Werkstatthandbuch Book 1 · Seiten 1301–1390

29-02-89 Engine Diagnosis and Service 29-02-89 a test light across the terminals on the harness 8 Remove the stator cap and dial indicator. connector female receptacle. While cranking the 9 Re-install the choke cap at index assuring that the engine the test light should glow. If light does not bimetol tang is properly inserted in the cam glow, repair and/or replace cranking electrical bimetol lever. Re-install air cleaner stud. circuit. Then repeat Step 3. If light glows, install water temperature switch and proceed. APPENDIX A EXCEPT MODEL 2700 4. Check for cranking solenoid activation when CARBURETOR battery voltage is ap

29-02-90 Engine Diagnosis and Service 29-02-90 tester, 14-0206 or equivalent, to cool choke until vacuum passage and hole in the choke plate lightly closes in the air horn. diaphragm, rotate the diaphragm 2. Note index position of bimetal cap and wrap counterclockwise until aligned. choke cap 90 degrees in the rich direction CCW NOTE: The H.C.S.P. diaphragm can only be from that position and secure. adjusted in increments of one full turn. The 3. Activate pulidown motor manually or with vacuum passage in the diaphragm must be external vacuum if the pulidown motor has an aligned with the vacuum passage on the

29-02-91 Engine Diagnosis and Service 29-02-91 G. Remove carburetor from vehicle. should be resting at the bend in the l-l.C.S.p. as shown 1. Remove the retaining "E" ring which holds the in Fig. 7. If not, repair and/or replace as required. choke operating rod to the cam lever and MODEL 2700 CARBURETOR CHOKE LINKAGE remove the linkage from the cam lever Fig. 7. CLEANING PROCEDURE 2. Open the throttle slightly and check cam lever 1 Remove choke cap. for freedom of movement. The choke cap spring should provide the only resistance and the cam 2 Using automatic choke cleaner C9A

29-02-92 Engine Diagnosis and Service 29.02-92 4. Again, press lightly on the CVR rod-if any NOTE: Even if the vehicle has less than 100 miles springback can be seen, the rod is not fully of operation, set the speed to the "normal" seated. Turn the adjusting screw clockwise by 1/4 engine specification and not the green engine turn increments until no sprinaback can be seen. spec. 5. Reset the choke cap to the specified setting. 10. With the engine idling, place the transmission selector in the position specified for the idle fuelSSD-13 IDLE FUEL MIX

29-02-93 Engine Diagnosis and Service 29-02-93 I While watching the tachometer, adjust the 4. If so equipped, disconnect the evaporative mixture screws/limiters clockwise lean by emission purge hose at the air cleaner and plug the number of turns specified for the speed the nipple. drop test, Note the drop in engine speed. 5. Disconnect the crankcase ventilation closure hose - If the measured speed drop is equal to or from the air cleaner and plug the nipple. drops off by more than including stall the 6. For vehicles equipped with Thermactor systems, speed

29-02-94 Engine Diagnosis and Service 29-02-94 C. Propane Enrichment Method for All Vehicle. reinstall all system components removed in Step 2. Equipped with Model 2700 Carburetors Also, move ‘TEE" from the PCV line that was CAUTION: Block the wheels before starting the installed in Step 4. engine. 8. Set curb idle speed to specification. If curb idle speed was adjusted in

29-02-95 Engine Diagnosis and Service 29-02-95 B. Measure the Ignition System Coil Reserve B. For EEC systems only, when replacing the Voltage. Specification: 28 Ky minimum. distributor cap, the brass "cross" surfaces To make this measurement, connect a diagnostic shown in Fig. 9 must be coated with D7AZ- console 36-0036 or equivalent, capable of 19A331-AA silicone grease or equivalent displaying high voltage and engine rpm readings Dow 111 or G.E. G-627 compound. to the vehicle. Its "clamp on" voltage pickup must be connected to the coil-to-distributor high COAT COMPLETE SURFACE tension wire. With the engine running at 1000

29-02-96 Engine Diagnosis and Service 29-02-96 plug wires connected to the cap. Do not remove VEHICLE. A functional check of the original and known the spark plug wires from the cap except for good module can quickly be accomplished by using the replacement. Using an ohmmeter, check the "RUN MODE TEST". resstance of each wire by connecting one meter ‘SUGGESTIONS FOR INTERMITTENT OPERATION lead to the spark plug terminal use adaptor if available and the other lead to the distributor EEC-DURA SPARK II APPLICATIONS ONLY cap insert. Replace any wires that are iiót within If ignition system becomes operative in the course specification. Visually inspect the spark p

_____________________________________________ ________________ 29-02-97 Engine Diagnosis and Service 29-02-97 START HERE STAHT MOOE rEST CONNECT A SCOPE WITH CLAMP-ON PICK-UP TO THE COIL HIGH TENSION WIRE. IF SCOPE IS UNAVAILABLE, REMOVE COIL WIRE FROM DISTRIBUTOR AND INSERT A MODIFIED SPARK PLUG SIDE ELECTRODE REMOVEDI INTO THE WIRE. GROUND SPARK PLUG SHELL. CRANK ENGINE WHILE CHECKING FOR SPARKS. NO SPARKS

