitman arm and right hand spindle.
4. Remove the steering wheel from the tapered section of the steering column shaft, Refer to the
Light Truck Shop Manual, Volume A, Section 13-06 for detailed service procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Center Link: > 881414 > Jul > 88 > Steering - Unequal Left and Right
Turn Angles > Page 5407
5. Place the wheel loosely on the shaft so that it can be easily removed by hand later.
6. Turn the steering wheel to the right stop.
7. Turn the steering wheel to the left stop while counting the number of turns.
8. Turn the wheel to the right one-half of the number of turns counted in Step 7. The steering gear
is now centered.
9. Without rotating the steering column, remove the steering wheel from the column and reinstall it
so that the clear vision is set at 0 degrees.
NOTE: THE STEERING COLUMN MUST NOT MOVE DURING THIS OPERATION OR THE
STEERING GEAR WILL BE OFF CENTER.
10. Repeat Steps 6, 7 and 8 to make sure the steering gear is centered.
11. Tighten steering wheel retaining to the torque specification listed in the Light Truck Shop
Manual, Volume A, Section 13-06.
12. Assemble the new drag link, tie rod end and adjusting sleeve.
13. Adjust the length of the drag link assembly so that it is about the same as the length of the old
drag link.
14. Install the new drag link. Refer to the Light Truck Shop Manual, Volume A, Section 13-24 for
service details.
NOTE: THE WHEELS MUST BE IN THE STRAIGHT-AHEAD POSITION AND THE STUDS
SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS SO THAT THE RUBBER
BALL SOCKETS WILL NOT BE PRELOADED AND CAUSE A DRIFT CONDITION.
15. Check and adjust toe. Refer to the Light Truck Shop Manual, Volume A, Section 14-01 for front
end alignment specifications and procedures.
NOTE: USE THE F SERIES PROCEDURE SINCE THE SYSTEM NOW HAS TWO (2)
ADJUSTING SLEEVES.
16. After toe is set, be sure to position the two (2) clamp bolts on the drag link adjusting sleeve
BELOW the linkage.
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible Under Basic
OPERATION: 881414A Warranty Coverage TIME:
1.2 Hrs.
DLR. CODING: Basic Part No. 3A131 Condition Code: 37
PART NUMBER PART NAME CLASS
E8UZ-3A131-A Socket - Steering Drag B
Link Arm
E8UZ-3A131-B Socket - Steering Drag C
Link Arm
E8UZ-3304-A Socket - Steering Drag B
Link Pitman Arm
E8UZ-3304-B Socket - Steering Drag C
Link Pitman Arm
D2TZ-3281-A Tube - Adjuster AG
E7TZ-3281-A Tube - Adjuster C
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Spindle
REMOVE
1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly.
3. Remove the caliper assembly from the rotor and hold it out of the way with wire. 4. Remove the
dust cap, cotter pin, nut retainer, nut, washer, and outer bearing, and remove the rotor from the
spindle. 5. Remove inner bearing cone and seal. Discard the seal. 6. Remove brake dust shield. 7.
Disconnect the steering linkage from the spindle arm by removing the cotter pin and nut, and then
removing the tie rod end from the spindle arm
with tie Rod End Remover, TOOL-3290-D or equivalent.
8. Remove the nut and lockwasher from the lock pin, and remove the lock pin. 9. Remove the
upper and lower spindle pin plugs; then, drive the spindle pin out from the top of the axle and
remove the spindle and thrust bearing.
Remove the spindle pin seal and thrust bearing.
INSTALL
1. Make sure the spindle pin hole in the axle is free of nicks, burrs, corrosion or foreign material.
Clean up the bore as necessary and lightly coat the
surface with a lithium-base grease, Long-Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or
equivalent.
2. Install a new spindle pin seal with the metal backing facing up towards the bushing into the
spindle. Gently press seal into position, being careful
not to distort the casing.
3. Install a new thrust bearing with the lip flange facing down towards the lower bushing. Press until
the bearing is firmly seated against the surface
of the spindle.
4. Lightly coat the bushing surfaces with grease and place the spindle in position on the axle. 5.
Hold the spindle with thrust bearing in place tight against the axle and measure the space between
the axle and the spindle at the top of the axle. If
the vehicle uses shims, select the proper shims and install.
6. Install the spindle pin with the "T" stamped on one end towards the top, and the notch in the pin
aligned with the lock pin hole in the axle. Insert
the spindle pin through the bushings and axle from the top until the spindle pin notch and axle lock
pin hole are in line.
7. Install the lock pin with the threads pointing forward and the wedge groove facing the spindle pin
notch. Firmly drive the lock pin into position
and mount the lockwasher and nut. Tighten the nut to 52-84 Nm (38-62 ft lb).
8. Install the spindle pin plugs into the threads at the top and bottom of the spindle. Tighten the
plugs to 48-67 Nm (35-50 ft lb). 9. Lubricate the spindle pin and bushings with Long-Life Lubricant
C1AZ-19590-BA (ESA-M1C75-B) or equivalent, through both fittings until
grease is visible seeping past the upper seal at the top and from the thrust bearing slip joint at the
bottom. If grease does not appear, recheck the installation procedure to correct the problem. Lack
of adequate lubrication will result in rapid failure of the spindle components.
10. Install the dust shield. 11. Pack the inner and outer bearing cone with bearing grease. Use a
bearing packer. If a bearing packer is unavailable, pack the bearing cone by hand
working the grease through the cage behind the rollers.
12. Install the inner bearing cone and seal. Install the hub and rotor on the spindle. 13. Install the
outer bearing cone, washer, and nut. Adjust bearing end play and install the nut retainer, cotter pin
and dust cap. 14. Install the caliper.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 5411
15. Connect the steering tie rod and drag link (if equipped) to the spindle. Tighten the nut to
specifications and advance the nut as required for
installation of the cotter pin.
16. Install the wheel and tire assembly. 17. Lower the vehicle. 18. Check and, if necessary adjust
the toe setting.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair
Power Steering Bleeding: Service and Repair
Four factors affect power operation of the steering system: fluid level and condition, drive belt
tension, pump pressure and steering gear adjustment. These should always be checked before
any major service operations are performed. Conditions such as, hard or loose steering, road
shock or vibrations are not always due to steering gear or pump, but are often related instead to
such factors as low tire pressure and front end alignment. These factors should be checked and
corrected before any adjustment of the steering gear is made.
CHECKING FLUID LEVEL
1. Run engine to normal operating temperature, then shut it off. Remove reservoir filler cap and
check oil level on dipstick. Level should be up to ``Full'' mark on dipstick.
2. If level is low, add power steering fluid to proper level on dipstick and replace filler cap. When
adding less than one pint of fluid, it is permissible to use automatic transmission fluid. When adding
larger quantities or when making a complete fluid change, it is recommended that special power
steering fluid be used.
3. When checking fluid level after system has been serviced, air must be bled from the system as
outlined under ``Bleeding System.''
BLEEDING SYSTEM
1. With wheels turned all the way to the left, add the recommended fluid to the ``Add'' mark on
dipstick.
2. Start engine. While running at fast idle, recheck fluid level and, if necessary, add fluid to the
``Add'' mark on dipstick.
3. Bleed system by turning wheels from side to side without hitting stops. Maintain fluid level just
above internal pump casting. Fluid with air in it will have a light tan appearance. This air must be
eliminated from fluid before normal steering action can be obtained.
4. Return wheels to center position and continue to run engine for two or three minutes, then shut it
off.
5. Road test vehicle to make sure steering functions normally and is free from noise.
6. Recheck fluid level, making sure level is at the ``Full'' mark.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Power Steering - Cooler Kit Availability
Power Steering Fluid Cooler: Technical Service Bulletins Power Steering - Cooler Kit Availability
Article No. 92-12-13
DATE: 06-3-92
STEERING-POWER-7.5L AND 7.3L-AVAILABILITY OF POWER STEERING COOLER KIT
LIGHT TRUCK: 1987-92 ECONOLINE
ISSUE: A power steering cooler kit is now available for service use. Econolines with 7.5L or 7.3L
Diesel engines which run 24 hours a day, accumulate high mileage quickly, or run in high ambient
temperatures may benefit from the installation of the cooler kit.
ACTION: If the customer desires to have a power steering cooler kit installed, it may be added at
the customer's expense. Refer to the Installation Sheet in the kit and the following procedure for
installation details.
The power steering cooler kit contains the following components.
^ One (1) Power Steering Oil Cooler Assembly
^ Two (2) Oil Cooler Hoses (3/8"I.D. X 36")
^ Four (4) Oil Cooler Hose Clamps
^ Two (2) "U" Clip Nuts
^ Two (2) Screw And Washer (M6Xl.OOX25 Hex HD Pit 9)
^ One (1) Instruction Sheet.
INITIAL INSPECTION
If a power steering fluid leak exists, inspect the steering gear input shaft seal, the sector shaft seal
and the power steering pump shaft seal to determine if they have become hard, brittle, or cracked.
These are signs of heat aged rubber. If this condition exists, replace the shaft seals.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Power Steering - Cooler Kit Availability > Page 5420
POWER STEERING COOLER KIT INSTALLATION
1. Mount the power steering cooler on the left side of the radiator support using the "U" clip nuts
and screws provided in the kit, Figure 1.
2. The low pressure fluid from the return line is routed from the steering gear, through the cooler
and back to the power steering pump reservoir.
3. Discard the rubber portion of the return line.
4. Route a new piece of hose (provided in the kit) from the bottom nipple of the cooler to the metal
tube of the return line which is still connected to the gear.
a. Cut to proper length.
b. Secure the hose with the hose clamps provided.
5. Route a hose from the top nipple of the cooler to the nipple on the power steering reservoir.
Clamp the hose securely at both ends.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Technical Service Bulletins > Power Steering - Cooler Kit Availability > Page 5421
NOTE: ROUTE AND SECURE HYDRAULIC LINES TO PREVENT ANY INTERFERENCE WITH
MOVING PARTS. ALSO, AVOID CONTACT WITH SHARP EDGES TO PREVENT CHAFFING OF
HOSES FROM HYDRAULIC MOVEMENT.
6. Refer to the appropriate model year Service Manual for proper fluid fill and start-up procedures.
PART NUMBER PART NAME CLASS
E7UZ-3D746-A Power Steering Cooler Kit CG
D5AZ-3D527-A Sector Shaft Seal AM
D6AZ-3D526-A Input Shaft Seal B
D2VY-3B592-A Power Steering Pump Shaft B
Seal
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
303000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation
Power Steering Pump: Service and Repair Removal and Installation
E-100-350
1. Disconnect pressure and return lines from pump.
2. Loosen belt tension adjusting bolt fully.
3. On models equipped with A/C, remove pump mounting bracket to A/C compressor mounting
bracket attaching bolts.
4. On all models, remove pump and mounting brackets from vehicle.
5. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5426
Power Steering Pump: Service and Repair Disassembly
Fig. 1 Exploded view of Ford Model CII power steering pump
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5427
Fig. 2 Positioning Pump In C-Clamp
Fig. 2 Positioning Pump In C-Clamp
1. Remove pulley from pump.
2. Remove outlet fitting, flow control valve and flow control valve spring from pump, then remove
reservoir, Fig. 1.
3. Place a suitable C-clamp in a vise.
4. Position lower support plate T78P-3733-A2 over pump rotor shaft.
5. Install upper compressor plate T78P-3733-A1 into upper portion of C-clamp.
6. While holding compressor tool, place pump assembly into C-clamp with rotor shaft facing
downward, Fig. 2.
7. Tighten C-clamp until a slight bottoming of valve cover is observed.
8. Through small hole located on side of pump housing, insert a suitable drift and push inward on
valve cover snap ring. While pushing inward on snap ring, place a screwdriver under snap ring
edge and remove ring from housing, Fig. 3.
9. Loosen C-clamp and remove upper compressor plate T78P-3733-A2, then remove pump
assembly.
10. Remove pump valve cover and O-ring.
11. Remove rotor shaft, upper plate, cam and rotor assembly and two dowel pins.
12. Remove lower plate and spring, by tapping housing on a flat surface.
13. Using a suitable screwdriver, remove rotor shaft seal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5428
Power Steering Pump: Service and Repair Assembly
Fig. 1 Exploded view of Ford Model CII power steering pump
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5429
Fig. 4 Installing Slipper Springs
Fig. 5 Installing Slippers
1. Position rotor on rotor shaft splines with triangle detent on rotor counter bore facing upward.
2. Install snap ring into groove on end of rotor shaft, Fig. 1.
3. Position insert cam over rotor. Ensure recessed notch on insert cam is facing upward.
4. With rotor extended upward approximately half out of cam, insert spring into rotor picket, Fig. 4.
5. Use a slipper to compress spring, then install slipper with groove facing cam, Fig. 5.
6. Perform steps 4 and 5 on slipper cavity beneath opposite inlet recess.
7. While holding cam stationary, index rotor left or right one space and install another spring and
slipper until all ten rotor cavities have been filled. Ensure rotor springs and slippers remain in
position while turning.
8. Apply Loctite No. 242 or 271 adhesive or equivalent to outside diameter of seal and Lockquick
NF or T primer or equivalent to seal bore in housing. Install rotor shaft seal using tool No.
T78P-3733-A3. Using a plastic mallet, drive seal into bore until properly seated.
9. Position pump plate on flat surface with pulley side facing downward.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5430
10. Install two dowel pins and spring into housing. Spring must be inserted with dished surface
facing upward.
11. Lubricate inner and outer O-ring seals with power steering fluid, then install seals on lower
pressure plate.
12. Install lower pressure plate into housing and over dowel pin with O-ring seals facing toward
front of pump. Position assembly on C-clamp. Place tool No. T78P-3733-A3 into rotor shaft hole
and press on lower plate lightly until it bottoms in pump housing. This will seat the outer O-ring
seal.
Upper Pressure Plate Installation
Fig. 8 Installing Valve Cover
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5431
Fig. 6 Assembling Cam, Slippers And Rotor
13. Install cam, rotor, rotor and slippers and rotor shaft assembly into pump housing over dowel
pins. When installing assembly into pump housing,stepped holes must be used for dowel pins and
notch in cam insert must be toward reservoir and approximately 180 degrees opposite square
mounting lug on housing, Fig. 6.
14. Position upper pressure plate over dowel pins with recess directly over recessed notch on cam
insert and approximately 180 degrees opposite square mounting lug, Fig. 7.
15. Lubricate O-ring seal with power steering fluid. Then, position O-ring on valve cover. Ensure
plastic baffle is securely in position on valve cover. A coat of petroleum jelly may be used to hold
baffle in position.
16. Insert valve cover over dowel pins. Ensure outlet fitting hole in valve cover is aligned with
square mounting lug on housing, Fig. 8.
17. Place assembly in C-clamp and compress valve cover into pump housing until snap ring groove
on housing is exposed.
18. Install valve cover snap ring in pump housing. Ensure snap ring ends are near access hole in
pump housing.
19. Remove pump assembly from C-clamp.
20. Lubricate O-ring seal with power steering fluid, then place seal on pump housing.
21. Install reservoir on pump housing.
22. Install flow control valve and spring into valve cover.
23. Lubricate O-ring seals with power steering fluid, then place seals on outlet fitting.
24. Install outlet fitting on valve cover. Torque outlet fitting to 25---34 ft. lbs. Use care not to cock
flow control valve when installing. Do not force valve forward otherwise damage to housing may
result.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5432
Power Steering Pump: Service and Repair Vane Type Pump W/ Integral Reservoir
Disassembly
Fig. 1 Vane type power steering pump w/integral reservoir disassembled (typical)
Fig. 2 Removing end plate retaining ring
Fig. 3 Removing flow control valve & spring
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5433
Fig. 4 Thrust plate & rotor installed on driveshaft
1. Referring to Fig. 1, carefully mount pump in vise with soft jaws and remove reservoir cap. When
clamping pump in vise, do not exert excessive force on front hub as this may distort drive shaft
bushing in housing.
2. Remove rear pump mounting stud and O-ring seal, pressure union and O-ring seal.
3. Remove reservoir, and second pressure union O-ring seal.
4. Using a small punch, depress end plate retaining ring enough to allow removal from groove. Use
the {1/8} inch diameter hole in housing, Fig. 2. Then remove retaining ring with screwdriver.
5. Remove end plate which is spring loaded and usually sits above housing level. If end plate
sticks, a slight rocking action should free it. If rocking action fails to free plate, use a magnet.
6. Remove two pressure springs from pump housing.
7. Remove flow control valve and spring by inverting housing. Do not disassemble flow control
valve as it is serviced as a unit and pre-set at the factory, Fig. 3.
8. Remove drive shaft key from slot in shaft. Then with end of shaft pointed downward, press down
until shaft is free.
9. Turn assembly over and remove drive shaft and rotary group.
10. Remove rotor retaining ring from groove in drive shaft. Remove rotor and thrust plate from
shaft, Fig. 4.
11. Remove and discard O-ring seals from pump housing. Remove driveshaft oil seal only if
inspection shows necessity for replacement.
Inspection
1. Clean all parts except the drive shaft oil seal in cleaning fluid. The seal will be damaged if
immersed in cleaning fluid.
2. Check fit of vanes in slots of rotor for tightness or excessive looseness. Vanes must fit snugly
but slide freely in slots in rotor. Tight fit of vanes in rotor can usually be corrected by thorough
cleaning. Replace rotor if excessive looseness exists between rotor and vanes. Replace vanes if
worn or scored.
3. Examine machined surfaces of pump ring for roughness or wear. Replace ring if roughness
cannot be corrected with crocus cloth.
4. Inspect thrust plate, pressure plate and end plate for wear, scores or other damage.
5. Inspect pump housing for cracks or damage. Check housing for evidence of wear or scoring.
6. Check all springs for free length, distortion or collapsed coils.
7. Inspect located dowel pins for distortion.
8. Examine outer diameter of flow control valve for scoring or roughness. Slight damage may be
cleaned up with crocus cloth. Check valve assembly for freedom of movement in bore of pump
housing.
9. Check all oil passages in pump parts for obstruction. Use a piece of tag wire to clean out holes.
10. Check bushing in pump housing for wear or damage.
Assembly
Fig. 4 Thrust plate & rotor installed on driveshaft
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5434
Fig. 5 Installing driveshaft assembly
Fig. 6 Installing pump ring
Fig. 7 Installing rotor vanes
1. Lubricate new O-ring seals with Vaseline and place in pump housing.
2. If drive shaft oil seal was removed during disassembly, lubricate new seal with Vaseline. Then
install seal in pump body front hub, using a suitable seal driver.
3. Position thrust plate and rotor on drive shaft. Then install rotor retaining ring in groove of drive
shaft, Fig. 4.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5435
4. Place pump housing on work bench as shown in Fig. 5 and install two pump ring dowel pins in
bore of housing.
5. Install drive shaft in housing, making sure shaft seats properly.
6. Install pump ring in housing over two dowel pins with rotation arrow on ring to rear of pump
housing, Fig. 6.Arrow on outer edge of pump ring points in direction of pump rotation
(counterclockwise when viewed from rear of pump).
7. Install rotor vanes in slots of pump rotor, with radius edge of vanes toward outside of rotor, Fig.
7.
Fig. 8 Installing pressure plate
Fig. 9 Installing pressure plate springs
8. Position pump housing on two wood blocks and push parts down into place as shown in Fig. 8.
9. Lubricate outside diameter and chamfer of pressure plate with Vaseline to insure against
damage to O-ring seals in housing. Then install pressure plate in housing over dowel pins.Ported
face of pressure plate goes toward pump ring, Fig. 8.
10. Using a 2{3/4} inch diameter sleeve to apply pressure to outer edge of pressure plate only,
press pressure plate into seat. Pressure plate will travel about {1/16} inch to seat. Do not press or
hammer on center of pressure plate as to do so will cause permanent distortion resulting in pump
failure.
11. Install two pressure plate springs, one over each dowel pin in pump housing, Fig. 9.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5436
Fig. 10 Installing end plate & retaining ring
Fig. 11 Installing flow control valve & spring
Fig. 12 Installing pressure union O-ring seal
12. Lubricate outside diameter and chamfer of end plate with Vaseline to insure against damage to
O-ring seal in housing. Then press end plate into housing. While holding end plate down in
housing, install end plate retaining ring. Be sure end plate is completely and solidly seated in
groove of housing, Fig. 10.
13. Remove assembly from press and place on work bench. Install flow control spring and valve in
bore of housing. Make sure hex head screw goes into housing bore, Fig. 11.
14. Position pressure union O-ring seal in bore of housing over flow control valve, Fig. 12.
15. Mount pump housing in vise with soft jaws and install reservoir.
16. Install pressure union and new O-ring seal in reservoir. Tighten union.
17. Install mounting stud and new O-ring seal in reservoir. Tighten stud.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5437
18. Install drive shaft key in slot in shaft. Support shaft on opposite side while installing key. Install
reservoir cap.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5438
Power Steering Pump: Service and Repair Vane Type Pump, Less Integral Reservoir
Fig. 1 Vane type power steering pump, less integral reservoir disassembled
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5439
Fig. 2 Removal & installation of return tube, control valve, driveshaft, ball bearing assembly &
driveshaft seal
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5440
Fig. 3 Removal & installation of rotating group
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Removal and Installation > Page 5441
Fig. 4 Removal & installation of sleeve assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering
Pressure Switch > Component Information > Locations
Power Steering Pressure Switch: Locations
Upper LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Technical
Service Bulletins > Customer Interest for Steering Column: > 931710 > Aug > 93 > Steering Column and Ignition Key - Gets
Hot
Steering Column: Customer Interest Steering Column and Ignition Key - Gets Hot
Article No. 93-17-10
08/18/93
^ STEERING - COLUMN AND IGNITION KEY GET HOT - 7.5L ENGINE AND AUTOMATIC
TRANSMISSION
^ IGNITION SWITCH - KEY AND STEERING COLUMN GET HOT - 7.5 ENGINE AND
AUTOMATIC TRANSMISSION
LIGHT TRUCK: 1987 E-250, E-350, F-250, F-350
ISSUE: The steering column and the ignition key may get hot if the column is not sealed. This
occurs because the exhaust manifold is close to the lower end of the steering column. When the
vehicle is pulling a heavy load the heat from the exhaust can travel up the outer tube assembly of
the steering column.
ACTION: Install a seal in the lower tube of the steering column. The seal prevents hot air from
moving up the outer tube assembly of column to the ignition key. Refer to the appropriate 1987-91
Service Manual, Steering Section, for service details.
PART NUMBER PART NAME CLASS
E9TZ-7C102-A Seal, Lower Tube Steering C
Column
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage
OPERATION DESCRIPTION TIME
931710A Install Seal - Econoline 1.2 Hrs.
931710B Install Seal - GF-Series 0.5 Hr.
DEALER CODING BASIC PART NO.
CONDITION CODE
3514 08
OASIS CODES: 112000, 303000, 403000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Column: > 931710 > Aug > 93 > Steering Column and
Ignition Key - Gets Hot
Steering Column: All Technical Service Bulletins Steering Column and Ignition Key - Gets Hot
Article No. 93-17-10
08/18/93
^ STEERING - COLUMN AND IGNITION KEY GET HOT - 7.5L ENGINE AND AUTOMATIC
TRANSMISSION
^ IGNITION SWITCH - KEY AND STEERING COLUMN GET HOT - 7.5 ENGINE AND
AUTOMATIC TRANSMISSION
LIGHT TRUCK: 1987 E-250, E-350, F-250, F-350
ISSUE: The steering column and the ignition key may get hot if the column is not sealed. This
occurs because the exhaust manifold is close to the lower end of the steering column. When the
vehicle is pulling a heavy load the heat from the exhaust can travel up the outer tube assembly of
the steering column.
ACTION: Install a seal in the lower tube of the steering column. The seal prevents hot air from
moving up the outer tube assembly of column to the ignition key. Refer to the appropriate 1987-91
Service Manual, Steering Section, for service details.
PART NUMBER PART NAME CLASS
E9TZ-7C102-A Seal, Lower Tube Steering C
Column
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage
OPERATION DESCRIPTION TIME
931710A Install Seal - Econoline 1.2 Hrs.
931710B Install Seal - GF-Series 0.5 Hr.
DEALER CODING BASIC PART NO.
CONDITION CODE
3514 08
OASIS CODES: 112000, 303000, 403000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Technical
Service Bulletins > Page 5459
Steering Column: Service Precautions
When the steering column is installed in the vehicle it is not susceptible to damage through
ordinary use; however, when it is removed, care must be taken during handling. Such actions as a
sharp blow on the end of the steering shaft or shift levers, leaning on the column assembly or
dropping of the assembly could loosen or shear the plastic shear joints or rivets used to maintain
column rigidity. Hammering, jolting or bumping on the steering shaft and gearshift tube must be
avoided during all service operations. If the shear pins are broken, the controlled length of the
telescoping design will be altered making these components unfit for further service. When
removing the steering wheel, only a steering wheel puller designed for this purpose must be used.
It is important that only the specified screws, bolts and nuts be used during the assembly
procedure and torqued to specifications to insure proper breakaway action of the column under
impact. Avoid using excessively long bolts or fasteners as they may prevent a portion of the
steering column from collapsing. When replacing fasteners, replace with ones of the same part
number or equivalent. When removing or installing the steering wheel, ignition switch, lock cylinder,
turn signal switch, neutral start switch, back-up light switch or adjusting column shift manual
transmission linkage refer to the appropriate vehicle chapter.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Technical
Service Bulletins > Page 5460
Steering Column: Description and Operation
ENERGY ABSORBING STEERING COLUMNS The energy absorbing function of the steering
column allows the column to collapse at a controlled rate during a severe collision. The collapsing
action reduces the possibility of the steering wheel being driven rearward towards the driver. If the
driver is thrown forward into the steering wheel, the column can collapse even further at the same
controlled rate, thereby reducing the force of impact. Several designs of steering column jackets
are used. There is the slip-tube design which is held together with plastic inserts or rivets that shear
upon impact and allow the column to collapse. And there is the slotted or corrugated mesh design
and bellows type design which shorten in length during impact. The shift tube is a two piece design
which is held together by injections of plastic that form the interconnecting inserts and shear pins.
Under impact, there is a gradual paring away of the inserts by the knife-like edge in the adjoining
tube section. The steering shaft is a two piece assembly. The upper piece is solid and has a double
flattened lower end. The lower piece is hollow and formed to fit over the double flattened section of
the upper piece. The purpose of the double flattened section is to provide continued steering action
even though the shaft is completely collapsed. Upon impact, the shear pins break off and the shaft
gradually telescopes against resistance provided by the plastic injections. The steering column
mounting bracket prevents the column from being shifted towards the driver during impact. It uses
two ``breakaway capsules'' that allow the mounting bracket to slip off its attaching points, allowing
the steering column to compress or yield in a forward direction under a severe impact from the
driver's end.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation
Steering Column: Service and Repair Removal and Installation
1980-87 E100-350 SERIES Removal
1. Apply parking brake and disconnect battery ground cable.
2. Remove two flexible coupling to steering shaft flange attaching nuts.
3. Remove shift linkage rod(s) from steering column.
4. Set wheels in straight ahead position and mark relationship of steering wheel and steering
column for proper installation.
5. Remove screws from underneath steering wheel, then lift horn switch assembly from steering
wheel.
6. Disconnect horn switch wires by pulling spade terminal from blade connectors, then squeeze
J-clip ground wire terminal and pull it out of hole in steering wheel.
7. Remove horn switch assembly, then the steering wheel retaining nut.
8. Using suitable puller, remove steering wheel from shaft. When servicing a tilt steering column,
the steering wheel must be in the full ``UP'' position when removed.
9. Remove steering column floor opening cover plate screws.
10. On 1980-81 models, remove shroud by pulling shroud tabs out of clip at bottom of column.
11. On 1982-87 models, remove shroud by loosening screw at bottom, placing shift lever in ``1'' on
manual 3 speed and automatic transmission models, and spreading shroud and withdrawing it from
instrument panel opening while pulling up and away from column.
12. Remove instrument cluster column opening cover.
13. Remove two column bracket to pedal support bracket attaching screws.
14. Disconnect turn signal/hazard warning and ignition switch wiring harnesses.
15. Remove steering column from vehicle, then the support bracket from column.
Installation
1. Position steering column in vehicle.
2. Connect turn signal/hazard warning and ignition switch wiring harnesses.
3. Insert steering shaft flange through floor opening so that flange engages flexible coupling, then
raise steering column up to pedal support bracket and loosely install column support bolts. When
the column has been removed, the flange assembly will be fully telescoped into the column. Gently
tap flange down to engage flexible coupling.
4. Loosely install flexible coupling flange nuts and floor plate fasteners.
5. Position steering wheel into place with retaining nut, aligning marks made during removal, and
torque nut to 30-40 ft. lbs.
6. Connect spade terminal of horn switch wire to blade connector and press J-clip ground terminal
fully into threaded hole.
7. Center horn switch on steering wheel and install attaching screws.
8. On 1980-81 models, align steering column and flexible coupling as follows:
a. Pull steering column upward until flexible coupling is positioned between flat, and concaved
upward {1/10} inch. b. Torque steering column to support bracket and steering column opening
cover plate to dash panel bolts to 8-20 ft. lbs. c. Insert a .010 inch shim between flexible coupling
right safety pin and steering column lower flange cutout then turn steering wheel one
revolution clockwise.
d. If shim cannot be removed, loosen cover plate clamp and plate attaching bolts and realign
column until shim can be removed when rotating
steering wheel.
e. Insert .010 inch shim between flexible coupling left safety pin and lower flange cutout, then turn
steering wheel one revolution
counterclockwise and check as in step 8d.
f. Install trim cover.
9. On 1982-87 models, align steering column and flexible coupling as follows:
a. Check for coupling pin to flange cutout clearance of .160 inch, adjusting as necessary. b. Torque
flange coupling nuts to 14-21 ft. lbs., steering column to support bracket bolts to 19-27 ft. lbs.,
steering column floor opening cover
plate to dash panel bolts to 12-18 ft. lbs., and steering column opening cover clamp bolt to 12-18 ft.
lbs.
10. Attach shift linkage rod(s).
11. Connect battery ground cable.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation > Page 5463
Steering Column: Service and Repair Disassembly
Non-Tilt Column
Fig. 1 Exploded view of non-tilt steering column. 1980---87 Bronco & F100-350 Series w/3 speed
man. trans.
Fig. 2 Exploded view of non-tilt steering column. 1980---87 Bronco & F100-350 Series w/4 speed
man. trans.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation > Page 5464
Fig. 3 Exploded view of non-tilt steering column. 1980---87 Bronco & F100-350 Series w/auto.
trans.
1. Remove turn signal lever.
2. On vehicles equipped with 3 speed manual or automatic transmission, drive out pivot pin and
remove hand shift lever.
3. Partially withdraw turn signal/hazard warning switch, and key warning buzzer terminal if
equipped, from upper flange, Figs. 1, 2 and 3.
4. Remove snap ring from upper steering shaft.
5. Remove lower bearing retainer from bottom of steering column.
6. Using suitable tool, gently tap steering shaft out of bottom of steering column. Harsh impacts at
either end of shaft may alter shaft in overall length, adversely affecting assembly.
7. On 1982 vehicles equipped with automatic transmission, remove shift tube retaining screw from
bottom of shift socket.
8. On 1983-87 vehicles equipped with automatic transmission, drill out shift tube retaining rivet from
bottom of shift socket.
9. On vehicles equipped with 3 speed manual or automatic transmission, withdraw shift tube
assembly from bottom of column.
10. On all vehicles, clip ignition switch in lock position and remove ignition switch and actuator rod.
11. On E100-350 equipped with automatic transmission, remove PRNDL21 hood and lens
assembly.
12. On all vehicles, loosen upper flange retaining nuts until only 1 or 2 threads remain engaged,
then pinch nuts toward each other and withdraw upper flange from outer tube.
13. On vehicles equipped with 3 speed manual or automatic transmission, remove shift socket from
outer tube.
14. On vehicles equipped with 4 speed manual transmission, remove flange extension from outer
tube.
15. Remove upper bearing and insulator cover from upper flange by gently tapping from opposite
side.
16. Remove flange retaining bolts and nuts.
17. On vehicles with manual transmission, remove snap ring from lock release lever assembly.
18. On vehicles equipped with manual transmission, remove lock release lever assembly through
hole on front of flange and remove spring from assembly.
19. On vehicles equipped with automatic transmission, remove PRNDL21 insert from front of
flange.
20. On all vehicles, place lock cylinder in ``Run'' position and remove retaining pin, then remove
lock cylinder from flange.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation > Page 5465
Fig. 11 Lower Bearing Retainer
21. Remove lock bearing snap ring, then the lock bearing.
22. Remove lock drive gear through lock cylinder opening, then the lock actuator assembly and
lock actuator insert.
23. On E100-350, disassemble steering column lower bearing retainer subassembly as follows:
a. Remove steering column lower bayonet flange and leaf spring, Fig. 10. Do not loosen leaf
spring. b. Remove lower bearing shaft clamp, bolt, and nut. c. Remove 3 screws and the lower
bearing assembly. d. Remove split retainer sleeve from lower bearing retainer assembly.
24. On vehicles equipped with 3 speed manual transmission, disassemble shift tube subassembly
as follows:
a. Hold shift tube above spring and push up and rotate lower shift arm until loading slot in arm
aligns with lower key. b. Remove lower arm and lower spacer. c. Rotate upper shift arm until
loading slot in arm aligns with lower key,then remove upper arm and upper spacer. d. Remove and
discard shift arm grommets.
Tilt Column
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation > Page 5466
Fig. 6 Exploded view of tilt steering column (typical). 1980---87 exc. Aerostar, Bronco II & 1983---87
Ranger
Fig. 7 Removing wire bale & tilt locking lever
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation > Page 5467
Fig. 8 Removing flange assembly pivot pins
1. Remove steering wheel and steering column, Fig. 6, from vehicle.
2. Remove turn signal actuator lever.
3. On models equipped with automatic transmission, drive out pivot pin and remove shift lever.
4. On 1980-S81 E100-S350 models, remove steering shaft lower flange and retaining clamp.
5. On all models, remove lower bearing retainer.
6. On models equipped with automatic transmission, remove shift tube retaining screw from bottom
of shift socket, then slide shift tube out of bottom of column.
7. On all models, remove lock drive gear.
8. Remove turn signal switch attaching screws, then the wiring harness-to-steering column tube
clips, if necessary.
9. Remove turn signal switch and harness from steering column.
10. Remove cover casting screws, then the casting from column.
11. Unhook and remove upper actuator from lower actuator.
12. Remove and discard lower flange-to-outer tube attaching screws.
13. Loosen ignition switch nut and washer assemblies and remove ignition rod from switch end.
14. Remove tilt mechanism, steering shaft and ignition actuation rod from steering column upper
end.
15. On models equipped with automatic transmission, remove shift socket, then the shift lever
indicator ring.
16. On models equipped with manual transmission, remove flange extension, then the key release
lever mechanism from tilt mechanism.
17. On all models, remove spring clips holding wire bale, then the bale, Fig. 7.
18. Drive out pin holding locking lever, then remove the lever and spring.
19. Remove column upper shaft snap ring.
20. Remove two pivot pins from side of casting assembly, then separate upper and lower flange
castings, Fig. 8. If pivot pins fit loosely in the lower flange, the pins must be discarded.
21. Position flange casting on suitable workbench with smaller bearing facing down.
22. Lightly tap on outer race of small bearing at each slot, using a small drift, and remove race and
bearing.
23. Invert flange casting and repeat step 22 on large bearing.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation > Page 5468
Steering Column: Service and Repair Assembly
Non-Tilt Column
1. On vehicles equipped with 3 speed manual transmission, place bushing in socket retainer in
outer tube.
2. On vehicles equipped with 3 speed manual transmission, place bushing on upper hub and wave
washer on lower hub of shift socket.
3. On vehicles equipped with 3 speed manual or automatic transmission, install shift socket in outer
tube.
4. On vehicles equipped with 4 speed manual transmission, install flange extension on outer tube.
5. Install lock actuator insert in rear of flange and torque screw to 15---25 inch lbs.
6. Insert lock actuator assembly through opening in front of flange until it bottoms against insert.
7. Install lock drive gear through lock cylinder opening so that last gear tooth aligns with last tooth
on actuator assembly when actuator is fully rearward.
8. Install lock bearing, then the lock bearing snap ring.
9. Place lock cylinder in ``ON'' position and depress retaining pin, then insert lock cylinder into
flange.
10. On vehicles equipped with automatic transmission, attach PRNDL21 insert to front of flange.
11. On vehicles equipped with manual transmission, position spring on lock release lever assembly
and position lever assembly through hole in front of flange, then tighten spring until lever assembly
drops into place.
12. On vehicles equipped with manual transmission, install snap ring on lock release lever
assembly.
13. On all vehicles, install flange retaining bolts through holes in flange and hand start nuts 1 to 2
threads.
14. On vehicles equipped with automatic transmission, place wave washer in flange hub.
15. Install subassembled flange onto outer tube by pinching nuts toward each other and pressing
flange in place, then torque nuts to 60---75 inch lbs.
16. On vehicles equipped with 3 speed manual transmission, assemble shift tube assembly as
follows:
a. Install grommets in shift tube, small end facing up. b. Stack upper spacer, upper arm, lower
spacer, and lower arm concentrically in order so that loading slots align. c. Press entire stack
through common loading slot on shift tube, then rotate stack components individually until arms are
aligned with their
keyways on shift key and spacers allow shift key to pass freely through operating slots.
17. On vehicles with 3 speed manual transmission, load shift tube assembly through lower opening
of column.
18. On vehicles equipped with automatic transmission, install shift tube retaining rivet through
bottom of shift socket.
19. On all vehicles, install steering shaft clip below knurl for upper bearing.
20. On Bronco and F100-350, ensure that shaft assembly length is 35.6 inches, adjusting as
necessary by tapping gently in appropriate direction.
21. Load shaft through bottom of column, being careful not to collapse steering shaft on Bronco
and F100-350.
22. Place cover insulator onto upper bearing and press onto knurl of steering shaft until snap ring
groove is visible above bearing.
23. Install snap ring on steering shaft in groove above bearing.
24. Install turn signal/hazard warning switch, torquing screws to 15---25 inch lbs.
25. On E100-350, subassemble lower bearing retainer assembly as follows:
a. Install split retainer sleeve into lower bearing retainer assembly with sleeve shoulder against
bearing. b. Loosely assemble clamp, bolt, and nut to lower bearing retainer assembly, ensuring that
bolt aligns with round groove in split retainer sleeve. c. Push split retainer sleeve shoulder down
and push clamp toward bearing, and torque clamp nut to 9-18 ft. lbs.
26. On Bronco and F100-350, install lower bearing retainer, ensuring that centerline of coupling
shaft attachment hole extends .8 inch below lower face of retainer, and torque screws to 12-20 inch
lbs.
27. On E100-350, install lower bearing retainer and telescope steering column lower bayonet shaft
fully toward lower end of column.
28. Install ignition switch actuator rod.
29. Install ignition switch and hand start retaining nuts with lock cylinder in lock position.
30. Torque switch retaining nuts to 40-65 inch lbs. and remove clip.
31. Install hand shift lever and secure by driving in pivot pin.
32. Install turn signal switch lever, torquing screws to 30---45 inch lbs.
AEROSTAR, BRONCO II & 1983-87 RANGER
Tilt Column
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and
Repair > Removal and Installation > Page 5469
Fig. 6 Installing Flange Assembly Pivot Pins
1. Position flange casting on suitable work bench with large bearing seat facing up.
2. Place large upper bearing over seat with open side facing inward. Position a suitable socket on
bearing outer race and lightly tap socket until bearing is seated. Use care to avoid contacting
bearing inner race as damage will result.
3. Invert flange casting and repeat step 2 on small bearing.
4. Install lower actuator with ignition switch rod attached.
5. Install upper and lower flanges with pivot pins. Ensure column position spring is seated properly
between upper and lower flange and wavy thrust washer is properly positioned between lower
flange and socket.
6. Install column upper shaft snap ring.
7. Install locking lever, spring and lever pin.
8. Position wire bale on upper casting and install spring clips, Fig. 9.
9. On models equipped with automatic transmission, install shift lever indicator ring on tilt
mechanism. Torque attaching screws to 10-20 inch lbs., then install shift socket.
10. On models equipped with manual transmission, attach key release mechanism to tilt
mechanism, then install flange extension and torque attaching screws to 10-20 inch lbs.
11. On all models, install tilt mechanism. Feed steering shaft down center of column and ignition
actuation rod through shift socket/flange extension along top of column outer tube.
12. Install flange retainer assemblies. Use new screws and torque to 50-68 inch lbs.
13. Install lower bearing retainer, then loosely attach ignition switch to outer tube.
14. Connect upper and lower actuators, then install column cover. Torque cover attaching screws
to 40-50 inch lbs.
15. Position turn signal switch and wiring harness in steering column. Attach wiring harness to
steering column tube clips, if necessary.
16. Install turn signal switch attaching screws and torque to 20-30 inch lbs.
17. Install turn signal lever, then the lock drive gear.
18. Install lock cylinder with key in ``On'' position. Ensure retaining pin is flush with cylinder.
19. On models equipped with automatic transmission, install shift lever and pivot pin.
20. On all models, install steering column.
1982-87 BRONCO, E100-350 & F100-350 SERIES, NON-TILT STEERING COLUMN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Sector Shaft > Component Information >
Adjustments
Sector Shaft: Adjustments
PITMAN SHAFT OVERCENTER PRELOAD
1. Perform steps 1 through 3 of ``Worm Bearing Preload, Adjust'' procedure.
2. Rotate worm shaft from one extreme to the other while counting total number of turns. Turn
worm shaft back halfway to center gear.
3. Using inch pound torque wrench, rotate worm shaft approximately 90 degrees across center.
Highest reading should be within specifications listed at end of section. Turn sector shaft adjusting
screw until proper specification is obtained.
4. Hold sector shaft adjusting screw and tighten locknut to 25 ft. lbs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Description
and Operation
Axle Beam: Description and Operation
Fig. 1 Twin I-Beam front axle
Fig. 2 Spindle used with twin I Beam front axle. Typical
EXC. 4 WHEEL DRIVE MODELS
Twin I-Beam Axle As illustrated in Fig. 1 there are two I-beam axles, one for each front wheel. One
end of each axle is attached to the spindle and a radius arm and the other end is attached to a
frame bracket on the opposite side of the vehicle. Each spindle is held in place on the axle by ball
joints or a spindle bolt which pivots in bushings pressed in the upper and lower ends of the spindle,
Fig. 2. On models equipped with spindle bolts, a thrust bearing is installed between the lower end
of the axle and the spindle to support the load on the axle. On all models, a spindle arm is installed
on each spindle for attachment to the steering linkage.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical
Service Bulletins > Customer Interest for Cross-Member: > 902317 > Nov > 90 > Driveline - Vibration Cross Member Cracks
Cross-Member: Customer Interest Driveline - Vibration Cross Member Cracks
^ VIBRATION - DRIVELINE - VEHICLES WITH C6 TRANSMISSION
^ DRIVELINE - VIBRATION - VEHICLES WITH C6 TRANSMISSION
Article No. 90-23-17 LIGHT TRUCK:
1987-88 E-350
ISSUE: A driveline vibration may be caused by a crack in the crossmember between the
transmission mounting bolts. This may occur on high GVW applications and trucks making multiple
stops and starts.
ACTION: Install a new # 2 transmission cross member if any cracks are found during the
inspection. Refer to the following procedure for service details. If no cracks are found, refer to the
NVH diagnostics in the 1987-88 Light Truck Shop Manual, Volume A, Section 18-01 for corrective
action.
Figure 1
1. Remove and throw away the cracked transmission cross member. Refer to the 1987-88 Light
Truck Shop Manual, Volume A, Section 17-01 for removal procedure.
2. Inspect the transmission insulator for damage.
a. If any damage is detected, replace the transmission insulator. Clean the threads with Ford Spot &
Stain Remover (B7A-19521-AA).
b. If the transmission insulator is not damaged, clean the bolt threads with a wire brush and Ford
Spot & Stain Remover (B7A-19521-AA).
3. Replace the insulator nuts and washers with new ones (N621945-S2).
4. Throw away the cross member to frame bolts and nuts. Replace them with new ones.
5. Apply Threadlocker 262 to all fasteners (Cross member-to-frame and cross member-to-insulator
nut). Be sure that all fastener surfaces are cleaned with Ford Spot & Stain Remover
(B7A-19521-AA).
6. Loosely install the new # 2 transmission cross member (E8UZ-6A023-A) to the frame side rails.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical
Service Bulletins > Customer Interest for Cross-Member: > 902317 > Nov > 90 > Driveline - Vibration Cross Member Cracks
> Page 5486
Figure 2
7. Loosely install a fabricated reinforcement strap under the cross member.
a. Refer to Figure 2 for strap specifications and dimensions
b. Start nuts and run up to the point where they will hold the reinforcement strap in place.
8. Tighten the cross member-to-frame bolts and nuts to 65-70 lb.ft. (88-95 N-m).
9. Tighten the transmission insulator nuts to 75-80 lb.ft. (102-108 N-m).
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
902317A Install Cross member 1.1 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
6A023 01
OASIS CODES: 703000, 305000, 504000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Cross-Member: > 902317 > Nov > 90 > Driveline - Vibration Cross
Member Cracks
Cross-Member: All Technical Service Bulletins Driveline - Vibration Cross Member Cracks
^ VIBRATION - DRIVELINE - VEHICLES WITH C6 TRANSMISSION
^ DRIVELINE - VIBRATION - VEHICLES WITH C6 TRANSMISSION
Article No. 90-23-17 LIGHT TRUCK:
1987-88 E-350
ISSUE: A driveline vibration may be caused by a crack in the crossmember between the
transmission mounting bolts. This may occur on high GVW applications and trucks making multiple
stops and starts.
ACTION: Install a new # 2 transmission cross member if any cracks are found during the
inspection. Refer to the following procedure for service details. If no cracks are found, refer to the
NVH diagnostics in the 1987-88 Light Truck Shop Manual, Volume A, Section 18-01 for corrective
action.
Figure 1
1. Remove and throw away the cracked transmission cross member. Refer to the 1987-88 Light
Truck Shop Manual, Volume A, Section 17-01 for removal procedure.
2. Inspect the transmission insulator for damage.
a. If any damage is detected, replace the transmission insulator. Clean the threads with Ford Spot &
Stain Remover (B7A-19521-AA).
b. If the transmission insulator is not damaged, clean the bolt threads with a wire brush and Ford
Spot & Stain Remover (B7A-19521-AA).
3. Replace the insulator nuts and washers with new ones (N621945-S2).
4. Throw away the cross member to frame bolts and nuts. Replace them with new ones.
5. Apply Threadlocker 262 to all fasteners (Cross member-to-frame and cross member-to-insulator
nut). Be sure that all fastener surfaces are cleaned with Ford Spot & Stain Remover
(B7A-19521-AA).
6. Loosely install the new # 2 transmission cross member (E8UZ-6A023-A) to the frame side rails.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Cross-Member: > 902317 > Nov > 90 > Driveline - Vibration Cross
Member Cracks > Page 5492
Figure 2
7. Loosely install a fabricated reinforcement strap under the cross member.
a. Refer to Figure 2 for strap specifications and dimensions
b. Start nuts and run up to the point where they will hold the reinforcement strap in place.
8. Tighten the cross member-to-frame bolts and nuts to 65-70 lb.ft. (88-95 N-m).
9. Tighten the transmission insulator nuts to 75-80 lb.ft. (102-108 N-m).
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
902317A Install Cross member 1.1 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
6A023 01
OASIS CODES: 703000, 305000, 504000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Spindle
REMOVE
1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly.
3. Remove the caliper assembly from the rotor and hold it out of the way with wire. 4. Remove the
dust cap, cotter pin, nut retainer, nut, washer, and outer bearing, and remove the rotor from the
spindle. 5. Remove inner bearing cone and seal. Discard the seal. 6. Remove brake dust shield. 7.
Disconnect the steering linkage from the spindle arm by removing the cotter pin and nut, and then
removing the tie rod end from the spindle arm
with tie Rod End Remover, TOOL-3290-D or equivalent.
8. Remove the nut and lockwasher from the lock pin, and remove the lock pin. 9. Remove the
upper and lower spindle pin plugs; then, drive the spindle pin out from the top of the axle and
remove the spindle and thrust bearing.
Remove the spindle pin seal and thrust bearing.
INSTALL
1. Make sure the spindle pin hole in the axle is free of nicks, burrs, corrosion or foreign material.
Clean up the bore as necessary and lightly coat the
surface with a lithium-base grease, Long-Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or
equivalent.
2. Install a new spindle pin seal with the metal backing facing up towards the bushing into the
spindle. Gently press seal into position, being careful
not to distort the casing.
3. Install a new thrust bearing with the lip flange facing down towards the lower bushing. Press until
the bearing is firmly seated against the surface
of the spindle.
4. Lightly coat the bushing surfaces with grease and place the spindle in position on the axle. 5.
Hold the spindle with thrust bearing in place tight against the axle and measure the space between
the axle and the spindle at the top of the axle. If
the vehicle uses shims, select the proper shims and install.
6. Install the spindle pin with the "T" stamped on one end towards the top, and the notch in the pin
aligned with the lock pin hole in the axle. Insert
the spindle pin through the bushings and axle from the top until the spindle pin notch and axle lock
pin hole are in line.
7. Install the lock pin with the threads pointing forward and the wedge groove facing the spindle pin
notch. Firmly drive the lock pin into position
and mount the lockwasher and nut. Tighten the nut to 52-84 Nm (38-62 ft lb).
8. Install the spindle pin plugs into the threads at the top and bottom of the spindle. Tighten the
plugs to 48-67 Nm (35-50 ft lb). 9. Lubricate the spindle pin and bushings with Long-Life Lubricant
C1AZ-19590-BA (ESA-M1C75-B) or equivalent, through both fittings until
grease is visible seeping past the upper seal at the top and from the thrust bearing slip joint at the
bottom. If grease does not appear, recheck the installation procedure to correct the problem. Lack
of adequate lubrication will result in rapid failure of the spindle components.
10. Install the dust shield. 11. Pack the inner and outer bearing cone with bearing grease. Use a
bearing packer. If a bearing packer is unavailable, pack the bearing cone by hand
working the grease through the cage behind the rollers.
12. Install the inner bearing cone and seal. Install the hub and rotor on the spindle. 13. Install the
outer bearing cone, washer, and nut. Adjust bearing end play and install the nut retainer, cotter pin
and dust cap. 14. Install the caliper.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 5496
15. Connect the steering tie rod and drag link (if equipped) to the spindle. Tighten the nut to
specifications and advance the nut as required for
installation of the cotter pin.
16. Install the wheel and tire assembly. 17. Lower the vehicle. 18. Check and, if necessary adjust
the toe setting.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > King Pin > Component Information > Service and
Repair
King Pin: Service and Repair
Spindle Bushings
Spindle Bushing Tools
REMOVE
1. Remove the spindle. Refer to Spindle/Service and Repair. 2. The bronze spindle bushings have
an inside diameter of 1.0552/1.0562 inch, use the following tools: Reamer D82T-3110-A, Bushing
Remover/Installer Driver, D82T-3110-B and Driver Handle D82T-3110-C or equivalents.
NOTE: Each side of the Bushing Remover/Installer Driver tool is marked with a "T" or a "B". Use
the side with the "T" stamping to install the top spindle bushing. Use the side with the "B" stamping
to install the bottom spindle bushing.
3. Remove and discard the seal from the bottom of the upper bushing bore of the upper spindle
yoke.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > King Pin > Component Information > Service and
Repair > Page 5500
Spindle Bushing Service
4. Remove and install the top spindle bushing first. Install the driver handle through the bottom
bore. Position a new bushing on the "T" side
stamping of the bushing Remover/Installer Driver. The bushing must be installed on the tool so the
open end grooves will face outward when installed. Position the new bushing and driver over the
old bushing, insert the handle into the driver and drive the old bushing out while the new bushing is
driven in. Drive until the tool is seated. The bushing will then be seated at the proper depth (2.03
mm [0.080 inch)] minimum from bottom of upper spindle boss).
Spindle Bushing Service
5. Remove and install the bottom spindle bushing. Install the Driver Handle through the top bushing
bore. Position a new bushing on the "B" side
stamping of the Bushing Remover/Installer Driver. The bushing must be installed on the tool so the
open-end grooves will face outward when installed. Position the new bushing and driver over the
old bushing in the bottom spindle bore. Insert the handle into the driver and drive the old bushing
out while the new bushing is driven in. Drive until the tool is seated. The bottom bushing will then
be seated at the proper depth (3.30 mm [0.130 inch] minimum from the top of the lower spindle
boss).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > King Pin > Component Information > Service and
Repair > Page 5501
Spindle Bushing Service
6. Ream the new bushings to 0.025-0.076 mm (0.001-0.003 inch) larger than the diameter of a new
spindle pin. Ream the top bushing first with the
reamer tool. Install the smaller diameter of the tool through the top bore and into the bottom bore
until the reaming threads are in position in the top bushing. Turn the tool until the threads exit the
top bushing. Ream the bottom bushing. The larger diameter portion of the tool will act as a pilot in
the top bushing to properly ream the bottom bushing.
7. Clean all the metal shavings from the bronze bushings after reaming. Coat the bushings and
spindle pin with Long Life Lubricant,
C1AZ-19590-BA (ESA-M1C75-B) or equivalent.
8. Install a new seal on Bushing Remover/Installer Driver tool on the side with the "T" stamping.
Install the handle into the driver and push the seal
into position in the bottom of the top bushing bore.
INSTALL
1. Reverse removal procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Radius Arm Bushing > Component
Information > Technical Service Bulletins > Customer Interest for Radius Arm Bushing: > 871122 > Jun > 87 > Front
Suspension - Squeaking Noise
Radius Arm Bushing: Customer Interest Front Suspension - Squeaking Noise
NOISE - "SQUEAK" - RADIUS ARM BUSHING Article No.
SPACER 87-11-22
LIGHT TRUCK: 1987 ECONOLINE
ISSUE: A "squeaking" noise from the front suspension when the brakes are applied at low speeds
may be caused by the radius arm bushing spacer. The bushing spacer may rub on the radius arm
stud during braking and squeak once the paint on the stud wears off (1000-2000 miles/1600-3200
kilometers).
Figure 18 - Article 87-11-22
ACTION: To correct this, install a pre-1987 level inner insulator (C5TZ-3B203-E), bushing spacer
(D7UZ-3B244-C), and outer insulator (C5TZ-3B203-D) on each radius arm using the following
service procedure, Figure 18.
NOTE: All three (3) parts MUST be changed at the same time to make sure the repair is effective.
NOTE: The 1987 level and pre-1987 level bushing spacer share the same service part number.
However, they are not interchangeable and the 1987 level spacer MUST not be used. The bushing
spacer(s) can be identified as follows.
Spacer Color Outside Diameter
1987 Level Dark Gray 70.0 mm dia. (2.7 inch dia.)
Pre-1987 Level Light Gray 64.0 mm dia. (2.5 inch dia.)
1. Raise vehicle and support front of vehicle on frame jacks.
2. Remove front tires/wheels.
3. Remove left radius arm nut and retainer.
4. Remove left radius arm to frame bracket.
5. Replace radius arm inner bushing and bushing spacer.
6. Install radius arm bracket. Torque bolts 75-105 ft.lbs. (102-142 N-m).
7. Install outer bushing, retainer, and nut. Torque nut 80-120 ft.lbs. (109-162 N-m).
8. Remove bolts holding fuel filter and position aside.
9. Remove transmission crossmember.
10. Remove exhaust system.
11. Remove right radius arm nut and retainer.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Radius Arm Bushing > Component
Information > Technical Service Bulletins > Customer Interest for Radius Arm Bushing: > 871122 > Jun > 87 > Front
Suspension - Squeaking Noise > Page 5511
12. Remove right radius arm to frame bracket.
13. Replace inner bushing and bushing spacer.
14. Position bracket to radius arm with outer bushing, retainer, and nut.
15. Install radius arm bracket to frame. Torque bolts 75-105 ft.lbs. (102-142 N-m).
16. Torque nut in Step 14 to 80-120 ft.lbs. (109- 162 N-m).
17. Install exhaust system.
18. Install transmission crossmember.
19. Reposition fuel filter and install bolts.
20. Install front tires/wheels.
21. Remove frame jacks and lower vehicle.
PART NUMBER PART NAME CLASS
C5TZ-3B203-E Insulator - Inner A
D7UZ-3B244-C Bushing Spacer B
C5TZ-3B203-D Insulator - Outer A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP871122A TIME:
1.3 Hrs.
DLR. CODING: Basic Part No. 3B244 - Code: 56
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Radius Arm Bushing > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Radius Arm Bushing: > 871122 > Jun > 87 >
Front Suspension - Squeaking Noise
Radius Arm Bushing: All Technical Service Bulletins Front Suspension - Squeaking Noise
NOISE - "SQUEAK" - RADIUS ARM BUSHING Article No.
SPACER 87-11-22
LIGHT TRUCK: 1987 ECONOLINE
ISSUE: A "squeaking" noise from the front suspension when the brakes are applied at low speeds
may be caused by the radius arm bushing spacer. The bushing spacer may rub on the radius arm
stud during braking and squeak once the paint on the stud wears off (1000-2000 miles/1600-3200
kilometers).
Figure 18 - Article 87-11-22
ACTION: To correct this, install a pre-1987 level inner insulator (C5TZ-3B203-E), bushing spacer
(D7UZ-3B244-C), and outer insulator (C5TZ-3B203-D) on each radius arm using the following
service procedure, Figure 18.
NOTE: All three (3) parts MUST be changed at the same time to make sure the repair is effective.
NOTE: The 1987 level and pre-1987 level bushing spacer share the same service part number.
However, they are not interchangeable and the 1987 level spacer MUST not be used. The bushing
spacer(s) can be identified as follows.
Spacer Color Outside Diameter
1987 Level Dark Gray 70.0 mm dia. (2.7 inch dia.)
Pre-1987 Level Light Gray 64.0 mm dia. (2.5 inch dia.)
1. Raise vehicle and support front of vehicle on frame jacks.
2. Remove front tires/wheels.
3. Remove left radius arm nut and retainer.
4. Remove left radius arm to frame bracket.
5. Replace radius arm inner bushing and bushing spacer.
6. Install radius arm bracket. Torque bolts 75-105 ft.lbs. (102-142 N-m).
7. Install outer bushing, retainer, and nut. Torque nut 80-120 ft.lbs. (109-162 N-m).
8. Remove bolts holding fuel filter and position aside.
9. Remove transmission crossmember.
10. Remove exhaust system.
11. Remove right radius arm nut and retainer.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Radius Arm Bushing > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Radius Arm Bushing: > 871122 > Jun > 87 >
Front Suspension - Squeaking Noise > Page 5517
12. Remove right radius arm to frame bracket.
13. Replace inner bushing and bushing spacer.
14. Position bracket to radius arm with outer bushing, retainer, and nut.
15. Install radius arm bracket to frame. Torque bolts 75-105 ft.lbs. (102-142 N-m).
16. Torque nut in Step 14 to 80-120 ft.lbs. (109- 162 N-m).
17. Install exhaust system.
18. Install transmission crossmember.
19. Reposition fuel filter and install bolts.
20. Install front tires/wheels.
21. Remove frame jacks and lower vehicle.
PART NUMBER PART NAME CLASS
C5TZ-3B203-E Insulator - Inner A
D7UZ-3B244-C Bushing Spacer B
C5TZ-3B203-D Insulator - Outer A
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP871122A TIME:
1.3 Hrs.
DLR. CODING: Basic Part No. 3B244 - Code: 56
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and
Repair
Spindle: Service and Repair
Spindle
REMOVE
1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly.
3. Remove the caliper assembly from the rotor and hold it out of the way with wire. 4. Remove the
dust cap, cotter pin, nut retainer, nut, washer, and outer bearing, and remove the rotor from the
spindle. 5. Remove inner bearing cone and seal. Discard the seal. 6. Remove brake dust shield. 7.
Disconnect the steering linkage from the spindle arm by removing the cotter pin and nut, and then
removing the tie rod end from the spindle arm
with tie Rod End Remover, TOOL-3290-D or equivalent.
8. Remove the nut and lockwasher from the lock pin, and remove the lock pin. 9. Remove the
upper and lower spindle pin plugs; then, drive the spindle pin out from the top of the axle and
remove the spindle and thrust bearing.
Remove the spindle pin seal and thrust bearing.
INSTALL
1. Make sure the spindle pin hole in the axle is free of nicks, burrs, corrosion or foreign material.
Clean up the bore as necessary and lightly coat the
surface with a lithium-base grease, Long-Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or
equivalent.
2. Install a new spindle pin seal with the metal backing facing up towards the bushing into the
spindle. Gently press seal into position, being careful
not to distort the casing.
3. Install a new thrust bearing with the lip flange facing down towards the lower bushing. Press until
the bearing is firmly seated against the surface
of the spindle.
4. Lightly coat the bushing surfaces with grease and place the spindle in position on the axle. 5.
Hold the spindle with thrust bearing in place tight against the axle and measure the space between
the axle and the spindle at the top of the axle. If
the vehicle uses shims, select the proper shims and install.
6. Install the spindle pin with the "T" stamped on one end towards the top, and the notch in the pin
aligned with the lock pin hole in the axle. Insert
the spindle pin through the bushings and axle from the top until the spindle pin notch and axle lock
pin hole are in line.
7. Install the lock pin with the threads pointing forward and the wedge groove facing the spindle pin
notch. Firmly drive the lock pin into position
and mount the lockwasher and nut. Tighten the nut to 52-84 Nm (38-62 ft lb).
8. Install the spindle pin plugs into the threads at the top and bottom of the spindle. Tighten the
plugs to 48-67 Nm (35-50 ft lb). 9. Lubricate the spindle pin and bushings with Long-Life Lubricant
C1AZ-19590-BA (ESA-M1C75-B) or equivalent, through both fittings until
grease is visible seeping past the upper seal at the top and from the thrust bearing slip joint at the
bottom. If grease does not appear, recheck the installation procedure to correct the problem. Lack
of adequate lubrication will result in rapid failure of the spindle components.
10. Install the dust shield. 11. Pack the inner and outer bearing cone with bearing grease. Use a
bearing packer. If a bearing packer is unavailable, pack the bearing cone by hand
working the grease through the cage behind the rollers.
12. Install the inner bearing cone and seal. Install the hub and rotor on the spindle. 13. Install the
outer bearing cone, washer, and nut. Adjust bearing end play and install the nut retainer, cotter pin
and dust cap. 14. Install the caliper.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and
Repair > Page 5521
15. Connect the steering tie rod and drag link (if equipped) to the spindle. Tighten the nut to
specifications and advance the nut as required for
installation of the cotter pin.
16. Install the wheel and tire assembly. 17. Lower the vehicle. 18. Check and, if necessary adjust
the toe setting.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information
> Service and Repair
Stabilizer Bar: Service and Repair
1. Disconnect both ends of stabilizer bar from link assembly on I-beam bracket.
2. On 1986---87 F-350 models equipped with Dana 60 Monobeam axle, remove nuts, washers and
bolts securing links to mounting brackets.
3. Remove stabilizer bar attaching bolts and the stabilizer bar. On 1980---87 F-150 4 4 and Bronco
models, the coil spring must be removed to facilitate removal of the stabilizer bar mounting bracket.
4. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Technical
Service Bulletins > Customer Interest for Subframe: > 902317 > Nov > 90 > Driveline - Vibration Cross Member Cracks
Subframe: Customer Interest Driveline - Vibration Cross Member Cracks
^ VIBRATION - DRIVELINE - VEHICLES WITH C6 TRANSMISSION
^ DRIVELINE - VIBRATION - VEHICLES WITH C6 TRANSMISSION
Article No. 90-23-17 LIGHT TRUCK:
1987-88 E-350
ISSUE: A driveline vibration may be caused by a crack in the crossmember between the
transmission mounting bolts. This may occur on high GVW applications and trucks making multiple
stops and starts.
ACTION: Install a new # 2 transmission cross member if any cracks are found during the
inspection. Refer to the following procedure for service details. If no cracks are found, refer to the
NVH diagnostics in the 1987-88 Light Truck Shop Manual, Volume A, Section 18-01 for corrective
action.
Figure 1
1. Remove and throw away the cracked transmission cross member. Refer to the 1987-88 Light
Truck Shop Manual, Volume A, Section 17-01 for removal procedure.
2. Inspect the transmission insulator for damage.
a. If any damage is detected, replace the transmission insulator. Clean the threads with Ford Spot &
Stain Remover (B7A-19521-AA).
b. If the transmission insulator is not damaged, clean the bolt threads with a wire brush and Ford
Spot & Stain Remover (B7A-19521-AA).
3. Replace the insulator nuts and washers with new ones (N621945-S2).
4. Throw away the cross member to frame bolts and nuts. Replace them with new ones.
5. Apply Threadlocker 262 to all fasteners (Cross member-to-frame and cross member-to-insulator
nut). Be sure that all fastener surfaces are cleaned with Ford Spot & Stain Remover
(B7A-19521-AA).
6. Loosely install the new # 2 transmission cross member (E8UZ-6A023-A) to the frame side rails.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Technical
Service Bulletins > Customer Interest for Subframe: > 902317 > Nov > 90 > Driveline - Vibration Cross Member Cracks >
Page 5533
Figure 2
7. Loosely install a fabricated reinforcement strap under the cross member.
a. Refer to Figure 2 for strap specifications and dimensions
b. Start nuts and run up to the point where they will hold the reinforcement strap in place.
8. Tighten the cross member-to-frame bolts and nuts to 65-70 lb.ft. (88-95 N-m).
9. Tighten the transmission insulator nuts to 75-80 lb.ft. (102-108 N-m).
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
902317A Install Cross member 1.1 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
6A023 01
OASIS CODES: 703000, 305000, 504000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Subframe: > 902317 > Nov > 90 > Driveline - Vibration Cross Member
Cracks
Subframe: All Technical Service Bulletins Driveline - Vibration Cross Member Cracks
^ VIBRATION - DRIVELINE - VEHICLES WITH C6 TRANSMISSION
^ DRIVELINE - VIBRATION - VEHICLES WITH C6 TRANSMISSION
Article No. 90-23-17 LIGHT TRUCK:
1987-88 E-350
ISSUE: A driveline vibration may be caused by a crack in the crossmember between the
transmission mounting bolts. This may occur on high GVW applications and trucks making multiple
stops and starts.
ACTION: Install a new # 2 transmission cross member if any cracks are found during the
inspection. Refer to the following procedure for service details. If no cracks are found, refer to the
NVH diagnostics in the 1987-88 Light Truck Shop Manual, Volume A, Section 18-01 for corrective
action.
Figure 1
1. Remove and throw away the cracked transmission cross member. Refer to the 1987-88 Light
Truck Shop Manual, Volume A, Section 17-01 for removal procedure.
2. Inspect the transmission insulator for damage.
a. If any damage is detected, replace the transmission insulator. Clean the threads with Ford Spot &
Stain Remover (B7A-19521-AA).
b. If the transmission insulator is not damaged, clean the bolt threads with a wire brush and Ford
Spot & Stain Remover (B7A-19521-AA).
3. Replace the insulator nuts and washers with new ones (N621945-S2).
4. Throw away the cross member to frame bolts and nuts. Replace them with new ones.
5. Apply Threadlocker 262 to all fasteners (Cross member-to-frame and cross member-to-insulator
nut). Be sure that all fastener surfaces are cleaned with Ford Spot & Stain Remover
(B7A-19521-AA).
6. Loosely install the new # 2 transmission cross member (E8UZ-6A023-A) to the frame side rails.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Subframe: > 902317 > Nov > 90 > Driveline - Vibration Cross Member
Cracks > Page 5539
Figure 2
7. Loosely install a fabricated reinforcement strap under the cross member.
a. Refer to Figure 2 for strap specifications and dimensions
b. Start nuts and run up to the point where they will hold the reinforcement strap in place.
8. Tighten the cross member-to-frame bolts and nuts to 65-70 lb.ft. (88-95 N-m).
9. Tighten the transmission insulator nuts to 75-80 lb.ft. (102-108 N-m).
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
902317A Install Cross member 1.1 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
6A023 01
OASIS CODES: 703000, 305000, 504000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Rear
Suspension Spring ( Coil / Leaf ): Service and Repair Rear
E-100---350
1. Raise rear of vehicle and support at frame. Support axle with a suitable jack.
2. Disconnect shock absorbers from lower mountings.
3. Remove 2 U-bolts and the U-bolt plate.
4. On E-100---150 models, lower axle assembly and remove upper and lower rear shackle bolts,
then pull rear shackle assembly from bracket and spring. Remove spring mounting nut and bolt,
then lower spring assembly from vehicle.
5. On E-250---350 models, lower axle assembly and remove spring front bolt from hanger. Remove
2 attaching bolts from rear of spring, then lower spring assembly from vehicle.
6. On all models, reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Rear > Page 5544
Suspension Spring ( Coil / Leaf ): Service and Repair Coil Spring
EXC. 4 WHEEL DRIVE MODELS
1. Raise front of vehicle and support with stands. Support axle with a suitable jack. The axle must
be supported when replacing spring and not be permitted to hang by brake hose. If length of brake
hose is not sufficient to permit spring replacement, it will be necessary to remove the disc brake
caliper. Do not suspend caliper by brake hose, if removed.
2. Disconnect shock absorber from lower mounting.
3. Remove spring upper retainer attaching bolts and the retainer.
4. Remove spring lower retainer attaching nut and the retainer.
5. Lower axle slowly and remove spring from vehicle.
6. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Air Shock Absorber
Suspension Strut / Shock Absorber: Service and Repair Front Air Shock Absorber
1. Disconnect shock absorber from upper mounting.
2. Disconnect shock absorber from lower mounting, then compress shock and remove from
vehicle.
3. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Front Air Shock Absorber > Page 5549
Suspension Strut / Shock Absorber: Service and Repair Rear
1. Raise and support rear of vehicle to a point where weight is relieved from rear springs and tires
are still in contact with floor.
2. Remove lower attaching nut and bolt from shock absorber and swing lower end free of mounting
bracket.
3. Remove upper attaching nut and the shock absorber.
4. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Wheel Bearing Torque Specification - Manual Correction
Wheel Bearing: Technical Service Bulletins Wheel Bearing Torque Specification - Manual
Correction
WHEEL BEARING - FRONT - ADJUSTING NUT TORQUE SPECIFICATION - SHOP MANUAL
CORRECTION
Article No. 88-4-15
LIGHT TRUCK: 1987-88 E-SERIES
ISSUE: The front wheel bearing adjusting nut torque specification as published in the 1987 and
1988 Light Truck Shop Manual, Volume A, Section 12-24-3, Figures 2 and 3 is incorrect.
ACTION: If service is required, torque the front wheel bearing adjusting nut to 22-25 ft.lbs. (30-33
N-m) and then back the adjusting nut off 1/8 turn as described in the Light Truck Shop Manual,
Volume A, Section 11-10-1.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 5554
Wheel Bearing: Specifications
Wheel Adjusting Nut [1] .......................................................................................................................
........................................... 30-33 Nm (22-25 ft lbs)
Bearing End Play
..............................................................................................................................................................
0.025-0.254mm (0.001-0.010 in)
[1] Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional
movement of the adjusting nut.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 5555
Wheel Bearing: Adjustments
1. Raise the vehicle until the tire clears the floor and install safety stands.
2. Remove the wheel cover.
3. Remove the grease cap from the hub. Wipe the excess grease from the end of the spindle.
Remove the cotter pin and locknut.
4. Loosen the adjusting nut three turns. Attempt to obtain running clearance between the rotor
brake surface and the disc pads by rocking the wheel,
hub and rotor assembly in and out several times to push the pads away from the rotor. If running
clearance cannot be maintained throughout bearing adjustment in Steps 5 and 6, the caliper must
be removed.
NOTE: Do not pry on the phenolic caliper piston.
5. Tighten the wheel adjusting nut to 30-33 Nm (22-25 ft lbs) while rotating the disc brake rotor in
the opposite direction.
6. Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional
movement of the adjusting nut. Bearing end play
should be 0.025-0.254mm (0.001-0.010 in). Bend the ends of the cotter pin around the castellated
flange of the locknut.
7. Check front wheel rotation. If the wheel rotates properly, reinstall the grease cap and wheel
cover. If rotation is noisy or rough, remove and inspect
the bearings. Service as required.
WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake
pedal travel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 5556
Wheel Bearing: Service and Repair
Wheel bearing lubricant is a lithium-base grease. Sodium-base grease is not compatible with
lithium-base grease and should not be intermixed. Therefore, do not lubricate front and/or rear
wheel bearings without first identifying the type of original wheel bearing lubricant. Usage of
incompatible bearing lubricants may result in premature lubricant breakdown.
REMOVAL
Front Hub And Rotor Assembly
1. Raise the vehicle until the tire clears the floor and remove the wheel and tire assembly.
2. Remove the brake caliper and secure to the underbody to prevent damage to the brake hose. It
is not necessary to disconnect the hose from the
caliper. Do not let the caliper hang with its weight on the brake hose or the hose may become
stretched, twisted or ruptured. See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair
3. Remove the grease cap, cotter pin, retainer adjusting nut and washer.
4. Remove the outer bearing cone and roller.
5. Pull the hub and rotor off the spindle and remove and discard the grease seal.
6. Remove the inner bearing cone and roller from the hub. Remove all traces of old lubricant from
bearings, hub and axle spindle.
7. Inspect the cups for scratches, pits or cracks. If the cups are worn or damaged, remove them
with a drift. Clean the inner and outer bearing cones
and rollers with solvent and dry thoroughly.
CAUTION: Do not spin the bearings dry with compressed air.
8. Inspect the cones and rollers for cracks, nicks, brinelling, or seized rollers. Inspect the grease
retainer and replace it if it is cracked, nicked, dented
or worn.
9. Cover the spindle with a clean cloth. A water dampened cloth or water based solution should be
used to remove and dust or loose dirt from the
brake assembly. Remove the cloth from the spindle carefully to prevent dirt from falling on the
spindle.
NOTE: Do not use compressed air.
INSTALLATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 5557
Installing Bearing Cups (Typical)
1. If inner or outer bearing cups were removed, install replacement inner and outer bearing cups in
the hub with the appropriate bearing cup replacer
tool. Be sure to seat the cups properly in the hub. The cups will be properly seated when they are
fully bottomed. Replace grease retainers. Polish grease retainer journal on spindle with 400 grit
sandpaper. Clean with clean cloth.
2. Pack the inside of the hub with lithium-base grease or equivalent. Fill the hub until the grease is
flush with the inside diameters of both bearing
cups. Pack the bearing cones and rollers with wheel bearing grease. Use a bearing packer for this
operation. If a packer is not available, work as much lubricant as possible between the rollers and
cages. Lubricate the cone surfaces with grease.
Installing Grease Seal (Typical)
3. Place the inner bearing cone and roller in the inner cup and install the new grease seal. Be sure
that the seal is fully seated.
4. Install the hub and rotor on the wheel spindle. Keep the hub centered on the spindle to prevent
damage to the grease retainer or the spindle threads.
5. Install the outer bearing cone and roller and the flat washer on the spindle, then install the
adjusting nut, and adjust the wheel bearing.
