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Attachment I - Technical Instructions For Recall 89E76

FIGURE 1:




Attachment I

TECHNICAL INSTRUCTIONS FOR RECALL 89E76


FOR VEHICLES WITH CALIBRATION 6-08A-R17 (REPAIR CODE A AND B VEHICLES)

1. Refer to Figure 1. Locate the crankcase vent assembly. Remove and discard the existing assembly and replace with new assembly (Part Number E8FZ-6769-A).
2. Locate, remove and discard the existing two-way vacuum delay valve (# 5, white) in the choke pulldown vacuum line. Install a 383003-S straight vacuum line connector in the vacuum line where the valve was installed.

3. Install a vacuum delay valve (Part Number D30Z-12A091-B, # 30, orange/black) in the vacuum line connected to the distributor vacuum diaphragm using a 3-inch length of vacuum hose (Part Number D0PZ-12226-B 5/32" i.d.). Position the orange side of the valve toward the distributor.

FIGURE 2:




Modify the Thermactor Air Control System as Follows:

4. Refer to Figure 2. Disconnect the black nylon vacuum line from the rear-facing opening of the three-way rubber tee connected to the air cleaner cold weather modulator. Plug the opening in the three-way rubber tee using a 383001-S stepped straight vacuum connector and a 382444-S vacuum cap (5/32" i.d.).

FIGURE 3:




5. Refer to Figure 3. Connect a 24-inch length of D0PZ-12226-B vacuum hose (5/32" i.d.) to the open end of the black nylon vacuum line (from step # 4), using a 90~ vacuum connector (Part Number 387065-S) and a 90~ 5/32" i.d. elbow to barbed nylon connector (Part Number E3TZ-9E499-C).

FIGURE 4:




6. Refer to Figure 4. Remove the white nylon vacuum line from the crankcase vent assembly. Replace the existing 90~ elbow on the nylon vacuum line with new elbow (Part Number E3TZ-9E499-C). Connect the elbow and nylon vacuum line to port "A" of the 383013-S three-way "Y" vacuum connector.

7. Connect port "C" of the three-way "Y" vacuum connector to the open port on the crankcase vent assembly using a one-inch length of D0PZ-12226-B vacuum hose (5/32" i.d.).
8. Connect port "B" of the three-way "Y" vacuum connector to the loose end of the 24-inch vacuum hose (from step # 5). Route the 24-inch vacuum hose behind the carburetor and down to the crankcase vent assembly taking normal precautions to protect the hose from sharp edges and excessive heat (such as the base of the EGR valve).

9. Install a D3FZ-12A091-A vacuum delay valve (# 5, white/black) in the vacuum line connected at the air control side of the combination air bypass and air control valve, using a 3-inch length of D0PZ-12226-B vacuum hose (5/32" i.d.). Position the white side of the delay valve toward the air control valve.





VEHICLE EMISSIONS CONTROL INFORMATION (VECI) AND AUTHORIZED MODIFICATIONS DECALS

10. Obtain the VECI decal from the owner and verify that the vehicle identification number (VIN) on the decal matches the VIN of the vehicle. Attach the decal over the existing decal on the vehicle. (Refer to the chart below [Step 5] for decal applications.)

11. Refer to Exhibit 1. Prepare and attach an Authorized Modifications decal as shown.


FOR VEHICLES WITH CALIBRATION 6-07A-R12 OR 6-07F-R12/R13 (REPAIR CODE C, D, E, F OR G VEHICLES)

1. Refer to Figure 1. Locate the crankcase vent assembly. Remove and discard the existing assembly and replace with new assembly (Part Number E8FZ-6769-A). Replace the existing 90 elbow on the nylon vacuum line with new elbow (Part Number E3TZ-9E499-C).

2. Locate, remove and discard the existing vacuum delay valve (# 2, brown/black) in the choke pulldown vacuum line. Install a 383004-S straight stepped vacuum line connector (3/16" x 1/4") in the vacuum line where the valve was installed.

3. Install a vacuum delay valve (Part Number D3AZ-12A091-A, # 10, yellow/black) in the vacuum line connected to the distributor vacuum diaphragm, using a 3-inch length of D0PZ-12226-B vacuum hose (5/32" i.d.). Position the yellow side of the valve toward the distributor.

4. Locate (Driver-side of the engine compartment, near the oil filter), remove and discard the existing vacuum retard delay valve (# 2, brown/white) in the vacuum line connected to the air control side of the combination air bypass and air control valve and replace with vacuum delay valve (Part Number E3AZ-12A091-E, # 5, black/white, polarized). Position the white side of the delay valve toward the air control valve.


VEHICLE EMISSIONS CONTROL INFORMATION (VECI) AND AUTHORIZED MODIFICATIONS DECALS

5. Obtain the VECI decal from the owner and verify that the vehicle identification number (VIN) on the decal matches the VIN of the vehicle. Attach the decal over the existing decal on the vehicle.

Decal Part Numbers (Base -9C485-)

Repair Code Model Year Part Number Calibration

A 1985 E5AE-CVP 6-08A-R17
B 1986 E6AE-ARB 6-08A-R17
C 1985 E5AE-CVS 6-07A-R12
D 1986 E6AE-APZ 6-07A-R12
E 1985 E5AE-CVL 6-07F-R12
F 1985 E5AE-CVM 6-07F-R13
G 1986 E6AE-ARA 6-07F-R13


6. Refer to Exhibit 1. Prepare and attach an Authorized Modifications decal as shown.
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