__________ 29-02-98 Engine Diagnosis and Service 29-02-98 START HERE RUN MODE TEST 1iUER THE MODULE WHITE WIRE TO RED WIRE AT MODULE NY PIERCING EOTH WIRES WITH A SMALL STRAIGHT PIN, TURN IGNITION SWITCH TO "RUN" POSITION. SPARKS TAP DISTRIBUTOR BASE WITH SCREWDRIVER. CHECK POR SPARKS WHILE TAPPING. IGNITION OK NO SPARKS IiEMOVE PIN FROM MODULES RED AND WHITE WIRES WITH IGNITION IN ‘RUN POSITION. MEASURE BATTERY VOLTAGE, MEASURE THE VOLTAGE ON THE NO MODULE’S RED WIRE WITHOUT DISCONNECTING ITS TWO WIRE CONNECTOR IEEE REFAIRcEEDT0

_________ ______ ______________ 29-02-99 Engine Diagnosis and Service 29-02-99 CYCLE IGNITION SWITCH FROM "RUN" TO "OFP", A SPARK SHOULD BE SEEN EACH TIME KEY IS TURNED "OFF". RETURN IGNITION SWITCH TD "RUN" POSITION. ISUBSTITUTE IDON’T INSTALLI AND GROUND SPARKS NO SPARKS KNOWN GOOD DISTRIBUTOR. SPIN THE IA SHAFTANDCHECK FOR SPARKS ISEE

29-02-100 Engine Diagnosis and Service 29-02-100 KNOWN GOOD DISTRIBUTOR ANY CALIBRATION- CLIP TO ENGINE 0

29-02-101 Engine Diagnosis and Service 29-02-101 "BATT"TERMINAL VI EW’A BALLAST RESISTOR IBBA-12250-AI 4’POLE RELAY 3.POL! RELAY STARTER RELAY R TO TO BATTERY BATTERY

____________ ______________________________ _______ __ __________________________________________________ ________________ __________________ ____________________ __________________________________________________ 29-02-102 Engine Diagnosis and Service 29-02-102 START HERE I RUN MODE TEST REMOVE COIL WIRE PROM DISTRIBUTOR AND LOCATE 114

__________ ________ 29-02-103 Engine Diagnosis and Service 29-02-103 START MODE TEST I_START HERE CRANK ENGINE, WHILE CHECKING I’-SPARKS PRIMARY FOR SPARKS. OK NO SPARKS MEASURE BATTERY VOLTAGE WHILE REPAIR THE WIRE CRANKINU, WITHOUT DISCONNECTING FEEDING THE THE MODULES1wOWEC

29-02-104 Engine Diagnosis and Service 29-02-104 TO VEHICLE HARNESS KNOWN GOOD DISTRIBUTOR ANY CALIBRATIUNI

_________________________ ________________________ _ 29-02-105 Engine Diagnosis and Service 29-02-105 START HERE I RUN MODETEST 4, INSERT TEST ADAPTOR SETWEEN VEHICLE WIRING HARNESS AND THE IGNITION MODULE’S FOUR PIN CDNNECTOR SEE FIG, 21 I. CONNEd A SCOPE WITH CLAMP-ON PICK-UP TO THE COIL HIGH TENSION WIRE, IP SCOPE IS UNAVAILABLE, HEMOVE CDILWIRE FROM DISTRIBUTOR _SPARK SEE START MODE

______ _____________ 29-02-106 Engine Diagnosis and Service 29-02-106 START MODE TEST START HERE WHILE CRANKING ENGINE, HEPEATEOLY CONNECT SPARKS IGNITION OK DIAGNOSTIC WIRE TO ENOINE GROUND, CHECK FOR SPARK WHEN WIRE IS REMOVED FROM GROUND. ND SPARKS FEEDING THE LETMOVETHEAOATORANDREONNEcTMTIONTMODULE NO YES -s-- NO RUN RUNS

______________________ _______ 29-02-107 Engine Diagnosis and Service 29-02-107 WITH IGNITION SWITCH N I DISCONNECT TEST ADAPTOR. BATTERY VOLTAGE I I JUMPER THE HARNESS WIRES 1 POSITION, MEASURE VOLTAGE I THAT MATE WITH THE MODULE ON BATTERY TERMINAL OF I GREEN AND BLACK WIRES, BY IGNITION COIL, LESS THAN 6V-1 I INSERTING A PAPER CLIP BE I TWEEN THEM, MEASURE VO

29-02-108 Engine Diagnosis and Service 29-02-108 TEST ADAPTOR 0 FUNCTIONAL SCHEMATIC MUELLER GO SERIES ALLIGATOR CLIP JUMPER WIRE TO ENGINE GROUND NOTE: WIRE CDLORS REFER