6. Install the retainer, new cotter pin, and grease cap.
7. Install the caliper.
8. Install the wheel and tire assembly.
9. Lower vehicle and torque the lug nuts to specification. Re-install the wheel cover or hub cap.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical
Service Bulletins > Page 5558
WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake
pedal travel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical
Service Bulletins > Customer Interest for Wheel Hub: > 932514 > Dec > 93 > Full Float Rear Hub/Shaft - Lubricant Leaks
Wheel Hub: Customer Interest Full Float Rear Hub/Shaft - Lubricant Leaks
Article No. 93-25-14
12/08/93
^ AXLE - "DANA" FULL FLOAT REAR - NEW HUB/SHAFT BOLTS AND REVISED TORQUE
SPECIFICATIONS
^ AXLE - "DANA" FULL FLOAT REAR - SHAFT/HUB BOLTS LOOSEN AND LEAK AXLE LUBE SERVICE TIPS
^ LEAKS - AXLE LUBE - REAR AXLE SHAFT/HUB BOLTS LOOSEN - SERVICE TIPS
LIGHT TRUCK: 1980-94 E-350 1988-94 F SUPER DUTY
ISSUE: The rear axle shaft/hub bolts may loosen and leak axle lube. This loosening can occur due
to increased torques at the rear wheels.
ACTION: Install new higher strength flange head bolts and improved cellulose gaskets, which
clamp the joint together tighter. Refer to the following service tips and revised torque specifications.
^ Do not use higher torques specified for these bolts on previously specified hex head bolts.
^ Always replace the bolts and gaskets together rather than reusing them when servicing the wheel
end.
^ The new cellulose gaskets and new flanged head bolts are designed to be used together;
therefore, neither part should be used with older stock parts.
NOTE: WHEN REMOVING THE BOLTS, LOOSEN THEM BY HAND BEFORE USING AN
IMPACT WRENCH. THE SHOCK LOAD APPLIED BY A POWER TOOL MAY CAUSE THE BOLT
TO SNAP BEFORE IT RELEASES.
NOTE:
WHEN SERVICING THE REAR AXLE HUB OR SHAFT, REPLACE THE BOLTS AND GASKET
WITH THE NEW PARTS. USE THE NEW TORQUE SPECIFICATIONS.
NOTE: SPECIAL LUBRICANTS ARE REQUIRED FOR DANA FULL FLOAT REAR AXLES. USE
FORD HYPOID GEAR LUBE (C6AZ-19580-E OR EQUIVALENT), OR FOR EXTREME SERVICE
APPLICATIONS, USE FORD HIGH PERFORMANCE REAR AXLE LUBE (F1TZ-19580-B OR
EQUIVALENT). REFER TO TSB 92-3-11 FOR ADDITIONAL LUBRICANT INFORMATION.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical
Service Bulletins > Customer Interest for Wheel Hub: > 932514 > Dec > 93 > Full Float Rear Hub/Shaft - Lubricant Leaks >
Page 5567
OTHER APPLICABLE ARTICLES: 92-3-11 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage For 1992/94 Models, Basic Warranty Coverage For All
Other Models
OPERATION DESCRIPTION TIME
932514A Replace Axle Shaft/Hub 0.4 Hr.
Gaskets And Bolts (One Side)
932514B Replace Axle Shaft/Hub 0.6 Hr.
Gaskets And Bolts (Both Sides)
DEALER CODING
BASIC PART NO. CONDITION CODE
4A140 33
OASIS CODES: 509000, 590000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 932514 > Dec > 93 > Full Float Rear Hub/Shaft Lubricant Leaks
Wheel Hub: All Technical Service Bulletins Full Float Rear Hub/Shaft - Lubricant Leaks
Article No. 93-25-14
12/08/93
^ AXLE - "DANA" FULL FLOAT REAR - NEW HUB/SHAFT BOLTS AND REVISED TORQUE
SPECIFICATIONS
^ AXLE - "DANA" FULL FLOAT REAR - SHAFT/HUB BOLTS LOOSEN AND LEAK AXLE LUBE SERVICE TIPS
^ LEAKS - AXLE LUBE - REAR AXLE SHAFT/HUB BOLTS LOOSEN - SERVICE TIPS
LIGHT TRUCK: 1980-94 E-350 1988-94 F SUPER DUTY
ISSUE: The rear axle shaft/hub bolts may loosen and leak axle lube. This loosening can occur due
to increased torques at the rear wheels.
ACTION: Install new higher strength flange head bolts and improved cellulose gaskets, which
clamp the joint together tighter. Refer to the following service tips and revised torque specifications.
^ Do not use higher torques specified for these bolts on previously specified hex head bolts.
^ Always replace the bolts and gaskets together rather than reusing them when servicing the wheel
end.
^ The new cellulose gaskets and new flanged head bolts are designed to be used together;
therefore, neither part should be used with older stock parts.
NOTE: WHEN REMOVING THE BOLTS, LOOSEN THEM BY HAND BEFORE USING AN
IMPACT WRENCH. THE SHOCK LOAD APPLIED BY A POWER TOOL MAY CAUSE THE BOLT
TO SNAP BEFORE IT RELEASES.
NOTE:
WHEN SERVICING THE REAR AXLE HUB OR SHAFT, REPLACE THE BOLTS AND GASKET
WITH THE NEW PARTS. USE THE NEW TORQUE SPECIFICATIONS.
NOTE: SPECIAL LUBRICANTS ARE REQUIRED FOR DANA FULL FLOAT REAR AXLES. USE
FORD HYPOID GEAR LUBE (C6AZ-19580-E OR EQUIVALENT), OR FOR EXTREME SERVICE
APPLICATIONS, USE FORD HIGH PERFORMANCE REAR AXLE LUBE (F1TZ-19580-B OR
EQUIVALENT). REFER TO TSB 92-3-11 FOR ADDITIONAL LUBRICANT INFORMATION.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 932514 > Dec > 93 > Full Float Rear Hub/Shaft Lubricant Leaks > Page 5573
OTHER APPLICABLE ARTICLES: 92-3-11 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage For 1992/94 Models, Basic Warranty Coverage For All
Other Models
OPERATION DESCRIPTION TIME
932514A Replace Axle Shaft/Hub 0.4 Hr.
Gaskets And Bolts (One Side)
932514B Replace Axle Shaft/Hub 0.6 Hr.
Gaskets And Bolts (Both Sides)
DEALER CODING
BASIC PART NO. CONDITION CODE
4A140 33
OASIS CODES: 509000, 590000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service
Tires: Technical Service Bulletins Tire Wear - Toe Set Prior Vehicle Service
Article No. 86-24-28
TIRE WEAR - TOE SET PRIOR TO VEHICLE PLACEMENT INTO SERVICE VEHICLES WITH SNOWPLOW SCHOOL BUSES, AMBULANCES
LIGHT TRUCK 1985-86 RANGER, F-SERIES, BRONCO, ECONOLINE
Certain model vehicles have a significant weight change on the front axle between manufacture by
Ford and placement into service. This occurs when incomplete vehicles are completed by a body
company or when equipment is added to a complete vehicle (i.e., winches, plows, tool boxes, etc.).
This weight change can affect toe setting so these vehicles require that toe be reset.
Figure 25
The tag shown in Figure 25 is attached to the steering column of vehicles originally built with the
intent to add additional equipment. These vehicles require toe reset. OTHER APPLICABLE
ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service > Page 5579
Tires: Technical Service Bulletins Front Tires - Irregular Wear Pattern
Article No. 86-24-27
TIRE WEAR - FRONT - IRREGULAR PATTERN
LIGHT TRUCK 1985-87 ALL LIGHT TRUCKS
Vehicles may experience front tire wear with all season/all terrain tires described as irregular, heel
and toe, or diagonal. The condition may be related to alignment settings, vehicle usage, and tire
tread/ carcass/compound design.
Tires with minimal wear conditions should be crossrotated to the rear and alignment checked and
set to Shop Manual preferred settings for toe.
In cases of severe wear, obtain the complete alignment readings and tire information. Contact both
your Ford Representative and Tire Manufacturer's Representative for their assistance and
participation in resolving the customer's concern. Contacting the "local" tire store may not obtain
the assistance which may be available from the tire manufacturer.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service > Page 5580
Tires: Technical Service Bulletins Tires - Best Pressure For Load Application
^33GTIRE - LOAD CAPACITY VERSUS INFLATION PRESSURE
^ TIRE - P - METRIC PASSENGER TIRES USED ON LIGHT TRUCKS
^ TIRE WEAR - EFFECTS OF INFLATION AND LOAD
Article No. 89-9-16
LIGHT TRUCK: 1984-89 ALL LIGHT TRUCK LINES
ISSUE: Tire wear can be affected by inflation and load. Good tread life is dependent on maintaining
proper air pressure in the tires. Other factors that affect tire wear are:
^ alignment
^ speed
^ road surfaces
ACTION: Keep tires inflated to the recommended pressures to obtain maximum tread life. Use the
following charts and procedures to arrive at the best tire pressure for each load application.
FIGURE 1
The chart in Figure 1 shows the affect of inflation and load on tire tread life. Use the chart by finding
the specified inflation pressure for the vehicle as shown on the certification label and locating that
pressure on the specified inflation pressure on the chart. The affects of actual air pressure and load
can now be read directly off the chart.
Tire load carrying capacity is a function of tire design and inflation pressures. Each tire has molded
into the sidewall a maximum pressure for a specific usage. Use the following guidelines to
determine load carrying capacity.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service > Page 5581
FIGURE 2
^ For P-metric passenger tires on passenger cars, the values are as shown on the tire.
^ For P-metric passenger tires on light trucks, the load ratings are reduced to 91% to reflect the
"harsher" truck environment, Figure 2.
^ For light truck style tires used on light trucks, the values are as shown for tires used in single
wheel applications.
^ For light truck style tires used in dual wheel applications, the tire capacities are derated.
Often, inflation pressures for specific vehicles are less than maximum capacity because the load to
be carried is less than the maximum tire capacity.
Inflation pressures for originally installed size tires on a vehicle are shown on the vehicle
certification label along with the tire size and rated capacity for the axle system. Check the size and
inflation information on the label to properly inflate the tires. Be sure that the same size tire is
actually on the vehicle and then inflate it to the label's specified pressure. If other than original size
tires are on the vehicle, the label's pressures are probably not correct
To find proper pressures for other than original tires, use the following procedure.
1. Obtain both front and rear axle capacity ratings (GAWRR and GAWRF).
2. Divide each number by 2 to obtain the capacity at the tire.
FIGURE 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Tire Wear - Toe Set Prior Vehicle Service > Page 5582
3. For single wheel usage, look up the pressure in the proper chart which will meet the needed
capacity, Figure 3.
4. Check the tire side wall label to see if it permits inflation to that pressure. If lower load range tires
were installed (i.e., C vs. D or E), the tires may not have the needed capability.
5. Divide the value found in Step 2 by 2 again to obtain individual tire requirements for dual rear
wheels.
6. Using a dual wheel inflation pressure chart, Figure 3, determine correct pressure to achieve
adequate load capacities.
7. Consult the local tire outlet or the tire manufacturer's home office about tires not shown in the
tables.
OTHER APPLICABLE ARTICLES: 87-10-11
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 3300
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot
Holes
Wheels: Customer Interest Wheel - Mounting Surface Distorted Lug/Pilot Holes
Article No. 91-11-16
05/30/91
^ WHEEL - DISTORTED PILOT HOLES OR LUG HOLES - WITH 16 X 6 SINGLE STEEL
WHEELS
^ VIBRATION - WHEEL MOUNTING SURFACE DISTORTED - WITH 16 X 6 SINGLE STEEL
WHEELS
LIGHT TRUCK: 1985-91 E-250-350, F-250-350
ISSUE: Wheel vibration may be caused by distorted pilot holes or lug holes on the wheel. This
does not allow sufficient clamp load between the lug nut, the wheel and the rotor/hub. It may also
be difficult to remove the distorted wheel from the vehicle or to place the wheel on the vehicle in a
different location.
ACTION: To determine if a wheel has been damaged and should not be reused, refer to the
following service procedure for details.
NOTE: THIS PROCEDURE ONLY APPLIES TO PART # E7UA-1015-JA (16 X 6 SINGLE STEEL
WHEEL)
INSPECT FOR WHEEL DAMAGE
1. Remove the wheel from the hub. If the wheel is difficult to remove, DO NOT reuse the wheel.
2. Visually inspect the wheel for distortion (turned-up) scallops in the pilot hole. If the pilot hole is
distorted, DO NOT reuse the wheel.
3. Inspect the distorted lug holes by placing a lug nut in the lug hole cone seat of the wheel and
inspect from the reverse side. If the lug protrudes through the lug hole, DO NOT reuse the wheel.
4. Inspect the wheel mounting surface for distortion.
a. Lay a straight edge across the mounting surface of the wheel (the surface of the wheel which
makes contact with the rear brake drum or front rotor).
b. The straight edge should contact the outer edge of the mounting surface, lying between the bolt
holes and across the center of the pilot hole.
c. The clearance between the straight edge and the pilot hole can not exceed 0.0300 inch, the
straight edge should not contact the pilot holes. If the clearance is more than 0.0300 or the straight
edge makes contact with the pilot holes, DO NOT reuse the wheel.
INSTALL WHEEL
1. Inspect for lubricants on the studs and lug nuts.
2. If lubricants are present, clean throughly using naphtha or equivalent.
3. Torque lug nuts to (140 ft.lbs./190 N-m) using a torque wrench according to the Shop Manual,
Section 04-04.
CAUTION: EXCESSIVE TORQUE MAY CAUSE DISTORTION OF THE WHEEL. INADEQUATE
TORQUE MAY NOT PROVIDE
ADEQUATE CLAMPING FORCE TO ASSURE WHEEL RETENTION.
PART NUMBER PART NAME CLASS
E5TZ-1015-B Wheel AM
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage
OPERATION DESCRIPTION TIME
911116A Wheel-Inspect 0.7 hrs
911116B Replace One Wheel And 0.4 Hr.
Dynamic Balance
911116C Replace Two Wheels And 0.8 Hr.
Dynamic Balance
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 911116 > May > 91 > Wheel - Mounting Surface Distorted Lug/Pilot
Holes > Page 5591
911116D Replace Three Wheels And 1.2 Hr.
Dynamic Balance
911116E Replace Four Wheels And 1.6 Hr.
Dynamic Balance
DEALER CODING
BASIC PART NO. CONDITION CODE
1015 67
OASIS CODES: 306000, 703000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 911116 > May > 91 > Wheel - Mounting Surface Distorted
Lug/Pilot Holes
Wheels: All Technical Service Bulletins Wheel - Mounting Surface Distorted Lug/Pilot Holes
Article No. 91-11-16
05/30/91
^ WHEEL - DISTORTED PILOT HOLES OR LUG HOLES - WITH 16 X 6 SINGLE STEEL
WHEELS
^ VIBRATION - WHEEL MOUNTING SURFACE DISTORTED - WITH 16 X 6 SINGLE STEEL
WHEELS
LIGHT TRUCK: 1985-91 E-250-350, F-250-350
ISSUE: Wheel vibration may be caused by distorted pilot holes or lug holes on the wheel. This
does not allow sufficient clamp load between the lug nut, the wheel and the rotor/hub. It may also
be difficult to remove the distorted wheel from the vehicle or to place the wheel on the vehicle in a
different location.
ACTION: To determine if a wheel has been damaged and should not be reused, refer to the
following service procedure for details.
NOTE: THIS PROCEDURE ONLY APPLIES TO PART # E7UA-1015-JA (16 X 6 SINGLE STEEL
WHEEL)
INSPECT FOR WHEEL DAMAGE
1. Remove the wheel from the hub. If the wheel is difficult to remove, DO NOT reuse the wheel.
2. Visually inspect the wheel for distortion (turned-up) scallops in the pilot hole. If the pilot hole is
distorted, DO NOT reuse the wheel.
3. Inspect the distorted lug holes by placing a lug nut in the lug hole cone seat of the wheel and
inspect from the reverse side. If the lug protrudes through the lug hole, DO NOT reuse the wheel.
4. Inspect the wheel mounting surface for distortion.
a. Lay a straight edge across the mounting surface of the wheel (the surface of the wheel which
makes contact with the rear brake drum or front rotor).
b. The straight edge should contact the outer edge of the mounting surface, lying between the bolt
holes and across the center of the pilot hole.
c. The clearance between the straight edge and the pilot hole can not exceed 0.0300 inch, the
straight edge should not contact the pilot holes. If the clearance is more than 0.0300 or the straight
edge makes contact with the pilot holes, DO NOT reuse the wheel.
INSTALL WHEEL
1. Inspect for lubricants on the studs and lug nuts.
2. If lubricants are present, clean throughly using naphtha or equivalent.
3. Torque lug nuts to (140 ft.lbs./190 N-m) using a torque wrench according to the Shop Manual,
Section 04-04.
CAUTION: EXCESSIVE TORQUE MAY CAUSE DISTORTION OF THE WHEEL. INADEQUATE
TORQUE MAY NOT PROVIDE
ADEQUATE CLAMPING FORCE TO ASSURE WHEEL RETENTION.
PART NUMBER PART NAME CLASS
E5TZ-1015-B Wheel AM
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage
OPERATION DESCRIPTION TIME
911116A Wheel-Inspect 0.7 hrs
911116B Replace One Wheel And 0.4 Hr.
Dynamic Balance
911116C Replace Two Wheels And 0.8 Hr.
Dynamic Balance
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 911116 > May > 91 > Wheel - Mounting Surface Distorted
Lug/Pilot Holes > Page 5597
911116D Replace Three Wheels And 1.2 Hr.
Dynamic Balance
911116E Replace Four Wheels And 1.6 Hr.
Dynamic Balance
DEALER CODING
BASIC PART NO. CONDITION CODE
1015 67
OASIS CODES: 306000, 703000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Page 5598
Wheels: Specifications
5 LUG WHEEL
1/2-20 ..................................................................................................................................................
........................................... 135 Nm (100 lb ft)
8 LUG WHEEL
9/16-18 ................................................................................................................................................
........................................... 190 Nm (140 lb ft)
NOTE: Torque specifications are for clean, dirt and paint free dry bolt and nut threads. Never use
oil or grease on studs and nuts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Wheel Bearing Torque Specification - Manual Correction
Wheel Bearing: Technical Service Bulletins Wheel Bearing Torque Specification - Manual
Correction
WHEEL BEARING - FRONT - ADJUSTING NUT TORQUE SPECIFICATION - SHOP MANUAL
CORRECTION
Article No. 88-4-15
LIGHT TRUCK: 1987-88 E-SERIES
ISSUE: The front wheel bearing adjusting nut torque specification as published in the 1987 and
1988 Light Truck Shop Manual, Volume A, Section 12-24-3, Figures 2 and 3 is incorrect.
ACTION: If service is required, torque the front wheel bearing adjusting nut to 22-25 ft.lbs. (30-33
N-m) and then back the adjusting nut off 1/8 turn as described in the Light Truck Shop Manual,
Volume A, Section 11-10-1.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Page 5603
Wheel Bearing: Specifications
Wheel Adjusting Nut [1] .......................................................................................................................
........................................... 30-33 Nm (22-25 ft lbs)
Bearing End Play
..............................................................................................................................................................
0.025-0.254mm (0.001-0.010 in)
[1] Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional
movement of the adjusting nut.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Page 5604
Wheel Bearing: Adjustments
1. Raise the vehicle until the tire clears the floor and install safety stands.
2. Remove the wheel cover.
3. Remove the grease cap from the hub. Wipe the excess grease from the end of the spindle.
Remove the cotter pin and locknut.
4. Loosen the adjusting nut three turns. Attempt to obtain running clearance between the rotor
brake surface and the disc pads by rocking the wheel,
hub and rotor assembly in and out several times to push the pads away from the rotor. If running
clearance cannot be maintained throughout bearing adjustment in Steps 5 and 6, the caliper must
be removed.
NOTE: Do not pry on the phenolic caliper piston.
5. Tighten the wheel adjusting nut to 30-33 Nm (22-25 ft lbs) while rotating the disc brake rotor in
the opposite direction.
6. Back off the adjusting nut 1/8 turn and install the retainer and new cotter pin without additional
movement of the adjusting nut. Bearing end play
should be 0.025-0.254mm (0.001-0.010 in). Bend the ends of the cotter pin around the castellated
flange of the locknut.
7. Check front wheel rotation. If the wheel rotates properly, reinstall the grease cap and wheel
cover. If rotation is noisy or rough, remove and inspect
the bearings. Service as required.
WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake
pedal travel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Page 5605
Wheel Bearing: Service and Repair
Wheel bearing lubricant is a lithium-base grease. Sodium-base grease is not compatible with
lithium-base grease and should not be intermixed. Therefore, do not lubricate front and/or rear
wheel bearings without first identifying the type of original wheel bearing lubricant. Usage of
incompatible bearing lubricants may result in premature lubricant breakdown.
REMOVAL
Front Hub And Rotor Assembly
1. Raise the vehicle until the tire clears the floor and remove the wheel and tire assembly.
2. Remove the brake caliper and secure to the underbody to prevent damage to the brake hose. It
is not necessary to disconnect the hose from the
caliper. Do not let the caliper hang with its weight on the brake hose or the hose may become
stretched, twisted or ruptured. See: Brakes and Traction Control/Disc Brake System/Brake
Caliper/Service and Repair
3. Remove the grease cap, cotter pin, retainer adjusting nut and washer.
4. Remove the outer bearing cone and roller.
5. Pull the hub and rotor off the spindle and remove and discard the grease seal.
6. Remove the inner bearing cone and roller from the hub. Remove all traces of old lubricant from
bearings, hub and axle spindle.
7. Inspect the cups for scratches, pits or cracks. If the cups are worn or damaged, remove them
with a drift. Clean the inner and outer bearing cones
and rollers with solvent and dry thoroughly.
CAUTION: Do not spin the bearings dry with compressed air.
8. Inspect the cones and rollers for cracks, nicks, brinelling, or seized rollers. Inspect the grease
retainer and replace it if it is cracked, nicked, dented
or worn.
9. Cover the spindle with a clean cloth. A water dampened cloth or water based solution should be
used to remove and dust or loose dirt from the
brake assembly. Remove the cloth from the spindle carefully to prevent dirt from falling on the
spindle.
NOTE: Do not use compressed air.
INSTALLATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Page 5606
Installing Bearing Cups (Typical)
1. If inner or outer bearing cups were removed, install replacement inner and outer bearing cups in
the hub with the appropriate bearing cup replacer
tool. Be sure to seat the cups properly in the hub. The cups will be properly seated when they are
fully bottomed. Replace grease retainers. Polish grease retainer journal on spindle with 400 grit
sandpaper. Clean with clean cloth.
2. Pack the inside of the hub with lithium-base grease or equivalent. Fill the hub until the grease is
flush with the inside diameters of both bearing
cups. Pack the bearing cones and rollers with wheel bearing grease. Use a bearing packer for this
operation. If a packer is not available, work as much lubricant as possible between the rollers and
cages. Lubricate the cone surfaces with grease.
Installing Grease Seal (Typical)
3. Place the inner bearing cone and roller in the inner cup and install the new grease seal. Be sure
that the seal is fully seated.
4. Install the hub and rotor on the wheel spindle. Keep the hub centered on the spindle to prevent
damage to the grease retainer or the spindle threads.
5. Install the outer bearing cone and roller and the flat washer on the spindle, then install the
adjusting nut, and adjust the wheel bearing.
6. Install the retainer, new cotter pin, and grease cap.
7. Install the caliper.
8. Install the wheel and tire assembly.
9. Lower vehicle and torque the lug nuts to specification. Re-install the wheel cover or hub cap.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Technical Service Bulletins > Page 5607
WARNING: Before driving the vehicle, pump the brake pedal several times to restore normal brake
pedal travel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information >
Technical Service Bulletins > Customer Interest for Wheel Cover: > 90118 > May > 90 > Wheel Cover - Centers Damaged
By Stones
Wheel Cover: Customer Interest Wheel Cover - Centers Damaged By Stones
Article No. 90-11-8
WHEEL COVERS-16 INCH TURBINE WHEEL-CENTERS
DAMAGED BY STONES
LIGHT TRUCK: 1986-90 E-250, E-350, F-250, F-350
ISSUE: The wheel cover centers may be damaged by stones and debris hitting the cover. This
condition is most noticeable during cold weather because the wheel cover material becomes very
brittle.
ACTION: Install new wheel covers made of a more durable plastic. The color of the new plastic
material is gray which will help hide any stone chips. Refer to the following Wheel Cover
Application Chart for correct parts usage.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901108A Install Wheel Covers 0.2 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
1130 01
OASIS CODES: 1052, 3300
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheel Cover: > 90118 > May > 90 > Wheel Cover - Centers
Damaged By Stones
Wheel Cover: All Technical Service Bulletins Wheel Cover - Centers Damaged By Stones
Article No. 90-11-8
WHEEL COVERS-16 INCH TURBINE WHEEL-CENTERS
DAMAGED BY STONES
LIGHT TRUCK: 1986-90 E-250, E-350, F-250, F-350
ISSUE: The wheel cover centers may be damaged by stones and debris hitting the cover. This
condition is most noticeable during cold weather because the wheel cover material becomes very
brittle.
ACTION: Install new wheel covers made of a more durable plastic. The color of the new plastic
material is gray which will help hide any stone chips. Refer to the following Wheel Cover
Application Chart for correct parts usage.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901108A Install Wheel Covers 0.2 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
1130 01
OASIS CODES: 1052, 3300
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Technical Service Bulletins > Customer Interest for Wheel Hub: > 932514 > Dec > 93 > Full Float Rear Hub/Shaft Lubricant Leaks
Wheel Hub: Customer Interest Full Float Rear Hub/Shaft - Lubricant Leaks
Article No. 93-25-14
12/08/93
^ AXLE - "DANA" FULL FLOAT REAR - NEW HUB/SHAFT BOLTS AND REVISED TORQUE
SPECIFICATIONS
^ AXLE - "DANA" FULL FLOAT REAR - SHAFT/HUB BOLTS LOOSEN AND LEAK AXLE LUBE SERVICE TIPS
^ LEAKS - AXLE LUBE - REAR AXLE SHAFT/HUB BOLTS LOOSEN - SERVICE TIPS
LIGHT TRUCK: 1980-94 E-350 1988-94 F SUPER DUTY
ISSUE: The rear axle shaft/hub bolts may loosen and leak axle lube. This loosening can occur due
to increased torques at the rear wheels.
ACTION: Install new higher strength flange head bolts and improved cellulose gaskets, which
clamp the joint together tighter. Refer to the following service tips and revised torque specifications.
^ Do not use higher torques specified for these bolts on previously specified hex head bolts.
^ Always replace the bolts and gaskets together rather than reusing them when servicing the wheel
end.
^ The new cellulose gaskets and new flanged head bolts are designed to be used together;
therefore, neither part should be used with older stock parts.
NOTE: WHEN REMOVING THE BOLTS, LOOSEN THEM BY HAND BEFORE USING AN
IMPACT WRENCH. THE SHOCK LOAD APPLIED BY A POWER TOOL MAY CAUSE THE BOLT
TO SNAP BEFORE IT RELEASES.
NOTE:
WHEN SERVICING THE REAR AXLE HUB OR SHAFT, REPLACE THE BOLTS AND GASKET
WITH THE NEW PARTS. USE THE NEW TORQUE SPECIFICATIONS.
NOTE: SPECIAL LUBRICANTS ARE REQUIRED FOR DANA FULL FLOAT REAR AXLES. USE
FORD HYPOID GEAR LUBE (C6AZ-19580-E OR EQUIVALENT), OR FOR EXTREME SERVICE
APPLICATIONS, USE FORD HIGH PERFORMANCE REAR AXLE LUBE (F1TZ-19580-B OR
EQUIVALENT). REFER TO TSB 92-3-11 FOR ADDITIONAL LUBRICANT INFORMATION.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Technical Service Bulletins > Customer Interest for Wheel Hub: > 932514 > Dec > 93 > Full Float Rear Hub/Shaft Lubricant Leaks > Page 5629
OTHER APPLICABLE ARTICLES: 92-3-11 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage For 1992/94 Models, Basic Warranty Coverage For All
Other Models
OPERATION DESCRIPTION TIME
932514A Replace Axle Shaft/Hub 0.4 Hr.
Gaskets And Bolts (One Side)
932514B Replace Axle Shaft/Hub 0.6 Hr.
Gaskets And Bolts (Both Sides)
DEALER CODING
BASIC PART NO. CONDITION CODE
4A140 33
OASIS CODES: 509000, 590000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 932514 > Dec > 93 > Full Float Rear
Hub/Shaft - Lubricant Leaks
Wheel Hub: All Technical Service Bulletins Full Float Rear Hub/Shaft - Lubricant Leaks
Article No. 93-25-14
12/08/93
^ AXLE - "DANA" FULL FLOAT REAR - NEW HUB/SHAFT BOLTS AND REVISED TORQUE
SPECIFICATIONS
^ AXLE - "DANA" FULL FLOAT REAR - SHAFT/HUB BOLTS LOOSEN AND LEAK AXLE LUBE SERVICE TIPS
^ LEAKS - AXLE LUBE - REAR AXLE SHAFT/HUB BOLTS LOOSEN - SERVICE TIPS
LIGHT TRUCK: 1980-94 E-350 1988-94 F SUPER DUTY
ISSUE: The rear axle shaft/hub bolts may loosen and leak axle lube. This loosening can occur due
to increased torques at the rear wheels.
ACTION: Install new higher strength flange head bolts and improved cellulose gaskets, which
clamp the joint together tighter. Refer to the following service tips and revised torque specifications.
^ Do not use higher torques specified for these bolts on previously specified hex head bolts.
^ Always replace the bolts and gaskets together rather than reusing them when servicing the wheel
end.
^ The new cellulose gaskets and new flanged head bolts are designed to be used together;
therefore, neither part should be used with older stock parts.
NOTE: WHEN REMOVING THE BOLTS, LOOSEN THEM BY HAND BEFORE USING AN
IMPACT WRENCH. THE SHOCK LOAD APPLIED BY A POWER TOOL MAY CAUSE THE BOLT
TO SNAP BEFORE IT RELEASES.
NOTE:
WHEN SERVICING THE REAR AXLE HUB OR SHAFT, REPLACE THE BOLTS AND GASKET
WITH THE NEW PARTS. USE THE NEW TORQUE SPECIFICATIONS.
NOTE: SPECIAL LUBRICANTS ARE REQUIRED FOR DANA FULL FLOAT REAR AXLES. USE
FORD HYPOID GEAR LUBE (C6AZ-19580-E OR EQUIVALENT), OR FOR EXTREME SERVICE
APPLICATIONS, USE FORD HIGH PERFORMANCE REAR AXLE LUBE (F1TZ-19580-B OR
EQUIVALENT). REFER TO TSB 92-3-11 FOR ADDITIONAL LUBRICANT INFORMATION.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 932514 > Dec > 93 > Full Float Rear
Hub/Shaft - Lubricant Leaks > Page 5635
OTHER APPLICABLE ARTICLES: 92-3-11 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage For 1992/94 Models, Basic Warranty Coverage For All
Other Models
OPERATION DESCRIPTION TIME
932514A Replace Axle Shaft/Hub 0.4 Hr.
Gaskets And Bolts (One Side)
932514B Replace Axle Shaft/Hub 0.6 Hr.
Gaskets And Bolts (Both Sides)
DEALER CODING
BASIC PART NO. CONDITION CODE
4A140 33
OASIS CODES: 509000, 590000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > Customer Interest: > 87721 > Apr > 87 > Wheels- Lug Nuts Bind On Studs
Wheel Fastener: Customer Interest Wheels- Lug Nuts Bind On Studs
Article No. WHEEL - LUG NUTS BIND ON STUDS - VEHICLES
87-7-21 WITH 9/16" STUDS AND SINGLE REAR WHEELS
LIGHT TRUCK: 1983-87 E-250/350, F-250/350
ISSUE: Some lug nuts may be difficult to remove due to nut crimping. The lug nuts are designed to
be free-running as opposed to a "prevailing" torque style. The freerunning nuts may have "crimped
in" against the stud when torqued.
ACTION: To correct this, use new replacement nuts which will not "crimp in" when tightened to the
recommended torque of 140 ft.lbs. (190 N-m).
CAUTION: Lug nuts should be torqued by hand, not with an impact wrench, and retorqued at
intervals specified in the Owner Guide.
PART NUMBER PART NAME CLASS
E7TZ-1120-A Lug Nut - R.H. Thread A
- Package of 4
E7TZ-1121-A Lug Nut - L.H. Thread A
- Package of 4
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP870721A - Replace lug nuts TIME:
0.5 Hr.
OPERATION: 1107B - Replace wheel studs
TIME: Refer to the appropriate Service Labor Time Standards Manual
OPERATION: "M" Time - Replace lug nut stuck on spinning stud, if required Requires District
Authorization DLR. CODING: Basic Part No. 1120 - Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper
Installation/Torqueing Procedure
Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure
Article No. 98-5A-4
^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP
^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP
FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA
1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97
PROBE 1994-97 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI
1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII
1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI
1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE
LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO
II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER
1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR
ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or
unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and
installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly
torqued wheel lug nuts may cause:
^ Brake vibration
^ Distortion of the wheel hub
^ Distortion of the brake rotor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper
Installation/Torqueing Procedure > Page 5649
^ Brake rotor runout
^ Damage to the wheel
^ Damage to the wheel nuts and studs
ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by
using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The
"ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or
uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools
will not reduce the output torque enough to prevent overtightening of the wheel lug nuts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper
Installation/Torqueing Procedure > Page 5650
NOTE:
REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE
CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO
PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE.
The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the
"ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250
lb-ft), usually this will be the lowest setting on the air impact tool.
The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set
(164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4)
lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at
1-800-ROT-UNDA (768-8632).
CAUTION:
AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE
"ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED.
NOTE:
DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE
HAND-TORQUED ONLY.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 97-17-6
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 301000, 303000, 306000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 87721 > Apr > 87 > Wheels- Lug Nuts
Bind On Studs
Wheel Fastener: All Technical Service Bulletins Wheels- Lug Nuts Bind On Studs
Article No. WHEEL - LUG NUTS BIND ON STUDS - VEHICLES
87-7-21 WITH 9/16" STUDS AND SINGLE REAR WHEELS
LIGHT TRUCK: 1983-87 E-250/350, F-250/350
ISSUE: Some lug nuts may be difficult to remove due to nut crimping. The lug nuts are designed to
be free-running as opposed to a "prevailing" torque style. The freerunning nuts may have "crimped
in" against the stud when torqued.
ACTION: To correct this, use new replacement nuts which will not "crimp in" when tightened to the
recommended torque of 140 ft.lbs. (190 N-m).
CAUTION: Lug nuts should be torqued by hand, not with an impact wrench, and retorqued at
intervals specified in the Owner Guide.
PART NUMBER PART NAME CLASS
E7TZ-1120-A Lug Nut - R.H. Thread A
- Package of 4
E7TZ-1121-A Lug Nut - L.H. Thread A
- Package of 4
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP870721A - Replace lug nuts TIME:
0.5 Hr.
OPERATION: 1107B - Replace wheel studs
TIME: Refer to the appropriate Service Labor Time Standards Manual
OPERATION: "M" Time - Replace lug nut stuck on spinning stud, if required Requires District
Authorization DLR. CODING: Basic Part No. 1120 - Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper
Installation/Torqueing Procedure
Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure
Article No. 98-5A-4
^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP
^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP
FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA
1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97
PROBE 1994-97 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI
1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII
1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI
1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE
LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO
II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER
1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR
ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or
unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and
installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly
torqued wheel lug nuts may cause:
^ Brake vibration
^ Distortion of the wheel hub
^ Distortion of the brake rotor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper
Installation/Torqueing Procedure > Page 5660
^ Brake rotor runout
^ Damage to the wheel
^ Damage to the wheel nuts and studs
ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by
using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The
"ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or
uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools
will not reduce the output torque enough to prevent overtightening of the wheel lug nuts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper
Installation/Torqueing Procedure > Page 5661
NOTE:
REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE
CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO
PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE.
The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the
"ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250
lb-ft), usually this will be the lowest setting on the air impact tool.
The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set
(164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4)
lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at
1-800-ROT-UNDA (768-8632).
CAUTION:
AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE
"ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED.
NOTE:
DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE
HAND-TORQUED ONLY.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 97-17-6
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 301000, 303000, 306000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > Page 5662
Wheel Fastener: Specifications
5 LUG WHEEL
1/2-20 ..................................................................................................................................................
........................................... 135 Nm (100 lb ft)
8 LUG WHEEL
9/16-18 ................................................................................................................................................
........................................... 190 Nm (140 lb ft)
NOTE: Torque specifications are for clean, dirt and paint free dry bolt and nut threads. Never use
oil or grease on studs and nuts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Technical Service Bulletins > Page 5663
Wheel Fastener: Service and Repair
Lug Nut Torque Patterns
IMPORTANT
Check all parts, including rims, lug studs, lug nuts, and mating surfaces of hubs and tire rims for
rust, damage, or dirt. Clean mating surfaces with a wire brush to remove any foreign material.
Replace any damaged parts as needed. Careless installation of tire/rim assemblies in a vehicle is a
major cause of tire installation problems. Proper installation, including fastener torque, is essential
to economical, safe and trouble free service. Use only the proper sizes and types of fasteners for
safe and proper service. Tighten the fasteners a quarter turn at a time using the tightening
sequence diagram as a guide. This is very important to prevent misalignment of the wheel.
Continue tightening the fasteners in sequence until the fasteners are tightened to the proper torque
(See WHEEL FASTENER TORQUE).
CAUTION: Improper torque or tightening sequence can cause distortion, fatigue cracks, or
alignment problems. After driving the vehicle for a short distance, recheck the wheel fastener
torque. Parts will usually seat naturally, reducing the torque on the fasteners. Retorque all
fasteners to the proper torque.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Air Door Actuator
Air Door Actuator / Motor: Locations Air Door Actuator
Vacuum Components
Rear Middle Of Plenum
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Air Door Actuator > Page 5670
Air Door Actuator / Motor: Locations Blend Door Motor
Heat/Defrost Vacuum Motor
Vacuum Components
Inside Middle Part Of Plenum
Outside-Recirculate Door Vacuum Motor
Vacuum Components
Right Of A/C Evaporator
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Page 5671
Air Door Actuator / Motor: Service and Repair
Fig. 12 Vacuum motor removal & installation
For vacuum motor replace, refer to Fig. 12.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Customer Interest for Blower Motor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only
Blower Motor: Customer Interest Auxiliary Blower Motor - Operates On High Only
^ AIR CONDITIONING - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY
^ HEATER - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY
Article No. 88-20-13
LIGHT TRUCK: 1985-88 ECONOLINE
ISSUE: An auxiliary blower motor that only operates in the high speed mode may be caused by an
open thermal limiter on the auxiliary blower motor resistor. The current location of the resistor does
not allow the thermal limiter to properly cool.
ACTION: Install a new blower motor resistor in a new location to achieve better cooling of the
thermal limiter. Refer to the following service procedure for removal and installation instructions.
1. Remove the auxiliary "A/C-Heater" or "Heater" cover assembly.
2. Disconnect the blower motor resistor wiring connectors.
3. Remove the resistor and two (2) mounting clips from the resistor mounting posts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Customer Interest for Blower Motor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only >
Page 5680
FIGURE 7
4. Cut out the template, Figure 7.
FIGURE 8
5. Position the template on the plastic case as shown in Figure 8.
6. Scribe the plastic case to correctly locate the resistor opening and two (2) mounting screw holes.
7. Cut the resistor opening with a hot knife or a saw. Using a 5/32" drill bit, drill the two (2) new
mounting screw holes.
8. Install the two (2) resistor mounting clips removed in Step 3 over the new mounting screw holes.
9. Position the new blower motor resistor, (E8UZ- 19A706-A) with the windings facing upward.
FIGURE 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Customer Interest for Blower Motor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only >
Page 5681
10. Install the two (2) mounting screws, Figure 9.
NOTE: MAKE SURE THE BLOWER MOTOR RESISTOR COILS OR COIL TERMINALS ARE NOT
TOUCHING THE PLASTIC CASE. ADJUST THE MOUNTING LOCATION IF NECESSARY.
11. Reconnect the blower motor resistor wiring connectors.
12. Make sure the auxiliary blower motor operates at each speed mode.
13. Reinstall the auxiliary "A/C-Heater" or "Heater" cover assembly.
PART NUMBER PART NAME CLASS
E8UZ-19A706-A Resistor-Blower Motor B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: 882013A TIME:
0.7 Hr.
DLR. CODING: Basic Part No. 19A706 Condition Code: 46
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Blower Motor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On
High Only
Blower Motor: All Technical Service Bulletins Auxiliary Blower Motor - Operates On High Only
^ AIR CONDITIONING - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY
^ HEATER - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY
Article No. 88-20-13
LIGHT TRUCK: 1985-88 ECONOLINE
ISSUE: An auxiliary blower motor that only operates in the high speed mode may be caused by an
open thermal limiter on the auxiliary blower motor resistor. The current location of the resistor does
not allow the thermal limiter to properly cool.
ACTION: Install a new blower motor resistor in a new location to achieve better cooling of the
thermal limiter. Refer to the following service procedure for removal and installation instructions.
1. Remove the auxiliary "A/C-Heater" or "Heater" cover assembly.
2. Disconnect the blower motor resistor wiring connectors.
3. Remove the resistor and two (2) mounting clips from the resistor mounting posts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Blower Motor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On
High Only > Page 5687
FIGURE 7
4. Cut out the template, Figure 7.
FIGURE 8
5. Position the template on the plastic case as shown in Figure 8.
6. Scribe the plastic case to correctly locate the resistor opening and two (2) mounting screw holes.
7. Cut the resistor opening with a hot knife or a saw. Using a 5/32" drill bit, drill the two (2) new
mounting screw holes.
8. Install the two (2) resistor mounting clips removed in Step 3 over the new mounting screw holes.
9. Position the new blower motor resistor, (E8UZ- 19A706-A) with the windings facing upward.
FIGURE 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Blower Motor: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On
High Only > Page 5688
10. Install the two (2) mounting screws, Figure 9.
NOTE: MAKE SURE THE BLOWER MOTOR RESISTOR COILS OR COIL TERMINALS ARE NOT
TOUCHING THE PLASTIC CASE. ADJUST THE MOUNTING LOCATION IF NECESSARY.
11. Reconnect the blower motor resistor wiring connectors.
12. Make sure the auxiliary blower motor operates at each speed mode.
13. Reinstall the auxiliary "A/C-Heater" or "Heater" cover assembly.
PART NUMBER PART NAME CLASS
E8UZ-19A706-A Resistor-Blower Motor B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: 882013A TIME:
0.7 Hr.
DLR. CODING: Basic Part No. 19A706 Condition Code: 46
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications > Less
A/C
Fig. 38 Blower motor current draw & voltage test chart
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications > Less
A/C > Page 5691
Fig. 39 Blower motor current draw & voltage test chart.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications > Page
5692
Blower Motor: Locations
RH Side Of Engine Compartment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions
Blower Motor: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 5695
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 5696
Blower Motor: Electrical Diagrams
Fig. 6 Auxiliary Blower Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 5697
Fig. 37 Heater Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection
> Blower Motor Current Draw, HEATER
Blower Motor: Testing and Inspection Blower Motor Current Draw, HEATER
Fig. 38 Blower motor current draw & voltage test chart
1. Disconnect blower motor electrical connector.
2. Connect ammeter between positive terminal on motor and corresponding terminal of wire
harness electrical connector.
3. Connect jumper wire between two negative terminals.
4. Place system temperature control lever in mid-range position (halfway between COOL and
WARM). Place function selector lever in HEAT or VENT position on models less A/C or MAX. A/C
on models with A/C. Ensure blower is on.
5. With engine running, operate blower in all speeds. Note current draw for each blower speed.
Ensure battery voltage is approximately 14.2 volts when performing this test.
6. Current draw for each blower speed should be as shown in Fig. 38.
7. Disconnect ammeter and jumper wire, then connect electrical connector to blower motor.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection
> Blower Motor Current Draw, HEATER > Page 5700
Blower Motor: Testing and Inspection W/ MTC
Fig. 39 Blower motor current draw & voltage test chart.
1. Disconnect blower motor electrical connector.
2. Connect ammeter between positive terminal on motor and corresponding terminal of wire
harness electrical connector.
3. Connect jumper wire between two negative terminals.
4. Place system temperature control lever in mid-range position (halfway between COOL and
WARM). Place function selector lever in HEAT or VENT position on models less A/C or MAX. A/C
on models with A/C. Ensure blower is on.
5. With engine running, operate blower in all speeds. Note current draw for each blower speed.
Ensure battery voltage is approximately 14.2 volts when performing this test.
6. Current draw for each blower speed should be as shown in Fig. 39.
7. Disconnect ammeter and jumper wire, then connect electrical connector to blower motor.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and Inspection
> Page 5701
Blower Motor: Service and Repair
Fig. 25 Blower motor removal
Less Air Conditioning
1. Disconnect blower motor electrical leads and blower motor ground wire, Fig. 25.
2. Remove blower motor assembly retaining screws and remove blower motor.
3. Reverse procedure to install.
Fig. 26 Blower motor removal
With Air Conditioning
1. Disconnect battery ground cable.
2. Disconnect electrical leads from resistor, Fig. 26.
3. Remove blower scroll cover.
4. Push wiring grommet forward out of hole in blower motor housing.
5. Remove four blower mounting plate retaining screws and remove blower motor.
6. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations
Blower Motor Relay: Locations
LH Side Of Dash
LH Corner Of Engine Compartment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > Customer Interest: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only
Blower Motor Resistor: Customer Interest Auxiliary Blower Motor - Operates On High Only
^ AIR CONDITIONING - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY
^ HEATER - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY
Article No. 88-20-13
LIGHT TRUCK: 1985-88 ECONOLINE
ISSUE: An auxiliary blower motor that only operates in the high speed mode may be caused by an
open thermal limiter on the auxiliary blower motor resistor. The current location of the resistor does
not allow the thermal limiter to properly cool.
ACTION: Install a new blower motor resistor in a new location to achieve better cooling of the
thermal limiter. Refer to the following service procedure for removal and installation instructions.
1. Remove the auxiliary "A/C-Heater" or "Heater" cover assembly.
2. Disconnect the blower motor resistor wiring connectors.
3. Remove the resistor and two (2) mounting clips from the resistor mounting posts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > Customer Interest: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only > Page 5713
FIGURE 7
4. Cut out the template, Figure 7.
FIGURE 8
5. Position the template on the plastic case as shown in Figure 8.
6. Scribe the plastic case to correctly locate the resistor opening and two (2) mounting screw holes.
7. Cut the resistor opening with a hot knife or a saw. Using a 5/32" drill bit, drill the two (2) new
mounting screw holes.
8. Install the two (2) resistor mounting clips removed in Step 3 over the new mounting screw holes.
9. Position the new blower motor resistor, (E8UZ- 19A706-A) with the windings facing upward.
FIGURE 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > Customer Interest: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only > Page 5714
10. Install the two (2) mounting screws, Figure 9.
NOTE: MAKE SURE THE BLOWER MOTOR RESISTOR COILS OR COIL TERMINALS ARE NOT
TOUCHING THE PLASTIC CASE. ADJUST THE MOUNTING LOCATION IF NECESSARY.
11. Reconnect the blower motor resistor wiring connectors.
12. Make sure the auxiliary blower motor operates at each speed mode.
13. Reinstall the auxiliary "A/C-Heater" or "Heater" cover assembly.
PART NUMBER PART NAME CLASS
E8UZ-19A706-A Resistor-Blower Motor B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: 882013A TIME:
0.7 Hr.
DLR. CODING: Basic Part No. 19A706 Condition Code: 46
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only
Blower Motor Resistor: All Technical Service Bulletins Auxiliary Blower Motor - Operates On High
Only
^ AIR CONDITIONING - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY
^ HEATER - AUXILIARY BLOWER MOTOR OPERATES ON HIGH ONLY
Article No. 88-20-13
LIGHT TRUCK: 1985-88 ECONOLINE
ISSUE: An auxiliary blower motor that only operates in the high speed mode may be caused by an
open thermal limiter on the auxiliary blower motor resistor. The current location of the resistor does
not allow the thermal limiter to properly cool.
ACTION: Install a new blower motor resistor in a new location to achieve better cooling of the
thermal limiter. Refer to the following service procedure for removal and installation instructions.
1. Remove the auxiliary "A/C-Heater" or "Heater" cover assembly.
2. Disconnect the blower motor resistor wiring connectors.
3. Remove the resistor and two (2) mounting clips from the resistor mounting posts.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only
> Page 5720
FIGURE 7
4. Cut out the template, Figure 7.
FIGURE 8
5. Position the template on the plastic case as shown in Figure 8.
6. Scribe the plastic case to correctly locate the resistor opening and two (2) mounting screw holes.
7. Cut the resistor opening with a hot knife or a saw. Using a 5/32" drill bit, drill the two (2) new
mounting screw holes.
8. Install the two (2) resistor mounting clips removed in Step 3 over the new mounting screw holes.
9. Position the new blower motor resistor, (E8UZ- 19A706-A) with the windings facing upward.
FIGURE 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Technical Service Bulletins: > 882013 > Sep > 88 > Auxiliary Blower Motor - Operates On High Only
> Page 5721
10. Install the two (2) mounting screws, Figure 9.
NOTE: MAKE SURE THE BLOWER MOTOR RESISTOR COILS OR COIL TERMINALS ARE NOT
TOUCHING THE PLASTIC CASE. ADJUST THE MOUNTING LOCATION IF NECESSARY.
11. Reconnect the blower motor resistor wiring connectors.
12. Make sure the auxiliary blower motor operates at each speed mode.
13. Reinstall the auxiliary "A/C-Heater" or "Heater" cover assembly.
PART NUMBER PART NAME CLASS
E8UZ-19A706-A Resistor-Blower Motor B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: 882013A TIME:
0.7 Hr.
DLR. CODING: Basic Part No. 19A706 Condition Code: 46
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition
Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Engine - Lack of Power and/or No
Start Condition
Article No. 95-7-11
04/10/95
^ LACK OF POWER - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
^ NO START - VEHICLES WITH 7.5L ENGINE AND CATALYTIC CONVERTER
LIGHT TRUCK: 1988-93 ECONOLINE, F-25O, F-350
CALIBRATION: 8-97A-R02, 8-97A-R10, 8-98A-R02, 8-98A-R10, 0-97A-R05, 0-97A-R10,
0-98F-R05, 0-98F-R10, 1-97A-R00, 1-98F-R00, 1-98C-R00, 0-98C-R00, 9-98A-R00, 0-98E-R05,
0-98E-R10, 0-98A-R05, 0-98A-R10, 1-98A-R00, 1-98E-R00, 2-98E-R00, 2-98E-R10, 2-98A-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS
MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD
CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
This TSB does not include the F-47/53 Series, over 14,000 lb GVW being covered by Owner
Notification Program 94B37.
ISSUE: Some vehicles may exhibit a lack of power or a no start condition. This condition may be
diagnosed as an exhaust restriction caused by a plugged catalytic converter and/or muffler. Idle
quality may be poor during both cold and warm engine temperatures.
ACTION: Determine if the catalyst is plugged and replace as necessary. Replace the Powertrain
Control Module (PCM) with a new PCM which has a new operating strategy, the Idle Speed Control
(ISO) Actuator and the Expansion Chamber. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 5727
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 5728
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 5729
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 5730
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 5731
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 5732
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 5733
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 5739
1. Determine if the catalyst is plugged. Refer to TSB 94-2-23 and the flow chart (Figure 1) in this
article. Service as required.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 5740
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 5741
2. Replace the Powertrain Control Module (see Application Charts in Figures 2 and 3). Refer to the
appropriate Service Manual for removal and installation procedures.
3. Replace the Idle Speed Control Actuator (see Application Charts in Figures 2 and 3). Refer to
the appropriate Service Manual for removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 5742
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for
removal and installation procedures.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 5743
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 5744
The new PCM has a new strategy that will use a three-digit self test error code. Figures 5 and 6 list
the cross reference between two- and three-digit codes.
CORE RETURN PROCEDURE
Please refer to the Instruction Sheet included with the new PCM to immediately return the PCM
core via the Fedex AWB/Shipper enclosed.
^ For vehicles repaired under warranty, return the core immediately once the Blue FPS700 tag is
received. Return the core ASAP to Ford Electronics.
^ For non-warranty vehicles, return the core immediately to Ford Electronics via Fedex
AWB/Shipper enclosed.
This is a pilot Federal Express core return program initiated to address return of cores. Dealer must
use airbills included in cartons. Use the following procedure to ship the PCM cores.
SHIPPING PROCEDURE
1. Take the Fedex airbill and fill in all the sender information in Area 1 - your dealership name and
address; you do not need to enter your own Fedex account number.
2. On the line immediately below your City/State is a line labeled Your international Billing
Reference Information" - you will see pre-printed "DLR # /Y Shipper # " - you must enter your
five-digit dealer code number, then the six-digit "Y" shipper number for this part shipment. DEALER
NUMBER THEN "Y" SHIPPER NUMBER, IN THAT ORDER.
3. Everything else on the airbill has been completed for you, please do not change anything.
4. Call Fedex at 1-800-238-5355 to schedule a pickup. Call as early in the day as possible and ask
that the Fedex Courier come to the Parts Department for a pickup. Keep the pink copy of the airbill
for your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Blower Motor Resistor: > 95711 > Apr > 95 > Engine - Lack of Power
and/or No Start Condition > Page 5745
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of
modifications performed. Select a prominent place adjacent to the Vehicle Emission Control
Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install
the decal, and cover it with a clear plastic decal shield.
Parts Block
OTHER APPLICABLE ARTICLES: 94-2-23 WARRANTY STATUS: Eligible Under The Provisions
Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
950711A Perform Exhaust System 0.8 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1988-91 F-250-350 And 1988-93 Econoline
950711B Perform Exhaust System 1.2 Hr.
Diagnosis (Refer To TSB 94-2-23), Replace ISC, PCM And Replace Idle Air Bypass Hose With
Integral Chamber - 1992-93 F-250-350
DEALER CODING
BASIC PART NO. CONDITION CODE
12A650 2G01
OASIS CODES: 403000, 603300, 614000, 614500, 690000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Technical
Service Bulletins > Page 5746
Blower Motor Resistor: Locations
Inside Plenum
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations >
Auxiliary Blower Switch
Blower Motor Switch: Locations Auxiliary Blower Switch
Behind Heater Control Assembly
RH Side Of Control Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations >
Auxiliary Blower Switch > Page 5751
Blower Motor Switch: Locations Front Blower Switch
LH Side Of Control Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications
Air Conditioning Specifications
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 5756
Compressor Clutch: Testing and Inspection
Compressor clutch diagnosis (Part 1 of 2).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 5757
Fig. 8 Compressor clutch diagnosis (Part 2 of 2).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations
Compressor Clutch Coil: Locations
On Compressor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Service and Repair > FS-6, Nippon 6P148, 6E171, 10P15, FX-15
Compressor Clutch Coil: Service and Repair FS-6, Nippon 6P148, 6E171, 10P15, FX-15
CLUTCH FIELD COIL
REMOVAL
1. Remove clutch hub and pulley.
2. Remove snap ring retaining clutch field coil on front of compressor.
3. Remove field coil.
INSTALLATION
1. Position clutch field coil to compressor, engaging locator pin on compressor head with hole in
clutch field coil.
2. Install snap ring to retain clutch field coil on compressor with bevel side out.
3. Install pulley and hub on compressor.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Service and Repair > FS-6, Nippon 6P148, 6E171, 10P15, FX-15 > Page 5763
Compressor Clutch Coil: Service and Repair HR-980 (Clutch Hub, Pulley & Field Coil Replace)
Removal
Fig. 1 Clutch assembly exploded view
1. Hold clutch hub with suitable spanner wrench and remove retaining nut, Fig. 1.
2. Remove clutch hub using tool No. T80L19703-B or equivalent, then withdraw shims, noting
thickness for assembly.
3. Remove clutch pulley retaining nut using spanner wrench T83P-19623-A or equivalent.
4. Remove pulley and bearing assembly and field coil from compressor, using suitable puller if
necessary.
5. If pulley bearing is to be replaced, proceed as follows:
a. Support pulley with large opening of tool No. T80L-19703-E or equivalent, then drive bearing
from pulley using suitable spacer. b. Place pulley friction face over small opening in support tool. c.
Position new bearing in bore and seat bearing using suitable driver. d. Stake bearing to pulley in
three equally spaced positions, taking care not to damage bearing. Do not stake bearing in
locations used to
stake the removed bearing.
Installation
1. Thoroughly clean front of compressor.
2. Mount clutch field coil on compressor with electrical connector on top and slots in coil engaging
housing lugs.
3. Align pulley bearing with boss on compressor head, then slide pulley and bearing assembly onto
compressor. The bearing should be a slip fit on compressor head when properly aligned. However,
if difficulty is encountered when installing bearing and pulley assembly, lightly tap assembly using
driver T80L-19703-J or equivalent and a light hammer.
4. Apply suitable thread locking compound to threads of pulley retaining nut. Install nut and torque
to 56-70 ft. lbs. using a suitable spanner wrench.
5. Mount clutch hub shims and clutch on compressor, ensuring drive key is properly aligned with
keyway, then press hub into position using tool No. T80L-19703-F or equivalent. Do not attempt to
drive clutch hub onto shaft, as compressor will be damaged.
6. Install hub retaining nut and torque to 10-14 ft. lbs.
7. Check air gap between hub and pulley mating surface at three equally spaced positions and
record the readings.
8. Rotate pulley one-half turn and repeat step 7.
9. If smallest measured air gap is not within specifications, replace hub shims as needed to obtain
specified clearance.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component
Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15
Compressor Clutch Hub: Service and Repair FS-6, Nippon, 6P148, 6E171, 10P15, FX-15
Removal
Fig. 1 Clutch hub removal
1. Remove clutch hub retaining nut using spanner wrench T81P-19623-MH or equivalent.
2. Remove clutch hub and shims from compressor shaft with tool T80L-19703-B or equivalent, Fig.
1. Holding tool with 1 inch wrench, tighten bolt with 1/2 inch wrench.
Fig. 2 Disassembled view of clutch assembly. FS-6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component
Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 5768
Fig. 3 Disassembled view of clutch assembly. 6P148
3. Remove clutch pulley retaining snap ring, Figs. 2 and 3.
Fig. 4 Clutch pulley removal
4. Remove pulley and bearing assembly from compressor. If pulley and bearing assembly cannot
be removed by hand, use a suitable puller, Fig. 4.
Installation
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component
Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 5769
Clutch Pulley Installation
1. Clean pulley bearing surface of compressor.
2. Install pulley and bearing on compressor. Bearing should be a slip fit onto compressor head. If
difficulty is encountered installing pulley, gently tap pulley on compressor using tool T80L-19703-J
or equivalent, Fig. 5. Be sure pulley bearing is aligned with compressor head.
3. Install pulley retaining snap ring with bevel side out.
Fig. 6 Clutch hub installation
4. Install clutch hub on compressor shaft using new shims between clutch hub and end of shaft. Be
sure shaft key is aligned with keyway in clutch hub. Do not attempt to drive hub on compressor
shaft as damage to compressor will result. Use tool T80L-19703-F or equivalent if hub will not
easily slide on compressor shaft, Fig. 6.
5. Install hub retaining nut on compressor shaft and torque to 10-14 ft. lbs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component
Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 5770
Fig. 7 Checking clutch air gap
6. Check clutch air gap between hub and pulley mating surface in three locations equally spaced,
Fig. 7. Then rotate pulley one-half turn and check air gap again. The smallest air gap must be
within specification. Add or remove shims until desired limit is attained.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component
Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 5771
Compressor Clutch Hub: Service and Repair HR-980
Removal
Fig. 1 Clutch assembly exploded view
1. Hold clutch hub with suitable spanner wrench and remove retaining nut, Fig. 1.
2. Remove clutch hub using tool No. T80L19703-B or equivalent, then withdraw shims, noting
thickness for assembly.
3. Remove clutch pulley retaining nut using spanner wrench T83P-19623-A or equivalent.
4. Remove pulley and bearing assembly and field coil from compressor, using suitable puller if
necessary.
5. If pulley bearing is to be replaced, proceed as follows:
a. Support pulley with large opening of tool No. T80L-19703-E or equivalent, then drive bearing
from pulley using suitable spacer. b. Place pulley friction face over small opening in support tool. c.
Position new bearing in bore and seat bearing using suitable driver. d. Stake bearing to pulley in
three equally spaced positions, taking care not to damage bearing. Do not stake bearing in
locations used to
stake the removed bearing.
Installation
1. Thoroughly clean front of compressor.
2. Mount clutch field coil on compressor with electrical connector on top and slots in coil engaging
housing lugs.
3. Align pulley bearing with boss on compressor head, then slide pulley and bearing assembly onto
compressor. The bearing should be a slip fit on compressor head when properly aligned. However,
if difficulty is encountered when installing bearing and pulley assembly, lightly tap assembly using
driver T80L-19703-J or equivalent and a light hammer.
4. Apply suitable thread locking compound to threads of pulley retaining nut. Install nut and torque
to 56-70 ft. lbs. using a suitable spanner wrench.
5. Mount clutch hub shims and clutch on compressor, ensuring drive key is properly aligned with
keyway, then press hub into position using tool No. T80L-19703-F or equivalent. Do not attempt to
drive clutch hub onto shaft, as compressor will be damaged.
6. Install hub retaining nut and torque to 10-14 ft. lbs.
7. Check air gap between hub and pulley mating surface at three equally spaced positions and
record the readings.
8. Rotate pulley one-half turn and repeat step 7.
9. If smallest measured air gap is not within specifications, replace hub shims as needed to obtain
specified clearance.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component
Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15
Compressor Pulley: Service and Repair FS-6, Nippon, 6P148, 6E171, 10P15, FX-15
Removal
Fig. 1 Clutch hub removal
1. Remove clutch hub retaining nut using spanner wrench T81P-19623-MH or equivalent.
2. Remove clutch hub and shims from compressor shaft with tool T80L-19703-B or equivalent, Fig.
1. Holding tool with 1 inch wrench, tighten bolt with 1/2 inch wrench.
Fig. 2 Disassembled view of clutch assembly. FS-6
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component
Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 5776
Fig. 3 Disassembled view of clutch assembly. 6P148
3. Remove clutch pulley retaining snap ring, Figs. 2 and 3.
Fig. 4 Clutch pulley removal
4. Remove pulley and bearing assembly from compressor. If pulley and bearing assembly cannot
be removed by hand, use a suitable puller, Fig. 4.
Installation
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component
Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 5777
Clutch Pulley Installation
1. Clean pulley bearing surface of compressor.
2. Install pulley and bearing on compressor. Bearing should be a slip fit onto compressor head. If
difficulty is encountered installing pulley, gently tap pulley on compressor using tool T80L-19703-J
or equivalent, Fig. 5. Be sure pulley bearing is aligned with compressor head.
3. Install pulley retaining snap ring with bevel side out.
Fig. 6 Clutch hub installation
4. Install clutch hub on compressor shaft using new shims between clutch hub and end of shaft. Be
sure shaft key is aligned with keyway in clutch hub. Do not attempt to drive hub on compressor
shaft as damage to compressor will result. Use tool T80L-19703-F or equivalent if hub will not
easily slide on compressor shaft, Fig. 6.
5. Install hub retaining nut on compressor shaft and torque to 10-14 ft. lbs.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component
Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 5778
Fig. 7 Checking clutch air gap
6. Check clutch air gap between hub and pulley mating surface in three locations equally spaced,
Fig. 7. Then rotate pulley one-half turn and check air gap again. The smallest air gap must be
within specification. Add or remove shims until desired limit is attained.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component
Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 5779
Compressor Pulley: Service and Repair HR-980 (Clutch Hub, Pulley & Field Coil Replace)
Removal
Fig. 1 Clutch assembly exploded view
1. Hold clutch hub with suitable spanner wrench and remove retaining nut, Fig. 1.
2. Remove clutch hub using tool No. T80L19703-B or equivalent, then withdraw shims, noting
thickness for assembly.
3. Remove clutch pulley retaining nut using spanner wrench T83P-19623-A or equivalent.
4. Remove pulley and bearing assembly and field coil from compressor, using suitable puller if
necessary.
5. If pulley bearing is to be replaced, proceed as follows:
a. Support pulley with large opening of tool No. T80L-19703-E or equivalent, then drive bearing
from pulley using suitable spacer. b. Place pulley friction face over small opening in support tool. c.
Position new bearing in bore and seat bearing using suitable driver. d. Stake bearing to pulley in
three equally spaced positions, taking care not to damage bearing. Do not stake bearing in
locations used to
stake the removed bearing.
Installation
1. Thoroughly clean front of compressor.
2. Mount clutch field coil on compressor with electrical connector on top and slots in coil engaging
housing lugs.
3. Align pulley bearing with boss on compressor head, then slide pulley and bearing assembly onto
compressor. The bearing should be a slip fit on compressor head when properly aligned. However,
if difficulty is encountered when installing bearing and pulley assembly, lightly tap assembly using
driver T80L-19703-J or equivalent and a light hammer.
4. Apply suitable thread locking compound to threads of pulley retaining nut. Install nut and torque
to 56-70 ft. lbs. using a suitable spanner wrench.
5. Mount clutch hub shims and clutch on compressor, ensuring drive key is properly aligned with
keyway, then press hub into position using tool No. T80L-19703-F or equivalent. Do not attempt to
drive clutch hub onto shaft, as compressor will be damaged.
6. Install hub retaining nut and torque to 10-14 ft. lbs.
7. Check air gap between hub and pulley mating surface at three equally spaced positions and
record the readings.
8. Rotate pulley one-half turn and repeat step 7.
9. If smallest measured air gap is not within specifications, replace hub shims as needed to obtain
specified clearance.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service and Repair > With HR-980 Compressor
Compressor Shaft Seal: Service and Repair With HR-980 Compressor
Removal
Fig. 2 Compressor shaft seal assembly exploded view
1. Discharge A/C system and remove compressor from vehicle.
2. Mount compressor in holding fixture T57L-500-B or equivalent.
3. remove clutch hub, pulley and field coil as outlined, then pry drive key from compressor shaft,
taking care not to damage shaft.
4. Pry dust shield from compressor, Fig. 2, taking care not to damage housing.
5. Remove ceramic seat retaining ring, then clean area surrounding compressor seal to prevent dirt
from entering compressor.
6. Insert tool No. T71P-19703-M or equivalent into recess of ceramic seat, tighten tool outer sleeve
to expand tool into seat, then pull seat from compressor using a twisting motion.
7. Remove ceramic seat O-ring from compressor neck.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service and Repair > With HR-980 Compressor > Page 5784
Fig. 3 Compressor seal replacement tool
8. Insert tool No. T71P-19703-G or equivalent into compressor neck. Rotate tool clockwise while
pressing against seal to engage tangs on tool, Fig. 3, then pull seal from compressor.
Installation
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service and Repair > With HR-980 Compressor > Page 5785
Fig. 4 Seal seat O-ring installation
1. Inspect compressor shaft and seal seat areas, and clean or repair as necessary.
2. Coat new O-ring seal with clean refrigerant oil. Refer to Fig. 4 and install O-ring as follows:
a. Position O-ring guide over compressor shaft and insert O-ring into installation tool. b. Install
O-ring and sleeve assembly over guide. c. Slide installer over guide and into sleeve, bottoming
installer against guide. d. Lift up on O-ring sleeve to allow O-ring to slip into installed position, then
remove sleeve, installer and guide.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service and Repair > With HR-980 Compressor > Page 5786
Fig. 3 Compressor seal replacement tool
3. Coat new shaft seal with clean refrigerant oil and mount seal on tool No. T71P-19703-G or
equivalent, Fig. 3.
4. Place suitable seal protector over compressor shaft, then press seal into compressor with
twisting motion until seal engages flats on compressor shaft and is fully seated.
5. Press down and rotate seal installer to disengage tangs, then remove installer.
6. Coat ceramic seat with clean refrigerant oil and grip seat with tool No. T71P-19703-M or
equivalent.
7. Install ceramic seat with clockwise rotation, taking care not to damage or dislodge O-ring.
8. Remove ceramic seat installer and protective sleeve.
9. Install snap ring with flat side toward ceramic seat and ensure snap ring is fully seated in groove.
Do not tap against snap ring to seat ring in groove, as ceramic seat may be damaged.
10. Install dust shield in compressor neck.
11. Install clutch drive key and clutch components previously removed.
12. Reinstall compressor. Ensure system is properly charged with refrigerant oil, evacuate and
recharge system, then check for leaks.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service and Repair > With HR-980 Compressor > Page 5787
Compressor Shaft Seal: Service and Repair With FX-15 Compressor
Removal
Fig. 2 Compressor shaft seal assembly exploded view
1. Discharge A/C system and remove compressor from vehicle.
2. Mount compressor in holding fixture T57L-500-B or equivalent.
3. remove clutch hub, pulley and field coil as outlined, then pry drive key from compressor shaft,
taking care not to damage shaft.
4. Pry dust shield from compressor, Fig. 2, taking care not to damage housing.
5. Remove ceramic seat retaining ring, then clean area surrounding compressor seal to prevent dirt
from entering compressor.
6. Insert tool No. T71P-19703-M or equivalent into recess of ceramic seat, tighten tool outer sleeve
to expand tool into seat, then pull seat from compressor using a twisting motion.
7. Remove ceramic seat O-ring from compressor neck.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service and Repair > With HR-980 Compressor > Page 5788
Fig. 3 Compressor seal replacement tool
8. Insert tool No. T71P-19703-G or equivalent into compressor neck. Rotate tool clockwise while
pressing against seal to engage tangs on tool, Fig. 3, then pull seal from compressor.
Installation
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service and Repair > With HR-980 Compressor > Page 5789
Fig. 4 Seal seat O-ring installation
1. Inspect compressor shaft and seal seat areas, and clean or repair as necessary.
2. Coat new O-ring seal with clean refrigerant oil. Refer to Fig. 4 and install O-ring as follows:
a. Position O-ring guide over compressor shaft and insert O-ring into installation tool. b. Install
O-ring and sleeve assembly over guide. c. Slide installer over guide and into sleeve, bottoming
installer against guide. d. Lift up on O-ring sleeve to allow O-ring to slip into installed position, then
remove sleeve, installer and guide.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service and Repair > With HR-980 Compressor > Page 5790
Fig. 3 Compressor seal replacement tool
3. Coat new shaft seal with clean refrigerant oil and mount seal on tool No. T71P-19703-G or
equivalent, Fig. 3.
4. Place suitable seal protector over compressor shaft, then press seal into compressor with
twisting motion until seal engages flats on compressor shaft and is fully seated.
5. Press down and rotate seal installer to disengage tangs, then remove installer.
6. Coat ceramic seat with clean refrigerant oil and grip seat with tool No. T71P-19703-M or
equivalent.
7. Install ceramic seat with clockwise rotation, taking care not to damage or dislodge O-ring.
8. Remove ceramic seat installer and protective sleeve.
9. Install snap ring with flat side toward ceramic seat and ensure snap ring is fully seated in groove.
Do not tap against snap ring to seat ring in groove, as ceramic seat may be damaged.
10. Install dust shield in compressor neck.
11. Install clutch drive key and clutch components previously removed.
12. Reinstall compressor. Ensure system is properly charged with refrigerant oil, evacuate and
recharge system, then check for leaks.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service
Bulletins > Customer Interest: > 872019 > Oct > 87 > A/C Condenser Outlet Tube - Refrigerant Leak
Condenser HVAC: Customer Interest A/C Condenser Outlet Tube - Refrigerant Leak
Article No. AIR CONDITIONING - LEAKS REFRIGERANT 87-20-19 CONDENSER OUTLET TUBE CRACKED
LIGHT TRUCK: 1984-87 ECONOLINE
ISSUE: Refrigerant leaks at the condenser outlet tube to the receiver/drier fitting may be caused by
a fitting that was overtightened during production. The overtightening of the fitting may cause the
condenser outlet tube to crack.
ACTION: To correct this, install a new condenser outlet tube. Torque the outlet tube to
receiver/drier fitting to 5-10 ft.lbs. (7-13 N-m).
NOTE: It is not necessary to replace the condenser assembly.
PART NUMBER PART NAME CLASS
E4UZ-19835-A Condenser Outlet Tube B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: SP872019A TIME:
0.9 Hr. DLR. CODING: Basic Part No. 19835 - Code: 01
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 95184 > Sep > 95 > Air Conditioning - Approved Flushing Procedures
Condenser HVAC: All Technical Service Bulletins Air Conditioning - Approved Flushing Procedures
Article No. 95-18-4
09/11/95
AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP
FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT,
MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95
ASPIRE 1995-96 CONTOUR
LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ
1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE
1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES
1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96
WINDSTAR
This TSB is being republished in its entirety to include Labor Operations for system flushing.
ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC
method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This
procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The
types of contamination flushed include particle matter which results from compressor or desiccant
failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford
authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral
oil for capacity reasons.
ACTION: Refer to the following text for proper flushing procedures.
The flushing procedure is a two-step process which involves the use of an A/C Flusher. The
Flusher is used to do the following:
1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of
normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the
solvent is returned to the reservoir for continued circulation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 95184 > Sep > 95 > Air Conditioning - Approved Flushing Procedures > Page
5804
2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125
psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat
exchangers.
Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher,
014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15
L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford
Motor Company for flushing A/C systems. The use of other equipment or solvent may cause
damage to the A/C system and the flushing unit.
Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to
continue air purge for the entire 30 minutes as specified may result in residual amounts of flush
solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead
to A/C system failure.
Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses.
Internal plumbing and material make-up of these components make it impossible to properly
remove the debris and/or residual flushing solvent.
One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended
for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but
under no circumstances should it be used on more than one (1) vehicle. The filter used when
flushing is also intended for use on one (1) vehicle only.
NOTE:
DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE
A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN
ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS.
Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed.
Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are
clogged with debris, hose replacement is required.
Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and
receiver/drier when servicing an A/C system with a compressor or desiccant failure.
The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for
capacity reasons.
^ 1993 Probe 2.0L and 2.5L
^ 1988-90 Escort 1.9L EFI
^ 1989-93 Thunderbird Super Coupe
^ 1986-92 Mark VII
^ 1991-93 Capri 1.6L and 1.6T
^ 1988-93 Festiva 1 .3L
^ 1987-90 Tracer 1.6L
^ 1985-89 XR4Ti
^ 1988-89 Scorpio
OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All
Other 1992-95 Models
OPERATION DESCRIPTION TIME
951804A Flush Evaporator 1.0 Hr.
951804B Flush Condenser 1.0 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
19703 49
OASIS CODES: 208000, 208200, 208999
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 872019 > Oct > 87 > A/C Condenser Outlet Tube - Refrigerant Leak
Condenser HVAC: All Technical Service Bulletins A/C Condenser Outlet Tube - Refrigerant Leak
Article No. AIR CONDITIONING - LEAKS REFRIGERANT 87-20-19 CONDENSER OUTLET TUBE CRACKED
LIGHT TRUCK: 1984-87 ECONOLINE
ISSUE: Refrigerant leaks at the condenser outlet tube to the receiver/drier fitting may be caused by
a fitting that was overtightened during production. The overtightening of the fitting may cause the
condenser outlet tube to crack.
