1990 Ford Truck Emmisions Manual

APpropriate service methods and proper repair procedures are essential
fOr the safe, reliable operation Of all motor vehicles as well as the per
sonal safety of the Individual doing the work. This Shop Manual provides
general directions fOr accomplishing service and repair work with tested,
effective techniQues. Following them will help assure reliability.
There are numerous variations In procedures. techniques. tOOlS. and
parts fOr servicing vehicles. as well as In the skill of the Individual doing
the work. This Manual cannot possibly anticipate all such variations and
provide advice or cautions as to each. Accordingly. anyone who departs
from the Instructions provided In this Manual must first establish that he
compromises neither his personal safety nor the vehicle Integrity by his
Choice Of methods, tools or parts.
Notes, cautions, and warnings

AS you read through the procedures, you will come across NOTES. CAU
TIONS. and WARNINGS. Each one Is there fOr a specific purpose. NOTES
give you added InfOrmation that will help you to complete a particular
proce dure. CAUTIONS are given to prevent you from making an error that
could damage the vehicle. WARNINGS remind you to be especially careful
In those areas where carelessness can cause personal Injury. The
fOllowing list contains some general WARNINGS that you should follow
when you work on a vehicle.
• Always wear safety glasses for eye protection.
• use safety stands whenever a procedure reQuires you to be under the
vehIcle.
• Be sure that the Ignition switch Is always In the OFF position, unless
otherwise required by the procedure.
• Set the parking brake when working on the vehicle. If you have an
automatic transmission, set It In PARK unless Instructed otherwise for a
specific operation. If you have a manual transmission. It should be In
REVERSE (engine OFF) or NEUTRAL (engine ON) unless Instructed
other wise for a specific operation. Place wood blocks (4" x 4" or larger)
to the front and rear surfaces of the tires to provide further restraint
from Inadvertent vehicle movement.
• Operate the engine only In a well-ventilated area to avoid the danger Of
carbon monoxide.
• Keep yourself and your clothing away from moving parts. when the
engine Is running, especially the fan and belts.
• TO prevent serious bu,-ns, avoid contact With hot metal parts such as the
radiator. exhaust manifOld, tall pipe. catalytic converter and mUf fler.
• Do not smoke while working on a vehicle.
• TO avoid Injury. always remove rings. watches, loose hanging jewelry,
and loose clothing before beginning to work on ,a vehicle.
Keep hands and other objects clear of the radiator fan blades. The elec
•
tric cooling fan on the Escort can start to operate at any time by an
Increase In underhood temperature, even though the Ignition Is In the
OFF position. Other vehicles With an electric cooling fan can start at any
time for the same reason, but only when the Ignition switch Is In the
RUN position. Therefore, care should be taken to ensure that the
electric cooling fan motor Is completely disconnected when working
under the hood.
DAVE GRAHAM INC. 2012
ALL RIGHTS RESERVED
Foreword
This 1990 Car Shop Manual
provides information
covering Emissions for all
1990 Ford Motor Company
Passenger Cars and Trucks
manufactured in the United
States and Canada.
Complete emissions related
diagnostic procedures for all
affected systems or
components are covered in
this manual.
The descriptions and

specifications contained in
this manual were in effect at
the time this manual was
approved for printing. Ford
Motor Company reserves
the right to discontinue
models at any time, or
change specifications or
design without notice and
without incurring obligation.
For service
information on
specific vehicle
lines for Body,
Chassis and
Electrical;
powertrains; and
/ or Pre-Delivery
and Lubrication,
refer to the
Passenger Car
and Truck Cross
Index pages in
the front of this
manual.
~trbict
~ublication5
Ford Parts and Service Division
Copyright © 1989, Ford Motor Company

ALL RIGHTS RESERVED
passenger Car
Cross Reference Index
vehicle Lines Mustang
Lincoln TOwn car, Crown
Victoria / Orand Marauls
TempoI Topaz, Escort
Mark VII
Taurus/Sable
ThunderbirdICougar
Continental
All Models
NAAO car & Truck Models
Non-NAAO Cars
content
Body, Chassis, Electrical,
POwertraln, Maintenance,
Lubrication

POwertraln, Maintenance,
Lubrication Powertraln, Maintenance,
Lubrication
Body, Chassis, "Electrical,

POwertraln, Maintenance, Body, Chassis, Electrical,
Lubrication Powertraln, Maintenance,
Lubrication

Powertrain, Maintenance, pre-Delivery
Lubrication
Engine/Emissions Diagnosis
Powertrain, Maintenance,
Lubrication Non-NAAO EngineIEmissions
Diagnosis

ALL RIGHTS RESERVED
Truck
Cross Reference Index
Aerostar, Ranger, Bronco II (1 Of 2)
Aerostar. Ranger, Bronco II (2 Of 2)

vehicle Lines
Econollne, F-serles, Bronco All Truck Series and car Models All
Econonne, F-Serles, Bronco NAAO car and Truck Models
Medium/Heavy Duty B-, C·, F-600 content