29-02-109 Engine Diagnosis and Service 29-02-109 b. If the stator pale is between two 11spokes", the 3. Remove the rotor alignment tool if used in primary wires are probably crossed see Fig. 22. previous step and remove the two screws If the position is incorrect, proceed to Step 3. securing the rotor to the distributor shaft. Remove 3. Visually check the color continuity of both the the rotor. orange and purple wires through the distributor Caution: Do not rotate the crankshaft once to engine harness connector A and through the the rotor has been removed. module to engine harness connector B before 4. Place the new rotor on the distributor shaf

29-02.110 Engine Diagnosis and Service 29-02-110 the rotor or adapter is damaged and alignment SSD-15--IGNfl’loN TIMING is not possible, then position the crankshaft at the Application: All Engines Except Those Equipped No. I cylinder TDC position by aligning the zero with an EEC System mark on the damper with the pointer on the front If for any reason any "Dura Spark’’ two-piece cover. distributor cap cap and adaptor must be removed, the From this point on d0 not rotate the crankshaft. top portion of the cap must be removed

29-02-111 Engine Diagnosis and Service 29-02111 7. If more than ± 2 degrees, loosen the distributor distributors. Increase engine speed to 2500 rpm hold-down bolt and adjust initial timing to to verify available vacuum. If no vacuum is specification by rotating the distributor against available within 60 seconds, vacuum system is at rotor rotation to advance the timing, or with rotor fault, perform SSD-3. If a vacuum is available, rotation to retard the timing. When the white perform Step C-2. mark Step 1 is directly in line with the pointer, 2. Install distributor vacuum line without spark ignition timing is correct. Tighten hold-down bolt delay valv

29-02.112 Engine Diagnosis and Service 29-02-112 5. With TSP de-energized 2.81 engine at curb Internal Fuel Bowl Vent Clearance Set and External idle and vent valve plunger depressed, Vent Check measure the clearance between the vent valve plunger and the actuating lever. 2700 Carburetor Internal Vent Setting 1. Inspect the valve and linkage for damage. 6. Clearance should be within specification. Bend 2. Disconnect the bowl vent line at the carburetor. actuating lever as required to obtain the Ch

29-02-113 Engine Diagnosis and Service 29-02-113 6. With the ignition switch in the off position, set the choke plate in the open position. Make sure that the fast idle cam mechanism is set at the engine curb idle position. Gently operate the vacuum hand pump and observe one of the following: a. If the hand pump does not produce a vacuum, proceed to Step 7. b. If a vacuum of 5-10 in Hg is present, perform Steps 8-12. 7. With the ignition off, set the throttle to the maximum "High Cam" position. Gently operate the vacuum hand pump and observe one of the following: B

29-02-114 Engine Diagnosis and Service 29-02-114 1. Disconnect the electrical lead to the bowl vent A. Rocker Arm Assemblies-individually mounted. solenoid and connect it to one lead of a test light. 1. Check for loose mounting stud and nut or bolt. Connect the second test light lead to ground. 2. Check for plugged oil feed in rocker arm. 2. With the ignition switch in the on position, B. Rocker Arm Shaft Assemblies observe one of the following:

29-02-115 Engine Diagnosis and Service 29-02-115 arm. If oiling is insufficient for this condition to c. Fuel bowl and primary and secondary main occur, check oil passages for blockage. metering jet channels. C. Push Rods d. Primary and secondary main well channels. 1. Check for bent push rods. 5. Using compressed air, dry off the items removed 2. Check for proper rotation of push rods. in Steps 2 b, c, d, e, and f above. D. Positive Rotator and Keys 6. Install new fuel filter. 1. Check for proper operation of positive

29-02-116 Engine Diagnosis and Service 29.02-116 1. Clean carburetor in the following sequence: c. Remove and clean idle jet and pump discharge a. Set choke on high cam position and scribe a weight and ball. line on the air horn corresponding to the bottom d. Remove and clean vacuum power valve, main of the "V.’ notch on the accelerator pump lever. metering jet and pump diaphragm assembly. See b. Remove external connections, air horn hold Fig. 28. down screws, and air cleaner stud. Lift air horn e. Using compressed air, dry all parts, blow out assembly vertically from carburetor and place all channels, parts, an

29.02-117 Engine Diagnosis and Seryice 29-02-117 2. Reinstall carburetor an vehicle with new gasket. 11. Check idle speed and idle fuel mixture to comply 3. Install new fuel filter. with specification. Adjust as required. 4. Check all idle speeds and idle fuel mixture. Adlust Appendix "A" Model 2700 Carburetor as required and install new limiter at maximum rich position. If electric cranking solenoid fails to click or a new solenoid check Carburetor removed from vehicle. 1. Remove electric

29-02-118 Engine Diagnosis and Service 29-02-118 SPRING Eu. Remove the main system feedback metering needle housing from the mainbody. 3. Clean the fuel bowl and all the items removed in Step 2. 4. Using compressed air, blow out the following main body channels in the listed order:

29-02-119 Engine Diagnosis and Service 29-02-119 550-22 EVAPORATIVE EMISSION CONTROL C. With the purge valve still removed from the SYSTEM evaporative canister, connect a vacuum source to the purge valve and apply 5" Hg vacuum. With VAPOR PURGE CONTROL VALVE the engine idling, listen for a strong hissing. If I. Engine Will Not Start or Run a strong hissing is not heard, replace the valve. A. Remove the purge line from the PCY line "Tee" D. Disconnect the vacuum source from the purge and cap. Attempt to start the engine.

