Air Cleaner - Sealing Procedure
84ford14Article No. 83-25-21-S
AIR CLEANER SEALING - 4.9L (1982-83 F-SERIES AND BRONCO ONLY) AND ALL UNITS WITH 5.0L, 5.8L OR 7.5L ENGINES. UNITS OPERATED IN DUSTY AND/OR OFF-ROAD CONDITIONS
- ARTICLE ALSO INCLUDES SEALING OF 7200VV CARBURETOR ON UNITS SO EQUIPPED
LIGHT TRUCKS 1980-83 E, F AND BRONCO
This is a re-write of TSB 83-25-21 (December 12, 1983). The air cleaner part numbers listed in the TSB are of insufficient detail and are therefore being deleted from the TSB.
Due to the variety of different air cleaners used, part numbers have not been included in this TSB. See your normal parts listing for these part numbers.
The subject vehicles operated in dusty/off-road conditions may experience an air cleaner sealing concern which could lead to engine oil consumption or, on 7200 VV carburetor equipped vehicles, a poor running condition. The following procedure should minimize these concerns.
1. Remove the air cleaner assembly from the engine and remove any loose debris from inside the tray. Replace the air cleaner assembly (9600) on all 1983 4.9L, 5.0L, 5.8L and, 7.5L equipped light trucks except the 1983 Econoline with the 4.9L engine.
Due to the variety of different air cleaners used, part numbers have not been included in this TSB. See your normal parts listings for these part numbers.
2. Wipe the sealing surfaces clean on the tray and cover and inspect for any dents or damage that would prevent a good seal. Replace any damaged components.
3. Inspect the air cleaner to carburetor gasket for proper installation. If the gasket appears crimped or damaged, replace it with a new sticky-back gasket. Prior to replacing the gasket, clean the carburetor flange. Install the new gasket sticky side down and press all the gasket down to assure a tight bond.
Gasket parts numbers: 4.9L - C8DZ-9654-A, 5.0L/5.8L/7.5L - D8ZZ-9654-A.
FIGURE 24:
4. For F-Series and Bronco only, relocate the zip tube inlet. a) Detach the zip tube inlet from the radiator support. b) Move the inlet to the top rear of the wheel wellhousing per Figure 24. c) Secure the zip tube to the top of the housing with a nylon tie-down
strap. NOTE: At high temperatures, an octane ping may occur. If it persists, the zip tube must be reinstalled to the radiator support.
5. Replace the PCV filter. For 4.9L, 5.0L-2V, 5.8L-2V and 7.5L-4V engines replace the PCV filter in the air cleaner with an in-line filter.
a. Remove and discard the crankcase breather cap to PCV filter hose (closure hose), PCV filter in the air cleaner, the adapter at the air cleaner and the adapter retaining clip.
b. Drill a 5/16" hole in the side wall of the air cleaner approximately 12" to the rear of the existing crankcase closure hole for 5.0L and 5.8L and approximately 6" to the rear on 7.5L. (The 4.9L does not need a new hole).
c. Install a 1/2" hose (E2AZ-6853-A) to the existing adaptor in the valve cover oil fill cap (2 pcs. 2-5/8" long for 4.9L, 18" long for 5.0L/5.8L, 12" long for 7.5L).
d. At a convenient location, cut the hose and install an in-line filter E2AZ-6A768-A for 5.0L, 5.8L and 7.5L. On the 4.9L, install the filter between the 2-5/8" long pieces installed in (c.).
NOTE: Install the filter with the wire mesh toward the oil fill cap. The mesh can be seen by looking into the end of the filter assembly.
e. Install an adapter E43Z-9E606-A in the air cleaner and attach using a retaining clip 383741-S. Center the adapter elbow in the new hole for 5.0L, 5.8L and 7.5L. Use the existing PCV filter (closure) pack hole for 4.9L.
f. Cut the PCV filter (closure) hose to proper length and attach to the adapter.
g. Plug the old hole in the tray with plug 377678-S for 5.0L, 5.8L and 7.5L only.
FIGURE 25:
6. For 5.0L and 5.8L engines with a 7200 VV carburetor, clean and seal the carburetor to prevent dirt migration through the choke rod and accelerator pump rod holes (Refer to Figure 25).
a. Remove the carburetor from the vehicle.
b. Without disassembling the carburetor, thoroughly clean with Ford Automatic Choke Cleaner or equivalent, all of the choke linkage and accelerator pump linkage on the top and sides of the carburetor. Pay particular attention to the top and bottom of the upper body casting around the choke and accelerator pump rods. Allow cleaner to evaporate or blow dry with shop air.
c. Remove stepper motor, gasket, pintle and spring. Clean pintle and pintle cavity in main body casting thoroughly with Ford Automatic Choke Cleaner or equivalent. Do not re-install stepper motor at this time.
FIGURE 24:
d. Hold throttle lever in the wide-open throttle position to raise the accelerator pump rod. With a toothpick, or other sharp tool, apply any commercially available silicone RTV (such as Dow Corning "Silastic") to the top side of the upper body casting around the accelerator pump rod (Figure 24). Fill the hole completely around the rods from the top side only and release the throttle lever.
e. With a rubber band, tie the throttle lever in closed-throttle position. Push fast idle cam to "off" position so that choke rod is fully raised. Fast idle cam should remain in "off" position.
f. With a toothpick, apply silicone RTV to bottom side of upper body casting around the choke shaft rod. Fill the hole completely around the rod from the bottom side only.
g. Install the spring, pintle, gasket, and stepper motor.
h. Allow carburetor to stand at room temperature for 24 hours without disturbing silicone RTV.
i. After 24-hour cure, remove rubber band from throttle lever, and open throttle to break (free) accelerator pump rod from silicone RTV. Bulk of RTV sealant should remain attached to upper body.
j. Manually exercise choke linkage to break (free) choke rod from silicone RTV. Bulk of RTV sealant should remain attached to upper body.
k. Re-install carburetor on vehicle.
7. Re-install and secure the air cleaner assembly as follows:
a. Set the air cleaner tray assembly on the carburetor and check that nothing is preventing the tray seating securely and completely sealing the flange.
b. Connect and secure the vacuum hoses.
c. Install and seat a new heavy duty air cleaner element in the tray. Use E2TZ-9601-B (FA-732) for 4.9L and E0TZ-9601-A (FA-688) for 5.0L/5.8L. Use non-heavy duty element for 7.5L.
NOTE: Use of incorrect element will allow dirt to be ingested and will damage the engine.
d. Install the air cleaner cover and place the washer grommet rubber side down. Torque the wing nut hand tight (20 in.lbs.). Try to rotate the air cleaner assembly slightly. If it resists rotation, sealing to the carburetor is assured.
e. Connect the crankcase filter hose securely.
f. Install the heat riser tube. Connect the fresh air zip tube.
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
E2AZ-6A768-A PCV Filter C
E2AZ-6853-A 1/2" PCV Hose C
E43Z-9E606-A Adapter C
E2TZ-9601-B Air Filter Element AM
E0TZ-9601-A Air Filter Element AM
C6TZ-9697-A Washer AM
D8ZZ-9654-A Gasket A
377678-S Plug BR
E3AZ-19562-A RTV Sealer A
390013-S36B Wing Nut S
C8DZ-9654-A Gasket AM
OTHER APPLICABLE ARTICLES: 83-25-21
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: SP9600C84
TIME: 6 cyl. - 0.5 Hr. 8 cyl. - 1.1 Hrs. DLR. CODING: Basic Part No. 9600 Code: 49