Through 8000 Series
BOdY/ Chassis/Electrical
Engine BOdy/ Electrical
Body/ Chassis/ Electrical!Engine pre-Delivery (Volume F)
Engine/ Emissions Diagnosis

Engine/ Chassis

ALL RIGHTS RESERVED
What's New
In This Manual
The fOllowing is a list of the modifications to this manual fOr 1990.
New or Modified Applications

• 1990 1/2 1.9L SEFI MA Escort/Tracer (EDIS Ignition)
• 2.3L EFI MA CalifOrnia - Mustang
• 2.9L EFI Scorpio
• 2.9L EFI MA Ranger/ Bronco II
• 3.0L EFI probe
• 4.0L EFI MA Ranger/ Bronco III Aerostar (EDIS Ignition)
• 4.9L EFI Truck with Electronically Controlled (E40D)
Transmission
• S.OL SEFI MA California - LIncoln Town car, Crown
Victoria / Orand Marquis (Sedan)
Modified Manual sections

• A Diagnostic Flowchart has been added to "How to Use This
Manual"
• Diagnostic Routines, Section 2, has added On-line Automatic
Service Information System (OASIS) reference numbers
• Fuel Delivery Systems, Section 11, has added an In Tank
Reservoir UTR) fuel delivery system
• Ignition Systems, Timing procedures and Diagnosis, Section
13, has added Electronic Dlstrlbutorless Ignition Systems (EDIS)
• EEC-IV Monitor BOX: Intermittent Fault Diagnosis, Section 18,
Is Included as a part of this manual
~ew or Modified Pinpoint Tests

• AA has been added to diagnose "NO Starts" on EDIS
applications
• DA has been revised to cover all 2-wlre temperature sensors
(ACT, ECT, and VAT)
• DR has been added to diagnose the Cylinder Identification
(CID) sensor on 19901/2 1.9L SEFI MA Escort/Tracer
applications
• H has been revised to Include 4-wlre HEOO sensors
• KF has been added to diagnose the Electrodrlve Fan (EDF)
control on 19901/2 1.9L SEFI MA Escort/Tracer applications
• KH has been added for Service Pin adjustment on 2.9L EFI
Scorpio applications
• Nand P have been revised to Include EDIS applications

ALL RIGHTS RESERVED
Table of contents
section Title section Number How to use This Manual .1

GlOssary 11 Emissions control Identification /Application 1
Diagnostic Routines 2 Emission Related components 3
Carburetors, Throttle Bodies, and Injectors 4 Catalyst and Exhaust
Systems 5 Exhaust Gas Recirculation (EGR) Systems 6 Evaporative
Emission Systems 7 Inlet Air Temperature Systems 8 positive
crankcase ventilation (PCV) Systems 9 Thermactor Systems
(Secondary Air InJection) 10 Fuel Delivery Systems 11 6.1L/7.0L
Heavy DUty Truck "CHECK ENGINE" LIght 12 Ignition System,
Timing Procedures and Diagnosis 13 How to Use Oulck Test .III
EEC-IV Oulck Test Procedures and Appendix 14 EEC-IV Engine
Supplement-passenger Car 15 EEC-IV Engine Supplement-Light
Truck 16 EEC-IV Pinpoint Test Procedures 17 EEC-IV Monitor Box:
Intermittent Fault Diagnosis 18 Diesel Dlagnosls-6.6L and 7.8L
Engines 19 Diesel Dlagn~sls-7 .3L Englne 20
ALL RIGHTS RESERVED
How TO use This Manual

Special Notes:
• This,manual is designed to diagnose gasoline and diesel
engine systems.
• In each case, begin diagnosis with Section 2, Diagnostic Routines. Section 2 defines the probable
causes of the
vehicle's symptoms. It functions as a checklist to ensure
that all potential causes are reviewed.
• If a diagnostic procedure does not find the solution to
a vehicle symptom, it is important to return to Section
2 to review all other possible causes of the symptom.
Refer to Section 3 for component descriptions and part
• numbers.
• Component locations can be found in the Electrical and
Vacuum Trouble-Shooting Manuals (EVTM's).
• The EEC-IV Diagnostics Sections are interrelated and
should be used in conjunction with each other.
• Refer to Section 1, Emission Control

Identification /Application, to identify the emission
components on the vehicle. For vehicles with diesel
engines, refer to Sections 19 and 20.
• Begin diagnosis with the Diagnostic Routines in Section
2.
• Read all special notes.
• Prevent any unsafe or hazardous conditions by
following the notes, cautions and warnings listed
at the
beginning of this book.
• After service, always verify that the repair corrected
the customer complaint.
IDon'tI
• Skip from Section to Section.

