Engine - Stalls At Idle
87ford12Article No. STALLS - AT IDLE - 5.0L - EGR VALVE
87-1-15 STUCK OPEN
FORD 1983-85 MUSTANG, LTD, THUNDERBIRD, CROWN VICTORIA
LINCOLN-MERCURY 1983 MARK VI; 1983-85 CAPRI, MARQUIS, COUGAR, GRAND MARQUIS, CONTINENTAL, MARK VII, LINCOLN TOWN CAR
CALIBRATION: 5.0L with EEC III and EEC IV
WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under federal or local laws.
ISSUE: Stalling at idle may be caused by carbon deposits in the pintle area of the EGR valve causing the pintle to stick in the open position.
ACTION: A new carbon trap to correct this condition has been developed and can be installed using the following procedure.
CALIBRATION CHART:
NOTE: This repair procedure applies only to the vehicles listed in the calibration chart below. If the vehicle calibration is not listed, do not perform this TSB.
1. Perform EEC Self-Test. Service codes as required.
2. Remove EGR valve and using vacuum pump, Rotunda number 021-00037, apply vacuum to diaphragm and inspect valve pintle and seat.
NOTE: If carbon build-up is not excessive (carbon chunks not larger than 1/8 inch) refer to TSB 86-2-22 to repair concern. Do not continue with this TSB.
3. Clean EGR pintle and seat with a wire brush and compressed air. If EGR valve pintle seat is damaged, replace valve.
Figure 9:
4. Remove EGR cooler and hoses, Figure 9. Prior to running engine, cap the EGR cooler hoses.
5. Inspect EGR spacer and intake manifold passage for carbon. Remove carbon build-up by running engine for 30 seconds with EGR valve removed.
6. Install new EGR gasket (E5DZ-9D476-A) and install EGR carbon trap.
NOTE: Use carbon trap (E7PZ-9F464-A) for cast iron intake manifold and (E7PZ- 9F464-B) for aluminum intake manifold.
7. Place second EGR gasket over carbon trap and install EGR valve and retaining nuts. Torque retaining nuts to 12-18 ft.lbs. (16-24 N-m). Reconnect vacuum hose and electrical connectors.
8. Remove EGR water inlet connector from intake manifold and install pipe plug (87838-S101 with sealant. Torque to 12-21 ft.lbs. (16-28 N-m). Install vacuum cap (C9AZ-9C492-A) on three-way tee and secure with a new clamp (C9AZ-8287-A).
9. Start engine and check for coolant, exhaust or vacuum leaks.
10. Test drive vehicle.
NOTE: If detonation (ping) is present, retard ignition timing in 2~ increments until detonation is gone. Do NOT exceed a maximum of 6~ below required specification. Obtain Ford Authorized Modifications Decal if timing is changed.
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
E5DZ-9D476-A EGR Gasket B
E7PZ-9F464-A Carbon Trap - Cast Iron C
Intake Manifold
E7PZ-9F464-B Carbon Trap - Aluminum C
Intake Manifold
87838-S101 Pipe Plug BR
C9AZ-9C492-A Vacuum Cap A
C9AZ-8287-A Clamp AG
OTHER APPLICABLE ARTICLES: 86-2-22
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual
OPERATION: SP870115A
TIME: 1.5 Hr. DLR. CODING: Basic Part No. 9F483 - Code: N9