Engine - Stalls/Hesitates/Long Cranking Times
Article No.93-12-6
06/09/93
^ HESITATION ON ACCELERATION AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA
^ IDLE - ROUGH - AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA
^ LONG CRANK TIMES - 2.3L, 2.3L OHC, 3.8L NA
^ STALL AT IDLE AND UPON GEAR ENGAGEMENT AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA
^ STALL AT IDLE AND UPON GEAR ENGAGEMENT AFTER COLD START - 2.3L, 2.3L OHC. 3.8L NA
^ ENGINE - INTAKE VALVE CLEANING PROCEDURE - 2.3L, 2.3L OHC, 3.8L NATURALLY ASPIRATED
FORD:
1988-92 MUSTANG, TAURUS, TEMPO, THUNDERBIRD
LINCOLN-MERCURY:
1988-92 CONTINENTAL, COUGAR, SABLE, TOPAZ
LIGHT TRUCK:
1988-92 RANGER
This TSB Article is being republished in its entirety to update the Intake Valve Deposit (IVD) inspection/cleaning procedure and to provide technical service tips for the 2.3L OHC engine.
ISSUE:
Vehicles with excessive intake valve deposit (IVD) may exhibit the following driveability concerns after a cold start. These drive concerns may also result from the use of fuels that have low volatility, such as high octane, "premium" fuels.
^ Long crank times
^ Idle stall after initial cold start
^ Stall upon gear engagement
^ Rough idle after cold start
^ Hesitation on acceleration after cold start
^ Hesitation/Stall on initial acceleration (3.8L N/A applications)
When these deposits are dry, they act like sponges which absorb engine fuel. This may result in a lean engine run condition after an initial cold start. The drive conditions normally occur at ambient temperatures of 40~ F (4~ C) to 70~ F (21~ C).
ACTION:
An IVD inspection and cleaning procedure has been developed using the Rotunda 014-00975 Carbon Blaster Kit. If service is required, use the following procedure to correct the stated driveability concerns.
NOTE:
MANY FLUIDS ARE AVAILABLE TO CLEAN FUEL INJECTORS. SOME INJECTOR CLEANING FLUIDS ALSO CLAIM TO REMOVE INTAKE VALVE DEPOSITS (IVD). ENGINEERING EVALUATION OF THESE FLUIDS INDICATES NO ABILITY TO REMOVE THE IVD CAUSING THE STATED DRIVEABILITY CONCERNS. IF DRIVEABILITY CONCERNS HAVE BEEN AFFECTED BY INJECTOR CLEANING FLUIDS, IT IS MOST LIKELY DUE TO CLEAN-UP OF PORT FUEL INJECTOR DEPOSITS. IVD IS MORE DIFFICULT TO REMOVE THAN PORT FUEL INJECTOR DEPOSITS. IVD MUST BE COMPLETELY REMOVED AS OUTLINED IN THIS TSB ARTICLE TO RESTORE COLD-START DRIVEABILITY PERFORMANCE. THE OVERUSE OF THESE FLUIDS MAY CAUSE ENGINE DAMAGE NOT COVERED UNDER WARRANTY.
1. Perform underhood inspection of vacuum lines and wiring.
2. Perform normal Engine Emissions Diagnostics. Refer to the Engine/Emissions Diagnostics Shop Manual or the Powertrain Control/Emissions Diagnosis Manual.
3. If normal Engine/Emissions Diagnostics have not resolved the driveability concerns, proceed with the following IVD inspection.
INTAKE VALVE DEPOSIT INSPECTION PROCEDURE
1. Remove any two (2) spark plugs. Use a remote starter switch to bump the engine over until the intake valve is fully open in the cylinder to be inspected.
2. Using the 014-00975 Automotive Borescope or equivalent, inspect the backside of the intake valves through the spark plug holes for the presence of carbon deposits.
CAUTION:
DO NOT BUMP THE ENGINE WITH THE BORESCOPE IN THE SPARK PLUG HOLE OR ATTEMPT TO VIEW THE VALVE WHILE ROTATING THE ENGINE. THIS MAY RESULT IN BORESCOPE OR ENGINE DAMAGE.
CAUTION:
DO NOT POWER THE BORESCOPE LIGHT SOURCE FROM A CAR BATTERY WHILE IT IS UNDER CHARGE. FOR EXAMPLE, IF THE ENGINE IS RUNNING, THE LAMP MAY FAIL.
3. Compare the deposits with the Intake Valve Deposit Rating System Chart, Figure 1.
a. If either of the intake valves appear to have a carbon deposit level of 7 or less (lower number rating), intake valve cleaning is required.
b. Proceed to the IVD Cleaning Procedure.
4. If no carbon deposits are seen or the deposit level is 8 or cleaner, the drive concern may be the result of low volatility fuel. Refer to TSB 91-8-13 and proceed to Fuel Recommendation.
CLEANING PROCEDURE
NOTE:
BEFORE BEGINNING THE IVD CLEANING PROCEDURE, USE THE FOLLOWING CARBON BLASTER TIPS:
^ Be sure that compressed shop air is dry. Drain compressor of water regularly.
^ remove any in-line equipment oilers from the air line to be used with the carbon blaster
^ Be sure to store walnut shells in a water tight container with the lid on.