29-02-120 Engine Diagnosis and Service 29-02-120 Range, 0-25 ±/- 5 inches Hg B. Vehicle Will Not Start or Run Resolution, 0.5 inch Hg 1. Verify that the IGNITION key is "OFF." Accuracy, ±/- 3 percent of full scale, maximum 2. Remove the primary connector from the ignition C. Vacuum tester: model 2 1-0014 or equivalent. coil and disconnect the four pin circular 0. Tachometer connector at the IGNITION MODULE. Requirements: Range, 0-3000 RPM

29-02-121 Engine Diagnosis and Service 29-02-121 b Record the time on the data chart. A. Battery Voltage Not Within Limits 3. Test Sequence Ill. Start and run engine at idle to normal operating a Set engine rpm in the 2200-2600 range. temperature upper radiator hose hot and b Reconnect the control vacuum line to the pressurized and set the Test Selector VACUUM GAGE TEE. SWITCH to position 1. c Disconnect the vacuum line from the Cold 1. If the reading is less than 11 .5 volts, check for Temperature Switch PINK HOSE. one or more of the following conditions: d Apply 4.5-5.5 in. Hg v

29-02-122 Engine Diagnosis and Service 29-02-122 f Set the Test Selector Switch to pOsition 8. 8. Disconnect and plug the vacuum hose from the g If the reading is greater than 4.0 ohms, Cold Temperature Switch. replace the ECU and retest." a Set the Test Selector Switch to position 2. h If the reading is less than 4.0 ohms repair b Run engine in the 2200-2800 rpm range. or replace the harness

29-02-123 Engine Diagnosis and Service 29-02-123 1. EGO Sensor Rich, Control Vacuum High, d Use the DVOM to measure the resistance Vacuum Solenoid Light "on" of the Vacuum Solenoid Regulator coil. a Check for proper operation of the CHOKE per With the Selector switch in the 200 ohm SSD-12 and retest. If the complaint is still position, this reading should be between present proceed to the next step. 30-55 ohms. If reading is not within this b Check for proper operation of the range, replace Vacuum Solenoid Regu CARBURETOR per SSD-31 and retest.** lator and retest.** If the reading is within

29-02-124 Engine Diagnosis and Service 29-02-124 move aside the air output hose from the AIR SENSOR. If the reading is 0.25 volts or less, BYPASS VALVE. Start engine and let it idle indicating the lean mixture, the system is until it has reached normal operating O.K. Check the TESTER per TESTER temperature upper radiator hose hot and MANUAL to verify it is functioning prop pressurized. Then operate engine for a erly. minimum of 3 minutes between 2200 and e Reconnect vacuum hose to fitting. 2800 rpm. Reduce engine speed to curb idle and immediately perform Step f and obtain D. Vacuum Solenoid Light Not Within Limits reading

29-02-125 Engine Diagnosis and Service 29-02-125 Test Selector Switch No. 2 No. 1 Cold Temperature vehicle Switch and Vacuum Feedback Test Battery Throttle Angle EGO Sensor Regulator vacuum Sequence Vehicle Condition Voltage Switch Indicator light control I 1.

29-02-126 Engine Diagnosis and Service 29-02-126 - COLD TEMPERATURE VACUUM SWITCH TO DUAL BED FEE0eACK -0- CATALYTIC PVS CONVERTER EGO DVOM SPECIAL

29-02-127 Engine Diagnosis and Service 29-02-127 * If the reading is 3 ohms or greater, II. Test Equipment Required replace or repair Circuit 687A and re A. Essential Special Service Tools. *. test* 1. Meter: Digital volt/ohm meter DVOM d Set the Test Selector Switch to position T78L-50-DVOM 12. Attach TESTER continuity lead 2. Tester: Model T781-50-EEC-1 Including test probe to circuit 77, located in the harness fixtures: connector which mates to the Vacuum a. Sensors3 blue, yellow, brown Solenoid Regulator

29-02-128 Engine Diagnosis and Service 29-02-128 V. Engine Will Not Start VI. Engine Runs This procedure assumes that the other diagnostic A. Depress and hold the "NO START" switch on procedures SSD’s have been run in accordance TESTER. Set ignition key to "start" position with the appropriate routines. while attempting to start engine. A. Vehicle Conditioning 1. If vehicle starts, release the "NO START" 1. Block both front wheels. button and proceed to Step V-B. 2. Put the parking brake on and set transmis 2. If vehicle fails to s

29-02-129 Engine Diagnosis and Service 29-02-129 EEC-I MODULE IECAI CP SENSOR MAP SENSOR 5CR POSITION SENSOR THERMACTOR AIR BYPASS

29-02-130 Engine Diagnosis and Service 29-02-130 Test Selector Switch Position - -- - Spark 1 2 13 4 5 6 1 8 Advance Vehicle Condition Vref MAP TP P BCT IAT TAB EVP degrees TESTSEQIJENCEI

