Air Injection Control Valve - Replacement Kit
Article No. 85-25-15VALVE/AIR CONTROL - NEW SERVICE REPLACEMENT KIT - 2.3L OHC
FORD 1981-82 MUSTANG, FAIRMONT, GRANADA
LINCOLN-MERCURY 1981-82 CAPRI, ZEPHYR, COUGAR
CALIBRATION: All 50 State calibrations
WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws.
The air control valve used on 1981-82 2.3L OHC engines is no longer available in service and has been replaced by a new valve and vacuum harness assembly. When it becomes necessary to replace the air control valve, use the following installation procedure:
1. Remove the two vacuum hoses from the air control valve on the vehicle.
2. Loosen the thermactor hose clamps and remove the hoses from the valve.
3. Remove the three screws that attach the air control valve to the mounting bracket. Remove the valve.
4. Install the new air control valve (E1AZ-9F491-A) to the bracket using the three screws; tighten screws carefully to prevent stripping the plastic body.
5. Attach the thermactor hoses and tighten the clamps.
6. Attach the black plastic vacuum line (or the short formed vacuum hose connected to the delay valve for non-feedback carburetor applications) to the air control valve vacuum nipple pointing up.
Figure 14 - Vacuum Hose Connection:
Figure 15 - Vacuum Hose Connection:
7. Locate the formed vacuum hose that is connected to the top of the vacuum solenoid on the right side of the cowl. (Vacuum hose will have red plastic line or vacuum check valve connected to the other end.) See Figures 14 and 15.
Figure 13 - VACUUM HARNESS (E5PZ-9E455-A):
8. Cut the vacuum hose 1.5 inches from the plastic line or check valve.
9. Install the new vacuum harness (E5PZ-9E455-A).
10. Insert points A and B of the harness into the vacuum hose that was cut. Point A toward the solenoid. (See Figure 13)
11. Route the long vacuum hose along the rocker cover with the existing vacuum harness.
12. Connect point D of the harness to the nipple on the air control valve that points toward the front of the vehicle.
13. Connect point C to the pink vacuum line that was removed from the original air control valve.
14. Secure the added vacuum harness to the existing harness with several bundling straps.
15. Verify that no vacuum lines or thermactor hoses are contacting the exhaust manifold so that the valves in the added harness will not rattle.
Authorized Modifications Decal:
16. Add modification decal next to the existing emission decal.
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
E1AZ-9F491-A Valve - Air Control R
E5PZ-9E455-A Harness - Vacuum CG
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: SP9491A85
TIME: 0.5 Hr. DLR. CODING: Basic Part No. DRIVE - Code: 42