ALL RIGHTS RESERVED
1990 EngineI Emissions Diagnosis

1-----41.1 Other Shop I----~.I Verify
I SYMPTOM)
SECTION 2
"Diagnostic Routines"
Manual Flowchart
t----------.~--- ------ Manuals Repair List of Probable

Causes
I
+I
I
I
SECTIONS 3, 4, 5, 6, 7, *Includes: -Schematics
8, 9, 10, 11, 12, 13, 14, -Service Code Definitions
17, 18, 19, 20 - Pin Usage Charts
-Sensor/Actuator Reference
Diagnostics for: Value Charts
- EEC-IV Systems COMPLEMENTARY INFORMATION
- Emissions Related
Systems In Engine/Emissions
- Diesel Systems Diagnosis Manual:
- SECTION 1: Emissions
Control Identificationl
Application
,
- SECTION 15: Engine
I Verify Repair 1 Supplement-Passenger

Car*
- SECTION 16: Engine
Supplement-Light
Truck*
(EVTM's)
Outside Engine/Emissions
Diagnosis Manual: - OASIS Messages
- Technical Service
- Electrical and Vacuum Bulletins (TSB's)
rrouble-Shooting Manuals

ALL RIGHTS RESERVED
Glossary
Contents
Glossary 1
ALL RIGHTS RESERVED
Glossary
1
Glossary
The glossary is a list of technical terms or acronyms and their definitions. It is not intended to be a
dictionary of components and their functions. If you desire a detailed description of a specific
component, refer to the related Shop Manual Group.
4EAT: 4-Speed Electronic Automatic ACl: Automatic Adjustable Shock
Transaxle. Controller.
4X4l: 4X4 Low input switch. A/Cl BIMET: Air Cleaner Bimetal sensor.
A4lD: Automatic 4-Speed Lock-up-converter ACD: Air Conditioner Demand switch.
Drive.
ACT: Air Charge Temperature sensor or its
A/C: Air Conditioning. signal circuit.
ACC: AIC Clutch Compressor signal input to ACV: (Thermactor) Air Control Valve.
the EEC-IV processor relating status of the
AIC clutch. AHFSS: Air Condition/Heater Function Select
Switch input to the EEC-IV processor relating
ACCS: AIC Cycling Switch. status of the AIC heater function select switch.
AIC P: AIC Pressure Cut-out switch. AIR BPV: (Thermactor) Air Bypass Valve.
AIC DV: Air Cleaner Duct and Valve AM1: Thermactor Air Management.1 (TAB).
motor.
AM2: Thermactor Air Management 2 (TAD). which connects in series with the processor
and the EEC-IV harness and permits
AMBIENT TEMPERATURE: Temperature of measurements of processor inputs and
air surrounding an object e.g., temperature outputs.
where vehicle is being worked on.
BOO: Brake On-Off input to the EEC-IV
AOD: Automatic Overdrive. processor. indicating a braking drive mode.
ANTI·BFV: Anti-Backfire Valve. BP: Barometric Pressure sensor or its
A/T: Automatic Transmission. signal circuit.
ATDC: After Top Dead Center. BPA: By-Pass Air Solenoid. Used to control
AVOM: Analog Volt-Ohm Meter. idle speed on EFI and SEFI vehicles.
AXOD: Automatic Transaxle Overdrive. BREAKOUT BOX: A service tool that "tees"
in-between the EEC-IV processor and the
AXOD·E: Automatic Transaxle Overdrive, 60-pin harness connector. The breakout box
Electronically Controlled. contains 60 test pins that can be probed for
BASE IDLE: Idle RPM determined by throttle EEC-IV testing.
lever hardset on throttle body while Idle BTDC: B.ef.ore Top Dead Center.
Speed Control is fully retracted and
disconnected. . BV: Bowl Vent (Carburetor Fuel Bowl) BVT:
BATT: Battery Back Pressure Variable Transducer.
BATT(+): Battery positive post or its circuit. CANP: Canister Purge solenoid or its
con'trol circuit.
BATT( -): Battery negative post or its
circuit. CSE GND: Case Ground (EEC-IV processor
case).
BOB: (Breakout Box) An EEC-IV test device

ALL RIGHTS RESERVED
2 Glossary Glossary
CATALYST: A muffler-like device in the connected to the distributor thru a harness
exhaust system containing a monolithic connector, not a direct plug in connection.
substrate (a ceramic honeycomb structure)
that is coated with catalytic metals such as CCC: Converter Clutch Control solenoid or
platinum or palladium. When hot exhaust its control circuit.
gases come in contact with these metals a CCD: Computer Controlled Dwell.
chemical reaction takes place to consume
unburned hydrocarbon, carbon monoxide and CCO: Converter Clutch Override output
nitrous oxides. from the EEC-IV processor to the
transmission.
CBD: Closed Bowl Distributor. With this
design, the TFI-IV module is electrically CCS: Coast Clutch Solenoid or its control
circuit. electronic tripminder.
CES: Clutch Engage Switch. DPDIS: Dual Plug Distributorless Ignition
CFI: Central Fuel Injection. A computer System.
controlled fuel metering system which DPH: Dual Plug Head.
sprays atomized fuel into a throttle body
mounted atop the intake manifold. DPI: Dual Plug Inhibit.
"CHECK ENGINE" OR "SERVICE ENGINE DV: Delay Valve.