CRANKSHAFT MANIFOLD E.G,R. VALVE BAROMETRIC THROTTLE ENGINE INLET AIR POSITION ABSOLUTE AND PRESSURE POSITION COOLANT TEMPERATURE SENSOR PRESSURE POSITION SENSOR SENSOR TEMPERATURE SENSOR Ce SENSOR SENSOR BPI tT SENSOR fIAT g__J 3’f-C 1W ECTI :ii4!1111 CONNECTOR KE ii BLUE

29-02-132 Engine Diagnosis and Service 29-02-132 b. IAT Sensor: Install BROWN fixture b. If the complaint still has not been re to the harness IAT Sen solved, perform one of the following sor connector. steps as required. 4. Operate engine at "curb idle", in "park" 14 Go to the next step in the Diagnostic until the thermostat is open and the upper Routine. radiator hose is hot and pressurized. Gather 2. Repeat the routine from the begin data for Test Sequence II per the following ning. steps and re

29-02-133 Engine Diagnosis and Service 29-02-133 * If the reference voltage does not c. Set the TSS switch to position "12". come within limits, proceed to the * If the reading is less than 100 ohms next step. or more than 250 ohms, repair short f. Disconnect the Manifold Absolute Pres or open in circuit 351 and/or 359 of sure MAP Sensor at its connector. wiring harness and retest.1 * If the reference voltage is between * If the reading is between 100 and 250 8.3 and 9.5 volts, replace M

29-02-134 Engine Diagnosis and Service 29-02-134 * If the reading is between 3xl000 * If the reading is between 100 and and 5x1000 ohms, proceed to the 250 ohms, inspect the sensor leads next step. and connector. If damaged,’repair. d. Connect DVOM between circuit 355 and If ok, replace BP sensor and re circuit 359 of the connector. Set DVOM test.fl switch to 2000 ohms range. Verify the * If the voltage is still out of limits, throttle is in the closed position i.e., off replace t

29.02-135 Engine Diagnosis and Service 29-02-135 * If the reading is between 100 and after release of throttle for return to 250 ohms, proceed to the next step. curb idle. If not, check thermactor air * If the reading is less than 100 ohms, bypass valve per SSD-5. 1 or more than 250 ohms, repair the c. If complaint still isn’t resolved replace short or open in circuit 357 and/or ECA 1. 359 and retest.1 8. EGR Valve Position EVP Sensor Not b. Connect the DVOM between circuit 357 Within Limits and circuit 359 of t

29-02-136 Engine Diagnosis and Service 29-02-136 assembly and retest. 1 * If the maximum pressure is less

29-02-137 Engine Diagnosis and Service 29-02-137 SSD-26 ENGINE IDLE SPEEDS B. Fast Idle RPM 1. Revise the distributor vacuum advance hose asA. Pre-Adjustment Instructions All Engine Speeds follows: NOTE . Leave all vacuum signal hoses attached to the a. On all engines except 2.BL/5.OL 302 CID air cleaner assembly when relocating the assembly to engines with Model 2700 carburetor, remove perform carburetor adjustments. The Air cleaner the spark delay valve, if so equipped, and route assembly must be installed, however, when

29-02-138 Engine Diagnosis and Service 29-02-138 7. Repeat Steps 4 thru 6 until the required fast idle Turn the TSP-ON idle odusting screw until rpm can be repeated. the specified curb idle rpm is obtained. 8. Turn the engine off. Reconnect the vacuum 2 TSP-OFF rpm lines/spark delay valve if so equipped With the engine running, collapse the TSP removed in Steps 1 thru 3. plunger by forcing the throttle lever pad C. Curb Idle Speed Also Includes "A/C-Off". "A/C oginst the plunger. Turn the throttle stop on", and "TsP OFF" Speeds. If so Specified adjusting screw until the specified TSP-OFF 1. Before

29-02-139 Engine Diagnosis and Service 29-02-139 plunger and check the clearance between the 2S1/5.OL/5.8L/6.6L 302/351 W/35 1 M/400 plunger and throttle lever pad. Adjust if not CID Engines with Model 2150 Carburetor in specified limits. 281/50L 302 CID Engines with Model b. Anti-Diesel TSP 2700 Carburetor 1 Curb Idle RPM NOTE: On engines equipped with the Model Turn the TSP-ON adjusting screw until the 2700 carburetor, the accelerator pump lever specified curb idle rpm is obtained. lash must be checked and adjusted if 2 TSP-OFF RPM

29-02-140 Engine Diagnosis and Service 29-02-140 -After completion, move the climate contr& 3. Stop engine. Remove all test equipment, selector to the "OFF" position. Reconnect the reconnect automatic parking brake release if A/C compressor clutch wire. disconnected, and torque the air cleaner wing 2 A/C-Off RPM nuts to specification. Turn the throttle stop adjusting screw until the specified A/C-OFF rpm is obtained. SSD-27 V.O.A. PNEUMATIC EGR SYSTEM I. Pneumatic EGR Valve Diagnostic Proce

