Technical Information

Service Part

AFFECTED VEHICLES:
1988-89 Model Escort - California, 1.9L engines with manual transmission
- Engine Calibrations 8-07E-R00 and 8-07E-R10

INSTRUCTIONS

1. Disconnect battery negative cable.

2. Remove air cleaner outlet tube.





3. Remove bolts attaching EGR Back Pressure Variable Transducer (BVT) bracket to engine. (Fig. 1)

4. Disconnect vacuum fitting from BVT. Remove nuts retaining BVT to bracket.

5. Disconnect throttle cable and speed control cable, if so equipped, from throttle lever.

6. Remove clamp and disconnect large vacuum hose from vacuum fitting on intake manifold. Position hose out of the way. (Fig. 2)

7. Disconnect vacuum hose from EGR valve. Remove two retaining nuts. Remove EGR valve and gasket. (Fig. 2)

8. Clean EGR valve gasket material from intake manifold. Install new EGR valve and gasket. Tighten nuts to 18-26 N-m (13-19 lb.ft.). (Fig. 2)

9. Connect vacuum hose to EGR valve.

10. Connect large vacuum hose to vacuum fitting on intake manifold. Make sure that hose clamp is properly positioned. (Fig. 2)

11. Position new BVT to bracket. Install two nuts. (Fig. 1)





12. Position BVT in vehicle and connect threeport vacuum fitting to BVT valve. (Fig. 3)

13. Position BVT bracket and throttle cable bracket to engine. Install retaining bolts to 14-20 N-m (11-14 lb.ft.). (Fig. 1)

14. Connect throttle cable and speed control cable to throttle lever, if so equipped.

15. Connect battery negative cable.

NOTE:
After battery is reconnected, the vehicle may show driveability concerns. It may be necessary to drive the vehicle 10 miles or more to allow the EEC-IV microprocessor to relearn values for optimum driveability and performance.

16. Raise vehicle on hoist.








17. Remove hose clamp. Disconnect thermactor air hose from catalyst. (Fig. 4)

18. Remove two bolts and springs retaining catalyst to exhaust pipe. Lower catalyst out of the way. (Fig. 4)

19. Loosen nut retaining air pipe to exhaust pipe orifice. (Fig. 5)

20. Remove orifice fitting from exhaust pipe. (Fig. 5)

21. Using a small wire brush, clean inside of exhaust pipe and orifice opening in exhaust pipe. (Fig. 6)

22. Apply anti-seize compound to threads of new orifice. Install orifice into exhaust pipe. (Fig. 5)

23. Position air pipe into orifice. (Fig. 5)

24. Position new exhaust gasket between catalyst and exhaust pipe. Install new spring and bolt assemblies. Tighten to 28-40 N-m (21-29 lb.ft.). (Fig. 4)

25. Connect thermactor air hose to catalyst and position clamp in place. (Fig. 4)

26. Lower vehicle.

27. Connect Rotunda Air Bypass Valve Actuator 113-00009 into Fuel Injector Tester/Cleaner 113-00001 or equivalent.





28. Disconnect air by-pass valve connector on throttle body and connect actuator to air by-pass valve. (Fig. 7)

29. Start actuator.

30. Spray just enough Carburetor Tune-Up Cleaner D9AZ-19579-AA or equivalent into throttle bore to wet bore and throttle plate.

31. Spray carburetor tune-up cleaner for about five seconds into idle air by-pass valve inlet passage while actuator is operating.

32. Stop actuator. Let everything soak for 15 minutes.

33. After soaking, saturate cleaning brush with solvent and brush between throttle bore and plate while holding throttle wide open.

34. Repeat, saturating brush and scrubbing for one to two minutes making sure to reach into corners where throttle shaft meets with bore wall.

35. Start actuator.

36. Spray carburetor tune-up cleaner into throttle bore to wash away residue. Do NOT SPRAY FOR LONGER THAN 6 CONTINUOUS SECONDS.

37. Spray carburetor tune-up cleaner into idle air bypass valve passage leading to inlet valve.

CAUTION:
Do not spray for longer than 6 continuous seconds on engines that have air flow meters and are not running.

38. Stop actuator.

NOTE:
Make sure throttle plate operates freely and closes properly.

39. Install air cleaner outlet duct. Tighten clamps to 1.4-2-3 N-m (13-20 lb.in.).

40. Start and run engine for about one minute to dry out solvent residue.

41. Operate actuator to make sure solvent is purged from idle air by-pass valve.

42. Disconnect air bypass valve actuator from idle air by-pass valve.

43. Connect idle air by-pass valve connector.

44. Remove radiator sight shield.

45. Remove old Vehicle Emission Control Information (VECI) decal from sight shield.

46. Clean residue from old VECI decal from sight shield using Metal Brake Parts Cleaner E6AZ-19579-BA or equivalent.





47. Apply new VECI decal and Authorized Modifications decal onto sight shield. (Fig. 8)

CAUTION:
Apply VECI decal E8AE-9C485-AJZ to 1988 vehicles. Apply VECI decal E9AE-9C485-BLB to 1989 vehicles.

48. Install sight shield onto radiator support.

49. Start engine and warm to normal operating temperature.

50. Adjust base ignition timing to 6~BTDC. Refer to VECI decal for procedure.

51. Check idle speed. If necessary, adjust idle speed to 950 rpm. Refer to Section 4 of the 1988 Engine/Emissions Diagnosis Manual.