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
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.
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.
4. Replace the Expansion Chamber shown in Figure 4. Refer to the appropriate Service Manual for removal and installation procedures.
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.
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