SOON" LIGHT: A dash panel light used either
DVOM: Digital Volt-Ohm Multimeter that
to aid in the identification and diagnosis of
displays voltage or resistance
EEC system problems or to indicate that
measurements in digital form on a liquid
maintenance is required on non-EEC
crystal display (LCD).
equipped vehicles.
CID: Cylinder Identification sensor or its DV TW: Delay Valve Two-Way.
signal circuit. EATC: Electronic Automatic Temperature
ClC: Converter Lock-up Clutch. Control.
CLUTCH: Clutch engagement switch or its E40D: Electronic 4-Speed Overdrive

control circuit. transmission.
COC: Conventional Oxidation Catalyst. ECA: Electronic Control Assembly.

COMPUTED TIMING: The total spark ECT: Engine Coolant Temperature sensor
advance in degrees before top dead center. or its signal circuit.
Calculated by the EEC-IV processor based on
input from a number of sensors. EDF: Electro-Drive Fan relay or its control
circuit.
CONTINUOUS SELF-TEST: A continuous
test of the EEC-IV system conducted EDIS: Electronic Distributorless Ignition
whenever the vehicle is in operation. System (high data rate).
CURB IDLE: Computer controlled Idle rpm.
EEC: Electronic Engine Control. A computer
CWM: Cold Weather Modulator. controlled system of engine control.
DCl: Data Communications Link. EEGR: Electronic EGR Valve (Sonic).

DFS: Decel Fuel Shut-off. EFI: Electronic Fuel Injection. A computer
controlled fuel system that distributes
DIS: Distributorless Ignition System (low atomized fuel through an injector located in
data rate). each intake port of the engine. The fuel
DOL: Data Output Link. Fuel calculation injectors are fired using bank-to-bank
data from the EEC-IV processor to the circuitry.

ALL RIGHTS RESERVED
3
Glossary
Glossary
EGO: Exhaust Gas Oxygen sensor or its EGRC: EGR Control vacuum solenoid valve
signal circuit. or its control circuit.
EGOG: EGO Ground. EGRV: EGR Vent vacuum solenoid valve or its
control circuit.
EGR: Exhaust Gas Recirculation system
designed to allow the flow of inert exhaust EHC: Exhaust Heat Control vacuum
gases into the combustion chamber to cool solenoid valve or its control circuit.
the combustion and thus reduce nitrous
oxides in the exhaust. . ENGINE RUNNING SELF-TEST: A test of
the EEC-IV system conducted with the
EGR S/O: EGR Shut Off. engine running and the vehicle at rest.
the DIS TFI-IV module which provides a
EPC: Electronic Pressure Control (used in filtered ignition signal to the processor in
E40D transmissions). order to control dwell. .
ER: Engine Running Self-Test (same as FUEL RICH/LEAN: A qualitative evaluation of
KOER). air/fuel ratio based on an A/F value known as
stoichiometry or 14.7. In the EEC-IV system
ERS: Engine rpm Sensor or its signal
rich/lean is determined by a voltage signal
circuit.
from the EGO sensor. An excess of oxygen
EVP: EGA Valve Position sensor or its (lean) is an EGO voltage of less than .4 volts,
signal circuit. a rich condition is indicated by an EGO
voltage of greater than .6 volts.
EVR: EGR Vacuum Regulator solenoid or
its control circuit. FWD: Front Wheel Drive.
FBC: Feedback Carburetor. An MCU GND or GRND: A common ground circuit

controlled fuel system employing a stepper for all vehicle power.
motor or a dithering solenoid that controls
GOOSE: A brief openning and closing of
fuel/air mixture by bleeding air into the' main
the throttle.
and idle systems of the carburetor.
HALL EFFECT: A process where current is
FCS: Fuel Control Solenoid or its control
passed through a small slice of semi
circuit.
conductor material at the same time as a
FI: Fuel Injector or its control circuit. magnetic field to produce a small voltage in
the semi-conductor.
FIPL: Fuel Injection Pump Lever sensor or its
signal circuit. HBV: Heater Blower Voltage input to the
EEC-IV processor reflecting heater blower
FLC: Fluid Lock-Up Converter. voltage demand.
FMEM: Failure Mode Effects Management.
This alternative strategy protects vehicle HEDF: High speed Electro-Drive Fan relay
function from adverse effects of an EEC or its control circuit.
component failure.
HEGO: Heated EGO sensor or its signal
FP: Fuel Pump relay or its control circuit. circuit.
FPM: Fuel Pump Monitor. A circuit in the HEGOG or HEGO GND: Heated EGO
EEC system used to monitor the electric Ground. .
fuel pump operation on some EEC-IV
equipped vehicles. HIC: Hot Idle Compensator.
FTO: Filtered Tach Output. An output from

ALL RIGHTS RESERVED
4 Glossary Glossary
IBP: Integral Back Pressure.

