PCV System Modification

1. Remove and discard PCV hose from location shown in Figure 5.





2. Thread bolt (from Kit 9A474) and sleeve (from Tool Kit 303-592) into PCV hose fitting. See Figure 6.

NOTE:
Tighten bolt until sleeve contacts fitting. Do not tighten bolt any further, as damage to the manifold can occur.





3. Position Replacer Tool 303-592 on bolt head. Bolt head will fit into the slot in the tool. See Figure 7.

4. Attach locking pliers to the fitting only. DO NOT position pliers on sleeve. Sleeve is part of tool kit. Refer to Figure 7.

5. Obtain Selector Shaft Seal Remover/Replacer (T94P-7025-HH) from your 1994 1/2 Contour/Mystique Essential Special Service Tool Kit. Also obtain Slide Hammer T50T-100-A.

6. Screw T94P-7025-HH onto the slide hammer.





7. Slide Tool T94P-7025-HH over Tool 303-592. See Figure 8.

8. With slide hammer and all tools horizontal, remove fitting from the manifold. Remove sleeve from bolt and return sleeve to tool kit.





9. Apply Stud and Bearing Mount (EOAZ-19554-BA) to shaft of new 3-tap fitting, then position 3-tap fitting in location where old fitting was removed. Refer to Figure 9.

10. Position Replacer 303-592 on new 3-tap fitting as shown in Figure 9.

11. Unscrew T94P-7025-HH from slide hammer, then remove the hammer part of the slide hammer shaft.

12. Reinstall T94P-7025-HH on the Slide Hammer T5OT-100-A shaft.





13. Slide Tool T94P-7025-HH over Tool 303-592. See Figure 10.





14. Using a normal hammer on the end of the slide hammer shaft, install 3-tap fitting into the manifold. See Figure 11. The fitting will not sit flush up against the manifold; there will be a slight gap between the fitting and the manifold.





15. Cut PCV valve hose six (6) inches from the PCV valve. See Figure 12.





16. Install new tee into PCV hose that was cut in previous step. Refer to Figure 13 (Location A).

17. Connect formed PCV hose to tee. Refer to Figure 13 (Location B).

18. Connect other end of formed PCV hose to 3-tap fitting. Refer to Figure 13 (Location C).

19. Install the insulation above the PCV valve. The insulation should touch the grommet when the PCV valve is installed. Refer to Figure 13 (Location D).

20. Cap fitting end with supplied vacuum cap. See Figure 13 (Location E).





21. Using screw clamps from kit, install PCV heat hoses on 3-tap fitting. Tighten clamps to 1-4 Nm (9-35 lb/in). See Figure 14.





22. Locate the heater coolant tubes. On the rear of the heater coolant tubes there is a small hose (communicator hose) that connects the two (2) tubes together. Remove this small hose. See Figure 15.