EGR Valve - Buzzing/Engine Surge
83ford12
Article No. 83-13-28
ENGINE SURGE/EGR NOISE (2.0L/2.3L) HOT ON ROAD LOADS - ALL CALIBRATIONS
LIGHT TRUCKS ALL RANGERS
CALIBRATIONS: All 2.0L/2.3L
New EGR valves will improve most concerns of EGR buzz and engine surge at light tip-in and road loads.
If the concern is an EGR buzz noise only, remove and replace the EGR valve with the appropriate valve from the following chart.
If the concern involves engine surge, perform the fuel control feedback solenoid functional check as outlined in TSB 83-10-23 dated May 17, 1983. If the concern persists after this check, temporarily disconnect and plug the vacuum line to the EGR valve and test drive the vehicle. If there is a substantial improvement in the surge condition, replace the EGR valve with the appropriate valve from the following chart.
If there is little or no improvement with the EGR disconnected, other causal factors should be investigated without replacement of the EGR valve. With testing completed, ensure that the EGR vacuum line is reconnected.
New EGR
Calibration Engineering/Identification Service Part
Number Number Number
3-49S E27E-9H495-E3A/E3B
3-49T E37E-9H495-G3A E3TZ-9H495-AD
3-50Y E37E-9H495-J3A
3-41P E27E-9H495-H3A/H3B
3-49G - 3-49Y E37E-9H495-E3A
3-50H E37E-9H495-K3A E3TZ-9H495-W
E27E-9H495-G3A/G3B
3-50S E37E-9H495-A3A E3TZ-9H495-Z
E37E-9H495-M3A
3-49H E37E-9H495-N3A E3TZ-9H495-AA
3-49Y E37E-9H495-P3A E3TZ-9H495-AB
3-41D E27E-9H495-F3A/F3B E3TZ-9H495-AC
E37E-9H495-F3A
3-41S E37E-9H495-L3A E3TZ-9H495-AE
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
E3TZ-9H495-AD EGR Valve Assembly C
(Cal. 3-49S, 3-49T, 3-50Y)
E3TZ-9H495-W EGR Valve Assembly C
(Cal. 3-41P, 3-49G, 3-49Y, 3-50H)
E3TZ-9H495-Z EGR Valve Assembly C
(Cal. 3-50S)
E3TZ-9H495-AA EGR Valve Assembly C
(Cal. 3-49H)
E3TZ-9H495-AB EGR Valve Assembly C
(Cal. 3-49Y)
*E3TZ-9H495-AC EGR Valve Assembly C
(Cal. 3-41D)
E3TZ-9H495-AE EGR Valve Assembly C
(Cal. 3-41S)
* -Part available after 6-24-83
OTHER APPLICABLE ARTICLES: 83-10-23
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time.
DLR. CODING: Basic Part No. 9H495 Code: 56
Article No. 83-10-23
SURGE, POOR FUEL ECONOMY AND/OR ROUGH IDLING (2.0L/2.3L WITH MCU CONTROLS)
LIGHT TRUCKS 1983 RANGER
CALIBRATION: ALL MCU
Concerns of poor fuel economy, rough engine idle when stabilized, and/or stumbles or surges at higher speeds may be due to a sticking carburetor feedback control solenoid.
To check for proper function of the fuel control solenoid, turn the ignition to the "ON" position. A good (nonsticking) feedback control solenoid can be felt or heard oscillating at a constant frequency. If the solenoid is not functioning, check for the proper signal to the solenoid (7-8 VDC). If the proper signal is present at the solenoid connector, install a new feedback solenoid (E3PZ- 9S565-A) and a new solenoid gasket (E1PZ-9S521-A)
Figure 19:
To gain access to the feedback solenoid, remove, the air cleaner assembly. When removing the air cleaner assembly, DO NOT deform the air cleaner support bracket. Be sure to disconnect the air cleaner support bracket (Figure 19) from the engine lifting eye and disconnect the duct and valve assembly support bracket. Failure to do this will result in warping the bracket and tray thus preventing the tray from sealing to the carburetor air cleaner gasket. Install a new carburetor to air cleaner gasket (C8DZ-9654-A).
CAUTION: EXTREME CARE MUST BE TAKEN WHEN CLEANING THE CARBURETOR ASSEMBLY AIR INTAKE AREA OR WHEN TESTING THE CARBURETOR FOR VACUUM LEAKS. DO NOT ALLOW ANY CLEANING SOLVENTS OR LUBRICANTS TO ENTER THE FRESH AIR INLETS TO THE FEEDBACK SOLENOID. CLEANING SOLVENT WILL DAMAGE INTERNAL SOLENOID PARTS.
When installing the air cleaner tray, rotate the tray until the mounting bracket is against the lifting eye, If the mounting bracket slot does not align with the tapped hole in the lifting eye, gently bend the bracket (while holding the tray) in the appropriate direction until the hole and slot align (Figure 19).
Figure 18:
The air cleaner cover seal may be misaligned. Visually inspect the cover. The foam seal must not be obviously out of alignment with respect to the metal surface of the cover (Figure 18). Extreme misalignment will prevent the cover from properly sealing to the filter element. Inspect the filter element for dirt accumulation and if necessary, replace the filter element (9601). If the air cleaner cover seal is not acceptable, replace the air cleaner cover (E3TZ-9661-A). Seat the air cleaner assembly on the carburetor, insuring that the carburetor gasket is in place. Before securing the air cleaner support bracket to the lifting eye, install the sealing washer (9697) with the rubber side down. Then install the wingnut. Seat the wing nut on the washer, turning it four (4) full turns after initial contact with the washer.
NOTE: Dirt contamination is the most probable cause of fuel solenoid sticking. To preclude future solenoid concerns, the following areas should be periodically inspected for proper sealing:
^ Proper contact between air cleaner tray and carburetor gasket.
^ Sealing washer in place with rubber side down.
^ Air cleaner wing nut torqued to four (4) full turns after initial contact with sealing washer.
PART NUMBER PART NAME CLASS
E3PZ-9S565-A Feedback Solenoid B
E1PZ-9S521-A Solenoid Gasket W
C8DZ-9654-A Air Cleaner Gasket AM
E3TZ-9661-A Air Cleaner Cover Assembly CG
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: M
TIME: "Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9661 Code: 24