Engine - No Start/Idle Rough/Spark Knock
85ford09Article No. 85-9-22
NO START - 2.3L HSC
IDLE ROUGH - 2.3L HSC COLD
SPARK KNOCK - 2.3L HSC - COLD
FORD 1984-1985 TEMPO
LINCOLN-MERCURY 1984-1985 TOPAZ
The above concerns can be caused by the distributor Hall Effect sensor. When the above concerns occur only
at cold tempertures and the engine starts and run satisfactorily when warm, use the first diagnostic procedure. If the concern is no start, use the second procedure.
If a T.F.I. is removed from the distributor and the stator connector is soft or mushy, replace the stator.
ROUGH IDLE OR SPARK KNOCK WHEN COLD, OK WHEN WARM
TEST PROCEDURE TEST RESULT TEST RESOLUTION
TEST 1
NOTE: This procedure should be performed if the cusNOTE: The stator conditomer complains of a rough idle or spark knock on a tion must exist when test
cold engine only (i.e. during the initial engine warm- is performed. If not, the
up period after a long engine-off soak). test is not conclusive.
Step 1. Cold soak the vehicle.
NOTE: This procedure must be performed with the vehicle at or below the temperature where symptom occurs, except as noted.
Step 2. Key in "OFF" position.
Step 3. Disconnect the SPOUT connector.
Step 4. Attach the negative (-) VOM lead to the distributor
base.
Step 5. Start the engine and measure the battery voltage at
(positive + VOM lead to battery positive terminal) 1200- 1500 RPM.
Figure 20 - Voltage Measurement:
Step 6. Measure the voltage on the TFI module side of the
SPOUT connector at 1200-1500 RPM (Figure Yes Go to Test 2
20).
Step 7. Is the voltage at the TFI connector greater than 40% of No Replace the stator
the battery voltage? (.4 X's Step 5) assembly.
TEST 2
Step 1. Measure the voltage on the TFI module side of the NOTE: The stator condi-
SPOUT connector at approximately 1200 RPM and at tion must exist when test
approximately 4000 RPM. is performed. If not, the
CAUTION: PERFORM THIS STEP WITH THE test is not conclusive. HOOD CLOSED.
Step 2. Is the voltage at 4000 RPM less than 90% of the Yes Replace the stator
voltage at 1200 RPM (.9 X's volts at 4000 RPM). assembly.
No Go to Test 3
TEST 3
Step 1. Warm the engine to normal operating temperature.
Step 2. Measure the voltage on the TFI module side of the
SPOUT connector at 1200-1500 RPM.
Step 3. Is the voltage obtained in Test 1, Step 6 less than Yes Replace the stator
90% of the voltage obtained in Step 2 of this test (.9 X's assembly.
Test 1 Step 2)?
No Stator assembly is OK
WILL NOT START, HARD START OR STARTS BUT WILL NOT RUN
TEST PROCEDURE TEST RESULT TEST RESOLUTION
TEST 1
Step 1. Verify the symptom.
Step 2. With the ignition key in the "Off" position, discon-
nect the SPOUT connector. Yes Go to Test 4
Step 3. Does the vehicle start and continue to run? No Go to Test 2
TEST 2
NOTE: This test should be performed using an analog type voltmeter
Step 1. Remove the coil wire from the distributor cap and
ground it.
Step 2. Attach the negative (-) VOM lead to the distributor
base.
Step 3. Measure the battery voltage while cranking the
engine (Positive + VOM lead to battery positive terminal).
Step 4. Measure the voltage on the TFI module side of the
SPOUT connector (Figure 20) while cranking the engine.
Step 5. Is the voltage at the TFI connector between 35% and Yes Go to Test 5
60% of the battery voltage from Step 3.? No Go to Test 3
(.35 X's Step 3) (.6 X's Step 3)
WILL NOT START, HARD START OR STARTS BUT WILL NOT RUN
TEST PROCEDURE TEST RESULT TEST RESOLUTION
TEST 3
Step 1. Separate wiring harness connector from ignition NOTE: The stator condi-
module. Inspect for dirt, corrosion, and damage. tion must exist when test
NOTE: PUSH connector tabs to separate. is performed. If not, the test is not conclusive.
