Fuel/Emissions - Surging Condition
84ford21Article No. 84-1-19
SURGE - (2.0L/2.3L) - CALIBRATION CHANGE - 3-49S-R01, R10, R11 WITH MANUAL TRANSMISSION - EXCEPT CALIFORNIA
LIGHT TRUCKS 1983 RANGER
CALIBRATIONS: 3-49S-R01, R10, R11 ONLY
Carburetor, distributor, EGR valve and air cleaner delay valves along with vacuum schematic changes can be made to improve surge condition.
Ranger calibrations 3-49S-R01, R10 or R11 may exhibit a mild surge that can be objectionable to some customers even after all actions called for in TSB 83-14-22 are completed. If this situation is encountered, it is important to first verify that all actions
called for in TSB 83-14-22 have, in fact, been completed. If the actions in TSB 83-14-22 do not reduce the surge condition sufficiently to satisfy the customer, the following procedure is available to revise these calibrations.
NOTE: It should be understood before these modifications are made that they may not sufficiently reduce surge to satisfy a very critical customer, but they will improve the calibration to a level similar to those in current production.
1. Replace EGR valve and gasket.
Figure 20:
2. Replace carburetor and gasket. Reinstall vacuum hoses to carb as follows: (Figure 20)
a. The hose which formerly connected to the upper carb "B" port will now connect to the front "D" port. To do this, disconnect this hose (18" black) from the orange plastic hose in the harness which leads to the black box. The new carb should have a 10-1/2" orange hose attached to the front port, if not, fabricate as required and connect this hose to the orange plastic hose in harness.
b. The 5-1/4" white hose (from the electric PVS valve) which formerly was connected to the lower carb port "A" is now connected to the upper port "B".
c. (3-49S-R10 and R11 only) Disconnect the 16-1/2" tan distributor hose from the 4-way plastic tee behind the carburetor. Cut 5-1/2" off the tan hose. Connect the shortened tan hose to the 8" black formed hose which is on the lower port "A" of the new carb.
d. Disconnect the hose assembly which ran from the old carb pulldown motor to the vacuum harness leading to the black box. (This assembly may have a brown and black delay valve). Discard the assembly and cap the resulting open port in the harness. (The new carb has a selfcontained pulldown hose.)
e. Reconnect the electrical connection at the choke cap, using the appropriate solderless connectors and insulator sleeves.
3. Replace the air cleaner bi-metal sensor (9E607).
4. Replace the vacuum retard delay valve which is between the bi-metal sensor and the duct and valve motor (pink replaces blue). (12A208).
Figure 21:
Figure 22:
5. (3-49S-R10 and R11 only) Add CSSA system as outlined below (See Figure 21 or 21 and 23).
NOTE: Before this operation, the coolant system is to be drained to a level below the fittings involved.
a. Unclamp and disconnect (E27E-18N333-AB) water by-pass hose from (E37E-18C603-AA)
fitting, which is located to the rear and outboard on the intake manifold (Figure 21).
b. Disconnect the vacuum harness from the yellow 3 port PVS which is on the fitting. Remove the PVS and save (Figure 21).
c. Remove the fitting (E37E-18C603-AA) from the intake manifold and scrap (Figure 21).
d. Install the new fitting (E3TZ-18C603-A) into the intake manifold so that the 2 tapped holes are facing directly outboard. Coat the threads with ESE-M4G203-A3 or equivalent before installation, and torque to specification (10-15 ft.lbs.).
e. Coat the yellow 3 port PVS with sealer ESEM4G203-A3 or equivalent before installing into the hole nearest the intake manifold of the new fitting. Torque the PVS to specification (10 ft.lbs.) with the nipples vertically up.
f. Before installing the new green 3 port PVS (D5ZZ-8A564-A) in the other hole of the fitting, use sealer (ESE-M4G203-A or equivalent) and install vacuum nipples vertically up. Torque to specification (10-15 ft.lbs.).
g. Connect and clamp the water by-pass hose (E27E-18N333-AB) to the new fitting.
h. Connect the vacuum harness back to the yellow 3 port PVS.
i. Disconnect the 5/32" I.D. tan stripe hose from the distributor leaving the other end of the hose intact. Cut 4" off this hose and reconnect it to the vacuum nipple on the green PVS which is closest to the fitting.
j. Cut a 13" piece of bulk 5/32" I.D. vacuum hose (D0PZ-12226-B or equivalent), connecting one end to the distributor and the other end to the center nipple on the green PVS.
k. Cut a 14" piece of bulk 5/32" I.D. vacuum hose connecting one end to the open nipple created in step 2c and the other end to the open nipple on the green PVS.