ACTION: To correct this, install a new condenser outlet tube. Torque the outlet tube to
receiver/drier fitting to 5-10 ft.lbs. (7-13 N-m).
NOTE: It is not necessary to replace the condenser assembly.
PART NUMBER PART NAME CLASS
E4UZ-19835-A Condenser Outlet Tube B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: SP872019A TIME:
0.9 Hr. DLR. CODING: Basic Part No. 19835 - Code: 01
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Condenser HVAC: > 932410 > Nov > 93 > Instrument Cluster Warning Lights Dimly Lit
Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit
Article No. 93-24-10
11/24/93
^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG,
THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO
LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND
MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ
LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91
AEROSTAR 1991-93 EXPLORER
ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of
the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch.
ACTION:
If the vehicle displays the subject symptoms and meets the following conditions, replace the
ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for
1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks,
Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the
Parts Block in this article for correct parts usage.
CONDITIONS
^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring
schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Condenser HVAC: > 932410 > Nov > 93 > Instrument Cluster Warning Lights Dimly Lit > Page 5814
^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part
Number Chart.
NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL
HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN
IMPROVED TO CORRECT THE SUBJECT ISSUE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models
Except Lincolns. Major Component Warranty Coverage For Lincolns
OPERATION DESCRIPTION TIME
932410A Replace Ignition Switch - 0.5 Hr.
All Light and Compact Trucks
DEALER CODING
BASIC PART NO. CONDITION CODE
11572 X1
OASIS CODES: 201000, 201100, 206000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Condenser HVAC: > 932410 > Nov > 93 > Instrument Cluster Warning Lights Dimly Lit > Page 5820
^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part
Number Chart.
NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL
HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN
IMPROVED TO CORRECT THE SUBJECT ISSUE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models
Except Lincolns. Major Component Warranty Coverage For Lincolns
OPERATION DESCRIPTION TIME
932410A Replace Ignition Switch - 0.5 Hr.
All Light and Compact Trucks
DEALER CODING
BASIC PART NO. CONDITION CODE
11572 X1
OASIS CODES: 201000, 201100, 206000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service
Bulletins > Page 5821
Condenser HVAC: Service and Repair
1. Discharge refrigerant from system.
2. Disconnect compressor discharge line and liquid line from condenser and cap both lines.
3. Remove two screws attaching hood latch to radiator support and position latch aside.
4. Remove nine screws attaching top edge of radiator grille to radiator support.
5. Remove screw attaching center area of grille to grille center support.
6. Remove grille center support to radiator support attaching screw.
Fig. 1 Receiver & condenser assembly
7. Working under vehicle, reposition splash shields and remove two condenser lower retaining
nuts, Fig. 1.
8. Remove two bolts attaching top of condenser to radiator upper support.
9. Remove four bolts attaching each end of radiator upper support to radiator side supports.
10. Pull top edge of grille forward, remove radiator upper support, and lift condenser from vehicle.
11. Reverse procedure to install. Use new O-rings lubricated with refrigerant oil.
12. Leak test, evacuate and charge system. Check system for proper operation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Control Assembly, HVAC
Control Assembly: Service and Repair Control Assembly, HVAC
Fig. 8 Control assembly removal
1. Remove knobs from control assembly levers.
2. Remove applique.
3. Remove control assembly from mounting bracket, Fig. 8.
4. Carefully pull control assembly from opening in mounting bracket and disconnect control cables,
wiring connectors and vacuum harness from control assembly.
5. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Control Assembly, HVAC > Page 5826
Control Assembly: Service and Repair Control Panel Assembly Replace
Fig. 8 Control assembly removal
1. Remove knobs from control assembly levers.
2. Remove applique.
3. Remove control assembly from mounting bracket, Fig. 8.
4. Carefully pull control assembly from opening in mounting bracket and disconnect control cables,
wiring connectors and vacuum harness from control assembly.
5. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information >
Technical Service Bulletins > A/C - New Refrigerant O-Rings
A/C Coupler O-ring: Technical Service Bulletins A/C - New Refrigerant O-Rings
Article No. 91-22-5 10/30/91
AIR CONDITIONING - NEW REFRIGERANT FITTING "O" RINGS (GREEN COLOR) AVAILABLE
TO PROVIDE IMPROVED SEALING AND DURABILITY
FORD: 1985-86 LTD 1985-92 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO,
THUNDERBIRD 1986-92 TAURUS
LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-92 CONTINENTAL,
COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-92 SABLE 1991-92
TRACER
LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150-350 SERIES,
RANGER 1986-92 AEROSTAR 1988-92 F SUPER DUTY 1989-92 F-47 1991-92 EXPLORER
ISSUE: New refrigerant 0-rings (GREEN COLOR) are available for use in the Ford Spring Lock
Coupling (SLC) and threaded (Tube-0) connections. The new GREEN COLORED 0-ring material
provides improved sealing and longer seal life. Use of any other 0-ring for Ford refrigerant fittings is
not recommended and may result in premature leakage at the fitting.
ACTION: If a refrigerant system repair is made which requires an A/C fitting to be disconnected,
replace the existing 0-rings with the new GREEN COLORED type. Refer to the following 0-ring
Usage Chart for identifying the correct 0-ring.
O-RING USAGE CHART
(SLC) (SLC) (TUBE-0) (TUBE-0)
MOTORCRAFT SERVICE MOTORCRAFT SERVICE
SIZE PART NO. PART NO. PART NO. PART NO.
3/8" YF-1753 391302-S100 YF-1753 391302-S100
1/2" YF-1754 391303-S100 YF-1754 391303-S100
5/8" YF-1755 391304-S100 YF-1756 391306-S100
3/4" YF-1752 3913O5-S100 YF-1757 391307-S100
PART NUMBER PART NAME CLASS
391302-S100 3/8" 0-ring (SLC & TUBE-0, S
Pkg./6)
391303-S100 1/2" 0-ring (SLC & TUBE-0, S
Pkg./6)
391304-S100 5/8" 0-ring (SLC, Pkg./6) S
391306-S100 5/8" 0-ring (TUBE-0, Pkg./6) S
391305-S100 3/4" 0-ring (SLC, Pkg./6) S
391307-S100 3/4" 0-ring (TUBE-0, Pkg./4) S
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:
90-14-8
WARRANTY STATUS: INFORMATION ONLY OASIS CODES:
208000, 208999
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment
Evaporator Case: Customer Interest A/C - Condensate Leaks Into Passenger Compartment
Article No. 86-23-14
A/C CONDENSATE LEAKS INTO PASSENGER COMPARTMENT OR DISCHARGES FROM THE
INSTRUMENT PANEL REGISTERS
LIGHT TRUCK 1975-87 ECONOLINE
Condensate may leak from the blower motor area or be expelled through the A/C registers during
high temperature/high humidity conditions when the system is operated in Norm A/C and high
blower.
In these cases, condensate collects in the temperature blend door area and leaks out the seams of
the blower case and/or becomes airborne and is expelled through the A/C registers.
Check to assure that the evaporator housing has been sealed and the straight condensate drain
tube has been installed as outlined in this article. Then, procure and install a new venturi tube and
deflector in the evaporator assembly using the following service procedure.
SERVICE PROCEDURE
A/C Condensate Leaks Into Passenger Compartment - Vehicles Built Prior To March, 1986
Due to improper condensate drainage, water can accumulate in the bottom of the temperature
blend door frame assembly and spill into the blower housing. If this condition occurs, insufficient
sealing at the blower housing to evaporator housing flange and at the blower scroll cover to blower
housing may allow leakage into the passenger compartment from these areas.
An accumulation of water in the blower housing may result in water being blown through the
register ducts and register outlets.
To correct the condition, one or more of the following service procedures should be initiated in the
sequence listed. They are to be initiated on a customer complaint basis.
NOTE: Operation of the blower at a lower speed than Hi will allow accumulated condensate to
drain out the drain tube. Therefore, operation of the blower below HI where possible, or periodic
reduction of the blower speed from HI, will significantly reduce moisture accumulation. Also, when
comfort will allow, operation of the air conditioner in MAX A/C rather than NORM A/C will reduce
condensate accumulation by reducing the humidity entering the vehicle.
Econoline Vehicles With (Production) Aspirator Drain Tube Built After March, 1984
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5840
Figure 22
Drain Tube Replacement (Refer to Figure 22)
1. Pull the aspirator air hose from the aspirator outlet drain tube assembly.
2. Remove the aspirator outlet drain tube assembly from the barbed connection of the plastic
evaporator drain tube projecting inboard from the bottom of the housing.
3. Remove the plastic evaporator drain tube and seal attached to the bottom of the evaporator
housing by removing the two attaching screws with a 5/16 inch socket. Replace existing drain tube
with E5UZ-19858-B drain assembly shown in Figure 22. Apply silicone sealer to the seal surface to
insure a complete seal. Install seal, drain tube and attaching screws.
4. Plug aspirator air hose with rubber cap 382443-S or similar and tape hose out of the way on the
underside of evaporator housing.
Econoline Vehicles With "Duck Bill" Drain Tube Built Prior to March, 1984
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5841
Figure 23
"Duck Bill" Drain Tube Replacement
1. Remove the original drain tube located in the engine compartment on the bottom of the
evaporator housing - two screws (Figure 23).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5842
Figure 24
2. Install the new check valve and drain tube assembly and retainer (service kit D6UZ-19858-B)
using the two hex head 5/8 inch long, No. 10 screws provided (Figure 24). Note that the key tab fits
into the slot towards the front of the vehicle. Two spring nuts are available in the kit, if required.
3. Apply a liberal bead of fillet of silicone sealer to both sides of the sealing surfaces to seal any air
leak paths due to housing surface irregularities.
Procedure For Inspection And Repair Of Evaporator/Blower Housing Flange And Cover Leaks Into
Passenger Compartment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5843
Figure 25
1. If equipped with an EEC IV system module in front of blower housing, remove module cover and
dash flange attaching screws and lay module aside (Figure 25).
2. Check the lower flange of the blower housing to evaporator housing seal and the
OUTSIDE-RECIRC door shaft lower pivot for leaks by plugging the drain tube and placing the
FUNCTION lever in MAX A/C. Then, pour a sufficient quantity of warm water through the RECIRC
door opening until the water level is approximately 3/8 inch deep. If leakage is noted, drain housing
and proceed to the next step. Otherwise, remove plug from drain tube, drain housing and proceed
to Step 6.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5844
Figure 25
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5845
Figure 26
3. If leakage was noted from the bottom end of the OUTSIDE-RECIRC door shaft, blow
compressed air around the end of the shaft area until thoroughly dry. Apply black silicone sealer,
D6AZ-19562-A, liberally to cover completely the end of the shaft and boss to seal the area to the
housing (Figure 26). If leakage was not noted from the evaporator core lower mounting screw, blow
compressed air around the screw head until dry and apply black silicone sealer, D6AZ-19562-A, to
cover the screw head (Figure 26).
4. If leakage was noted from the flange, remove the blower motor resistor connections and the
blower scroll cover (Figure 25). Remove eight screws from the bottom and sides of the housing
flange (two screws inside blower housing). Leave the top three screws in place, as well as the
vacuum actuator shaft clip (Figure 26).
5. Pry the lower flanges of the blower and evaporator housing apart. Thoroughly blow dry the
sealing areas with compressed air. Apply a continuous bead of black silicone rubber sealer on the
sealing surfaces across the bottom flange and 1-1/2 inches up both sides (Figure 26). Carefully
place flanges together and reassemble eight screws. Allow time for the sealer to set up and repeat
leak test of Step 2.
6. Remove blower scroll cover and inspect blower housing cover seal for full contact impression
with edge of blower housing. If full contact is not evident or seal is damaged, replace seal or repair
skip areas with silicone sealer.
7. Reassemble blower scroll cover and electrical connections, and EEC IV system module (if so
equipped).
8. Check for proper blower operation as described in the applicable Shop Manual.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5846
Figure 27
Service Procedure
NOTE: Prior to venturi tube installation, the evaporator housing sealing procedures and installation
of the straight condensate drain tube as described in TSB 85-11-16 and TSB 86-9- 14, must be
performed (Figure 27). (Do not install screen or drain tube in motor blower housing.)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5847
Figure 28
1. Remove the blower motor resistor connections from the blower scroll cover (Figure 28).
2. Remove the blower scroll cover (seven screws) and the blower motor (four screws) from the
blower housing (push/pull the blower motor wire grommet toward the inside of the evaporator).
3. Set the A/C control to an A/C position.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5848
Figure 29
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5849
Figure 34
4. Fabricate template A as shown in Figure 34. Align the template in the blower scroll housing by
aligning the template small hole with the screw hole and scribe the D shape hole on the plastic
blower housing. Remove the template and drill two small holes in the housing (Figure 29) in the
scribed area. Then, cut away the remaining plastic with a sharp X-acto knife. Be careful not to
damage the blend door frame during drilling and cutting.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5850
Figure 30
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5851
Figure 35
5. Fabricate template B as shown in Figure 35 to properly locate the drain hole and insert it in the
door frame assembly. Align the template notch with the lower rib as shown in Figure 30.
6. CAUTION: Insert a small section of scrap metal through the door opening and into the gap
between the right side of the door frame assembly and the evaporator core face to prevent damage
to the evaporator core during the following drilling operation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5852
Figure 30
7. Drill a small pilot hole at the location indicated by template B and then follow with a 1/4 inch drill
being careful to ensure that the edge of the hole is flush with the bottom floor of the frame
assembly and also to not damage the evaporator core. Remove the scrap metal piece and
template B after drilling. See Figure 30.
8. Clean the evaporator floor with a suitable solvent and dry thoroughly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5853
Figure 31
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5854
Figure 32
Figure 33
9. Install the deflector (E7UZ-19B898-A) in the evaporator housing by applying RTV sealant to the
deflector flange, inserting it through the door opening, aligning it with the evaporator face and the
door assembly and then firmly pressing the flange against the evaporator case floor until the
sealant sets. See Figures 31 and 33.
10. Apply sealant to the flange of the venturi tube (E7UZ-18K368-A) and insert the tube through the
hole made in Step 4. See Figure 33. Ensure that the tube end is aligned with the hole made in Step
7. Verify that a 1/8 inch gap exists between the bottom of the tube end and the housing wall for
trapped condensate to exit. See Figure 33. If required, slot the screw hole.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger
Compartment > Page 5855
11. Inspect the blower scroll cover seal for full contact impression with the edge of the blower
housing. If full contact is not evident or the seal is damaged, replace the seal or repair the skipped
areas with RTV sealer.
12. Reassemble the blower, blower scroll, electrical connections and check for proper blower
operation as described in the applicable Shop Manual. Be sure that the blower motor wire grommet
is pulled into the hole in the housing.
PART NUMBER PART NAME CLASS
E5UZ-19858-B Check Valve Assembly A
Production Aspirator Drain Tube Built March, 1984 thru September, 1984
D6UZ-19858-B Check Valve Assembly B
"Duck Bill" Drain Tube Built Prior to March, 1984
E7UZ-19B898-A Deflector C
E7UZ-18K368-A Venturi C
382443-S Rubber Cap BS
D6AZ-19562-A Silicone Sealer A
OTHER APPLICABLE ARTICLES: 86-9-14, 85-11-16 WARRANTY STATUS: Reimbursable within
the provisions of the Warranty and Policy Manual. OPERATION: SP19858A85 TIME:
1.2 Hrs. - Vehicles produced from 1975-84 (produced prior to March, 1984).
1.5 Hrs. - Vehicles produced from March, 1984. OPERATION: SP18424A86 - To be performed
only after one of the above operations has been completed. TIME:
0.9 Hr. DLR. CODING: Basic Part No. 19858 - Code: 48
(Figures 22 through 35 on following pages)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment
Evaporator Case: All Technical Service Bulletins A/C - Condensate Leaks Into Passenger
Compartment
Article No. 86-23-14
A/C CONDENSATE LEAKS INTO PASSENGER COMPARTMENT OR DISCHARGES FROM THE
INSTRUMENT PANEL REGISTERS
LIGHT TRUCK 1975-87 ECONOLINE
Condensate may leak from the blower motor area or be expelled through the A/C registers during
high temperature/high humidity conditions when the system is operated in Norm A/C and high
blower.
In these cases, condensate collects in the temperature blend door area and leaks out the seams of
the blower case and/or becomes airborne and is expelled through the A/C registers.
Check to assure that the evaporator housing has been sealed and the straight condensate drain
tube has been installed as outlined in this article. Then, procure and install a new venturi tube and
deflector in the evaporator assembly using the following service procedure.
SERVICE PROCEDURE
A/C Condensate Leaks Into Passenger Compartment - Vehicles Built Prior To March, 1986
Due to improper condensate drainage, water can accumulate in the bottom of the temperature
blend door frame assembly and spill into the blower housing. If this condition occurs, insufficient
sealing at the blower housing to evaporator housing flange and at the blower scroll cover to blower
housing may allow leakage into the passenger compartment from these areas.
An accumulation of water in the blower housing may result in water being blown through the
register ducts and register outlets.
To correct the condition, one or more of the following service procedures should be initiated in the
sequence listed. They are to be initiated on a customer complaint basis.
NOTE: Operation of the blower at a lower speed than Hi will allow accumulated condensate to
drain out the drain tube. Therefore, operation of the blower below HI where possible, or periodic
reduction of the blower speed from HI, will significantly reduce moisture accumulation. Also, when
comfort will allow, operation of the air conditioner in MAX A/C rather than NORM A/C will reduce
condensate accumulation by reducing the humidity entering the vehicle.
Econoline Vehicles With (Production) Aspirator Drain Tube Built After March, 1984
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5861
Figure 22
Drain Tube Replacement (Refer to Figure 22)
1. Pull the aspirator air hose from the aspirator outlet drain tube assembly.
2. Remove the aspirator outlet drain tube assembly from the barbed connection of the plastic
evaporator drain tube projecting inboard from the bottom of the housing.
3. Remove the plastic evaporator drain tube and seal attached to the bottom of the evaporator
housing by removing the two attaching screws with a 5/16 inch socket. Replace existing drain tube
with E5UZ-19858-B drain assembly shown in Figure 22. Apply silicone sealer to the seal surface to
insure a complete seal. Install seal, drain tube and attaching screws.
4. Plug aspirator air hose with rubber cap 382443-S or similar and tape hose out of the way on the
underside of evaporator housing.
Econoline Vehicles With "Duck Bill" Drain Tube Built Prior to March, 1984
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5862
Figure 23
"Duck Bill" Drain Tube Replacement
1. Remove the original drain tube located in the engine compartment on the bottom of the
evaporator housing - two screws (Figure 23).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5863
Figure 24
2. Install the new check valve and drain tube assembly and retainer (service kit D6UZ-19858-B)
using the two hex head 5/8 inch long, No. 10 screws provided (Figure 24). Note that the key tab fits
into the slot towards the front of the vehicle. Two spring nuts are available in the kit, if required.
3. Apply a liberal bead of fillet of silicone sealer to both sides of the sealing surfaces to seal any air
leak paths due to housing surface irregularities.
Procedure For Inspection And Repair Of Evaporator/Blower Housing Flange And Cover Leaks Into
Passenger Compartment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5864
Figure 25
1. If equipped with an EEC IV system module in front of blower housing, remove module cover and
dash flange attaching screws and lay module aside (Figure 25).
2. Check the lower flange of the blower housing to evaporator housing seal and the
OUTSIDE-RECIRC door shaft lower pivot for leaks by plugging the drain tube and placing the
FUNCTION lever in MAX A/C. Then, pour a sufficient quantity of warm water through the RECIRC
door opening until the water level is approximately 3/8 inch deep. If leakage is noted, drain housing
and proceed to the next step. Otherwise, remove plug from drain tube, drain housing and proceed
to Step 6.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5865
Figure 25
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5866
Figure 26
3. If leakage was noted from the bottom end of the OUTSIDE-RECIRC door shaft, blow
compressed air around the end of the shaft area until thoroughly dry. Apply black silicone sealer,
D6AZ-19562-A, liberally to cover completely the end of the shaft and boss to seal the area to the
housing (Figure 26). If leakage was not noted from the evaporator core lower mounting screw, blow
compressed air around the screw head until dry and apply black silicone sealer, D6AZ-19562-A, to
cover the screw head (Figure 26).
4. If leakage was noted from the flange, remove the blower motor resistor connections and the
blower scroll cover (Figure 25). Remove eight screws from the bottom and sides of the housing
flange (two screws inside blower housing). Leave the top three screws in place, as well as the
vacuum actuator shaft clip (Figure 26).
5. Pry the lower flanges of the blower and evaporator housing apart. Thoroughly blow dry the
sealing areas with compressed air. Apply a continuous bead of black silicone rubber sealer on the
sealing surfaces across the bottom flange and 1-1/2 inches up both sides (Figure 26). Carefully
place flanges together and reassemble eight screws. Allow time for the sealer to set up and repeat
leak test of Step 2.
6. Remove blower scroll cover and inspect blower housing cover seal for full contact impression
with edge of blower housing. If full contact is not evident or seal is damaged, replace seal or repair
skip areas with silicone sealer.
7. Reassemble blower scroll cover and electrical connections, and EEC IV system module (if so
equipped).
8. Check for proper blower operation as described in the applicable Shop Manual.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5867
Figure 27
Service Procedure
NOTE: Prior to venturi tube installation, the evaporator housing sealing procedures and installation
of the straight condensate drain tube as described in TSB 85-11-16 and TSB 86-9- 14, must be
performed (Figure 27). (Do not install screen or drain tube in motor blower housing.)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5868
Figure 28
1. Remove the blower motor resistor connections from the blower scroll cover (Figure 28).
2. Remove the blower scroll cover (seven screws) and the blower motor (four screws) from the
blower housing (push/pull the blower motor wire grommet toward the inside of the evaporator).
3. Set the A/C control to an A/C position.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5869
Figure 29
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5870
Figure 34
4. Fabricate template A as shown in Figure 34. Align the template in the blower scroll housing by
aligning the template small hole with the screw hole and scribe the D shape hole on the plastic
blower housing. Remove the template and drill two small holes in the housing (Figure 29) in the
scribed area. Then, cut away the remaining plastic with a sharp X-acto knife. Be careful not to
damage the blend door frame during drilling and cutting.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5871
Figure 30
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5872
Figure 35
5. Fabricate template B as shown in Figure 35 to properly locate the drain hole and insert it in the
door frame assembly. Align the template notch with the lower rib as shown in Figure 30.
6. CAUTION: Insert a small section of scrap metal through the door opening and into the gap
between the right side of the door frame assembly and the evaporator core face to prevent damage
to the evaporator core during the following drilling operation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5873
Figure 30
7. Drill a small pilot hole at the location indicated by template B and then follow with a 1/4 inch drill
being careful to ensure that the edge of the hole is flush with the bottom floor of the frame
assembly and also to not damage the evaporator core. Remove the scrap metal piece and
template B after drilling. See Figure 30.
8. Clean the evaporator floor with a suitable solvent and dry thoroughly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5874
Figure 31
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5875
Figure 32
Figure 33
9. Install the deflector (E7UZ-19B898-A) in the evaporator housing by applying RTV sealant to the
deflector flange, inserting it through the door opening, aligning it with the evaporator face and the
door assembly and then firmly pressing the flange against the evaporator case floor until the
sealant sets. See Figures 31 and 33.
10. Apply sealant to the flange of the venturi tube (E7UZ-18K368-A) and insert the tube through the
hole made in Step 4. See Figure 33. Ensure that the tube end is aligned with the hole made in Step
7. Verify that a 1/8 inch gap exists between the bottom of the tube end and the housing wall for
trapped condensate to exit. See Figure 33. If required, slot the screw hole.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into
Passenger Compartment > Page 5876
11. Inspect the blower scroll cover seal for full contact impression with the edge of the blower
housing. If full contact is not evident or the seal is damaged, replace the seal or repair the skipped
areas with RTV sealer.
12. Reassemble the blower, blower scroll, electrical connections and check for proper blower
operation as described in the applicable Shop Manual. Be sure that the blower motor wire grommet
is pulled into the hole in the housing.
PART NUMBER PART NAME CLASS
E5UZ-19858-B Check Valve Assembly A
Production Aspirator Drain Tube Built March, 1984 thru September, 1984
D6UZ-19858-B Check Valve Assembly B
"Duck Bill" Drain Tube Built Prior to March, 1984
E7UZ-19B898-A Deflector C
E7UZ-18K368-A Venturi C
382443-S Rubber Cap BS
D6AZ-19562-A Silicone Sealer A
OTHER APPLICABLE ARTICLES: 86-9-14, 85-11-16 WARRANTY STATUS: Reimbursable within
the provisions of the Warranty and Policy Manual. OPERATION: SP19858A85 TIME:
1.2 Hrs. - Vehicles produced from 1975-84 (produced prior to March, 1984).
1.5 Hrs. - Vehicles produced from March, 1984. OPERATION: SP18424A86 - To be performed
only after one of the above operations has been completed. TIME:
0.9 Hr. DLR. CODING: Basic Part No. 19858 - Code: 48
(Figures 22 through 35 on following pages)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Air Conditioning - Approved Flushing Procedures
Evaporator Core: Technical Service Bulletins Air Conditioning - Approved Flushing Procedures
Article No. 95-18-4
09/11/95
AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP
FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT,
MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95
ASPIRE 1995-96 CONTOUR
LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ
1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE
1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES
1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96
WINDSTAR
This TSB is being republished in its entirety to include Labor Operations for system flushing.
ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC
method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This
procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The
types of contamination flushed include particle matter which results from compressor or desiccant
failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford
authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral
oil for capacity reasons.
ACTION: Refer to the following text for proper flushing procedures.
The flushing procedure is a two-step process which involves the use of an A/C Flusher. The
Flusher is used to do the following:
1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of
normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the
solvent is returned to the reservoir for continued circulation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Air Conditioning - Approved Flushing Procedures > Page 5881
2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125
psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat
exchangers.
Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher,
014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15
L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford
Motor Company for flushing A/C systems. The use of other equipment or solvent may cause
damage to the A/C system and the flushing unit.
Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to
continue air purge for the entire 30 minutes as specified may result in residual amounts of flush
solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead
to A/C system failure.
Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses.
Internal plumbing and material make-up of these components make it impossible to properly
remove the debris and/or residual flushing solvent.
One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended
for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but
under no circumstances should it be used on more than one (1) vehicle. The filter used when
flushing is also intended for use on one (1) vehicle only.
NOTE:
DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE
A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN
ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS.
Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed.
Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are
clogged with debris, hose replacement is required.
Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and
receiver/drier when servicing an A/C system with a compressor or desiccant failure.
The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for
capacity reasons.
^ 1993 Probe 2.0L and 2.5L
^ 1988-90 Escort 1.9L EFI
^ 1989-93 Thunderbird Super Coupe
^ 1986-92 Mark VII
^ 1991-93 Capri 1.6L and 1.6T
^ 1988-93 Festiva 1 .3L
^ 1987-90 Tracer 1.6L
^ 1985-89 XR4Ti
^ 1988-89 Scorpio
OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All
Other 1992-95 Models
OPERATION DESCRIPTION TIME
951804A Flush Evaporator 1.0 Hr.
951804B Flush Condenser 1.0 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
19703 49
OASIS CODES: 208000, 208200, 208999
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Page 5882
Evaporator Core: Service and Repair
Fig. 14 Standard evaporator core removal
Standard Evaporator
1. Disconnect blower resistor wiring and vacuum line from outside recirculated door vacuum motor,
Fig. 14.
2. Remove A/C blower cover. Then remove push nut from outside recirculated door shaft.
3. Disconnect control cable from evaporator housing. Remove A/C blower housing.
4. Partially drain engine coolant and disconnect heater hoses from heater core.
5. Remove battery from vehicle. Discharge refrigerant from system.
6. Disconnect refrigerant lines from evaporator core. Plug all open connections to prevent entry of
dirt and moisture into system.
7. Remove drain tube from bottom of evaporator case assembly. Then remove evaporator
assembly from dash, Fig. 14.
8. Remove blend door and housing. Then remove insulation tape from expansion valve bulb.
9. Remove evaporator tube retainer and seal, then the de-icing switch and evaporator core.
10. Reverse procedure to install. Use new O-rings lubricated with refrigerant oil.
11. Evacuate, charge and leak test system. Check for proper operation.
Fig. 15 Auxiliary evaporator core removal
Auxiliary Evaporator
1. Remove first bench seat, if equipped.
2. Remove cover assembly, Fig. 15.
3. Discharge refrigerant from system.
4. Disconnect refrigerant lines from evaporator core. Plug all open connections to prevent entry of
dirt and moisture into system.
5. On models equipped with an auxiliary heater, disconnect and plug heater hoses from auxiliary
heater core.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service
Bulletins > Page 5883
6. On all models, remove four screws securing evaporator core and mounting bracket to auxiliary
case assembly.
7. Remove evaporator core, expansion valve and core mounting plate from case.
8. Reverse procedure to install. Use new O-rings lubricated with refrigerant oil.
9. Evacuate, charge and leak test system. Check for proper operation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Locations
Evaporator Temperature Sensor / Switch: Locations
A/C EVAPORATOR DE-ICING SWITCH
RH Dash Panel
RH Dash Panel Attached To Evaporator
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Service and Repair
Expansion Block/Orifice Tube: Service and Repair
1. Discharge refrigerant from system.
2. Disconnect liquid line from evaporator core inlet tube.
3. Pour a small amount of refrigerant oil into inlet tube to lubricate orifice tube O-rings and inlet
tube.
Fig. 5 Fixed orifice tube removal
4. Using a suitable removal tool, engage the tool with the two tangs on the orifice tube, Fig. 5. Do
not twist or rotate the fixed orifice tube in the evaporator core inlet tube, as it may break off.
5. Hold T-handle of removal tool to prevent it from turning, and run nut down against evaporator
core tube until orifice tube is pulled from inlet tube.
6. Reverse procedure to install. Use new O-rings lubricated with refrigerant oil.
7. Leak test, evacuate and charge system. Check system for proper operation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations
Expansion Valve: Locations
Fig. 7 Auxiliary system expansion valve removal
1. Remove first bench seat, if equipped.
2. Remove auxiliary heater-A/C cover assembly, Fig. 7.
3. Discharge refrigerant from system.
4. Disconnect liquid line from expansion valve and cap liquid line, Fig. 7.
5. Remove insulating tape from evaporator core outlet tube. Then remove clamp and expansion
valve capillary bulb from outlet tube of evaporator core.
6. Remove expansion valve from evaporator core inlet tube.
7. Reverse procedure to install. Use new O-rings lubricated with refrigerant oil.
8. Leak test, evacuate and charge system. Check system for proper operation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations > Page
5893
Expansion Valve: Service and Repair
Fig. 6 Expansion valve removal
1. Disconnect battery cables and remove battery from vehicle.
2. Discharge refrigerant from system.
3. Disconnect liquid inlet hose from expansion valve, Fig. 6, and cap hose.
4. Remove bulb insulation from suction outlet line.
5. Remove capillary tube bulb clamp from suction outlet line.
6. Remove expansion valve from evaporator liquid inlet line.
7. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Locations
Heater Control Valve: Locations
Rear Of Engine Compartment
Above RH Rear Side Of Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary (Rear)
Heater Core: Service and Repair Auxiliary (Rear)
REMOVAL
1. Remove the first bench seat, if so equipped.
Fig. 5 - Auxiliary System Cover Removal And Installation.
2. Remove the auxiliary heater and/or air conditioning cover screws (Fig. 5), and remove the cover.
3. Remove the strap retaining the heater core in the auxiliary system case. 4. Remove the heater
hoses from the auxiliary heater core (2 clamps), and plug the hoses. 5. Disengage the wire
assembly from the heater core seal.
Fig. 12 - Heater Core And Resistor.
6. Slide the heater core and seal assembly out of the housing slot (Fig. 12).
INSTALLATION
1. Position the wire assembly to one side and slide the heater core and seal assembly into the
housing slot. 2. Install the heater hoses on the heater core tubes (2 clamps). 3. Fill the cooling
system and check for leaks.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary (Rear) > Page 5901
4. Install a new strap to retain the heater core in the case assembly. 5. Install the auxiliary heater
and/or air conditioner cover (Fig. 5). 6. Install the bench seat (if so equipped) and tighten the
retaining bolts to 34-61 Nm (25-45 ft lb).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary (Rear) > Page 5902
Heater Core: Service and Repair With A/C
REMOVAL
Fig. 19 - Manual A/C Heater System Heater Core Installation.
1. Disconnect electrical leads from resistor on front face of A/C blower scroll cover (Fig. 19.) 2.
Disconnect vacuum line from the outside-recirculated door vacuum motor. 3. Remove A/C blower
cover (five screws plus two screws attaching the blower scroll cover to plenum assembly).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary (Rear) > Page 5903
Fig. 15 - A/C Vacuum Motor Installation.
4. Remove pushnut, vacuum motor arm and washer from the outside-recirculated door shaft (Fig.
15, view X). 5. Remove control cable from bracket (one screw) and slide it over bracket. Remove
cable clip from blend door shaft. 6. Remove A/C blower motor housing (eleven screws). 7. Remove
the blend door. 8. Remove the heater hoses from the heater core and plug the hoses. 9. Remove
the two heater core retaining brackets (two screws).
10. Remove the heater core and seal assembly.
INSTALLATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary (Rear) > Page 5904
1. Position the heater core and seal assembly and install the core retaining brackets and screws. 2.
Install the heater hoses to the heater core (two clamps) and fill the cooling system. 3. Install the
blend door and frame assembly with seal in place between flanges. 4. Install the A/C blower motor
housing (eleven screws). 5. Position control cable clip to the blend door shaft. 6. Install control
cable to bracket attaching screw (one screw). 7. Install the washer, vacuum motor arm and pushnut
on the outside-recirculation doorshaft. 8. Install A/C blower cover (five screws plus two screws
attaching the blower scroll cover-to-plenum assembly). 9. Connect vacuum line to
outside-recirculated vacuum motor.
10. Connect the electrical leads to the resistor. 11. Adjust the control cable.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary (Rear) > Page 5905
Heater Core: Service and Repair Without A/C
REMOVAL
1. Disconnect the battery cables. 2. Remove the battery (on dual battery equipped vehicles,
passenger side battery).
Fig. 5 - Blower Motor And Wheel Assembly
3. Disconnect the resistor wiring harness. (Fig. 5.) 4. Disconnect the blower motor lead wire
(orange/black) at wiring harness (Fig. 5). 5. Remove ground wire (black) mounting screw from dash
panel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary (Rear) > Page 5906
Fig. 8a - Heater Hose Installation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary (Rear) > Page 5907
Fig. 8b - Heater Hose Installation.
6. Disconnect heater hoses from the core tube and plug the hoses. Remove plastic strap retaining
the heater hoses to the heater assembly (Fig. 8).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary (Rear) > Page 5908
Fig. 9 - Heater Core Installation.
Fig. 13 - Heater Assembly Installation.
7. Remove five heater mounting attachment nuts from inside of vehicle (Figs. 9 and 13.) 8. Remove
heater assembly. 9. Remove the case seal from the face of the case and remove retainer (two
screws) (Fig. 9).
10. Slide core and seal assembly out of case.
INSTALLATION
1. Slide the new heater core and seal assembly into the heater core case and install the retainer
with two attaching screws. 2. Install the case seal to the face of the case using care to correctly
align the seal over the five case bolts. 3. Install the heater assembly by reassembling the five
mounting attachment nuts from inside the vehicle. 4. Connect the heater hoses to the heater core
with new clamps and install the plastic strap. 5. Install the black ground wire to the dash panel (one
screw). 6. Connect the blower motor lead wire (orange/black) to the wiring harness. 7. Connect the
resistor wiring harness to the resistor.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Auxiliary (Rear) > Page 5909
8. Install the battery and connect the battery cable. 9. Add engine coolant and check heater
operation.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > NHTSA89V139000 > Aug > 89 > Recall 89V139000: Heater Hose Rerouting/Repair
Heater Hose: Recalls Recall 89V139000: Heater Hose Rerouting/Repair
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN UNDERHOOD FIRE. RE-ROUTE AND REPAIR HOSE, AS
NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: GAS CHASSIS - CUTAWAY AND VAN AMBULANCES.
1985 FORD TRUCK E350 1986 FORD TRUCK E350 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > NHTSA89V150000 > Aug > 89 > Recall 89V150000: Heater Hose Rerouting
Heater Hose: Recalls Recall 89V150000: Heater Hose Rerouting
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN
UNDERHOOD FIRE. RE-ROUTE HOSE AS NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: AMBULANCES BUILT ON FORD E350 CHASSIS.
1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > NHTSA89V075000 > Apr > 89 > Recall 89V075000: Heater Hose Rerouting
Heater Hose: Recalls Recall 89V075000: Heater Hose Rerouting
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN
UNDERHOOD FIRE. RE-ROUTE AND SPLICE HOSE AS NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: BUSES BUILT ON FORD E350 CHASSIS.
1986 FORD TRUCK E350
1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement
Technical Service Bulletin # 88S99 Date: 880901
Recall - Heater/Engine Bypass Hose Replacement
At Dealers By Order as Req'd -0- % of Parts Direct Shipped to Dealers
At PDC By Now Temporary Maximum
Date in Owner Letter 9/2/88 Order Quantity of 2 Kits
RECALL NUMBER
88S99
Date: Sept., 1988
PLEASE GIVE COPIES OF THIS BULLETIN TO YOUR PARTS AND SERVICE MANAGERS
TO: All Ford and Heavy Truck Dealers
SUBJECT: Safety Recall 88S99 - Heater and Engine Bypass Hose Replacement and Muffler
Inspections/Replacement on Certain 1983 through 1987-model 5.8L-4V H.D. and 7.5L Engine
Equipped Ford Econoline-Based Ambulances
IN CARES/OASIS - YES
REFUND CLAIMING - USE FORM 1863
MODIFICATION CLAIMING - USE FORM 1864
VEHICLES AFFECTED:
Ford Motor Company is initiating a safety recall of certain 1983 through 1987-model Econoline
E250/E350- based ambulances equipped with 7.5 Liter engines as well as certain 1985 through
1987-model Econoline E250/E350-based ambulances equipped with 5.8L 4V H.D. engines. All
involved vehicles are rated over 8,500 lbs. GW.
REASONS FOR THIS RECALL:
Investigations of recent fires involving Econolinebased ambulances have disclosed a potential for
engine compartment heater or engine bypass hoses to wear-out prematurely and rupture, allowing
engine coolant to come in contact with hot engine exhaust manifolds and possibly ignite. Testing
has indicated that worn-out hoses are not able to withstand the prolonged periods of extreme
engine operating temperatures and higher engine cooling system pressures encountered during
EMS severe-duty cycles.
ACTION BY FORD: All ambulances returned for the service provided by this Safety Recall will be
modified as follows;
^ Replacement of existing engine compartment heater and bypass hoses with silicone/NOMEX
hoses.
^ Replacement of the radiator cap.
^ Replacement of the engine coolant with a 50/50 mix of water and antifreeze. This mixture of
coolant will provide freeze protection for most areas. Extreme cold-weather areas should be
provided with a 60/40 mixture of coolant and water.
^ Pressure test the cooling system.
^ Inspection and, if necessary, installation of aluminized stainless steel mufflers on 1985-87-model
7.5L dual-thermactor engine equipped vehicles.
^ High heat resistance aluminized stainless steel mufflers will be installed on those ambulances
equipped with 1985-1987 7.5L, dual thermactor air pump-equipped engines that did not have those
mufflers installed in connection with safety recall 87M53. A temporary shortage of aluminized
stainless steel mufflers last year required the use of substitute mufflers on ambulances that were
found in need of muffler replacement at that time.
^ Underbody inspection for loose, mispositioned or missing heat-shielding parts. Contact the
Special Toll-Free Econoline/Ambulance Hotline for authorization to perform modifications as a
result of this inspection.
This service will be performed at no cost. Owner/ operators win be provided with information about
replacement recommendations for engine coolant and heater and engine bypass hoses.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5930
REFUNDS: Owner/operators of 1985-87-model 7.5L dual-thermactor engine equipped vehicles will
be provided refunds for Ford-sourced aluminized stainless steel mufflers which may have been
installed at their expense under Safety Recall 87M53. DEALERS ARE INSTRUCTED TO
PROVIDE REFUNDS TO OWNERS WHO ADEQUATELY PROVE SUCH A PURCHASE AND TO
CLAIM FOR REFUNDS USING FORM 1863.
DEALER RESPONSIBILITIES:
Owners will be told that they may wish to inform the National Highway Traffic Safety Administration
if the recall is not performed without charge or within a reasonable time after the vehicle is brought
to their dealership for repair.
REPAIR CODES: REFER TO ATTACHMENT II, EXHIBIT 1 - THE "REPAIR CODES" SHOWN ON
THE REFERENCED ATTACHMENT HAVE BEEN DEVELOPED TO ASSIST YOU IN SELECTING
THE CORRECT EXHAUST SYSTEM MUFFLERS FOR SPECIFIC VEHICLES. THESE "REPAIR
CODES" WILL BE PRINTED ON THE OWNER LETTER AND THE CLAIM FORM 1864. USE THE
CODES TO DETERMINE REQUIRED MUFFLERS AND WHEN PREPARING CLAIM FORMS
AND SERVICE DOCUMENTS.
CARES/OASIS: Dealers are to check the CARES and OASIS programs todetermine if an affected
vehicle is involved in other recalls.
CLAIM FORMS: USE CLAIM FORM 1864 FOR THE MODIFICATIONS REQUIRED FOR THIS
RECALL. USE CLAIM FORM 1863 FOR REFUNDS TO OWNERS WHO PREVIOUSLY PAID FOR
INSTALLATION Of FORD-SOURCED ALUMINIZEDSTAINLESS STEEL MUFFLERS. Refer to
Attachment I for preparation instructions.
PARTS Refer to Attachment II.
REQUIREMENTS:
LABOR ALLOWANCE: Refer to Attachment II.
TECHNICAL INSTRUCTIONS:
Refer to Attachment III.
OWNER NOTIFICATION:
Owner/operators will be notified with the letter shown on Attachment IV.
FPSD ASSISTANCE: Contact your FPSD District Service Engineer with any problems you have
concerning this recall. Additionally, a special toll-free Econoline/Ambulance Technical Hotline is
available to assist in resolving unusual repair issues technicians may encounter.
Personnel are available daily from 7:30 A.M. to 6:00 P.M., Eastern Time to provide technical
assistance by calling 1-800-445-1571.
Administrative Instructions
SAFETY RECALL 88S99 ADMINISTRATIVE INSTRUCTIONS Attachment I VEHICLES
AFFECTED:
Certain 1983 through 1987-model Econoline E250/E350- based ambulances equipped with 7.5
Liter engines as well as certain 1985 through 1987-model Econoline E250/E330- based
ambulances equipped with 5.8 Liter 4V H.D. Engines. All affected vehicles are rated over 8,500 lbs.
GVW.
REPORTING COMPLETIONS: Only the Form 1864 will be accepted for reimbursement for
modifications performed under this recall. Upon completion of the required service, the Form 1864
must be completely filled out and signed by authorized dealer personnel. CLAIM SUBMISSION:
The claims must be entered through the Direct Warranty Entry (DWE) system. Dealers without
DWE capability must mail the second copy of the Form 1864 for reimbursement. Should your
dealership receive pre-printed Forms 1864 with a seven digit claim number, you must drop the first
digit and enter only the last six digits. You must sight verify the claim number for accuracy. It is
important that all claims be filed for all completed units so you will be reimbursed and our records
will show completion.
REFUNDS: Refund requests submitted under Safety Recall 88S99 are governed by the following
guidelines:
^ Owner/operators of 1985-87 model ambulances with 7.5L dual thermactor engines are eligible for
a refund if they paid for a muffler replacement under Safety Recall 87M53 and the replacement
muffler was the new ribbed design, aluminized stainless steel muffler (See Attachment II, Exhibit 2
for eligible muffler part numbers). Paid repair orders or invoices presented by the owner/operator
requesting a refund must show one of the eligible muffler part numbers.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5931
^ Refunds include return of any deductible amount owners may have paid.
^ A copy of the paid repair orders or parts purchase receipts must be retained in your service file
for at least one year following the date of Company notification of payment.
^ Owner refund requests must be submitted on separate Warranty Claim Form 1863. In addition to
the information shown for the special preparation of Owner Refund
claims (Reference: Warranty and Policy Manual - Subject 6.1, Page 18), please enter the
information shown below:
Causal Basic Part Number - 88S99
Condition Code - OB
Labor Operation - REFUND
Administrative Allowance - 0.2 Hr.
Program Code - 88S99
^ An administrative allowance of 0.2 hours will be allowed for processing each eligible owner
refund request. To claim the allowance, enter ALLOW in the Labor Operation No. column and 0.2
in the Scheduled Time column. Extend the 0.2 hours at your authorized warranty labor rate and
enter the result in the Amount column.
^ Please provide prompt refund to all eligible owners who respond to this recall with proper repair
documentation.
Labor and Parts Ordering Instructions
SAFETY RECALL 88S99 LABOR AND PARTS ORDERING INSTRUCTIONS
Attachment II
PARTS ORDERING: Service parts required for this recall may be ordered through normal
channels. Refer to the following material and Attachment II, Exhibits 1 and 2.
Coolant Ordering
^ Since most areas will require a 50/50 mixture of antifreeze and water, order and claim for the
amount of coolant required to service each ambulance using the following information:
- In extreme cold weather areas use a 60/40 mixture, order and claim appropriately.
- Order enough coolant (Ford Part Number E2FZ-19549-AA, or equivalent) to fill the entire engine
cooling system. In most cases, 3 gallons of antifreeze and 3 gallons of water should be adequate to
attain a 50/50 mix
Service Part Number
Description Class Dealer Price
E2FZ-19549-AA Coolant, Engine V $8.65/Gallon a/
E3UZ-18472-C Kit, Heater Hose BG $64.65
E8UZ-8597-A Hose, Engine Bypass (5.8L Engs.
CG $2.25
Only)
a/ Based on $51.90, Carton 6 Gallons, order this part number or use locally purchased equivalent.
Use dealer aquisition cost for locally purchased equivalent.
Scheduled Time
LABOR OPERATIONS: Basic Labor Operation (Hours)
Inspection of the Ambulance Underbody and Exhaust System, Installation of Heater and Engine
Bypass Hose Improvement
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5932
Modifications. . . . . . . . . . . . . 2.1 Insert in Box "B" of Form 1864
LABOR OPERATIONS: (Cont'd.)
Scheduled Time
Basic Labor Operation (Hours)
Supplemental Labor Operations (Additive to Above)
Replacement of the Exhaust System Muffler, and Attaching Parts (7.5L Dual-Thermactor Engine
Equipped Vehicles . . . . . . . .
0.8 Insert in Box "B" of Form 1864
Note: Use this supplemental time when replacing mufflers on 7.5L Dual-Thermactor Engine
equipped vehicles. This time may also be used when replacing mufflers performed at owners'
expense.)
Additional Time to Access Engine Bypass Hoses on 7.5L Engine Equipped Vehicles . . . . . . . . . . . .
.
0.4 Insert in Box "B" of Form 1864
Administrative Allowance (Additive to Above)
Administrative Allowance . . . . . 0.1 Hr.
The Supplemental Labor Operations and the 0.1 hour administrative allowance must be added
before inserting the total labor time in Box "B" of the Form 1864.
Repair Code Description
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5933
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5934
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Technical Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTIONS
Attachment III
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5935
TECHNICAL INSTRUCTIONS:
Inspections:
^ Underbody - All Vehicles
1. Inspect the underbody and exhaust system for missing, loose or mispositioned heat-shielding
parts (Refer to Safety Recall 87M53 instructions).
If you discover any conditions as a result of this inspection that requires modification, please
contact the Special Toll-Free Econoline/Ambulance Hotline, 1-800-445-1571, for authorization.
Contact your District Office if the Hotline is not available.
^ Mufflers - All Vehicles
2. Refer to Attachment III, Exhibit 1. Remove the exhaust system muffler heat shields.
3. Inspect the muffler per the instructions contained in Attachment III, Exhibit 1.
^ Replace unacceptable mufflers and attaching parts at the OWNERS EXPENSE ON:
i) 1983 through 1987-model 7.5L single-thermactor engine equipped vehicles; ii) 1985 through
1987-model, 5.8L 4V H.D. engine equipped vehicles.
^ Replace any mufflers that are not Ford-sourced aluminized stainless steel and attaching parts at
FORD EXPENSE on 1985 through 1987-model, 7.5L dual thermactor engine equipped vehicles.
^ Heater and Bypass Hose Replacement:
4. Refer to Attachment III, Exhibit 2. Replace the engine compartment heater and engine bypass
hoses as shown on the referenced attachment. Note: The 5.8L 4V H.D. engines require a formed
bypass hose. This is not in the heater hose/bypass parts kit. Order this hose separately.
5. Pressure test the cooling system and replace existing radiator cap.
NOTE: Owners will be instructed to retorque hose clamps to 2.5-3.0 N-m (22-26 in.lbs.) when
coolant leakage is observed.
MODIFICATION DECAL: Prepare an "Authorized Modifications" decal (Form FPS-8262) as shown
below. Affix the decal to a flat clean surface on
the radiator support. (Order the "Authorized Modifications" decal on your Weekly Stock Order Pad.)
Specific Technical Repair Code and Parts Ordering Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
Exhaust System-Ford Components-Correct Routing and Retention
1983-1985 7.5L MODELS (MODELS WITH SINGLE AIR PUMP) 1985-1/2-1987 5.8L MODELS
(OVER 8500 GVW WITH 4 BARREL CARBURETOR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5936
FIGURE 1
The Ford exhaust system as shown in Figure 1, provides the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheatng.
FIGURE 3
Inspect the exhaust system for leaks or ruptures. FOR 5.8L ONLY, it may be necessary to remove
the heat shields as shown in Figure 3. Inspect the muffler outer wrapper lock seam for separation.
If any such problems are found, notify the customer and request permission to repair the problem,
at the customer's expense. Note any such problems and the customer's reaction to your repair
request on your internal repair order form and retain in your records.
If a non-Ford exhaust system or exhaust components is noted on the unit, inform the customer of
the potential for durability reduction, exhaust flow restriction, or overheating as indicated above.
Note any such discrepancy and the customer's reaction on your internal repair order form and
retain in your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5937
FIGURE 1
ALL 5.8L AND ONLY CALIFORNIA CALIBRATION 7.5L: If the unit is not equiped with the all-steel
hangers shown in Figure 1, order and install the Ford Service Part as indicated in the attached
chart. SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
FIGURE 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5938
1985-1/2 - 1987 7.5L MODELS (MODELS WITH DUAL AIR PUMPS - SEE FIGURE 5)
FIGURE 2
The Ford exhaust system as shown in Figure 2, provdes the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheating.
FIGURE 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5939
FIGURE 4
Remove the heat shields covering the muffler by removing the retaining clamps securing the
shields as shown in Figure 3. If the muffler is a non-Ford design or is a non-ribbed design (Figure
4), remove the Muffler and Outlet Pipe Assembly and replace with the heavy duty ribbed muffler
assembly as indicated in the attached chart.
If the muffler is the heavy duty type (ribbed design - Figure 4), installed during the 1987 M53 recall,
inspect the entire surface of the muffler for cracks or openings. If any such openings are found,
replace the Muffler and Outet Pips Assembly with a new heavy duty ribbed muffler assembly.
Advise the Ambulance Technical Hot Line 1-800-445-1571, if you find a ribbed muffler with cracks
or openings.
FIGURE 2
If the unit is not equipped with the all-steel hangers as shown in Figure 2, order and install the Ford
Service Part as indicated in the attached chart. ATTACHMENT III EXHIBIT 1 PAGE 3 OF 3
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5940
KIT NUMBER E3UZ-18472-C HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED
AMBULANCES WITH 7.5L OR 5.8L 4V H.D. ENGINES SPECIAL NOTE: The following instructions
describe the installation procedure for the heater hose/bypass hose improvement package. It is
designed specially for Ford E-350 and E-250 (over 8500 pounds GVWR) based ambulances. The
original Ford heater hose system has probably been modified by the ambulance body builder. It is
not possible to identify all the designs and modifications used by these manufacturers. If you
encounter difficulties not anticipated in these instructions, contact the Ford Ambulance Recall
Hotline on 1-800-445-1571. PARTS LIST
Item Description Part Number Quantity
1 Silicons Hose - 5/8" I.D. *EST-M2D309-A 96"
2 Hose Clamp 388652-S2 20
3 "Y" Fitting D8UH-18663-AA 2
4 Tie Strap - 1/4" Wide 384213-S 10
5 Radiator Cap E5TH-8100-AA 1
*Engineering Specification Number
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5941
FIGURE 1
HEATER HOSE REMOVAL
1. Close the shutoff valves that connect the rear heater unit to the Ford installed heater hoses (See
Figure 1). Be sure to close both the supply and return hose valves. Failure to close these valves
could cause coolant fill problems later.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5942
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT.
2. Drain the coolant from the radiator by removing the radiator cap and carefully opening the drain
cock at the bottom of the radiator. After the coolant has drained from the radiator, close the drain
cock and discard the radiator cap.
3. Disconnect and remove any objects, such as thermactor pump filter/silencer or coolant overflow
bottle, obstructing access to the heater hoses.
4. Inspect the hoses for chaffing or cuts (See Figure 1). Note the position of any straps or clamps
for securing the new hoses at time of installation.
5. Disconnect the vacuum line from the water supply valve.
6. Disconnect the inlet and outlet hoses from the heater core, engine block, and rear heater shutoff
valves (See Figure 1). Loosen each clamp and cut the hose first to prevent core damage. DO NOT
twist hoses in the removal process. Disconnect the hoses from any locating clips. Discard all hose
clamps.
NOTE: DO NOT disconnect the hoses routed from the shutoff valves to the rear heater unit.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5943
FIGURE 1
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5944
FIGURE 2
HEATER HOSE INSTALLATION
1. Using hoses (Item 1), hose clamps (Item 2) and "Y" fittings (Item 3), assemble duplicate hose
layouts of the removed hose assemblies (Figure 1).
NOTE: The hoses leading from the "Y" fittings may have to be slightly longer than the original
hoses to avoid any kinks or bends. This is due to the replacement fittings having a different angle in
the "Y" than the original "Y" or "T" fittings. Silicone hoses require the special clamps Included in the
kit to prevent cutting the hose. DO NOT use any other type of clamp.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 1 OF 5
on 1-800-445-1571 if you have any questions.
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
2. Remove the vacuum operated water supply valve from the old hose assembly and install it into
the new hose assembly.
NOTE: Make sure that the flow arrow stamped on the valve is pointing toward the heater core.
3. Torque the clamps (Item 2) to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
4. Connect the hose assemblies with clamps (Item 2) to the engine block, heater core and rear shut
off valves.
5. Torque the clamps to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
6. Connect the vacuum line to the water supply valve.
7. Using tie straps (Item 4), secure the hoses to an adjacent engine component to prevent chaffing
or cutting during engine operation. The hoses may be secured in a manner similar to the original
method if the removed hoses were not damaged as noted earlier. If the original hoses were
damaged, route the hoses and secure them in a manner to prevent hose damage during engine
operation.
WATER BYPASS HOSE REMOVAL AND INSTALLATION FOR VEHICLES WITH 7.5L ENGINES
1. Remove the distributer vacuum hose to improve accessibility to the water bypass hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5945
FIGURE 2
2. Remove the water bypass hose and clamps (See Figure 2). Discard the clamps.
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
CAUTION: DO NOT ALTER (CUT OFF) THE INTAKE MANIFOLD AND/OR THE WATER PUMP
HOSE CONNECTIONS. ANY
DAMAGE SUCH AS SHARP EDGES, TO THESE CONNECTIONS WILL RESULT IN DAMAGE
TO THE NEW BYPASS HOSE DURING INSTALLATION.
4. Using the removed hose as a pattern, cut a piece of silicone hose (Item 1) to the proper length
and position it on the intake manifold bypass connection.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 3 OF 5
on 1-800-445-1571 if you have any questions
FIGURE 3
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D ENGINES
5. Position two (2) new hose clamps (Item 2) on the new hose, installed in Step 4, toward the
intake manifold. (See Figure 3.)
6. Bend (double over) the new bypass hose downward and slide the hose on to the water pump
bypass hose connection. (See Figure 3.)
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5946
FIGURE 4
FOR VEHICLES WITH 5.8L ENGINES
1. Remove the distributor vacuum hose to improve accessibility to the water bypass hose.
2. Remove the water bypass hose and clamps (See Figure 4). Discard the clamps.
Don't forget... ATTACHMENT III
call the Special Econline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 4 OF 5
on 1-800-445-1571 if you have any questions!
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
4. Position a new formed bypass hose (Part number E8UZ-8597-A) on the intake manifold bypass
connection.
5. Position two (2) new hose clamps (Item 2) on the new hose toward the intake manifold.
6. Bend and slide the hose on to the water pump bypass hose connection.
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to:) 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose, PRESSURE TEST COOLING SYSTEM
1. Reinstall all of the objects such as the thermactor pump filter/silencer or coolant overflow bottle,
that obstructed access to the heater hoses.
2. Fill the cooling system with a coolant mixture of 50/50 Ford Long Life Coolant E2FZ-19549-AA
(ESE-M97B44-A) or equivalent and water, to 38 mm (1.5 inches) below the cap seal.
3. Install radiator cap (Item 5)
WARNING: DO NOT STAND IN LINE WITH OR NEAR THE RADIATOR FAN WHEN THE
ENGINE IS RUNNING.
4. Start the engine, let it warm until the upper radiator hose is hot, shut off the engine. Allow the
engine to cool, remove the cap and check the coolant level. Fill as required.
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5947
5. Using the Rotunda Cooling System Pressurization Kit 021-00012, pressurize the cooling system
to 20 psi and check for leaks. Be sure to follow the instructions in the kit on the recommmended
method of connecting the tester to the radiator.
6. If any leaks are found, correct as needed.
7. Pressure test the cooling system until no leaks we found.
8. Rechock the coolant level in the radiator to make sure that it is 38 mm (1.5 inches ) below the
cap seal. If it is not, fill as required.
9. Reinstall the radiator cap and add coolant to the overflow bottle as required.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 5 OF 5
on 1-800-445-1571 if you have any questions!
Owner & Operator Letter Information
Attachment IV
September 2, 1988
Dear Owner/Operator:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
Ford Motor Company has determined that a defect which relates to Motor Vehicle Safety evists in
certain 1983-1987 Econoline-based ambulances equipped with 7.5 liter or 5.8 liter 4V H.D. V8
engines. Due to the prolonged periods of extreme engine operating temperatures and cooling
system pressures encountered during EMS severe-duty cycles, heater or engine bypass hoses
may wear-out prematurely and burst. Engine coolant ("antifreeze") from a burst hose may cause a
fire if it sprays onto an overheated engine exhaust manifold, especially if the coolant is
overconcentrated.
Ford Motor Company is now asking that you return your Econoline-based ambulance to your Ford
or Ford Heavy Truck Dealer for corrective action.
COOLING SYSTEM SERVICE
At no cost to you, your dealer will:
- replace certain "rubber" heater hoses installed by Ford Motor Company when the vehicle was
manufactured (ie., up to the auxiliary heater shut-off valves), with new "SILICONE/NOMEX" heater
hose;
- replace engine bypass hoses
- replace the engine coolant (with a proper 50/50 mixture);
- install a new radiator cap;
- pressure test the cooling system.
Most ambulances also have auxiliary heater systems. The ambulance body manufacturer typically
installs these heater systems. While these hoses are not part of this safety recall, we strongly
recommend that you consider replacing all non-silicone/Nomex @ auxiliary heater hoses also. THE
COST OF REPLACING THE AUXILIARY HEATER HOSES WILL BE AT YOUR EXPENSE. IF
LEAKS ARE FOUND IN OTHER COMPONENTS OF THE ENGINE COOLING SYSTEM, WHEN
THE SYSTEM IS PRESSURE TESTED SUCH AS THE RADIATOR OR RADIATOR HOSES, THE
COST OF REPAIRING THOSE COMPONENTS WILL BE AT YOUR EXPENSE.
FOR ALL HEATER SYSTEM HOSE REPLACEMENTS, FORD RECOMMENDS THAT YOU
SPECIFY HOSES MADE ONLY FROM THE "SILICONE/NOMEX" MATERIAL. SILICONE HOSES
ALSO REQUIRE SPECIAL HOSE CLAMPS TO PREVENT CUTTING THE HOSE. USE ONLY
THE HOSE CLAMPS RECOMMENDED BELOW WITH SILICONE HOSES.
When purchasing replacements, the following parts should be specified:
Ford Service Motorcraft Brand
Part Name Part Number Part Number
- SILICONE/NOMEX E8TZ-18472-H KH-15
Heater Hose - 25 foot lengths
- Formed Water Pump Bypass E8UZ-8597-A KMS-1776
Hose (for 5.8L 4V H.D. Engine)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5948
- Hose Clamps D9AZ-8287-C YF-842
It is important also that the proper torque be used when attaching the special hose clamps required
for SILICONE/NOMEX hoses. Your dealer will properly torque clamps when they install the heater
and engine bypass hoses on your ambulance. If you should notice coolant seepage, retorque the
clamps to 2.5 to 3.0 N-m (22-26 in.lbs.).
These parts are available through your Ford, Lincoln-Mercury or Ford Heavy Truck Dealer. They
are also available through any Motorcraft parts distributor.
Ford recommends that you always replace these SILICONE/NOMEX HEATER SYSTEM hoses
every 48,000 miles or 48 months, whichever comes first. Non-silicone hoses should be replaced
every 24,000 miles or 24 months, whichever comes first.
It is important that your ambulance cooling system have the proper anti-freeze coolant and water
mixture for adequate freeze protection. Please read and observe the recommendations on the
attachment, "The Importance of Proper Cooling System Anti-freeze Mixtures".
EXHAUST SYSTEM SERVICE
^ Certain 198-5-1987 Model Ambulances with 7.5 Liter/Dual Thermactor Engines
Ambulances with 7.5 Liter V8 engines and a dual-thermactor emission system will have a new
aluminized stainless steel muffler installed. Mufflers and installation will be free of charge.
Some of these ambulances may have already had new alumunized stainless steel mufflers
installed during the earlier recall. These vehicles will not need new mufflers.
^ Refunds for Certain Later Model Muffler Replacements
As noted above, some of these ambulances with 7.5 liter/dual thermactor engines may have
received the new aluminized stainless steel mufflers during the service for the earlier Safety Recall
87M53. If you paid to have these new aluminized stainless steel mufflers installed, you are entitled
to a refund for the costs of parts and labor. If you are entitled to this refund, please present your
paid receipt to any Ford or Ford Heavy Truck Dealer who will process a refund for you.
This receipt must show the date of repair, the part numbers for the new aluminized stainless steel
muffler and attaching parts as well as the parts and labor costs.
^ Other 7.5 Liter and 5.8 Liter 4V H.D. Engine Equipped Ambulances
Ambulances with 7.5 Liter V8 engines and a single thermactor emission system as well as all
1985-1987 model ambulances with 5.8 Liter 4V H.D. V8 engines will only have the muffler
inspected. Replacement of defective mufflers will be the owner's responsibility.
SCHEDULE SERVICE AT ANY FORD OR FORD HEAVY TRUCK DEALER NOW
Since the cooling system parts, mufflers and instructions are now available, we urge you to
schedule this service as quickly as possible.
NOTE: ANY FORD OR FORD HEAVY TRUCK DEALER CAN DO THE COOLING SYSTEM AND
MUFFLER SERVICE.
Before you return your vehicle for this service, we urge you to review the cooling system
information sent to you in June, 1988. Some cooling system maintenance may be needed now.
COMPUTER FORM
The computer form included with this letter may include a special part code. Your dealer will need
to know this code when you call to make an appointment. The code, located in the box labeled "Kit
Code", half way down the right side of the form, will be a single digit number from 1 through 8.
IMPORTANT NOTE
If your vehicle is not operated solely on propane and has not yet been modified to correct a fuel
system over-pressurization concern, announced in July, 1987 as Safety Recall 87M53, or has only
received the earlier (prior to late-October, 1987) Phase I fuel system modifications, you need to
have these modifications done as promptly as possible. You may want to have all of the required
services performed together.
NOTE: ONLY OUR SPECIALLY TRAINED DEALERS CAN WORK ON THE FUEL SYSTEM AND
SYSTEM MODIFICATIONS.
A listing of our specially trained dealers is enclosed.
THANK YOU FOR YOUR CONTINUED COOPERATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > 88S99 > Sep > 88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5949
We are sorry that we must inconvenience you again by asking you to return your Econoline-based
ambulance to your Ford or Ford Heavy Truck dealer. However we do wish to maintain your
confidence in our vehicle. Thank you for your continued cooperation in this matter of mutual
concern. THE IMPORTANCE OF PROPER COOLING SYSTEM ANTI-FREEZE MIXTURE
It is extremely important that the proper anti-freeze mixture be used in your ambulance cooling
system, and that it be maintained at recommended levels.
Ford recommends that a reasonably fresh 50% anti-freeze concentrate and 50% water mixture be
maintained in the cooling system of your ambulances at all times. This mixture provides adequate
freeze protection for most areas (50/50 mixtures provide protection to - 35~F). It also provides
optimum engine cooling and corrosion protection for the system.
Increasing the anti-freeze concentration above 50% will reduce engine cooling and result in hotter
engine operation. If you are in extremely cold area, it is permissible to use a 60% anti-freeze
concentrate and 40% water providing protection to approximately - 60~F, but only during the winter
months. (This is a revised coolant manufacturer recommendation from the information sent to you
in June, 1988, in a Motorcraft booklet "Cooling System Operation and Maintenance", dated April,
1979). The mixture should be returned to 50/50 at the end of your cold season. As the concentrate
percentage gets larger beyond 60% concentrate, the freeze protection is less. A 100% anti-freeze
concentration only protects your cooling system to - 8~F.
Decreasing the anti-freeze concentration below 40% reduces corrosion and freeze protection
(40/60 mixtures provides protection to - 10~F).
Remember:
^ Maintain cooling system mixtures at 50/50. Do not allow the mixture to be above 60/40.
^ Replace your cooling system mixture annually.
^ Replace lost coolant with a 50/50 mixture. Keep a pre-mixed supply of 50/50 mixture to refill the
system.
^ Do not refill your system with pure anti-freeze.
^ Regularly inspect and repair any cooling system leaks.
^ Replace cooling system hoses before they fail. Follow the Ford recommended replacement
intervals.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Recalls: > NHTSA88V133000 > Aug > 88 > Recall 88V133000: Cooling System Hose Replacement
Heater Hose: Recalls Recall 88V133000: Cooling System Hose Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: >
NHTSA89V139000 > Aug > 89 > Recall 89V139000: Heater Hose Rerouting/Repair
Heater Hose: Recalls Recall 89V139000: Heater Hose Rerouting/Repair
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN UNDERHOOD FIRE. RE-ROUTE AND REPAIR HOSE, AS
NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: GAS CHASSIS - CUTAWAY AND VAN AMBULANCES.
1985 FORD TRUCK E350 1986 FORD TRUCK E350 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: >
NHTSA89V150000 > Aug > 89 > Recall 89V150000: Heater Hose Rerouting
Heater Hose: Recalls Recall 89V150000: Heater Hose Rerouting
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN
UNDERHOOD FIRE. RE-ROUTE HOSE AS NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: AMBULANCES BUILT ON FORD E350 CHASSIS.
1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: >
NHTSA89V075000 > Apr > 89 > Recall 89V075000: Heater Hose Rerouting
Heater Hose: Recalls Recall 89V075000: Heater Hose Rerouting
HEATER HOSE MAY BE INCORRECTLY ROUTED. HOSE COULD WEAR THROUGH AND
LEAK WHICH COULD RESULT IN AN
UNDERHOOD FIRE. RE-ROUTE AND SPLICE HOSE AS NECESSARY.
SYSTEM: HEATER HOSE.
VEHICLE DESCRIPTION: BUSES BUILT ON FORD E350 CHASSIS.
1986 FORD TRUCK E350
1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement
Technical Service Bulletin # 88S99 Date: 880901
Recall - Heater/Engine Bypass Hose Replacement
At Dealers By Order as Req'd -0- % of Parts Direct Shipped to Dealers
At PDC By Now Temporary Maximum
Date in Owner Letter 9/2/88 Order Quantity of 2 Kits
RECALL NUMBER
88S99
Date: Sept., 1988
PLEASE GIVE COPIES OF THIS BULLETIN TO YOUR PARTS AND SERVICE MANAGERS
TO: All Ford and Heavy Truck Dealers
SUBJECT: Safety Recall 88S99 - Heater and Engine Bypass Hose Replacement and Muffler
Inspections/Replacement on Certain 1983 through 1987-model 5.8L-4V H.D. and 7.5L Engine
Equipped Ford Econoline-Based Ambulances
IN CARES/OASIS - YES
REFUND CLAIMING - USE FORM 1863
MODIFICATION CLAIMING - USE FORM 1864
VEHICLES AFFECTED:
Ford Motor Company is initiating a safety recall of certain 1983 through 1987-model Econoline
E250/E350- based ambulances equipped with 7.5 Liter engines as well as certain 1985 through
1987-model Econoline E250/E350-based ambulances equipped with 5.8L 4V H.D. engines. All
involved vehicles are rated over 8,500 lbs. GW.
REASONS FOR THIS RECALL:
Investigations of recent fires involving Econolinebased ambulances have disclosed a potential for
engine compartment heater or engine bypass hoses to wear-out prematurely and rupture, allowing
engine coolant to come in contact with hot engine exhaust manifolds and possibly ignite. Testing
has indicated that worn-out hoses are not able to withstand the prolonged periods of extreme
engine operating temperatures and higher engine cooling system pressures encountered during
EMS severe-duty cycles.
ACTION BY FORD: All ambulances returned for the service provided by this Safety Recall will be
modified as follows;
^ Replacement of existing engine compartment heater and bypass hoses with silicone/NOMEX
hoses.
^ Replacement of the radiator cap.
^ Replacement of the engine coolant with a 50/50 mix of water and antifreeze. This mixture of
coolant will provide freeze protection for most areas. Extreme cold-weather areas should be
provided with a 60/40 mixture of coolant and water.
^ Pressure test the cooling system.
^ Inspection and, if necessary, installation of aluminized stainless steel mufflers on 1985-87-model
7.5L dual-thermactor engine equipped vehicles.
^ High heat resistance aluminized stainless steel mufflers will be installed on those ambulances
equipped with 1985-1987 7.5L, dual thermactor air pump-equipped engines that did not have those
mufflers installed in connection with safety recall 87M53. A temporary shortage of aluminized
stainless steel mufflers last year required the use of substitute mufflers on ambulances that were
found in need of muffler replacement at that time.
^ Underbody inspection for loose, mispositioned or missing heat-shielding parts. Contact the
Special Toll-Free Econoline/Ambulance Hotline for authorization to perform modifications as a
result of this inspection.
This service will be performed at no cost. Owner/ operators win be provided with information about
replacement recommendations for engine coolant and heater and engine bypass hoses.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5975
REFUNDS: Owner/operators of 1985-87-model 7.5L dual-thermactor engine equipped vehicles will
be provided refunds for Ford-sourced aluminized stainless steel mufflers which may have been
installed at their expense under Safety Recall 87M53. DEALERS ARE INSTRUCTED TO
PROVIDE REFUNDS TO OWNERS WHO ADEQUATELY PROVE SUCH A PURCHASE AND TO
CLAIM FOR REFUNDS USING FORM 1863.
DEALER RESPONSIBILITIES:
Owners will be told that they may wish to inform the National Highway Traffic Safety Administration
if the recall is not performed without charge or within a reasonable time after the vehicle is brought
to their dealership for repair.
REPAIR CODES: REFER TO ATTACHMENT II, EXHIBIT 1 - THE "REPAIR CODES" SHOWN ON
THE REFERENCED ATTACHMENT HAVE BEEN DEVELOPED TO ASSIST YOU IN SELECTING
THE CORRECT EXHAUST SYSTEM MUFFLERS FOR SPECIFIC VEHICLES. THESE "REPAIR
CODES" WILL BE PRINTED ON THE OWNER LETTER AND THE CLAIM FORM 1864. USE THE
CODES TO DETERMINE REQUIRED MUFFLERS AND WHEN PREPARING CLAIM FORMS
AND SERVICE DOCUMENTS.
CARES/OASIS: Dealers are to check the CARES and OASIS programs todetermine if an affected
vehicle is involved in other recalls.
CLAIM FORMS: USE CLAIM FORM 1864 FOR THE MODIFICATIONS REQUIRED FOR THIS
RECALL. USE CLAIM FORM 1863 FOR REFUNDS TO OWNERS WHO PREVIOUSLY PAID FOR
INSTALLATION Of FORD-SOURCED ALUMINIZEDSTAINLESS STEEL MUFFLERS. Refer to
Attachment I for preparation instructions.
PARTS Refer to Attachment II.
REQUIREMENTS:
LABOR ALLOWANCE: Refer to Attachment II.
TECHNICAL INSTRUCTIONS:
Refer to Attachment III.
OWNER NOTIFICATION:
Owner/operators will be notified with the letter shown on Attachment IV.
FPSD ASSISTANCE: Contact your FPSD District Service Engineer with any problems you have
concerning this recall. Additionally, a special toll-free Econoline/Ambulance Technical Hotline is
available to assist in resolving unusual repair issues technicians may encounter.
Personnel are available daily from 7:30 A.M. to 6:00 P.M., Eastern Time to provide technical
assistance by calling 1-800-445-1571.
Administrative Instructions
SAFETY RECALL 88S99 ADMINISTRATIVE INSTRUCTIONS Attachment I VEHICLES
AFFECTED:
Certain 1983 through 1987-model Econoline E250/E350- based ambulances equipped with 7.5
Liter engines as well as certain 1985 through 1987-model Econoline E250/E330- based
ambulances equipped with 5.8 Liter 4V H.D. Engines. All affected vehicles are rated over 8,500 lbs.
GVW.
REPORTING COMPLETIONS: Only the Form 1864 will be accepted for reimbursement for
modifications performed under this recall. Upon completion of the required service, the Form 1864
must be completely filled out and signed by authorized dealer personnel. CLAIM SUBMISSION:
The claims must be entered through the Direct Warranty Entry (DWE) system. Dealers without
DWE capability must mail the second copy of the Form 1864 for reimbursement. Should your
dealership receive pre-printed Forms 1864 with a seven digit claim number, you must drop the first
digit and enter only the last six digits. You must sight verify the claim number for accuracy. It is
important that all claims be filed for all completed units so you will be reimbursed and our records
will show completion.
REFUNDS: Refund requests submitted under Safety Recall 88S99 are governed by the following
guidelines:
^ Owner/operators of 1985-87 model ambulances with 7.5L dual thermactor engines are eligible for
a refund if they paid for a muffler replacement under Safety Recall 87M53 and the replacement
muffler was the new ribbed design, aluminized stainless steel muffler (See Attachment II, Exhibit 2
for eligible muffler part numbers). Paid repair orders or invoices presented by the owner/operator
requesting a refund must show one of the eligible muffler part numbers.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5976
^ Refunds include return of any deductible amount owners may have paid.
^ A copy of the paid repair orders or parts purchase receipts must be retained in your service file
for at least one year following the date of Company notification of payment.