^ Remove unused walnut shells from the carbon blaster when IVD procedure is completed. Do not store walnut shells in carbon blaster.
1. Remove the upper intake manifold assembly, fuel rail and injectors. Refer to the instructions in the appropriate Service Manual.
2. Insert the Rotunda 014-00975 Automotive Borescope or equivalent through the fuel injector holes into the lower intake manifold to determine which intake valves are in the closed position.
CAUTION:
DO NOT ROTATE THE ENGINE WITH THE BORESCOPE IN THE FUEL INJECTOR HOLE. THIS MAY RESULT IN BORESCOPE OR ENGINE DAMAGE.
3. Perform the intake valve carbon cleaning procedure, using the Rotunda Tool 014-00975 Carbon Blaster and Automotive Borescope Kit, or equivalent, on the intake valves that are in the closed position.
NOTE:
DETAILED WRITTEN INSTRUCTIONS AND A PROCEDURAL VIDEO TAPE ARE INCLUDED WITH THE ROTUNDA CARBON BLASTER AND AUTOMOTIVE BORESCOPE KIT.
TECHNICAL TIP - 2.3L OHC ENGINE
When IVD cleaning is performed on the 2.3L OHC dual plug engine, the vacuum should be connected to the lower intake manifold as follows:
^ Remove flex hose and manifold adapter from the hand held vacuum.
^ Insert tapered end of vacuum hose into intake port of manifold using a twisting motion to ensure a tight fit.
^ Proceed with the IVD cleaning process.
(CLEANING PROCEDURE CONTINUED)
When the cleaning procedure is complete, the backside of the intake valve and cylinder port area surrounding the valve will be free of deposits. Confirm complete deposit removal by borescope inspection. (Normal IVD cleaning time is 1 to 1-1/2 minutes per valve.)
4. Bump the engine until the remaining intake valves to be cleaned are in the closed position. Repeat Cleaning Procedure Step # 3.
5. Inspect all intake valves to verify complete carbon deposit removal.
6. Install the fuel rail, fuel injectors, and upper intake manifold using a new intake manifold gasket. Refer to the Dealer Master Parts Catalog for correct part number.
7. Proceed to FUEL RECOMMENDATION.
FUEL RECOMMENDATION
Fuels that do not contain the proper detergent additives may result in the formation of intake system deposits, including clogged port fuel injectors and intake valve deposits. To assist the customer in selecting the proper fuel, provide the customer with a copy of the "Clean Gasoline" Flyer, Figure 2.
Refer to OASIS special service messages 9000 through 9023 to identify appropriate brands of fuel. To access these messages, enter the vehicle VIN and Service Code 404000. The fuel list will be updated periodically. Gasolines on this list are advertised as having intake system deposit control detergents. Regular use of these fuels should minimize or eliminate accumulation of intake system deposits.
NOTE:
IF A HIGH QUALITY FUEL IS CONTINUOUSLY USED WHICH CONTAINS INTAKE SYSTEM DEPOSIT CONTROL DETERGENTS AND OTHER ADDITIVES, AFTERMARKET ADDITIVES SHOULD NEVER NEED TO BE ADDED TO THE FUEL TANK.
Fuels that vaporize poorly may cause similar symptoms or may contribute to symptoms related to intake system deposits. Refer to TSB 91-8-13 for additional information.
OTHER APPLICABLE ARTICLES:
91-10-9, 91-11-4, 91-8-13
SUPERSEDES: 92-19-3
WARRANTY STATUS:
Eligible Under Basic Warranty Coverage and Powertrain For 1991 And Prior Cars And Light Trucks (Excluding Lincolns), Eligible For Bumper To Bumper For 1991 Lincolns And All 1992 Cars And Light Trucks
OPERATION DESCRIPTION TIME
931206A Perform Engine Emission 0.5 Hr.
Test And Underhood
Inspection
931206B Perform Engine Emission 1.0 Hr.
Test, Underhood Inspection
And Intake Valve Inspection
931206C Perform Engine Emission 3.8 Hr.
Test, Underhood Inspection,
Intake Valve Inspection And
Cleaning Of Intake Valves -
1988-1992 2.3L Ranger
931206D Perform Engine Emission 3.3 Hr.
Test, Underhood Inspection,
Intake Valve Inspection And
Cleaning Of Intake Valves -
1988-1992 2.3L
Tempo/Topaz
931206E Perform Engine Emission 3.8 Hr.
Test, Underhood Inspection,
Intake Valve Inspection And
Cleaning Of Intake Valves -
1988-1992 2.3L Mustang
931206F Perform Engine Emission 4.1 Hr.
Test, Underhood Inspection,
Intake Valve Inspection And
Cleaning Of Intake Valves -
1988-1992 3.8L N/A
Taurus/Sable And
Continental
931206G Perform Engine Emission 3.8 Hr.
Test, Underhood Inspection,
Intake Valve Inspection And
Cleaning Of Intake Valves -
1988-1992 3.8L N/A
Thunderbird/Cougar
DEALER CODING
BASIC PART NO. CONDITION CODE
6507 49
OASIS CODES:
499000, 602300, 607000, 607400, 608000, 608400, 609000, 609400, 611000, 611500