1. Cut the hose just installed 2" from the green PVS and install the (D7AZ-12A225-A) blue vacuum restrictor.
Figure 23:
m. Use (95874-S) bundling strap to tie the new hoses free of the accelerator linkage and the EGR tube (use Figure 23 to verify proper hose routing).
n. Refill engine coolant system.
Figure 22:
6. (3-49S-R01 only) Revise Cold Start Spark Advance system as follows (Figure 22).
a. Remove the vacuum connectors from the blue 2 port PVS (E1SE-9D473-AA) and the yellow cold weather modulator (D8BE-9E862-AA).
b. Remove the cold weather modulator from the air cleaner and plug the hole with 377678-S rubber plug.
c. Disconnect the 11" tan distributor hose at both ends and discard. The sub-harness which has so far been disconnected from the blue PVS and yellow CWM still has two connections to the engine. Disconnect one hose from the red vacuum restrictor and the other from the 5-way tee behind the carburetor. Discard the subharness. Cap (382444-S) the open nipple on the 5-way tee. Replace the red vacuum restrictor with a new blue one (D7AZ-12A225-A).
d. Remove the blue 2 port PVS arid replace it with a green 3 port PVS (D5ZZ-8A564-A). The coolant does not have to be drained if the switch is made quickly.
e. Using bulk 5/32" vacuum hose, cut and fit the following connections:
^ From the blue vacuum restrictor to the top (outermost) port on the green PVS valve.
^ From the distributor to the center port on the green PVS valve.
^ From the lower port "A" of the carburetor to the remaining port (closest to the threads) on the green PVS valve.
f. Use bundling straps (95873-S) where necessary to the new hoses free of the accelerator linkage and the EGR tube.
NOTE: Hoses should be 3" minimum from the EGR tube (without insulation) 1" minimum from EGR tube (with insulation).
7. Replace distributor and set timing at 6~ BTC.
Figure 22:
Figure 23:
8. Confirm that revised vacuum routing conforms to Figure 22 for 349S-R1 and Figure 23 for 349S-R10 and 349S-R11.
The following is an Add/Delete Parts list for revision of calibrations 3-49S-R01, 3-49S-R10, and 3-49S-R11.
PARTS LIST FOR R01, R10, AND R11 (SEE FIGURES 22, 23 AS APPROPRIATE)
Add P/N Description Class Delete P/N
E3TZ-9510-N Carburetor W E27E-9510-FB
C8DZ-9654-A Carburetor Gasket AM -
95874-S Bundling Strap AG -
E3TZ-9H495-AA EGR Valve Assembly C E27E-9H495-EA/EB/JA
D7FZ-9D476-B EGR Gasket B -
E3TZ-12127-FA Distributor C E27E-12127-BA
D7FZ-9E607-A Bi-Metal Sensor BM D42F-9E607-AA
E3AZ-12A208-E Retard Delay Valve C D8AE-9E897-AA
D7AZ-12A225-A Restrictor A -
Figure 22:
PARTS LIST FOR CSSA REVISIONS - 3-49S-R01 ONLY (FIGURE 22)
Add Description Class Delete
D5ZZ-8A564-A 3 Port PVS (green) A D5DE-9F454-B1A (blue)
D7AZ-12A225-A Vacuum Restrictor A D6DZ-12A225-A (red)
(blue)
377678-S Rubber Plug BR -
382444-S Cap BS -
95874-S Bundling Strap AG -
Figure 23:
PARTS LIST FOR CSSA ADDITION - 3-49S-R10 AND R11 ONLY (FIGURE 23)
Add Description Class Delete
E3TZ-18C603-A Vacuum Control Switch C -
- Vacuum Control Switch C E37E-18C603-AA
D577-8A564-A 3 Port PVS (green) A -
D7AZ-12A225-A Vacuum Restrictor A -
(blue)
95874-S Bundling Strap AG -
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.
OTHER APPLICABLE ARTICLES: 83-14-22
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. DRIVE Code: H8