^ Owner refund requests must be submitted on separate Warranty Claim Form 1863. In addition to
the information shown for the special preparation of Owner Refund
claims (Reference: Warranty and Policy Manual - Subject 6.1, Page 18), please enter the
information shown below:
Causal Basic Part Number - 88S99
Condition Code - OB
Labor Operation - REFUND
Administrative Allowance - 0.2 Hr.
Program Code - 88S99
^ An administrative allowance of 0.2 hours will be allowed for processing each eligible owner
refund request. To claim the allowance, enter ALLOW in the Labor Operation No. column and 0.2
in the Scheduled Time column. Extend the 0.2 hours at your authorized warranty labor rate and
enter the result in the Amount column.
^ Please provide prompt refund to all eligible owners who respond to this recall with proper repair
documentation.
Labor and Parts Ordering Instructions
SAFETY RECALL 88S99 LABOR AND PARTS ORDERING INSTRUCTIONS
Attachment II
PARTS ORDERING: Service parts required for this recall may be ordered through normal
channels. Refer to the following material and Attachment II, Exhibits 1 and 2.
Coolant Ordering
^ Since most areas will require a 50/50 mixture of antifreeze and water, order and claim for the
amount of coolant required to service each ambulance using the following information:
- In extreme cold weather areas use a 60/40 mixture, order and claim appropriately.
- Order enough coolant (Ford Part Number E2FZ-19549-AA, or equivalent) to fill the entire engine
cooling system. In most cases, 3 gallons of antifreeze and 3 gallons of water should be adequate to
attain a 50/50 mix
Service Part Number
Description Class Dealer Price
E2FZ-19549-AA Coolant, Engine V $8.65/Gallon a/
E3UZ-18472-C Kit, Heater Hose BG $64.65
E8UZ-8597-A Hose, Engine Bypass (5.8L Engs.
CG $2.25
Only)
a/ Based on $51.90, Carton 6 Gallons, order this part number or use locally purchased equivalent.
Use dealer aquisition cost for locally purchased equivalent.
Scheduled Time
LABOR OPERATIONS: Basic Labor Operation (Hours)
Inspection of the Ambulance Underbody and Exhaust System, Installation of Heater and Engine
Bypass Hose Improvement
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5977
Modifications. . . . . . . . . . . . . 2.1 Insert in Box "B" of Form 1864
LABOR OPERATIONS: (Cont'd.)
Scheduled Time
Basic Labor Operation (Hours)
Supplemental Labor Operations (Additive to Above)
Replacement of the Exhaust System Muffler, and Attaching Parts (7.5L Dual-Thermactor Engine
Equipped Vehicles . . . . . . . .
0.8 Insert in Box "B" of Form 1864
Note: Use this supplemental time when replacing mufflers on 7.5L Dual-Thermactor Engine
equipped vehicles. This time may also be used when replacing mufflers performed at owners'
expense.)
Additional Time to Access Engine Bypass Hoses on 7.5L Engine Equipped Vehicles . . . . . . . . . . . .
.
0.4 Insert in Box "B" of Form 1864
Administrative Allowance (Additive to Above)
Administrative Allowance . . . . . 0.1 Hr.
The Supplemental Labor Operations and the 0.1 hour administrative allowance must be added
before inserting the total labor time in Box "B" of the Form 1864.
Repair Code Description
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5978
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5979
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Technical Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTIONS
Attachment III
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5980
TECHNICAL INSTRUCTIONS:
Inspections:
^ Underbody - All Vehicles
1. Inspect the underbody and exhaust system for missing, loose or mispositioned heat-shielding
parts (Refer to Safety Recall 87M53 instructions).
If you discover any conditions as a result of this inspection that requires modification, please
contact the Special Toll-Free Econoline/Ambulance Hotline, 1-800-445-1571, for authorization.
Contact your District Office if the Hotline is not available.
^ Mufflers - All Vehicles
2. Refer to Attachment III, Exhibit 1. Remove the exhaust system muffler heat shields.
3. Inspect the muffler per the instructions contained in Attachment III, Exhibit 1.
^ Replace unacceptable mufflers and attaching parts at the OWNERS EXPENSE ON:
i) 1983 through 1987-model 7.5L single-thermactor engine equipped vehicles; ii) 1985 through
1987-model, 5.8L 4V H.D. engine equipped vehicles.
^ Replace any mufflers that are not Ford-sourced aluminized stainless steel and attaching parts at
FORD EXPENSE on 1985 through 1987-model, 7.5L dual thermactor engine equipped vehicles.
^ Heater and Bypass Hose Replacement:
4. Refer to Attachment III, Exhibit 2. Replace the engine compartment heater and engine bypass
hoses as shown on the referenced attachment. Note: The 5.8L 4V H.D. engines require a formed
bypass hose. This is not in the heater hose/bypass parts kit. Order this hose separately.
5. Pressure test the cooling system and replace existing radiator cap.
NOTE: Owners will be instructed to retorque hose clamps to 2.5-3.0 N-m (22-26 in.lbs.) when
coolant leakage is observed.
MODIFICATION DECAL: Prepare an "Authorized Modifications" decal (Form FPS-8262) as shown
below. Affix the decal to a flat clean surface on
the radiator support. (Order the "Authorized Modifications" decal on your Weekly Stock Order Pad.)
Specific Technical Repair Code and Parts Ordering Instructions
SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
Exhaust System-Ford Components-Correct Routing and Retention
1983-1985 7.5L MODELS (MODELS WITH SINGLE AIR PUMP) 1985-1/2-1987 5.8L MODELS
(OVER 8500 GVW WITH 4 BARREL CARBURETOR)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5981
FIGURE 1
The Ford exhaust system as shown in Figure 1, provides the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheatng.
FIGURE 3
Inspect the exhaust system for leaks or ruptures. FOR 5.8L ONLY, it may be necessary to remove
the heat shields as shown in Figure 3. Inspect the muffler outer wrapper lock seam for separation.
If any such problems are found, notify the customer and request permission to repair the problem,
at the customer's expense. Note any such problems and the customer's reaction to your repair
request on your internal repair order form and retain in your records.
If a non-Ford exhaust system or exhaust components is noted on the unit, inform the customer of
the potential for durability reduction, exhaust flow restriction, or overheating as indicated above.
Note any such discrepancy and the customer's reaction on your internal repair order form and
retain in your records.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5982
FIGURE 1
ALL 5.8L AND ONLY CALIFORNIA CALIBRATION 7.5L: If the unit is not equiped with the all-steel
hangers shown in Figure 1, order and install the Ford Service Part as indicated in the attached
chart. SAFETY RECALL 88S99 TECHNICAL INSTRUCTION - MUFFLERS
FIGURE 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5983
1985-1/2 - 1987 7.5L MODELS (MODELS WITH DUAL AIR PUMPS - SEE FIGURE 5)
FIGURE 2
The Ford exhaust system as shown in Figure 2, provdes the correct routing and exhaust gas flow
capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes
could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow,
and therefore, reduce engine performance or cause overheating.
FIGURE 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5984
FIGURE 4
Remove the heat shields covering the muffler by removing the retaining clamps securing the
shields as shown in Figure 3. If the muffler is a non-Ford design or is a non-ribbed design (Figure
4), remove the Muffler and Outlet Pipe Assembly and replace with the heavy duty ribbed muffler
assembly as indicated in the attached chart.
If the muffler is the heavy duty type (ribbed design - Figure 4), installed during the 1987 M53 recall,
inspect the entire surface of the muffler for cracks or openings. If any such openings are found,
replace the Muffler and Outet Pips Assembly with a new heavy duty ribbed muffler assembly.
Advise the Ambulance Technical Hot Line 1-800-445-1571, if you find a ribbed muffler with cracks
or openings.
FIGURE 2
If the unit is not equipped with the all-steel hangers as shown in Figure 2, order and install the Ford
Service Part as indicated in the attached chart. ATTACHMENT III EXHIBIT 1 PAGE 3 OF 3
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5985
KIT NUMBER E3UZ-18472-C HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED
AMBULANCES WITH 7.5L OR 5.8L 4V H.D. ENGINES SPECIAL NOTE: The following instructions
describe the installation procedure for the heater hose/bypass hose improvement package. It is
designed specially for Ford E-350 and E-250 (over 8500 pounds GVWR) based ambulances. The
original Ford heater hose system has probably been modified by the ambulance body builder. It is
not possible to identify all the designs and modifications used by these manufacturers. If you
encounter difficulties not anticipated in these instructions, contact the Ford Ambulance Recall
Hotline on 1-800-445-1571. PARTS LIST
Item Description Part Number Quantity
1 Silicons Hose - 5/8" I.D. *EST-M2D309-A 96"
2 Hose Clamp 388652-S2 20
3 "Y" Fitting D8UH-18663-AA 2
4 Tie Strap - 1/4" Wide 384213-S 10
5 Radiator Cap E5TH-8100-AA 1
*Engineering Specification Number
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5986
FIGURE 1
HEATER HOSE REMOVAL
1. Close the shutoff valves that connect the rear heater unit to the Ford installed heater hoses (See
Figure 1). Be sure to close both the supply and return hose valves. Failure to close these valves
could cause coolant fill problems later.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5987
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT.
2. Drain the coolant from the radiator by removing the radiator cap and carefully opening the drain
cock at the bottom of the radiator. After the coolant has drained from the radiator, close the drain
cock and discard the radiator cap.
3. Disconnect and remove any objects, such as thermactor pump filter/silencer or coolant overflow
bottle, obstructing access to the heater hoses.
4. Inspect the hoses for chaffing or cuts (See Figure 1). Note the position of any straps or clamps
for securing the new hoses at time of installation.
5. Disconnect the vacuum line from the water supply valve.
6. Disconnect the inlet and outlet hoses from the heater core, engine block, and rear heater shutoff
valves (See Figure 1). Loosen each clamp and cut the hose first to prevent core damage. DO NOT
twist hoses in the removal process. Disconnect the hoses from any locating clips. Discard all hose
clamps.
NOTE: DO NOT disconnect the hoses routed from the shutoff valves to the rear heater unit.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5988
FIGURE 1
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5989
FIGURE 2
HEATER HOSE INSTALLATION
1. Using hoses (Item 1), hose clamps (Item 2) and "Y" fittings (Item 3), assemble duplicate hose
layouts of the removed hose assemblies (Figure 1).
NOTE: The hoses leading from the "Y" fittings may have to be slightly longer than the original
hoses to avoid any kinks or bends. This is due to the replacement fittings having a different angle in
the "Y" than the original "Y" or "T" fittings. Silicone hoses require the special clamps Included in the
kit to prevent cutting the hose. DO NOT use any other type of clamp.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 1 OF 5
on 1-800-445-1571 if you have any questions.
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
2. Remove the vacuum operated water supply valve from the old hose assembly and install it into
the new hose assembly.
NOTE: Make sure that the flow arrow stamped on the valve is pointing toward the heater core.
3. Torque the clamps (Item 2) to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
4. Connect the hose assemblies with clamps (Item 2) to the engine block, heater core and rear shut
off valves.
5. Torque the clamps to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper
torque. Retorquing the clamps may cut the silicone hoses.
6. Connect the vacuum line to the water supply valve.
7. Using tie straps (Item 4), secure the hoses to an adjacent engine component to prevent chaffing
or cutting during engine operation. The hoses may be secured in a manner similar to the original
method if the removed hoses were not damaged as noted earlier. If the original hoses were
damaged, route the hoses and secure them in a manner to prevent hose damage during engine
operation.
WATER BYPASS HOSE REMOVAL AND INSTALLATION FOR VEHICLES WITH 7.5L ENGINES
1. Remove the distributer vacuum hose to improve accessibility to the water bypass hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5990
FIGURE 2
2. Remove the water bypass hose and clamps (See Figure 2). Discard the clamps.
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
CAUTION: DO NOT ALTER (CUT OFF) THE INTAKE MANIFOLD AND/OR THE WATER PUMP
HOSE CONNECTIONS. ANY
DAMAGE SUCH AS SHARP EDGES, TO THESE CONNECTIONS WILL RESULT IN DAMAGE
TO THE NEW BYPASS HOSE DURING INSTALLATION.
4. Using the removed hose as a pattern, cut a piece of silicone hose (Item 1) to the proper length
and position it on the intake manifold bypass connection.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 3 OF 5
on 1-800-445-1571 if you have any questions
FIGURE 3
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D ENGINES
5. Position two (2) new hose clamps (Item 2) on the new hose, installed in Step 4, toward the
intake manifold. (See Figure 3.)
6. Bend (double over) the new bypass hose downward and slide the hose on to the water pump
bypass hose connection. (See Figure 3.)
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5991
FIGURE 4
FOR VEHICLES WITH 5.8L ENGINES
1. Remove the distributor vacuum hose to improve accessibility to the water bypass hose.
2. Remove the water bypass hose and clamps (See Figure 4). Discard the clamps.
Don't forget... ATTACHMENT III
call the Special Econline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 4 OF 5
on 1-800-445-1571 if you have any questions!
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR
5.8L 4V H.D. ENGINES
3. Carefully remove any hose material which may have adhered to the intake manifold or water
pump connections. Clean the connections with emery cloth or a file so that no burrs or rough
surfaces are evident.
4. Position a new formed bypass hose (Part number E8UZ-8597-A) on the intake manifold bypass
connection.
5. Position two (2) new hose clamps (Item 2) on the new hose toward the intake manifold.
6. Bend and slide the hose on to the water pump bypass hose connection.
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water
pump bypass hose connection.
7. Position the bypass hose clamps and torque to:) 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose, PRESSURE TEST COOLING SYSTEM
1. Reinstall all of the objects such as the thermactor pump filter/silencer or coolant overflow bottle,
that obstructed access to the heater hoses.
2. Fill the cooling system with a coolant mixture of 50/50 Ford Long Life Coolant E2FZ-19549-AA
(ESE-M97B44-A) or equivalent and water, to 38 mm (1.5 inches) below the cap seal.
3. Install radiator cap (Item 5)
WARNING: DO NOT STAND IN LINE WITH OR NEAR THE RADIATOR FAN WHEN THE
ENGINE IS RUNNING.
4. Start the engine, let it warm until the upper radiator hose is hot, shut off the engine. Allow the
engine to cool, remove the cap and check the coolant level. Fill as required.
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE
ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN
DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID
HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE
EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE
ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND
TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED
FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN
RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5992
5. Using the Rotunda Cooling System Pressurization Kit 021-00012, pressurize the cooling system
to 20 psi and check for leaks. Be sure to follow the instructions in the kit on the recommmended
method of connecting the tester to the radiator.
6. If any leaks are found, correct as needed.
7. Pressure test the cooling system until no leaks we found.
8. Rechock the coolant level in the radiator to make sure that it is 38 mm (1.5 inches ) below the
cap seal. If it is not, fill as required.
9. Reinstall the radiator cap and add coolant to the overflow bottle as required.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 5 OF 5
on 1-800-445-1571 if you have any questions!
Owner & Operator Letter Information
Attachment IV
September 2, 1988
Dear Owner/Operator:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor
Vehicle Safety Act.
Ford Motor Company has determined that a defect which relates to Motor Vehicle Safety evists in
certain 1983-1987 Econoline-based ambulances equipped with 7.5 liter or 5.8 liter 4V H.D. V8
engines. Due to the prolonged periods of extreme engine operating temperatures and cooling
system pressures encountered during EMS severe-duty cycles, heater or engine bypass hoses
may wear-out prematurely and burst. Engine coolant ("antifreeze") from a burst hose may cause a
fire if it sprays onto an overheated engine exhaust manifold, especially if the coolant is
overconcentrated.
Ford Motor Company is now asking that you return your Econoline-based ambulance to your Ford
or Ford Heavy Truck Dealer for corrective action.
COOLING SYSTEM SERVICE
At no cost to you, your dealer will:
- replace certain "rubber" heater hoses installed by Ford Motor Company when the vehicle was
manufactured (ie., up to the auxiliary heater shut-off valves), with new "SILICONE/NOMEX" heater
hose;
- replace engine bypass hoses
- replace the engine coolant (with a proper 50/50 mixture);
- install a new radiator cap;
- pressure test the cooling system.
Most ambulances also have auxiliary heater systems. The ambulance body manufacturer typically
installs these heater systems. While these hoses are not part of this safety recall, we strongly
recommend that you consider replacing all non-silicone/Nomex @ auxiliary heater hoses also. THE
COST OF REPLACING THE AUXILIARY HEATER HOSES WILL BE AT YOUR EXPENSE. IF
LEAKS ARE FOUND IN OTHER COMPONENTS OF THE ENGINE COOLING SYSTEM, WHEN
THE SYSTEM IS PRESSURE TESTED SUCH AS THE RADIATOR OR RADIATOR HOSES, THE
COST OF REPAIRING THOSE COMPONENTS WILL BE AT YOUR EXPENSE.
FOR ALL HEATER SYSTEM HOSE REPLACEMENTS, FORD RECOMMENDS THAT YOU
SPECIFY HOSES MADE ONLY FROM THE "SILICONE/NOMEX" MATERIAL. SILICONE HOSES
ALSO REQUIRE SPECIAL HOSE CLAMPS TO PREVENT CUTTING THE HOSE. USE ONLY
THE HOSE CLAMPS RECOMMENDED BELOW WITH SILICONE HOSES.
When purchasing replacements, the following parts should be specified:
Ford Service Motorcraft Brand
Part Name Part Number Part Number
- SILICONE/NOMEX E8TZ-18472-H KH-15
Heater Hose - 25 foot lengths
- Formed Water Pump Bypass E8UZ-8597-A KMS-1776
Hose (for 5.8L 4V H.D. Engine)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5993
- Hose Clamps D9AZ-8287-C YF-842
It is important also that the proper torque be used when attaching the special hose clamps required
for SILICONE/NOMEX hoses. Your dealer will properly torque clamps when they install the heater
and engine bypass hoses on your ambulance. If you should notice coolant seepage, retorque the
clamps to 2.5 to 3.0 N-m (22-26 in.lbs.).
These parts are available through your Ford, Lincoln-Mercury or Ford Heavy Truck Dealer. They
are also available through any Motorcraft parts distributor.
Ford recommends that you always replace these SILICONE/NOMEX HEATER SYSTEM hoses
every 48,000 miles or 48 months, whichever comes first. Non-silicone hoses should be replaced
every 24,000 miles or 24 months, whichever comes first.
It is important that your ambulance cooling system have the proper anti-freeze coolant and water
mixture for adequate freeze protection. Please read and observe the recommendations on the
attachment, "The Importance of Proper Cooling System Anti-freeze Mixtures".
EXHAUST SYSTEM SERVICE
^ Certain 198-5-1987 Model Ambulances with 7.5 Liter/Dual Thermactor Engines
Ambulances with 7.5 Liter V8 engines and a dual-thermactor emission system will have a new
aluminized stainless steel muffler installed. Mufflers and installation will be free of charge.
Some of these ambulances may have already had new alumunized stainless steel mufflers
installed during the earlier recall. These vehicles will not need new mufflers.
^ Refunds for Certain Later Model Muffler Replacements
As noted above, some of these ambulances with 7.5 liter/dual thermactor engines may have
received the new aluminized stainless steel mufflers during the service for the earlier Safety Recall
87M53. If you paid to have these new aluminized stainless steel mufflers installed, you are entitled
to a refund for the costs of parts and labor. If you are entitled to this refund, please present your
paid receipt to any Ford or Ford Heavy Truck Dealer who will process a refund for you.
This receipt must show the date of repair, the part numbers for the new aluminized stainless steel
muffler and attaching parts as well as the parts and labor costs.
^ Other 7.5 Liter and 5.8 Liter 4V H.D. Engine Equipped Ambulances
Ambulances with 7.5 Liter V8 engines and a single thermactor emission system as well as all
1985-1987 model ambulances with 5.8 Liter 4V H.D. V8 engines will only have the muffler
inspected. Replacement of defective mufflers will be the owner's responsibility.
SCHEDULE SERVICE AT ANY FORD OR FORD HEAVY TRUCK DEALER NOW
Since the cooling system parts, mufflers and instructions are now available, we urge you to
schedule this service as quickly as possible.
NOTE: ANY FORD OR FORD HEAVY TRUCK DEALER CAN DO THE COOLING SYSTEM AND
MUFFLER SERVICE.
Before you return your vehicle for this service, we urge you to review the cooling system
information sent to you in June, 1988. Some cooling system maintenance may be needed now.
COMPUTER FORM
The computer form included with this letter may include a special part code. Your dealer will need
to know this code when you call to make an appointment. The code, located in the box labeled "Kit
Code", half way down the right side of the form, will be a single digit number from 1 through 8.
IMPORTANT NOTE
If your vehicle is not operated solely on propane and has not yet been modified to correct a fuel
system over-pressurization concern, announced in July, 1987 as Safety Recall 87M53, or has only
received the earlier (prior to late-October, 1987) Phase I fuel system modifications, you need to
have these modifications done as promptly as possible. You may want to have all of the required
services performed together.
NOTE: ONLY OUR SPECIALLY TRAINED DEALERS CAN WORK ON THE FUEL SYSTEM AND
SYSTEM MODIFICATIONS.
A listing of our specially trained dealers is enclosed.
THANK YOU FOR YOUR CONTINUED COOPERATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: > 88S99 > Sep >
88 > Recall - Heater/Engine Bypass Hose Replacement > Page 5994
We are sorry that we must inconvenience you again by asking you to return your Econoline-based
ambulance to your Ford or Ford Heavy Truck dealer. However we do wish to maintain your
confidence in our vehicle. Thank you for your continued cooperation in this matter of mutual
concern. THE IMPORTANCE OF PROPER COOLING SYSTEM ANTI-FREEZE MIXTURE
It is extremely important that the proper anti-freeze mixture be used in your ambulance cooling
system, and that it be maintained at recommended levels.
Ford recommends that a reasonably fresh 50% anti-freeze concentrate and 50% water mixture be
maintained in the cooling system of your ambulances at all times. This mixture provides adequate
freeze protection for most areas (50/50 mixtures provide protection to - 35~F). It also provides
optimum engine cooling and corrosion protection for the system.
Increasing the anti-freeze concentration above 50% will reduce engine cooling and result in hotter
engine operation. If you are in extremely cold area, it is permissible to use a 60% anti-freeze
concentrate and 40% water providing protection to approximately - 60~F, but only during the winter
months. (This is a revised coolant manufacturer recommendation from the information sent to you
in June, 1988, in a Motorcraft booklet "Cooling System Operation and Maintenance", dated April,
1979). The mixture should be returned to 50/50 at the end of your cold season. As the concentrate
percentage gets larger beyond 60% concentrate, the freeze protection is less. A 100% anti-freeze
concentration only protects your cooling system to - 8~F.
Decreasing the anti-freeze concentration below 40% reduces corrosion and freeze protection
(40/60 mixtures provides protection to - 10~F).
Remember:
^ Maintain cooling system mixtures at 50/50. Do not allow the mixture to be above 60/40.
^ Replace your cooling system mixture annually.
^ Replace lost coolant with a 50/50 mixture. Keep a pre-mixed supply of 50/50 mixture to refill the
system.
^ Do not refill your system with pure anti-freeze.
^ Regularly inspect and repair any cooling system leaks.
^ Replace cooling system hoses before they fail. Follow the Ford recommended replacement
intervals.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > 902317 > Nov > 90 > Recalls for Heater Hose: >
NHTSA88V133000 > Aug > 88 > Recall 88V133000: Cooling System Hose Replacement
Heater Hose: Recalls Recall 88V133000: Cooling System Hose Replacement
EXTREME OPERATING CONDITIONS COULD CAUSE PREMATURE DETERIORATION OF
THE ENGINE COMPARTMENT HEATER HOSES OR ENGINE BYPASS HOSES. ENGINE
COOLANT COULD DISCHARGE ONTO THE ENGINE AND ITS EXHAUST MANIFOLD
CREATING THE POTENTIAL FOR A FIRE DUE TO THE HIGH ENGINE EXHAUST MANIFOLD
TEMPERATURES. REPLACE HOSES AND RADIATOR CAPS; INSTALL HIGH HEAT
RESISTANCE ALUMINIZED STAINLESS STEEL MUFFLERS.
SYSTEM: ENGINE HOSES.
VEHICLE DESCRIPTION: AMBULANCE VEHICLES MANUFACTURED FROM FORD CUT
AWAY CHASSIS AND VANS.
1983 FORD TRUCK E250 1983 FORD TRUCK E350 1984 FORD TRUCK E250 1984 FORD
TRUCK E350 1985 FORD TRUCK E250 1985 FORD TRUCK E350 1986 FORD TRUCK E250
1986 FORD TRUCK E350 1987 FORD TRUCK E250 1987 FORD TRUCK E350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Heater Hose: > Page 5999
Air Injection Check Valve: Description and Operation Anti-Backfire Gulp Valve
Fig. 73 Anti-backfire gulp valve
The anti-backfire gulp valve, used on some vehicles, routes a portion of thermactor air to the intake
manifold and is activated by intake manifold vacuum signal, Fig. 73. This valve is located
downstream from the air bypass valve and functions only during periods of sudden decrease in
manifold pressure.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair
Receiver Dryer: Service and Repair
Fig. 1 Receiver & condenser assembly
The receiver/dryer must be replaced any time the system has been left open for more than one
month, there is evidence of moisture in the system, the system is badly contaminated, or the
receiver/dryer is restricted, plugged or perforated. The receiver/dryer does not necessarily need to
be replaced every time there is a loss of refrigerant charge, a component is replaced or the outer
shell of the unit is dented.
1. Discharge refrigerant from system.
2. Disconnect compressor discharge line and liquid line from condenser and cap both lines.
3. Remove two screws attaching hood latch to radiator support and position latch aside.
4. Remove nine screws attaching top edge of radiator grille to radiator support.
5. Remove screw attaching center area of grille to grille center support.
6. Remove grille center support to radiator support attaching screw.
7. Working under vehicle, reposition splash shields and remove two condenser lower retaining
nuts, Fig. 1.
8. Remove two bolts attaching top of condenser to radiator upper support.
9. Remove four bolts attaching each end of radiator upper support to radiator side supports.
10. Pull top edge of grille forward, remove radiator upper support, and lift condenser from vehicle.
11. Reverse procedure to install. Use new O-rings lubricated with refrigerant oil.
12. Leak test, evacuate and charge system. Check system for proper operation.
13. Disconnect refrigerant tubes from receiver/dryer, Fig. 1.
14. Remove receiver/dryer attaching screws, then the receiver/dryer assembly.
15. Reverse procedure to install. Use new O-rings lubricated with suitable oil.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Identification of Non Approved Refrigerants
Technical Service Bulletin # 99-19-6 Date: 990920
A/C - Identification of Non Approved Refrigerants
Article No. 99-19-6
09/20/99
^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS
^ AIR CONDITIONING - PURGING AIR FROM SYSTEM
FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD
1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA
1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO
II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD,
RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000
WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991
CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO
SERIES 1997-1998 AEROMAX, LOUISVILLE
LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII
2000 LS 1998-2000 NAVIGATOR
MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR
1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI
1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER
1997-2000 MOUNTAINEER
MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Identification of Non Approved Refrigerants > Page 6007
This TSB article is being republished in its entirety to add model year vehicles
ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are
being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved
refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety,
durability, and performance concerns if they are installed in Ford A/C systems. Identification of the
type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent
dealer service equipment and refrigerant supplies from being contaminated with non-approved
refrigerants.
ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a
recovery machine to prevent cross-contamination of the recovery machine and other A/C systems
being serviced with that recovery machine. Refer to the following text.
OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4
SUPERSEDES: 98-12-8
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles
OPERATION DESCRIPTION TIME
991906A Test A/C System For 0.3 Hr.
Contaminated Refrigerant
DEALER CODING
CONDITION
BASIC PART NO. CODE
R-12 49
OASIS CODES: 208000, 208999
A/C Refrigerant Analyzer Function
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Identification of Non Approved Refrigerants > Page 6008
Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for
use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a
quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or
flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system
and automatically purge air from the system.
The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from
automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes
through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor
calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid
Crystal Display (LCD).
The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the
sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green
"PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity
levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will
light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and
"HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards.
The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or
above. The analyzer eliminates the effect of air
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Identification of Non Approved Refrigerants > Page 6009
when determining the refrigerant sample content because air is not considered a contaminant
although air can affect A/C system performance. Air will automatically be purged until a pure
refrigerant with a less than 2% by weight air measurement is reached.
Recovery of Contaminated Refrigerant
If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12
recovery/recycling equipment. Take the following actions:
1. Repeat the test to verify contaminated refrigerant is present.
2. Advise the customer of the contaminated A/C system and any additional cost to repair the
system. The customer may wish to return to the service facility which performed the last A/C
service.
3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant. This equipment must only be used to recover
contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C
service facility in your area which has the proper equipment for refrigerant recovery.
Repairing A Contaminated A/C System
Once the contaminated refrigerant is removed from the system it will be necessary to repair the
system. Ford recommends that you do the following to be sure a quality repair is made:
1. Determine the cause of the failure.
2. Determine which parts will need to be replaced.
3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated
refrigerant.
4. Install a new suction/accumulator.
5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present
in the system.
6. Evacuate the system for 45 minutes.
7. Recharge the system, verify proper operation, and leak test.
Disposal of Contaminated Refrigerant
Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are
companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not
evaluated the processes of the listed refrigerant disposal companies and is not endorsing or
promoting their companies Business transactions are between the dealership and disposal
companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip
cylinder shipping.
^ Omega Refrigerant Reclamation
^ 5263 North Fourth St.
^ Irwindale, CA 91706
^ (310) 698-0991 FAX: (310) 696-7908
^ Full Cycle Global
^ 2966 Wireton
^ Blue Island, IL 60406
^ (708) 388-8551 FAX: (708) 399-6550
^ U.S. Refrigerant Reclaim, Inc.
^ 12420 North Green River Road
^ Evansville, IN 47711
^ (800) 207-5931 FAX: (812) 867-1463
^ Full Cycle Global
^ 343 South Airline Highway
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > A/C - Identification of Non Approved Refrigerants > Page 6010
^ Gonzales, LA 70737
^ (504) 644-5333 FAX: (504) 644-1609
^ CFC Reclamation
^ 1321 Swift North
^ Kansas City, MO 64116
^ (816) 471-2511
^ Full Cycle Global
^ 550 James St.
^ Lakewood, NJ 08701
^ (908) 370-3400 FAX: (908) 370-3088
^ National Refrigerants, Inc.
^ 11401 Roosevelt Blvd.
^ Philadelphia, PA 19154
^ (215) 698-6620 FAX: (215) 602-8205
^ Gartech Refrigerant Reclamation
^ 2002 Platinum
^ Garland, TX 75042
^ (214) 272-4070 FAX: (214) 272-6548
^ Refrigerant Reclaim Services
^ 121 S. Norwood Dr.
^ Hurst, TX 76053-7807
^ (817) 282-0022 FAX: (800) 831-6182
^ Full Cycle Global
^ 2055 Silber, Suite 109
^ Houston, TX 77055
^ (713) 681-7370 FAX: (713) 681-9947
^ Refrigerant Reclaim, Inc.
^ 122 Old Stage Coach Road
^ Dumfries, VA 22026
^ (800) 238-5902 FAX: (703) 441-0393
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved
Refrigerants
Technical Service Bulletin # 99-19-6 Date: 990920
A/C - Identification of Non Approved Refrigerants
Article No. 99-19-6
09/20/99
^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS
^ AIR CONDITIONING - PURGING AIR FROM SYSTEM
FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD
1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA
1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO
II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD,
RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000
WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991
CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO
SERIES 1997-1998 AEROMAX, LOUISVILLE
LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII
2000 LS 1998-2000 NAVIGATOR
MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR
1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI
1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER
1997-2000 MOUNTAINEER
MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved
Refrigerants > Page 6016
This TSB article is being republished in its entirety to add model year vehicles
ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are
being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved
refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety,
durability, and performance concerns if they are installed in Ford A/C systems. Identification of the
type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent
dealer service equipment and refrigerant supplies from being contaminated with non-approved
refrigerants.
ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a
recovery machine to prevent cross-contamination of the recovery machine and other A/C systems
being serviced with that recovery machine. Refer to the following text.
OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4
SUPERSEDES: 98-12-8
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles
OPERATION DESCRIPTION TIME
991906A Test A/C System For 0.3 Hr.
Contaminated Refrigerant
DEALER CODING
CONDITION
BASIC PART NO. CODE
R-12 49
OASIS CODES: 208000, 208999
A/C Refrigerant Analyzer Function
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved
Refrigerants > Page 6017
Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for
use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a
quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or
flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system
and automatically purge air from the system.
The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from
automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes
through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor
calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid
Crystal Display (LCD).
The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the
sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green
"PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity
levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will
light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and
"HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards.
The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or
above. The analyzer eliminates the effect of air
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved
Refrigerants > Page 6018
when determining the refrigerant sample content because air is not considered a contaminant
although air can affect A/C system performance. Air will automatically be purged until a pure
refrigerant with a less than 2% by weight air measurement is reached.
Recovery of Contaminated Refrigerant
If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12
recovery/recycling equipment. Take the following actions:
1. Repeat the test to verify contaminated refrigerant is present.
2. Advise the customer of the contaminated A/C system and any additional cost to repair the
system. The customer may wish to return to the service facility which performed the last A/C
service.
3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for
capturing and storing contaminated refrigerant. This equipment must only be used to recover
contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C
service facility in your area which has the proper equipment for refrigerant recovery.
Repairing A Contaminated A/C System
Once the contaminated refrigerant is removed from the system it will be necessary to repair the
system. Ford recommends that you do the following to be sure a quality repair is made:
1. Determine the cause of the failure.
2. Determine which parts will need to be replaced.
3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated
refrigerant.
4. Install a new suction/accumulator.
5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present
in the system.
6. Evacuate the system for 45 minutes.
7. Recharge the system, verify proper operation, and leak test.
Disposal of Contaminated Refrigerant
Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are
companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not
evaluated the processes of the listed refrigerant disposal companies and is not endorsing or
promoting their companies Business transactions are between the dealership and disposal
companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip
cylinder shipping.
^ Omega Refrigerant Reclamation
^ 5263 North Fourth St.
^ Irwindale, CA 91706
^ (310) 698-0991 FAX: (310) 696-7908
^ Full Cycle Global
^ 2966 Wireton
^ Blue Island, IL 60406
^ (708) 388-8551 FAX: (708) 399-6550
^ U.S. Refrigerant Reclaim, Inc.
^ 12420 North Green River Road
^ Evansville, IN 47711
^ (800) 207-5931 FAX: (812) 867-1463
^ Full Cycle Global
^ 343 South Airline Highway
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved
Refrigerants > Page 6019
^ Gonzales, LA 70737
^ (504) 644-5333 FAX: (504) 644-1609
^ CFC Reclamation
^ 1321 Swift North
^ Kansas City, MO 64116
^ (816) 471-2511
^ Full Cycle Global
^ 550 James St.
^ Lakewood, NJ 08701
^ (908) 370-3400 FAX: (908) 370-3088
^ National Refrigerants, Inc.
^ 11401 Roosevelt Blvd.
^ Philadelphia, PA 19154
^ (215) 698-6620 FAX: (215) 602-8205
^ Gartech Refrigerant Reclamation
^ 2002 Platinum
^ Garland, TX 75042
^ (214) 272-4070 FAX: (214) 272-6548
^ Refrigerant Reclaim Services
^ 121 S. Norwood Dr.
^ Hurst, TX 76053-7807
^ (817) 282-0022 FAX: (800) 831-6182
^ Full Cycle Global
^ 2055 Silber, Suite 109
^ Houston, TX 77055
^ (713) 681-7370 FAX: (713) 681-9947
^ Refrigerant Reclaim, Inc.
^ 122 Old Stage Coach Road
^ Dumfries, VA 22026
^ (800) 238-5902 FAX: (703) 441-0393
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor
Replacement
Technical Service Bulletin # 98-12-5 Date: 980622
A/C - Filtering Refrigerant After Compressor Replacement
Article No. 98-12-5
06/22/98
AIR CONDITIONING - FILTERING REFRIGERANT
AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS
FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS
1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86
CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92
MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII
1995-98-MYSTIQUE 1999 COUGAR
LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150,
F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98
EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER
1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to revise the Service Procedure and to update
the model years.
ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the
refrigerant system cleaned to remove any debris or contaminants that may be present to prevent
damage to the replacement compressor.
ACTION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor
Replacement > Page 6024
Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor.
Refer to the following Service Procedure for details.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 96-15-5
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major
Component Warranty Coverage For All Other Lincoins
OPERATION DESCRIPTION TIME
981205A Kit Installation 1.2 Hrs.
981205B Extra Time For Refrigerant 0.4 Hr.
(R-12) Recovery
DEALER CODING
CONDITION
BASIC PART NO. CODE
19703 49
OASIS CODES: 208000, 208999
Service Procedure
THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C
FLUSHER.
CAUTION
THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT
SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND
BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM
IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED
BEFORE STARTING THE FILTERING PROCEDURE.
Each Service Filter Kit includes the following items:
^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice
tube)
^ One (1) Instruction Sheet
NOTE
ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY
WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET
WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM
FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE
TUBE AFTER FILTERING IS COMPLETE.
CAUTION
FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN
THE APPROPRIATE SERVICE OR WORKSHOP MANUAL.
1. Before removing any refrigerant system components, recover the refrigerant from the system
following the recycling methods outlined In the appropriate Service/Workshop Manual.
2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container.
3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The
quantity of the new oil to be added is the amount to match that drained from the old accumulator
plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction
accumulator/drier part number.
CAUTION
REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12
SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a
SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE
TO SYSTEM COMPONENTS.
4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube
part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and
the evaporator, replace the liquid line assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor
Replacement > Page 6025
5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1.
a. Be sure orifice inlet is toward the condenser.
b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible
refrigerant hose of 2500 psi burst rating. Individual fittings are also available.
6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a
calibrated container.
7. Drain the oil from the replacement compressor into a clean calibrated container.
NOTE:
IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD
COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP
MANUAL PROCEDURES.
8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10
service compressor does not contain any oil and can be used with an R-12 or an R-134a system.
CAUTION
REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL
WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT
IN DAMAGE TO SYSTEM COMPONENTS.
^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz),
pour the same amount of clean refrigerant oil into the new compressor.
^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3
oz) of clean refrigerant oil into the new compressor.
9. Install the new compressor following Service/Workshop Manual procedures. Make sure all
mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if
necessary.
10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures.
11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make
sure they do not interfere with other engine compartment components. If necessary, use tie straps
to make adjustments.
12. Set the A/C control on Max A/C, high blower and temperature control at full cold.
a. Start engine and let idle briefly.
b. Be sure A/C system is operating properly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor
Replacement > Page 6026
13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at
800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system
operating.
14. Stop the engine.
NOTE:
IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE
PROCEEDING.
15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from
the liquid line.
16. Discard the filter. It can be used one (1) tie only.
17. Reconnect the liquid line back into the system.
18. Evacuate, charge and leak test the system. Make any necessary adjustments.
19. Check the operation of the system in all models.
PART NUMBER PART NAME
F8VZ-19E773-AA Filter Kit
F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only)
F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant
Systems Only)
NOTE
THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS
THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR
TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip
Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Substitutes Service Tip
Article No. 96-17-10
08/12/96
AIR CONDITIONING - USE OF R-12 REFRIGERANT SUBSTITUTES - SERVICE TIP
FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-94 TEMPO 1986-93 TAURUS 1988-93
FESTIVA 1989-93 PROBE
LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7,
ZEPHYR 1982-86 CAPRI 1982-93 COUGAR 1982-94 CONTINENTAL 1983-86 MARQUIS
1984-92 MARK VII 1984-94 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER
MERKUR: 1985-89 XR4TI 1988-90 SCORPIO
LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES 1983-93
RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993
VILLAGER
MEDIUM/HEAVY TRUCK: 1985-94 CARGO SERIES, F & B SERIES, L SERIES
This TSB article is being republished in its entirety to list Environmental Protection Agency (EPA)
reviewed NC substitutes for R-12 refrigerant.
ISSUE: A number of manufacturers are producing refrigerant products which are described as
being direct replacements for refrigerant R-12.
ACTION: If service is required, use only new or of known quality recycled refrigerant R-12. Ford
Motor Company has approved R-134a as the only refrigerant substitute for R-12.
CAUTION:
USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN
SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS.
INFORMATION FROM THE EPA
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip
> Page 6031
This information has been taken from EPA documents to address Ford specific applications and
recommendations. Further EPA information on ozone-depleting substances and regulations
regarding its handling can be found on the Internet at World Wide Web site:
http://www.epa.gov/ozone/
In 1994, EPA established the Significant New Alternatives Policy (SNAP) program to review
alternatives to ozone-depleting substances like R-12. EPA examines new substitutes for their
ozone depleting, global warming, flammability, and toxicity characteristics. The SNAP process does
not test these substitutes for A/C system compatibility, reliability, durability, or performance.
Under the SNAP rule, each new refrigerant must be used in accordance with the following
conditions:
1. Unique Fittings - Each new refrigerant must be used with a unique set of fittings to prevent the
accidental mixing of different refrigerants.
2. Unique Equipment - Each refrigerant must have dedicated recovery/recycling equipment for that
refrigerant.
3. Labels - Whether a vehicle is originally designed to use a new refrigerant or is retrofitted, the
technician must apply a detailed label giving specific information about the alternative. This label
covers up information about the old refrigerant and provides valuable details on the alternative and
how it was used. The technician is required to fill in their name, company performing the retrofit,
address and the date retrofitted.
4. Remove Original Refrigerant - The original R-12 must be removed from the system prior to
charging with the new refrigerant. This will guarantee that the largest amount of clean R-12 is
available for use in vehicles that still need it.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip
> Page 6032
A summary of the refrigerants reviewed under EPA's SNAP program for use in motor vehicle air
conditioning systems is in the table.
OTHER APPLICABLE ARTICLES: 91-9-7, 96-15-7
SUPERSEDES: 93-23-11
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208999, 290000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes
Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes
Article No. 94-14-3
07/13/94
Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip
FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93
FESTIVA 1989-93 PROBE
LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7,
ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK
VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER
MERKUR: 1986-89 SCORPIO, XR4TI
LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90
BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993
VILLAGER
MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000,
CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES
This TSB is being republished in its entirety to include Heavy Truck models.
ISSUE:
A number of manufacturers are producing refrigerant products which are described as being direct
replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely
damage the A/C system components.
ACTION:
If service is required, use only NEW or RECYCLED refrigerant R-12.
Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time.
R-134a is approved only for systems which specify R-134a,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes > Page 6037
and is not compatible with R-12 systems.
R-22 likewise, is not compatible with R-12 systems.
CAUTION:
USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN
SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS.
OTHER APPLICABLE ARTICLES: 91-9-7
SUPERSEDES: 93-23-11
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208999, 290000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 93206 > Sep > 93 > Air Conditioning - Use of Correct Fluorescent
Tracer Dye
Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye
Article No. 93-20-6
09/29/93
AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP
FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93
FESTIVA 1989-93 PROBE
LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7,
ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK
VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER
LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90
BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER
ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may
damage the air conditioning system. Some of these materials may not be compatible with Ford A/C
systems.
ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied
Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor
Company.
NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 208999
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > 9197 > May > 91 > A/C - R12 Refrigerant Service Tips
Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Service Tips
Article No. 91-9-7
05/01/91
AIR CONDITIONING - REFRIGERANT R-12 - SERVICE TIPS
FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO,
THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE
LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS,
MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER 1991 CAPRI
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES,
RANGER 1986-91 AEROSTAR 1988-91 F SUPER DUTY 1991 EXPLORER
MEDIUM/HEAVY TRUCK: 1985-90 C SERIES 1985-91 CL-CLT-9000 SERIES, F & B SERIES, L
SERIES 1986-91 CARGO SERIES
ISSUE: A number of manufacturers are producing refrigerant products which are described as
being direct replacements for Refrigerant R-12. The use of any unauthorized substitute refrigerant
may severely damage the A/C components.
ACTION: If service is required, use only NEW or RECYCLED Refrigerant R-12.
CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY
RESULT IN SEVERE DAMAGE TO THE A/C
SYSTEM COMPONENTS.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
208000, 208200
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > Page 6046
Technical Service Bulletin # 98-12-5 Date: 980622
A/C - Filtering Refrigerant After Compressor Replacement
Article No. 98-12-5
06/22/98
AIR CONDITIONING - FILTERING REFRIGERANT
AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS
FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS
1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86
CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92
MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII
1995-98-MYSTIQUE 1999 COUGAR
LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150,
F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98
EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER
1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to revise the Service Procedure and to update
the model years.
ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the
refrigerant system cleaned to remove any debris or contaminants that may be present to prevent
damage to the replacement compressor.
ACTION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > Page 6047
Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor.
Refer to the following Service Procedure for details.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 96-15-5
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major
Component Warranty Coverage For All Other Lincoins
OPERATION DESCRIPTION TIME
981205A Kit Installation 1.2 Hrs.
981205B Extra Time For Refrigerant 0.4 Hr.
(R-12) Recovery
DEALER CODING
CONDITION
BASIC PART NO. CODE
19703 49
OASIS CODES: 208000, 208999
Service Procedure
THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C
FLUSHER.
CAUTION
THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT
SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND
BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM
IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED
BEFORE STARTING THE FILTERING PROCEDURE.
Each Service Filter Kit includes the following items:
^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice
tube)
^ One (1) Instruction Sheet
NOTE
ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY
WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET
WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM
FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE
TUBE AFTER FILTERING IS COMPLETE.
CAUTION
FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN
THE APPROPRIATE SERVICE OR WORKSHOP MANUAL.
1. Before removing any refrigerant system components, recover the refrigerant from the system
following the recycling methods outlined In the appropriate Service/Workshop Manual.
2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container.
3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The
quantity of the new oil to be added is the amount to match that drained from the old accumulator
plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction
accumulator/drier part number.
CAUTION
REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12
SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a
SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE
TO SYSTEM COMPONENTS.
4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube
part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and
the evaporator, replace the liquid line assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > Page 6048
5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1.
a. Be sure orifice inlet is toward the condenser.
b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible
refrigerant hose of 2500 psi burst rating. Individual fittings are also available.
6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a
calibrated container.
7. Drain the oil from the replacement compressor into a clean calibrated container.
NOTE:
IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD
COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP
MANUAL PROCEDURES.
8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10
service compressor does not contain any oil and can be used with an R-12 or an R-134a system.
CAUTION
REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL
WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT
IN DAMAGE TO SYSTEM COMPONENTS.
^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz),
pour the same amount of clean refrigerant oil into the new compressor.
^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3
oz) of clean refrigerant oil into the new compressor.
9. Install the new compressor following Service/Workshop Manual procedures. Make sure all
mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if
necessary.
10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures.
11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make
sure they do not interfere with other engine compartment components. If necessary, use tie straps
to make adjustments.
12. Set the A/C control on Max A/C, high blower and temperature control at full cold.
a. Start engine and let idle briefly.
b. Be sure A/C system is operating properly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > Page 6049
13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at
800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system
operating.
14. Stop the engine.
NOTE:
IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE
PROCEEDING.
15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from
the liquid line.
16. Discard the filter. It can be used one (1) tie only.
17. Reconnect the liquid line back into the system.
18. Evacuate, charge and leak test the system. Make any necessary adjustments.
19. Check the operation of the system in all models.
PART NUMBER PART NAME
F8VZ-19E773-AA Filter Kit
F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only)
F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant
Systems Only)
NOTE
THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS
THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR
TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > Page 6050
Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye
Article No. 93-20-6
09/29/93
AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP
FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93
FESTIVA 1989-93 PROBE
LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7,
ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK
VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER
LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90
BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER
ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may
damage the air conditioning system. Some of these materials may not be compatible with Ford A/C
systems.
ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied
Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor
Company.
NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 208999
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > Page 6051
Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes
Article No. 94-14-3
07/13/94
Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip
FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93
FESTIVA 1989-93 PROBE
LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7,
ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK
VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER
MERKUR: 1986-89 SCORPIO, XR4TI
LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90
BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993
VILLAGER
MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000,
CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES
This TSB is being republished in its entirety to include Heavy Truck models.
ISSUE:
A number of manufacturers are producing refrigerant products which are described as being direct
replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely
damage the A/C system components.
ACTION:
If service is required, use only NEW or RECYCLED refrigerant R-12.
Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time.
R-134a is approved only for systems which specify R-134a,
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service
Bulletins > Technical Service Bulletins for Refrigerant: > Page 6052
and is not compatible with R-12 systems.
R-22 likewise, is not compatible with R-12 systems.
CAUTION:
USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN
SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS.
OTHER APPLICABLE ARTICLES: 91-9-7
SUPERSEDES: 93-23-11
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208999, 290000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
With Front A/C
Refrigerant Capacity ............................................................................................................................
........................................................................ 3.5 lbs
With Front and Rear A/C
Refrigerant Capacity ............................................................................................................................
...................................................................... 4.25 lbs
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 6055
Refrigerant: Fluid Type Specifications
Type .....................................................................................................................................................
............................................... Refrigerant 12 (R-12) Ford Part Number .............................................
........................................................................................................................................
D4AZ-19B519-A
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement
Technical Service Bulletin # 98-12-5 Date: 980622
A/C - Filtering Refrigerant After Compressor Replacement
Article No. 98-12-5
06/22/98
AIR CONDITIONING - FILTERING REFRIGERANT
AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS
FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP
1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS
1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86
CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92
MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII
1995-98-MYSTIQUE 1999 COUGAR
LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150,
F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98
EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER
1999 SUPER DUTY F SERIES
This TSB article is being republished in its entirety to revise the Service Procedure and to update
the model years.
ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the
refrigerant system cleaned to remove any debris or contaminants that may be present to prevent
damage to the replacement compressor.
ACTION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 6060
Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor.
Refer to the following Service Procedure for details.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 96-15-5
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major
Component Warranty Coverage For All Other Lincoins
OPERATION DESCRIPTION TIME
981205A Kit Installation 1.2 Hrs.
981205B Extra Time For Refrigerant 0.4 Hr.
(R-12) Recovery
DEALER CODING
CONDITION
BASIC PART NO. CODE
19703 49
OASIS CODES: 208000, 208999
Service Procedure
THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C
FLUSHER.
CAUTION
THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT
SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND
BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM
IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED
BEFORE STARTING THE FILTERING PROCEDURE.
Each Service Filter Kit includes the following items:
^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice
tube)
^ One (1) Instruction Sheet
NOTE
ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY
WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET
WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM
FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE
TUBE AFTER FILTERING IS COMPLETE.
CAUTION
FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN
THE APPROPRIATE SERVICE OR WORKSHOP MANUAL.
1. Before removing any refrigerant system components, recover the refrigerant from the system
following the recycling methods outlined In the appropriate Service/Workshop Manual.
2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container.
3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The
quantity of the new oil to be added is the amount to match that drained from the old accumulator
plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction
accumulator/drier part number.
CAUTION
REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12
SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a
SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE
TO SYSTEM COMPONENTS.
4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube
part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and
the evaporator, replace the liquid line assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 6061
5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1.
a. Be sure orifice inlet is toward the condenser.
b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible
refrigerant hose of 2500 psi burst rating. Individual fittings are also available.
6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a
calibrated container.
7. Drain the oil from the replacement compressor into a clean calibrated container.
NOTE:
IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD
COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP
MANUAL PROCEDURES.
8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10
service compressor does not contain any oil and can be used with an R-12 or an R-134a system.
CAUTION
REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL
WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT
IN DAMAGE TO SYSTEM COMPONENTS.
^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz),
pour the same amount of clean refrigerant oil into the new compressor.
^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3
oz) of clean refrigerant oil into the new compressor.
9. Install the new compressor following Service/Workshop Manual procedures. Make sure all
mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if
necessary.
10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures.
11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make
sure they do not interfere with other engine compartment components. If necessary, use tie straps
to make adjustments.
12. Set the A/C control on Max A/C, high blower and temperature control at full cold.
a. Start engine and let idle briefly.
b. Be sure A/C system is operating properly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service
Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 6062
13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at
800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system
operating.
14. Stop the engine.
NOTE:
IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE
PROCEEDING.
15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from
the liquid line.
16. Discard the filter. It can be used one (1) tie only.
17. Reconnect the liquid line back into the system.
18. Evacuate, charge and leak test the system. Make any necessary adjustments.
19. Check the operation of the system in all models.
PART NUMBER PART NAME
F8VZ-19E773-AA Filter Kit
F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only)
F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant
Systems Only)
NOTE
THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS
THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR
TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
With Front A/C
Refrigerant Oil System Capacity .........................................................................................................
.......................................................................... 10 oz
With Front and Rear A/C
Refrigerant Oil System Capacity .........................................................................................................
.......................................................................... 10 oz
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 6067
Refrigerant Oil: Fluid Type Specifications
Compressor ................................................................................................................... 500 viscosity
(C9AZ-19557-B or Motorcraft VN-2 or equivalent)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Service and Repair > Cycling Clutch Switch Replace
Refrigerant Pressure Sensor / Switch: Service and Repair Cycling Clutch Switch Replace
The clutch cycling pressure switch is mounted on a schrader type fitting on the accumulator.
Replacement of switch does not require discharge of refrigerant from system.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Service and Repair > Cycling Clutch Switch Replace > Page 6072
Refrigerant Pressure Sensor / Switch: Service and Repair HR-980
The clutch cycling pressure switch is mounted on a schrader type fitting on the accumulator.
Replacement of switch does not require discharge of refrigerant from system.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations
Blower Motor Relay: Locations
LH Side Of Dash
LH Corner Of Engine Compartment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations > Auxiliary Blower Switch
Blower Motor Switch: Locations Auxiliary Blower Switch
Behind Heater Control Assembly
RH Side Of Control Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Locations > Auxiliary Blower Switch > Page 6082
Blower Motor Switch: Locations Front Blower Switch
LH Side Of Control Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Locations
Evaporator Temperature Sensor / Switch: Locations
A/C EVAPORATOR DE-ICING SWITCH
RH Dash Panel
RH Dash Panel Attached To Evaporator
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Service and Repair > Cycling Clutch Switch Replace
Refrigerant Pressure Sensor / Switch: Service and Repair Cycling Clutch Switch Replace
The clutch cycling pressure switch is mounted on a schrader type fitting on the accumulator.
Replacement of switch does not require discharge of refrigerant from system.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Service and Repair > Cycling Clutch Switch Replace > Page 6090
Refrigerant Pressure Sensor / Switch: Service and Repair HR-980
The clutch cycling pressure switch is mounted on a schrader type fitting on the accumulator.
Replacement of switch does not require discharge of refrigerant from system.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Description
and Operation
Vacuum Harness HVAC: Description and Operation
Engine vacuum systems a pre-assembled harness which features colored nylon vacuum lines. The
color is a visual aid both in production and in service. The emission decal on the engine provides a
colored schematic of the vacuum hookup which corresponds with the pre-assembled harness.
Vacuum hose harnesses consist of nylon hoses a .150 inch outer diameter and a .090 inch inner
diameter bonded to nylon or rubber connectors. Occasionally a rubber hose may be connected to
the harness. The nylon connectors have rubber inserts to provide a seal between the nylon
connector and the component connection.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Locations
Vacuum Reservoir HVAC: Locations
LH Side Of Dash
RH Rear Corner Of Engine Compartment
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Locations
> Page 6097
Vacuum Reservoir HVAC: Description and Operation
Fig. 37 Vacuum reservoirs
The vacuum reservoir, Fig. 37, used on some vehicles, acts as an accumulator and prevents
sudden drops or rapid fluctuations in a vacuum signal during acceleration. If vacuum in the
reservoir leaks more than 1/2 inch Hg in 1 minute, the reservoir is defective and must be replaced.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Locations
> Page 6098
Vacuum Reservoir HVAC: Service and Repair
1983-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect the two vacuum lines connected to the reservoir ports.
2. Remove reservoir retaining nuts from the underside of the left hand apron, then the reservoir.
3. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Diagrams >
Diagram Information and Instructions
Seat Belt: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Diagrams >
Diagram Information and Instructions > Page 6105
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Diagrams >
Diagram Information and Instructions > Page 6106
Fig. 54 Seatbelt Retractor Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information >
Locations
Seat Belt Buckle Switch: Locations
Part Of Driver`s Seatbelt
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Technical
Service Bulletins > Safety Belt - Tongue Cover Now Available
Seat Belt Latch: Technical Service Bulletins Safety Belt - Tongue Cover Now Available
SAFETY BELT - TONGUE COVER SERVICE PART
AVAILABILITY
Article No. 88-25-2
FORD: 1974-88 ALL
LINCOLN-MERCURY: 1974-88 ALL
LIGHT-TRUCK: 1974-88 ALL
MEDIUM/HEAVY: 1974-88
ISSUE: The safety belt tongue cover is now available for service. It is no longer necessary to
replace the entire safety belt assembly in the event a buckle and tongue cover requires service.
ACTION: No corrective action is required. Refer to the following application chart for the correct
service part number.
NOTE: THE SAFETY BELT TONGUE COVERS ARE SERVICED IN A NEUTRAL COLOR AND
MUST BE PAINTED TO MATCH.
SAFETY BELT TONGUE COVER APPLICATION CHART MODEL YEAR
VEHICLE SERVICE PART NO.
1986-88 Taurus/Sable E7DZ-54612A64-A
1974-88 All Other Vehicles E7FZ-61612A64-A
PART NUMBER PART NAME CLASS
E7DZ-54612A64-A Safety Belt Tongue Cover Package of 4
BM
E7FZ-61612A64-A Safety Belt Tongue Cover Package of 4
B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
"INFORMATION ONLY"
OASIS CODES: 1050, 1051, 1800
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Component Information > Locations
Seat Belt Buckle Switch: Locations
Part Of Driver`s Seatbelt
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > Customer Interest for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way
Communications - Whine/Buzz
Citizens Band Radio (CB): Customer Interest Radio/Two-Way Communications - Whine/Buzz
Article No. 91-17-5 08/21/91
^ FUEL SYSTEM - FUEL PUMP "WHINE/BUZZ" NOISE COMES THROUGH ENTERTAINMENT
OR TWO-WAY COMMUNICATION RADIO
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINE/BUZZ" NOISE
CAUSED BY FUEL PUMP
^ NOISE - "WHINE/BUZZ" - COMES THROUGH ENTERTAINMENT OR TWO-WAY
COMMUNICATION RADIO
FORD: 1984 THUNDERBIRD 1984-85 MUSTANG 1984-86 LTD 1985-87 TEMPO 1986-89
TAURUS 1987 EXP 1987-90 ESCORT
LINCOLN-MERCURY: 1984 CONTINENTAL, COUGAR, MARK VII 1984-85 CAPRI 1984-86
MARQUIS 1985-87 TOPAZ 1986-89 SABLE 1987 LYNX
LIGHT TRUCK: 1985-87 RANGER 1985-88 BRONCO, F-150-350 SERIES 1986 AEROSTAR
1986-87 BRONCO II 1986-91 ECONOLINE
ISSUE: A "whining/buzzing" noise may come from the entertainment or two-way communication
radio on vehicles with an in-tank electric fuel pump. This occurs because of electrical interference
from the fuel pump.
ACTION: Install a noise filter kit (E7PZ-9B357-A) consisting of an RFI noise filter, electrical
terminals and a piece of shrink tubing. Refer to the following service procedure.
1. Remove the fuel pump/sender unit from the fuel tank. Refer to the appropriate Shop Manual for
removal procedure.
2. Disconnect the heavy red and black wires from the pump terminals.
3. Inspect the fuel pump electrical terminals.
^ If the fuel pump has threaded terminals, go to Step 4.
^ If the fuel pump has spade terminals, go to Step 7.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > Customer Interest for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way
Communications - Whine/Buzz > Page 6127
Figure 1
4. For Threaded Terminals - Insert RFI noise filter into the pump collar and onto the threaded
terminals, Figure 1.
a. Observe polarity marking on fuel pump and RFI noise filter.
b. Install nuts and tighten securely.
5. Cut the ring terminals from the red and black wire ends and discard.
CAUTION: BE SURE NOT TO CUT THE WIRE TOO SHORT.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > Customer Interest for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way
Communications - Whine/Buzz > Page 6128
a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire.
b. Install the small female spade terminal onto the red wire and the large female spade terminal
onto the black wire.
c. Crimp and solder new terminals onto the wires.
d. Put shrink tubing over the new crimp and solder connection.
6. Install wires on the RFI noise filter terminals.
NOTE: BE SURE TO OBSERVE POLARITY MARKINGS.
Go to Step 12.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > Customer Interest for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way
Communications - Whine/Buzz > Page 6129
Figure 2
7. For Spade Terminals - Measure from fuel pump electrical connectors toward the mounting flange
and cut two (2) two inch jumper wires from the pump wires, Figure 2.
a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire.
b. Install the small female spade terminal onto the red wire end and the large female spade
terminal onto the black wire end.
c. Crimp and solder new terminals onto the wires.
d. Put shrink tubing over the new crimp and solder connection.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > Customer Interest for Citizens Band Radio (CB): > 91175 > Aug > 91 > Radio/Two-Way
Communications - Whine/Buzz > Page 6130
8. Strip 3/8" (9.525 mm) of insulation from each end of the wires attached to the mounting flange.
a. Slide a 1" (25.4 mm) piece of heat shrink tubing over each end of wire.
b. Wrap and solder the wires to the ring terminals of the RFI noise filter (red wire to positive
terminal, black wire to negative terminals).
c. Push heat shrink tubing over soldered wire ends and shrink.
9. Attach jumper wires to the RFI noise filter spade terminals.
NOTE: BE SURE TO OBSERVE POLARITY MARKINGS.
10. Attach the jumper wires to the electrical fuel pump terminals.
NOTE: BE SURE TO OBSERVE POLARITY MARKINGS.
11. Use tie straps to attach the RFI noise filter to the pick-up/return tubing of the pump/sender unit.
NOTE: MAKE SURE WIRES ARE SECURELY ATTACHED.
12. Reinstall the fuel pump/sender in the vehicle. Refer to the appropriate service manual for
service details and required parts.
PART NUMBER PART NAME CLASS
E7PZ-9B357-A Noise Filter Kit C
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:
87-20-13
WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION
TIME
911705A Aerostar, Ranger And 1.5 Hr.
Econoline With Mid-Ship Fuel Tank.
911705B F-Series With Mid-Ship Fuel 1.3 Hr.
Tank Or Ranger With Aft Of Axle Fuel Tank.
911705C Bronco II, F-Series And 1.6 Hr.
Bronco With Aft Of Axle Fuel Tank.
911705D Econoline With Aft Of Axle 1.2 Hr.
Fuel Tank.
911705E Additional Time - F-Series 0.2 Hr.
Equipped With Spare Tire Carrier.
911705F All Cars 1.3 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
9H307 56
OASIS CODES: 205000, 207000, 404000, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Citizens Band Radio (CB): > 91175 > Aug > 91 >
Radio/Two-Way Communications - Whine/Buzz
Citizens Band Radio (CB): All Technical Service Bulletins Radio/Two-Way Communications Whine/Buzz
Article No. 91-17-5 08/21/91
^ FUEL SYSTEM - FUEL PUMP "WHINE/BUZZ" NOISE COMES THROUGH ENTERTAINMENT
OR TWO-WAY COMMUNICATION RADIO
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINE/BUZZ" NOISE
CAUSED BY FUEL PUMP
^ NOISE - "WHINE/BUZZ" - COMES THROUGH ENTERTAINMENT OR TWO-WAY
COMMUNICATION RADIO
FORD: 1984 THUNDERBIRD 1984-85 MUSTANG 1984-86 LTD 1985-87 TEMPO 1986-89
TAURUS 1987 EXP 1987-90 ESCORT
LINCOLN-MERCURY: 1984 CONTINENTAL, COUGAR, MARK VII 1984-85 CAPRI 1984-86
MARQUIS 1985-87 TOPAZ 1986-89 SABLE 1987 LYNX
LIGHT TRUCK: 1985-87 RANGER 1985-88 BRONCO, F-150-350 SERIES 1986 AEROSTAR
1986-87 BRONCO II 1986-91 ECONOLINE
ISSUE: A "whining/buzzing" noise may come from the entertainment or two-way communication
radio on vehicles with an in-tank electric fuel pump. This occurs because of electrical interference
from the fuel pump.
ACTION: Install a noise filter kit (E7PZ-9B357-A) consisting of an RFI noise filter, electrical
terminals and a piece of shrink tubing. Refer to the following service procedure.
1. Remove the fuel pump/sender unit from the fuel tank. Refer to the appropriate Shop Manual for
removal procedure.
2. Disconnect the heavy red and black wires from the pump terminals.
3. Inspect the fuel pump electrical terminals.
^ If the fuel pump has threaded terminals, go to Step 4.
^ If the fuel pump has spade terminals, go to Step 7.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Citizens Band Radio (CB): > 91175 > Aug > 91 >
Radio/Two-Way Communications - Whine/Buzz > Page 6136
Figure 1
4. For Threaded Terminals - Insert RFI noise filter into the pump collar and onto the threaded
terminals, Figure 1.
a. Observe polarity marking on fuel pump and RFI noise filter.
b. Install nuts and tighten securely.
5. Cut the ring terminals from the red and black wire ends and discard.
CAUTION: BE SURE NOT TO CUT THE WIRE TOO SHORT.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Citizens Band Radio (CB): > 91175 > Aug > 91 >
Radio/Two-Way Communications - Whine/Buzz > Page 6137
a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire.
b. Install the small female spade terminal onto the red wire and the large female spade terminal
onto the black wire.
c. Crimp and solder new terminals onto the wires.
d. Put shrink tubing over the new crimp and solder connection.
6. Install wires on the RFI noise filter terminals.
NOTE: BE SURE TO OBSERVE POLARITY MARKINGS.
Go to Step 12.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Citizens Band Radio (CB): > 91175 > Aug > 91 >
Radio/Two-Way Communications - Whine/Buzz > Page 6138
Figure 2
7. For Spade Terminals - Measure from fuel pump electrical connectors toward the mounting flange
and cut two (2) two inch jumper wires from the pump wires, Figure 2.
a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire.
b. Install the small female spade terminal onto the red wire end and the large female spade
terminal onto the black wire end.
c. Crimp and solder new terminals onto the wires.
d. Put shrink tubing over the new crimp and solder connection.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Citizens Band Radio (CB): > 91175 > Aug > 91 >
Radio/Two-Way Communications - Whine/Buzz > Page 6139
8. Strip 3/8" (9.525 mm) of insulation from each end of the wires attached to the mounting flange.
a. Slide a 1" (25.4 mm) piece of heat shrink tubing over each end of wire.
b. Wrap and solder the wires to the ring terminals of the RFI noise filter (red wire to positive
terminal, black wire to negative terminals).
c. Push heat shrink tubing over soldered wire ends and shrink.
9. Attach jumper wires to the RFI noise filter spade terminals.
NOTE: BE SURE TO OBSERVE POLARITY MARKINGS.
10. Attach the jumper wires to the electrical fuel pump terminals.
NOTE: BE SURE TO OBSERVE POLARITY MARKINGS.
11. Use tie straps to attach the RFI noise filter to the pick-up/return tubing of the pump/sender unit.
NOTE: MAKE SURE WIRES ARE SECURELY ATTACHED.
12. Reinstall the fuel pump/sender in the vehicle. Refer to the appropriate service manual for
service details and required parts.
PART NUMBER PART NAME CLASS
E7PZ-9B357-A Noise Filter Kit C
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:
87-20-13
WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION
TIME
911705A Aerostar, Ranger And 1.5 Hr.
Econoline With Mid-Ship Fuel Tank.
911705B F-Series With Mid-Ship Fuel 1.3 Hr.
Tank Or Ranger With Aft Of Axle Fuel Tank.
911705C Bronco II, F-Series And 1.6 Hr.
Bronco With Aft Of Axle Fuel Tank.
911705D Econoline With Aft Of Axle 1.2 Hr.
Fuel Tank.
911705E Additional Time - F-Series 0.2 Hr.
Equipped With Spare Tire Carrier.
911705F All Cars 1.3 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
9H307 56
OASIS CODES: 205000, 207000, 404000, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Audio Control Relay
> Component Information > Locations
Audio Control Relay: Locations
Right Of Radio, Near Amplifier
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio Power Boost Switch > Component Information > Locations
Radio Power Boost Switch: Locations
Attached To RH Cowl
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest: > 91175 > Aug > 91
> Radio/Two-Way Communications - Whine/Buzz
Radio/Stereo Noise Filter: Customer Interest Radio/Two-Way Communications - Whine/Buzz
Article No. 91-17-5 08/21/91
^ FUEL SYSTEM - FUEL PUMP "WHINE/BUZZ" NOISE COMES THROUGH ENTERTAINMENT
OR TWO-WAY COMMUNICATION RADIO
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINE/BUZZ" NOISE
CAUSED BY FUEL PUMP
^ NOISE - "WHINE/BUZZ" - COMES THROUGH ENTERTAINMENT OR TWO-WAY
COMMUNICATION RADIO
FORD: 1984 THUNDERBIRD 1984-85 MUSTANG 1984-86 LTD 1985-87 TEMPO 1986-89
TAURUS 1987 EXP 1987-90 ESCORT
LINCOLN-MERCURY: 1984 CONTINENTAL, COUGAR, MARK VII 1984-85 CAPRI 1984-86
MARQUIS 1985-87 TOPAZ 1986-89 SABLE 1987 LYNX
LIGHT TRUCK: 1985-87 RANGER 1985-88 BRONCO, F-150-350 SERIES 1986 AEROSTAR
1986-87 BRONCO II 1986-91 ECONOLINE
ISSUE: A "whining/buzzing" noise may come from the entertainment or two-way communication
radio on vehicles with an in-tank electric fuel pump. This occurs because of electrical interference
from the fuel pump.
ACTION: Install a noise filter kit (E7PZ-9B357-A) consisting of an RFI noise filter, electrical
terminals and a piece of shrink tubing. Refer to the following service procedure.
1. Remove the fuel pump/sender unit from the fuel tank. Refer to the appropriate Shop Manual for
removal procedure.
2. Disconnect the heavy red and black wires from the pump terminals.
3. Inspect the fuel pump electrical terminals.
^ If the fuel pump has threaded terminals, go to Step 4.
^ If the fuel pump has spade terminals, go to Step 7.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest: > 91175 > Aug > 91
> Radio/Two-Way Communications - Whine/Buzz > Page 6156
Figure 1
4. For Threaded Terminals - Insert RFI noise filter into the pump collar and onto the threaded
terminals, Figure 1.
a. Observe polarity marking on fuel pump and RFI noise filter.
b. Install nuts and tighten securely.
5. Cut the ring terminals from the red and black wire ends and discard.
CAUTION: BE SURE NOT TO CUT THE WIRE TOO SHORT.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest: > 91175 > Aug > 91
> Radio/Two-Way Communications - Whine/Buzz > Page 6157
a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire.
b. Install the small female spade terminal onto the red wire and the large female spade terminal
onto the black wire.
c. Crimp and solder new terminals onto the wires.
d. Put shrink tubing over the new crimp and solder connection.
6. Install wires on the RFI noise filter terminals.
NOTE: BE SURE TO OBSERVE POLARITY MARKINGS.
Go to Step 12.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest: > 91175 > Aug > 91
> Radio/Two-Way Communications - Whine/Buzz > Page 6158
Figure 2
7. For Spade Terminals - Measure from fuel pump electrical connectors toward the mounting flange
and cut two (2) two inch jumper wires from the pump wires, Figure 2.
a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire.
b. Install the small female spade terminal onto the red wire end and the large female spade
terminal onto the black wire end.
c. Crimp and solder new terminals onto the wires.
d. Put shrink tubing over the new crimp and solder connection.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest: > 91175 > Aug > 91
> Radio/Two-Way Communications - Whine/Buzz > Page 6159
8. Strip 3/8" (9.525 mm) of insulation from each end of the wires attached to the mounting flange.
a. Slide a 1" (25.4 mm) piece of heat shrink tubing over each end of wire.
b. Wrap and solder the wires to the ring terminals of the RFI noise filter (red wire to positive
terminal, black wire to negative terminals).
c. Push heat shrink tubing over soldered wire ends and shrink.
9. Attach jumper wires to the RFI noise filter spade terminals.
NOTE: BE SURE TO OBSERVE POLARITY MARKINGS.
10. Attach the jumper wires to the electrical fuel pump terminals.
NOTE: BE SURE TO OBSERVE POLARITY MARKINGS.
11. Use tie straps to attach the RFI noise filter to the pick-up/return tubing of the pump/sender unit.
NOTE: MAKE SURE WIRES ARE SECURELY ATTACHED.
12. Reinstall the fuel pump/sender in the vehicle. Refer to the appropriate service manual for
service details and required parts.
PART NUMBER PART NAME CLASS
E7PZ-9B357-A Noise Filter Kit C
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:
87-20-13
WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION
TIME
911705A Aerostar, Ranger And 1.5 Hr.
Econoline With Mid-Ship Fuel Tank.
911705B F-Series With Mid-Ship Fuel 1.3 Hr.
Tank Or Ranger With Aft Of Axle Fuel Tank.
911705C Bronco II, F-Series And 1.6 Hr.
Bronco With Aft Of Axle Fuel Tank.
911705D Econoline With Aft Of Axle 1.2 Hr.
Fuel Tank.
911705E Additional Time - F-Series 0.2 Hr.
Equipped With Spare Tire Carrier.
911705F All Cars 1.3 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
9H307 56
OASIS CODES: 205000, 207000, 404000, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91175
> Aug > 91 > Radio/Two-Way Communications - Whine/Buzz
Radio/Stereo Noise Filter: All Technical Service Bulletins Radio/Two-Way Communications Whine/Buzz
Article No. 91-17-5 08/21/91
^ FUEL SYSTEM - FUEL PUMP "WHINE/BUZZ" NOISE COMES THROUGH ENTERTAINMENT
OR TWO-WAY COMMUNICATION RADIO
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINE/BUZZ" NOISE
CAUSED BY FUEL PUMP
^ NOISE - "WHINE/BUZZ" - COMES THROUGH ENTERTAINMENT OR TWO-WAY
COMMUNICATION RADIO
FORD: 1984 THUNDERBIRD 1984-85 MUSTANG 1984-86 LTD 1985-87 TEMPO 1986-89
TAURUS 1987 EXP 1987-90 ESCORT
LINCOLN-MERCURY: 1984 CONTINENTAL, COUGAR, MARK VII 1984-85 CAPRI 1984-86
MARQUIS 1985-87 TOPAZ 1986-89 SABLE 1987 LYNX
LIGHT TRUCK: 1985-87 RANGER 1985-88 BRONCO, F-150-350 SERIES 1986 AEROSTAR
1986-87 BRONCO II 1986-91 ECONOLINE
ISSUE: A "whining/buzzing" noise may come from the entertainment or two-way communication
radio on vehicles with an in-tank electric fuel pump. This occurs because of electrical interference
from the fuel pump.
ACTION: Install a noise filter kit (E7PZ-9B357-A) consisting of an RFI noise filter, electrical
terminals and a piece of shrink tubing. Refer to the following service procedure.