HlOS: Hardware Limited Operation
Strategy. Certain types of computer IDLE liMITER: A device to control minimum
malfunctions will place the EEC-IV and maximum idle fuel richness. The idle
processor into HLOS mode. Output limiter is intended to prevent unauthorized
commands are replaced with fixed values. persons from making overly rich idle
adjustments.
HO: High Output.
10M: Ignition Diagnostics Monitor. A
HSC: High Swirl Combustion.
continuous monitor of the ignition input to
lAS: Inlet Ai'r Solenoid valve or its control the EEC-IV processor used to detect
circuit. intermittent ignition faults.
its signal circuit.
IGN: Ignition circuit or system.
MCU: Microprocessor Control Unit.
INJ: Injector (Fuel).
INJ GND: Injector Ground (Fuel). MECS: Mazda Equipped Control System.
IRCM: Integrated Relay Control Module. MIL: (Malfunction Indicator Light) An

electric circuit between the EEC-IV
ISC: Idle Speed Control. Currently there are processor and the "CHECK ENGINE" or
two types of computer controlled idle speed "SERVICE ENGINE SOON" light on the
control: DC motor ISC and air bypass ISC. dash panel of EEC-equipped vehicles.
ITR: In-Tank Reservoir. MLP: Manual Lever Position sensor or its
ITS: Idle Tracking Switch. Used on CFI signal circuit.
vehicles to inform EEC if the throttle is in
MONITOR BOX: An optional EEC-IV test
contact with the DC motor.
device which connects in series with the
KAM: Keep Alive Memory. A series of vehicle EEC-IV processor and its harness, and
battery powered memory locations in the permits measurements in various units of
microprocessor which allows the processor inputs and outputs.
microprocessor to store input failures
identified during normal operation for use in MIT: Manual Transmission
later diagnostic routines and adapts some NOS: Neutral Drive Switch or its signal
calibration parameters to compensate for circuit.
changes in the vehicle system.
NGS: Neutral Gear Switch or its signal
KAPWR: Keep Alive Power.
circuit.
KEY ON ENGINE RUNNING SELF-TEST: A
test of the EEC-IV system conducted with NPS: Neutral Pressure Switch or its signal
power applied and the engine at rest. circuit.
KOEO: Key On Engine Off Self-Test. OASIS: On-line Automobile Service

KOER: Key On Engine Running Self-Test Information System.
(same as Engine Running (ER) Self-Test).
OCC: Output Circuit ChQck.
KS: Knock Sensor or its signal circuit. l: OCll: Overdrive Cancel Indicator Light.
Liters. OCS: Overdrive Cancel Switch.
lUS: Lock Up Solenoid. OCT ADJ: Octane Adjust device which
MA or MAF: Mass Air Flow Sensor or its modifies spark advance.
signal circuit. OHC: Overhead Cam.
MAP: Manifold Absolute Pressure sensor or

ALL RIGHTS RESERVED
5
Glossary
Glossary
OVERLAY CARD: A plastic card used with
the Monitor box to identify EEC-IV signals for
each engine. The card also programs the
OPEN CIRCUIT: A circuit which does not monitor for auto mode measurements.
provide a complete path for the flow of
current. PCV: Positive Crankcase Ventilation. A
system which controls the flow of
OSC: Output State Check. crankcase vapors into the engine intake
manifold where they are burned in
combustion rather than being discharged
into the atmosphere.
PFE: Pressure Feedback EGR sensor or its

signal circuit.
PIP: Profile Ignition Pickup. A "hall effect"

vane switch that furnishes crankshaft
position data to the EEC-IV processor.
PROCESSOR: EEC-IV Electronic Control

Assembly.
PSPS: Power Steering Pressure Switch. An

EEC-IV processor input to regulate idle
speed based on power steering load
demand.
PULSE AIR SYSTEM: Part of the emission

control system that utilizes a reed-type check
valve which allows air to be drawn into the
exhaust system as a result of exhaust pulses.
PVS: Ported Vacuum Switch..
PWR GND: Power Ground. '
QUICK TEST: A functional diagnostic test of

the EEC system consisting of vehicle
preparation and hookup, Key On Engine
Off, Engine Running and Continuous Self
Tests.
RECORDER: An optional EEC-IV test device

which works jointly with the Monitor box. It
allows up to 8 EEC-IV signals to be
electronically recorded over a 50 second
period.
RELAY: A switching device operated by a

low current circuit which controls the
opening and closing of another circuit of
higher current capacity.
RELIEF VALVE: A pressure limiting valve

located in the exhaust chamber of the
thermactor air pump. It functions to relieve
part of the exhaust airflow if the pressure
exceeds a calibrated value.
RWD: Rear Wheel Drive.
Running, and Continuous.
SAW: Spark Angle Word. Timing
information sent from EEC-IV to the EDIS SHO: Super High Output.
module. This information is used by the
EDIS module to calculate final ignition SHORT CIRCUIT: An undesirable connection
between a circuit and any other point.
timing.
SIG RTN: Signal Return circuit for all
SBS: Supercharger Bypass Solenoid or its
sensor signals except HEGO.
control circuit.
SIL: Shift Indicator Light. A system that
SC: Super Charged.
provides a visual indication to the driver of a
SDV: Spark Delay Valve. vehicle when to shift to the next higher gear
to obtain optimum fuel economy.
SEFI: Sequential Electronic Fuel Injection. A
computer controlled fuel system that SOLENOID: A wire coil with a moveable
distributes atomized fuel through an injector core that changes position by means of
located in each intake port of the engine. Each electro-magnetism when current flows
injector is fired separately· and has individual through the coil.
circuits.
SPOUT: Spark Output Signal from the
SELF~TEST: Oneof three subsets of the EEC EEC-IV processor.
Quick Test: Key On Engine Off, Engine

