Attachment III - Technical Instructions

EMISSIONS CONTROL SYSTEM MODIFICATION

AFFECTED VEHICLES:
1987 Model Escort, Lynx and EXP - California, 1.9L engines with manual transmission - Engine Calibration 7-07E-R10

INSTRUCTIONS

1. Record radio stations for reprogramming upon completion of procedure.

2. Disconnect battery negative cable.

3. Remove air cleaner outlet tube.





4. Remove bolts attaching EGR Back Pressure Variable Transducer (BVT) bracket to engine. (Fig. 1)

5. Disconnect vacuum fitting from BVT. Remove nuts retaining BVT to bracket.

6. Disconnect throttle cable and speed control cable, if so equipped, from throttle lever.





7. Remove clamp and disconnect large vacuum hose from vacuum fitting on intake manifold. Position hose out of the way. (Fig. 2)

8. Disconnect vacuum hose from EGR valve. Remove two retaining nuts. Remove EGR valve and gasket. (Fig. 2)

9. Clean EGR valve gasket material from intake manifold. Install new EGR valve and gasket. Tighten nuts to 18-26 N-m (13-19 lb.ft.). (Fig. 2)

10. Connect vacuum hose to EGR valve.

11. Connect large vacuum hose to vacuum fitting on intake manifold. Make sure that hose clamp is properly positioned. (Fig. 2)

12. Position new BVT to bracket. Install two nuts. (Fig. 1)





13. Position BVT in vehicle and connect threeport vacuum fitting to BVT valve. (Fig. 3)

14. Position BVT bracket and throttle cable bracket to engine. Install retaining bolts to 14-20 N-m (11-14 lb.ft.). (Fig. 1)

15. Connect throttle cable and speed control cable to throttle lever, if so equipped.

16. Install air cleaner outlet duct. Tighten clamps to 1.4-2.3 N-m (13-20 lb.in.).

17. Connect battery negative cable.

NOTE:
After battery is reconnected, the vehicle may show driveability concerns. It may be necessary to drive the vehicle 10 miles or more to allow the EEC-IV microprocessor to relearn values for optimum driveability and performance.

18. Raise vehicle on hoist.





19. Remove hose clamp. Disconnect thermactor air hose from catalyst. (Fig. 4)

20. Remove two bolts, springs, clamp and nuts retaining catalyst to exhaust pipe. Remove catalyst assembly. (Fig. 4)





21. Loosen nut retaining air tube to exhaust pipe orifice. (Fig. 5)

22. Remove orifice fitting from exhaust pipe. (Fig. 5)





23. Using a small wire brush, clean inside of exhaust pipe and orifice opening in exhaust pipe. (Fig. 6)

24. Apply anti-seize compound to threads of new orifice. Install orifice into exhaust pipe. (Fig. 5)

25. Position air tube into orifice. (Fig. 5)

26. Position new exhaust gasket between catalyst and exhaust pipe. Install new spring and bolt assemblies. Tighten to 28-40 N-m (21-29 lb.ft.). (Fig. 4)

27. Connect thermactor air hose to catalyst and position new clamp in place. (Fig. 4)

28. Clean and hilite timing mark on harmonic balancer.

29. Lower vehicle.

30. Set initial engine ignition timing to 6~ BTDC.

31. Start engine and warm to normal operating temperature.

32. Check idle speed. If necessary, adjust idle speed to 950 rpm. Refer to Section 4 of the 1990 Engine/Emissions Diagnosis Manual.

33. Attach Vehicle Emissions Control Information and preprinted Authorized Modifications Labels.

34. Reprogram radio stations and clock.





VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL

1. Remove existing VECI label, clean label mounting surface.

2. Attach new label provided in parts kit.





AUTHORIZED MODIFICATIONS DECAL

The preprinted Authorized Modifications Decal shown below is provided in the parts kit.

^ Insert your P & A Code and date and attach the Authorized Modifications Decal to a clean surface on the fan shroud.

^ Place the clear overlay on the decal.