1. Remove the fuel pump/sender unit from the fuel tank. Refer to the appropriate Shop Manual for
removal procedure.
2. Disconnect the heavy red and black wires from the pump terminals.
3. Inspect the fuel pump electrical terminals.
^ If the fuel pump has threaded terminals, go to Step 4.
^ If the fuel pump has spade terminals, go to Step 7.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91175
> Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6165
Figure 1
4. For Threaded Terminals - Insert RFI noise filter into the pump collar and onto the threaded
terminals, Figure 1.
a. Observe polarity marking on fuel pump and RFI noise filter.
b. Install nuts and tighten securely.
5. Cut the ring terminals from the red and black wire ends and discard.
CAUTION: BE SURE NOT TO CUT THE WIRE TOO SHORT.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91175
> Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6166
a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire.
b. Install the small female spade terminal onto the red wire and the large female spade terminal
onto the black wire.
c. Crimp and solder new terminals onto the wires.
d. Put shrink tubing over the new crimp and solder connection.
6. Install wires on the RFI noise filter terminals.
NOTE: BE SURE TO OBSERVE POLARITY MARKINGS.
Go to Step 12.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91175
> Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6167
Figure 2
7. For Spade Terminals - Measure from fuel pump electrical connectors toward the mounting flange
and cut two (2) two inch jumper wires from the pump wires, Figure 2.
a. Install a 1" (25.4 mm) piece of heat shrink tubing over each end of wire.
b. Install the small female spade terminal onto the red wire end and the large female spade
terminal onto the black wire end.
c. Crimp and solder new terminals onto the wires.
d. Put shrink tubing over the new crimp and solder connection.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91175
> Aug > 91 > Radio/Two-Way Communications - Whine/Buzz > Page 6168
8. Strip 3/8" (9.525 mm) of insulation from each end of the wires attached to the mounting flange.
a. Slide a 1" (25.4 mm) piece of heat shrink tubing over each end of wire.
b. Wrap and solder the wires to the ring terminals of the RFI noise filter (red wire to positive
terminal, black wire to negative terminals).
c. Push heat shrink tubing over soldered wire ends and shrink.
9. Attach jumper wires to the RFI noise filter spade terminals.
NOTE: BE SURE TO OBSERVE POLARITY MARKINGS.
10. Attach the jumper wires to the electrical fuel pump terminals.
NOTE: BE SURE TO OBSERVE POLARITY MARKINGS.
11. Use tie straps to attach the RFI noise filter to the pick-up/return tubing of the pump/sender unit.
NOTE: MAKE SURE WIRES ARE SECURELY ATTACHED.
12. Reinstall the fuel pump/sender in the vehicle. Refer to the appropriate service manual for
service details and required parts.
PART NUMBER PART NAME CLASS
E7PZ-9B357-A Noise Filter Kit C
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:
87-20-13
WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION
TIME
911705A Aerostar, Ranger And 1.5 Hr.
Econoline With Mid-Ship Fuel Tank.
911705B F-Series With Mid-Ship Fuel 1.3 Hr.
Tank Or Ranger With Aft Of Axle Fuel Tank.
911705C Bronco II, F-Series And 1.6 Hr.
Bronco With Aft Of Axle Fuel Tank.
911705D Econoline With Aft Of Axle 1.2 Hr.
Fuel Tank.
911705E Additional Time - F-Series 0.2 Hr.
Equipped With Spare Tire Carrier.
911705F All Cars 1.3 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
9H307 56
OASIS CODES: 205000, 207000, 404000, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Radio/Stereo Noise Filter: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down
Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut
Down
^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY
CHARGE
^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L
^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF
Article No. 90-18-3 FORD:
1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD
1986-90 TAURUS
LINCOLN-MERCURY: 1983-87 LYNX
1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86
CAPRI, MARQUIS 1986-90 SABLE
LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1988-90 F SUPER DUTY
ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been
shut off. There may also be a no start condition or a discharged battery. These conditions are
caused by a sticking fuel pump relay.
ACTION: Install a new fuel pump relay. Refer to the following procedure for service details.
1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for
troubleshooting details.
2. Install a new fuel pump relay, if the old one is defective.
3. Check the vehicle for proper operation.
PART NUMBER PART NAME
F19Z-9345-A Fuel Pump Relay Assy.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
901803A 1985-86 LTD/Marquis 0.6 Hr.
(includes pinpoint test)
901803A 1990 Town Car (includes 0.4 Hr.
pinpoint test)
901803A All Other Cars (includes 0.5 Hr.
pinpoint test)
901803A All Trucks (includes pinpoint 0.5 Hr.
test)
DEALER CODING
BASIC PART NO. CONDITION CODE
9345 09
OASIS CODES: 404000, 603300, 203000, 203100, 702000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 6179
Radio/Stereo Noise Filter: Locations
RH Fender Apron
RH Radiator Support
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Audio Control Relay > Component Information > Locations
Audio Control Relay: Locations
Right Of Radio, Near Amplifier
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Radio Power Boost Switch > Component Information > Locations
Radio Power Boost Switch: Locations
Attached To RH Cowl
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6193
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6194
Fig. 55 Trailer/Camper Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay >
Component Information > Locations
Trailer Lighting Relay: Locations
LH Rear Fender Below LH Tail Light
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 6202
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 6203
Fig. 55 Trailer/Camper Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service
Bulletins > Running Boards - Noise/Vibration Installation Tips
Auxiliary Step / Running Board: Technical Service Bulletins Running Boards - Noise/Vibration
Installation Tips
Article No. 95-8-6
04/24/95
^ RUNNING BOARDS - INCORRECTLY INSTALLED - NVH CONCERNS
^ NOISE - VIBRATION - RUNNING BOARDS - INCORRECTLY INSTALLED
LIGHT TRUCK: 1987-90 BRONCO II 1987-95 BRONCO, ECONOLINE, F-150-350 SERIES,
RANGER 1988-95 F SUPER DUTY 1991-95 EXPLORER
This TSB is being republished in its entirety to include vehicles through the 1995 model year.
ISSUE: Running boards which are incorrectly installed may result in noise/vibration complaints.
ACTION: Install running boards to either the body or frame; NEVER to both unless the mounting
system uses isolated mounts. A manufacturer's instruction to attach running boards to both body
and frame should be immediately questioned because such action provides a direct path from
chassis to body for road vibration and noise.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-4-11 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 108000, 702000, 703000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Technical Service Bulletins > Door Latches - Adjustment/Modification Prohibition
Front Door Latch: Technical Service Bulletins Door Latches - Adjustment/Modification Prohibition
Article No. 91-8-4
04/17/91
LATCHES - DOOR - REPLACEMENT REQUIRED
FORD: 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO,
THUNDERBIRD 1986 LTD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE
LINCOLN-MERCURY: 1985-87 LYNX
1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR
1986-91 SABLE 1987-91 TRACER
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350
SERIES, RANGER 1989-91 F SUPER DUTY 1991 EXPLORER
MEDIUM/HEAVY TRUCK:1985-90 C SERIES
1985-91 CL-9000, F & B SERIES, L SERIES 1986-91 CARGO SERIES
ISSUE: Rework of door latches has been reported from Service Investigation Reports. This is
unacceptable as it may affect proper latch function.
ACTION: Replace latches which function improperly and can not be adjusted.
WARNING: NEVER REWORK OR MODIFY A LATCH ASSEMBLY, ALWAYS REPLACE THE
LATCH ASSEMBLY.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Service and Repair
Front Door Window Regulator: Service and Repair
Window Regulator
Fig. 5
Special Service Tools
E-150-E-350, F-150-F-350 and Bronco
Removal 1. Remove door trim panel and access cover, if so equipped. 2. Support glass in the full
UP position. 3. Remove center pin from regulator attaching rivets with drift punch. Then, drill head
from each rivet using a 6.35mm (1/4-inch) drill and remove
rivet. Be careful not to route out sheet metal holes during drilling (Fig. 5).
4. Disengage regulator arm from glass bracket and remove regulator.
Installation 1. Position regulator in door and insert arm into glass bracket channel (Fig. 5). 2.
Position regulator to inner panel and install rivets using Rotunda Hydraulic Rivet Gun 107-00600 or
equivalent to attach regulator to inner panel.
A 1/4 inch-20 x 1 /2 inch screw and washer assembly and a 1/4 inch-20 nut and washer assembly
may be used in place of the rivets if rivets are not available (equivalent metric retainers may also
be used).
3. Check operation of window mechanism and install door trim panel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Technical Service Bulletins > Door Latches - Adjustment/Modification Prohibition
Rear Door Latch: Technical Service Bulletins Door Latches - Adjustment/Modification Prohibition
Article No. 91-8-4
04/17/91
LATCHES - DOOR - REPLACEMENT REQUIRED
FORD: 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO,
THUNDERBIRD 1986 LTD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE
LINCOLN-MERCURY: 1985-87 LYNX
1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR
1986-91 SABLE 1987-91 TRACER
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350
SERIES, RANGER 1989-91 F SUPER DUTY 1991 EXPLORER
MEDIUM/HEAVY TRUCK:1985-90 C SERIES
1985-91 CL-9000, F & B SERIES, L SERIES 1986-91 CARGO SERIES
ISSUE: Rework of door latches has been reported from Service Investigation Reports. This is
unacceptable as it may affect proper latch function.
ACTION: Replace latches which function improperly and can not be adjusted.
WARNING: NEVER REWORK OR MODIFY A LATCH ASSEMBLY, ALWAYS REPLACE THE
LATCH ASSEMBLY.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction
Sliding Door: Customer Interest Body/Frame - Water Leak Identification and Correction
Article No. 92-9-10
04/22/92
LEAKS WATER - IDENTIFICATION AND CORRECTION
LIGHT TRUCK: 1984-91 ECONOLINE
This TSB Article was originally published as TSB 84-19-15 on September 12, 1984. It is being
republished because the basic water leak corrective procedures and techniques remain applicable
for the more recent models as well.
ISSUE: The water leak identification and correction procedures outlined in this article are the most
common conditions you may encounter. It is unlikely that you will ever find it necessary to perform
all of the possible corrections on a single vehicle. Each vehicle is unique and, therefore, careful
attention is required in evaluating the vehicle and making the necessary corrections.
ACTION: If service is required, use the following procedure to identify and correct the water leaks.
DIAGNOSING WATER LEAKS
The actual sources of these various water leaks may often be misleading.
^ The spot where the water shows up is not always the location of the trouble.
^ Do not always rely on the service order, or even the customer, to pinpoint the actual leak area.
^ The description of the water leak will usually reflect only where the water is noticeable, not
necessarily where the cause is located.
GENERAL TEST PROCEDURES
Although every dealership has its own method for testing water leaks, the following methods will be
helpful to the technician in solving the more difficutt and persistent water leaks.
NOTE: DETECTION OF WATER LEAKS IN THE REAR CARGO FLOOR AREA MAY BE
ENHANCED BY PLACING A LARGE LIGHT BULB IN THE CARGO AREA, RAISING THE
VEHICLE ON A HOIST AND CHECKING THE FLOOR PAN JOINT FOR ANY LIGHT SHINING
THROUGH.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6232
LOCATION OF "WET AREAS
Areas to examine for potential wet spots are shown in Figure 1 and are described as follows:
a. Front Door Step Well
b. Base of "B" Pillar on Floor
c. Side Door Step Well
d. Base of "C" Pillar on Floor
e. Forward of Rear Wheelhouse on Floor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6233
f. Behind Rear Wheelhouse on Floor
g. Around Fuel Filler Housing on Floor
h. Base of Rear Cargo Doors on Floor
i. Rear Corners of Floor
j. Miscellaneous - All Window and Door Weatherstrips
SEALING MATERIALS
A list of sealing materials is shown below.
1. Silicone Rubber Adhesive
^ Clear - Ford (D6AZ-19562-AA) or 3M 08661
^ Black - Ford (D6AZ-19562-BA) or 3M 08662
These are rapid curing adhesives/sealants formulated for such uses as sealing leaks, remounting
trim and servicing torn weatherstripping adheres to a wide variety of surfaces.
2. Weatherstrip Adhesive
^ Yellow Colored - Ford (E8AZ-19552-A)
This adhesive holds weatherstripping on doors, bodies, cowl ventilators and other locations. It is
used to service loose weatherstripping or install new weatherstripping. It is also used to bond
numerous rubber-to-metal, rubber-to-wood, rubber-to-cardboard and rubber-to-rubber surfaces. It
stops leaks in windows set in rubber mouldings. It sets up fast.
3. Joint and Seam Sealer
^ White - 3M 08646 (Cartridge Type)
^ Black - 3M 08648 (Cartridge Type)
This joint and seam sealer is a firm setting, but flexible sealer for interior and exterior body joints
and seams. Typical applications are in floor and wheelwell areas. It skins over quickly and can be
painted in about 30 minutes.
WET AREAS - ILLUSTRATIONS
Water entry in the front door step well (Wet Area A) may be from the locations.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6234
^ Header Joints "B" Pillar (RH/LH) - Figure 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6235
^ Cowl Side - wheelhouse (RH/LH) - Figure 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6236
^ Underside - wheelhouse (RH/LH) - Figure 4
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6237
^ Vent Air Valve - Cowl Side Outer (RH) - Figure 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6238
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6239
^ Door and Vent Window Weatherstrips (RH/LH) - Figures 18-19
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6240
Water entry at the base of the "B" pillar on the floor (Wet Area B) may be from the "B" pillar to
bodyside vertical seam (LH) - Figure 6.
Water entry in the side door step well (Wet Area C) may be from the following locations.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6241
^ Header Joint "B" Pillar (RH) - Figure 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6242
^ Header Joint "C" Pillar (RH) - Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6243
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6244
^ Door and Vent Window Weatherstrips (RH/LH) - Figures 18-19
Water entry at the base of the "C" pillar on the floor (Wet Area D) may be from the following
locations.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6245
^ Front Sliding Door Track Reinforcement (RH) - Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6246
^ Drip Rail and Clips (RH/LH) - Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6247
^ "C" Pillar to Bodyside Seam (RH) - Figure 7
Water entry forward of the rear wheelhouse (Wet Areas E and G) may be from the following
locations.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6248
^ Sliding Door Track Reinforcement to Bodyside (RH) - Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6249
^ Sliding Door Track Reinforcement to Bodyside - Forward Pilot Hole (RH) - Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6250
^ Drip Rail and Clips (RH/LH) - Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6251
^ Underside of Wheelhouse to Bodyside Along Radius (RH/LH) - Figure 11
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6252
^ Fuel Filler Housing - Auxiliary Tank (LH) - Figure 12
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6253
^ Auxiliary Gas Filler Door Bumper Holes - Backside (LH) - Figure 14
^ Auxiliary Fuel Filler Door Opening Flange (LH) - Figure 14
^ Horizontal Flange Inside of Fuel Filler Opening (LH) - Figure 14
Water entry behind the rear wheelhouse and rear corners of floor (Wet Area F and 1) may be from
the following locations.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6254
^ Underside of Wheelhouse to Bodyside Along Radius (RH/LH) - Figure 11
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6255
^ Drip Rail and Clips (RH/LH) - Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6256
^ Floor Pan to Wheelhouse at Ends - Topside and Underside (RH/LH) - Figure 13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6257
^ Side Marker Lamp (RH/LH) - Figure 17
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6258
^ Rear End of Sliding Door Track (RH) - Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6259
^ Sliding Door Track Reinforcement - Rearward Pilot Hole (RH) - Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6260
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6261
Water entry at the base of the rear cargo doors (Wet Areas H) may be from mispositioned trim filler
blocks or the "D" pillar to quarter panel seam - Figures 15 and 16.
PART NUMBER PART NAME CLASS
D6AZ-19562-BA Silicone Rubber Sealer - Black B
D6AZ-195662-AA Silicone Rubber Sealer - Clear B
E8AZ-19552-A Weatherstrip Adhesive B
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 84-19-15
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > Customer Interest for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water Leak
Identification and Correction > Page 6262
WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 111000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction
Sliding Door: All Technical Service Bulletins Body/Frame - Water Leak Identification and Correction
Article No. 92-9-10
04/22/92
LEAKS WATER - IDENTIFICATION AND CORRECTION
LIGHT TRUCK: 1984-91 ECONOLINE
This TSB Article was originally published as TSB 84-19-15 on September 12, 1984. It is being
republished because the basic water leak corrective procedures and techniques remain applicable
for the more recent models as well.
ISSUE: The water leak identification and correction procedures outlined in this article are the most
common conditions you may encounter. It is unlikely that you will ever find it necessary to perform
all of the possible corrections on a single vehicle. Each vehicle is unique and, therefore, careful
attention is required in evaluating the vehicle and making the necessary corrections.
ACTION: If service is required, use the following procedure to identify and correct the water leaks.
DIAGNOSING WATER LEAKS
The actual sources of these various water leaks may often be misleading.
^ The spot where the water shows up is not always the location of the trouble.
^ Do not always rely on the service order, or even the customer, to pinpoint the actual leak area.
^ The description of the water leak will usually reflect only where the water is noticeable, not
necessarily where the cause is located.
GENERAL TEST PROCEDURES
Although every dealership has its own method for testing water leaks, the following methods will be
helpful to the technician in solving the more difficutt and persistent water leaks.
NOTE: DETECTION OF WATER LEAKS IN THE REAR CARGO FLOOR AREA MAY BE
ENHANCED BY PLACING A LARGE LIGHT BULB IN THE CARGO AREA, RAISING THE
VEHICLE ON A HOIST AND CHECKING THE FLOOR PAN JOINT FOR ANY LIGHT SHINING
THROUGH.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6268
LOCATION OF "WET AREAS
Areas to examine for potential wet spots are shown in Figure 1 and are described as follows:
a. Front Door Step Well
b. Base of "B" Pillar on Floor
c. Side Door Step Well
d. Base of "C" Pillar on Floor
e. Forward of Rear Wheelhouse on Floor
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6269
f. Behind Rear Wheelhouse on Floor
g. Around Fuel Filler Housing on Floor
h. Base of Rear Cargo Doors on Floor
i. Rear Corners of Floor
j. Miscellaneous - All Window and Door Weatherstrips
SEALING MATERIALS
A list of sealing materials is shown below.
1. Silicone Rubber Adhesive
^ Clear - Ford (D6AZ-19562-AA) or 3M 08661
^ Black - Ford (D6AZ-19562-BA) or 3M 08662
These are rapid curing adhesives/sealants formulated for such uses as sealing leaks, remounting
trim and servicing torn weatherstripping adheres to a wide variety of surfaces.
2. Weatherstrip Adhesive
^ Yellow Colored - Ford (E8AZ-19552-A)
This adhesive holds weatherstripping on doors, bodies, cowl ventilators and other locations. It is
used to service loose weatherstripping or install new weatherstripping. It is also used to bond
numerous rubber-to-metal, rubber-to-wood, rubber-to-cardboard and rubber-to-rubber surfaces. It
stops leaks in windows set in rubber mouldings. It sets up fast.
3. Joint and Seam Sealer
^ White - 3M 08646 (Cartridge Type)
^ Black - 3M 08648 (Cartridge Type)
This joint and seam sealer is a firm setting, but flexible sealer for interior and exterior body joints
and seams. Typical applications are in floor and wheelwell areas. It skins over quickly and can be
painted in about 30 minutes.
WET AREAS - ILLUSTRATIONS
Water entry in the front door step well (Wet Area A) may be from the locations.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6270
^ Header Joints "B" Pillar (RH/LH) - Figure 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6271
^ Cowl Side - wheelhouse (RH/LH) - Figure 3
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6272
^ Underside - wheelhouse (RH/LH) - Figure 4
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6273
^ Vent Air Valve - Cowl Side Outer (RH) - Figure 5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6274
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6275
^ Door and Vent Window Weatherstrips (RH/LH) - Figures 18-19
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6276
Water entry at the base of the "B" pillar on the floor (Wet Area B) may be from the "B" pillar to
bodyside vertical seam (LH) - Figure 6.
Water entry in the side door step well (Wet Area C) may be from the following locations.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6277
^ Header Joint "B" Pillar (RH) - Figure 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6278
^ Header Joint "C" Pillar (RH) - Figure 7
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6279
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6280
^ Door and Vent Window Weatherstrips (RH/LH) - Figures 18-19
Water entry at the base of the "C" pillar on the floor (Wet Area D) may be from the following
locations.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6281
^ Front Sliding Door Track Reinforcement (RH) - Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6282
^ Drip Rail and Clips (RH/LH) - Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6283
^ "C" Pillar to Bodyside Seam (RH) - Figure 7
Water entry forward of the rear wheelhouse (Wet Areas E and G) may be from the following
locations.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6284
^ Sliding Door Track Reinforcement to Bodyside (RH) - Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6285
^ Sliding Door Track Reinforcement to Bodyside - Forward Pilot Hole (RH) - Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6286
^ Drip Rail and Clips (RH/LH) - Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6287
^ Underside of Wheelhouse to Bodyside Along Radius (RH/LH) - Figure 11
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6288
^ Fuel Filler Housing - Auxiliary Tank (LH) - Figure 12
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6289
^ Auxiliary Gas Filler Door Bumper Holes - Backside (LH) - Figure 14
^ Auxiliary Fuel Filler Door Opening Flange (LH) - Figure 14
^ Horizontal Flange Inside of Fuel Filler Opening (LH) - Figure 14
Water entry behind the rear wheelhouse and rear corners of floor (Wet Area F and 1) may be from
the following locations.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6290
^ Underside of Wheelhouse to Bodyside Along Radius (RH/LH) - Figure 11
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6291
^ Drip Rail and Clips (RH/LH) - Figure 9
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6292
^ Floor Pan to Wheelhouse at Ends - Topside and Underside (RH/LH) - Figure 13
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6293
^ Side Marker Lamp (RH/LH) - Figure 17
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6294
^ Rear End of Sliding Door Track (RH) - Figure 8
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6295
^ Sliding Door Track Reinforcement - Rearward Pilot Hole (RH) - Figure 10
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6296
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6297
Water entry at the base of the rear cargo doors (Wet Areas H) may be from mispositioned trim filler
blocks or the "D" pillar to quarter panel seam - Figures 15 and 16.
PART NUMBER PART NAME CLASS
D6AZ-19562-BA Silicone Rubber Sealer - Black B
D6AZ-195662-AA Silicone Rubber Sealer - Clear B
E8AZ-19552-A Weatherstrip Adhesive B
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 84-19-15
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Sliding Door: > 92910 > Apr > 92 > Body/Frame - Water
Leak Identification and Correction > Page 6298
WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 111000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > Customer Interest: > 902317 > Nov > 90 > Driveline - Vibration Cross Member Cracks
Cross-Member: Customer Interest Driveline - Vibration Cross Member Cracks
^ VIBRATION - DRIVELINE - VEHICLES WITH C6 TRANSMISSION
^ DRIVELINE - VIBRATION - VEHICLES WITH C6 TRANSMISSION
Article No. 90-23-17 LIGHT TRUCK:
1987-88 E-350
ISSUE: A driveline vibration may be caused by a crack in the crossmember between the
transmission mounting bolts. This may occur on high GVW applications and trucks making multiple
stops and starts.
ACTION: Install a new # 2 transmission cross member if any cracks are found during the
inspection. Refer to the following procedure for service details. If no cracks are found, refer to the
NVH diagnostics in the 1987-88 Light Truck Shop Manual, Volume A, Section 18-01 for corrective
action.
Figure 1
1. Remove and throw away the cracked transmission cross member. Refer to the 1987-88 Light
Truck Shop Manual, Volume A, Section 17-01 for removal procedure.
2. Inspect the transmission insulator for damage.
a. If any damage is detected, replace the transmission insulator. Clean the threads with Ford Spot &
Stain Remover (B7A-19521-AA).
b. If the transmission insulator is not damaged, clean the bolt threads with a wire brush and Ford
Spot & Stain Remover (B7A-19521-AA).
3. Replace the insulator nuts and washers with new ones (N621945-S2).
4. Throw away the cross member to frame bolts and nuts. Replace them with new ones.
5. Apply Threadlocker 262 to all fasteners (Cross member-to-frame and cross member-to-insulator
nut). Be sure that all fastener surfaces are cleaned with Ford Spot & Stain Remover
(B7A-19521-AA).
6. Loosely install the new # 2 transmission cross member (E8UZ-6A023-A) to the frame side rails.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > Customer Interest: > 902317 > Nov > 90 > Driveline - Vibration Cross Member Cracks > Page 6308
Figure 2
7. Loosely install a fabricated reinforcement strap under the cross member.
a. Refer to Figure 2 for strap specifications and dimensions
b. Start nuts and run up to the point where they will hold the reinforcement strap in place.
8. Tighten the cross member-to-frame bolts and nuts to 65-70 lb.ft. (88-95 N-m).
9. Tighten the transmission insulator nuts to 75-80 lb.ft. (102-108 N-m).
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
902317A Install Cross member 1.1 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
6A023 01
OASIS CODES: 703000, 305000, 504000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 902317 > Nov > 90 > Driveline - Vibration Cross Member Cracks
Cross-Member: All Technical Service Bulletins Driveline - Vibration Cross Member Cracks
^ VIBRATION - DRIVELINE - VEHICLES WITH C6 TRANSMISSION
^ DRIVELINE - VIBRATION - VEHICLES WITH C6 TRANSMISSION
Article No. 90-23-17 LIGHT TRUCK:
1987-88 E-350
ISSUE: A driveline vibration may be caused by a crack in the crossmember between the
transmission mounting bolts. This may occur on high GVW applications and trucks making multiple
stops and starts.
ACTION: Install a new # 2 transmission cross member if any cracks are found during the
inspection. Refer to the following procedure for service details. If no cracks are found, refer to the
NVH diagnostics in the 1987-88 Light Truck Shop Manual, Volume A, Section 18-01 for corrective
action.
Figure 1
1. Remove and throw away the cracked transmission cross member. Refer to the 1987-88 Light
Truck Shop Manual, Volume A, Section 17-01 for removal procedure.
2. Inspect the transmission insulator for damage.
a. If any damage is detected, replace the transmission insulator. Clean the threads with Ford Spot &
Stain Remover (B7A-19521-AA).
b. If the transmission insulator is not damaged, clean the bolt threads with a wire brush and Ford
Spot & Stain Remover (B7A-19521-AA).
3. Replace the insulator nuts and washers with new ones (N621945-S2).
4. Throw away the cross member to frame bolts and nuts. Replace them with new ones.
5. Apply Threadlocker 262 to all fasteners (Cross member-to-frame and cross member-to-insulator
nut). Be sure that all fastener surfaces are cleaned with Ford Spot & Stain Remover
(B7A-19521-AA).
6. Loosely install the new # 2 transmission cross member (E8UZ-6A023-A) to the frame side rails.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Technical Service Bulletins: > 902317 > Nov > 90 > Driveline - Vibration Cross Member Cracks > Page 6314
Figure 2
7. Loosely install a fabricated reinforcement strap under the cross member.
a. Refer to Figure 2 for strap specifications and dimensions
b. Start nuts and run up to the point where they will hold the reinforcement strap in place.
8. Tighten the cross member-to-frame bolts and nuts to 65-70 lb.ft. (88-95 N-m).
9. Tighten the transmission insulator nuts to 75-80 lb.ft. (102-108 N-m).
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
902317A Install Cross member 1.1 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
6A023 01
OASIS CODES: 703000, 305000, 504000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise
Drive Belt: All Technical Service Bulletins Accessory Drive Belt - Chirp or Squeal Noise
Article No. 94-10-19
05/18/94
^ ACCESSORY DRIVE BELT - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR
OR LOSS - VEHICLES WITH 4.9L ENGINE
^ ENGINE - 4.9L - FEAD BELT "CHIRP"/"SQUEAL" NOISE AND BELT EDGE WEAR OR LOSS
^ NOISE - "CHIRP"/"SQUEAL" SOUND FROM FEAD BELT - VEHICLES WITH 4.9L ENGINE
LIGHT TRUCK: 1987-94 ECONOLINE, F-150-350 SERIES
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise > Page 6320
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise > Page 6321
This TSB article is being republished in its entirety to provide specific bolt number references in
Figures 3 and 4.
ISSUE: Front-end accessory drive belt (FEAD) belt noise may be heard and excessive belt edge
wear or loss may occur.
^ The "chirp" noise may occur at constant engine speeds and all engine loads. It is caused by
belt/pulley misalignment.
^ The belt "squeal" noise is intermittent and is heard during engine speed variations, usually at
engine start up. The noise is caused by belt slippage.
^ Belt edge wear and/or belt loss is caused by belt mistracking across the automatic belt tensioner.
If the automatic belt tensioner is out of parallel, the belt can be "driven" to either flange of the
pulley, causing belt edge wear and in some cases, the loss of the belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise > Page 6322
ACTION: Use the following service procedure to correct these conditions.
BELT CHIRP
1. Start the engine and while idling, wet the ribbed side of belt by spraying water on the belt where
it enters the A/C compressor pulley.
2. Listen for belt "chirp" as the belt dries at the entrance point of each grooved pulley to identify the
noisy pulley.
3. If the "chirp" is at the power steering pulley entry, check for belt mistracking on the tensioner
pulley, otherwise go to Step 13.
4. Check press of the power steering pulley. The pulley hub should be flush with the end of the
pump shaft.
5. If the pulley is flush, start engine and while idling, visually compare the size of the gaps between
the belt and front and rear flange of the tensioner pulley. If the larger gap is twice as wide as the
smaller gap, Figure 2, proceed with Step 6, otherwise, go to Step 13.
6. Mark the accessory drive belt with an arrow to denote rotation of belt. Remove belt.
7. Loosen all fasteners attaching A/C bracket to cylinder block and cylinder head. See Figures 3
and 4.
8. Tighten nuts # 3 (and, on 1987-93 model only, bolts # 4) on side of cylinder block to 62 N-m (46
lb.ft).
9. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
10. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
11. Install the accessory drive belt. Be sure belt is installed with arrow mark denoting original
rotation of belt.
12. Start engine and check for belt "chirp" noise.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise > Page 6323
13. Remove the accessory drive belt and replace it with a new service replacement belt. See
Figure 1 for correct belt usage.
BELT SQUEAL - F-SERIES
1. Remove the accessory drive belt automatic tensioner assembly. Refer to the appropriate Truck
service Manual, Section 03-05, for the removal procedure.
2. Replace it with automatic tensioner assembly (E7TZ-6B209-G). Refer to the appropriate Truck
service Manual, Section 03-05, for the installation procedure.
3. Replace the accessory drive belt.
BELT SQUEAL - ECONOLINE (A/C EQUIPPED MODELS ONLY)
1. Remove and discard the accessory drive belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise > Page 6324
2. Remove 90 mm diameter pulley from automatic tensioner assembly. Discard bolt, pulley and
bearing dust shield. Refer to Figure 5.
3. Install new 76 mm pulley, bearing, dust shield and bolt assembly (E7UZ-8678-A) to automatic
tensioner assembly. See Figure 5.
4. Install new accessory drive belt. (1987-93 models - E7UZ-8620-J, 1994 models - E8TZ-8620-S).
BELT EDGE WEAR AND LOSS
1. Remove and replace accessory drive belt with new service replacement belt. See Figure 1 for
correct parts usage.
2. Start engine and while idling, observe location of belt on automatic tensioner pulley. If belt tracks
near the pulley flange, Figure 2, replace with automatic tensioner (E7TZ-6B209-G).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise > Page 6325
3. Start engine and observe belt movement. If belt moves too far rearward on tensioner pulley,
proceed as follows:
a. With belt installed, loosen all A/C bracket fasteners. Belt tension will pull A/C bracket inboard
towards the engine. (Refer to Figures 3 and 4 for bolt and nut position identification.)
b. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
c. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
d. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
4. Start engine and observe belt movement. If belt moves too far forward on tensioner pulley,
proceed as follows:
a. Remove accessory drive belt and loosen all A/C bracket fasteners.
b. Pull A/C bracket toward driver's side of vehicle.
c. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
d. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
e. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-9-14 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic
Warranty Coverage For All Other Models, Emission Warranty For Belt Loss On Vehicles Equipped
With Thermactor Pumps
OPERATION DESCRIPTION TIME
941019A Correct Belt Chirp 0.6 Hr.
E-Series
941019B Correct Belt Chirp 0.5 Hr.
F-Series
941019C Additional Time To Adjust 0.3 Hr.
A/C Bracket If Gap Is Too Large - E&F; Series
941019D Correct Belt Squeal 0.5 Hr.
E-Series
941019E Correct Belt Squeal 0.3 Hr.
F-Series
941019F Correct Belt Edge Wear or
0.6 Hr.
Belt Loss - E-Series
941019G Correct Belt Edge Wear Or
0.4 Hr.
Belt Loss - F-Series
941019H Additional Time To Adjust 0.2 Hr.
A/C Bracket To Correct Belt Tracking - E&F; Series
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise > Page 6326
DEALER CODING
BASIC PART NO. CONDITION CODE
6B209 56
OASIS CODES: 497000, 702000, 702000, 790000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 94110 > Jan > 94 > Accessory Drive Belt - Noise/Excessive
Wear
Drive Belt: All Technical Service Bulletins Accessory Drive Belt - Noise/Excessive Wear
Article No. 94-1-10
01/12/94
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - EXCESSIVE IDLER/TENSIONER PULLEY
WEAR
^ BELT - FRONT END ACCESSORY DRIVE (FEAD) - NEW BELT FOR ABRASIVE
ENVIRONMENT
^ NOISE - "THUMP" FROM FRONT END ACCESSORY DRIVE (FEAD) BELT - BELT EDGE
STARTS TO FRAY
LIGHT TRUCK: 1987-93 BRONCO, ECONOLINE, F-150-350 SERIES
ISSUE: Front End Accessory Drive (FEAD) belts have a cloth backing which can trap abrasive
particles, resulting in belt wear and erosion of the idler pulleys.
ACTION: Replace the current FEAD belt with a new neoprene-backed belt which does not retain
abrasive particles or promote pulley wear. Refer to the following procedure for service details.
1. Inspect the tensioner and idler pulleys for wear of the drive surfaces.
NOTE:
NOMINAL PULLEY DIAMETER IS 90 mm (3.453") OR 76 mm (2.916"); PULLEYS WORN TO 88
mm (3.377") OR 74 mm (2.839") SHOULD BE REPLACED.
2. Select the appropriate neoprene-backed belt and install per standard belt routing (refer to
Service Manual Section 03-05).
3. Insure that all belt vee's are in all pulley grooves.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 94110 > Jan > 94 > Accessory Drive Belt - Noise/Excessive
Wear > Page 6331
Parts Block
OTHER APPLICABLE ARTICLES: 89-10-11 WARRANTY STATUS: Eligible Under The Provisions
Of The Bumper To Bumper Warranty Coverage For 1992-93 Models And Eligible Under Basic
Warranty Coverage For Other Model Years. Emission Warranty Coverage Applies If Vehicle Is
Equipped With Thermactor System
OPERATION DESCRIPTION TIME
940110A Replace Belt - 0.3 Hr.
F-Series/Bronco
940110B Replace Belt And Tensioner 0.4 Hr.
- F-Series/Bronco
940110C Replace Belt - Econoline 0.4 Hr.
940110D Replace Belt And Tensioner 0.5 Hr.
- Econoline
DEALER CODING
BASIC PART NO. CONDITION CODE
8620 30
OASIS CODES: 497000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 8718 > Jan > 87 > Accessory Drive Belt - `V' Ribbed Belt
Cracking
Drive Belt: All Technical Service Bulletins Accessory Drive Belt - `V' Ribbed Belt Cracking
ACCESSORY DRIVE BELT - "V" RIBBED BELT Article No.
CRACKING 87-1-8
FORD 1983 FAIRMONT; 1983-86 LTD; 1983-87 ESCORT, EXP, MUSTANG, THUNDERBIRD,
CROWN VICTORIA; 1984-87 TEMPO; 1986-87 TAURUS
LINCOLN-MERCURY 1983 LN7, ZEPHYR, MARK VI; 1983-86 CAPRI, MARQUIS; 1983-87 LYNX,
GRAND MARQUIS, COUGAR, LINCOLN TOWN CAR; 1984-87 TOPAZ, MARK VII; 1986-87
SABLE
MERKUR 1985-87 XR4Ti
LIGHT TRUCK 1987 E SERIES, F SERIES
ISSUE: Minor cracks of the accessory belt ribs are a normal wear condition. Besides the normal
cracking, Front Wheel Drive (FWD) vehicles may also have a build-up of belt dust (a black,
fluffy-looking material) in the general path of the accessory drive belt.
Figure 3
ACTION: This belt dust and the minor belt cracking does not require the accessory drive belt to be
replaced. Replacing the belt is only necessary after cracking has caused "rib chunk out", see
Figure 3. When two or more ribs next to each other lose a section 1-1/2 inch or longer, the belt
should be replaced.
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise > Page 6341
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise > Page 6342
This TSB article is being republished in its entirety to provide specific bolt number references in
Figures 3 and 4.
ISSUE: Front-end accessory drive belt (FEAD) belt noise may be heard and excessive belt edge
wear or loss may occur.
^ The "chirp" noise may occur at constant engine speeds and all engine loads. It is caused by
belt/pulley misalignment.
^ The belt "squeal" noise is intermittent and is heard during engine speed variations, usually at
engine start up. The noise is caused by belt slippage.
^ Belt edge wear and/or belt loss is caused by belt mistracking across the automatic belt tensioner.
If the automatic belt tensioner is out of parallel, the belt can be "driven" to either flange of the
pulley, causing belt edge wear and in some cases, the loss of the belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise > Page 6343
ACTION: Use the following service procedure to correct these conditions.
BELT CHIRP
1. Start the engine and while idling, wet the ribbed side of belt by spraying water on the belt where
it enters the A/C compressor pulley.
2. Listen for belt "chirp" as the belt dries at the entrance point of each grooved pulley to identify the
noisy pulley.
3. If the "chirp" is at the power steering pulley entry, check for belt mistracking on the tensioner
pulley, otherwise go to Step 13.
4. Check press of the power steering pulley. The pulley hub should be flush with the end of the
pump shaft.
5. If the pulley is flush, start engine and while idling, visually compare the size of the gaps between
the belt and front and rear flange of the tensioner pulley. If the larger gap is twice as wide as the
smaller gap, Figure 2, proceed with Step 6, otherwise, go to Step 13.
6. Mark the accessory drive belt with an arrow to denote rotation of belt. Remove belt.
7. Loosen all fasteners attaching A/C bracket to cylinder block and cylinder head. See Figures 3
and 4.
8. Tighten nuts # 3 (and, on 1987-93 model only, bolts # 4) on side of cylinder block to 62 N-m (46
lb.ft).
9. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
10. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
11. Install the accessory drive belt. Be sure belt is installed with arrow mark denoting original
rotation of belt.
12. Start engine and check for belt "chirp" noise.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise > Page 6344
13. Remove the accessory drive belt and replace it with a new service replacement belt. See
Figure 1 for correct belt usage.
BELT SQUEAL - F-SERIES
1. Remove the accessory drive belt automatic tensioner assembly. Refer to the appropriate Truck
service Manual, Section 03-05, for the removal procedure.
2. Replace it with automatic tensioner assembly (E7TZ-6B209-G). Refer to the appropriate Truck
service Manual, Section 03-05, for the installation procedure.
3. Replace the accessory drive belt.
BELT SQUEAL - ECONOLINE (A/C EQUIPPED MODELS ONLY)
1. Remove and discard the accessory drive belt.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise > Page 6345
2. Remove 90 mm diameter pulley from automatic tensioner assembly. Discard bolt, pulley and
bearing dust shield. Refer to Figure 5.
3. Install new 76 mm pulley, bearing, dust shield and bolt assembly (E7UZ-8678-A) to automatic
tensioner assembly. See Figure 5.
4. Install new accessory drive belt. (1987-93 models - E7UZ-8620-J, 1994 models - E8TZ-8620-S).
BELT EDGE WEAR AND LOSS
1. Remove and replace accessory drive belt with new service replacement belt. See Figure 1 for
correct parts usage.
2. Start engine and while idling, observe location of belt on automatic tensioner pulley. If belt tracks
near the pulley flange, Figure 2, replace with automatic tensioner (E7TZ-6B209-G).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise > Page 6346
3. Start engine and observe belt movement. If belt moves too far rearward on tensioner pulley,
proceed as follows:
a. With belt installed, loosen all A/C bracket fasteners. Belt tension will pull A/C bracket inboard
towards the engine. (Refer to Figures 3 and 4 for bolt and nut position identification.)
b. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
c. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
d. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
4. Start engine and observe belt movement. If belt moves too far forward on tensioner pulley,
proceed as follows:
a. Remove accessory drive belt and loosen all A/C bracket fasteners.
b. Pull A/C bracket toward driver's side of vehicle.
c. Tighten bolt # 1 on front of cylinder head to 47 N-m (35 lb.ft).
d. Tighten bolt # 2 on side of cylinder head to 47 N-m (35 lb.ft).
e. Tighten nuts # 3 (and for 1993 and prior model years, bolts # 4) on side of cylinder block to 62
N-m (46 lb.ft).
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-9-14 WARRANTY STATUS: Eligible
Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic
Warranty Coverage For All Other Models, Emission Warranty For Belt Loss On Vehicles Equipped
With Thermactor Pumps
OPERATION DESCRIPTION TIME
941019A Correct Belt Chirp 0.6 Hr.
E-Series
941019B Correct Belt Chirp 0.5 Hr.
F-Series
941019C Additional Time To Adjust 0.3 Hr.
A/C Bracket If Gap Is Too Large - E&F; Series
941019D Correct Belt Squeal 0.5 Hr.
E-Series
941019E Correct Belt Squeal 0.3 Hr.
F-Series
941019F Correct Belt Edge Wear or
0.6 Hr.
Belt Loss - E-Series
941019G Correct Belt Edge Wear Or
0.4 Hr.
Belt Loss - F-Series
941019H Additional Time To Adjust 0.2 Hr.
A/C Bracket To Correct Belt Tracking - E&F; Series
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 941019 > May > 94 > Accessory Drive Belt - Chirp or Squeal
Noise > Page 6347
DEALER CODING
BASIC PART NO. CONDITION CODE
6B209 56
OASIS CODES: 497000, 702000, 702000, 790000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Cross-Member: > 94110 > Jan > 94 > Accessory Drive Belt - Noise/Excessive
Wear > Page 6352
Parts Block
OTHER APPLICABLE ARTICLES: 89-10-11 WARRANTY STATUS: Eligible Under The Provisions
Of The Bumper To Bumper Warranty Coverage For 1992-93 Models And Eligible Under Basic
Warranty Coverage For Other Model Years. Emission Warranty Coverage Applies If Vehicle Is
Equipped With Thermactor System
OPERATION DESCRIPTION TIME
940110A Replace Belt - 0.3 Hr.
F-Series/Bronco
940110B Replace Belt And Tensioner 0.4 Hr.
- F-Series/Bronco
940110C Replace Belt - Econoline 0.4 Hr.
940110D Replace Belt And Tensioner 0.5 Hr.
- Econoline
DEALER CODING
BASIC PART NO. CONDITION CODE
8620 30
OASIS CODES: 497000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Technical Service Bulletins >
Customer Interest for Subframe: > 902317 > Nov > 90 > Driveline - Vibration Cross Member Cracks
Subframe: Customer Interest Driveline - Vibration Cross Member Cracks
^ VIBRATION - DRIVELINE - VEHICLES WITH C6 TRANSMISSION
^ DRIVELINE - VIBRATION - VEHICLES WITH C6 TRANSMISSION
Article No. 90-23-17 LIGHT TRUCK:
1987-88 E-350
ISSUE: A driveline vibration may be caused by a crack in the crossmember between the
transmission mounting bolts. This may occur on high GVW applications and trucks making multiple
stops and starts.
ACTION: Install a new # 2 transmission cross member if any cracks are found during the
inspection. Refer to the following procedure for service details. If no cracks are found, refer to the
NVH diagnostics in the 1987-88 Light Truck Shop Manual, Volume A, Section 18-01 for corrective
action.
Figure 1
1. Remove and throw away the cracked transmission cross member. Refer to the 1987-88 Light
Truck Shop Manual, Volume A, Section 17-01 for removal procedure.
2. Inspect the transmission insulator for damage.
a. If any damage is detected, replace the transmission insulator. Clean the threads with Ford Spot &
Stain Remover (B7A-19521-AA).
b. If the transmission insulator is not damaged, clean the bolt threads with a wire brush and Ford
Spot & Stain Remover (B7A-19521-AA).
3. Replace the insulator nuts and washers with new ones (N621945-S2).
4. Throw away the cross member to frame bolts and nuts. Replace them with new ones.
5. Apply Threadlocker 262 to all fasteners (Cross member-to-frame and cross member-to-insulator
nut). Be sure that all fastener surfaces are cleaned with Ford Spot & Stain Remover
(B7A-19521-AA).
6. Loosely install the new # 2 transmission cross member (E8UZ-6A023-A) to the frame side rails.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Technical Service Bulletins >
Customer Interest for Subframe: > 902317 > Nov > 90 > Driveline - Vibration Cross Member Cracks > Page 6365
Figure 2
7. Loosely install a fabricated reinforcement strap under the cross member.
a. Refer to Figure 2 for strap specifications and dimensions
b. Start nuts and run up to the point where they will hold the reinforcement strap in place.
8. Tighten the cross member-to-frame bolts and nuts to 65-70 lb.ft. (88-95 N-m).
9. Tighten the transmission insulator nuts to 75-80 lb.ft. (102-108 N-m).
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
902317A Install Cross member 1.1 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
6A023 01
OASIS CODES: 703000, 305000, 504000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Subframe: > 902317 > Nov > 90 > Driveline - Vibration Cross Member Cracks
Subframe: All Technical Service Bulletins Driveline - Vibration Cross Member Cracks
^ VIBRATION - DRIVELINE - VEHICLES WITH C6 TRANSMISSION
^ DRIVELINE - VIBRATION - VEHICLES WITH C6 TRANSMISSION
Article No. 90-23-17 LIGHT TRUCK:
1987-88 E-350
ISSUE: A driveline vibration may be caused by a crack in the crossmember between the
transmission mounting bolts. This may occur on high GVW applications and trucks making multiple
stops and starts.
ACTION: Install a new # 2 transmission cross member if any cracks are found during the
inspection. Refer to the following procedure for service details. If no cracks are found, refer to the
NVH diagnostics in the 1987-88 Light Truck Shop Manual, Volume A, Section 18-01 for corrective
action.
Figure 1
1. Remove and throw away the cracked transmission cross member. Refer to the 1987-88 Light
Truck Shop Manual, Volume A, Section 17-01 for removal procedure.
2. Inspect the transmission insulator for damage.
a. If any damage is detected, replace the transmission insulator. Clean the threads with Ford Spot &
Stain Remover (B7A-19521-AA).
b. If the transmission insulator is not damaged, clean the bolt threads with a wire brush and Ford
Spot & Stain Remover (B7A-19521-AA).
3. Replace the insulator nuts and washers with new ones (N621945-S2).
4. Throw away the cross member to frame bolts and nuts. Replace them with new ones.
5. Apply Threadlocker 262 to all fasteners (Cross member-to-frame and cross member-to-insulator
nut). Be sure that all fastener surfaces are cleaned with Ford Spot & Stain Remover
(B7A-19521-AA).
6. Loosely install the new # 2 transmission cross member (E8UZ-6A023-A) to the frame side rails.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Subframe: > 902317 > Nov > 90 > Driveline - Vibration Cross Member Cracks > Page
6371
Figure 2
7. Loosely install a fabricated reinforcement strap under the cross member.
a. Refer to Figure 2 for strap specifications and dimensions
b. Start nuts and run up to the point where they will hold the reinforcement strap in place.
8. Tighten the cross member-to-frame bolts and nuts to 65-70 lb.ft. (88-95 N-m).
9. Tighten the transmission insulator nuts to 75-80 lb.ft. (102-108 N-m).
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS:
Eligible Under Basic Warranty Coverage
OPERATION DESCRIPTION TIME
902317A Install Cross member 1.1 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
6A023 01
OASIS CODES: 703000, 305000, 504000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Component
Information > Service and Repair
Dashboard / Instrument Panel: Service and Repair
Fig. 12 Instrument Panel Attaching Locations. 1986-87 E-series.
Refer to Fig. 12 when performing this procedure.
1. Disconnect negative battery cable. 2. Remove Lefthand finish panel screws and pull rearward to
disengage friction cups, then disconnect wiring connectors and remove panel. 3. Remove screws
at top and bottom of instrument cluster finish panel, then pull rearward and disconnect
speedometer and wiring connectors. 4. Remove cluster. 5. Remove radio and clock, if equipped. 6.
Remove A/C grille from righthand end of instrument panel pad, if equipped. 7. Remove pad
attaching nuts, then the pad. 8. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Diagrams > Diagram
Information and Instructions
Door Locks: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Diagrams > Diagram
Information and Instructions > Page 6381
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Diagrams > Diagram
Information and Instructions > Page 6382
Door Locks: Electrical Diagrams
Fig. 45 Power Door Lock Wiring Circuit. Less Power Windows
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Diagrams > Diagram
Information and Instructions > Page 6383
Fig. 46 Power Door Lock Wiring Circuit (Part 1 of 2). With Power Windows
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Component Information > Diagrams > Diagram
Information and Instructions > Page 6384
Fig. 46 Power Door Lock Wiring Circuit (Part 2 of 2). With Power Windows
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 8871033088 > Mar > 88 > Power Door
Locks - Are Inoperative
Power Door Lock Actuator: Customer Interest Power Door Locks - Are Inoperative
LOCKS - POWER - ROD RETAINER CLIP ASSEMBLY BREAKS OR DISENGAGES
POWER DOOR LOCKS - INOPERATIVE - ROD RETAINER CLIP BREAKS OR DISENGAGES
Article No. 88-7-1
FORD: 1980-82 GRANADA 1980-83 FAIRMONT 1980-88 MUSTANG, THUNDERBIRD, CROWN
VICTORIA 1983-86 LTD 1984-85 ESCORT 1984-88 TEMPO 1986-88 TAURUS
LINCOLN-MERCURY: 1980 MONARCH
1980-81 LINCOLN 1980-83 ZEPHYR, MARK VI 1980-86 CAPRI 1980-88 COUGAR, GRAND
MARQUIS 1982-88 CONTINENTAL, LINCOLN TOWN CAR 1983-86 MARQUIS 1984-85 LYNX
1984-88 TOPAZ, MARK VII 1986-88 SABLE
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1980-88 ECONOLINE 1981-88 F SERIES 1985-86 RANGER, BRONCO II
ISSUE: Inoperative power door locks maybe caused by a broken or disengaged lock rod retainer
clip assembly. The broken or disengaged retainer clip allows the power lock actuator to disconnect
from the actuator rod.
ACTION: To correct this, install a new lock rod retainer clip assembly made out of stronger
material. Refer to the following removal and installation procedure.
1. Remove door trim panel and water shield.
2. Remove broken or disengaged retainer assembly and replace it with new retainer assembly
(E8AZ-5421952-A).
NOTE: To prevent damage, make sure the latch assembly is supported from behind before tapping
the retainer assembly into the latch assembly. Be careful not to bend the lever of the latch.
3. In some cases, the latch assembly may have to be removed to provide enough space to install
the retainer assembly. Refer to Section 44 of the appropriate Shop Manual for latch removal and
installation procedures.
4. Reinstall water shield and door trim panel.
PART NUMBER PART NAME CLASS
E8AZ-5421952-A Retainer Clip Assembly BG
OTHER APPLICABLE ARTICLES: 85-12-3 WARRANTY STATUS:
"INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 8871033088 > Mar > 88 >
Power Door Locks - Are Inoperative
Power Door Lock Actuator: All Technical Service Bulletins Power Door Locks - Are Inoperative
LOCKS - POWER - ROD RETAINER CLIP ASSEMBLY BREAKS OR DISENGAGES
POWER DOOR LOCKS - INOPERATIVE - ROD RETAINER CLIP BREAKS OR DISENGAGES
Article No. 88-7-1
FORD: 1980-82 GRANADA 1980-83 FAIRMONT 1980-88 MUSTANG, THUNDERBIRD, CROWN
VICTORIA 1983-86 LTD 1984-85 ESCORT 1984-88 TEMPO 1986-88 TAURUS
LINCOLN-MERCURY: 1980 MONARCH
1980-81 LINCOLN 1980-83 ZEPHYR, MARK VI 1980-86 CAPRI 1980-88 COUGAR, GRAND
MARQUIS 1982-88 CONTINENTAL, LINCOLN TOWN CAR 1983-86 MARQUIS 1984-85 LYNX
1984-88 TOPAZ, MARK VII 1986-88 SABLE
MERKUR: 1985-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1980-88 ECONOLINE 1981-88 F SERIES 1985-86 RANGER, BRONCO II
ISSUE: Inoperative power door locks maybe caused by a broken or disengaged lock rod retainer
clip assembly. The broken or disengaged retainer clip allows the power lock actuator to disconnect
from the actuator rod.
ACTION: To correct this, install a new lock rod retainer clip assembly made out of stronger
material. Refer to the following removal and installation procedure.
1. Remove door trim panel and water shield.
2. Remove broken or disengaged retainer assembly and replace it with new retainer assembly
(E8AZ-5421952-A).
NOTE: To prevent damage, make sure the latch assembly is supported from behind before tapping
the retainer assembly into the latch assembly. Be careful not to bend the lever of the latch.
3. In some cases, the latch assembly may have to be removed to provide enough space to install
the retainer assembly. Refer to Section 44 of the appropriate Shop Manual for latch removal and
installation procedures.
4. Reinstall water shield and door trim panel.
PART NUMBER PART NAME CLASS
E8AZ-5421952-A Retainer Clip Assembly BG
OTHER APPLICABLE ARTICLES: 85-12-3 WARRANTY STATUS:
"INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Technical Service Bulletins > Page 6399
Power Door Lock Actuator: Locations
Circuit Location Amp Windshield Wiper.....................Fuse Panel................7.5
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Locations
Power Door Lock Relay: Locations
Lower Cowl Near Fuse Block
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Mirrors > Component Information > Technical Service Bulletins > Mirrors Optional Right Side Mirror Head
Mirrors: Technical Service Bulletins Mirrors - Optional Right Side Mirror Head
MIRROR - RH - NON-CONVEX 8" X 5" WITH BRIGHT TRIM
Article No. 90-12-12
LIGHT TRUCK: 1987-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
ISSUE: An optional RH flat mirror head replacement part is now available for service. It can be
purchased by the customer if it is preferred instead of the convex type mirror.
ACTION: Install a RH flat mirror head at the customer's request and expense. Refer to the 1990
Ranger/Bronco II Shop Manual, Section 01-09 and the Econoline/F-Series/Bronco Shop Manual,
Section 35-50 for service details.
NOTE: INFORM THE CUSTOMER THAT ALTHOUGH THE FIELD OF VIEW WILL BE SMALLER,
THIS MIRROR MEETS ALL FEDERAL REQUIREMENTS.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
1300
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and
Instructions
Mirrors: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and
Instructions > Page 6409
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and
Instructions > Page 6410
Fig. 47 Power Mirror Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal
Paint: Technical Service Bulletins Paint - Iron Particle Removal
Article No. 95-6-1
03/27/95
^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION
^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN
DISCOLORATION OR ETCHING
FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP
1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994-95
ASPIRE 1995 CONTOUR
LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN
CAR 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER
1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 MYSTIQUE
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after
BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and
after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after
WINDSTAR
MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B
SERIES, L SERIES 1986 and after CARGO SERIES
ISSUE: Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail
shipments, combustion engines, jet engines, body shops, etc. These particles
mechanically/magnetically bond to vehicles' painted surfaces. Moisture and temperature combine
with the particles to create a chemical reaction. The reaction causes the particles to corrode and
enter into the physical paint film.
ACTION: To remove these particles/contaminants, USE ONLY the following procedure. The
procedure must be performed before any buffing, polishing, color sanding or refinishing is
attempted. The materials in this procedure are alkaline, acidic and neutral. They must be used in
the specified order.
CAUTION:
ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR
UNSATISFACTORY REPAIR AND MAY RESULT IN
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 6416
POSSIBLE DAMAGE TO THE PAINTED SURFACES AND TRIM.
WARNING:
THE TECHNICIAN MUST WEAR PROTECTIVE CLOTHING AND EYE PROTECTION TO
PREVENT SKIN IRRITATION.
CAUTION:
THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO
ALUMINUM, FLEXIBLE PAINTED SURFACES OR OTHER PAINTED SURFACES. FOLLOW
DIRECTIONS EXACTLY AND RINSE THOROUGHLY AFTER EACH STEP.
NOTE:
THIS DECONTAMINATION PROCEDURE IS DESIGNED TO REMOVE SURFACE
CONTAMINANTS FROM THE PAINT ON VEHICLES THAT HAVE BEEN CONTAMINATED UP
TO 120 DAYS. VEHICLES WHICH HAVE EXPERIENCED THE CONDITION LONGER THAN
THIS PERIOD MAY REQUIRE AN ADDITIONAL TREATMENT TO REMOVE FERROUS METAL
CONTAMINANTS.
IDENTIFICATION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 6417
For ease of identifying, the Radio Shack Model 63-851, 30X, lighted, magnifier is recommended.
1. Ferrous Metal
^ Light colored vehicles: Small rust orange dots with black in center of stain.
^ Dark colored vehicles: Small white or silver dots with a "rainbow hue" around the particle. The
surface will also feel rough to the touch.
2. Industrial Fallout
^ The surface feels rough to the touch and may exhibit crystalline deposits.
^ Usually ferrous metal is present, as well as water spots.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 6418
3. Acid Rain
^ Surface will exhibit irregular discolored spotting.
^ Dark colored vehicles will show cloudy or greying spots where the acids have started to etch
away the paint.
NOTE:
IN EXTREME CASES ETCHING OF THE SURFACE WILL BE VISIBLE OR FELT.
DECONTAMINATION
Use Finish Kare Inc. products 1119/883/11850 to decontaminate the paint surface. Follow the
manufacturer's recommended procedures.
NOTE:
FORD DOES NOT RECOMMEND THE USE OF OXALIC ACIDS OR OTHER "FALLOUT
REMOVERS".
1. Rinse off dust and debris with cold water. Be sure to start at the bottom and work up.
2. Prepare product "1119" by mixing one (1) part "1119" with four (4) parts cold water.
3. Use clean wash mitt and apply mixture to entire car, starting at the bottom and working up to the
top surface. Keep car wet with the solution for 5 to 10 minutes. Do not allow product to dry on the
car, and do not allow it to streak down the sides. Rewipe with mitt if necessary to avoid streaks.
4. Rinse car with cold water.
5. Dry the flat surfaces of the vehicle hood, roof and deck lid.
6. Apply product "883" directly to the contaminated surfaces using a clean dry sponge, wash mitt,
or soft truck brush ("883" is ready to use from the bottle, with no mixing involved). Keep the areas
wet with the "883" for 5 to 7 minutes. Do not allow to dry on the car. Wipe down to the body line on
the sides.
7. Prepare product "118SC" by mixing 1 oz (0.03 L) with 1 gal (3.785 L) of water.
8. Shampoo the vehicle with "118SC" shampoo mixture using a clean wash mitt and then rinse with
cold water.
NOTE:
DO NOT USE "1185C" MITT WITH "1119" OR "883" SOLUTIONS. USE SEPARATE MITTS AND
ALWAYS KEEP THEM SEPARATE.
9. Inspect paint surface to see if rust particles have been removed. If rust particles have been on
the vehicle for a long time, it may be necessary to repeat each of the above steps.
NOTE:
THE NEUTRALIZER CONCENTRATE IS A HEAVY DUTY SHAMPOO AND CAN BE USED IN AN
AUTOMATIC CAR WASH SYSTEM.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 6419
CORRECTION OF SURFACE FOLLOWING DECONTAMINATION:
1. Visually inspect surface for evidence of removal of ferrous metal particles, crystalline deposits
and water spots. Acid rain discoloring or etching will require either buffing, color sanding or
refinishing if etching is visible.
2. Use the buffing products from only one (1) manufacturer. Do not intermix products.
3. Always follow the manufacturer's product sequence. Use appropriate pads with each product as
recommended by the manufacturer.
NOTE:
DO NOT REMOVE MORE THAN 0.3 OF A MIL OF PAINT MATERIAL, OR REPAINTING WILL BE
REQUIRED.
4. Use a dual action sander (D/A Sander) with a velcro-mount backing plate and appropriate foam
pad for final polishing swirl removal.
5. Use an alcohol and water mixture (1:4 ratio) to clean buffed areas to verify removal of scratches
and swirls before application of final protective glaze.
NOTE:
FREQUENT WASHING OF VEHICLES IS IMPORTANT. CONTAMINANTS SETTLE ONTO THE
VEHICLE EVERY DAY. USE CLEAN WATER (DEIONIZED, REVERSE OSMOSIS, ETC.) TWICE
WEEKLY TO REMOVE HEAVY DUST, AND PARTICULATES. THE USE OF A NEUTRAL pH
CAR WASH SOAP EVERY TWO (2) WEEKS IS RECOMMENDED TO NEUTRALIZE VEHICLE
CONTAMINATION.
Parts Block
NOTE:
DEALERS SHOULD USE PROGRAM CODE R-23 AND CONDITION CODES C5 AND C6. REFER
TO W & P MANUAL, SECTION 5-1, PAGE 3.
OTHER APPLICABLE ARTICLES: 91-18-1, 92-6-4 WARRANTY STATUS: Eligible Under The
Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage
OPERATION DESCRIPTION TIME
950601A Decontaminate And Surface 0.6 Hr.
Correction - Aspire
950601B Decontaminate And Surface 0.6 Hr.
Correction - Escort/Tracer
950601C Decontaminate And Surface 0.6 Hr.
Correction - Probe
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 6420
950601D Decontaminate And Surface 0.6 Hr.
Correction - Contour/Mystique
950601E Decontaminate And Surface 0.6 Hr.
Correction - Mustang
950601F Decontaminate And Surface 0.7 Hr.
Correction - Taurus/Sable
950601G Decontaminate And Surface 0.7 Hr.
Correction - Thunderbird/Cougar
950601H Decontaminate And Surface 0.7 Hr.
Correction - Crown Victoria/Grand Marquis
950601I Decontaminate And Surface 0.7 Hr.
Correction - Mark VIII
950601J Decontaminate And Surface 0.7 Hr.
Correction - Continental
950601K Decontaminate And Surface 0.6 Hr.
Correction - Capri
950601L Decontaminate And Surface 0.8 Hr.
Correction - Town Car
950601M Decontaminate And Surface 0.7 Hr.
Correction - Villager
950601N Decontaminate And Surface 0.6 Hr.
Correction - Windstar
9506010 Decontaminate And Surface 0.7 Hr.
Correction - Aerostar
950601P Decontaminate And Surface 0.6 Hr.
Correction - Bronco
9506010 Decontaminate And Surface 1.1 Hrs.
Correction - Econoline
950601R Decontaminate And Surface 0.9 Hr.
Correction - F-Series
950601S Decontaminate And Surface 0.6 Hr.
Correction - Explorer
950601T Decontaminate And Surface 0.7 Hr.
Correction - Ranger
950601U Decontaminate And Surface 0.5 Hr.
Correction - F-Super Duty
950601V Decontaminate And Surface 0.7 Hr.
Correction - F/B-Series
950601W Decontaminate And Surface 0.7 Hr.
Correction - L-Series
950601X Decontaminate And Surface 0.5 Hr.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Iron Particle Removal > Page 6421
Correction - Cargo
950601Y Decontaminate And Surface 0.6 Hr.
Correction - Tempo/Topaz
DEALER CODING
BASIC PART NO. CONDITION CODE
ENTRE C5 OR C6
OASIS CODES: 106000
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal
Paint: Technical Service Bulletins Paint - Iron Particle Removal
Article No. 95-6-1
03/27/95
^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION
^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN
DISCOLORATION OR ETCHING
FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP
1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994-95
ASPIRE 1995 CONTOUR
LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN
CAR 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER
1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 MYSTIQUE
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after
BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and
after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after
WINDSTAR
MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B
SERIES, L SERIES 1986 and after CARGO SERIES
ISSUE: Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail
shipments, combustion engines, jet engines, body shops, etc. These particles
mechanically/magnetically bond to vehicles' painted surfaces. Moisture and temperature combine
with the particles to create a chemical reaction. The reaction causes the particles to corrode and
enter into the physical paint film.
ACTION: To remove these particles/contaminants, USE ONLY the following procedure. The
procedure must be performed before any buffing, polishing, color sanding or refinishing is
attempted. The materials in this procedure are alkaline, acidic and neutral. They must be used in
the specified order.
CAUTION:
ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR
UNSATISFACTORY REPAIR AND MAY RESULT IN
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6427
POSSIBLE DAMAGE TO THE PAINTED SURFACES AND TRIM.
WARNING:
THE TECHNICIAN MUST WEAR PROTECTIVE CLOTHING AND EYE PROTECTION TO
PREVENT SKIN IRRITATION.
CAUTION:
THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO
ALUMINUM, FLEXIBLE PAINTED SURFACES OR OTHER PAINTED SURFACES. FOLLOW
DIRECTIONS EXACTLY AND RINSE THOROUGHLY AFTER EACH STEP.
NOTE:
THIS DECONTAMINATION PROCEDURE IS DESIGNED TO REMOVE SURFACE
CONTAMINANTS FROM THE PAINT ON VEHICLES THAT HAVE BEEN CONTAMINATED UP
TO 120 DAYS. VEHICLES WHICH HAVE EXPERIENCED THE CONDITION LONGER THAN
THIS PERIOD MAY REQUIRE AN ADDITIONAL TREATMENT TO REMOVE FERROUS METAL
CONTAMINANTS.
IDENTIFICATION
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6428
For ease of identifying, the Radio Shack Model 63-851, 30X, lighted, magnifier is recommended.
1. Ferrous Metal
^ Light colored vehicles: Small rust orange dots with black in center of stain.
^ Dark colored vehicles: Small white or silver dots with a "rainbow hue" around the particle. The
surface will also feel rough to the touch.
2. Industrial Fallout
^ The surface feels rough to the touch and may exhibit crystalline deposits.
^ Usually ferrous metal is present, as well as water spots.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6429
3. Acid Rain
^ Surface will exhibit irregular discolored spotting.
^ Dark colored vehicles will show cloudy or greying spots where the acids have started to etch
away the paint.
NOTE:
IN EXTREME CASES ETCHING OF THE SURFACE WILL BE VISIBLE OR FELT.
DECONTAMINATION
Use Finish Kare Inc. products 1119/883/11850 to decontaminate the paint surface. Follow the
manufacturer's recommended procedures.
NOTE:
FORD DOES NOT RECOMMEND THE USE OF OXALIC ACIDS OR OTHER "FALLOUT
REMOVERS".
1. Rinse off dust and debris with cold water. Be sure to start at the bottom and work up.
2. Prepare product "1119" by mixing one (1) part "1119" with four (4) parts cold water.
3. Use clean wash mitt and apply mixture to entire car, starting at the bottom and working up to the
top surface. Keep car wet with the solution for 5 to 10 minutes. Do not allow product to dry on the
car, and do not allow it to streak down the sides. Rewipe with mitt if necessary to avoid streaks.
4. Rinse car with cold water.
5. Dry the flat surfaces of the vehicle hood, roof and deck lid.
6. Apply product "883" directly to the contaminated surfaces using a clean dry sponge, wash mitt,
or soft truck brush ("883" is ready to use from the bottle, with no mixing involved). Keep the areas
wet with the "883" for 5 to 7 minutes. Do not allow to dry on the car. Wipe down to the body line on
the sides.
7. Prepare product "118SC" by mixing 1 oz (0.03 L) with 1 gal (3.785 L) of water.
8. Shampoo the vehicle with "118SC" shampoo mixture using a clean wash mitt and then rinse with
cold water.
NOTE:
DO NOT USE "1185C" MITT WITH "1119" OR "883" SOLUTIONS. USE SEPARATE MITTS AND
ALWAYS KEEP THEM SEPARATE.
9. Inspect paint surface to see if rust particles have been removed. If rust particles have been on
the vehicle for a long time, it may be necessary to repeat each of the above steps.
NOTE:
THE NEUTRALIZER CONCENTRATE IS A HEAVY DUTY SHAMPOO AND CAN BE USED IN AN
AUTOMATIC CAR WASH SYSTEM.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6430
CORRECTION OF SURFACE FOLLOWING DECONTAMINATION:
1. Visually inspect surface for evidence of removal of ferrous metal particles, crystalline deposits
and water spots. Acid rain discoloring or etching will require either buffing, color sanding or
refinishing if etching is visible.
2. Use the buffing products from only one (1) manufacturer. Do not intermix products.
3. Always follow the manufacturer's product sequence. Use appropriate pads with each product as
recommended by the manufacturer.
NOTE:
DO NOT REMOVE MORE THAN 0.3 OF A MIL OF PAINT MATERIAL, OR REPAINTING WILL BE
REQUIRED.
4. Use a dual action sander (D/A Sander) with a velcro-mount backing plate and appropriate foam
pad for final polishing swirl removal.
5. Use an alcohol and water mixture (1:4 ratio) to clean buffed areas to verify removal of scratches
and swirls before application of final protective glaze.
NOTE:
FREQUENT WASHING OF VEHICLES IS IMPORTANT. CONTAMINANTS SETTLE ONTO THE
VEHICLE EVERY DAY. USE CLEAN WATER (DEIONIZED, REVERSE OSMOSIS, ETC.) TWICE
WEEKLY TO REMOVE HEAVY DUST, AND PARTICULATES. THE USE OF A NEUTRAL pH
CAR WASH SOAP EVERY TWO (2) WEEKS IS RECOMMENDED TO NEUTRALIZE VEHICLE
CONTAMINATION.
Parts Block
NOTE:
DEALERS SHOULD USE PROGRAM CODE R-23 AND CONDITION CODES C5 AND C6. REFER
TO W & P MANUAL, SECTION 5-1, PAGE 3.
OTHER APPLICABLE ARTICLES: 91-18-1, 92-6-4 WARRANTY STATUS: Eligible Under The
Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage
OPERATION DESCRIPTION TIME
950601A Decontaminate And Surface 0.6 Hr.
Correction - Aspire
950601B Decontaminate And Surface 0.6 Hr.
Correction - Escort/Tracer
950601C Decontaminate And Surface 0.6 Hr.
Correction - Probe
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6431
950601D Decontaminate And Surface 0.6 Hr.
Correction - Contour/Mystique
950601E Decontaminate And Surface 0.6 Hr.
Correction - Mustang
950601F Decontaminate And Surface 0.7 Hr.
Correction - Taurus/Sable
950601G Decontaminate And Surface 0.7 Hr.
Correction - Thunderbird/Cougar
950601H Decontaminate And Surface 0.7 Hr.
Correction - Crown Victoria/Grand Marquis
950601I Decontaminate And Surface 0.7 Hr.
Correction - Mark VIII
950601J Decontaminate And Surface 0.7 Hr.
Correction - Continental
950601K Decontaminate And Surface 0.6 Hr.
Correction - Capri
950601L Decontaminate And Surface 0.8 Hr.
Correction - Town Car
950601M Decontaminate And Surface 0.7 Hr.
Correction - Villager
950601N Decontaminate And Surface 0.6 Hr.
Correction - Windstar
9506010 Decontaminate And Surface 0.7 Hr.
Correction - Aerostar
950601P Decontaminate And Surface 0.6 Hr.
Correction - Bronco
9506010 Decontaminate And Surface 1.1 Hrs.
Correction - Econoline
950601R Decontaminate And Surface 0.9 Hr.
Correction - F-Series
950601S Decontaminate And Surface 0.6 Hr.
Correction - Explorer
950601T Decontaminate And Surface 0.7 Hr.
Correction - Ranger
950601U Decontaminate And Surface 0.5 Hr.
Correction - F-Super Duty
950601V Decontaminate And Surface 0.7 Hr.
Correction - F/B-Series
950601W Decontaminate And Surface 0.7 Hr.
Correction - L-Series
950601X Decontaminate And Surface 0.5 Hr.
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 6432
Correction - Cargo
950601Y Decontaminate And Surface 0.6 Hr.
Correction - Tempo/Topaz
DEALER CODING
BASIC PART NO. CONDITION CODE
ENTRE C5 OR C6
OASIS CODES: 106000
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS
Information
Paint: Technical Service Bulletins Paint - Preparation Procedure And MSDS Information
Article No. 94-23-4
11/14/94
PAINT - PRIMED SHEET METAL - PREP PROCEDURE AND MSDS INFORMATION
FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP
1984 and after TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE
LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN
CAR 1981-87 LYNX 1984-92 MARK VII 1984 and after TOPAZ 1986 and after SABLE 1987-89
TRACER 1991-94 CAPRI 1993 and after MARK VIII
MERKUR: 1985-89 XR4TI 1988-90 SCORPIO
LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after
BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and
after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 WINDSTAR
MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B
SERIES, L SERIES 1986 and after CARGO SERIES
ISSUE: This procedure is being published to advise all body and paint technicians about proper
procedures for preparation of sheet metal parts coated with electrodeposition primer (E-Coat).
ACTION: When prepping a replacement body panel for installation, it is mandatory to leave the
E-Coat intact. DO NOT SAND OFF THE E-COAT.
Improper preparation with excessive sanding of the E-Coat to bare metal will jeopardize the sheet
metal warranty and overall customer satisfaction. In particular, the E-Coat is necessary to protect
the parts from rust. Light scuff sanding using a Scotch Brite pad or wet 320 grit sand paper is
recommended for minor flaws. If a minor flaw exists, wet sand or scuff out the flaw and prime the
repair area. Again, do not remove all of the E-Coat from the panel.
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS
Information > Page 6437
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS
Information > Page 6438
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS
Information > Page 6439
WARNING:
LEAD CONTAMINATION POTENTIAL: THE ELECTRODEPOSITION PRIMER USED BY FORD
MOTOR COMPANY OVER BASE METAL ON SERVICE REPLACEMENT PARTS OR
COMPLETED VEHICLES CONTAINS SMALL AMOUNTS OF LEAD FOR CORROSION
PROTECTION OF STEEL. EXCESSIVE DUSTS GENERATED BY UNNECESSARY AND
IMPROPER SANDING MAY CONTAIN AIRBORNE LEAD CONTAMINATION IN EXCESS OF
OSHA STANDARDS. INFORMATION REGARDING THE HAZARDS OF LEAD CAN BE FOUND
IN THE CHEMICAL FACT SHEETS IN THE FIGURES IN THIS ARTICLE.
NOTE:
READ ALL INFORMATION IN THIS TECHNICAL SERVICE BULLETIN CAREFULLY AND
FORWARD TO ALL EMPLOYEES PERFORMING PAINT PREPPING OPERATIONS. DEALERS
SHOULD CONTACT LEGAL COUNSEL AND/OR LOCAL OSHA
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS
Information > Page 6440
AUTHORITIES FOR DIRECTION REGARDING OSHA LEAD STANDARD REQUIREMENTS.
If a replacement body panel contains more than a minor flaw in the E-coat, it should be returned.
Contact your Customer Service representative for instructions.
If more extensive sanding, other than that described above, is necessary, (e.g., refinishing original
vehicle sheet metal) follow the procedures outlined below:
ALTERNATIVE SANDING PROCEDURES WHEN EXTENSIVE SANDING IS REQUIRED
The following procedures for sheet metal preparation by sanding or media blasting are based on
tests conducted by Ford Motor Company in accordance with requirements set forth in the Federal
OSHA Inorganic Lead Standard 29 CFR 1910.1025.