ALL RIGHTS RESERVED
6 Glossary Glossary
SS1: Shift Solenoid 1 or its control circuit. STI: Self Test Input circuit in the EEC and
MCU systems used to initiate Self-Test.
SS2: Shift Solenoid 2 or its control circuit.
STO: Self Test Output circuit in the EEC and
SS 3/4-4/3: (Shift Solenoid 3/4-4/3) Output MCU systems that transmits service codes
from the EEC-IV processor to the transmission (pulses) to either a VOM or STAR tester.
that selects 3rd and 4th gears.
TAB/TAD: Thermactor Air Bypass/
STAR: Self-Test Automatic Readout. A Thermactor Air Diverter vacuum solenoid
testing device in which the EEC and MCU valves or their control circuits.
systems output service codes in a digital
format. TCP: Temperature Compensated
(Acceleration) Pump. circuit.
TFI: Thick Film Ignition. An ignition module TSP: Throttle Solenoid Positioner. TTS:
comprised of a custom integrated circuit, Transmission Temperature Switch. TVS:
Darlington output device and associated thick
film integrated components. Temperature Vacuum Switch. TVV:
Thermal Vent Valve.
TGS: Top Gear Switch. A lock out
mechanism that prevents the SlL from TWC: Three Way Catalyst.
lighting when the vehicle is in top gear.
VAF: Vane Air Flow sensor or its signal
THERMACTOR: A system for injection of circuit.
air into the exhaust system to aid in the
VAT: Vane Air Temperature sensor or its
control of hydrocarbon and carbon
signal circuit.
monoxides in the exhaust.
VBAT: Vehicle Battery voltage.
THERMACTOR II: See Pulse Air System.
VCK-V: Vacuum Check Valve.
THS: Transmission Hydraulic Switch. An
input to the processor that indicates the VCV: Vacuum CO':ltrol Valve.
occurance of a shift between specific VDV: Vacuum Delay Valve.
gears.
VM: Vane Meter.
THS 3/2: Transmission Hydraulic
YOM: Volt-Ohm Meter used to measure
Switch 3rd/2nd gear.
voltage and resistance. Readings are
THS 4/3: Transmission Hydraulic indicated by sweep hand on a printed
Switch 4th/3rd gear. scale rather than a digital display.
TIMING: Relationship between spark plug VOTM: Vacuum Operated Throttle
firing and piston position usually expressed in Modulator.
crank shaft degrees before (BTDC) or after
(ATDC) top dead center of the compression VPWR: Vehicle Power supply voltage
stroke. regulated to 10-14 volts.
TIV: Thermactor Idle Vacuum Valve. VR/S: Vacuum Regulator/Solenoid.
TK: Throttle Kicker vacuum solenoid valve or VRDV: Vacuum Retard Delay Valve.
its control circuit.
VREF: Reference voltage supplied by the
TOT: Transmission Oil Temperature Sensor EEC-IV processor to some sensors and
or its signal circuit. regulated to 4-6 volts.
TP: Throttle Position sensor or its signal

ALL RIGHTS RESERVED
Glossary
7
Glossary
VRESER: Vacuum Reservoir. VSS: Vehicle Speed Sensor or its signal
circuit.
VREST: Vacuum Restrictor.
VR or VRS: Variable Reluctance Sensor. A VVA: Venturi Vacuum Amplifier.
non-contact transducer that converts VVC: Variable Voltage Choke relay or its
mechanical motion into electrical control control circuit.
signals.
VVV: Vacuum Vent Valve.
VRV: Vacuum Regulator Valve.
WAC: Wide-open throttle AIC Cutoff.
VSC: Vehicle Speed Control sensor or its
signal circuit. WOT: Wide-Open Throttle.
ALL RIGHTS RESERVED
SECTION 1
Emission Control
Identification/Application
Contents
Vehicle Emission Control Information Decal 1-1
Vehicle Emission Control Information Decal Location 1-2
Emission Control Application:
Car 1-3
Light Truck 1-4
Medium/Heavy Truck 1-5

ALL RIGHTS RESERVED
Emission Control IdentlflcatlonlApplication
1-1
Vehicle Emission Control Information Decal
Each vehicle is equipped with a decal (Figure. 1) containing emission control data that applies
specifically to that vehicle and engine. The specifications provided on the decal are critical to
servicing emissions systems.
1IIlCUUM HOlE MlUTINQ
FORD MOTOR COMPANY

IMPORTANT VEHICLE INFORMATION
'nlll y[HICU IS EOUII-1tC WITH HC IVIE..I I"ST'DIS. IIll.! "aos AND IIll.!
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Figure 1 Typical Vehicle Emission Control Information Decal
In addition to the tune-up specifications and procedures_ the emission decal shows a color coded
schematic of the engine vacuum system. The color coding on the schematic represents the actual
color coding on the vacuum hoses. However, there will be instances where an individual hose
color will not agree.