Step 2. Disconnect wire at S terminal of starter relay.
Step 3. Attach negative (-) VOM lead to distributor base.
Step 4. Measure battery voltage (Positive + VOM lead to
positive battery terminal).
Figure 21 - Terminal Voltage Measurement:
Step 5. Measure the Number 3 terminal voltage by
attaching VOM to small straight pin inserted into ignition module connector terminal (Figure 21) and turning ignition switch to the run position.
Yes Replace the stator
CAUTION: Do not allow straight pin to contact electrical assembly. ground. No Inspect for faults in
Step 6. Is the voltage at Terminal No. 3 greater than 90% wiring harness and
of battery voltage (.9 X's Step 3)? connectors?
Refer to vehicle wiring
NOTE: After this test, turn the ignition switch diagram for appropriate off, remove the straight pin and reconnect the circuit.
wire to "S" terminal of starter relay and Damaged or worn igni-
ignition module. tion switch. Refer to Shop
Manual, Group 33.
TEST 4
Step 1. Turn the ignition switch to the "OFF" position.
Step 2. Attach the negative (-) VOM lead to the distributor
base.
Step 3. Start the engine and measure the battery voltage at
1200-1500 RPM (Positive + VOM lead to positive battery terminal).
Figure 20 - Voltage Measurement:
Step 4. Measure the voltage on the TFI module side of the
SPOUT connector (Figure 20) at 1200-1500 RPM. Yes Go to Test 5
Step 5. Is the voltage at the TFI module between 40% and No Replace the stator
60% of battery voltage from Step 3? assembly.
NOTE: Stator condition must exist when test is performed. If not, test is inconclusive.
WILL NOT START, HARD START OR STARTS BUT WILL NOT RUN
TEST PROCEDURE TEST RESULT TEST RESOLUTION
TEST 5
Step 1. Turn the ignition switch to the "OFF" position. NOTE: Stator condition
performed or test is not
Step 2. Remove the coil wire from the distributor cap and must exist when test is
ground it. conclusive.
Step 3. Turn the ignition switch to the "ON" position
Step 4. Attach the positive (+) VOM lead to the TFI module
side of the SPOUT connector.
Step 5. Bump the starter until the voltage level drops to less
than 6 volts with the engine not moving.
Step 6. Is the voltage at the TFI connector less than 0.5 Yes Stator assembly is OK
volts? No Replace the stator
assembly.
UNIVERSAL DISTRIBUTOR W/EEC (OTHER THAN 1.6L)
STATOR ASSEMBLY REPLACEMENT
NOTE: Do not attempt to replace the stator without an arbor press.
Removal
1. Using a screwdriver, remove the distributor cap, position the cap and wires aside so as not to interfere with the work area. - Remove TFI module connector.
2. Remove distributor from block per the distributor removal procedure.
3. Remove rotor.
4. Remove the two screws holding the TFI module to the base.
5. Remove the module, wipe the grease from the base and module, keeping the surfaces free of dirt.
6. If the distributor uses the push-on rotor, remove the two screws holding the armature and remove the armature.
NOTE: Hold the gear to loosen the armature screws, do not hold the armature.
7. To ease re-assembly, mark with a felt tip pen, the armature, gear and collar if present (Refer to the following chart.) to note orientation.
8. Remove and discard pins in gear and collar if present (Refer to chart.).
Figure 22 - Bearing Removal:
9. Invert the distributor and place in the Axle Bearing/ Seal Plate (Tool T75L-1165-B) and press off the gear using the Bearing Removal Tool (75L-1165-A) as shown in Figure 22.
10. Deburr and polish shaft with emery paper and wipe such that the shaft slides out freely from distributor base.
11. Remove shaft assembly.
12. Remove thrust washer from distributor shaft and retain.
13. Remove octane rod retaining screw and retain.
14. Remove octane rod assembly and retain.
15. Remove two stator assembly screws and retain.
16. Remove stator assembly from top of bowl.
17. Inspect base bushing for wear or signs of excess heat concentration, replace complete distributor assembly if damaged.