SANDING PROCEDURE
1. Each technician performing the sanding operation MUST wear an approved respirator with high
efficiency particulate filter (HEPA).
2. Technicians should use dual action sander with vacuum collection.
3. The vacuum equipment MUST be equipped with a HEPA filter on the air exhaust. Dealers are
cautioned not to exhaust vacuum air into the atmosphere. Operators are cautioned to follow the
manufacturer's guidelines for maintenance and the replacement of filters.
MEDIA BLASTING PROCEDURE
1. Testing has shown that plastic media blasting meets OSHA lead standard requirements and is
efficient when the manufacturer's published procedures are followed.
2. The operator must wear an air supplied hood using compressed air free from carbon monoxide,
oil, water, and other contamination when performing this operation. Specifics of the media blasting
procedure for whole body paint removal have been previously published.
NOTE:
PLEASE READ THE CHEMICAL FACT SHEETS IN THE FIGURES.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 106000
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures
Technical Service Bulletin # 91181 Date: 910905
Exterior Paint - Comprehensive Repair Procedures
Article No. 91-18-1 09/05/91
PAINT-EXTERIOR-COMPREHENSIVE REPAIR PROCEDURES
FORD: 1985-86 LTD 1985-92 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO,
THUNDERBIRD 1986-92 TAURUS 1988-92 FESTIVA 1989-92 PROBE
LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-92 CONTINENTAL,
COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-92 SABLE 1988-92
TRACER
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150-350 SERIES,
RANGER 1986-92 AEROSTAR 1991 EXPLORER
ISSUE: A comprehensive paint repair procedure TSB has been developed for service use. It
includes the following paint repair topics:
Section (A) has been superseded by TSB # 9264, dated 3/92.
(B) Exterior Color Peeling From Ultra Violet Light
(C) Lower Body Stone Protection Repair Tips
(D) Procedures For PVC Body Side Moldings
(E) Lower Body-Side Stone Chip Protection Program
(F) Surface Defect Removal Without Repainting
(G) 1991 Color Matched/Compatible Spray Primer Chart
(H) Repair For Tinted Clearcoat
(I) Frequently Used And Paintable Plastics
(J) 1992 Paint Codes
ACTION: If paint repair is required, refer to the following procedures for paint restoration.
Section A Has Been Superseded By TSB # 9264, Dated 3/92.
CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN
CORROSION OF ANODIZED ALUMINUM OR
STAINLESS STEEL PARTS
PROCEDURE # 2
FINISH KARE FORMULA # 1119 AND # 883 (Buffered solution not as harsh on aluminum parts)
WARNING: FOR YOUR SAFETY, USE RUBBER GLOVES, GOGGLES AND PROTECTIVE
CLOTHING WHEN HANDLING THESE PRODUCTS.
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures >
Page 6445
1. Apply hot diluted solution with soft mitt.
2. Agitate to create suds. Suds hold the acid solution in suspension and to the surface creating
greater and extended activity.
3. Allow 3 to 5 minutes dwell time.
4. Rinse with COLD WATER.
5. Apply # 883 per label instructions.
LIQUID NEUTRALIZER CONCENTRATE
1. Using a mitt, thoroughly go over the entire surface with the diluted solution (50-1) of water and #
118 Liquid Neutralizer Concentrate. Then wipe dry.
2. If the iron particles are not totally removed after 2 washings, use one or both of the following
service actions.
a. Sand with micro fine sandpaper (1500 Grid or greater) in localized areas.
b. Buff with very light compound and polish with wax in localized areas.
WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL
TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'S) OR EXCESS
MATERIALS.
(B) Paint Exterior Color Peeling From Ultra Violet Light
Paint may be damaged because of ultra violet light absorption through the color coat. This damage
will cause the top coat to peel to the E-coat primer.
If service is required, use the following procedure to correct the concerns.
NOTE: READ THE ENTIRE SERVICE PROCEDURE BEFORE STARTING REPAIRS.
WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE
RESPIRATOR AND USE OTHER RECOMMENDED SAFETY EQUIPMENT.
1. Wash the vehicle with soap and water.
2. Verify topcoat adhesion by applying a 2 inch wide masking tape strip on all body panels above
and below the beltline on each panel.
a. Pull the tape up quickly.
b. Inspect the adhesive side of the tape for paint removal.
NOTE: IF PAINT WAS REMOVED DURING THE TAPE TEST, THE ENTIRE PANEL SHOULD BE
STRIPPED AND REFINISHED AS NECESSARY.
3. Remove all trim (mouldings, name plates, striping, etc.) from the areas which will be repainted.
NOTE: ALL REQUIRED REPLACEMENT MOULDINGS AND STRIPES SHOULD BE ORDERED
AND RECEIVED PRIOR TO REPAIRING THE CUSTOMER'S VEHICLE.
4. Wipe the entire vehicle with wax and grease remover.
^ BASF Product # 900 Prekleano
^ PPG Product # DX300
^ S-W Product # R7-K156
^ DuPont Product # 3919 S
^ Sikkens Product # M 600
5. Mask off all areas on the vehicle which are not going to be painted or will be affected by
overspray (engine compartment, wheels, etc.).
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Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures >
Page 6446
6. Remove the paint to bare metal from all the areas of the vehicle which are going to be repainted.
Use one of the following methods.
SAND THE AFFECTED AREAS TO BARE METAL USING 40 GRIT 3M GREEN CORPS
SANDING DISCS OR EQUIVALENT AND A SOFT PAD ON A 1700 RPM POLISHER. KEEP THE
POLISHER MOVING TO AVOID DEVELOPING HOT SPOTS ON THE METAL.
NOTE: CHEMICAL STRIPPING IS NOT RECOMMENDED.
NOTE: IF AVAILABLE, PAINT MAY BE REMOVED USING A PLASTIC MEDIA BLAST SYSTEM.
IF THIS PROCESS IS USED, EXTRA
CARE MUST BE TAKEN DURING THE MASKING PROCESS TO PREVENT DAMAGE TO
GLASS, MOULDING, ETC.
7. Blow off the entire vehicle to remove loose dust and debris.
NOTE: IF RUST IS PRESENT, USE APPROPRIATE METAL CLEANER AND CONDITIONER
(PHOSPHATE COATING) OVER BARE METAL AREAS.
8. Wipe all affected areas with a fast dry enamel reducer solvent, followed by a dry wipe using a
clean, lint free cloth to remove all residue.
CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL
RESULT IN POPPING OF THE COATINGS TO
BE APPLIED FOLLOWING THIS STEP.
NOTE: THIS STEP WILL REDUCE THE POSSIBILITY OF FLASH RUST.
^ BASF Product # BR 50
^ PPG Product # DX 300
^ S-W Product # R7 K156
^ DuPont Product # 3812 S
^ Sikkens Product # 123 FAST
9. Apply two medium wet coats (1.0 mil total) of self-etching, anti-corrosion primer using the
manufacturer's recommendations and flash times.
^ BASF Product # DE-17
^ PPG Product # DP EPOXY PRIMER
^ S-W Product # E2-6980
^ DuPont Product # VARIPRIME
^ Sikkens Product # WASH FILLER 580
10. Apply three medium wet coats (2.0 mils total) of acrylic urethane primer surfacer following the
manufacturer's recommended procedures.
^ BASF Product # DP-20 PRIMER/SUFACER
^ PPG Product # K-36
^ S-W Product # P6-M49 OR P6-A48
^ DuPont Product # URO PRIMERFILLER
^ Sikkens Product # AUTOCRYL 3+1 FILLER
11. Sand the vehicle using one of the following methods:
^ Wet-sand by hand using 400 grit or finer sandpaper.
^ Dry-sand by hand using 320 grit or finer sandpaper.
12. Blow the entire vehicle off to remove loose dust and debris.
13. Demask (remove all paper and tape) as necessary to remove the primer and dirt buildup on the
paper and tape.
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Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures >
Page 6447
14. Wipe the entire vehicle with wax and grease remover, followed by a dry wipe using a clean, lint
free cloth to remove all residue.
CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL
RESULT IN POPPING OF THE COATINGS TO
BE APPLIED FOLLOWING THIS STEP.
^ BASF Product # 901 PRE-PAINT CLEANER
^ PPG Product # DX 330
^ S-W Product # R7-K156
^ DuPont Product # 3812 S
^ Sikkens Product # M 600
15. Mask all areas on the vehicle which are not to be painted or will be affected by paint overspray
(engine compartment, wheels, etc.).
NOTE: APPLY BASECOAT/CLEAR COAT ONLY TO SURFACES WHICH ORIGINALLY HAD
BASECOAT/CLEAR COAT
16. Apply three medium wet coats (enough material to hide primer) of acrylic enamel base coat or
acrylic urethane monocoat following the manufacturer's recommended procedure.
^ BASF Product # DIAMONT BASECOAT/Solo
^ PPG Product # DELTRON BASECOAT DBC/Deltron
^ S-W Product # ULTRA BASE/Ultra One Stage
^ DuPont Product # CHROMABASE/Cronar
^ Sikkens Product # AUTO BASE/Autocryl
17. Apply two medium wet coats of 2K acrylic urethane enamel clear coat, following manufacturer's
recommended procedure.
^ BASF Product # DIAMONT CLEAR 88/89
^ PPG Product # CONCEPT 2001 DCU
^ S-W Product # CC-650 OR CC-640
^ DuPont Product # 1080 S URO CLEAR
^ Sikkens Product # AUTO CLEAR
18. After the paint is dry, demask the entire vehicle and clean up any areas which have overspray.
19. Polish the vehicle as necessary to remove any defects in the paint which may create a
customer concern.
CAUTION: USE LOW SPEED (1700 RPM MAXIMUM) POLISHER.
20. Install all trim (mouldings, name plates, striping, etc.) on the vehicle which were removed prior
to repainting.
21. Clean the exterior and interior of the vehicle thoroughly, including air ducts and other areas
which are prone to accumulating dust. This step is essential to ensure customer satisfaction.
WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL
TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS
MATERIALS.
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Figure 1
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Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures >
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Figure 2
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Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures >
Page 6450
Figure 3
STRIP AND REFINISH CLAIMING METHODOLOGY
The claiming instructions shown in Figure 1 are applicable to the repair of the EXTERIOR COLOR
PEELING FROM ULTRA VIOLET LIGHT concern covered in this TSB only. See the SAMPLE
CLAIMS, Figures 2 and 3, for examples.
(C) Lower Body Stone Protection Repair Tips
Ford has introduced a vinyl anti-stone abrasion material for the lower exterior body surfaces of
selected passenger vehicles and light trucks. The anti-stone abrasion material is applied to the
lower fenders, rocker panels, lower doors, quarter panel dogleg, and lower rear of quarter panel
behind the wheel. The anti-stone abrasion material will usually end at a body character line.
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While primarily for servicing of factory-applied protective coating, the following provides installation
information. If the vehicle has experienced body damage in the factory-applied material protective
area, the sheet metal damage must be serviced prior to the application of the new protective
coating.
SMALL AREAS - MINOR DEFECTS (VEHICLES WITH FACTORY SPRAYED-ON VINYL)
A small dent in the sheet metal that did not mar the vinyl surface, can possibly be corrected with
proper bumping tools without damage to the vinyl coating. However, noticeable scratches or
gouges (not over 1/2 inch in diameter) or dings and dents that when "ironed out" show vinyl
damage, can be satisfactorily serviced with the following procedure:
1. Solvent-wipe the damaged area with "Silicone and Wax Remover."
2. Using a heat gun or lamp, soften the vinyl coating of the damaged area until it can be scraped off
with a putty knife or a similar tool. If necessary, sand off any hard to remove coating using an
orbital disc sander (No. 80 Disc). (The spray-on vinyl protective coatings may not be suitable for
"spot" application. See Manufacturer's label for instructions.)
3. Perform necessary servicing to correct the sheet metal damage.
4. Using white bodyfiller, fill the damaged area. Follow the instructions on the label and blend the
bodyfiller with the surrounding sheet metal.
5. Allow the bodyfiller to completely cure and then carefully sand the area smooth, removing any
high spots.
6. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material.
LARGE DAMAGED AREAS - VEHICLE WITH FACTORY SPRAYED ON VINYL
Peeling or damage over a large area will necessitate removal of the factory sprayed-on vinyl
coating. The following procedure is suggested.
NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR, OR
QUARTER PANEL REPLACEMENT IS
REQUIRED (OR IN AN INITIAL INSTALLATION), DISREGARD STEPS NO. 1 AND NO. 2.
1. Using a heat gun or lamp, soften the vinyl coating until it is pliable. Scrape coating off with a
putty knife or a similar tool. If necessary, sand off any hard to remove coating using an orbital disc
sander (No. 80 Disc). (The vinyl material, abrasion resistant coating may not be suitable for "spot"
applications. See manufacturer's label for instructions.)
2. Perform necessary servicing to correct the sheet metal damage.
3. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material.
COATING APPLICATIONS
Approximately two quarts will be required for an initial installation on a passenger car or F-Series.
Slightly more will be required for an Econoline. The specified dry film thickness of 15 to 20 mils
(.015 to .020 inch) will require at least three, possibly four, applications of coating material, with
"flash off" time between coats. Spray coat complete panels only.
The coating must be applied with commercial equipment by an experienced automotive painter.
The coating must be thoroughly agitated before application. The material is heavy bodied. A
pressure cup spray gun or "Rocker Schutz Gun" is recommended.
COATING PREPARATION - MASKING VEHICLE
Install suitable covers over the wheels.
NOTE: IF THE VEHICLE HAS LOWER BODY SIDE MOULDINGS (12-14 INCHES ABOVE THE
"TURN UNDER" OF THE ROCKER PANEL),
THE MOULDING CAN SERVE AS THE UPPER MARGIN OF THE AREA TO BE COATED. IF
THE VEHICLE DOES NOT HAVE SUITABLE MOULDINGS, A SCULPTURE OR BREAK LINE IN
THE SHEET METAL CAN BE UTILIZED. THIS LINE SHOULD BE SELECTED TO ENSURE
ADEQUATE PROTECTION OF THE PAINTED SURFACES.
VEHICLES WITH BODY SIDE MOULDINGS
1. Masking tape should be positioned so that the moulding lower edge is also covered. The
adjoining sheet metal should be left uncovered too so anti-stone, abrasion vinyl can be applied.
VEHICLES WITHOUT BODY SIDE MOULDINGS
2. If the contour of the body side has a break line, the upper coating margin must be masked off
using 3M "Fine Line" Tape.
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a. The normal masking tape and paper protection for the body side should be applied first and
positioned about a quarter inch above the margin line.
b. The "Fine Line" tape should then be applied over the regular masking tape with the lower edge
at the upper coating margin line. Extend this "Fine Line" tape into the wheel opening, in the
absence of wheel opening mouldings, allowing the flange to be coated.
c. The anti-stone abrasion coating does not adhere well to flexible plastic parts. If left exposed, they
must be masked off.
d. It is not necessary to mask off the body door openings in the coating area, as they will be
uniformly coated where the door margins allow the coating to enter.
NOTE: DOOR OPENING AREAS SHOULD BE CLEANED TO ASSURE COATING ADHERENCE.
COATING PREPARATION - SHEET METAL
REPAIRED SHEETMETAL
1. Scuff sand (No. 180 Grit Paper) the glossy surface of the painted areas to be coated.
2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover.
3. Remove sanding dust using compressed air and lint-free tack cloth.
NEW SHEET METAL
1. Sand off (No. 180 Grit Paper) the prime paint in the area to be coated.
2. Using a lint-free cloth, solvent wipe the area to be coated with wax and grease remover.
3. Remove sanding dust using compressed air and a lint-free tack cloth.
NEW INSTALLATION
1. The glossy surface of the paint in the coating area must be sanded with a D/A sander. A 220/240
Grit Disc does a good, fast job. DO NOT sand through the primer.
2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover.
3. Remove sanding dust using compressed air and a lint-free tack cloth.
SPRAY PROCEDURE
The lower exposed painted fender, rocker, and quarter panel down flanges should be protected.
The vehicle must be elevated high enough so that the painter can spray this area effectively. When
an initial installation is to be made, a remote two-quart capacity pressure cup makes a much more
efficient tool, as the spray gun can be used closer to the floor. The spray gun, fluid hose and/or cup
must be cleaned immediately after use. Refer to manufacturer's recommended cleaning procedure.
Lacquer thinner can be used when the suggested clean up material is unavailable.
WARNING: WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR
AND USE ALL OTHER RECOMMENDED SAFETY EOUIPMENT.
1. After preparing the new or damaged area(s), mix either Epoxy primer or Self-etch prime, per
manufacturer's label instructions, and spray bare metal areas.
^ BASF DE15 or DE17
^ Sikkens Metalflex CR Primer (1 coat only)
^ DuPont Variprime
^ S-W E2G 980 GBP Etching Filler
^ PPG DP 40 (only)
2. Apply 1-2 light prime coats over the bare metal areas.
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3. Allow the material to dry for 15-20 minutes before applying the anti-stone abrasion material.
4. Mix and apply anti-stone abrasion material per manufacturer's label instructions over the primed
area.
NOTE: AN ORANGE PEELED FINISH IS NORMAL WITH THESE PRODUCTS.
^ BASF Glassohyd 1109-1240/6
^ Sikkens 0TO Bodycoat
^ DuPont 123-5 Vinyl
^ S-W G/W 295 Vinyl Gravel Guard
^ PPG DX 54 Roadguard
^ 3M Rocker Schutz
NOTE: SOME ANTI-STONE ABRASION MATERIAL MAY REQUIRE A SLIGHTLY DIFFERENT
MIXING PREPARATION, PROCEDURE
AND APPLICATION. SOME ANTI-STONE ABRASION MATERIALS CAN NOT BE USED FOR
SPOT REPAIR. CHECK WITH THE PAINT MANUFACTURER FOR RECOMMENDATIONS
ABOUT THEIR PRODUCT.
5. Allow the stone abrasion material to dry. Heat can be used to accelerate the drying time. Check
the manufacturer's instructions.
COLOR COAT
The complete coated area, as well as the upper raw edge, must be covered with color coat. Mask
off the upper margin line using "Fine Line" tape positioned 1/16 inch above the coating edge. Using
appropriate service paint and application procedures, the protective coating area can now be finish
painted with monocoat or a basecoat/clearcoat urethane system.
NOTE: IF DAMAGED SHEET METAL EXTENDS ABOVE THE PROTECTIVE COATING AREA,
NORMAL PRIME/COLOR PAINT PROCEDURES SHOULD BE FOLLOWED.
CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL
TECHNIQUES FOR ANY VOLATILE ORGANIC
COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS.
Figure 4
Refer to the Lower Body Stone Protection Chart, Figure 4, for the material and labor hours
involved.
(D) Procedure For PVC Body Side Moldings
If replacement of the body side molding is necessary, some dealer service kits will be supplied
"paint to match."
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The painting procedures in the following instructions (also included with the part) address materials
from five (5) major aftermarket paint suppliers. Use the paint system materials you are the most
familiar with.
NOTE: CAREFULLY READ ALL LABEL WARNINGS BEFORE APPLYING THESE PRODUCTS.
WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE
RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT.
SIKKENS PRODUCTS
PREPARATION
1. Degrease with M600 wax and grease remover.
2. Scuff with # 320 dry paper or Scotchbrite 7447 (red).
3. Repeat degreasing step.
4. Spray two medium coats of Plastoflex primer. Allow 5 to 10 minutes flash between coats.
5. Allow 20 minutes flash-off at 70~ F before topcoating.
TOPCOATING
1. Mix Autocryl color with Elast-O-Actif 50:50 by volume.
2. Mix this material with 1.2.3 hardner and 1.2.3 reducer (use correct reducer for temperature)
100:50:30 by volume.
3. Apply three medium coats, allowing enough flash off to dry to a light touch.
4. Dry one hour at 140~F after 10 minutes flash off or dry 24 hours at 75~F.
PPG PRODUCTS
PPG MONO-COAT SYSTEMS
1. Solvent wipe with DX330 Acryli-clean.
2. Scuff with red Scotchbrite pad.
3. Repeat solvent wipe.
TOPCOATING
1. Mix and apply Deltron topcoat color with DX-369 Flexative per label instructions.
2. Use 40-50 PSI at the gun.
PPG BASECOAT/CLEARCOAT SYSTEMS
PREPARATION
1. Solvent wipe with SX330 Acryli-clean.
2. Scuff with red Scotchbrite pad.
3. Repeat solvent wipe.
TOPCOATING
1. Mix and apply Deltron basecoat color (DBU), with the recommended reducer for the
temperature, per label instructions.
2. Mix and apply clearcoat material DBU-88 or DCU-2001, with DX-369 Flexative, per label
instructions.
SHERWIN-WILLIAMS PRODUCTS
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Ultrabase 7 Basecoat/Clearcoat or Ultra One Stage Acrylic Urethane Enamel
PREPARATION
1. Wash the material with a mild detergent and wipe dry.
2. Solvent wash with R7 K 156 and wipe dry.
3. Clean with a tack cloth.
4. Apply desired system with correct amount of Multi-flex, V6 V 299.
TOPCOATING
Prepare topcoating as follows:
^ S-W Ultra One Stage: (Mono-coat) 4 Parts Color 3 Parts SSR 650 Reducer 1 Part V6 V 440 or
SSH 520 2 Parts V6 V 299
^ S-W UB7 Basecoat: 8 Parts Basecoat Color 8 Parts Stabilizer 1 Part V6 V 299
^ S-W UB7 Clearcoat: 4 Parts T1 C 650 Clearcoat 2 Parts T1 C 650 Reducer 1 Part CCH 690 1
Part V6 V 299
^ S-W Ultra One Stage: (Mono-coat) Apply 2-3 medium wet coats at 50 PSI
^ UB7 Basecoat: Apply 2-3 medium coats at 45 PSI
^ UB7 Clearcoat: Apply 2-3 medium coats at 50 PSI
DUPONT PRODUCTS
DUPONT CRONAR POLYOXITHANE MONOCOAT SYSTEM
PREPARATION
1. Wash the surface thoroughly with a mild detergent.
2. Clean with Prep Sol.
TOPCOATING
1. Add 8 parts of Cronar single stage enamel.
2. Add 1 part Cronar initiator 9404S.
3. Add two parts of (9475S, 9485S, or 9495S,) depending on shop temperature.
4. Add 2 parts flex-additive 9250S.
5. Mix thoroughly.
6. Spray at 45-55 PSI at the gun, 2-3 medium wet coats or until hiding.
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7. If a clear coat is applied, use 9500S.
DUPONT CENTARI MONO-COAT ENAMEL SYSTEMS
PREPARATION
1. Wash the surface thoroughly with a mild detergent.
2. Clean with Prep Sol.
TOPCOATING (Follow Manufacturer's Recommendation)
1. Add 8 parts of Centari enamel color and 1 part 793S hardener.
2. Add 4 parts of (8022S, 8093S, or 8096S) reducer, depending on shop temperature.
3. Add 355S flex additive per label instructions.
4. Mix thoroughly.
5. Spray 2-3 wet coats, with 5 minutes flash time, at 50-65 PSI.
BASF PRODUCTS
The following procedure is applicable to 4 paint systems in the BASF paint line. Read individual
"system" instructions carefully.
PREPARATION
1. Solvent wipe the molding with RM Pre-klean-o 900.
2. Sand with 400 grit sand paper and rinse with 901 pre-paint cleaner.
TOPCOATING BASECOAT
^ "Glasurit" 54-line color 2 vol. parts
^ 54-line reducer 1 vol. part
^ "Diamont" basecoat color 2 vol. parts
^ B R Diamont reducer 2 vol. parts
^ "Miracryl" basecoat color 2 vol. parts
^ BCR reducer 2 vol. parts
^ "Supreme Gold" basecoat color 2 vol. parts
^ LBR reducer 2 vol. parts
Apply basecoat color until hiding is achieved. Allow 3-5 minutes flash time between coats.
NOTE: USE APPROPRIATE REDUCER FOR SHOP CONDITIONS. ALLOW 15 MINUTES
FLASH-OFF BEFORE SPRAYING CLEARCOAT.
TOPCOATING
Apply clearcoat per manufacturer's label instructions:
CLEARCOAT REDUCTIONS
^ DC-88 Diamont Clear 4 Vol. Parts
^ DH-44 Diamont Hardener 1 Vol. Part
^ MC-1000 Clear 4 Vol. Parts
^ 894 Hardener 1 Vol. Part
^ LC-1300 Supreme Gold Clear 4 Vol. Parts
^ LH-1301 Hardener 1 Vol. Part
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^ 92354 Glasurit Clear 100 Parts
^ 521-111 Elastifier 20 Parts
^ 929-29 Hardener 60 Parts
Apply 2 wet coats with 5 to 10 minutes flash time between coats. Overnight dry or force dry at
140~F for 30 minutes.
CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL
TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS
MATERIALS.
(E) Lower Body-Side Stone Chip Protection Program
Ford Motor Company has recently initiated a program to provide improved stone-chip protection on
some vehicles and to increase the corrosion protection on cars and trucks.
Some customers are unaware of body side anti-stone chip protection which appears as wavy
orange peel texture on the lower body areas.
Ford is increasing the use of PVC (poly vinyl chloride) material which is applied in a thicker coating
on the lower body-side. This material has been in use on vehicles destined for the Canadian
market for many years.
This PVC material is now applied at the following plants on ALL vehicles.
^ Edison - Ranger
^ Hermosillo - Escort/Tracer
^ Louisville - Ranger and Explorer
^ Ohio Truck - Econoline
^ Wayne - Escort/Tracer
This process is also planned for Kansas City, Oakville, Twin Cities and Wixom.
This material can be identified by the "orange peel" appearance and a visible "break-line" between
protected and unprotected areas in the lower body areas.
CAUTION: THIS PROTECTION MUST NOT BE REMOVED IF VEHICLE IS EXPECTED TO
MAINTAIN THE CORROSION PROTECTION.
Some customers have expressed concerns due to the appearance of the treated areas. These
customers did not know about the extra protection this material provides their vehicle. Once
explained, customers were pleased with the added protection and accepted the orange peel finish.
NOTE: DEALERS SHOULD ADVISE THEIR SALES PEOPLE, SERVICE PEOPLE, AND
CUSTOMERS, OF THE REASONS AND BENEFITS
OF THIS PROTECTION. CANADIAN DEALERS STRESS THIS AS A SELLING POINT WITH
THEIR SALES PEOPLE. IT IS CONSIDERED A COMPETITIVE ADVANTAGE.
(F) Surface Defect Removal Without Repainting
Exterior paint surface damage or imperfections, where the primer coat does not show through,
should be restored without repainting. The restoration of gloss and luster, after the condition has
been repaired, is possible with new techniques and improved materials.
The following procedure is applicable to surface conditions such as dirt particles, orange peel, runs,
sags, industrial fallout stains, swirl marks, light scratches and other minor surface imperfections.
For dirt particles or scratches in several localized areas, the entire panel should be refinished to
maintain a uniform appearance.
PREPARATION
To repair the affected surface it must be clean and dry. Mask off adjacent panels, mouldings, stripe
and character lines as required.
CAUTION: EYE PROTECTION, AND FACE MASK SHOULD BE WORN. RINGS, BRACELETS,
WATCHES AND BELT BUCKLES MUST BE
REMOVED TO PREVENT ACCIDENTAL DAMAGE TO PAINT FINISH.
SERVICE PROCEDURE
1. Remove sanding marks with rubbing compound.
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2. Swirl marks, evident after buffing, are removed by polishing.
3. Remove light scratches and small dirt particles with a power buffer and medium buffing
compound followed with polishing.
4. Remove deeper scratches and heavy dirt particles or orange peel, by wet sanding.
5. Buff with compound to remove the sanding marks and then polish to remove the swirl marks
from the buffing operation.
NOTE: PERFORM A TRIAL REPAIR WITH A SMALL AREA. FIRST, TRY POLISHING; IF THIS IS
NOT SUCCESSFUL, TRY BUFFING
AND, FINALLY, USE WET SANDING TO REMOVE THE CONDITION. USE MOST EFFECTIVE
TECHNIQUE ON REMAINDER OF AREAS. AN OUTLINE OF THE COMPLETE PROCEDURE
AND REQUIRED MATERIALS FOLLOWS.
POLISHING - VERY MINOR SCRATCHES OR SWIRL MARKS AND/OR RESTORING A DULL
FINISH
1. Apply a small amount of Meguiar's Mirror Glaze, or equivalent, to the affected panel (or pad).
2. Use a suitable electric or air powered polish/buffing wheel (1750 max. RPM) and a Meguiar's
Finesse Polishing Pad, or equivalent, to polish the affected area until all swirl marks are gone and
desired luster is obtained.
3. When polishing, keep the pad flat against the surface. Do not bear down. The weight of the
buffer is sufficient.
CAUTION: DO NOT MIX PRODUCTS! USE A SEPARATE, DEDICATED BUFFING PAD FOR
EACH PRODUCT TO ACHIEVE DESIRED
RESULTS.
Variable speed buffers are available in a variety of buffing speeds. The recommended speed range
is 1200-1750 RPM.
COMPOUNDING - LIGHT SCRATCHES, SMALL DIRT PARTICLES, MINOR GRIND MARKS,
AND SANDING MARKS
1. Apply Meguiar's Rubbing Compound (medium) or equivalent to the panel with a clean compound
pad on the wheel.
2. Spread the compound evenly and continue buffing until the condition is removed.
3. Keep the wheel flat to the surface and use light to moderate pressure and long strokes.
4. Periodically check the finish and add compound as required.
5. When buffing is complete, polish the panel as described previously.
Twisted wool cutting pads are the most effective compounding pads to use with Glaze Machine
Cleaner for removing paint defects and heavy oxidation. Following the use of a wool compounding
pad, it may be necessary to polish the finish with No. 2 Mirror Glaze Hi-Tech Cleaner using a Mirror
Glaze Finesse Polishing Pad to remove the deep swirl marks.
GENERAL TECHNIQUES AND HINTS
^ "Foam" buffing pads create added gloss and depth of color on all types of paint finishes without
creating buffer swirl marks.
^ When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount
of material, slower buffing motion and added downward pressure to increase cutting action.
^ Always apply cleaner to buffing pad, not directly on the oxidized paint surface. Dry paint absorbs
material into pores upon contact.
^ Always keep the face of the buffing pad completely flat to the surface, reducing the risk of buffer
swirl marks. Watch your pad, especially on angled surfaces, to be certain that it stays flat.
^ Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions
and overlap by 50% the buffing pattern left by the previous pass. This insures uniform coverage
and allows both material and buffer to perform at maximum efficiency.
^ Avoid buffing directly on raised character lines. The reduced paint film on these surfaces
increases the risk of paint burn through. It is best to buff up to them from each side.
^ Always use a "wet buff" technique on a basecoat/clearcoat finish. This is a precaution against
buffer swirls. Stop buffing just after the product begins to break down and before an overall dry,
glossy finish appears. After "wet buffing", use a towel to wipe off the excess material.
^ Always use a "dry buff" technique on light colored, conventional paint finishes. Continue buffing
until the material breaks down and only a slight film remains for final wipe off.
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^ If a paint blemish remains after buffing, reapply a small amount of material over the blemish.
Confine your buffing strokes to the immediate area of the blemish while applying additional
downward pressure and keeping the pad flat.
NOTE: ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH
TO PREVENT EXCESSIVE HEAT
BUILD-UP AND POSSIBLE BURN THROUGH. STOP IMMEDIATELY IF THE SURFACE
BECOMES TOO HOT TO LAY THE PALM OF YOUR HAND ON IT.
NOTE: HEAT BUILD-UP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY
APPEAR ACROSS THE SURFACE BEING
BUFFED AND THE PRODUCT MAY DRY LIKE A FILM AND REFUSE TO BUFF OUT. TO
REMEDY, WIPE THE AREA DOWN WITH COOL WATER, DRY THE SURFACE AND RESUME
BUFFING ... AT A LOWER RPM IF POSSIBLE.
NOTE: STATIC: STATIC ELECTRICITY MAY BE PRESENT ON PAINTED
FIBERGLASS/PLASTIC SURFACE BEING BUFFED, THE
MATERIAL MAY DRY LIKE A FILM OR TURN "GUMMY" AND BEGIN TO BALL UP. TO
REMEDY, GROUND THE SURFACE BEING BUFFED TO METAL.
WET SANDING
Paint defects and sanding marks must be completely removed without using compounds and
abrasive cleaners that scar the finish.
Mirror Glaze Hi-Tech Finesse Sanding Papers provide uniformity in grit particle size and
distribution. Using these precision made sanding papers, water sanding marks can be removed
with Meguiar's cleaner and finesse polishing pads.
^ Typical paint defects that are repaired with this system include: dirt-in paint, solvent pop,
cratering, orange peel, drips, scratches, water spots, and acid rain.
^ Always use the least abrasive (highest grit) sanding products possible to do this job.
The following wet sanding procedure utilizes light grit sand paper or sanding blocks for removal of
surface damage. These materials cut quickly leaving a uniform finish requiring a minimum of
buffing to restore gloss.
PROCEDURE
1. Squeeze water to flush the area to be sanded. Continue to flush water to the surface during
sanding for maximum lubrication.
2. Use small circular motions to contain the abrasion to the immediate area of the defect. Keep the
blocks in water when not in use.
3. If the sanding block is cutting too slow, switch to a lower grade block and resume sanding. When
90% of the defect is removed, switch to a 2000 grade Finesse Sanding Paper or Sanding Block to
finish smoothing and prepare the surface for buffing.
4. Finesse Sanding Blocks can be shaped to work on any angle. When the block is wet, rub it
against a dry sanding block for shaping.
5. When using Finesse Sanding Papers, wrap the paper tightly around a E-7200 Backing Pad. This
pad evenly distributes pressure over the entire surface of the sanding paper. This creates a uniform
sanding pattern.
6. Plan your strokes to limit the abrasion to the smallest area possible.
NOTE: ALWAYS SAND IN ONE DIRECTION AND KEEP YOUR STROKES STRAIGHT.
7. Always finish sanding with 2000 Grit Finesse Sanding Paper. This eliminates the need for
compounding.
8. Buff out sanding marks by applying Meguiar's Cleaner with a Finesse "Foam" Polishing Pad.
Follow with a Mirror Glaze Polish for swirl-free gloss.
WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL
TECHNIQUES FOR ANY VOLATILE ORGANIC
COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS
RUNS AND SAGS REMOVAL
This procedure consists of shaving the run or sag flush with a commercial single edge razor blade,
shaving file or sanding with a hard block and then compounding.
NOTE: IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST
DULL THE CORNERS WITH SANDPAPER TO AVOID SCRATCHING THE ADJACENT PANEL
FINISH.
MEGUIAR'S PRODUCTS
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Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures >
Page 6460
PART
NUMBER GRADE PART NAME
S-1005 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Half Sheets
S-1205 1200
S-1505 1600
S-2005 2000
S-1000 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Full Sheets
8-1200 1200
8-1500 1500
S-2000 2000
E-7200 - Mirror Glaze Hi-Tech Finesse Backing Pad
E-2000 - Mirror Glaze Hi-Tech Tach Sponge
K-400 400 Mirror Glaze Hi-Tech Finesse Sanding Blocks
K-1000 1000
K-1500 1500
K-2000 2000
K-3000 3000
Other Applicable Articles: 82-3-3
(G) Color Compatible Spray Primer Chart
Ford has released color compatible spray primers for exterior and some interior surfaces.
Colored sprayed primers are being used by our "Best-in-Class" competition and are now being
implemented at Ford in order to improve process capability and to help in minimizing unsightly
paint chipping from stone abrasion. Color keyed (matched) spray primer for exterior body colors is
being used in an effort to help in the elimination of unsightly paint chipping from stone abrasion.
As with "Best-In-Class" competition, the engine compartment will be left with color compatible
primer only and not be topcoated as per past practice.
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Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures >
Page 6461
Figure 5
When any paint repair is required, remember that the vehicle may have a colored primer. Refer to
the Spray Primer Chart, Figure 5. This information may be of help in correction of exterior paint
color match concerns.
(H) Paint Repair For Tinted Clear Coat
Ford introduced (Early Spring, 1991) a new paint color using a tinted clearcoat. The first color to
use this new system is Rio Red.
If a paint repair is necessary, refer to the following procedure for repair instructions.
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Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures >
Page 6462
BACKGROUND
The Probe production paint system for Rio Red includes a Medium Green E-Coat primer, a Light
Gray spray primer, bright Rio Red (E4) basecoat and a slightly Red tinted clearcoat topcoat.
NOTE: BEFORE ANY REPAIRS ARE BEGUN, IT IS CRITICAL THAT PRIMER, RED BASECOAT
AND TINTED CLEARCOAT BE SPRAYED ON A TEST PANEL. THE COLOR MATCH IN EACH
STEP IS VERY IMPORTANT FOR A SUCCESSFUL REPAIR.
WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE
RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT.
SMALL SPOT REPAIR PROCEDURE
1 Wash the vehicle with detergent soap and
water.
2 Wipe the vehicle down with wax and grease
remover.
3. Sand the spot using 400 grit paper. Do not sand through the E-coat.
4. Wipe the sanded surface again with wax and grease remover/pre-cleaner.
^ BASF Product # 90 Pre-Kleano
^ PPG Product # DX 330
^ S-W Product # R7-K156
^ DuPont Product # 3919 S
^ Sikkens Product # M 600
5. Mix and apply tintable (Light Gray) self-etching or epoxy primer per manufacturer's label
instructions.
NOTE: COLOR MATCH OF PRIME COAT IS KEY IN COLOR MATCH OF REPAIRED AREA.
^ BASF Product # DE 17
^ PPG Product # DP 40
^ S-W Product # E2-G973
^ DuPont Product # 615S
^ Sikkens Product # 1016
6. Mix and apply bright Rio Red base coat material per manufacturer's label instructions.
NOTE: COLOR MATCH OF BASE CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED
AREA.
7. Mix and apply red tinted clearcoat material per manufacturer's label instructions.
NOTE: COLOR MATCH OF TINTED CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED
AREA.
FULL PANEL REPAIR PROCEDURE
1. Wash the vehicle with detergent soap and water.
2. Wipe the vehicle down with wax and grease remover.
3. Sand the complete panel and feather edge into the next panel using 400 grit paper. Do not sand
through the E-Coat primer.
4. Wipe the sanded surface with wax and grease remover.
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Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures >
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5. Mix and apply tintable (light gray) primer per manufacturer's label instructions.
6. Mix and apply Rio Red basecoat per manufacturer's label instructions.
7. Mix and apply Red tinted clearcoat per manufacturer's label instructions.
8. Mix and apply one coat of non-tinted clearcoat per manufacturer's label instructions.
NOTE: COLOR MATCH OF EACH COAT ARE KEY TO COLOR MATCH OF FINISH REPAIR.
WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL
TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C's) OR EXCESS
MATERIALS.
(I) Paintable Plastics
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Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures >
Page 6464
Figure 6
The Paintable Plastics Chart, Figure 6, is a summary of widely used plastics in our industry. The
standard symbol should be located on the part for ease of material identification.
If painting or repair of these plastics is necessary, the following chart identifies those materials
which can be painted. Refer to paint manufacturer for specific paint material recommendations.
NOTE: MATERIALS MAY REQUIRE PRIME COAT SEE "YES", UNDER "CAN BE PAINTED"
COLUMN.
(J) 1992 Paint Color Codes
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Bulletins > Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures >
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Figure 7
The 1992 Paint Color Codes are listed in Figure 7.
NOTE: REFER TO THE SERVICE LABOR TIME STANDARDS MANUAL AND THE SPECIFIC
PROCEDURE WITHIN THIS BULLETIN FOR REIMBURSEMENT.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OASIS CODES:
106000
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure
Technical Service Bulletin # 90153 Date: 900719
Lower Body Stone Protection - Repair Procedure
PAINT - LOWER BODY STONE PROTECTION REPAIR TIPS Article No. 90-15-3 FORD:
1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS
1988-90 FESTIVA, PROBE
LINCOLN-MERCURY: 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII,
TOPAZ,
TOWN CAR 1986-90 SABLE
1987-90 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER
1988-90 F SUPER DUTY
ISSUE: A service repair procedure has been developed to restore damaged factory-applied lower
body stone protection vinyl material.
ACTION: If service is required, use the following procedure to restore damaged lower body stone
protected areas.
This abrasion resistant coating material (D9AZ-19515-A) is primarily for repair of factory-applied
protective coatings. However, this material may also be installed on previously unprotected
vehicles.
If the vehicle has body damage in the area of the factory-applied coating, body damage must be
repaired before repairing the protective coating.
WARNING: WHENEVER USING PAINT, SOLVENT, REFINISHING OR RECONDITIONING
MATERIALS, WEAR A NOSE OR FACE MASK, PLUS HAVE ADEQUATE VENTILATION IN THE
WORK AREA.
Large Repair Areas
A large repair area, resulting from peeling or damage, will require removal of the factory-applied
vinyl coating.
NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR OR
QUARTER PANEL REPLACEMENT IS REQUIRED, (OR IN AN INITIAL INSTALLATION), SKIP
STEPS # 1 - 3.
1. Use a heat gun or lamp to soften the vinyl coating until it is pliable.
2. Scrape off the softened vinyl with a putty knife or similar tool. If necessary, sand off any
hard-to-remove vinyl coating using an orbital disc sander (# 80 Disc).
NOTE: THE REPAIR MATERIAL, ABRASION RESISTANT COATING (D9AZ-19515-A), IS NOT
SUITABLE FOR "SPOT" REPAIRS. THE
OLD COATING MUST BE REMOVED COMPLETELY FROM EACH DAMAGED PANEL.
3. Make the necessary repairs to the sheet metal.
Coating Preparation and Applications:
The abrasion resistant coating is available in quart cans. About two quarts will be required for an
initial installation on a passenger car similar to a factory-applied system. Slightly more will be
required for a larger vehicle such as an Econoline.
The specified dry film thickness of 15 to 20 mils (.015 to .020") will require at least three or possibly
four applications of coating material, with flash off time allowed between coats. As with painting,
spray coat the complete lower panel.
The adherence of this coating to properly prepared sheet metal is excellent and it is not necessary
to prime the repaired sheet metal. However, adhesion will be adversely affected unless the sheet
metal (either repaired or new) is prepared in accordance with the following procedure.
Coating Preparation - Masking Car
1. Install covers over the wheels.
2. Determine the area to be coated.
^ If the vehicle has lower body side mouldings (12-14" above the "turn under" of the rocker Panel),
the moulding can serve as the upper margin of the area to be coated.
^ If the vehicle does not have suitable mouldings, a sculpture or break line in the sheet metal can
be used.
^ The method used in masking off the upper coating margin line will depend on the presence or
absence of mouldings in this area.
VEHICLES WITH SIDE MOULDINGS
3. Position the masking tape so that the moulding lower side is covered down to, but not on the
sheet metal.
VEHICLES WITHOUT SIDE MOULDINGS
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Page 6470
4. If the contour of the body side has a break line, or if an arbitrary line is chosen, mask off the
upper coating margin using Scotch "Fine Line" tape. This is available nationally from 3M Company
Distributors.
a. Apply the normal masking tape and paper protection for the vehicle body side first. Position them
about a 1/4" above the margin line.
b. Apply the "Fine Line" tape over the regular masking tape with the lower edge at the upper
coating margin line.
c. Extend this "Fine Line" tape into the wheel opening, in absence of wheel opening mouldings, to
allow the flange to be coated.
d. Since the protective coating does not adhere well to flexible plastic stone shields, mask off the
front of the plastic rear stone shield, if exposed.
NOTE: IT IS NOT NECESSARY TO MASK OFF THE BODY DOOR OPENINGS IN THE
COATING AREA BECAUSE THEY WILL BE
UNIFORMLY COATED WHERE THE DOOR MARGINS ALLOW THE COATING TO ENTER.
HOWEVER, THESE DOOR OPENING AREAS SHOULD BE CLEANED TO ASSURE COATING
ADHERENCE.
Coating Preparation - Sheet Metal
REPAIRED SHEET METAL
1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover
and allow to flash off.
2. Scuff sand (# 180 Grit Paper) the glossy surface of the painted areas to be coated.
3. Remove sanding dust using a lint-free tack cloth and compressed air.
NEW SHEET METAL
1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover
and allow to flash off.
2. Scuff sand (# 180 Grit Paper) the prime paint in the area to be coated.
3. Remove sanding dust using a lint-free tack cloth and compressed air.
INITIAL INSTALLATION
1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover.
2. Sand the glossy surface of the paint in the coating area. (A D/A sander, 220/240 Grit Disc does a
good fast job.)
CAUTION: DO NOT SAND THROUGH THE COLOR COAT INTO THE PRIMER.
3. Remove sanding dust using a lint-free tack cloth and compressed air.
Coating Application
Coating applications must be applied with care.
^ The coating must be applied with commercial equipment by an experienced automotive painter.
^ The coating must be thoroughly agitated and used without thinning.
^ Since the material is reasonably heavy-bodied, a pressure cup equipped spray gun is
recommended.
^ Satisfactory coating appearance (orange peel) will result with gun pressure of approximately 30
P.S.I. and cup pressures of approximately 15 P.S.I.
Spray Procedure
Since the lower exposed painted fender, rocker and quarter panel down flanges are to be coated,
the vehicle should be elevated high enough so that the painter can spray this area effectively.
When an initial installation is to be made, a remote, two-quart capacity pressure cup makes a much
more efficient tool because the spray gun can be used closer to the floor.
The spray gun, fluid hose and cup must be cleaned immediately after use. While lacquer thinner
may be used when the suggested clean up material is unavailable, the Ford Vinyl Paint Precleaner
(VC-542-A) is quicker and much more efficient.
With the spray gun at 30 P.S.I. and pressure feed cup at 15 P.S.I. proceed as follows:
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1. Apply a wet, sag-free coat. Allow 3 to 5 minutes flash off.
2. Apply a second wet, sag-free coat. Allow 3 to 5 minutes flash off.
3. Apply a third wet, sag-free coat. Allow 3 to 5 minutes flash off.
4. Apply a final wet, sag-free coat. Allow 3 to 5 minutes flash off. Pull off the "Fine Line" tape,
exposing the raw upper edge of the coating.
5. Immediately clean the spray equipment using Ford Vinyl Paint Precleaner (VC-542-A) or
equivalent.
6. Air drying time depends on the refinishing materials that are used.
^ If you refinish with acrylic lacquer, allow one hour for drying (at 70~F).
^ If you refinish with acrylic enamel, allow two hours for drying (at 70~F).
Color Coat
In order to paint the entire coated area as well as the upper raw edge, mask off the upper margin
line using the "Fine Line" tape. Position the tape 1/16" above the coating edge. The protective
coating area can now be finish painted.
NOTE: IF DAMAGED SHEET METAL EXTENDS ABOVE THE PROTECTIVE COATING AREA,
NORMAL PRIME/COLOR PAINT PROCEDURES SHOULD BE FOLLOWED.
Suggested Equipment
^ DeVilbiss - Spray Gun - Model JGA-502-704-FX or equivalent
^ DeVilbiss - Remote Pressure Cup - Model KB-520 (2 Quarts), Model KB-521 (1 Quart) or
equivalent
^ Binks - Spray Gun - Model 62 (# 63 Air Cap, # SS Fluid Tip, # 363 AN Needle)
^ Binks - Attached Pressure Cup - Model 80 (1 Quart, with Air Adjusting Gage) or equivalent.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
1100, 1800
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials
Paint: Technical Service Bulletins Paint - Cosmetic Damage From Airborn Materials
PAINT COSMETIC DAMAGE FROM AIRBORN MATERIALS Article No. 89-13-3 FORD:
1989 and prior ALL FORD LINES
LINCOLN-MERCURY: 1989 and prior ALL LINCOLN-MERCURY LINES
LIGHT TRUCK: 1989 and prior ALL LIGHT TRUCK LINES
ISSUE: Paint may be damaged from various sources of airborn materials. The two different types
are:
^ Inorganic
^ Organic
Sometimes it is hard to identify the type of paint damage and know how to remove it. This TSB
article gives detailed information and descriptions of both types of airborn materials. It also outlines
the service procedures for treating them.
ACTION: If service is required, identify the source of damage involved by referring to the following
information. Use the following recommended service procedure to correct concerns.
INORGANIC AIRBORN MATERIAL
The effects of inorganic airborn materials can be seen as:
^ Dark blotches in the paint where the pigment in the paint surface has been attacked
^ Irregular spots that are cracked or etched around the edges and dull in the centers.
^ Small orange colored spots caused by iron particles may appear on the paint surface.
Generally, materials that attack a paint film are either acidic or alkaline in nature.
Sulfuric and nitric acids, in general, cause extreme damage to automative paint finishes. Even very
small concentrations of the same materials can cause chemical spotting damage. Due to
evaporation and condensation, these acids can create severe etching "spots" that may eventually
crack or lift the paint film after some time in service.
Although some automotive finishes are more resistant than others, none are completely immune to
these chemicals. The most resistant paints used today are the urethanes because their resin
system is least likely to react with chemicals. Air dry coatings are more susceptible to attack only
when they are fresh. The longer the paint dries the more resistant it becomes.
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Bulletins > Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials >
Page 6476
Metallic colors are more intolerant to chemicals because aluminum flake is fairly reactive with either
an acid or alkali. The following chart contains the most common acid materials found on automotive
finishes. The chart shows a color, the corresponding damage appearance and also the chemical
causal agent. It is not applicable for Basecoat/Clearcoat finishes.
* "Caustic" refers to any alkaline substance that may be "harsh" or "corrosive" depending on
strength or concentration.
The following "pH" chart show the relationship between acidic and alkaline chemicals and their
corresponding pH values. This chart is provided for informational reference only. ORGANIC
AIRBORN MATERIALS
Organic damage is generally easier to identify. Organic damage is mostly due to tree sap, bird and
insect droppings, dead insects (Figure 8) and pollen. Tree sap is easily identified by clear raised
drops that may be hard or sticky. Bee or bug dropping spots may appear brownish or yellow in
color, about an eighth to a quarter inch in diameter. Dead and decomposing insect bodies are
readily visible to the eye. Pollen deposits are small yellow clusters. Each of these items is
potentially damaging to any currently available paint system. Other noticeable traits of organic
damage are spots that are raised (swelling) micro-crazing (cracked) and pitting, due to pollen
eating into the paint film. The active ingredients in most organic contaminants are tannic and formic
acids . These acids are found in berries and bodily fluids of insects and birds.
Investigations completed at dealerships show that the bright lot lights tend to attract insects. The
use of "soft lights" for display and storage lot illumination will help reduce damage resulting from
decomposing bugs and droppings by decreasing the number of bugs attracted to these lights.
Organic damage is accelerated by heat. During very hot weather conditions, it is important to wash
vehicles more often.
ORGANIC AND INORGANIC REPAIR PROCEDURES FOR MILD DAMAGE
Iron dust particles may imbed themselves into the paint film. On some light colored vehicles after
some weathering, tiny dots of rust start to appear. They
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Bulletins > Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials >
Page 6477
feel rough to the touch and are difficult to remove. The best way to remove these particles is by
treating the finish with an oxalic acid-detergent-water wash. Use the following procedure to perform
this service repair.
NOTE: OXALIC ACID WASH IS ALSO PRE-PACKAGED IN VARIOUS STRENGTHS UNDER
VARIOUS BRAND NAMES, IF YOU CHOOSE NOT TO MIX YOUR OWN BATCHES.
1. Wash and degrease the vehicle first, using Ford Multi Purpose Cleaner (B8A-19523-B) or
equivalent, and a suitable wax and grease remover. If this does not remove all of the iron particles,
proceed with the oxalic acid wash.
2. Prepare a quantity of oxalic acid-detergent-water solution as follows:
a. Dissolve 6-8 ounces of Oxalic Acid (powder) in one gallon of warm water.
b. Add 1-2 tablespoons full of non-alkaline detergent such as Ford Multi Purpose Cleaner.
3. Apply this solution liberally to all affected surfaces of the vehicle with a large sponge. Keep the
surface wet until the technician can no longer feel any surface roughness with bare or gloved
fingertips.
NOTE: IF THIS IS NOT DONE THOROUGHLY, STAINING MAY REDEVELOP IF IRON
PARTICLES ARE LEFT BEHIND.
4. Rinse the area with clean water.
CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN
CORROSION OF ANODIZED ALUMINUM OR
STAINLESS STEEL PARTS WITH PROLONGED CONTACT.
5. If the iron particles are not totally removed after 2 washings, use one or both of the procedures
listed for minor chemical contamination.
NOTE: THE USE OF POLISHING (WITH WAX), SANDING WITH MICRO FINE SANDPAPER
(1500 GRIT OR GREATER) OR BUFFING WITH VERY LIGHT COMPOUND SHOULD ONLY BE
DONE AS A LAST RESORT.
CHEMICAL CONTAMINATION
Chemical contamination, either acid or alkali, can cause off-color spots and crack the paint film. In
the presence of moisture (dew), sulfur contamination will change the color (light/dark) of the paint
pigments. (This does not apply to Basecoat/Clearcoat)
Since this contamination affects the pigments, lacquers and enamels show no difference in
resistance. Production thermal drying and air drying finishes are likely to be spotted.
Minor chemical contamination can be removed by using the following step by step procedure.
1. Wash the vehicle first by using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent to
remove the exterior foreign materials.
2. If the spotting is extensive and on the horizontal surfaces, then machine polish.
3. Apply a light grit polishing compound to the affected surface by using a soft brush. The
compound should be applied to a small area at a time so that it can be buffed out while still wet to
get maximum cutting efficiency.
4. Polish off the spots using a buffer operating at 1700-1800 rpm. Confine polishing to the spotted
areas. Repeat as necessary until all spots have been removed.
5. Remove spots on curved surfaces, near edges, and next to mouldings or ornaments by hand
polishing as follows:
a. Apply some polishing compound to a cotton cloth. (Do not use a synthetic cloth.)
b. Rub vigorously until the spots are no longer visible.
c. Clean off excess polishing compound by using a clean cloth and compressed air.
6. Buff out the polishing marks and bring up the gloss by using a buffer equipped with a clean, dry
lambs wool pad.
NOTE: IF POLISHING DOES NOT SUFFICIENTLY REMOVE DAMAGE, THE VEHICLE CAN BE
WET SANDED USING 1500 GRIT SANDPAPER AND THE FOLLOWING PROCEDURE
Wet Sanding Procedure
1. Clean the exterior surface of the vehicle with Ford Multi Purpose cleaner or an equivalent to
remove all contamination.
2. Apply 1500 grit sandpaper to a rubber padded sanding block to sand the paint surface.
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Bulletins > Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials >
Page 6478
3. Use a squirt bottle filled with water to lubricate the 1500 grit sandpaper as you begin to sand only
the damaged areas. Water is an abrasive as well as a lubricant in this step.
NOTE: IF THE DAMAGE HAS GONE DEEPLY INTO THE PAINT FILM AND IT WILL NOT
POLISH OR SAND OUT, THEN REFINISHING IS REQUIRED.
ORGANIC MATERIAL REPAIR PROCEDURE FOR MILD DAMAGE
Minor organic damage can be removed by using the following step by step procedure.
1. Wash and degrease the vehicle thoroughly by using Ford Multi Purpose Cleaner (B8A-19523-B)
or equivalent and a wax and grease remover to remove all organics.
2. Inspect the vehicle horizontal surfaces. If spotting or paint film swelling is extensive, use a buffer
to repair.
3. Apply a light grit polishing compound to the affected areas by using a soft brush. The compound
should be applied to a small area at a time so that it can be buffed out while still wet to get
maximum efficiency.
4. Polish off the spots or swelling marks using a buffer that operates between 1700-1800 rpm.
Polishing should be confined to the affected areas only. Repeat as necessary until all spots or
marks are removed.
5. Remove spots on curved surfaces, near edges, and next to mouldings or ornaments by hand
polishing as follows:
a. Apply some polishing compound to a cotton cloth. (Do not use a synthetic cloth.)
b. Rub vigorously until the spots are no longer visible.
c. Clean off excess polishing compound by using a clean cloth and compressed air.
6. Buff out the polishing marks and bring up the gloss by using a buffer equipped with a clean, dry
lambs wool pad.
NOTE: IF POLISHING DOES NOT SUFFICIENTLY REMOVE DAMAGE, THE VEHICLE CAN BE
WET SANDED USING 1500 GRIT SANDPAPER AND THE FOLLOWING PROCEDURE.
Wet Sanding Procedure
1. Clean the exterior surface of the vehicle with Ford Multi Purpose cleaner or an equivalent to
remove all organics.
2. Apply 1500 grit sandpaper to a rubber padded sanding block to sand the paint surface.
3. Use a squirt bottle filled with water to lubricate the 1500 grit sandpaper as you begin to sand only
the damaged areas. Water is an abrasive as well as a lubricant in this step.
NOTE: IF THE DAMAGE HAS GONE DEEPLY INTO THE PAINT FILM AND IT WILL NOT
POLISH OUT, THEN REFINISHING IS REQUIRED.
PAINT RECONDITIONING PROCEDURES FOR SEVERE DAMAGE
Acrylic enamel single stage or base/clear paint systems should be painted by using the following
procedure.
1. .Wash the vehicle with Ford Multi Purpose Cleaner or equivalent to remove all organic materials.
2. Wash the areas to be painted with wax and grease remover.
3. Prepare the area as follows:
a. Neutralize the affected areas with baking soda (sodium bicarbonate) and water.
b. Rinse the surface off with plain water.
c. Wash the panel with a mild soapy detergent.
d. Dry the panel completely.
NOTE: IF THE DAMAGE IS THROUGH THE TOP COAT FINISH AND INTO THE PRIMERS, THE
PANEL MUST BE SANDED DOWN TO BARE METAL OR PLASTIC AND THEN REFINISHED.
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Page 6479
4. Apply a self-etching primer for metal surfaces only.
NOTE: A FLEX ADDITIVE MAY BE NECESSARY WHEN WORKING WITH FLEXIBLE PLASTICS
Then proceed as follows:
a. Let dry per instructions.
b. Apply a two component urethane primer surfacer.
c. Sand the surface with 400 grit sandpaper to get to proper finish.
d. Finish sanding with 600 grit sandpaper.
5. Solvent wash panel with wax and grease remover. Then, tack wipe it.
6. Apply base coat or top coat material per applicable paint system.
NOTE: THE USE OF ACRYLIC URETHANE ENAMEL IS HIGHLY RECOMMENDED FOR THIS
TYPE OF REPAIR.
7. Apply clear acrylic urethane if you are using a base/clear paint system.
WAYS TO MINIMIZE EFFECTS OF AIRBORN MATERIAL DAMAGE
During the past year, Ford Motor Company and major paint suppliers have participated in a survey
to analyze the effects of airborn materials. This survey was conducted on foreign and domestic
vehicles. It resulted in the following interesting conclusions.
1. Keeping the vehicles clean, washing frequently with de-ionized water and drying by hand or
mechanical means will help minimize the effects of inorganic and organic materials.
2. Spray washing without rubbing will not totally remove all residue on the surface of the vehicle.
Damage could possibly occur over a longer period of time.
3. Care should be taken to not allow any painted vehicle surface to become wet in direct sunlight.
(A sprinkler system can cause damage if the vehicles are not dried.) Possible alkaline water or
mineral deposit may be the cause.
4. The use of "Soft Lights" for lighting around storage lots and showing areas will minimize the
attraction of insects and the possibility of organic damage.
5. Ford Motor Company is piloting a program for a transit/storage coating to be applied on the
horizontal surfaces of all vehicles. These coatings have shown good protection to the paint surface.
They are clear in color and should be left on the vehicles until they are sold.
6. We are testing many "permanent paint sealants" used by dealers. Until all testing is completed,
we cannot give any recommendations for what products to use. Testing has shown that a sealant
that allows water to bead up on the vehicle does not help to dissipate the materials on the paint
surface. Sheeting of water on the vehicle is highly desirable.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
1100
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 87243 > Dec > 87 > Vinyl Tape Stripes - Poor Adhesion
Paint: Technical Service Bulletins Vinyl Tape Stripes - Poor Adhesion
Article No. 87-24-3 PAINT - AFTERMARKET VINYL TAPE STRIPES - POOR ADHESION VEHICLES BUILT BEFORE 06/01/87 FORD:
1987-88 ESCORT, EXP, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, CROWN VICTORIA
LINCOLN-MERCURY: 1987 LYNX 1987-88 TOPAZ, SABLE, COUGAR, GRAND MARQUIS,
MARK VII, CONTINENTAL, LINCOLN TOWN CAR
LIGHT TRUCK: 1987-88 AEROSTAR, RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO
ISSUE: Poor adhesion of aftermarket vinyl tape stripes may be caused by the paint on the vehicle
reacting with the type of adhesive used on the vinyl tape stripe. ACTION:
To prevent vinyl tape stripe adhesion concerns, Ford recommends the use of a vinyl tape stripe
with a more aggressive adhesive applied to the backside of the stripe. The improved vinyl tape
stripe material can be purchased directly from one of the Original Equipment Manufacturers (OEM)
listed on page 02 of this TSB.
Kaye Screen Printing Company Attn:
Bill Farnen 1614 Clay Street Detroit, Michigan 48211 (313) 872-4048
3M - 3M Center Automotive Systems Division Building 223-1S St. Paul, Minnesota 55144 (612)
733-8632 Avery Graphic Systems 1875 Research Drive Suite 200 Troy, Michigan 48083 (313)
689-1600
Trim Line, Inc. Attn:
Virginia Cornell 3810 Rosin Court Sacramento, California 95834-0400 (800) 824-5182 Outside
Calif. (800) 852-7733 Inside Calif.
OTHER APPLICABLE ARTICLES: 87-18-4 WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > 87151 > Jul > 87 > Paint - Difficulty Matching Production Colors
Paint: Technical Service Bulletins Paint - Difficulty Matching Production Colors
PAINT - DIFFICULTY MATCHING AFTERMARKET Article No.
COLORS WITH FORD PRODUCTION COLORS 87-15-1
FORD: 1986-88 ALL CAR LINES
LINCOLN-MERCURY: 1986-88 ALL CAR LINES
MERKUR: 1986-88 XR4Ti 1988 SCORPIO
LIGHT TRUCK: 1986-88 ALL LIGHT TRUCK LINES
ISSUE: Paint audits and field reports have indicated concerns in matching aftermarket paint colors
to the Ford production paint colors. This matching concern seems to be greater when comparing
the metallic paints.
ACTION: To correct this, DuPont and PPG Aftermarket Divisions will supply color variance decks
by August 1, 1987 to DuPont and PPG Distributors and District Offices for distribution to
dealerships. Updated color variance decks will be sent during October, 1987 and will then continue
to be sent on a regular basis.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY"
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6488
Technical Service Bulletin # 91181 Date: 910905
Exterior Paint - Comprehensive Repair Procedures
Article No. 91-18-1 09/05/91
PAINT-EXTERIOR-COMPREHENSIVE REPAIR PROCEDURES
FORD: 1985-86 LTD 1985-92 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO,
THUNDERBIRD 1986-92 TAURUS 1988-92 FESTIVA 1989-92 PROBE
LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-92 CONTINENTAL,
COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-92 SABLE 1988-92
TRACER
MERKUR: 1985-89 XR4TI 1988-89 SCORPIO
LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150-350 SERIES,
RANGER 1986-92 AEROSTAR 1991 EXPLORER
ISSUE: A comprehensive paint repair procedure TSB has been developed for service use. It
includes the following paint repair topics:
Section (A) has been superseded by TSB # 9264, dated 3/92.
(B) Exterior Color Peeling From Ultra Violet Light
(C) Lower Body Stone Protection Repair Tips
(D) Procedures For PVC Body Side Moldings
(E) Lower Body-Side Stone Chip Protection Program
(F) Surface Defect Removal Without Repainting
(G) 1991 Color Matched/Compatible Spray Primer Chart
(H) Repair For Tinted Clearcoat
(I) Frequently Used And Paintable Plastics
(J) 1992 Paint Codes
ACTION: If paint repair is required, refer to the following procedures for paint restoration.
Section A Has Been Superseded By TSB # 9264, Dated 3/92.
CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN
CORROSION OF ANODIZED ALUMINUM OR
STAINLESS STEEL PARTS
PROCEDURE # 2
FINISH KARE FORMULA # 1119 AND # 883 (Buffered solution not as harsh on aluminum parts)
WARNING: FOR YOUR SAFETY, USE RUBBER GLOVES, GOGGLES AND PROTECTIVE
CLOTHING WHEN HANDLING THESE PRODUCTS.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6489
1. Apply hot diluted solution with soft mitt.
2. Agitate to create suds. Suds hold the acid solution in suspension and to the surface creating
greater and extended activity.
3. Allow 3 to 5 minutes dwell time.
4. Rinse with COLD WATER.
5. Apply # 883 per label instructions.
LIQUID NEUTRALIZER CONCENTRATE
1. Using a mitt, thoroughly go over the entire surface with the diluted solution (50-1) of water and #
118 Liquid Neutralizer Concentrate. Then wipe dry.
2. If the iron particles are not totally removed after 2 washings, use one or both of the following
service actions.
a. Sand with micro fine sandpaper (1500 Grid or greater) in localized areas.
b. Buff with very light compound and polish with wax in localized areas.
WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL
TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'S) OR EXCESS
MATERIALS.
(B) Paint Exterior Color Peeling From Ultra Violet Light
Paint may be damaged because of ultra violet light absorption through the color coat. This damage
will cause the top coat to peel to the E-coat primer.
If service is required, use the following procedure to correct the concerns.
NOTE: READ THE ENTIRE SERVICE PROCEDURE BEFORE STARTING REPAIRS.
WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE
RESPIRATOR AND USE OTHER RECOMMENDED SAFETY EQUIPMENT.
1. Wash the vehicle with soap and water.
2. Verify topcoat adhesion by applying a 2 inch wide masking tape strip on all body panels above
and below the beltline on each panel.
a. Pull the tape up quickly.
b. Inspect the adhesive side of the tape for paint removal.
NOTE: IF PAINT WAS REMOVED DURING THE TAPE TEST, THE ENTIRE PANEL SHOULD BE
STRIPPED AND REFINISHED AS NECESSARY.
3. Remove all trim (mouldings, name plates, striping, etc.) from the areas which will be repainted.
NOTE: ALL REQUIRED REPLACEMENT MOULDINGS AND STRIPES SHOULD BE ORDERED
AND RECEIVED PRIOR TO REPAIRING THE CUSTOMER'S VEHICLE.
4. Wipe the entire vehicle with wax and grease remover.
^ BASF Product # 900 Prekleano
^ PPG Product # DX300
^ S-W Product # R7-K156
^ DuPont Product # 3919 S
^ Sikkens Product # M 600
5. Mask off all areas on the vehicle which are not going to be painted or will be affected by
overspray (engine compartment, wheels, etc.).
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6490
6. Remove the paint to bare metal from all the areas of the vehicle which are going to be repainted.
Use one of the following methods.
SAND THE AFFECTED AREAS TO BARE METAL USING 40 GRIT 3M GREEN CORPS
SANDING DISCS OR EQUIVALENT AND A SOFT PAD ON A 1700 RPM POLISHER. KEEP THE
POLISHER MOVING TO AVOID DEVELOPING HOT SPOTS ON THE METAL.
NOTE: CHEMICAL STRIPPING IS NOT RECOMMENDED.
NOTE: IF AVAILABLE, PAINT MAY BE REMOVED USING A PLASTIC MEDIA BLAST SYSTEM.
IF THIS PROCESS IS USED, EXTRA
CARE MUST BE TAKEN DURING THE MASKING PROCESS TO PREVENT DAMAGE TO
GLASS, MOULDING, ETC.
7. Blow off the entire vehicle to remove loose dust and debris.
NOTE: IF RUST IS PRESENT, USE APPROPRIATE METAL CLEANER AND CONDITIONER
(PHOSPHATE COATING) OVER BARE METAL AREAS.
8. Wipe all affected areas with a fast dry enamel reducer solvent, followed by a dry wipe using a
clean, lint free cloth to remove all residue.
CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL
RESULT IN POPPING OF THE COATINGS TO
BE APPLIED FOLLOWING THIS STEP.
NOTE: THIS STEP WILL REDUCE THE POSSIBILITY OF FLASH RUST.
^ BASF Product # BR 50
^ PPG Product # DX 300
^ S-W Product # R7 K156
^ DuPont Product # 3812 S
^ Sikkens Product # 123 FAST
9. Apply two medium wet coats (1.0 mil total) of self-etching, anti-corrosion primer using the
manufacturer's recommendations and flash times.
^ BASF Product # DE-17
^ PPG Product # DP EPOXY PRIMER
^ S-W Product # E2-6980
^ DuPont Product # VARIPRIME
^ Sikkens Product # WASH FILLER 580
10. Apply three medium wet coats (2.0 mils total) of acrylic urethane primer surfacer following the
manufacturer's recommended procedures.
^ BASF Product # DP-20 PRIMER/SUFACER
^ PPG Product # K-36
^ S-W Product # P6-M49 OR P6-A48
^ DuPont Product # URO PRIMERFILLER
^ Sikkens Product # AUTOCRYL 3+1 FILLER
11. Sand the vehicle using one of the following methods:
^ Wet-sand by hand using 400 grit or finer sandpaper.
^ Dry-sand by hand using 320 grit or finer sandpaper.
12. Blow the entire vehicle off to remove loose dust and debris.
13. Demask (remove all paper and tape) as necessary to remove the primer and dirt buildup on the
paper and tape.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6491
14. Wipe the entire vehicle with wax and grease remover, followed by a dry wipe using a clean, lint
free cloth to remove all residue.
CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL
RESULT IN POPPING OF THE COATINGS TO
BE APPLIED FOLLOWING THIS STEP.
^ BASF Product # 901 PRE-PAINT CLEANER
^ PPG Product # DX 330
^ S-W Product # R7-K156
^ DuPont Product # 3812 S
^ Sikkens Product # M 600
15. Mask all areas on the vehicle which are not to be painted or will be affected by paint overspray
(engine compartment, wheels, etc.).
NOTE: APPLY BASECOAT/CLEAR COAT ONLY TO SURFACES WHICH ORIGINALLY HAD
BASECOAT/CLEAR COAT
16. Apply three medium wet coats (enough material to hide primer) of acrylic enamel base coat or
acrylic urethane monocoat following the manufacturer's recommended procedure.
^ BASF Product # DIAMONT BASECOAT/Solo
^ PPG Product # DELTRON BASECOAT DBC/Deltron
^ S-W Product # ULTRA BASE/Ultra One Stage
^ DuPont Product # CHROMABASE/Cronar
^ Sikkens Product # AUTO BASE/Autocryl
17. Apply two medium wet coats of 2K acrylic urethane enamel clear coat, following manufacturer's
recommended procedure.
^ BASF Product # DIAMONT CLEAR 88/89
^ PPG Product # CONCEPT 2001 DCU
^ S-W Product # CC-650 OR CC-640
^ DuPont Product # 1080 S URO CLEAR
^ Sikkens Product # AUTO CLEAR
18. After the paint is dry, demask the entire vehicle and clean up any areas which have overspray.
19. Polish the vehicle as necessary to remove any defects in the paint which may create a
customer concern.
CAUTION: USE LOW SPEED (1700 RPM MAXIMUM) POLISHER.
20. Install all trim (mouldings, name plates, striping, etc.) on the vehicle which were removed prior
to repainting.
21. Clean the exterior and interior of the vehicle thoroughly, including air ducts and other areas
which are prone to accumulating dust. This step is essential to ensure customer satisfaction.
WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL
TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS
MATERIALS.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6492
Figure 1
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6493
Figure 2
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6494
Figure 3
STRIP AND REFINISH CLAIMING METHODOLOGY
The claiming instructions shown in Figure 1 are applicable to the repair of the EXTERIOR COLOR
PEELING FROM ULTRA VIOLET LIGHT concern covered in this TSB only. See the SAMPLE
CLAIMS, Figures 2 and 3, for examples.
(C) Lower Body Stone Protection Repair Tips
Ford has introduced a vinyl anti-stone abrasion material for the lower exterior body surfaces of
selected passenger vehicles and light trucks. The anti-stone abrasion material is applied to the
lower fenders, rocker panels, lower doors, quarter panel dogleg, and lower rear of quarter panel
behind the wheel. The anti-stone abrasion material will usually end at a body character line.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6495
While primarily for servicing of factory-applied protective coating, the following provides installation
information. If the vehicle has experienced body damage in the factory-applied material protective
area, the sheet metal damage must be serviced prior to the application of the new protective
coating.
SMALL AREAS - MINOR DEFECTS (VEHICLES WITH FACTORY SPRAYED-ON VINYL)
A small dent in the sheet metal that did not mar the vinyl surface, can possibly be corrected with
proper bumping tools without damage to the vinyl coating. However, noticeable scratches or
gouges (not over 1/2 inch in diameter) or dings and dents that when "ironed out" show vinyl
damage, can be satisfactorily serviced with the following procedure:
1. Solvent-wipe the damaged area with "Silicone and Wax Remover."
2. Using a heat gun or lamp, soften the vinyl coating of the damaged area until it can be scraped off
with a putty knife or a similar tool. If necessary, sand off any hard to remove coating using an
orbital disc sander (No. 80 Disc). (The spray-on vinyl protective coatings may not be suitable for
"spot" application. See Manufacturer's label for instructions.)
3. Perform necessary servicing to correct the sheet metal damage.
4. Using white bodyfiller, fill the damaged area. Follow the instructions on the label and blend the
bodyfiller with the surrounding sheet metal.
5. Allow the bodyfiller to completely cure and then carefully sand the area smooth, removing any
high spots.
6. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material.
LARGE DAMAGED AREAS - VEHICLE WITH FACTORY SPRAYED ON VINYL
Peeling or damage over a large area will necessitate removal of the factory sprayed-on vinyl
coating. The following procedure is suggested.
NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR, OR
QUARTER PANEL REPLACEMENT IS
REQUIRED (OR IN AN INITIAL INSTALLATION), DISREGARD STEPS NO. 1 AND NO. 2.
1. Using a heat gun or lamp, soften the vinyl coating until it is pliable. Scrape coating off with a
putty knife or a similar tool. If necessary, sand off any hard to remove coating using an orbital disc
sander (No. 80 Disc). (The vinyl material, abrasion resistant coating may not be suitable for "spot"
applications. See manufacturer's label for instructions.)
2. Perform necessary servicing to correct the sheet metal damage.
3. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material.
COATING APPLICATIONS
Approximately two quarts will be required for an initial installation on a passenger car or F-Series.
Slightly more will be required for an Econoline. The specified dry film thickness of 15 to 20 mils
(.015 to .020 inch) will require at least three, possibly four, applications of coating material, with
"flash off" time between coats. Spray coat complete panels only.
The coating must be applied with commercial equipment by an experienced automotive painter.
The coating must be thoroughly agitated before application. The material is heavy bodied. A
pressure cup spray gun or "Rocker Schutz Gun" is recommended.
COATING PREPARATION - MASKING VEHICLE
Install suitable covers over the wheels.