ALL RIGHTS RESERVED
1-2
Emission Control Identification/Application Vehicle Emission Control Information
Decal Location
VEHICLE EMISSION CONTROL INFORMATION DECAL LOCATION

VEHICLE LOCATION
Escort 1.9L Radiator Sight Shield
Tempo/Topaz 2.3L Resonator Assembly
Mustang 2.3L, 5.0L Coil Appearance Cover
Thunderbird/Cougar 3.8L Radiator Support
Taurus/Sable 2.5L, 3.0L, 3.8L Radiator Sight Shield
Continental 3.8L Radiator Sight Shield
Fan Shroud
Crown Victoria/ Grand Marquis 5.0L, 5.8L
Mark VII, Lincoln Town Car 5.0L Fan Shroud
Ranger, Bronco II, Aerostar All Engines Radiator Support
Econoline All Engines Under Hood
F-Series All Engines Under Hood
Engine Calibration Identification
The Emission Calibration Number Label, which contains the engine calibration number, is
located on the driver's side door or door post pillar.
,,
CALIBRATION
ETALONNAGE
CALI BRACION
E9"'E~061·ABY
\. j;76A-ROO
ENGINE CALIBRATION
NUMBER A9427·B
Figure 2 Emission Calibration Number Label

ALL RIGHTS RESERVED
Emission Control IdentlflcationlApplication

1-3
Emission Control Application
PASSENGER CAR - 50 STATES/CANADA
Catalyst(s) Idle
Vehicle Fuel System Electronic EGR secondary Ignition Speed "Engine Application Type Location Type, Mfg Eng Ctrl System Air System
System Control
Close DCM Close BPA
1.9L Escort TWC CFI EEC-IV PFE None TFI-IV Mount 1.9L Escort/Tracer TWC EFI EEC-IV PFE None EDIS Mount 1.9L HO Escort
TWC BPA EFI BPA
DBUB EFI EEC·IV BVT Dual PA TFI-IV COC 2.3l0HC Mustang TWC TB EEC-IV EEGR· None TFI-IV TWC UB Calif-MA
2.3L HSC TWC & COC :
49 States/ PA Canada Tempo/Topaz DBUB EFI EEC-IV ·PFE TFI-IV BPA California TWC MTA
2.3l HSC
PA States/ COC
Plus 49 TWC & Tempo/Topaz DBUB EFI EEC-IV PFE TFI-IV BPA Canada
TWC EEGR PA TFI·IV DCM

California TWC MTA 2.5L HSC Taurus DBUB CFI EEC·IV COC 2.9L Scorpio TWC DBUB EFI EEC-IV None None TFI-IV BPA
EFI EEC-IV 3.0L
Probe TWC UB None TFI·IV Calif-PFE None Calif-TFI- BPA Taurus TWC UE EFI EEC·IV IV/CCD
None None DIS BPA Thunderbird/ (2) TWC None DIS BPA
3.0L SHO Taurus/Sable TWC UE SEFI-MA' EEC-IV Calif-PFE 3.8L SC TB SEFI-MA EEC-IV PFE
(2) TWC TFI-IV/ BPA (2) TWC TB TFf-IV/
Cougar TWC Thunderbird/ TB SEFI EEC-IV PFE None Cougar TWC CBD 3.8L Continental SEFI EEC-IV PFE CT
BPA (2) TWC' TB TFI-IV/ BPA
TWC UB CBO Taurus/Sable SEFI EEC-IV PFE CT TWC UB CBD
Crown Victoria/
SEFI
Grand Marquis (2) TWC TB SPA . US Sedans·MA
5.0L Calif EEC-IV EEGR MTA TFI-IV Ford Police (2) cae Town Car
(2) TWC TB MTA TFI-IV BPA
Mark VII SEFI EEC-IV EEGR (2) COC UB Crown
5.0l HO Victoria/
(2) TWC TB SEFI-MA EEC-IV EEGR MTA TFI-IV BPA
Mustang (2) COC UB
Grand Marquis (2) TWC 7200-VV OS 1/ TSP
5.8L DBUB MCU IBP MTA (Canada) cae FBC. Ford Ford Police
ABBREVIATIONS:
EEC-IV = Electronic Engine MTA = Managed Thermactor Air
BPA - Bypass Air Control - System-IV
BVT - Back Pressure Variable Transducer OHC = Overhead Cam
CCD - Computer Controlled Dwell CFI - EEGR = Electronic EGR Valve
PA = Pulse Air
Central Fuel Injection (Sonic)
PFE = Pressure Feedback Electronic
cae - Conventional Oxidation EFI = Electronic Fuel Injection EGR
Catalyst SEFI = Sequential EFI
= Exhaust Gas Recirculation HSC TB = Toe Board
CT - Conventional Thermactor
DBUB .. Dual Brick Underbody = High Swirl Combustion TFI = Thick Film Ignition
DCM - D.C. Motor IBP = Integral Back Pressure
DIS - Oistributorless Ignition System TSP = Throttle Solenoid Positioner
(low data rate) MA = Mass Air
TWC = Three-Way Catalyst
OS-II - Duraspark II MCU = Microprocessor Control Unit
EOIS = Electronic Oistributorless Ignition " UB = Underbody
MFG = Manufacturer
System (high data rate)