29-02-141 Engine Diagnosis and Service 29-02-141 8. Remove all test equipment, reconnect pressure 6. Recheck the idle quality. If there is improvement line and install air cleaner. Torque wing nut to in idle quality, retain the new EGR valve. If specification. there is no improvement in the idle quality, the problem is elsewhere. Reinstall the original EGR B. If the engine idle quality is not acceptable, the valve and perform further engine diagnosis. EGR valve may not be sealing properly. To

29-02-142 Engine Diagnosis and Service 29-02-142 quality improved when the output line was SSD-31 CARBURETOR FEEDBACK SYSTEM removed, replace the signal conditioner. E. Remove the manifodl vacuum line to signal I. Carburetor Feedback Diaphragm Assembly conditioner. The output pressure of the signal A. Not Used in 1978 conditioner should be less than 1-0 in Hg 0.5 psi. B. Holley Model 6500 Feedback Carburetor F. Increase the engine speed to approximately 2000 rpm, the output should remain at Zero. If not, 1, With the engine off, disconnect the vacuum replace the signal conditioner.

29-02.143 Engine Diagnosis and Service 29-02-143 NE[OL[ STEM SENSOR CONNECTOR BOTTOM OF FUEL BOWL I-LU-I VALVI- SEAT THROTTLE ANOLE SENSOR LOCATED AT THE BOTTOM CARBURETOR FUEL OF THE FUEL EOWL A 4483-lA

29-03-1 Thermactor Systems 29-03-1 PART Thermactor System 29-03 SUBJECT PAGE SUBJECT PAGE GENERAL INFORMATION GENERAL INFORMATION Cont’d. Thermactor System Air Pump Type 03-1 Exhaust Check Valve 03-5 Air Bypass Valves 03-1 Vacuum Differential Valve VDV 03-3 Air Supply Pump 03-1 Vacuum Vent Valve 03-4 Differential Valve Delay

29-03-2 Thermactor Systems 29-03-2 AIR SUPPLY AIR BYPASS CHECK VALVE VALVE-9B289 FIG. 2 Mustang II 302 CID V-8 Thermactor System again on both sides of the diaphragm through a small orifice in the diaphragm. The normally-closed, timed bypass valve used with catalytic systems operates as follows: During normal opera

29-03-3 Thermactor Systems 29-03-3 CONTROL NORMAL OPERATION MANIFOLD VACUUM AIR INLET PULLS DIAPHRAGM UP, PROM THERMACTOR 2 VALVE IS UNSEATED PUMP -

29-03-4 Thermactor Systems 29-03-4 SENSE VACUUM VACUUM VENT AIR SENSE VACUUM OUTLET AIR OUTLET AIR INLET IFROM AIR PUMPI AIR INLET IFPOM AIR PU

29-03-5 Thermactor Systems 29-03-5 EXHAUST CHECK VALVE FIG. 12 continuing the combustion of unburned gases in the same manner as the conventional air pump type The exhaust gas check valve allows thermactor air Thermactor system. to enter the exhaust port drillings, but prevents the reverse flow of exhaust gases in the event of improper operation of system components. The valve is located *OIAFHRAOM between the bypass valve and the exhaust port drillings, either mounted on the external air manifold or directly SEAr on the engine. THERMACTOR II SYSTEM Pulsed Air Type

29-03-6 Thermactor Systems 29-03-6 REED VALVE CHECK VALVE CROSS SECTION A4089’IC FIG. 12 Exhaust Check Valve A4S33.1 A FIG. 13 Thermactor II Air Inlet Valve AIR ITO

29-06-1 Electronic Engine Control EEC System 29-06-1 Electronic Engine 29-06 Control EEC System Lincoln Versailles W/5.OL 302 CUD Only SUBJECT PAGE SUBJECT PAGE DESCRIPTION DESCRIPTION Cont’d. General 06-1 Thermactor Air Bypass Solenoid 06-9 EEC System Components 06-1 Exhaust Gas Recirculating EUR System 06-4 EG R Valve and Sensor Assembly 06-4 Electric Control Assembly ECA 06-1

29-06-2 Electronic Engine Control EEC System 29-06-2 INLEf AIR TEMP SENSOR- MODEL 2700 VV ELECTRONIC CALIBRATION CONTROL ASSEMBLY ASSEMBLY PROCESSOR ECA ASSEMBLY LOCATED IN PASSENGER COMPARTMENT

29-06-3 Electronic Engine Control EEC System 29-06-3 EEC Crankshaft Ia provide the EEC system with an accurate "reference timing" indication when pistons reach top dead center TDC the rear of the crankshaft is fitted with a four-lobe "pulse ring" Fig. 4. FIG. 2 Electronic Control Assembly ECA contains the "memory" and programming for the processor assembly. It is capable of: * Providing calibration information for that particular vehicle, for use by the processor assembly. * Storing calc

__ 29-06-4 Electronic Engine Control EEC System 29-06-4 * Part Throttle cruise * Wide Open Throttle maximum acceleration EXHAUST GAS RECIRCULATION EGR SYSTEM The EGR system used with Versailles consists of three major components Fig. 7: 1. EGR valve/sensor assembly 2