NOTE: IF THE VEHICLE HAS LOWER BODY SIDE MOULDINGS (12-14 INCHES ABOVE THE
"TURN UNDER" OF THE ROCKER PANEL),
THE MOULDING CAN SERVE AS THE UPPER MARGIN OF THE AREA TO BE COATED. IF
THE VEHICLE DOES NOT HAVE SUITABLE MOULDINGS, A SCULPTURE OR BREAK LINE IN
THE SHEET METAL CAN BE UTILIZED. THIS LINE SHOULD BE SELECTED TO ENSURE
ADEQUATE PROTECTION OF THE PAINTED SURFACES.
VEHICLES WITH BODY SIDE MOULDINGS
1. Masking tape should be positioned so that the moulding lower edge is also covered. The
adjoining sheet metal should be left uncovered too so anti-stone, abrasion vinyl can be applied.
VEHICLES WITHOUT BODY SIDE MOULDINGS
2. If the contour of the body side has a break line, the upper coating margin must be masked off
using 3M "Fine Line" Tape.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6496
a. The normal masking tape and paper protection for the body side should be applied first and
positioned about a quarter inch above the margin line.
b. The "Fine Line" tape should then be applied over the regular masking tape with the lower edge
at the upper coating margin line. Extend this "Fine Line" tape into the wheel opening, in the
absence of wheel opening mouldings, allowing the flange to be coated.
c. The anti-stone abrasion coating does not adhere well to flexible plastic parts. If left exposed, they
must be masked off.
d. It is not necessary to mask off the body door openings in the coating area, as they will be
uniformly coated where the door margins allow the coating to enter.
NOTE: DOOR OPENING AREAS SHOULD BE CLEANED TO ASSURE COATING ADHERENCE.
COATING PREPARATION - SHEET METAL
REPAIRED SHEETMETAL
1. Scuff sand (No. 180 Grit Paper) the glossy surface of the painted areas to be coated.
2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover.
3. Remove sanding dust using compressed air and lint-free tack cloth.
NEW SHEET METAL
1. Sand off (No. 180 Grit Paper) the prime paint in the area to be coated.
2. Using a lint-free cloth, solvent wipe the area to be coated with wax and grease remover.
3. Remove sanding dust using compressed air and a lint-free tack cloth.
NEW INSTALLATION
1. The glossy surface of the paint in the coating area must be sanded with a D/A sander. A 220/240
Grit Disc does a good, fast job. DO NOT sand through the primer.
2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover.
3. Remove sanding dust using compressed air and a lint-free tack cloth.
SPRAY PROCEDURE
The lower exposed painted fender, rocker, and quarter panel down flanges should be protected.
The vehicle must be elevated high enough so that the painter can spray this area effectively. When
an initial installation is to be made, a remote two-quart capacity pressure cup makes a much more
efficient tool, as the spray gun can be used closer to the floor. The spray gun, fluid hose and/or cup
must be cleaned immediately after use. Refer to manufacturer's recommended cleaning procedure.
Lacquer thinner can be used when the suggested clean up material is unavailable.
WARNING: WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR
AND USE ALL OTHER RECOMMENDED SAFETY EOUIPMENT.
1. After preparing the new or damaged area(s), mix either Epoxy primer or Self-etch prime, per
manufacturer's label instructions, and spray bare metal areas.
^ BASF DE15 or DE17
^ Sikkens Metalflex CR Primer (1 coat only)
^ DuPont Variprime
^ S-W E2G 980 GBP Etching Filler
^ PPG DP 40 (only)
2. Apply 1-2 light prime coats over the bare metal areas.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6497
3. Allow the material to dry for 15-20 minutes before applying the anti-stone abrasion material.
4. Mix and apply anti-stone abrasion material per manufacturer's label instructions over the primed
area.
NOTE: AN ORANGE PEELED FINISH IS NORMAL WITH THESE PRODUCTS.
^ BASF Glassohyd 1109-1240/6
^ Sikkens 0TO Bodycoat
^ DuPont 123-5 Vinyl
^ S-W G/W 295 Vinyl Gravel Guard
^ PPG DX 54 Roadguard
^ 3M Rocker Schutz
NOTE: SOME ANTI-STONE ABRASION MATERIAL MAY REQUIRE A SLIGHTLY DIFFERENT
MIXING PREPARATION, PROCEDURE
AND APPLICATION. SOME ANTI-STONE ABRASION MATERIALS CAN NOT BE USED FOR
SPOT REPAIR. CHECK WITH THE PAINT MANUFACTURER FOR RECOMMENDATIONS
ABOUT THEIR PRODUCT.
5. Allow the stone abrasion material to dry. Heat can be used to accelerate the drying time. Check
the manufacturer's instructions.
COLOR COAT
The complete coated area, as well as the upper raw edge, must be covered with color coat. Mask
off the upper margin line using "Fine Line" tape positioned 1/16 inch above the coating edge. Using
appropriate service paint and application procedures, the protective coating area can now be finish
painted with monocoat or a basecoat/clearcoat urethane system.
NOTE: IF DAMAGED SHEET METAL EXTENDS ABOVE THE PROTECTIVE COATING AREA,
NORMAL PRIME/COLOR PAINT PROCEDURES SHOULD BE FOLLOWED.
CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL
TECHNIQUES FOR ANY VOLATILE ORGANIC
COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS.
Figure 4
Refer to the Lower Body Stone Protection Chart, Figure 4, for the material and labor hours
involved.
(D) Procedure For PVC Body Side Moldings
If replacement of the body side molding is necessary, some dealer service kits will be supplied
"paint to match."
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6498
The painting procedures in the following instructions (also included with the part) address materials
from five (5) major aftermarket paint suppliers. Use the paint system materials you are the most
familiar with.
NOTE: CAREFULLY READ ALL LABEL WARNINGS BEFORE APPLYING THESE PRODUCTS.
WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE
RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT.
SIKKENS PRODUCTS
PREPARATION
1. Degrease with M600 wax and grease remover.
2. Scuff with # 320 dry paper or Scotchbrite 7447 (red).
3. Repeat degreasing step.
4. Spray two medium coats of Plastoflex primer. Allow 5 to 10 minutes flash between coats.
5. Allow 20 minutes flash-off at 70~ F before topcoating.
TOPCOATING
1. Mix Autocryl color with Elast-O-Actif 50:50 by volume.
2. Mix this material with 1.2.3 hardner and 1.2.3 reducer (use correct reducer for temperature)
100:50:30 by volume.
3. Apply three medium coats, allowing enough flash off to dry to a light touch.
4. Dry one hour at 140~F after 10 minutes flash off or dry 24 hours at 75~F.
PPG PRODUCTS
PPG MONO-COAT SYSTEMS
1. Solvent wipe with DX330 Acryli-clean.
2. Scuff with red Scotchbrite pad.
3. Repeat solvent wipe.
TOPCOATING
1. Mix and apply Deltron topcoat color with DX-369 Flexative per label instructions.
2. Use 40-50 PSI at the gun.
PPG BASECOAT/CLEARCOAT SYSTEMS
PREPARATION
1. Solvent wipe with SX330 Acryli-clean.
2. Scuff with red Scotchbrite pad.
3. Repeat solvent wipe.
TOPCOATING
1. Mix and apply Deltron basecoat color (DBU), with the recommended reducer for the
temperature, per label instructions.
2. Mix and apply clearcoat material DBU-88 or DCU-2001, with DX-369 Flexative, per label
instructions.
SHERWIN-WILLIAMS PRODUCTS
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6499
Ultrabase 7 Basecoat/Clearcoat or Ultra One Stage Acrylic Urethane Enamel
PREPARATION
1. Wash the material with a mild detergent and wipe dry.
2. Solvent wash with R7 K 156 and wipe dry.
3. Clean with a tack cloth.
4. Apply desired system with correct amount of Multi-flex, V6 V 299.
TOPCOATING
Prepare topcoating as follows:
^ S-W Ultra One Stage: (Mono-coat) 4 Parts Color 3 Parts SSR 650 Reducer 1 Part V6 V 440 or
SSH 520 2 Parts V6 V 299
^ S-W UB7 Basecoat: 8 Parts Basecoat Color 8 Parts Stabilizer 1 Part V6 V 299
^ S-W UB7 Clearcoat: 4 Parts T1 C 650 Clearcoat 2 Parts T1 C 650 Reducer 1 Part CCH 690 1
Part V6 V 299
^ S-W Ultra One Stage: (Mono-coat) Apply 2-3 medium wet coats at 50 PSI
^ UB7 Basecoat: Apply 2-3 medium coats at 45 PSI
^ UB7 Clearcoat: Apply 2-3 medium coats at 50 PSI
DUPONT PRODUCTS
DUPONT CRONAR POLYOXITHANE MONOCOAT SYSTEM
PREPARATION
1. Wash the surface thoroughly with a mild detergent.
2. Clean with Prep Sol.
TOPCOATING
1. Add 8 parts of Cronar single stage enamel.
2. Add 1 part Cronar initiator 9404S.
3. Add two parts of (9475S, 9485S, or 9495S,) depending on shop temperature.
4. Add 2 parts flex-additive 9250S.
5. Mix thoroughly.
6. Spray at 45-55 PSI at the gun, 2-3 medium wet coats or until hiding.
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6500
7. If a clear coat is applied, use 9500S.
DUPONT CENTARI MONO-COAT ENAMEL SYSTEMS
PREPARATION
1. Wash the surface thoroughly with a mild detergent.
2. Clean with Prep Sol.
TOPCOATING (Follow Manufacturer's Recommendation)
1. Add 8 parts of Centari enamel color and 1 part 793S hardener.
2. Add 4 parts of (8022S, 8093S, or 8096S) reducer, depending on shop temperature.
3. Add 355S flex additive per label instructions.
4. Mix thoroughly.
5. Spray 2-3 wet coats, with 5 minutes flash time, at 50-65 PSI.
BASF PRODUCTS
The following procedure is applicable to 4 paint systems in the BASF paint line. Read individual
"system" instructions carefully.
PREPARATION
1. Solvent wipe the molding with RM Pre-klean-o 900.
2. Sand with 400 grit sand paper and rinse with 901 pre-paint cleaner.
TOPCOATING BASECOAT
^ "Glasurit" 54-line color 2 vol. parts
^ 54-line reducer 1 vol. part
^ "Diamont" basecoat color 2 vol. parts
^ B R Diamont reducer 2 vol. parts
^ "Miracryl" basecoat color 2 vol. parts
^ BCR reducer 2 vol. parts
^ "Supreme Gold" basecoat color 2 vol. parts
^ LBR reducer 2 vol. parts
Apply basecoat color until hiding is achieved. Allow 3-5 minutes flash time between coats.
NOTE: USE APPROPRIATE REDUCER FOR SHOP CONDITIONS. ALLOW 15 MINUTES
FLASH-OFF BEFORE SPRAYING CLEARCOAT.
TOPCOATING
Apply clearcoat per manufacturer's label instructions:
CLEARCOAT REDUCTIONS
^ DC-88 Diamont Clear 4 Vol. Parts
^ DH-44 Diamont Hardener 1 Vol. Part
^ MC-1000 Clear 4 Vol. Parts
^ 894 Hardener 1 Vol. Part
^ LC-1300 Supreme Gold Clear 4 Vol. Parts
^ LH-1301 Hardener 1 Vol. Part
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6501
^ 92354 Glasurit Clear 100 Parts
^ 521-111 Elastifier 20 Parts
^ 929-29 Hardener 60 Parts
Apply 2 wet coats with 5 to 10 minutes flash time between coats. Overnight dry or force dry at
140~F for 30 minutes.
CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL
TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS
MATERIALS.
(E) Lower Body-Side Stone Chip Protection Program
Ford Motor Company has recently initiated a program to provide improved stone-chip protection on
some vehicles and to increase the corrosion protection on cars and trucks.
Some customers are unaware of body side anti-stone chip protection which appears as wavy
orange peel texture on the lower body areas.
Ford is increasing the use of PVC (poly vinyl chloride) material which is applied in a thicker coating
on the lower body-side. This material has been in use on vehicles destined for the Canadian
market for many years.
This PVC material is now applied at the following plants on ALL vehicles.
^ Edison - Ranger
^ Hermosillo - Escort/Tracer
^ Louisville - Ranger and Explorer
^ Ohio Truck - Econoline
^ Wayne - Escort/Tracer
This process is also planned for Kansas City, Oakville, Twin Cities and Wixom.
This material can be identified by the "orange peel" appearance and a visible "break-line" between
protected and unprotected areas in the lower body areas.
CAUTION: THIS PROTECTION MUST NOT BE REMOVED IF VEHICLE IS EXPECTED TO
MAINTAIN THE CORROSION PROTECTION.
Some customers have expressed concerns due to the appearance of the treated areas. These
customers did not know about the extra protection this material provides their vehicle. Once
explained, customers were pleased with the added protection and accepted the orange peel finish.
NOTE: DEALERS SHOULD ADVISE THEIR SALES PEOPLE, SERVICE PEOPLE, AND
CUSTOMERS, OF THE REASONS AND BENEFITS
OF THIS PROTECTION. CANADIAN DEALERS STRESS THIS AS A SELLING POINT WITH
THEIR SALES PEOPLE. IT IS CONSIDERED A COMPETITIVE ADVANTAGE.
(F) Surface Defect Removal Without Repainting
Exterior paint surface damage or imperfections, where the primer coat does not show through,
should be restored without repainting. The restoration of gloss and luster, after the condition has
been repaired, is possible with new techniques and improved materials.
The following procedure is applicable to surface conditions such as dirt particles, orange peel, runs,
sags, industrial fallout stains, swirl marks, light scratches and other minor surface imperfections.
For dirt particles or scratches in several localized areas, the entire panel should be refinished to
maintain a uniform appearance.
PREPARATION
To repair the affected surface it must be clean and dry. Mask off adjacent panels, mouldings, stripe
and character lines as required.
CAUTION: EYE PROTECTION, AND FACE MASK SHOULD BE WORN. RINGS, BRACELETS,
WATCHES AND BELT BUCKLES MUST BE
REMOVED TO PREVENT ACCIDENTAL DAMAGE TO PAINT FINISH.
SERVICE PROCEDURE
1. Remove sanding marks with rubbing compound.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6502
2. Swirl marks, evident after buffing, are removed by polishing.
3. Remove light scratches and small dirt particles with a power buffer and medium buffing
compound followed with polishing.
4. Remove deeper scratches and heavy dirt particles or orange peel, by wet sanding.
5. Buff with compound to remove the sanding marks and then polish to remove the swirl marks
from the buffing operation.
NOTE: PERFORM A TRIAL REPAIR WITH A SMALL AREA. FIRST, TRY POLISHING; IF THIS IS
NOT SUCCESSFUL, TRY BUFFING
AND, FINALLY, USE WET SANDING TO REMOVE THE CONDITION. USE MOST EFFECTIVE
TECHNIQUE ON REMAINDER OF AREAS. AN OUTLINE OF THE COMPLETE PROCEDURE
AND REQUIRED MATERIALS FOLLOWS.
POLISHING - VERY MINOR SCRATCHES OR SWIRL MARKS AND/OR RESTORING A DULL
FINISH
1. Apply a small amount of Meguiar's Mirror Glaze, or equivalent, to the affected panel (or pad).
2. Use a suitable electric or air powered polish/buffing wheel (1750 max. RPM) and a Meguiar's
Finesse Polishing Pad, or equivalent, to polish the affected area until all swirl marks are gone and
desired luster is obtained.
3. When polishing, keep the pad flat against the surface. Do not bear down. The weight of the
buffer is sufficient.
CAUTION: DO NOT MIX PRODUCTS! USE A SEPARATE, DEDICATED BUFFING PAD FOR
EACH PRODUCT TO ACHIEVE DESIRED
RESULTS.
Variable speed buffers are available in a variety of buffing speeds. The recommended speed range
is 1200-1750 RPM.
COMPOUNDING - LIGHT SCRATCHES, SMALL DIRT PARTICLES, MINOR GRIND MARKS,
AND SANDING MARKS
1. Apply Meguiar's Rubbing Compound (medium) or equivalent to the panel with a clean compound
pad on the wheel.
2. Spread the compound evenly and continue buffing until the condition is removed.
3. Keep the wheel flat to the surface and use light to moderate pressure and long strokes.
4. Periodically check the finish and add compound as required.
5. When buffing is complete, polish the panel as described previously.
Twisted wool cutting pads are the most effective compounding pads to use with Glaze Machine
Cleaner for removing paint defects and heavy oxidation. Following the use of a wool compounding
pad, it may be necessary to polish the finish with No. 2 Mirror Glaze Hi-Tech Cleaner using a Mirror
Glaze Finesse Polishing Pad to remove the deep swirl marks.
GENERAL TECHNIQUES AND HINTS
^ "Foam" buffing pads create added gloss and depth of color on all types of paint finishes without
creating buffer swirl marks.
^ When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount
of material, slower buffing motion and added downward pressure to increase cutting action.
^ Always apply cleaner to buffing pad, not directly on the oxidized paint surface. Dry paint absorbs
material into pores upon contact.
^ Always keep the face of the buffing pad completely flat to the surface, reducing the risk of buffer
swirl marks. Watch your pad, especially on angled surfaces, to be certain that it stays flat.
^ Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions
and overlap by 50% the buffing pattern left by the previous pass. This insures uniform coverage
and allows both material and buffer to perform at maximum efficiency.
^ Avoid buffing directly on raised character lines. The reduced paint film on these surfaces
increases the risk of paint burn through. It is best to buff up to them from each side.
^ Always use a "wet buff" technique on a basecoat/clearcoat finish. This is a precaution against
buffer swirls. Stop buffing just after the product begins to break down and before an overall dry,
glossy finish appears. After "wet buffing", use a towel to wipe off the excess material.
^ Always use a "dry buff" technique on light colored, conventional paint finishes. Continue buffing
until the material breaks down and only a slight film remains for final wipe off.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6503
^ If a paint blemish remains after buffing, reapply a small amount of material over the blemish.
Confine your buffing strokes to the immediate area of the blemish while applying additional
downward pressure and keeping the pad flat.
NOTE: ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH
TO PREVENT EXCESSIVE HEAT
BUILD-UP AND POSSIBLE BURN THROUGH. STOP IMMEDIATELY IF THE SURFACE
BECOMES TOO HOT TO LAY THE PALM OF YOUR HAND ON IT.
NOTE: HEAT BUILD-UP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY
APPEAR ACROSS THE SURFACE BEING
BUFFED AND THE PRODUCT MAY DRY LIKE A FILM AND REFUSE TO BUFF OUT. TO
REMEDY, WIPE THE AREA DOWN WITH COOL WATER, DRY THE SURFACE AND RESUME
BUFFING ... AT A LOWER RPM IF POSSIBLE.
NOTE: STATIC: STATIC ELECTRICITY MAY BE PRESENT ON PAINTED
FIBERGLASS/PLASTIC SURFACE BEING BUFFED, THE
MATERIAL MAY DRY LIKE A FILM OR TURN "GUMMY" AND BEGIN TO BALL UP. TO
REMEDY, GROUND THE SURFACE BEING BUFFED TO METAL.
WET SANDING
Paint defects and sanding marks must be completely removed without using compounds and
abrasive cleaners that scar the finish.
Mirror Glaze Hi-Tech Finesse Sanding Papers provide uniformity in grit particle size and
distribution. Using these precision made sanding papers, water sanding marks can be removed
with Meguiar's cleaner and finesse polishing pads.
^ Typical paint defects that are repaired with this system include: dirt-in paint, solvent pop,
cratering, orange peel, drips, scratches, water spots, and acid rain.
^ Always use the least abrasive (highest grit) sanding products possible to do this job.
The following wet sanding procedure utilizes light grit sand paper or sanding blocks for removal of
surface damage. These materials cut quickly leaving a uniform finish requiring a minimum of
buffing to restore gloss.
PROCEDURE
1. Squeeze water to flush the area to be sanded. Continue to flush water to the surface during
sanding for maximum lubrication.
2. Use small circular motions to contain the abrasion to the immediate area of the defect. Keep the
blocks in water when not in use.
3. If the sanding block is cutting too slow, switch to a lower grade block and resume sanding. When
90% of the defect is removed, switch to a 2000 grade Finesse Sanding Paper or Sanding Block to
finish smoothing and prepare the surface for buffing.
4. Finesse Sanding Blocks can be shaped to work on any angle. When the block is wet, rub it
against a dry sanding block for shaping.
5. When using Finesse Sanding Papers, wrap the paper tightly around a E-7200 Backing Pad. This
pad evenly distributes pressure over the entire surface of the sanding paper. This creates a uniform
sanding pattern.
6. Plan your strokes to limit the abrasion to the smallest area possible.
NOTE: ALWAYS SAND IN ONE DIRECTION AND KEEP YOUR STROKES STRAIGHT.
7. Always finish sanding with 2000 Grit Finesse Sanding Paper. This eliminates the need for
compounding.
8. Buff out sanding marks by applying Meguiar's Cleaner with a Finesse "Foam" Polishing Pad.
Follow with a Mirror Glaze Polish for swirl-free gloss.
WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL
TECHNIQUES FOR ANY VOLATILE ORGANIC
COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS
RUNS AND SAGS REMOVAL
This procedure consists of shaving the run or sag flush with a commercial single edge razor blade,
shaving file or sanding with a hard block and then compounding.
NOTE: IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST
DULL THE CORNERS WITH SANDPAPER TO AVOID SCRATCHING THE ADJACENT PANEL
FINISH.
MEGUIAR'S PRODUCTS
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6504
PART
NUMBER GRADE PART NAME
S-1005 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Half Sheets
S-1205 1200
S-1505 1600
S-2005 2000
S-1000 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Full Sheets
8-1200 1200
8-1500 1500
S-2000 2000
E-7200 - Mirror Glaze Hi-Tech Finesse Backing Pad
E-2000 - Mirror Glaze Hi-Tech Tach Sponge
K-400 400 Mirror Glaze Hi-Tech Finesse Sanding Blocks
K-1000 1000
K-1500 1500
K-2000 2000
K-3000 3000
Other Applicable Articles: 82-3-3
(G) Color Compatible Spray Primer Chart
Ford has released color compatible spray primers for exterior and some interior surfaces.
Colored sprayed primers are being used by our "Best-in-Class" competition and are now being
implemented at Ford in order to improve process capability and to help in minimizing unsightly
paint chipping from stone abrasion. Color keyed (matched) spray primer for exterior body colors is
being used in an effort to help in the elimination of unsightly paint chipping from stone abrasion.
As with "Best-In-Class" competition, the engine compartment will be left with color compatible
primer only and not be topcoated as per past practice.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6505
Figure 5
When any paint repair is required, remember that the vehicle may have a colored primer. Refer to
the Spray Primer Chart, Figure 5. This information may be of help in correction of exterior paint
color match concerns.
(H) Paint Repair For Tinted Clear Coat
Ford introduced (Early Spring, 1991) a new paint color using a tinted clearcoat. The first color to
use this new system is Rio Red.
If a paint repair is necessary, refer to the following procedure for repair instructions.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6506
BACKGROUND
The Probe production paint system for Rio Red includes a Medium Green E-Coat primer, a Light
Gray spray primer, bright Rio Red (E4) basecoat and a slightly Red tinted clearcoat topcoat.
NOTE: BEFORE ANY REPAIRS ARE BEGUN, IT IS CRITICAL THAT PRIMER, RED BASECOAT
AND TINTED CLEARCOAT BE SPRAYED ON A TEST PANEL. THE COLOR MATCH IN EACH
STEP IS VERY IMPORTANT FOR A SUCCESSFUL REPAIR.
WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE
RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT.
SMALL SPOT REPAIR PROCEDURE
1 Wash the vehicle with detergent soap and
water.
2 Wipe the vehicle down with wax and grease
remover.
3. Sand the spot using 400 grit paper. Do not sand through the E-coat.
4. Wipe the sanded surface again with wax and grease remover/pre-cleaner.
^ BASF Product # 90 Pre-Kleano
^ PPG Product # DX 330
^ S-W Product # R7-K156
^ DuPont Product # 3919 S
^ Sikkens Product # M 600
5. Mix and apply tintable (Light Gray) self-etching or epoxy primer per manufacturer's label
instructions.
NOTE: COLOR MATCH OF PRIME COAT IS KEY IN COLOR MATCH OF REPAIRED AREA.
^ BASF Product # DE 17
^ PPG Product # DP 40
^ S-W Product # E2-G973
^ DuPont Product # 615S
^ Sikkens Product # 1016
6. Mix and apply bright Rio Red base coat material per manufacturer's label instructions.
NOTE: COLOR MATCH OF BASE CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED
AREA.
7. Mix and apply red tinted clearcoat material per manufacturer's label instructions.
NOTE: COLOR MATCH OF TINTED CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED
AREA.
FULL PANEL REPAIR PROCEDURE
1. Wash the vehicle with detergent soap and water.
2. Wipe the vehicle down with wax and grease remover.
3. Sand the complete panel and feather edge into the next panel using 400 grit paper. Do not sand
through the E-Coat primer.
4. Wipe the sanded surface with wax and grease remover.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6507
5. Mix and apply tintable (light gray) primer per manufacturer's label instructions.
6. Mix and apply Rio Red basecoat per manufacturer's label instructions.
7. Mix and apply Red tinted clearcoat per manufacturer's label instructions.
8. Mix and apply one coat of non-tinted clearcoat per manufacturer's label instructions.
NOTE: COLOR MATCH OF EACH COAT ARE KEY TO COLOR MATCH OF FINISH REPAIR.
WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL
TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C's) OR EXCESS
MATERIALS.
(I) Paintable Plastics
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6508
Figure 6
The Paintable Plastics Chart, Figure 6, is a summary of widely used plastics in our industry. The
standard symbol should be located on the part for ease of material identification.
If painting or repair of these plastics is necessary, the following chart identifies those materials
which can be painted. Refer to paint manufacturer for specific paint material recommendations.
NOTE: MATERIALS MAY REQUIRE PRIME COAT SEE "YES", UNDER "CAN BE PAINTED"
COLUMN.
(J) 1992 Paint Color Codes
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6509
Figure 7
The 1992 Paint Color Codes are listed in Figure 7.
NOTE: REFER TO THE SERVICE LABOR TIME STANDARDS MANUAL AND THE SPECIFIC
PROCEDURE WITHIN THIS BULLETIN FOR REIMBURSEMENT.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OASIS CODES:
106000
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6510
Paint: Technical Service Bulletins Vinyl Tape Stripes - Poor Adhesion
Article No. 87-24-3 PAINT - AFTERMARKET VINYL TAPE STRIPES - POOR ADHESION VEHICLES BUILT BEFORE 06/01/87 FORD:
1987-88 ESCORT, EXP, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, CROWN VICTORIA
LINCOLN-MERCURY: 1987 LYNX 1987-88 TOPAZ, SABLE, COUGAR, GRAND MARQUIS,
MARK VII, CONTINENTAL, LINCOLN TOWN CAR
LIGHT TRUCK: 1987-88 AEROSTAR, RANGER, BRONCO II, E-SERIES, F-SERIES, BRONCO
ISSUE: Poor adhesion of aftermarket vinyl tape stripes may be caused by the paint on the vehicle
reacting with the type of adhesive used on the vinyl tape stripe. ACTION:
To prevent vinyl tape stripe adhesion concerns, Ford recommends the use of a vinyl tape stripe
with a more aggressive adhesive applied to the backside of the stripe. The improved vinyl tape
stripe material can be purchased directly from one of the Original Equipment Manufacturers (OEM)
listed on page 02 of this TSB.
Kaye Screen Printing Company Attn:
Bill Farnen 1614 Clay Street Detroit, Michigan 48211 (313) 872-4048
3M - 3M Center Automotive Systems Division Building 223-1S St. Paul, Minnesota 55144 (612)
733-8632 Avery Graphic Systems 1875 Research Drive Suite 200 Troy, Michigan 48083 (313)
689-1600
Trim Line, Inc. Attn:
Virginia Cornell 3810 Rosin Court Sacramento, California 95834-0400 (800) 824-5182 Outside
Calif. (800) 852-7733 Inside Calif.
OTHER APPLICABLE ARTICLES: 87-18-4 WARRANTY STATUS: "INFORMATION ONLY"
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Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6511
Paint: Technical Service Bulletins Paint - Preparation Procedure And MSDS Information
Article No. 94-23-4
11/14/94
PAINT - PRIMED SHEET METAL - PREP PROCEDURE AND MSDS INFORMATION
FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP
1984 and after TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE
LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN
CAR 1981-87 LYNX 1984-92 MARK VII 1984 and after TOPAZ 1986 and after SABLE 1987-89
TRACER 1991-94 CAPRI 1993 and after MARK VIII
MERKUR: 1985-89 XR4TI 1988-90 SCORPIO
LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after
BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and
after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 WINDSTAR
MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B
SERIES, L SERIES 1986 and after CARGO SERIES
ISSUE: This procedure is being published to advise all body and paint technicians about proper
procedures for preparation of sheet metal parts coated with electrodeposition primer (E-Coat).
ACTION: When prepping a replacement body panel for installation, it is mandatory to leave the
E-Coat intact. DO NOT SAND OFF THE E-COAT.
Improper preparation with excessive sanding of the E-Coat to bare metal will jeopardize the sheet
metal warranty and overall customer satisfaction. In particular, the E-Coat is necessary to protect
the parts from rust. Light scuff sanding using a Scotch Brite pad or wet 320 grit sand paper is
recommended for minor flaws. If a minor flaw exists, wet sand or scuff out the flaw and prime the
repair area. Again, do not remove all of the E-Coat from the panel.
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Bulletins > Technical Service Bulletins for Paint: > Page 6512
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6513
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Technical Service Bulletins for Paint: > Page 6514
WARNING:
LEAD CONTAMINATION POTENTIAL: THE ELECTRODEPOSITION PRIMER USED BY FORD
MOTOR COMPANY OVER BASE METAL ON SERVICE REPLACEMENT PARTS OR
COMPLETED VEHICLES CONTAINS SMALL AMOUNTS OF LEAD FOR CORROSION
PROTECTION OF STEEL. EXCESSIVE DUSTS GENERATED BY UNNECESSARY AND
IMPROPER SANDING MAY CONTAIN AIRBORNE LEAD CONTAMINATION IN EXCESS OF
OSHA STANDARDS. INFORMATION REGARDING THE HAZARDS OF LEAD CAN BE FOUND
IN THE CHEMICAL FACT SHEETS IN THE FIGURES IN THIS ARTICLE.
NOTE:
READ ALL INFORMATION IN THIS TECHNICAL SERVICE BULLETIN CAREFULLY AND
FORWARD TO ALL EMPLOYEES PERFORMING PAINT PREPPING OPERATIONS. DEALERS
SHOULD CONTACT LEGAL COUNSEL AND/OR LOCAL OSHA
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Bulletins > Technical Service Bulletins for Paint: > Page 6515
AUTHORITIES FOR DIRECTION REGARDING OSHA LEAD STANDARD REQUIREMENTS.
If a replacement body panel contains more than a minor flaw in the E-coat, it should be returned.
Contact your Customer Service representative for instructions.
If more extensive sanding, other than that described above, is necessary, (e.g., refinishing original
vehicle sheet metal) follow the procedures outlined below:
ALTERNATIVE SANDING PROCEDURES WHEN EXTENSIVE SANDING IS REQUIRED
The following procedures for sheet metal preparation by sanding or media blasting are based on
tests conducted by Ford Motor Company in accordance with requirements set forth in the Federal
OSHA Inorganic Lead Standard 29 CFR 1910.1025.
SANDING PROCEDURE
1. Each technician performing the sanding operation MUST wear an approved respirator with high
efficiency particulate filter (HEPA).
2. Technicians should use dual action sander with vacuum collection.
3. The vacuum equipment MUST be equipped with a HEPA filter on the air exhaust. Dealers are
cautioned not to exhaust vacuum air into the atmosphere. Operators are cautioned to follow the
manufacturer's guidelines for maintenance and the replacement of filters.
MEDIA BLASTING PROCEDURE
1. Testing has shown that plastic media blasting meets OSHA lead standard requirements and is
efficient when the manufacturer's published procedures are followed.
2. The operator must wear an air supplied hood using compressed air free from carbon monoxide,
oil, water, and other contamination when performing this operation. Specifics of the media blasting
procedure for whole body paint removal have been previously published.
NOTE:
PLEASE READ THE CHEMICAL FACT SHEETS IN THE FIGURES.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 106000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Power Door Lock Relay: Locations
Lower Cowl Near Fuse Block
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins >
Seat Leather - Cleaning Procedure Tips
Seat Cover: Technical Service Bulletins Seat Leather - Cleaning Procedure Tips
Article No. 98-17-1
09/01/98
SEAT - LEATHER CLEANING PROCEDURE - SERVICE TIP
FORD: 1984-94 TEMPO 1984-97 THUNDERBIRD 1984-98 CROWN VICTORIA, ESCORT,
MUSTANG 1986-98 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR
LINCOLN-MERCURY: 1984-94 TOPAZ 1984-97 COUGAR 1984-98 GRAND MARQUIS, TRACER
1984-99 TOWN CAR 1986-98 SABLE 1993-98 MARK VIII 1995-98 MYSTIQUE 1995-99
CONTINENTAL 1999 COUGAR
LIGHT TRUCK: 1983-98 RANGER 1984-96 BRONCO 1984-97 F-250 HD 1984-98 ECONOLINE,
F-150, F-250 LD 1986-97 AEROSTAR 1991-98 EXPLORER 1993-98 VILLAGER 1996-98
WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F
SERIES
This TSB article is being republished in its entirety to include the latest level parts and to include a
revised Service Procedure.
ISSUE
The following TSB contains information regarding the cleaning of interior leather seats and trim.
Improper cleaning procedures may damage the leather. If seats are not cleaned on a regular basis
(every 4-6 weeks), normal wear and tear can cause excessive soiling.
ACTION
Ford Motor Company has developed a new kit (Deluxe Leather Care Kit - F8AZ-19G253-AA) to
clean soiled seats without damaging the top coat of the leather. The kit contains a leather and vinyl
cleaner along with a specially formulated sponge.
Refer to the text for cleaning leather seats and trim.
The Deluxe Leather Care Kit has been tested and approved for use on all Ford and
Lincoln/Mercury leather and vinyl seating surfaces, and if used as directed, should be used for
service repairs. Many household cleaners and sponges are too harsh to be used on leather and
may actually cause permanent damage to the surface.
Use this material on leather and vinyl seats that:
^ show excessive soiling
^ have been stained with coffee, lipstick, etc.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins >
Seat Leather - Cleaning Procedure Tips > Page 6525
Refer to the instructions included in the kit for specific application procedures.
After cleaning surface with cleaner and sponge, wipe area with water and a cotton cloth.
NOTE
AVOID EXCESSIVE APPLICATION OF CLEANER ALONG STITCHING.
PART NUMBER PART NAME
F8AZ-19G253-AA Deluxe Leather Care Kit
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 97-14-2
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 101000, 107000, 190000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and
Inspection
Brake Switch (Cruise Control): Testing and Inspection
Perform this test only when brake application will not disconnect the speed control system.
1. Check operation of stop lamps by applying approximately 6 lbs. of pressure to brake pedal. If
more than 6 lbs. is required, check brake pedal actuation and stop lamp switch.
2. If stop lamps do not function properly, check bulbs, circuit fuse or stop lamp switch.
3. If stop lamps function properly, check for battery voltage at 6 way connector using black wire
w/green stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 series, or white wire
w/pink stripe on 1981-82 F-100-350 and Bronco series, or white wire w/purple stripe on 1983
F-100-350, Bronco and Ranger, 1984-87 F-150-350, Ranger, 1984-87 Bronco II and 1986-87
Aerostar.
4. Depress brake pedal until stop lamps are illuminated. Check voltage at red wire w/black stripe on
1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 models, or the light green wire on
1981-83 F-100-350 and Bronco, 1984-87 F-150-350 and Bronco, 1983-87 Ranger, 1984-87 Bronco
II and 1986-87 Aerostar. The difference between the two voltage readings must not exceed 1.5
volts. If voltage is greater, a high resistance exists in the circuit and must be found and corrected.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Service and Repair
Clutch Switch: Service and Repair
1. Remove bracket mounting screw(s).
2. Disconnect electrical connector and remove switch and bracket assembly.
3. Remove switch from bracket.
4. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Brush Assembly > Component Information > Technical Service
Bulletins > Customer Interest for Cruise Control Brush Assembly: > 8934 > Feb > 89 > Speed Control - Abnormal Operation
When Hot
Cruise Control Brush Assembly: Customer Interest Speed Control - Abnormal Operation When Hot
Article No. 89-3-4
SPEED CONTROL - COAST AND ACCELERATION MODES - ABNORMAL OPERATION IN
HIGH AMBIENT TEMPERATURES
FORD: 1986-89 ALL
LINCOLN-MERCURY: 1986-89 ALL
LIGHT TRUCK: 1986-89 ALL
ISSUE: Abnormal speed control operation in the coast and acceleration modes may be caused by
loss of electrical contact between the steering wheel slip rings and brush assembly. This condition
usually occurs in high ambient temperatures when the steering wheel slip rings and brush
assembly are warm.
ACTION: Improve the electrical continuity of the steering wheel slip rings and brush assembly by
applying a new service released grease on the contact
area. Refer to the following procedure for service details.
1. Remove the steering wheel, Refer to the appropriate Car or Light Truck Shop Manual for service
details.
2. Clean the old grease from the steering wheel slip rings and brush assembly contact areas.
3. Apply the new service released grease, (E8AZ-19590-A), on the steering wheel slip rings and
brush assembly contact surfaces. This new grease can be identified by its bright orange/red color.
4. Reinstall steering wheel.
PART NUMBER PART NAME CLASS
E8AZ-19590-A Grease B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: 890304A TIME:
0.4 Hr.
DLR. CODING: Basic Part No. 9C899
Condition Code: 53
OASIS CODES: 2900
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Brush Assembly > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Brush Assembly: > 8934 > Feb > 89 > Speed Control Abnormal Operation When Hot
Cruise Control Brush Assembly: All Technical Service Bulletins Speed Control - Abnormal
Operation When Hot
Article No. 89-3-4
SPEED CONTROL - COAST AND ACCELERATION MODES - ABNORMAL OPERATION IN
HIGH AMBIENT TEMPERATURES
FORD: 1986-89 ALL
LINCOLN-MERCURY: 1986-89 ALL
LIGHT TRUCK: 1986-89 ALL
ISSUE: Abnormal speed control operation in the coast and acceleration modes may be caused by
loss of electrical contact between the steering wheel slip rings and brush assembly. This condition
usually occurs in high ambient temperatures when the steering wheel slip rings and brush
assembly are warm.
ACTION: Improve the electrical continuity of the steering wheel slip rings and brush assembly by
applying a new service released grease on the contact
area. Refer to the following procedure for service details.
1. Remove the steering wheel, Refer to the appropriate Car or Light Truck Shop Manual for service
details.
2. Clean the old grease from the steering wheel slip rings and brush assembly contact areas.
3. Apply the new service released grease, (E8AZ-19590-A), on the steering wheel slip rings and
brush assembly contact surfaces. This new grease can be identified by its bright orange/red color.
4. Reinstall steering wheel.
PART NUMBER PART NAME CLASS
E8AZ-19590-A Grease B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: 890304A TIME:
0.4 Hr.
DLR. CODING: Basic Part No. 9C899
Condition Code: 53
OASIS CODES: 2900
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations
Cruise Control Module: Locations
Under LH Side Of I/P, With Speed Control
LH Side Of I/P, Near Steering Column
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 6549
Cruise Control Module: Testing and Inspection
Use only a multi-meter of 5000 ohm/volt rating or higher when performing amplifier test.
``On'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground on models exc. 1983-87
Ranger, 1984-87 Bronco II and 1986-87 Aerostar or white wire w/purple stripe and ground on
1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar.
3. Battery voltage should be indicated when ``On'' switch on steering column is depressed and
held. If battery voltage is not indicated, check horn relay and perform control switch test.
4. Release ``On'' button. Voltmeter should indicate 7.8 volts indicating ``On'' circuit is engaged. If
voltage does not remain, check amplifier ground, fuses or circuit breakers or replace amplifier with
known good amplifier and repeat test.
5. Replace as necessary.
``Off'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground.
3. Depress ``Off'' button. Voltage should drop to zero indicating ``On'' circuit is de-energized.
4. If voltage does not drop to zero, perform ``Control Switch Test.''
``Set-Accelerate'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground.
3. Depress ``On'' switch, then hold ``Set-Accel'' button on steering wheel. Voltmeter should indicate
4.5 volts. Rotate steering wheel back and forth and check for voltmeter fluctuations. If reading
varies more than .5 volts, perform ``Control Switch Test.''
``Coast'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground.
3. Depress ``On'' switch, then depress and hold ``Coast'' button on steering wheel. Voltmeter
should indicate 1.5 volts. Rotate steering wheel back and forth and check for voltage fluctuations. If
reading varies more than .5 volts, perform ``Control Switch Test.''
``Resume'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground.
3. Depress and hold ``Resume'' button. Voltmeter should indicate 6.5 volts.
If all circuits are functioning properly, perform ``Servo Assembly
Test'' using a known good amplifier. Do not replace amplifier before performing servo test.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins >
Customer Interest for Cruise Control Servo: > 9278 > Mar > 92 > Speed Control - Intermittent or Inoperative
Cruise Control Servo: Customer Interest Speed Control - Intermittent or Inoperative
Article No. 92-7-8
03/25/92
^ SPEED CONTROL - INTERMITTENT OR INOPERATIVE - DURING WET WEATHER
CONDITIONS
^ WIRING - SPEED CONTROL INTERMITTENT OR INOPERATIVE - CONNECTOR
CORROSION
LIGHT TRUCK: 1986-90 BRONCO II 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES,
RANGER 1991 EXPLORER
This TSB article is being republished in its entirety to correct the grease part number suffix which
appeared in Step 5 of the service procedure.
ISSUE: Intermittent or inoperative speed control operation may occur during wet weather
operation. This may be caused by a corroded connector at the servo.
ACTION: Inspect the connector at the servo for corrosion to determine if replacement is required.
Refer to the following procedure for service details.
1. Disconnect the connector at the servo.
2. Blow dry the connector assembly with shop air.
3. Clean and inspect pins for corrosion.
4. Replace any damaged or corroded pins (D1AZ-14488-E).
5. Apply grease (F2AZ-19584-A) to both ends of the connector to prevent water entry.
6. Reconnect the connector at the servo.
PART NUMBER PART NAME CLASS
F2AZ-19684-A Grease C
D1AZ-14488-E Pin Connector C
SUPERSEDES: 92-1-7
WARRANTY STATUS: Eligible Under Basic Warranty
Coverage
OPERATION DESCRIPTION TIME
920708A Clean And Inspect Pins And
0.3 Hr.
Apply Grease To Connectors
920708B Clean And Inspect Pins 0.4 Hr.
Replace Damaged Pins As Necessary, Apply Grease To Connectors
DEALER CODING
BASIC PART NO. CONDITION CODE
14488 84
OASIS CODES: 203300, 205000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Cruise Control Servo: > 9278 > Mar > 92 > Speed Control - Intermittent or Inoperative
Cruise Control Servo: All Technical Service Bulletins Speed Control - Intermittent or Inoperative
Article No. 92-7-8
03/25/92
^ SPEED CONTROL - INTERMITTENT OR INOPERATIVE - DURING WET WEATHER
CONDITIONS
^ WIRING - SPEED CONTROL INTERMITTENT OR INOPERATIVE - CONNECTOR
CORROSION
LIGHT TRUCK: 1986-90 BRONCO II 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES,
RANGER 1991 EXPLORER
This TSB article is being republished in its entirety to correct the grease part number suffix which
appeared in Step 5 of the service procedure.
ISSUE: Intermittent or inoperative speed control operation may occur during wet weather
operation. This may be caused by a corroded connector at the servo.
ACTION: Inspect the connector at the servo for corrosion to determine if replacement is required.
Refer to the following procedure for service details.
1. Disconnect the connector at the servo.
2. Blow dry the connector assembly with shop air.
3. Clean and inspect pins for corrosion.
4. Replace any damaged or corroded pins (D1AZ-14488-E).
5. Apply grease (F2AZ-19584-A) to both ends of the connector to prevent water entry.
6. Reconnect the connector at the servo.
PART NUMBER PART NAME CLASS
F2AZ-19684-A Grease C
D1AZ-14488-E Pin Connector C
SUPERSEDES: 92-1-7
WARRANTY STATUS: Eligible Under Basic Warranty
Coverage
OPERATION DESCRIPTION TIME
920708A Clean And Inspect Pins And
0.3 Hr.
Apply Grease To Connectors
920708B Clean And Inspect Pins 0.4 Hr.
Replace Damaged Pins As Necessary, Apply Grease To Connectors
DEALER CODING
BASIC PART NO. CONDITION CODE
14488 84
OASIS CODES: 203300, 205000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins >
Page 6563
Cruise Control Servo: Locations
LH Side Of Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins >
Page 6564
Cruise Control Servo: Testing and Inspection
1981-83 F-100-350 & Bronco, 1984-87 F-150-350 & Bronco 1982-83 E-100-350 & 1984-87
E-150-350 Series
1. Disconnect ball chain from carburetor (if equipped), then the electrical connector at the amplifier.
2. Connect an ohmmeter between orange wire w/yellow hash and gray wire w/black hash at
connector. A resistance of 40 to 125 ohms should be obtained.
3. Connect an ohmmeter between orange wire w/yellow hash and white wire w/pink hash. A
resistance of 60 to 90 ohms should be obtained.
4. If equipped, connect ball chain to carburetor.
5. Start engine and ensure servo vacuum from engine exceeds 2.5 inches of Hg, then disconnect
servo from amplifier.
6. Connect orange wire w/yellow hash of servo to battery positive terminal and white wire w/pink
hash to ground, then momentarily touch gray wire w/black hash to ground. Servo throttle actuator
should pull in and engine RPM should increase. Throttle should hold in position or slowly release
chain tension.
7. Remove white wire w/pink hash and check for immediate release of chain tension from servo.
8. Replace servo if servo fails to function as described. Amplifier may need replacement if orange
wire w/yellow hash is shorted to either white-pink hash lead or gray-black hash lead.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins >
Page 6565
Cruise Control Servo: Service and Repair
Exc. 1986-87 Aerostar
1. Raise hood, then disconnect wiring harness connector at servo assembly. On some models, it
may be necessary to disconnect servo assembly at the amplifier under the dash and carefully pull
harness and connector through dash panel opening.
2. Disconnect ball chain at carburetor or adjuster from accelerator cable (as equipped), then
remove vacuum hose from servo assembly.
3. Remove servo assembly retaining pins and nuts, then the servo assembly from mounting
bracket.
4. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair
Cruise Control Servo Cable: Service and Repair
1. Remove servo assembly, then discard cable.
2. Attach new actuator cable to servo assembly.
3. Install servo assembly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations
Cruise Control Switch: Locations
Part Of Steering Wheel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram
Information and Instructions
Cruise Control Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6574
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6575
Cruise Control Switch: Electrical Diagrams
Fig. 38 Horn & Speed Control Wiring Circuit (Part 1 of 2)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6576
Fig. 38 Horn & Speed Control Wiring Circuit (Part 2 of 2)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6577
Cruise Control Switch: Testing and Inspection
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986 Aerostar Disconnect 6 way
connector from control switch at the amplifier, then perform the following checks:
1. Connect a voltmeter between light blue-black hash lead and ground, then depress the ``On''
button and check for battery voltage.
2. Turn ignition ``Off,'' then connect an ohmmeter between light blue-black hash lead and ground.
3. Rotate steering wheel throughout its full range while making the following checks:
a. Depress ``Off'' button and check for a reading of 0-1 ohm. b. Depress ``Set'' button and check for
a reading of 646-714 ohms. c. Depress and hold ``Coast'' switch and check for a reading of
114-126 ohms. d. On models with ``Resume,'' depress and hold ``Resume'' switch and check for a
reading of approximately 2200 ohms.
4. If resistance values are not as specified, inspect wiring, slip rings, turn signal copper brushes,
speed control switch and steering column for proper ground. Check for proper ground by
connecting an ohmmeter between upper steering column flange and a suitable ground. Resistance
should be less then 1/2 ohm. Rotate steering wheel throughout its full range and ensure flexible
coupling has a resistance of less than 1 ohm.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 6578
Cruise Control Switch: Service and Repair
1. Remove steering wheel pad attaching screws from behind steering wheel.
2. While pulling pad away from steering wheel, disconnect horn and speed control wire connectors
and remove pad.
3. Remove retaining nuts securing the speed control switches and trim plate retainer to the steering
wheel pad.
4. Disconnect wiring connector on rear of steering wheel pad assembly, then remove switch and
trim retainer assembly.
5. Remove speed control switches by snapping out of plastic retainer.
6. To remove the ground brush, remove steering wheel for access.
7. Snap the ground brush assembly out of the turn signal switch.
8. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Cruise Control Vacuum Vent Solenoid > Component Information > Locations
Cruise Control Vacuum Vent Solenoid: Locations
Top Of Brake Support
Top Of Brake Pedal Support
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component
Information > Locations
Cruise Control Module: Locations
Under LH Side Of I/P, With Speed Control
LH Side Of I/P, Near Steering Column
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component
Information > Locations > Page 6586
Cruise Control Module: Testing and Inspection
Use only a multi-meter of 5000 ohm/volt rating or higher when performing amplifier test.
``On'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground on models exc. 1983-87
Ranger, 1984-87 Bronco II and 1986-87 Aerostar or white wire w/purple stripe and ground on
1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar.
3. Battery voltage should be indicated when ``On'' switch on steering column is depressed and
held. If battery voltage is not indicated, check horn relay and perform control switch test.
4. Release ``On'' button. Voltmeter should indicate 7.8 volts indicating ``On'' circuit is engaged. If
voltage does not remain, check amplifier ground, fuses or circuit breakers or replace amplifier with
known good amplifier and repeat test.
5. Replace as necessary.
``Off'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground.
3. Depress ``Off'' button. Voltage should drop to zero indicating ``On'' circuit is de-energized.
4. If voltage does not drop to zero, perform ``Control Switch Test.''
``Set-Accelerate'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground.
3. Depress ``On'' switch, then hold ``Set-Accel'' button on steering wheel. Voltmeter should indicate
4.5 volts. Rotate steering wheel back and forth and check for voltmeter fluctuations. If reading
varies more than .5 volts, perform ``Control Switch Test.''
``Coast'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground.
3. Depress ``On'' switch, then depress and hold ``Coast'' button on steering wheel. Voltmeter
should indicate 1.5 volts. Rotate steering wheel back and forth and check for voltage fluctuations. If
reading varies more than .5 volts, perform ``Control Switch Test.''
``Resume'' Circuit Test
1. Turn ignition ``On.''
2. Connect a voltmeter between light blue wire w/black hash and ground.
3. Depress and hold ``Resume'' button. Voltmeter should indicate 6.5 volts.
If all circuits are functioning properly, perform ``Servo Assembly
Test'' using a known good amplifier. Do not replace amplifier before performing servo test.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Testing and Inspection
Brake Switch (Cruise Control): Testing and Inspection
Perform this test only when brake application will not disconnect the speed control system.
1. Check operation of stop lamps by applying approximately 6 lbs. of pressure to brake pedal. If
more than 6 lbs. is required, check brake pedal actuation and stop lamp switch.
2. If stop lamps do not function properly, check bulbs, circuit fuse or stop lamp switch.
3. If stop lamps function properly, check for battery voltage at 6 way connector using black wire
w/green stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 series, or white wire
w/pink stripe on 1981-82 F-100-350 and Bronco series, or white wire w/purple stripe on 1983
F-100-350, Bronco and Ranger, 1984-87 F-150-350, Ranger, 1984-87 Bronco II and 1986-87
Aerostar.
4. Depress brake pedal until stop lamps are illuminated. Check voltage at red wire w/black stripe on
1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 models, or the light green wire on
1981-83 F-100-350 and Bronco, 1984-87 F-150-350 and Bronco, 1983-87 Ranger, 1984-87 Bronco
II and 1986-87 Aerostar. The difference between the two voltage readings must not exceed 1.5
volts. If voltage is greater, a high resistance exists in the circuit and must be found and corrected.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Service and Repair
Clutch Switch: Service and Repair
1. Remove bracket mounting screw(s).
2. Disconnect electrical connector and remove switch and bracket assembly.
3. Remove switch from bracket.
4. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Locations
Cruise Control Switch: Locations
Part Of Steering Wheel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Diagrams > Diagram Information and Instructions
Cruise Control Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6599
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6600
Cruise Control Switch: Electrical Diagrams
Fig. 38 Horn & Speed Control Wiring Circuit (Part 1 of 2)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6601
Fig. 38 Horn & Speed Control Wiring Circuit (Part 2 of 2)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Diagrams > Page 6602
Cruise Control Switch: Testing and Inspection
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986 Aerostar Disconnect 6 way
connector from control switch at the amplifier, then perform the following checks:
1. Connect a voltmeter between light blue-black hash lead and ground, then depress the ``On''
button and check for battery voltage.
2. Turn ignition ``Off,'' then connect an ohmmeter between light blue-black hash lead and ground.
3. Rotate steering wheel throughout its full range while making the following checks:
a. Depress ``Off'' button and check for a reading of 0-1 ohm. b. Depress ``Set'' button and check for
a reading of 646-714 ohms. c. Depress and hold ``Coast'' switch and check for a reading of
114-126 ohms. d. On models with ``Resume,'' depress and hold ``Resume'' switch and check for a
reading of approximately 2200 ohms.
4. If resistance values are not as specified, inspect wiring, slip rings, turn signal copper brushes,
speed control switch and steering column for proper ground. Check for proper ground by
connecting an ohmmeter between upper steering column flange and a suitable ground. Resistance
should be less then 1/2 ohm. Rotate steering wheel throughout its full range and ensure flexible
coupling has a resistance of less than 1 ohm.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Diagrams > Page 6603
Cruise Control Switch: Service and Repair
1. Remove steering wheel pad attaching screws from behind steering wheel.
2. While pulling pad away from steering wheel, disconnect horn and speed control wire connectors
and remove pad.
3. Remove retaining nuts securing the speed control switches and trim plate retainer to the steering
wheel pad.
4. Disconnect wiring connector on rear of steering wheel pad assembly, then remove switch and
trim retainer assembly.
5. Remove speed control switches by snapping out of plastic retainer.
6. To remove the ground brush, remove steering wheel for access.
7. Snap the ground brush assembly out of the turn signal switch.
8. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Testing and Inspection
Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark
green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and
Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and
1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40
ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading
indicates an open coil.
2. Replace sensor if a correct reading has not been obtained.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Description
and Operation
Vacuum Vent Valve: Description and Operation
Fig. 24 Solenoid vacuum valve assembly. Normally closed type
Fig. 25 Solenoid vacuum valve assembly. Normally open & normally closed combination type
Fig. 26 Solenoid vacuum valve assembly. One port normally open & two port normally closed
combination type
There are three types of solenoid vacuum valve assemblies, Figs. 24, 25 and 26. The normally
closed solenoid vacuum valve assembly incorporates
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Description
and Operation > Page 6610
two vacuum ports and an atmospheric vent. When the solenoid is de-energized, the vacuum valve
assembly outlet port is open to the atmospheric vent and closed to the inlet port. When the
solenoid is energized, outlet port is open to the inlet port and closed to the atmospheric vent. Some
normally closed solenoid vacuum valves also incorporate a control bleed to prevent contamination
from the solenoid vacuum valve from entering the intake manifold. This solenoid valve assembly
can be used in the exhaust heat control valve , throttle kicker, air dump or air diverter valve
systems. The normally open and normally closed solenoid vacuum valve assembly, incorporates
two solenoid valves which operate independently of each other, but are mounted to a single
mounting bracket. Each solenoid valve controls a different device. This valve assembly is used to
control the Thermactor air bypass and Thermactor diverter. The one port normally open and two
port normally closed solenoid vacuum valve assembly also consist of two solenoid valve
assemblies mounted to a single mounting bracket. This valve assembly is used to control the A/C
throttle kicker and choke pulldown.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Description
and Operation > Page 6611
Vacuum Vent Valve: Testing and Inspection
1. Disconnect vacuum hose from the servo that leads to the dump valve.
2. Connect a hand vacuum pump to the hose, and draw vacuum. If vacuum cannot be obtained,
the hose or dump valve is leaking, and should be replaced.
3. Step on brake pedal. The vacuum should be released. If not, adjust or replace the dump valve.
2.5 inches of Hg is minimum vacuum for normal
servo operation. The vacuum source is a hose attached to a 5/16 inch engine vacuum fitting port
on all except 6.9 diesel. On the 6.9 diesel, the vacuum source is the vacuum reservoir ``Vac'' port.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Description
and Operation > Page 6612
Vacuum Vent Valve: Service and Repair
1. Remove vacuum hose from valve and remove bracket mounting screw.
2. Remove valve and bracket assembly.
3. Remove valve from the bracket.
4. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information >
Testing and Inspection
Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection
1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark
green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and
Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and
1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40
ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading
indicates an open coil.
2. Replace sensor if a correct reading has not been obtained.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Ammeter Gauge > Component Information
> Testing and Inspection
Ammeter Gauge: Testing and Inspection
The ammeter is an instrument used to indicate current flow into and out of the battery. When
electrical accessories in the vehicle draw more current than the alternator can supply, current flows
from the battery and the ammeter indicates a discharge ( - ) condition. When electrical loads of the
vehicle are less than alternator output, current is available to charge the battery, and the ammeter
indicates a charge (+) condition. If battery is fully charged, the voltage regulator reduces alternator
output to meet only immediate vehicle electrical loads. When this happens, ammeter reads zero.
Fig. 1 Conventional type ammeter
CONVENTIONAL AMMETER
A conventional ammeter must be connected between the battery and alternator in order to indicate
current flow. This type ammeter, Fig. 1, consists of a frame to which a permanent magnet is
attached. The frame also supports an armature and pointer assembly. Current in this system flows
from the alternator through the ammeter, then to the battery or from the battery through the
ammeter into the vehicle electrical system, depending on vehicle operating conditions. When no
current flows through the ammeter, the magnet holds the pointer armature so that the pointer
stands at the center of the dial. When current passes in either direction through the ammeter, the
resulting magnetic field attracts the armature away from the effect of the permanent magnet, thus
giving a reading proportional to the strength of the current flowing.
Troubleshooting When the ammeter apparently fails to register correctly, there may be trouble in
the wiring which connects the ammeter to the alternator and battery or in the alternator or battery
itself. To check the connections, first tighten the two terminal posts on the back of the ammeter.
Then, following each wire from the ammeter, tighten all connections on the ignition switch, battery
and alternator. Chafed, burned or broken insulation can be found by following each ammeter wire
from end to end. All wires with chafed, burned or broken insulation should be repaired or replaced.
After this is done, and all connections are tightened, connect the battery cable and turn on the
ignition switch. The needle should point slightly to the discharge ( - ) side. Start the engine and run
slightly above idling speed. The needle should move slowly to the charge side (+). If the pointer
does not move as indicated, the ammeter is out of order and should be replaced.
SHUNT TYPE AMMETER The shunt type ammeter is actually a specifically calibrated voltmeter. It
is connected to read voltage drop across a resistance wire (shunt) between the battery and
alternator. The shunt is located either in the vehicle wiring or within the ammeter itself. When
voltage is higher at the alternator end of the shunt, the meter indicates a charge (+) condition.
When voltage is higher at the battery end of the shunt, the meter indicates a discharge ( - )
condition. When voltage is equal at both ends of the shunt, the meter reads zero. Troubleshooting
Ammeter accuracy can be determined by comparing reading with an ammeter of known accuracy.
1. With engine stopped and ignition switch in RUN position, switch on headlamps and heater fan.
Meter should indicate a discharge ( - ) condition.
2. If ammeter pointer does not move, check ammeter terminals for proper connection and check for
open circuit in wiring harness. If connections and wiring harness are satisfactory, ammeter is
defective.
3. If ammeter indicates a charge (+) condition, wiring harness connections are reversed at
ammeter.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Locations
Audible Warning Device: Locations
At RH Side Of Fuse Block Bracket
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions
Audible Warning Device: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 6625
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 6626
Audible Warning Device: Electrical Diagrams
Fig. 43 Lights-On Warning Wiring Circuit (Part 1 of 2)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 6627
Fig. 43 Lights-On Warning Wiring Circuit (Part 2 of 2)
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 6628
Fig. 60 Seatbelt Warning Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Diagrams > Diagram Information and Instructions
Brake Warning Indicator: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 6633
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Diagrams > Diagram Information and Instructions > Page 6634
Fig. 57 Warning Indicators Wiring Circuit. Gasoline Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing
and Inspection
Clock: Testing and Inspection
Regulation of electric clocks is accomplished automatically by resetting the time. If the clock is
running fast, the action of turning the hands back to correct the time will automatically cause the
clock to run slightly slower. If the clock is running slow, the action of turning the hands forward to
correct the time will automatically cause the clock to run slightly faster (10 to 15 seconds daily). A
lockout feature prevents the clock regulator mechanism from being reset more than once per wind
cycle, regardless of the number of times the time is reset. After the clock rewinds, if the time is then
reset, automatic regulation will take place. If a clock varies over 10 minutes per day, it will never
adjust properly and must be repaired or replaced.
WINDING CLOCK WHEN CONNECTING BATTERY OR CLOCK WIRING The clock requires
special attention when reconnecting a battery that has been disconnected for any reason, a clock
that has been disconnected, or when replacing a blown clock fuse. It is very important that the
initial wind be fully made. The procedure is as follows:
1. Make sure that all other instruments and lights are turned off.
2. Connect positive cable to battery.
3. Before connecting the negative cable, press the terminal to its post on the battery. Immediately
afterward, strike the terminal against the battery post to see if there is a spark. If there is a spark,
allow the clock to run down until it stops ticking, and repeat as above until there is no spark. Then
immediately make the permanent connection before the clock can again run down. The clock will
run down in approximately two minutes.
4. Reset clock after all connections have been made. The foregoing procedure should also be
followed when reconnecting the clock after it has been disconnected, or if it has stopped because
of a blown fuse. Be sure to disconnect battery before installing a new fuse.
TROUBLESHOOTING If clock does not run, check for blown ``clock'' fuse. If fuse is blown, check
for short in wiring. If fuse is not blown, check for open circuit. With an electric clock, the most
frequent cause of clock fuse blowing is voltage at the clock which will prevent a complete wind and
allow clock contacts to remain closed. This may be caused by any of the following: discharged
battery, corrosion on contact surface of battery terminals, loose connections at battery terminals, at
junction block, at fuse clips, or at terminal connection of clock. Therefore, if in reconnecting battery
or clock it is noted that the clock is not ticking, always check for blown fuse, or examine the circuits
at the points indicated above to determine and correct the cause.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Coolant Level Indicator Lamp > Component
Information > Description and Operation
Coolant Level Indicator Lamp: Description and Operation
This lamp will be illuminated when engine coolant level in the radiator drops below a
pre-determined level. To turn lamp off, check cooling system, then add coolant to bring system to
proper level.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel >
Component Information > Service and Repair
Dashboard / Instrument Panel: Service and Repair
Fig. 12 Instrument Panel Attaching Locations. 1986-87 E-series.
Refer to Fig. 12 when performing this procedure.
1. Disconnect negative battery cable. 2. Remove Lefthand finish panel screws and pull rearward to
disengage friction cups, then disconnect wiring connectors and remove panel. 3. Remove screws
at top and bottom of instrument cluster finish panel, then pull rearward and disconnect
speedometer and wiring connectors. 4. Remove cluster. 5. Remove radio and clock, if equipped. 6.
Remove A/C grille from righthand end of instrument panel pad, if equipped. 7. Remove pad
attaching nuts, then the pad. 8. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations
Door Switch: Locations
Inside Doors
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > EGR Maintenance Light > Component
Information > Locations
EGR Maintenance Light: Locations
On Dash
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Component
Information > Technical Service Bulletins > Emission Maintenance Warning Module - Service
Emissions Maintenance Light: Technical Service Bulletins Emission Maintenance Warning Module
- Service
Article No. 89-22-8
^ EMISSION MAINTENANCE WARNING MODULE SERVICE INFORMATION
^ LAMP - "EMISSIONS/CHECK ENGINE" - EMISSION MAINTENANCE WARNING MODULE SERVICE INFORMATION
LIGHT TRUCK: 1985-89 BRONCO 1985-87 BRONCO II 1985-89 ECONOLINE, F-150, F-250,
F-350 1985-88 RANGER 1986-87 AEROSTAR
MEDIUM/HEAVY TRUCK: 1988-90 F & B SERIES
ISSUE: The Emission Maintenance Warning "EMW" module operates a light that is located on the
instrument panel. For 1985-87 model year vehicles, the light will display the word "EMISSIONS".
For 1988-89 model year vehicles, the light will display the words "CHECK ENGINE". When the light
is lit, it is indicating that the 60,000 mile emission maintenance should be performed. After the
maintenance is performed the EMW module must be reset to zero time. Another type of module is
the "IMS" module. This module is not part of the light circuit and does not require maintenance. At
a predetermined time, the IMS module directs the EEC IV processor to make a strategy change. A
third type of module is the "COMBO" module. This module combines the functions of the IMS and
the EMW modules.
ACTION: Refer to the following module application charts for the specific vehicle application and
location of the different types of modules.
NOTE: FOR APPLICATIONS NOT LOSTED IN THE FOLLOWING MODULE APPLICATION
CHARTS, THE "CHECK ENGINE" LIGHT IS CONTROLLED BY THE EEC IV PROCESSOR.
THESE VEHICLES DO NOT USE THE "EMW" MODULE.
1985 & 1986 MODULE APPLICATION CHART
1987 MODULE APPLICATION CHART
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Emissions Maintenance Light > Component
Information > Technical Service Bulletins > Emission Maintenance Warning Module - Service > Page 6654
1988 MODULE APPLICATION CHART
1989 MODULE APPLICATION CHART
1990 MODULE APPLICATION CHART PART NUMBER
PART NAME CLASS
E5TZ-12B514-C EMW Module - 1000 Hr BM
E5TZ-12B514-A EMW Module - 2000 Hr AM
E7TZ-12B514-A COMBO Module BM
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2300, 2500
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions
Fuel Gauge: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 6659
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 6660
Fuel Gauge: Electrical Diagrams
Fig. 26 Fuel Tank Selector Wiring Circuit. V8-302/5.0L & V8-460/7.5L Hot Fuel Handling
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 6661
Fig. 29 Fuel Tank Selector Wiring Circuit. V8-460/7.5L Hot Fuel Cutaway
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Diagrams > Diagram Information and Instructions > Page 6662
Fig. 28 Fuel Tank Selector Wiring Circuit. V8-351/5.8L Fuel Injected & V8-460/7.5L Non Hot Fuel
Handling
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Fuel Tank Sending Unit - Connector Replacement
Fuel Gauge Sender: Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement
FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT
WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT
Article No. 89-14-6
FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO,
THUNDERBIRD 1986-89 TAURUS
LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX
1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE
LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER
Figure 1
ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire
harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire
harness and cutting off the connector.
ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the
following procedure for service details.
1. Disconnect the battery ground.
2. Cut the connector from the new harness.
3. Leave 6-8 inches of wiring lead on the connector.
4. Remove the old connector from the fuel tank sending unit.
5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector.
6. Match the wire colors.
7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1.
8. Using a heat gun, seal the splice.
CAUTION: DO NOT USE AN OPEN FLAME.
9. Connect the battery ground.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Fuel Tank Sending Unit - Connector Replacement > Page 6667
10. Check the operation of the fuel gauge.
PART NUMBER PART NAME CLASS
E9FZ-9A400-A Wire Harness - Fuel Pump C
OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2300, 2310, 2400, 2770, 4500
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Technical Service Bulletins > Fuel Tank Sending Unit - Connector Replacement > Page 6668
Fuel Gauge Sender: Technical Service Bulletins Fuel Sender - Auxiliary Port Rubber Cap
Replacement
Article No. FUEL SYSTEM - 5.8L/7.5L - FUEL SENDER
87-7-26 AUXILIARY PORT - SERVICE REPLACEMENT RUBBER PORT CAP
LIGHT TRUCK: 1983-87 E-350
ISSUE: Recreational vehicles with cut away chassis are equipped with an auxiliary fuel port on the
fuel gauge sending unit of the aft fuel tank. The port is provided as a fuel source for a generator set
or other gasoline-powered accessories. When the auxiliary port is not used, it is covered with a
rubber port cap and clamped.
ACTION: If the rubber port cap requires replacement, use a new type service part EOPZ-9G270-A
(color coded with red paint). Be sure cap is securely clamped.
PART NUMBER PART NAME CLASS
EOPZ-9G270-A Port Cap C
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Locations > Auxiliary Tank Fuel Gauge Sender
Fuel Gauge Sender: Locations Auxiliary Tank Fuel Gauge Sender
Attached To Rear Fuel Tank
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Locations > Auxiliary Tank Fuel Gauge Sender > Page 6671
Fuel Gauge Sender: Locations Fuel Gauge Sender
Attached To Main Or Front Fuel Tank
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component
Information > Technical Service Bulletins > Customer Interest for Instrument Cluster / Carrier: > 932410 > Nov > 93 >
Instrument Cluster Warning Lights - Dimly Lit
Instrument Cluster / Carrier: Customer Interest Instrument Cluster Warning Lights - Dimly Lit
Article No. 93-24-10
11/24/93
^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG,
THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO
LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND
MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ
LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91
AEROSTAR 1991-93 EXPLORER
ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of
the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch.
ACTION:
If the vehicle displays the subject symptoms and meets the following conditions, replace the
ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for
1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks,
Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the
Parts Block in this article for correct parts usage.
CONDITIONS
^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring
schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component
Information > Technical Service Bulletins > Customer Interest for Instrument Cluster / Carrier: > 932410 > Nov > 93 >
Instrument Cluster Warning Lights - Dimly Lit > Page 6680
^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part
Number Chart.
NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL
HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN
IMPROVED TO CORRECT THE SUBJECT ISSUE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models
Except Lincolns. Major Component Warranty Coverage For Lincolns
OPERATION DESCRIPTION TIME
932410A Replace Ignition Switch - 0.5 Hr.
All Light and Compact Trucks
DEALER CODING
BASIC PART NO. CONDITION CODE
11572 X1
OASIS CODES: 201000, 201100, 206000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Cluster / Carrier: > 932410 > Nov >
93 > Instrument Cluster Warning Lights - Dimly Lit
Instrument Cluster / Carrier: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit
Article No. 93-24-10
11/24/93
^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG,
THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO
LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND
MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ
LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91
AEROSTAR 1991-93 EXPLORER
ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of
the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch.
ACTION:
If the vehicle displays the subject symptoms and meets the following conditions, replace the
ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for
1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks,
Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the
Parts Block in this article for correct parts usage.
CONDITIONS
^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring
schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Cluster / Carrier: > 932410 > Nov >
93 > Instrument Cluster Warning Lights - Dimly Lit > Page 6686
^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part
Number Chart.
NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL
HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN
IMPROVED TO CORRECT THE SUBJECT ISSUE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models
Except Lincolns. Major Component Warranty Coverage For Lincolns
OPERATION DESCRIPTION TIME
932410A Replace Ignition Switch - 0.5 Hr.
All Light and Compact Trucks
DEALER CODING
BASIC PART NO. CONDITION CODE
11572 X1
OASIS CODES: 201000, 201100, 206000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component
Information > Technical Service Bulletins > Page 6687
Instrument Cluster / Carrier: Service and Repair
Fig. 8 Instrument Cluster
E-100---350
1. Disconnect battery ground cable.
2. Remove steering column shroud.
3. On models equipped with tilt steering column, loosen column-to-band C support to provide
sufficient clearance for cluster removal.
4. On all models, remove 7 instrument cluster-to-instrument panel attaching screws.
5. Pull cluster back from panel and disconnect speedometer cable. It may be necessary to
disconnect speedometer cable from transmission to provide access to the quick disconnect on the
cluster.
6. Disconnect electrical connector from printed circuit board and remove cluster from vehicle, Fig.
9.
7. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component
Information > Locations
Low Fuel Lamp/Indicator: Locations
On Dash
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation
Maintenance Required Lamp/Indicator: Description and Operation
NOTE: This lamp is used only on models with Federal emissions systems.
The lamp will be illuminated after approximately 60,000 miles of operation. The amber lens is
located on the instrument panel and has the word Emissions, Emiss or EGR printed on it. On 1988
Ranger models with 2.0L/4-122 engine, the lamp lens will indicate Check Engine. After performing
the required emission control maintenance, the module must be replaced or reset, depending on
type of module used. On module equipped with reset feature, reset the module as follows:
1. Place ignition switch in the Off position.
2. On Aerostar models, the module is located under the instrument panel near the bulkhead
connector. On Bronco and F-Series, the module is attached to the instrument cluster to the left of
the steering column. On Bronco II and Ranger models, the module is located on the righthand side
of the instrument panel below the glove compartment. On E Series models, the module is located
under the lefthand side of the instrument panel.
3. On all models, insert a suitable phillips head screwdriver through .2 inch diameter hole located
on module near the reset sticker and lightly press down and hold.
4. While still lightly pressing down on screwdriver, turn ignition switch to Run position. The
emissions maintenance lamp should remain illuminated for as long as the screwdriver is pressing
down. Hold screwdriver in position for approximately five seconds.
5. Remove screwdriver, lamp should go out after approximately two to five seconds, indicating the
module has been reset. If lamp fails to go out, repeat reset procedure. Place ignition switch in the
Off position.
6. Turn ignition switch to Run position and check to ensure emission maintenance lamp is
illuminated for two to five seconds. After approximately two to five seconds the lamp should turn
off.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component
Information > Description and Operation
Malfunction Indicator Lamp: Description and Operation
Fig. 1 Jumper wire connections for resetting Check Engine Lamp.
1985-90 Models w/EEC-IV
This lamp will be illuminated when the ignition switch is placed in the On position. After engine is
started the lamp should go off, unless a problem has been detected by the EEC-IV system. After
diagnosis and repair, the Check Engine/MIL lamp will automatically reset when stored codes are
cleared from the EEC-IV system memory. After diagnosis and repair, EEC-IV memory may be
cleared of stored codes as follows:
1. With ignition switch in the Off position, connect a jumper wire between Self Test and Self Test
Input (STI) connectors, Fig. 1.
On Aerostar, the Self Test and STI connectors are gray in color and are located on lefthand fender
apron, near the Electronic Engine Control (EEC) relay. On Bronco and F Series, the Self Test and
STI connectors are located in the area of the EEC system charcoal canister. On Bronco II and
Ranger, the Self Test connector and STI connector are red in color and they are both located on
the righthand fender apron near the Electronic Engine Control (EEC) relay. On E Series, the Self
Test and the STI connectors are located on the righthand fender apron in the area of the MAP
sensor and starter motor relay.
2. Position ignition switch in On position, then disconnect jumper wire from test connector
terminals. Disconnect jumper as soon as Check Engine lamp starts flashing.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings
Odometer: Technical Service Bulletins Speedometer/Odometer - Inaccurate Readings
SPEEDOMETER - MECHANICAL/ELECTRONIC - INACCURATE SPEED READINGS AND
ODOMETER READINGS
Article No. 89-2-7
FORD: 1989 AND PRIOR ALL CAR LINES
LINCOLN-MERCURY: 1989 AND PRIOR ALL CAR LINES
LIGHT TRUCK: 1989 AND PRIOR ALL TRUCK LINES
ISSUE: The accuracy of speedometer/odometer readings may be influenced by several vehicle
components or systems. The information in this TSB article is intended to assist technicians in
speedometer/odometer concern diagnosis.