18. Inspect base "O" ring for cuts or damage and replace "O" ring if necessary.
19. Inspect base for cracks and wear. Replace complete distributor assembly if damage is found.
GEAR GEAR
THRUST ROLL PIN COLLAR
ENGINE GEAR PIN WASHER EXTRUSION COLLAR PIN
2.3L HSC 67555-S FLUSH
2.3L OHC 67555-S FLUSH
2.8L 67575-S FLUSH
3.8L 67555-S FLUSH x 67555-S
4.9L 67775-S2 x EXTRUDE EVENLY,
BOTH SIDES
5.0L 67555-S FLUSH x 67555-S
6.1L 67775-S2 EXTRUDE EVENLY, x 67555-S
BOTH SIDES
7.0L 67775-S2 EXTRUDE EVENLY, x 67555-S
BOTH SIDES
7.5L 67775-S2 EXTRUDE EVENLY, x 67555-S
BOTH SIDES
Re-Assembly and Installation
1. Place the stator assembly over the bushing and press down to seat.
2. Place the stator connector in position - tab should fit in notch on base and fastening eyelets aligned with screw holes.
3. Position wires away from moving parts.
4. Install the two stator screws and torque to specification (25-35 in.lbs.).
5. Reinstall the octane rod, inserting rod through the base hole.
6. Place end of octane rod onto the same post as the original stator. Only one post should easily fit in rod hole.
7. Firmly seat octane rod seal into housing.
8. Reinstall the octane rod screw and torque to specification (25-35 in.lbs.).
9. If required, reinstall the thrust washer on top of the bushing.
10. Apply a light coat of ESF-M2C70-A to the distributor shaft below the armature.
11. Insert the shaft through the base bushing.
12. Place the collar, if required, over the shaft and line up mark on armature and collar to aid alignment with original drill hole. Use a drift punch to assure proper alignment.
NOTE: Drill holes through shaft and collar should align on both sides of shaft. If holes do not align, the collar may be 180 degrees out of alignment on the shaft. Rotate the collar on the shaft one half rotation and recheck.
13. Insert new roll pin (Part No. 67555-S) through collar and shaft. Pin should be flush with both sides of collar when seated.
Figure 23 - Distributor with Push On Rotor:
14. If the distributor uses a push-on rotor, place a 1/2 inch deep well socket over the shaft (Figure 23), invert and place on arbor plate.
Figure 24 - Distributor with Screw-Down Motor:
14a. If the distributor uses a screw-down rotor, invert and place on arbor plate (Figure 24).
15. Place the distributor gear on the shaft and line up the mark on the armature and gear.
NOTE: The hole in the shaft and gear must be lined up as accurately as possible to assure ease of roll pin insertion.
Figure 25 - Shaft and Gear:
16. Place a 5/8 inch deep well socket over the shaft and gear (Figure 25) and press gear to align with original drill hole.
NOTE: If the gear holes do not align, the gear must be removed and repressed on. A drift punch will not align the holes. As in the collar, the holes should align.
17. Insert new roll pin (Refer to chart following Step 7 in the Removal Procedure) through gear and shaft. Pin should have proper extrusion, as referenced in same chart.
18. If the armature was removed, replace and torque screws to 25-35 in.lbs.
19. Check distributor for free movement over full rotation of shaft.
NOTE: If the armature hits the stator; replace the entire distributor.
20. Wipe back of module and distributor module mounting face free of all dirt.
21. Apply grease (No. WA10) to the back of the module and spread evenly (thin, even coverage).
22. Turn the distributor base upside down such that the stator connector is in full view.
23. Insert the module and watch that the three module pins are inserted into the stator connector. Fully seat the module into the connector and against the base.
24. Reinstall two module screws and torque to specification (25-35 in.lbs.).
25. Reinstall the distributor into block per distributor replacement procedure.
26. Connect TFI module to wiring harness.
27. Replace rotor and torque screws to specification.
28. Replace cap and torque screws to specification.
29. Retime engine.
PART NUMBER PART NAME CLASS
67775-S2 Pin BS
L7775-S2 Pin RS
E3ZZ-12A112-C Stator A
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: 12112D - Diagnosis
TIME: 0.3 Hr.
OPERATION: 12112D1 - Replace Stator
TIME: 1.6L, 2.3L HSC - 0.6 Hr. All others - 0.5 Hr. DLR. CODING: Basic Part No. 12A112 - Code: J5