PCV System Modification

1. Remove and discard PCV hose from location shown in Figure 21.





2. Thread bolt (from Kit 9A474) and sleeve (from Tool Kit 303-592) into the PCV hose fitting. See Figure 22.

NOTE:
Tighten bolt until sleeve contacts the 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 23.

4. Attach locking pliers to the fitting only. DO NOT position pliers on sleeve. Sleeve is part of tool kit. Refer to Figure 23.

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 T5OT-1OO-A.

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





7. Slide Tool T94P-7025-HH over Tool 303-592. See Figure 24.

8. With slide hammer and all tools horizontal, remove fitting from 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.





10. Position Replacer 303-592 on new 3-tap fitting as shown in Figure 25.

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-1 00-A shaft.





13. Slide Tool T94P-7025-HH over Tool 303-592. See Figure 26.





14. Using a normal hammer on the end of the slide hammer shaft, drive 3-tap fitting into the manifold. See Figure 27. 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 28.





16. Install new tee into PCV hose that was cut in previous step. Refer to Figure 29 (Location A).

17. Connect formed PCV hose to tee. Refer to Figure 29 (Location B).

18. Connect other end of formed PCV hose assembly 3-tap fitting. Refer to Figure 29 (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 29 (Location D).

20. Cap fitting end with supplied vacuum cap. See Figure 29 (Location E).





21. Using screw clamps from kit, install PCV heat hoses on 3-tap fitting. Tighten supplied clamps to 1-4 Nm (9-35 lb/in). See Figure 30.





NOTE:
Refer to Figure 31 when performing Steps 22 through 34.

22. Remove Engine Coolant Temperature (ECT) electrical connector, located on the front end of the heater coolant tube.

23. Disconnect wiring harness from heater coolant tubes.

24. Disconnect water bypass hose from heater coolant tube.

25. Disconnect heater hoses from heater coolant tubes.

26. Remove heater coolant tube retaining nut.

27. Using a forked-type tool, disconnect front of heater coolant tube from lower intake fitting.

28. Remove heater coolant tubes from engine.

29. Transfer ECT from old heater coolant tube to new heater coolant tube.

30. Install new heater coolant tubes on engine. Press down on front of tube to install it into lower intake fitting.

31. Install heater coolant tube retaining nut. Tighten nut to 16-24 Nm (12-18 lb/ft).

32. Connect both heater hoses and bypass hose to heater coolant tubes. Tighten clamps to 2-4 Nm (20-35 lb/in).

33. Connect ECT electrical connector.

34. Route wiring harness along heater coolant tubes.