29-06-5 Electronic Engine Control EEC System 29-06-5 EON POSITION SE NSOR ELECTRICAL SIGNAL TO ELECTRONIC CONTROL ASSEMBLY IECAI A4516-lA FIG. $ EGR Valve Used With EEC System FIG, 10 EGR Gas Cooler To properly control the air pressure used to operate the FOR valve, and to allow for application, hold and

29-06-6 Electronic Engine Control EEC System 29-06-6 TIlER MA CT OR CONTROL SOLENOID TO THENMACTOR BYPASS VALVE TOP VACUUM PORTI / TO MANIFDLD VACUUM A45l7-2A FIG, 11 Dual EGR Control Solenoids NORMALLY OPEN* FOR. SOLENOID VENT VALVE’ OPERATION "NORMALLY CLOSED" E.G,R. SOLENOID ‘P ESSIJRE VALVE" OPERATION NO P OWE A SYSTEM PRESSURE VENTED TO

‘4 "INCREASE EOn FLOW ‘MAINTAIN EGR PLOW" ‘01r AND PLUNGER LIFTS TO ALLOW AIR PRESSURE KEEPS RAISES FLOW TO EGR VALVE ENERGIZED PLUNGER NORMALLY CLOSED TO PREVENT

________ ______ 29-06-8 Electronic Engine Control EEC System 29-06-8 EGR VALVE MODEL 27DD CARBURETOR ‘VCNT SOLENOID VALVE PRESSURE’

29-06-9 Electronic Engine Control EEC System 29-06-9 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR COOLANT TEMPERATURE SENSOR ECT - The Manifold Absolute Pressure MAP sensor Fig. The engine coolant temperature sensor Fig. 17 is 15 monitors the changes in intake manifold pressure installed in the rear of the intake manifold and converts which result from changes in engine load, speed and engine coolant temperature into an electrical signal for atmospheric pressure. Manifold Absolute Pressure is the ECA to process. The sensor consists of a brass defined as barometric pressure minus manifold vacuum. housing which contains a thermistor variable resistor in The MAP sensor contains a pressure-sensing element which the resistance decreases as the

29-06-10 Electronic Engine Control EEC System 29-06-10 CENTER ELECTRODE CAP ROTOR DISTRIBUTOR BASE MOUNTING SLOT

29-06-11 Electronic Engine Control EEC System 29-06-11 applications. The actual firing order for the 5.OL 302 SPARK PLUG CONNECTFONSCID V-8 is 1-5-4-2-6-3-7-8, as noted on the intake manifold. 5.5/GELINOT USED351/400IN 19/ElCI DI VS NOTE: Do not attempt to remove any silicone coating from the rotor lower electrode blades or from the distributor cap electrodes, including the center plate electrodes. As this silicone compound ages, it has the appearance of being a contaminant of the cap and electrodes. This condition is normal and causes no performance loss. 5.OL

29-06-12 Electronic Engine Control EEC System 29-06-12 ALIGNMENT MOUNTING SCREWS ROTOR TOOL - T78P-12200-A ROTOR ALIGNMENT SLOTS ADAPTER ROTOR MOUNTING

29-06-13 Electronic Engine Control EEC System 29-06-13 COAT COMPLETE SURFACE TOP AND EDGES APPROXI MATELY 1116 THICK - 4 PLACES 112 INCH PARTIAL VIEW - EEC DISTRIBUTOR CAP A45291A

CRANKSHAFT MANIFOLD E.G.R. VALVE BAROMETRIC ENGINE INLET AIR POSITION CP ABSOLUTE AND PRESSURE THROTTLE TEMPERATuRE SENSOR PREsSuRE MAP POSITION SENSOR POSmOI ITP} TEMPERATURE SENSOR SENSOR SENSOR SENSOR SENSOR - C RED CONNECTOR 1 - A I- BLUE 14---IC I - B CONNECTOR F - -911112

29-07-1 Exhaust Gas Recirculation EGR System 29-07-1 Exhaust Gas Recirculation 29-07 EGR System All Models Except Versailles WI EEC System SUBJECT PAGE SUBJECT PAGE GENERAL INFORMATION GENERAL INFORMATION Cont.’d EGR Backpressure Transducer 01-1 Poppet Type 07.1 EGRICSC System 07-4 Tapered Stem Type - Internal 07-1 EGR System WOT Wide Open Throttle

29-07-2 Exhaust Gas Recirculation EGR System 29-07-2 PVS VALVE B+IIGNI NORMALLY OPEN SOLENOID VALVE SPEED SENSOR ELECTRONIC AMPLIFIER L

29-07-3 Exhaust Gas Recirculation EGR System 29-07-3 A4504-2A FIG. 2 Typical Modified Combined Vacuum Modified COVAC installation "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

29-07-4 Exhaust Gas Recirculation EGR System 29-07-4 POPPET TYPE INIENNAL TAPERED STEMTVPE VACUUM NIPPLE OJAPERACV VALVE SEAT OUTLET HESTRICTOP OPIFJCE USLO TO CONTOOL ILOEI C UT L E C ENLAHULU VIEW V ISIS ID FIG. 3 Typical EGR Valves is equal to, or greater than, the intake manifold vacuum. carburetor venturi vacuum tap is connected to the top This allows the EGR valve to

