Repair Procedure:

Figure 1:

Refer to Figure 1 for orientation of components in the following steps.
1. Attach vacuum control valve bracket (MD168506) to air control valve using bolt and washer (MF240051). Tighten bolt to 10 N-m (88 in.lbs.) torque.

2. Install vacuum control valve on bracket.

3. Install vacuum hose assembly (MD169530) as follows:

a. Remove existing green stripe vacuum hose between air control valve and solenoid valve.
b. Install green stripe hose from new vacuum harness to air control valve.
c. Install white stripe, red stripe, and blue stripe hoses to vacuum control valve.
d. Remove existing white stripe hose from solenoid valve, and cut off 100 mm (4 inches) from the end.
e. Install white stripe and green stripe hoses from new vacuum harness to solenoid valve.
f. Install existing white stripe hose, which was cut in step "d" above, to vacuum connector.
g. Remove air filter from rear side of solenoid valve and install green stripe hose from new vacuum harness in its place.
h. Cut existing white stripe hose 35 mm (1.25 inch) from blue connector and install vacuum "T" which is connected to the white stripe hose from the vacuum control valve.
i. Install clamp to existing white stripe hose.
j. Cut existing green stripe hose, between carburetor and vacuum switch, 40 mm (1.5 inches) from the carburetor and install vacuum "T" which is connected to the green stripe hose from the solenoid valve.
k. Secure green stripe hose to coolant hose with tie strap.


NOTE: THE REMAINDER OF THIS PROCEDURE REFERS TO COLT 3-DOOR HATCHRACK MODELS ONLY.

Figure 2:

4. Referring to procedures outlined in Group 23 of the 1988 Colt Service Manual (Publication # 81-270-8011) remove the right side shelf, trunk side, and rear end interior trim panels (Figure 2).

Figure 3:

5. Remove the right side air outlet garnish and the rear ventilator duct (Figure 3).

Figure 4:

6. Remove paper from sponge, PN MB878153, to expose adhesive used to secure the sponge to the ventilator duct. Insert the sponge into the ventilator duct, as shown in Figure 4, so that duct is sealed shut.
7. Install ventilator duct, air outlet garnish, and interior trim panels.

8. Using the appropriate service label, as called out in PARTS REQUIRED, affix the label to the underside of the hood.


POLICY: Reimbursable within the provisions of the warranty.