EGR Valve - Intermittent MIL ON
Article No.95-3-5
02/13/95
LAMP - MALFUNCTION INDICATOR LIGHT (MIL) - INTERMITTENT ACTIVATION - GT MODELS WITH 2.2L TURBO ENGINES
FORD:
1990-92 PROBE
This TSB is being republished in its entirety to correct the Pin numbers for the Pinpoint tests.
ISSUE:
The Malfunction Indicator Light (MIL) may illuminate intermittently. This may be caused by output voltage variations from the EGR Valve Position Sensor (EVP) as a result of carbon deposits on the Exhaust Gas Recirculation (EGR) valve.
ACTION:
Install a EGR Valve Plate Set which includes a spacer plate and 0-ring to move the EVP away from the EGR. Refer to the following procedure for service details.
SERVICE PROCEDURE
1. Remove the vacuum hose from the EGR valve, Figure 1.
2. If the MIL is on, install the break out box and turn the ignition switch to the RUN position.
a. Using a voltmeter, check the voltage between Pins 26 and 46. Verify that the voltage is between 4.5-5.5 volts.
b. Check the voltage between Pins 27 and 46. If the MIL is on and/or the voltage between Pins 27 and 46 is greater than 1.1 volts, proceed with the repair procedure.
3. Remove the EGR valve from the engine by removing the three (3) 10 mm bolts. Disconnect the vacuum line and disconnect the EVP sensor connector.
4. Loosen the two (2) screws on the position sensor of the EGR valve, Figure 2.
NOTE:
BE CAREFUL NOT TO DAMAGE THE SLOTS OF THE SCREWS WHILE REMOVING THEM.
5. Remove the O-ring (brown) between the position sensor and the diaphragm case.
6. Remove any dirt between the position sensor and the diaphragm case, Figure 3.
7. Install the new O-ring from the EGR Valve Plate Set by sliding it down to the groove on the flange part, Figure 4.
NOTE:
WHEN INSTALLING THE O-RING, BE CAREFUL NOT TO TWIST OR OTHERWISE DAMAGE IT.
8. Install the new plate from the EGR Valve Plate Set (F2PZ-9D475-J) and reinstall the position sensor on the EGR valve, Figure 5.
9. Install the EVP harness. Check the voltage values of the new EVP installation (Step 2). The voltage between Pins 27 and 46 should be between 0.3-0.8 volts.
10. Disconnect the break out box and reconnect the harness to the PCM.
11. Apply 19" Hg of vacuum to the EGR valve with a vacuum tester. Confirm that the valve holds more than 15" Hg for at least one (1) minute, Figure 6.
12. Reinstall the EGR valve on the engine.
13. Reconnect the vacuum hose.
PART NUMBER PART NAME
F2PZ-9D475-J EGR Valve Plate Set
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 93-22-5
WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992 Models, Basic Warranty Coverage For 1990/91 Models, And Emission Coverage For All Model Years
OPERATION DESCRIPTION TIME
950305A Check And Install EGR 0.6 Hr.
Valve Position Sensor Spacer Plate
DEALER CODING
BASIC PART NO. CONDITION CODE
9D475 41
OASIS CODES: 206000, 403000, 698298