2 9-07-5 Exhaust Gas Recirculation EGR System 29-07-5 TO 5CR VACUUM VALVE EXHAUST GAS ENTEIANCE FROM CROSSOVER AIR FILTER ENHAUST GAS TV INTAKE MANIFOLU PRESSURE

29-07-6 Exhaust Gas Recirculation EGR System 29-07-6 AMPLIFIER CODED FOR PORT CONNECTIONS: O - OUTPUT TO EGR VALVE V - VENTURI VACUUM R - FROM RESERVOIR A - ATMOSPHERE IVENTI 2-PORT S - VACUUM SCURCE EGR P V S ISPARI< OR EGR PORTI VALVE cP°AM Vl8461C FIG. 8 Typical EGR System With Venturi

29-07-7 - Exhaust Gas Recirculation EGR System 29-07-7 MANIFOLO VACUUM FITTING EGR VALVE CHECK VALVE *4505-24 FIG. 9 Exhaust Gas Recirculatlon and Coolant Spark Control EGR/CSC System VENTURI VACUUM DIAPHRAGM VALVE CALIBR

29-08-1 2.31 Feedback Carburetor Electronic Engine Control System 29-08-1 2.3L Feedback Carburetor 29-08 Electronic Engine Control System Pinto and Bobca t with 2.31 1-4 California Only SUBJECT PAGE SUBJECT PAGE DESCRIPTION DESCRIPTION Cont’d. Cold Temperature Vacuum Switch 08-8 Model 6500 Feedback Carburetor 08-3 Throttle Angle Vacuum Switch 08-8 Electronic Control Unit 08-7 Vacuum Solenoid/egulator 08-S Electronical

29-08-2 2.31 Feedback Carburetor Electronic Engine Control System 2948-2 MIXING CHAMDCR IMIDBED SHELL EXHAUST GASES FROM ENGINE CONVENTIONAL OXIDATION CATALYST ICOCI FLOW SECONDARY AIR INLET FITTING AIR PROM

29-08-3 2.3L Feedback Carburetor Electronic Engine Control System 29-08-3 EXHAUST CHECK VALVE EXHAUST DUAL CATALYTIC MANIFOLD CONVERTER ENGINE COOLANT TEMP. LOWER THAN 52°C 125° F AIR CLEANER THE RMAC TO R AIR MOUNTED TVS

__________ _________________ VACUUM LINES COLD TEMPERATURE SECONDARY AIR - - ELECTHICALWIRE CHECK

29-08-5 2.3L Feedback Carburetor Electronic Engine Control System 29-08-5 MODULATED FEEDBACK VACUUM SWITCHING FROM VACUUM REGULATOR/SOLENOID FRESH AIR SUPPLY TUBE rUEL BOWL TO VACUUM REGULATOR/SOLENOIDI A4495-2A FIG. 5 Model 6500 Carburetor-Externol VAC

29-08-6 2.31 Feedback Carburetor Electronic Engine Control System 29-08-6 spring causes the valve to move to its lowest richest AIR PASSAGE position, where maximum fuel can pass through the orifice. As vacuum is applied to the diaphragm, spring pressure is overcome and the metering rod rises, reducing the orifice area and permitting less fuel to pass. The metering valve is calibrated so that the SOLENOID maximum vacuum signal supplied by the vacuum regulator/solenoid 5 inches Hg raises the rod to its highest leanest position. In the open loop mode, a constant vacuum of 2-1/2" Hg is applied to the feedback valve diaphragm, holding SO LEN 01 D the metering rod at its mid.position. In closed loop ELECTRICALCONNECTION operation, the vacuum signal varies

29-08-7 2.3L Feedback Carburetor Electronic Engine Control System 29-08-7 flutes in the sensor shield. A vent is provided in the shell The EGO sensor monitors the air/fuel ratio and to allow atmospheric air to enter the inner portion of generates an output of 0.6 to 1.0 volts when surrounded the sensor body. The sensor connects to the vehicle by a rich exhaust gas mixture absence of oxygen and wiring harness with a connector that contacts the inner less than 0.2 volts when surrounded by a lean mixture positive terminal. The shell is the negative terminal presence of oxygen. This constantly changing voltage of the sensor, and provides the signal return path via signal is sent to the ECU for analysis. the engine block.

29-08-8 2.3L Feedback Carburetor Electronic Engine Control System 29-08-8 ECU when to change from "open loop" to "closed vacuum causes the switch contacts to open, signalling loop" operation. the ECU to operate in "closed loop" made. In this mode, there is full feedback control, and the ECU adlusts theThrottle Angle Vacuum Switch air/fuel ratio in response to EGO sensor signals. The throttle angle vacuum switch is a vacuum actuated electrical switch with noramlly closed contacts Cold Temperature Vacuum Switch Fig. 10. This vacuum switch is connected to vacuum The