ACTION: Use the following supplemental information below to assist in speedometer/odometer
diagnostics.
OPERATION
A mechanical analog speedometer displays vehicle speed and the odometer displays total distance
traveled. The speedometer/odometer assembly is cable driven by either a transmission or a
transaxle. All speedometer/odometer assemblies, except for police vehicles are the same with
respect to the speed accuracy tolerance used during calibration. The odometer gear ratio is fixed
so that all are identical and have no error in the speedometer head.
Electronic digital operation is similar. It could use a drive cable or a speed sensor to drive the
speedometer/odometer. An electronic signal is sent from a speed sensor to the digital
speedometer/ odometer assembly. The speed sensor is driven by a transmission or a transaxle,
similar to a cable.
Several areas of concern that may affect speedometer/ odometer readings are tires, axle gear ratio
and speedometer/odometer drive and driven gears.
TIRES
Improper tire rolling radius and inflation pressure, temperature and size may contribute to
inaccurate system readings. System accuracy testing should be performed after the tires are set at
the correct pressure as shown on the safety compliance certification label. The tires should be
warmed for a short period. Best results are obtained on smooth, dry pavement while driving at a
constant speed within the posted speed limit.
AXLE/TRANSAXLE RATIO
The gear ratio of the rear axle or the final drive ratio of the transaxle must be known to select or
check if the proper speedometer/odometer drive and driven gears are present. Various gear ratios
are available, but usually are not a concern when dealing with speedometer/odometer concerns
unless the gear ratio has been changed.
WARNING: NEVER CORRECT SPEEDOMETER READINGS BY CHANGING GEARS UNLESS
THE ODOMETER IS ALSO OFF. DRIVE/DRIVEN GEARS
The speedometer/odometer drive gear is located inside the transmission, transaxle or transfer case
and is not easily accessed for change. The driven gear rotates the speedometer cable. Rear wheel
drive vehicles have several driven gears with various numbers of teeth available to correct input to
the speedometer/odometer head. Front wheel drive vehicles generally do not offer different gears
for correction.
GENERAL DESCRIPTION
The maximum allowable odometer system accuracy error is +/- 3.75% of the actual distance
traveled. Ford Motor vehicles are well within those limits.
The speed indication is biased high, except on police vehicles with certified calibration
speedometers/ odometers. As a general rule, the indicated speed is equal to or greater than the
actual speed. This is intended to protect the consumer against violating speed laws. Most customer
concerns are related to speedometers reading too high at true speeds between 50 MPH and 65
MPH (80 - 105 Km/h). At that speed range, the worst case errors may indicate a speed that is 10%
greater than true speed.
The speedometer head is an instrument which processes information sent to it by the rotating
speedometer cable. If the system components send the
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings > Page 6701
wrong number of revolution per mile to the speedometer head, an inaccurate speed reading and
amount of distanced traveled will be displayed. Since there is no error in the fixed gear ratio of the
speedometer head odometer, start by checking the accuracy of the odometer even if the customer
concern indicates a speed accuracy problem. Odometer accuracy can be checked by using roads
established at mile increments or a known local course. If roads with mile markers are used, a five
mile stretch is recommended to allow for inaccuracies. If an error is greater than 3.75%, a change
to the transmission drive/driven gear selection, tire size, or tire inflation may need attention. The
odometer should be checked again to verify any corrective action. If the indicated speed error
exceeds 10% between 50 MPH and 60 MPH (80 - 105 Km/h), replace the speedometer/odometer
assembly. Vehicles with transfer cases that have fluctuating readings may be due to slippage of
drive gears, parts not splined or loose yoke nuts.
If the vehicle has speed control, the speed accuracy can be checked using the verified odometer
vs. time. The formula is as follows:
3600 divided by TIME (seconds to cover one mile) = TRUE MPH (Km/h) EXAMPLES:
60 MPH (96 Km/h) requires 60 seconds to cover one mile
55 MPH (88 Km/h) requires 65 and 3/4 seconds to cover one mile
50 MPH (80 Km/h) requires 72 seconds to cover one mile
ARTICLE SUPERSEDED: 84-14-6, date 7/3/84
WARRANTY STATUS: "INFORMATION ONLY"
OASIS CODES: 2300, 2310, 2400, 2500
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > Customer Interest: > 932410 > Nov > 93 > Instrument Cluster Warning Lights Dimly Lit
Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit
Article No. 93-24-10
11/24/93
^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG,
THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO
LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND
MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ
LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91
AEROSTAR 1991-93 EXPLORER
ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of
the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch.
ACTION:
If the vehicle displays the subject symptoms and meets the following conditions, replace the
ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for
1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks,
Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the
Parts Block in this article for correct parts usage.
CONDITIONS
^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring
schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > Customer Interest: > 932410 > Nov > 93 > Instrument Cluster Warning Lights Dimly Lit > Page 6710
^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part
Number Chart.
NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL
HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN
IMPROVED TO CORRECT THE SUBJECT ISSUE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models
Except Lincolns. Major Component Warranty Coverage For Lincolns
OPERATION DESCRIPTION TIME
932410A Replace Ignition Switch - 0.5 Hr.
All Light and Compact Trucks
DEALER CODING
BASIC PART NO. CONDITION CODE
11572 X1
OASIS CODES: 201000, 201100, 206000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 932410 > Nov > 93 > Instrument Cluster
Warning Lights - Dimly Lit
Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit
Article No. 93-24-10
11/24/93
^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER
8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION
SWITCHES AFTER 8/1/92
FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG,
THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO
LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND
MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ
LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91
AEROSTAR 1991-93 EXPLORER
ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of
the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch.
ACTION:
If the vehicle displays the subject symptoms and meets the following conditions, replace the
ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for
1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks,
Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the
Parts Block in this article for correct parts usage.
CONDITIONS
^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring
schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 932410 > Nov > 93 > Instrument Cluster
Warning Lights - Dimly Lit > Page 6716
^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part
Number Chart.
NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL
HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN
IMPROVED TO CORRECT THE SUBJECT ISSUE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of
The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models
Except Lincolns. Major Component Warranty Coverage For Lincolns
OPERATION DESCRIPTION TIME
932410A Replace Ignition Switch - 0.5 Hr.
All Light and Compact Trucks
DEALER CODING
BASIC PART NO. CONDITION CODE
11572 X1
OASIS CODES: 201000, 201100, 206000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Oil Level Warning Indicator: > 921514 > Jul > 92 >
Engine - Cooling Concerns and/or Vibration
Fan Clutch: All Technical Service Bulletins Engine - Cooling Concerns and/or Vibration
Article No. 92-15-14
09/15/92
^ COOLING SYSTEM - OVERHEATING - ENGINE FAN CLUTCH NOT FUNCTIONING
PROPERLY
^ ENGINE COOLING FAN CLUTCH - DIAGNOSTIC PROCEDURE
^ VIBRATION - ENGINE FAN CLUTCH NOT FUNCTIONING PROPERLY
LIGHT TRUCK: 1987-92 BRONCO, ECONOLINE, F-150-350 SERIES 1988-92 F SUPER DUTY
ISSUE: A comprehensive diagnostic procedure has been developed for determining if the engine
cooling fan clutch is functioning properly. A fan clutch that is not functioning properly may cause
engine cooling concerns and/or vibration.
ACTION: Use the following diagnostic procedure to determine if the fan clutch is functioning
properly. A fan clutch that is not functioning properly should be replaced.
CAUTION: DO NOT ATTEMPT TO MODIFY THE BI-METALLIC COIL ON THE FACE OF THE
FAN CLUTCH.
DIAGNOSTIC PROCEDURE
NOTE: PROCEED ONLY AFTER COMPLETING THE ENGINE COOLING DIAGNOSIS
PROCEDURE IN SECTION 03-03 AND THE ACCESSORY DRIVE BELT TENSION
PROCEDURE IN SECTION 03-05 OF THE APPROPRIATE SERVICE MANUAL.
1. Turn off the air conditioner, heater-A/C fan and radio.
2. Check for viscous drag...
a. Before starting the engine, rotate the fan and clutch assembly by hand. It should have some
viscous drag, but it should turn smoothly during the full 360~ of rotation.
b. Replace the fan clutch if it does not turn smoothly or does not turn at all. Refer to the Dealer
Master Parts Catalog for correct parts usage. Refer to the appropriate Service Manual, Section
03-05, for service details.
c. Replace the fan if there are any cracks.
d. If this is not the concern, go to Step 3.
3. Check for lack of viscous drag...
a. If the fan clutch spins with no viscous drag when it is cold, and it has not been run for an hour or
more, it should be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage.
Refer to the appropriate Service Manual, Section 03-05, for service details.
b. If this is not the concern, go to Step 4.
4. Check for excessive fan clutch bearing clearance (cold fan clutch)...
a. Hold the tip of the fan blade between the thumb and forefinger.
b. Lightly pull toward the radiator, then push toward the engine.
c. Repeat the motion several times.
^ The total rocking movement at the end of the fan blade should be 2/10" (5.1 mm) or less when no
more than eight (8) ounces of force is applied.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Oil Level Warning Indicator: > 921514 > Jul > 92 >
Engine - Cooling Concerns and/or Vibration > Page 6722
^ A force greater than eight (8) ounces may deflect the fan blade with erroneous results.
d. Replace the fan clutch if more than 2/10" (5.1 mm) of movement is observed. Refer to the Dealer
Master Parts Catalog for correct parts usage. Refer to the appropriate Service Manual, Section
03-05, for service details.
e. If this is not the concern, go to Step 5.
5. Install a temporary engine tachometer if the vehicle is not equipped with a tachometer.
NOTE: DURING THE FOLLOWING TESTS, BE SURE TO MONITOR THE ENGINE COOLANT
TEMPERATURE BY THE TEMPERATURE GAUGE IN THE INSTRUMENT CLUSTER. SHUT
OFF THE ENGINE IF THE TEMPERATURE RISES ABOVE THE MAXIMUM RECOMMENDED
LIMIT FOR THE ENGINE OR IF COOLANT IS DISCHARGED OUTSIDE THE SYSTEM. THE
TESTS CAN BE RESUMED USING THE FOLLOWING PROCEDURES AFTER THE COOLANT
TEMPERATURE DROPS TO A NORMAL OPERATING LEVEL.
NOTE: IF THE HOOD IS LEFT OPEN, THE FAN NOISE MAY BE EASIER TO HEAR.
WARNING: DO NOT STAND IN LINE WITH THE FAN.
6. Start the engine.
7. Check for fan disengagement and be aware of the following operational characteristics.
^ The fan clutch may be engaged when the engine is first started. This will be apparent from the
noise level of the fan which has a distinctive roar.
^ The fan clutch engagement is due to the viscous silicone fluid draining back and filling the gap
between input and output components.
^ Running the engine at a constant speed of about 2000 rpm should pump the fluid back to its
reservoir, disengaging the fan clutch after no more than five minutes.
^ As the fan speed declines, the noise will drop off to a level inaudible to most observers.
a. Continuing the test, if the fan clutch does not reengage after five more minutes at 2000 rpm, the
fan clutch should be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage.
Refer to the appropriate Service Manual, Section 03-05, for service details.
b. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
c. If this is not the concern, go to Step 8.
8. Stop the engine.
a. Cut and install a piece of cardboard large enough to cover the front of the radiator with a six inch
diameter hole in line with the fan clutch.
b. If it is not possible to install the cardboard directly against the radiator, attach it to the A/C
condenser.
9. Start the engine.
a. With the gas engine at 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm, the vehicle
temperature gauge will rise steadily as the engine warms and then appear to level off for a short
time when the thermostat opens.
b. Make note of the temperature gauge position when the thermostat opens. The engine coolant
temperature will continue to rise until the fan clutch engages.
10. Check for fan engagement...
a. Continue to observe the coolant temperature gauge. As the fan clutch engages, the fan noise
will continue to increase and then level off at full engagement. The fan clutch may cycle off-and-on
a few times during the initial engagement.
b. If the fan clutch does not engage before the maximum indicated safe operating engine coolant
temperature is reached, it should be replaced. Refer to the Dealer Master Parts Catalog for correct
parts usage. Refer to the appropriate Service Manual, Section 03-05, for service details.
c. Repeat the test procedure after fan clutch replacement to verify the fix and to assure customer
satisfaction. The rate of rise of the coolant
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Oil Level Warning Indicator: > 921514 > Jul > 92 >
Engine - Cooling Concerns and/or Vibration > Page 6723
temperature will slow down after clutch engagement, but it will continue to rise as long as the
radiator remains covered.
d. If this is not the concern, go to Step 11.
11. Check for fan disengagement...
a. After completion of the above tests, shut off the engine.
b. Remove the cardboard cover from the front of the radiator.
c. Restart and return the gas engine to 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm,
continuing to watch the coolant temperature which will begin to decrease. The fan rpm will drop to
a reduced noise level where it was before the cycle began which indicates that the fan clutch has
disengaged.
d. If the fan clutch remains engaged and the coolant temperature has dropped below the
thermostat opening temperature (as noted in Step 9) for at least five minutes, the fan clutch should
be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage. Refer to the
appropriate Service Manual, Section 03-05, for service details.
e. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
WARRANTY STATUS AND OPERATION DESCRIPTION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Oil Level Warning Indicator: > 921514 > Jul > 92 >
Engine - Cooling Concerns and/or Vibration > Page 6729
^ A force greater than eight (8) ounces may deflect the fan blade with erroneous results.
d. Replace the fan clutch if more than 2/10" (5.1 mm) of movement is observed. Refer to the Dealer
Master Parts Catalog for correct parts usage. Refer to the appropriate Service Manual, Section
03-05, for service details.
e. If this is not the concern, go to Step 5.
5. Install a temporary engine tachometer if the vehicle is not equipped with a tachometer.
NOTE: DURING THE FOLLOWING TESTS, BE SURE TO MONITOR THE ENGINE COOLANT
TEMPERATURE BY THE TEMPERATURE GAUGE IN THE INSTRUMENT CLUSTER. SHUT
OFF THE ENGINE IF THE TEMPERATURE RISES ABOVE THE MAXIMUM RECOMMENDED
LIMIT FOR THE ENGINE OR IF COOLANT IS DISCHARGED OUTSIDE THE SYSTEM. THE
TESTS CAN BE RESUMED USING THE FOLLOWING PROCEDURES AFTER THE COOLANT
TEMPERATURE DROPS TO A NORMAL OPERATING LEVEL.
NOTE: IF THE HOOD IS LEFT OPEN, THE FAN NOISE MAY BE EASIER TO HEAR.
WARNING: DO NOT STAND IN LINE WITH THE FAN.
6. Start the engine.
7. Check for fan disengagement and be aware of the following operational characteristics.
^ The fan clutch may be engaged when the engine is first started. This will be apparent from the
noise level of the fan which has a distinctive roar.
^ The fan clutch engagement is due to the viscous silicone fluid draining back and filling the gap
between input and output components.
^ Running the engine at a constant speed of about 2000 rpm should pump the fluid back to its
reservoir, disengaging the fan clutch after no more than five minutes.
^ As the fan speed declines, the noise will drop off to a level inaudible to most observers.
a. Continuing the test, if the fan clutch does not reengage after five more minutes at 2000 rpm, the
fan clutch should be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage.
Refer to the appropriate Service Manual, Section 03-05, for service details.
b. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
c. If this is not the concern, go to Step 8.
8. Stop the engine.
a. Cut and install a piece of cardboard large enough to cover the front of the radiator with a six inch
diameter hole in line with the fan clutch.
b. If it is not possible to install the cardboard directly against the radiator, attach it to the A/C
condenser.
9. Start the engine.
a. With the gas engine at 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm, the vehicle
temperature gauge will rise steadily as the engine warms and then appear to level off for a short
time when the thermostat opens.
b. Make note of the temperature gauge position when the thermostat opens. The engine coolant
temperature will continue to rise until the fan clutch engages.
10. Check for fan engagement...
a. Continue to observe the coolant temperature gauge. As the fan clutch engages, the fan noise
will continue to increase and then level off at full engagement. The fan clutch may cycle off-and-on
a few times during the initial engagement.
b. If the fan clutch does not engage before the maximum indicated safe operating engine coolant
temperature is reached, it should be replaced. Refer to the Dealer Master Parts Catalog for correct
parts usage. Refer to the appropriate Service Manual, Section 03-05, for service details.
c. Repeat the test procedure after fan clutch replacement to verify the fix and to assure customer
satisfaction. The rate of rise of the coolant
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Oil Level Warning Indicator: > 921514 > Jul > 92 >
Engine - Cooling Concerns and/or Vibration > Page 6730
temperature will slow down after clutch engagement, but it will continue to rise as long as the
radiator remains covered.
d. If this is not the concern, go to Step 11.
11. Check for fan disengagement...
a. After completion of the above tests, shut off the engine.
b. Remove the cardboard cover from the front of the radiator.
c. Restart and return the gas engine to 2700 to 3000 rpm or diesel engine at 2100 to 2300 rpm,
continuing to watch the coolant temperature which will begin to decrease. The fan rpm will drop to
a reduced noise level where it was before the cycle began which indicates that the fan clutch has
disengaged.
d. If the fan clutch remains engaged and the coolant temperature has dropped below the
thermostat opening temperature (as noted in Step 9) for at least five minutes, the fan clutch should
be replaced. Refer to the Dealer Master Parts Catalog for correct parts usage. Refer to the
appropriate Service Manual, Section 03-05, for service details.
e. Repeat the test procedure after fan clutch replacement to confirm the fix and to assure customer
satisfaction.
WARRANTY STATUS AND OPERATION DESCRIPTION
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component
Information > Technical Service Bulletins > Page 6731
Oil Level Warning Indicator: Description and Operation
This system is used to indicate a low engine oil level condition. The lamp will be illuminated during
engine starting. If oil level is sufficient, the lamp will go off when engine is operating. If oil level is
low the lamp will remain on until engine oil is added and the ignition switch is placed in the Off
position. The module may take a few minutes to reset. If the engine is started during this period,
the last recorded reading will be displayed.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component
Information > Testing and Inspection
Oil Pressure Gauge: Testing and Inspection
This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil
pressure gauge and a sending unit which are connected in series. The sending unit consists of a
diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm
actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil
pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge,
in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor
is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge
reading.
TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions
included with the tester.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations
Oil Pressure Sender: Locations
LH Side Of V8-460/7.
Top Center Rear Of Engine
Applicable to: 5L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator >
Component Information > Testing and Inspection
Oil Pressure Warning Lamp/Indicator: Testing and Inspection
Many trucks utilize a warning light on the instrument panel in place of the conventional dash
indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is
wired in series with the ignition switch and the engine unit--which is an oil pressure switch. The oil
pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on,
the warning light circuit is energized and the circuit is completed through the closed contacts in the
pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm,
opening the contacts, thereby breaking the circuit and putting out the light.
TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If
it does not light, disconnect the wire from the engine unit and ground the wire to the frame or
cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the
bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the
engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight
and properly grounded, it should be removed and a new one installed. (The presence of sealing
compound on the threads of the engine unit will cause a poor ground). If the warning light remains
lit when it normally should be out, replace the engine unit before proceeding further to determine
the cause for a low pressure indication. The warning light will sometimes light up or flicker when the
engine is idling, even though the oil pressure is adequate. However, the light should go out when
the engine speed is increased.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch >
Component Information > Locations
Parking Brake Warning Switch: Locations
Top Of Parking Brake Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Speedometer Module > Component Information > Technical Service Bulletins > Speedometer Display - Parts Return
Speedometer Module: Technical Service Bulletins Speedometer Display - Parts Return
TSB # MEMO 122187
December 21, 1987
To: All Ford and Lincoln Mercury Dealers
Subject: Request for Return of Speedo Display Assemblies E5SZ-17B383-AR E5SZ-17B383-CR
E69Z-17B383-B
Because the subject parts may not meet Ford's high quality requirements, all unused subject parts
should be withdrawn from inventory and returned to your facing P.D.C. within 30 days from the
date of this letter. Use the least expensive mode of transportation for your return. Replacement
stock is available for ordering immediately.
You are requested to complete a separate FPS-340 form in accordance with the instructions on the
front of this form. Annotate "Returned Per FPSD Instructions Purge No. PN 1042" in the
Customer's Detail Explanation Section and use Reason Code J (unsatisfactory Service Stock).
You will receive full credit in your parts statement for the price of each unused part returned, plus
the prepaid transportation cost. In order to receive return credit, all parts must be received at the
Parts Distribution Center within 30 days from the date of this letter. Material other than subject
parts received on this return will be sent back to you freight collect.
Any questions should be referred to your Zone Manager or facing P.D.C. Manager.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations
Door Switch: Locations
Inside Doors
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Tank Sending Unit - Connector
Replacement
Fuel Gauge Sender: Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement
FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT
WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT
Article No. 89-14-6
FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO,
THUNDERBIRD 1986-89 TAURUS
LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX
1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE
LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER
Figure 1
ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire
harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire
harness and cutting off the connector.
ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the
following procedure for service details.
1. Disconnect the battery ground.
2. Cut the connector from the new harness.
3. Leave 6-8 inches of wiring lead on the connector.
4. Remove the old connector from the fuel tank sending unit.
5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector.
6. Match the wire colors.
7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1.
8. Using a heat gun, seal the splice.
CAUTION: DO NOT USE AN OPEN FLAME.
9. Connect the battery ground.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Tank Sending Unit - Connector
Replacement > Page 6757
10. Check the operation of the fuel gauge.
PART NUMBER PART NAME CLASS
E9FZ-9A400-A Wire Harness - Fuel Pump C
OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES:
2300, 2310, 2400, 2770, 4500
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Technical Service Bulletins > Fuel Tank Sending Unit - Connector
Replacement > Page 6758
Fuel Gauge Sender: Technical Service Bulletins Fuel Sender - Auxiliary Port Rubber Cap
Replacement
Article No. FUEL SYSTEM - 5.8L/7.5L - FUEL SENDER
87-7-26 AUXILIARY PORT - SERVICE REPLACEMENT RUBBER PORT CAP
LIGHT TRUCK: 1983-87 E-350
ISSUE: Recreational vehicles with cut away chassis are equipped with an auxiliary fuel port on the
fuel gauge sending unit of the aft fuel tank. The port is provided as a fuel source for a generator set
or other gasoline-powered accessories. When the auxiliary port is not used, it is covered with a
rubber port cap and clamped.
ACTION: If the rubber port cap requires replacement, use a new type service part EOPZ-9G270-A
(color coded with red paint). Be sure cap is securely clamped.
PART NUMBER PART NAME CLASS
EOPZ-9G270-A Port Cap C
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Locations > Auxiliary Tank Fuel Gauge Sender
Fuel Gauge Sender: Locations Auxiliary Tank Fuel Gauge Sender
Attached To Rear Fuel Tank
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Locations > Auxiliary Tank Fuel Gauge Sender > Page 6761
Fuel Gauge Sender: Locations Fuel Gauge Sender
Attached To Main Or Front Fuel Tank
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Parking Brake Warning Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
Top Of Parking Brake Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Turbo Boost Gauge Sending Unit > Component Information > Locations
Turbo Boost Gauge Sending Unit: Locations
LH Side Of Diesel Engine
Front LH Side Of Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Cable > Component
Information > Testing and Inspection
Speedometer Cable: Testing and Inspection
The following material covers only that service on speedometers which is feasible to perform.
Repairs on the units themselves are not included as they require special tools and extreme care
when making repairs and adjustments that only an experienced speedometer mechanic should
attempt. The speedometer has two main parts, the speedometer head and the speedometer drive
cable. When the speedometer fails to indicate speed or mileage, the cable or cable housing is
probably broken. On vehicles are equipped with speed control, there is a speed sensor attached to
the transmission. This is used to sense the revolutions of cable assembly and to regulate speed
control.
SPEEDOMETER CABLE Most cables are broken due to lack of lubrication, or a sharp bend or kink
in the housing. A cable might break because of the speedometer head mechanism binds. In such
cases, the speedometer head should be repaired or replaced before a new cable or housing is
installed. A ``jumpy'' pointer condition, together with a scraping noise, is due, in most instances, to
a dry or kinked speedometer cable. The kinked cable rubs on the housing and winds up, slowing
down the pointer. The cable then unwinds and the pointer ``jumps.'' To check for kinks, remove the
cable, lay it on a flat surface and twist one end with the fingers. If it turns over smoothly the cable is
not kinked. But if part of the cable flops over as it is twisted, the cable is kinked and should be
replaced.
LUBRICATION The speedometer cable should be lubricated with special cable lubricant. Fill the
ferrule on the upper end of the housing with the cable lubricant. Insert the cable in the housing,
starting at the upper end. Turn the cable around carefully while feeding it into the housing. Repeat
filling the ferrule except for the last six inches of cable. Too much lubricant at this point may cause
the lubricant to work into the speedometer head.
INSTALLING CABLE During installation, if the cable sticks when inserted in the housing and will
not go through, the housing is damaged inside or kinked. Be sure to check the housing from one
end to the other. Straighten any sharp bends by relocating clamps or elbows. Replace housing if it
is badly kinked or broken. Position the cable and housing so that they lead into the head as straight
as possible. Check the new cable for kinks before installing it. Use wide, sweeping, gradual curves
where the cable comes out of the transmission and connects to the head so the cable will not be
damaged during installation. Arrange the housing so it does not lean against the engine because
heat from the engine may dry out the lubricant. If inspection indicates that the cable and housing
are in good condition, yet pointer action is erratic, check the speedometer head for possible
binding. The speedometer drive pinion should also be checked. If the pinion is dry or its teeth are
stripped, the speedometer may not register properly.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings
Speedometer Head: Technical Service Bulletins Speedometer/Odometer - Inaccurate Readings
SPEEDOMETER - MECHANICAL/ELECTRONIC - INACCURATE SPEED READINGS AND
ODOMETER READINGS
Article No. 89-2-7
FORD: 1989 AND PRIOR ALL CAR LINES
LINCOLN-MERCURY: 1989 AND PRIOR ALL CAR LINES
LIGHT TRUCK: 1989 AND PRIOR ALL TRUCK LINES
ISSUE: The accuracy of speedometer/odometer readings may be influenced by several vehicle
components or systems. The information in this TSB article is intended to assist technicians in
speedometer/odometer concern diagnosis.
ACTION: Use the following supplemental information below to assist in speedometer/odometer
diagnostics.
OPERATION
A mechanical analog speedometer displays vehicle speed and the odometer displays total distance
traveled. The speedometer/odometer assembly is cable driven by either a transmission or a
transaxle. All speedometer/odometer assemblies, except for police vehicles are the same with
respect to the speed accuracy tolerance used during calibration. The odometer gear ratio is fixed
so that all are identical and have no error in the speedometer head.
Electronic digital operation is similar. It could use a drive cable or a speed sensor to drive the
speedometer/odometer. An electronic signal is sent from a speed sensor to the digital
speedometer/ odometer assembly. The speed sensor is driven by a transmission or a transaxle,
similar to a cable.
Several areas of concern that may affect speedometer/ odometer readings are tires, axle gear ratio
and speedometer/odometer drive and driven gears.
TIRES
Improper tire rolling radius and inflation pressure, temperature and size may contribute to
inaccurate system readings. System accuracy testing should be performed after the tires are set at
the correct pressure as shown on the safety compliance certification label. The tires should be
warmed for a short period. Best results are obtained on smooth, dry pavement while driving at a
constant speed within the posted speed limit.
AXLE/TRANSAXLE RATIO
The gear ratio of the rear axle or the final drive ratio of the transaxle must be known to select or
check if the proper speedometer/odometer drive and driven gears are present. Various gear ratios
are available, but usually are not a concern when dealing with speedometer/odometer concerns
unless the gear ratio has been changed.
WARNING: NEVER CORRECT SPEEDOMETER READINGS BY CHANGING GEARS UNLESS
THE ODOMETER IS ALSO OFF. DRIVE/DRIVEN GEARS
The speedometer/odometer drive gear is located inside the transmission, transaxle or transfer case
and is not easily accessed for change. The driven gear rotates the speedometer cable. Rear wheel
drive vehicles have several driven gears with various numbers of teeth available to correct input to
the speedometer/odometer head. Front wheel drive vehicles generally do not offer different gears
for correction.
GENERAL DESCRIPTION
The maximum allowable odometer system accuracy error is +/- 3.75% of the actual distance
traveled. Ford Motor vehicles are well within those limits.
The speed indication is biased high, except on police vehicles with certified calibration
speedometers/ odometers. As a general rule, the indicated speed is equal to or greater than the
actual speed. This is intended to protect the consumer against violating speed laws. Most customer
concerns are related to speedometers reading too high at true speeds between 50 MPH and 65
MPH (80 - 105 Km/h). At that speed range, the worst case errors may indicate a speed that is 10%
greater than true speed.
The speedometer head is an instrument which processes information sent to it by the rotating
speedometer cable. If the system components send the
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings > Page 6775
wrong number of revolution per mile to the speedometer head, an inaccurate speed reading and
amount of distanced traveled will be displayed. Since there is no error in the fixed gear ratio of the
speedometer head odometer, start by checking the accuracy of the odometer even if the customer
concern indicates a speed accuracy problem. Odometer accuracy can be checked by using roads
established at mile increments or a known local course. If roads with mile markers are used, a five
mile stretch is recommended to allow for inaccuracies. If an error is greater than 3.75%, a change
to the transmission drive/driven gear selection, tire size, or tire inflation may need attention. The
odometer should be checked again to verify any corrective action. If the indicated speed error
exceeds 10% between 50 MPH and 60 MPH (80 - 105 Km/h), replace the speedometer/odometer
assembly. Vehicles with transfer cases that have fluctuating readings may be due to slippage of
drive gears, parts not splined or loose yoke nuts.
If the vehicle has speed control, the speed accuracy can be checked using the verified odometer
vs. time. The formula is as follows:
3600 divided by TIME (seconds to cover one mile) = TRUE MPH (Km/h) EXAMPLES:
60 MPH (96 Km/h) requires 60 seconds to cover one mile
55 MPH (88 Km/h) requires 65 and 3/4 seconds to cover one mile
50 MPH (80 Km/h) requires 72 seconds to cover one mile
ARTICLE SUPERSEDED: 84-14-6, date 7/3/84
WARRANTY STATUS: "INFORMATION ONLY"
OASIS CODES: 2300, 2310, 2400, 2500
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component
Information > Technical Service Bulletins > Speedometer Display - Parts Return
Speedometer Module: Technical Service Bulletins Speedometer Display - Parts Return
TSB # MEMO 122187
December 21, 1987
To: All Ford and Lincoln Mercury Dealers
Subject: Request for Return of Speedo Display Assemblies E5SZ-17B383-AR E5SZ-17B383-CR
E69Z-17B383-B
Because the subject parts may not meet Ford's high quality requirements, all unused subject parts
should be withdrawn from inventory and returned to your facing P.D.C. within 30 days from the
date of this letter. Use the least expensive mode of transportation for your return. Replacement
stock is available for ordering immediately.
You are requested to complete a separate FPS-340 form in accordance with the instructions on the
front of this form. Annotate "Returned Per FPSD Instructions Purge No. PN 1042" in the
Customer's Detail Explanation Section and use Reason Code J (unsatisfactory Service Stock).
You will receive full credit in your parts statement for the price of each unused part returned, plus
the prepaid transportation cost. In order to receive return credit, all parts must be received at the
Parts Distribution Center within 30 days from the date of this letter. Material other than subject
parts received on this return will be sent back to you freight collect.
Any questions should be referred to your Zone Manager or facing P.D.C. Manager.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Dash Gauge Test
Temperature Gauge: Testing and Inspection Dash Gauge Test
Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble
should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by
clamps, check to see whether the insulation has been severed, thereby grounding the wire. In the
case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of
the tank unit. The Constant Voltage Regulator (CVR) type indicator is a bimetal-resistance type
system consisting of an Instrument Voltage Regulator (IVR), an indicator gauge, and a variable
resistance sending unit. Current to the system is applied to the gauge terminals by the IVR, which
maintains an average-pulsating value of 5 volts. The indicator gauge consists of a pointer which is
attached to a wire-wound bimetal strip. Current passing through the coil heats the bimetal strip,
causing the pointer to move. As more current passes through the coil, heat increases, moving the
pointer farther. The circuit is completed through a sending unit which contains a variable resistor.
When resistance is high, less current is allowed to pass through the gauge, and the pointer moves
very little. As resistance decreases due to changing conditions in system being monitored, more
current passes through gauge coil, causing pointer to move farther. Do not apply battery voltage to
system or ground output terminals of IVR, as damage to system components or wiring circuits may
result.
DASH GAUGE TEST
1. Disconnect battery ground cable and remove gauge from vehicle.
2. Connect ohmmeter between gauge terminals and read coil winding resistance.
3. An upward movement of ohmmeter needle from 10 ohms to 14 ohms is normal, as test current
of ohmmeter causes a temperature rise in gauge coil windings.
4. If ohmmeter reads below 10 ohms or above 14 ohms, gauge is defective.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Dash Gauge Test > Page 6784
Temperature Gauge: Testing and Inspection Electrical Temperature Gauges
This temperature indicating system consists of a sending unit, located on the cylinder head,
electrical temperature gauge and an instrument voltage regulator. As engine temperature increases
or decreases, the resistance of the sending unit changes, in turn controlling current flow to the
gauge. When engine temperature is low, the resistance of the sending unit is high, restricting
current flow to the gauge, in turn indicating low engine temperature. As engine temperature
increases, the resistance of the ending unit decreases, permitting an increased current flow to the
gauge, resulting in an increased temperature reading.
TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions
included with the tester.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component
Information > Locations
Temperature Sensor (Gauge): Locations
LH Side Of V8-460/7.
LH Front Of Engine
Applicable to: 5L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator,
Engine Cooling > Component Information > Testing and Inspection
Temperature Warning Lamp/Indicator: Testing and Inspection
A bimetal temperature switch located in the cylinder head control the operation of a temperature
indicator light with a red lens. If the engine cooling system is not functioning properly and coolant
temperature exceeds a predetermined value, the warning light will illuminate.
TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a
burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when
the engine is running, check the wiring between light and switch for a ground, defective
temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is
functioning properly, a wire which is connected to the ground terminal of the ignition switch is
tapped into its circuit. When the ignition is in the ``Start'' (engine cranking) position, the ground
terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and
the ignition switch is in the ``On'' position, the test circuit is opened and the bulb is then controlled
by the temperature switch.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Turbo Boost Gauge > Turbo Boost Gauge
Sending Unit > Component Information > Locations
Turbo Boost Gauge Sending Unit: Locations
LH Side Of Diesel Engine
Front LH Side Of Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information
> Testing and Inspection
Volt Meter Gauge: Testing and Inspection
The voltmeter is a gauge which measures the electrical flow from the battery to indicate whether
the battery output is within tolerances. The voltmeter reading can range from 13.5---14.0 volts
under normal operating conditions. If an undercharge or overcharge condition is indicated for an
extended period, the battery and charging system should be checked.
TROUBLESHOOTING To check voltmeter, turn key and headlights on with engine off. Pointer
should move to 12.5 volts. If no needle movement is observed, check connections from battery to
circuit breaker. If connections are tight and meter shows no movement, check wire continuity. If
wire continuity is satisfactory, the meter is inoperative and must be replaced.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Manual Transmission
Backup Lamp Switch: Locations Manual Transmission
Rear Of V8-302/5.
Attached To Shifter Assembly
Applicable to: 0L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Locations > Manual Transmission > Page 6804
Backup Lamp Switch: Locations 3-Speed Manual Transmission
Attached To Transmission Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Brake Lamp: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 6809
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 6810
Fig. 35 Hazard Lights Wiring Circuit. With Stop & Turn Signals
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations
Brake Light Switch: Locations
Top Of Brake Support
Top Of Brake Pedal Support
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 6814
Brake Light Switch: Service and Repair
Fig. 6 Stop light switch replacement. Exc. 1980---83 E-100 w/manual brakes.
Fig. 7 Stop light switch replacement. 1980---83 E-100 w/manual brakes
1. Disconnect battery ground cable.
2. Disconnect electrical connector from switch, Figs. 6 and 7.
3. Remove hairpin retainer, then slide stop light switch, pushrod, nylon washers and bushings away
from pedal and remove the switch from vehicle.
4. Reverse procedure to install. Ensure stop light switch wires are of sufficient length to allow full
travel of the brake pedal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations
Door Switch: Locations
Inside Doors
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations
Behind LH Side Of I/P
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Locations
Hazard Warning Switch: Locations
Upper LH Side Of Steering Column
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams > Diagram Information and Instructions
Hazard Warning Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6827
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6828
Fig. 35 Hazard Lights Wiring Circuit. With Stop & Turn Signals
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Locations
Headlamp Dimmer Switch: Locations
LH Floor Board
LH Floor Board
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Diagram Information and Instructions
Headlamp Dimmer Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 6835
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Diagram Information and Instructions > Page 6836
Fig. 36 Headlamps Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations
Headlamp Switch: Locations
Behind LH Side Of I/P
I/P Left Of Steering Column
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions
Headlamp Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 6842
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 6843
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 6844
Headlamp Switch: Electrical Diagrams
Fig. 36 Headlamps Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 6845
Headlamp Switch: Testing and Inspection
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 6846
Headlamp Switch: Service and Repair
Fig. 5 Light Switch
E-100---350
1. Disconnect battery ground cable.
2. Remove knob and shaft assembly by depressing release button on switch housing and pulling
straight out.
3. Remove bezel or mounting nut from switch, Fig. 4.
4. Disconnect electrical connector from switch and remove switch from vehicle.
5. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations
Horn Relay: Locations
Horn Relay Location
Under LH Side Of I/P.
Under LH Side Of I/P, With Speed Control
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6851
Underneath LH Side Of I/P
Below LH Side Of I/P
Horn Relay With Speed Control
Bronco F-150 thru F-350, E-150 thru E-350 and Super F Series The horn relay is use on vehicles
equipped with speed control and is located under the left side of the instrument panel, left of the
steering column and is mounted on the outboard attaching screw of the speed control amplifier
module.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6852
Horn Relay: Testing and Inspection
Fig. 3 Speed control wiring diagram. 1981---83 E-100-350 & 1984-87 E-150-350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6853
Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6854
Fig. 5 Speed control wiring diagram. 1982---83 F-100-350, 1984---87 F-150-350 & 1982---87
Bronco
1981-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Locate horn relay wire connector marked X and Y, Figs. 3, 4 and 5.
2. Using connector X, locate wire 460, then using a suitable voltmeter, check for battery voltage at
male side of connector.
3. Using connector Y, locate wire 1, then using a suitable voltmeter, check for battery voltage at
female side of connector. Depress horn, voltmeter should read zero and horn should sound. If
battery voltage remains, circuit is open. Connectors should remain connected during testing.
4. Check horn relay by momentarily grounding circuit 1 to chassis. This bypasses horn switch and
horn should sound. If horn does not sound, check for battery voltage at connector X wire 6 during
relay operation. If voltage is present at circuit 6 during relay operation, an open circuit is indicated
between horn and connector X.
5. If relay does not operate with battery voltage present at circuit 460 and circuit 1 is grounded,
replace relay.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Marker Lamp: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 6859
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 6860
Fig. 21 Exterior Lights Wiring Circuit. Exc. V8-302/5.0L Engine W/Cutaway
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions
Parking Lamp: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 6865
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 6866
Fig. 21 Exterior Lights Wiring Circuit. Exc. V8-302/5.0L Engine W/Cutaway
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Horn Relay: Locations
Horn Relay Location
Under LH Side Of I/P.
Under LH Side Of I/P, With Speed Control
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 6871
Underneath LH Side Of I/P
Below LH Side Of I/P
Horn Relay With Speed Control
Bronco F-150 thru F-350, E-150 thru E-350 and Super F Series The horn relay is use on vehicles
equipped with speed control and is located under the left side of the instrument panel, left of the
steering column and is mounted on the outboard attaching screw of the speed control amplifier
module.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 6872
Horn Relay: Testing and Inspection
Fig. 3 Speed control wiring diagram. 1981---83 E-100-350 & 1984-87 E-150-350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 6873
Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 6874
Fig. 5 Speed control wiring diagram. 1982---83 F-100-350, 1984---87 F-150-350 & 1982---87
Bronco
1981-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar
1. Locate horn relay wire connector marked X and Y, Figs. 3, 4 and 5.
2. Using connector X, locate wire 460, then using a suitable voltmeter, check for battery voltage at
male side of connector.
3. Using connector Y, locate wire 1, then using a suitable voltmeter, check for battery voltage at
female side of connector. Depress horn, voltmeter should read zero and horn should sound. If
battery voltage remains, circuit is open. Connectors should remain connected during testing.
4. Check horn relay by momentarily grounding circuit 1 to chassis. This bypasses horn switch and
horn should sound. If horn does not sound, check for battery voltage at connector X wire 6 during
relay operation. If voltage is present at circuit 6 during relay operation, an open circuit is indicated
between horn and connector X.
5. If relay does not operate with battery voltage present at circuit 460 and circuit 1 is grounded,
replace relay.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay >
Component Information > Locations
Trailer Lighting Relay: Locations
LH Rear Fender Below LH Tail Light
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Manual Transmission
Backup Lamp Switch: Locations Manual Transmission
Rear Of V8-302/5.
Attached To Shifter Assembly
Applicable to: 0L Engine
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Locations > Manual Transmission > Page 6883
Backup Lamp Switch: Locations 3-Speed Manual Transmission
Attached To Transmission Assembly
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Brake Light Switch: Locations
Top Of Brake Support
Top Of Brake Pedal Support
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 6887
Brake Light Switch: Service and Repair
Fig. 6 Stop light switch replacement. Exc. 1980---83 E-100 w/manual brakes.
Fig. 7 Stop light switch replacement. 1980---83 E-100 w/manual brakes
1. Disconnect battery ground cable.
2. Disconnect electrical connector from switch, Figs. 6 and 7.
3. Remove hairpin retainer, then slide stop light switch, pushrod, nylon washers and bushings away
from pedal and remove the switch from vehicle.
4. Reverse procedure to install. Ensure stop light switch wires are of sufficient length to allow full
travel of the brake pedal.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations
Door Switch: Locations
Inside Doors
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Locations
Hazard Warning Switch: Locations
Upper LH Side Of Steering Column
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Diagram Information and Instructions
Hazard Warning Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6896
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6897
Fig. 35 Hazard Lights Wiring Circuit. With Stop & Turn Signals
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Locations
Headlamp Dimmer Switch: Locations
LH Floor Board
LH Floor Board
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Diagram Information and Instructions
Headlamp Dimmer Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6903
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6904
Fig. 36 Headlamps Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Locations
Headlamp Switch: Locations
Behind LH Side Of I/P
I/P Left Of Steering Column
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions
Headlamp Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6910
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6911
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6912
Headlamp Switch: Electrical Diagrams
Fig. 36 Headlamps Wiring Circuit
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 6913
Headlamp Switch: Testing and Inspection
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 6914
Headlamp Switch: Service and Repair
Fig. 5 Light Switch
E-100---350
1. Disconnect battery ground cable.
2. Remove knob and shaft assembly by depressing release button on switch housing and pulling
straight out.
3. Remove bezel or mounting nut from switch, Fig. 4.
4. Disconnect electrical connector from switch and remove switch from vehicle.
5. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Locations
Turn Signal Switch: Locations
Upper LH Side Of Steering Column
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Diagram Information and Instructions
Turn Signal Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6920
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 6921
Fig. 35 Hazard Lights Wiring Circuit. With Stop & Turn Signals
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 6922
Turn Signal Switch: Service and Repair
1. Disconnect battery ground cable.
2. Remove horn switch, then the steering wheel.
3. Remove turn signal switch lever by unscrewing from steering column.
4. On 1981---87 F-100---350 and Bronco models, remove lower steering column shroud.
5. On 1981---87 E-100---350 models, remove upper and lower steering column shrouds.
6. On all models, disconnect electrical connector from turn signal switch and remove switch
attaching screws.
7. On all models with tilt column and 1980 E-100---350, F-100---350 and Bronco with fixed column,
remove wires and terminals from steering column electrical connector, after noting color code and
location of each connector. Remove plastic cover sleeve, if equipped, from wiring harness, then lift
switch assembly out through top of column. On 1981---87 E-100---350 models equipped with tilt
column and automatic transmission, disconnect transmission selector indicator light electrical
connector from turn signal switch harness prior to removing the switch.
8. On all models with fixed column, except 1980 E-100---350, F-100---350 and Bronco, remove
switch assembly by lifting out of column while guiding connector plug through opening in shift
socket. On 1981---87 E-100---350 models equipped with fixed column and automatic transmission,
remove transmission selector indicator light assembly with turn signal switch.
9. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations
Trailer Lighting Relay: Locations
LH Rear Fender Below LH Tail Light
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations
> Turn Flasher
Turn Signal Flasher: Locations Turn Flasher
Behind LH Side Of I/P
HAZARD WARNING: Behind LH side Of I/P, On Fuse Panel TURN SIGNAL: Behind LH Side Of
I/P, On Fuse Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations
> Turn Flasher > Page 6931
Turn Signal Flasher: Locations Turn/Hazard Flasher
Behind LH Side Of I/P
HAZARD WARNING: Behind LH side Of I/P, On Fuse Panel TURN SIGNAL: Behind LH Side Of
I/P, On Fuse Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Diagram Information and Instructions
Turn Signal Lamp: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 6936
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams >
Diagram Information and Instructions > Page 6937
Fig. 35 Hazard Lights Wiring Circuit. With Stop & Turn Signals
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations
Turn Signal Switch: Locations
Upper LH Side Of Steering Column
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams >
Diagram Information and Instructions
Turn Signal Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 6943
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 6944
Fig. 35 Hazard Lights Wiring Circuit. With Stop & Turn Signals
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams >
Page 6945
Turn Signal Switch: Service and Repair
1. Disconnect battery ground cable.
2. Remove horn switch, then the steering wheel.
3. Remove turn signal switch lever by unscrewing from steering column.
4. On 1981---87 F-100---350 and Bronco models, remove lower steering column shroud.
5. On 1981---87 E-100---350 models, remove upper and lower steering column shrouds.
6. On all models, disconnect electrical connector from turn signal switch and remove switch
attaching screws.
7. On all models with tilt column and 1980 E-100---350, F-100---350 and Bronco with fixed column,
remove wires and terminals from steering column electrical connector, after noting color code and
location of each connector. Remove plastic cover sleeve, if equipped, from wiring harness, then lift
switch assembly out through top of column. On 1981---87 E-100---350 models equipped with tilt
column and automatic transmission, disconnect transmission selector indicator light electrical
connector from turn signal switch harness prior to removing the switch.
8. On all models with fixed column, except 1980 E-100---350, F-100---350 and Bronco, remove
switch assembly by lifting out of column while guiding connector plug through opening in shift
socket. On 1981---87 E-100---350 models equipped with fixed column and automatic transmission,
remove transmission selector indicator light assembly with turn signal switch.
9. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations
Power Window Relay: Locations
Lower LH Cowl, Near Fuse Block
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations
Power Window Switch: Locations
On Driver`s Door Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations
Power Window Motor: Locations
Behind Panels, Below Windows
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations >
Page 6959
Power Window Motor: Service and Repair
Power Window Motor
Removal 1. Disconnect the battery ground cable. 2. Remove the door trim panel.
3. Disconnect power window motor wire from wire harness connector (Fig. 10). 4. Check inside the
door to ensure electrical wires are not in line with holes to be drilled in the door inner panel. Using a
12.7mm (1 /2-inch)
diameter drill bit drill two holes in the door inner panel at the drill dimples located opposite the two
unexposed motor drive retainer screws (Fig. 10).
5. Remove the three motor mount retainer screws using two drilled holes and existing larger hole
access to screw heads (Fig. 10). 6. Push the motor toward the outside sheet metal to disengage
Ihe motor and drive from the regulator gear. After the motor and drive are disengaged
prop the window in full UP position.
7. Remove the motor and drive from inside the door.
Installation 1. Instal a new motor and drive assembly (Fig. 10). Tighten motor retaining screws to
5.6-9.6 N.m (50-85 in-lb). 2. Install two pieces of Pressure-Sensitive Waterproof Tape
D6AZ-19627-A or equivalent body tape (1 inch square) over drilled holes. 3. Connect power
window motor wiring, and battery ground cable. 4. Remove glass prop and check window
operation. 5. Ensure door drain holes are open. 6. Install trim panel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations
Power Window Relay: Locations
Lower LH Cowl, Near Fuse Block
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations
Power Window Switch: Locations
On Driver`s Door Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > Customer Interest: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip
Window Glass: Customer Interest Vent Windows - May Stick to Weatherstrip
GLASS - VENT WINDOWS - MANUAL - GLASS STICKS TO WEATHERSTRIP - VEHICLES
BUILT BEFORE 4/04/88
Article No. 88-14-1
FORD: 1984-88 ALL CAR LINES
LINCOLN-MERCURY: 1984-88 ALL CAR LINES
MERKUR: 1985-88 ALL CAR LINES
LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES
MEDIUM/HEAVY TRUCK: 1984-88 ALL MEDIUM/HEAVY TRUCK LINES
ISSUE: Manual vent windows that are not opened very often may stick to the vent window
weatherstrip making them hard to open. In some cases, the high opening efforts may cause the
weatherstrip to pull out of the vent division bar.
ACTION: To correct this, apply "Krytox" oil to the vent window weatherstrip using the following
service procedure.
FIGURE 1
1. Open the vent window all the way.
2. From inside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure
1.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > Customer Interest: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip > Page 6974
FIGURE 2
3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure
2.
4. Close and open vent window to make sure window operates correctly.
NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300
EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN.
OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under
Basic Warranty Coverage OPERATION: 881401A TIME:
0.3 Hr.
DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > Customer Interest: > 881115052588 > May > 88 > Power Window - Binding or Inoperative
Window Glass: Customer Interest Power Window - Binding or Inoperative
GLASS - POWER WINDOW - BINDING OR INOPERATIVE
POWER WINDOW -BINDING OR INOPERATIVE
Article No. 88-11-15
LIGHT TRUCK: 1987-88 ECONOLINE
ISSUE: An inoperative or binding power window during the up cycle may be caused by the motor
drive gears binding due to the weight of the window glass. The current window regulator does not
have a counterbalance spring to offset the weight of the glass during the up cycle.
ACTION: To correct this, install a new design window regulator with a counterbalance spring. Refer
to the 1988 Light Truck Shop Manual, Section 42-04-03 for removal and installation procedures.
PART NUMBER PART NAME CLASS
E8UZ-1523208-A Regulator Assembly - C
Right Hand
E8UZ-1523209-A Regulator Assembly - C
Left Hand
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible Under Basic Warranty coverage OPERATION: 881115A - One
regulator TIME:
0.6 Hr.
OPERATION: 881115B - Both regulators TIME:
1.0 Hr.
DLR. CODING: Basic Part No. 7023208 Condition Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > Customer Interest: > 8852 > Mar > 88 > Manual Vent Windows - Difficult to Open
Window Glass: Customer Interest Manual Vent Windows - Difficult to Open
GLASS - MANUAL VENT WINDOWS HARD TO OPEN
Article No. 88-5-2
FORD: 1980-88 CROWN VICTORIA 1981-86 THUNDERBIRD 1981-87 ESCORT 1984-86 LTD
LINCOLN-MERCURY: 1980-88 GRAND MARQUIS
1981-86 LYNX, COUGAR 1984-86 MARQUIS
LIGHT TRUCK: 1980-88 E-SERIES, F-SERIES, BRONCO 1983-88 RANGER 1984-88 BRONCO II
1986-88 AEROSTAR
ISSUE: Hard to open pivoting type vent windows may be caused by the glass sticking to the
weatherstrip on the division bar. The weatherstrip is often pulled out of the division bar when this
condition is present.
FIGURE 1
ACTION: To correct this, apply a strip of clear pressure sensitive tape on the inside vertical edge of
the vent window glass, Figure 1.
PART NUMBER PART NAME CLASS
E8AZ-19627-A Clear Pressure Sensitive B
Tape
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: 880502A - Both vent windows TIME:
0.3 Hr. DLR. CODING: Basic Part No. 7021402 Code:
41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > Customer Interest: > 87112 > Jun > 87 > Manual Vent Windows - Hard to Open
Window Glass: Customer Interest Manual Vent Windows - Hard to Open
Article No. GLASS - VENT WINDOWS - MANUAL 87-11-2 HARD TO OPEN
FORD: 1984-87 ALL CAR LINES
LINCOLN-MERCURY: 1984-87 ALL CAR LINES
LIGHT TRUCK: 1984-87 ALL LIGHT TRUCK LINES
Figure 2 - Article 87-11-2
ISSUE: Manual vent windows that are not opened very often may stick to the vent window
weatherstrip which makes them hard to open.
ACTION: To correct this, apply a thin coating of Silicone Lubricant (COAZ-19553-AA) to the vent
window weatherstrip as shown in Figure 2. This lubricant can be applied during dealer prep and/or
normal customer service visits.
NOTE: DO NOT USE AEROSOL SPRAY CANS.
PART NUMBER PART NAME CLASS
COAZ-19553-AA Silicone Lubricant B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP871102A - Both sides TIME:
0.3 Hr.
DLR. CODING: Basic Part No. 7021448 Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film
Window Glass: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film
Article No. 96-22-1
10/21/96
WINDSHIELD AND INTERIOR GLASS - FOG/FILM
FORD:
1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG,
THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97
CONTOUR
LINCOLN-MERCURY:
1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97
CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER
1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE
MERKUR:
1985-89 XR4TI 1988-90 SCORPIO
LIGHT TRUCK:
1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR,
ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER
1995-97 WINDSTAR
This TSB article is being republished in its entirety to update the model years.
ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog
can be advised that Ford Motor Company has extensively tested this material and found that it is
not a health hazard. The film is caused by some of the chemicals used during the manufacture of
the interior trim.
ACTION: At the present time, there is no known field fix to prevent the window fogging, however,
glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for
film removal.
PART NUMBER PART NAME
E4AZ-19C507-AA Ford Glass cleaner
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film >
Page 6992
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 86-13-6
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 102000, 107000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Glass: > 93211 > Oct > 93 > Glass - Iridescence or Mottling In
Tempered Glass
Window Glass: All Technical Service Bulletins Glass - Iridescence or Mottling In Tempered Glass
Article No. 93-21-1
10/13/93
GLASS - "IRIDESCENCE" OR "MOTTLING" IN TEMPERED GLASS
FORD: 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-88
EXP 1986-94 TAURUS 1989-93 FESTIVA
LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-92 MARK VII 1984-94 COUGAR,
GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1988-94
CONTINENTAL 1991-94 CAPRI, TRACER 1993-94 MARK VIII
LIGHT TRUCK: 1984-90 BRONCO II 1984-94 ECONOLINE, F-150-350 SERIES, RANGER
1986-94 AEROSTAR 1991-94 EXPLORER 1993-94 VILLAGER
ISSUE: Vehicles may exhibit iridescent spots or "mottling" in tempered glass under some lighting
conditions. This condition is caused by the tempering process.
ACTION: Explain to customers that "iridescence" or "mottling" of tempered glass is a normal
condition and that glass replacement is neither warranted nor necessarily effective in resolving the
condition.
DESCRIPTION OF CONDITION
The somewhat iridescent grayish or blueish and fairly geometric spots detected in side and rear
window tempered glass are characteristic of tempered glass.
The mottled appearance is noted only under certain conditions of lighting. The occurrence of
mottling does not affect glass quality or durability and cannot be reduced by scouring the glass
surface.
The boldness of the mottled pattern in a given glass may vary, depending upon lighting conditions,
but may appear intensified if viewed through polarized sunglasses.
CAUSES OF CONDITION
Atmospheric dust and other angular reflections can cause changes in the polarized properties of
natural light. This polarization, combined with the light polarizing properties imparted to tempered
glass by the forces of tension and compression (during the tempering process), cause the
iridescent or mottled appearance.
These are the same forces of compression and tension which make tempered glass so remarkably
strong. Windshields, which are annealed rather than tempered, do not exhibit iridescence.
OTHER APPLICABLE ARTICLES: 83-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 102000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Glass: > 88141 > Jul > 88 > Vent Windows - May Stick to
Weatherstrip
Window Glass: All Technical Service Bulletins Vent Windows - May Stick to Weatherstrip
GLASS - VENT WINDOWS - MANUAL - GLASS STICKS TO WEATHERSTRIP - VEHICLES
BUILT BEFORE 4/04/88
Article No. 88-14-1
FORD: 1984-88 ALL CAR LINES
LINCOLN-MERCURY: 1984-88 ALL CAR LINES
MERKUR: 1985-88 ALL CAR LINES
LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES
MEDIUM/HEAVY TRUCK: 1984-88 ALL MEDIUM/HEAVY TRUCK LINES
ISSUE: Manual vent windows that are not opened very often may stick to the vent window
weatherstrip making them hard to open. In some cases, the high opening efforts may cause the
weatherstrip to pull out of the vent division bar.
ACTION: To correct this, apply "Krytox" oil to the vent window weatherstrip using the following
service procedure.
FIGURE 1
1. Open the vent window all the way.
2. From inside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure
1.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Glass: > 88141 > Jul > 88 > Vent Windows - May Stick to
Weatherstrip > Page 7001
FIGURE 2
3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure
2.
4. Close and open vent window to make sure window operates correctly.
NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300
EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN.
OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under
Basic Warranty Coverage OPERATION: 881401A TIME:
0.3 Hr.
DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Glass: > 881115052588 > May > 88 > Power Window - Binding or
Inoperative
Window Glass: All Technical Service Bulletins Power Window - Binding or Inoperative
GLASS - POWER WINDOW - BINDING OR INOPERATIVE
POWER WINDOW -BINDING OR INOPERATIVE
Article No. 88-11-15
LIGHT TRUCK: 1987-88 ECONOLINE
ISSUE: An inoperative or binding power window during the up cycle may be caused by the motor
drive gears binding due to the weight of the window glass. The current window regulator does not
have a counterbalance spring to offset the weight of the glass during the up cycle.
ACTION: To correct this, install a new design window regulator with a counterbalance spring. Refer
to the 1988 Light Truck Shop Manual, Section 42-04-03 for removal and installation procedures.
PART NUMBER PART NAME CLASS
E8UZ-1523208-A Regulator Assembly - C
Right Hand
E8UZ-1523209-A Regulator Assembly - C
Left Hand
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible Under Basic Warranty coverage OPERATION: 881115A - One
regulator TIME:
0.6 Hr.
OPERATION: 881115B - Both regulators TIME:
1.0 Hr.
DLR. CODING: Basic Part No. 7023208 Condition Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Glass: > 8852 > Mar > 88 > Manual Vent Windows - Difficult to Open
Window Glass: All Technical Service Bulletins Manual Vent Windows - Difficult to Open
GLASS - MANUAL VENT WINDOWS HARD TO OPEN
Article No. 88-5-2
FORD: 1980-88 CROWN VICTORIA 1981-86 THUNDERBIRD 1981-87 ESCORT 1984-86 LTD
LINCOLN-MERCURY: 1980-88 GRAND MARQUIS
1981-86 LYNX, COUGAR 1984-86 MARQUIS
LIGHT TRUCK: 1980-88 E-SERIES, F-SERIES, BRONCO 1983-88 RANGER 1984-88 BRONCO II
1986-88 AEROSTAR
ISSUE: Hard to open pivoting type vent windows may be caused by the glass sticking to the
weatherstrip on the division bar. The weatherstrip is often pulled out of the division bar when this
condition is present.
FIGURE 1
ACTION: To correct this, apply a strip of clear pressure sensitive tape on the inside vertical edge of
the vent window glass, Figure 1.
PART NUMBER PART NAME CLASS
E8AZ-19627-A Clear Pressure Sensitive B
Tape
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty
Coverage OPERATION: 880502A - Both vent windows TIME:
0.3 Hr. DLR. CODING: Basic Part No. 7021402 Code:
41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Glass: > 87112 > Jun > 87 > Manual Vent Windows - Hard to Open
Window Glass: All Technical Service Bulletins Manual Vent Windows - Hard to Open
Article No. GLASS - VENT WINDOWS - MANUAL 87-11-2 HARD TO OPEN
FORD: 1984-87 ALL CAR LINES
LINCOLN-MERCURY: 1984-87 ALL CAR LINES
LIGHT TRUCK: 1984-87 ALL LIGHT TRUCK LINES
Figure 2 - Article 87-11-2
ISSUE: Manual vent windows that are not opened very often may stick to the vent window
weatherstrip which makes them hard to open.
ACTION: To correct this, apply a thin coating of Silicone Lubricant (COAZ-19553-AA) to the vent
window weatherstrip as shown in Figure 2. This lubricant can be applied during dealer prep and/or
normal customer service visits.
NOTE: DO NOT USE AEROSOL SPRAY CANS.
PART NUMBER PART NAME CLASS
COAZ-19553-AA Silicone Lubricant B
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the
provisions of the Warranty and Policy Manual OPERATION: SP871102A - Both sides TIME:
0.3 Hr.
DLR. CODING: Basic Part No. 7021448 Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film
Window Glass: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film
Article No. 96-22-1
10/21/96
WINDSHIELD AND INTERIOR GLASS - FOG/FILM
FORD:
1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG,
THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97
CONTOUR
LINCOLN-MERCURY:
1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97
CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER
1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE
MERKUR:
1985-89 XR4TI 1988-90 SCORPIO
LIGHT TRUCK:
1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR,
ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER
1995-97 WINDSTAR
This TSB article is being republished in its entirety to update the model years.
ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog
can be advised that Ford Motor Company has extensively tested this material and found that it is
not a health hazard. The film is caused by some of the chemicals used during the manufacture of
the interior trim.
ACTION: At the present time, there is no known field fix to prevent the window fogging, however,
glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for
film removal.
PART NUMBER PART NAME
E4AZ-19C507-AA Ford Glass cleaner
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page
7019
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 86-13-6
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 102000, 107000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Window Glass: > 93211 > Oct > 93 > Glass - Iridescence or Mottling In Tempered
Glass
Window Glass: All Technical Service Bulletins Glass - Iridescence or Mottling In Tempered Glass
Article No. 93-21-1
10/13/93
GLASS - "IRIDESCENCE" OR "MOTTLING" IN TEMPERED GLASS
FORD: 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-88
EXP 1986-94 TAURUS 1989-93 FESTIVA
LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-92 MARK VII 1984-94 COUGAR,
GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1988-94
CONTINENTAL 1991-94 CAPRI, TRACER 1993-94 MARK VIII
LIGHT TRUCK: 1984-90 BRONCO II 1984-94 ECONOLINE, F-150-350 SERIES, RANGER
1986-94 AEROSTAR 1991-94 EXPLORER 1993-94 VILLAGER
ISSUE: Vehicles may exhibit iridescent spots or "mottling" in tempered glass under some lighting
conditions. This condition is caused by the tempering process.
ACTION: Explain to customers that "iridescence" or "mottling" of tempered glass is a normal
condition and that glass replacement is neither warranted nor necessarily effective in resolving the
condition.
DESCRIPTION OF CONDITION
The somewhat iridescent grayish or blueish and fairly geometric spots detected in side and rear
window tempered glass are characteristic of tempered glass.
The mottled appearance is noted only under certain conditions of lighting. The occurrence of
mottling does not affect glass quality or durability and cannot be reduced by scouring the glass
surface.
The boldness of the mottled pattern in a given glass may vary, depending upon lighting conditions,
but may appear intensified if viewed through polarized sunglasses.
CAUSES OF CONDITION
Atmospheric dust and other angular reflections can cause changes in the polarized properties of
natural light. This polarization, combined with the light polarizing properties imparted to tempered
glass by the forces of tension and compression (during the tempering process), cause the
iridescent or mottled appearance.
These are the same forces of compression and tension which make tempered glass so remarkably
strong. Windshields, which are annealed rather than tempered, do not exhibit iridescence.
OTHER APPLICABLE ARTICLES: 83-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 102000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Service and Repair
Front Door Window Regulator: Service and Repair
Window Regulator
Fig. 5
Special Service Tools
E-150-E-350, F-150-F-350 and Bronco
Removal 1. Remove door trim panel and access cover, if so equipped. 2. Support glass in the full
UP position. 3. Remove center pin from regulator attaching rivets with drift punch. Then, drill head
from each rivet using a 6.35mm (1/4-inch) drill and remove
rivet. Be careful not to route out sheet metal holes during drilling (Fig. 5).
4. Disengage regulator arm from glass bracket and remove regulator.
Installation 1. Position regulator in door and insert arm into glass bracket channel (Fig. 5). 2.
Position regulator to inner panel and install rivets using Rotunda Hydraulic Rivet Gun 107-00600 or
equivalent to attach regulator to inner panel.
A 1/4 inch-20 x 1 /2 inch screw and washer assembly and a 1/4 inch-20 nut and washer assembly
may be used in place of the rivets if rivets are not available (equivalent metric retainers may also
be used).
3. Check operation of window mechanism and install door trim panel.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > Customer Interest for Window Seal: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip
Window Seal: Customer Interest Vent Windows - May Stick to Weatherstrip
GLASS - VENT WINDOWS - MANUAL - GLASS STICKS TO WEATHERSTRIP - VEHICLES
BUILT BEFORE 4/04/88
Article No. 88-14-1
FORD: 1984-88 ALL CAR LINES
LINCOLN-MERCURY: 1984-88 ALL CAR LINES
MERKUR: 1985-88 ALL CAR LINES
LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES
MEDIUM/HEAVY TRUCK: 1984-88 ALL MEDIUM/HEAVY TRUCK LINES
ISSUE: Manual vent windows that are not opened very often may stick to the vent window
weatherstrip making them hard to open. In some cases, the high opening efforts may cause the
weatherstrip to pull out of the vent division bar.
ACTION: To correct this, apply "Krytox" oil to the vent window weatherstrip using the following
service procedure.
FIGURE 1
1. Open the vent window all the way.
2. From inside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure
1.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > Customer Interest for Window Seal: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip > Page
7036
FIGURE 2
3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure
2.
4. Close and open vent window to make sure window operates correctly.
NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300
EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN.
OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under
Basic Warranty Coverage OPERATION: 881401A TIME:
0.3 Hr.
DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Seal: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip
Window Seal: All Technical Service Bulletins Vent Windows - May Stick to Weatherstrip
GLASS - VENT WINDOWS - MANUAL - GLASS STICKS TO WEATHERSTRIP - VEHICLES
BUILT BEFORE 4/04/88
Article No. 88-14-1
FORD: 1984-88 ALL CAR LINES
LINCOLN-MERCURY: 1984-88 ALL CAR LINES
MERKUR: 1985-88 ALL CAR LINES
LIGHT TRUCK: 1984-88 ALL LIGHT TRUCK LINES
MEDIUM/HEAVY TRUCK: 1984-88 ALL MEDIUM/HEAVY TRUCK LINES
ISSUE: Manual vent windows that are not opened very often may stick to the vent window
weatherstrip making them hard to open. In some cases, the high opening efforts may cause the
weatherstrip to pull out of the vent division bar.
ACTION: To correct this, apply "Krytox" oil to the vent window weatherstrip using the following
service procedure.
FIGURE 1
1. Open the vent window all the way.
2. From inside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure
1.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Window Seal: > 88141 > Jul > 88 > Vent Windows - May Stick to Weatherstrip
> Page 7042
FIGURE 2
3. From outside of vehicle, apply "Krytox" oil on the weatherstrip sealing lips of vent window, Figure
2.
4. Close and open vent window to make sure window operates correctly.
NOTE: CONTACT EXCEL INDUSTRIES, INC. TO ORDER "KRYTOX" OIL: (904) 286-8300
EXTENSION 305 REPRESENTATIVE: RACHEL FLYNN.
OTHER APPLICABLE ARTICLES: Supersedes 87-11-2 WARRANTY STATUS: Eligible Under
Basic Warranty Coverage OPERATION: 881401A TIME:
0.3 Hr.
DLR. CODING: Basic Part No. 7022296 - Car 7021448 - Truck Condition Code: 41
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
Windshield/Interior Glass - Fog/Film
Windshield: Technical Service Bulletins Windshield/Interior Glass - Fog/Film
Article No. 96-22-1
10/21/96
WINDSHIELD AND INTERIOR GLASS - FOG/FILM
FORD:
1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG,
THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97
CONTOUR
LINCOLN-MERCURY:
1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97
CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER
1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE
MERKUR:
1985-89 XR4TI 1988-90 SCORPIO
LIGHT TRUCK:
1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR,
ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER
1995-97 WINDSTAR
This TSB article is being republished in its entirety to update the model years.
ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog
can be advised that Ford Motor Company has extensively tested this material and found that it is
not a health hazard. The film is caused by some of the chemicals used during the manufacture of
the interior trim.
ACTION: At the present time, there is no known field fix to prevent the window fogging, however,
glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for
film removal.
PART NUMBER PART NAME
E4AZ-19C507-AA Ford Glass cleaner
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins >
Windshield/Interior Glass - Fog/Film > Page 7047
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 86-13-6
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 102000, 107000
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Diagrams > Diagram Information and Instructions
Windshield Washer Relay: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7054
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7055
Windshield Washer Relay: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7056
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Locations
Wiper Control Module: Locations
Upper LH Side Of I/P
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Diagrams > Diagram Information and Instructions
Wiper Relay: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 7064
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 7065
Wiper Relay: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Diagrams > Diagram Information and Instructions > Page 7066
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Diagram Information and Instructions
Windshield Washer Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7072
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7073
Windshield Washer Switch: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7074
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations
Wiper Switch: Locations
Upper LH Side Of I/P
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Diagram Information and Instructions
Wiper Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7080
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7081
Wiper Switch: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7082
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Page 7083
Wiper Switch: Testing and Inspection
Fig. 4 Wiper Switch Continuity Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Page 7084
Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Page 7085
Fig. 5 Wiper Switch Continuity Test
1. Check continuity between switch terminals, Figs. 4 through 6.
2. To detect marginal operation of switch, rotate or slide switch control knob while each reading is
being taken.
3. If switch does not show continuity or if poor continuity exists at any switch position, replace
switch.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Page 7086
Wiper Switch: Service and Repair
E-100---350
1. Disconnect battery ground cable.
2. Remove wiper switch knob.
3. Remove ignition switch bezel from finish panel.
4. Remove light switch knob and shaft assembly by depressing release button on switch housing
and pulling straight out.
5. Remove 2 lower attaching screws from finish panel, then pry the 2 upper retainers away from
instrument panel.
6. Disconnect wiper switch electrical connector, then remove switch attaching screws and the
switch from vehicle.
7. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations
Windshield Washer Motor: Locations
LH Fender
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams >
Diagram Information and Instructions
Windshield Washer Motor: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 7092
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 7093
Windshield Washer Motor: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams >
Diagram Information and Instructions > Page 7094
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams
> Diagram Information and Instructions
Windshield Washer Pump: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams
> Diagram Information and Instructions > Page 7099
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams
> Diagram Information and Instructions > Page 7100
Windshield Washer Pump: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams
> Diagram Information and Instructions > Page 7101
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams >
Diagram Information and Instructions
Windshield Washer Relay: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams >
Diagram Information and Instructions > Page 7106
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams >
Diagram Information and Instructions > Page 7107
Windshield Washer Relay: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams >
Diagram Information and Instructions > Page 7108
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Diagram Information and Instructions
Windshield Washer Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Diagram Information and Instructions > Page 7113
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Diagram Information and Instructions > Page 7114
Windshield Washer Switch: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Diagram Information and Instructions > Page 7115
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations
Wiper Control Module: Locations
Upper LH Side Of I/P
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair
Wiper Gear Box: Service and Repair
1. Disconnect battery ground cable.
2. Remove both wiper arm and blade assemblies.
3. Remove cowl grille attaching screws and raise the grille slightly.
4. Disconnect windshield washer fluid hose, then remove cowl grille.
5. Remove clip securing right and left linkage and the retaining clip from wiper motor arm.
6. Remove 3 pivot body-to-cowl panel attaching screws, then the arm and pivot shaft assembly.
7. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations
Wiper Motor: Locations
LH Side Of Dash Panel
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions
Wiper Motor: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7127
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7128
Wiper Motor: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram
Information and Instructions > Page 7129
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 7130
Wiper Motor: Testing and Inspection
Fig. 2 Wiper Motor Current Draw Test
E-100---350 Series
1. Disconnect wiper motor linkage.
2. Connect positive lead from multimeter to center terminal on motor end plate and the green lead
from tester to battery positive post, Fig. 2. Motor terminals are too small to make necessary test
connections without using connector sleeves and wires between motor terminals and tester.
Suitable connector sleeves should be crimped onto both ends of wires.
3. Connect jumper wire from battery negative post to low speed terminal on motor end plate and
read current draw, then move jumper wire from low speed terminal to high speed terminal and read
current draw.
4. If current draw exceeds 3.5 amps, ensure that output arm or windlatch mechanism are not
binding or damaged, and replace wiper motor.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 7131
Wiper Motor: Service and Repair
E-100---350
1. Disconnect battery ground cable.
2. Remove fuse panel and bracket assembly.
3. Disconnect wiper motor electrical connectors from motor brush cap and gearbox cover.
4. Remove both wiper arm and blade assemblies.
5. Remove outer air inlet cowl, then the motor drive arm-to-linkage mounting arm and pivot shaft
assembly retaining clip.
6. Remove wiper motor attaching bolts and the wiper motor.
7. Reverse procedure to install.
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Diagrams >
Diagram Information and Instructions
Wiper Motor Timer: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Diagrams >
Diagram Information and Instructions > Page 7136
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Diagrams >
Diagram Information and Instructions > Page 7137
Wiper Motor Timer: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Diagrams >
Diagram Information and Instructions > Page 7138
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram
Information and Instructions
Wiper Relay: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram
Information and Instructions > Page 7143
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram
Information and Instructions > Page 7144
Wiper Relay: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram
Information and Instructions > Page 7145
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations
Wiper Switch: Locations
Upper LH Side Of I/P
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram
Information and Instructions
Wiper Switch: Diagram Information and Instructions
Symbol Identification
Wire Color Code Identification
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 7151
NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the
wire, and the second color is the tracer marking of the wire. If the second color is followed by by a
D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks.
For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and
BK/W H is a black wire with white hash marks.
BL: Blue BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue
LG: Light Green N:
Natural
O: Orange
PK: Pink R:
Red
P: Purple
T: Tan
V: Violet
W: White
Y: Yellow
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 7152
Wiper Switch: Electrical Diagrams
Fig. 58 Windshield Wiper/Washer Wiring Circuit. Less Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 7153
Fig. 59 Windshield Wiper/Washer Wiring Circuit. Interval
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7154
Wiper Switch: Testing and Inspection
Fig. 4 Wiper Switch Continuity Test
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7155
Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350
Ford E 350 Van Workshop Manual (V8-460 7.5L VIN L 4-BBL (1987))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 7156
Fig. 5 Wiper Switch Continuity Test
1. Check continuity between switch terminals, Figs. 4 through 6.
2. To detect marginal operation of switch, rotate or slide switch control knob while each reading is
being taken.
3. If switch does not show continuity or if poor continuity exists at any switch position, replace
switch.
