Clutch - Rough Engagement/Stalling When Cold
BULLETIN NUMBER ISSUE DATE GROUPSB86-02-006 August 1, 1986 FUEL
VEHICLES AFFECTED
1986 Trooper II (KT) models with 4ZD1 gasoline engine before VIN G5431603 (production date 04/05/86).
SERVICE INFORMATION
Affected vehicles may exhibit either or both of the following cold driveability conditions:
a. Rough clutch engagement when engine is cold.
b. Hesitation or stall when throttle pedal is depressed after clutch engagement.
The first condition can be eliminated by removing the clutch damper from the clutch pedal assembly. The second condition can be eliminated with the installa- tion of a redesigned accelerator pump link and the addition of a distributor vacuum switching valve (VSV).
PARTS INFORMATION
The following parts are available from your facing Parts Distribution Center:
Part Number Description
8-94436-184-0 Field Fix Set (Federal)
8-94436-185-0 Field Fix Set (California)
Each set consists of one each of the following eight parts:
Part Number Description
8-94433-750-0 Carburetor Link Kit
8-94429-764-0 Rubber Hose Assembly
8-94174-068-0 Vacuum Switching Valve Assembly
8-94429-765-0 Harness Assembly
8-94429-766-0 OR Hose Routing Label (Federal)
8-94429-767-0 Hose Routing Label (California)
9-01960-612-0 Bolt
9-09110-406-0 Nut
9-09160-606-0 Washer
FIGURE 1 - CLUTCH DAMPER:
SERVICE PROCEDURE
Clutch Damper
1. Remove the clips from the mounting pins at the top and bottom of the clutch damper (Figure 1).
2. Remove the damper and washers from the vehicle.
FIGURE 2 - EARLY FUEL EVAPORATION (EFE) HEATER WIRING CONNECTOR:
Distributor VSV and Accelerator Pump Link
To install the VSV:
1. Disconnect the negative battery cable.
2. Remove the air cleaner assembly as described in the Workshop Manual.
3. Separate the Early Fuel Evaporation (EFE) heater wiring connector (Figure 2).
FIGURE 3 - VACUUM HOSE:
4. Remove and discard the vacuum hose between the carburetor and the distributor vacuum tube (Figure 3).
FIGURE 4 - PLUG LOCATION:
5. Remove the plug from the hole in the right-hand inner fender (Figure 4).
FIGURE 5 - NEW RUBBER HOSE ASSEMBLY:
6. Connect the new rubber hose assembly and the wiring harness assembly to the VSV as shown in Figure 5.
FIGURE 6 - RUBBER HOSE ASSEMBLY:
7. Use the nut, bolt and washer to fasten the VSV to the right-hand inner fender. Tighten the bolt securely.
8. Connect the rubber hose assembly to the carburetor and distributor vacuum tube as shown in Figure 6.
FIGURE 7 - HEATER CONNECTORS:
9. Connect the new harness assembly to the EFE heater connectors as shown in Figure 7.
10. Place the new hose routing label over the existing label (located on the underside of the hood).
FIGURE 8 - ACCELERATOR PUMP LINK:
FIGURE 9 - ACCELERATOR PUMP LINK:
To install the accelerator pump link (Figure 8):
1. Remove the assist spring.
2. Remove the upper cotter pin and E-clip.
3. Slide the pump lever off of the carburetor. Save the nylon bushing and washer for re-use.
4. Remove the lower cotter pin and washer and slide the link out of the throttle lever. Remove the second washer from the link.
5. Install the new pump lever, link and assist spring onto the carburetor. Be sure to install the nylon
bushing and washer at the upper mounting point. Figure 9 shows the new parts installed.
6. Install the air cleaner assembly.
7. Connect the negative battery cable.
WARRANTY INFORMATION
Operation number: 030298
Trouble code: 71
Parts: Dealer cost + 25%
Time allowance: .9