ALL RIGHTS RESERVED
1-4 Emission Control IdentificationlApplication Emission Control Application
LIGHT TRUCK - 50 STATES/CANADA
Catalyst(s) Fuel Idle

Vehicle System Electronic EGR Secondary Ignition Speed Engine Application Type Location Type, Mfg
Eng Ctrl System Air System System Control
2.3L TWC BPA
Ranger DBUB EFI EEC-IV EEGR None DIS OHC TWC 2.9L Ranger/ TWC (2) SBUB EFI EEC-IV None
TFI-IV BPA EDIS BPA

None Bronco II TWC 2.9L Ranger/ TWC US #1 EFI-MA EEC-IV None None MA
EEC-IV None None TFI-IV BPA

Bronco II TWC UB #2 3.0L Aerostar TWC (2) SBUB EFI TWC 4.0L
Ranger,
TWC UB #1
Bronco II EFI-MA EEC-IV None None EDIS BPA
MA TWC UB #2 Aeroster
E-Series/ * MTA/ EFI EEC-IV EEGR
TWC UB #1 4.9L F-Series (2) CDC UB #2 AM1, AM2 TFI-IV BPA Bronco
E-Series/ MTA/ EFI EEC-IV EEGR
TWC UB #1 5.0L F-Series (2) CDC UB #2 AM1, AM2 TFI-IV BPA Bronco
E-Series/ MTA/ EEC-IV EEGR
TWC UB #1 5.8L F-Series (2) CDC UB #2 EFI AM1, AM2 TFI-IV BPA Bronco
ABBREVIATIONS:
EEGR = Electronic EGR Valve (Sonic) EDIS =
AM1, AM2 = Air Management 1, 2 Electronic Distributorless Ignition System (high data
BPA = Bypass Air rate)
CDC = Conventional Oxidation Catalyst CT = EFI = Electronic Fuel Injection MA = Mass Air
Conventional Thermactor MTA = Managed Thermactor Air NFB =
DBUB = Dual Brick Underbody Non-Feedback Carburetor PFE = Pressure
DCM = D.C. Motor Feedback Electronic SBUB = Single Brick
DIS = Distributorless Ignition System Underbody TFI-IV = Thick Film Ignition
(low data rate) TWC = Three-Way Catalyst
OS-II = Duraspark II . UB = Underbody
EEC-IV = Electronic Engine Control - System-IV
* All 4.9L light trucks weighing under 8500 Ibs. with an automatic transmission calibration use MTA/AM7 only.

ALL RIGHTS RESERVED
Emission Control IdentlflcationlApplication

1-5
Emission Control Application

MEDIUM/HEAVY TRUCK - 50 STATES/CANADA
Catalyst(s) Idle
Vehicle Fuel System Electronic EGR Thermactor Ignition Speed Engine Application Type Location Type, Mfg
Eng Ctrl System System System Control
TFI-IV BPA E-Series/

4.9L E-Series/ TWC UB #1 EFI EEC-IV EEGR MTA/ F-Series COC UB #2. AM1, AM2 5.8L
MTA/ TFI-IV BPA 2380EG-2V
REDOX UB EFI EEC-IV EEGR F-Series AM1, AM2 6.1L F-Series None NA None Ported CT
None 4190EG-4V CT OS-II None (3)
OS-II Holley 7.0L F-Series None NA None Ported Holley 7.5L E-Series/ UB EFI EEC-IV
TFI-IV/ BPA
EEGR MTA F-Series REDOX CBO ABBREVIATIONS:
EGR = Exhaust Gas Recirculation
AM1, AM2 = Air Management 1, 2
MFG = Manufacturer
BPA = Bypass Air
MTA = Managed Thermactor 'Air NA = Not
CBD = Closed Bowl Distributor
Applicable
COC = Conventional Oxidation Catalyst CT =
REDOX = Reduction-Oxidation TFI-IV = Thick
Conventional Thermactor
Film Ignition TWC = Three-Way Catalyst UB =
OS-II = Duraspark !I
Underbody
EEC-IV = Electronic Engine Control - System-IV
V = Venturi
EEGR = Electronic EGR Valve (Sonic) EFI =
Electronic Fuel Injection

ALL RIGHTS RESERVED
SECfION 2
Diagnostic Routines
Contents
Preface to Diagnostic Routines 2-1
Diagnostic Routine Index 2-2
Diagnostic Routines 2-3

ALL RIGHTS RESERVED
Diagnostic Routines
2·1
Diagnostic Routines
PREFACE
The Diagnostic Routines list the components and systems that can contribute to· a particular
condition in the order of probability, ease of accomplishment, and accessibility. These Routines can
be used as check lists for· reference in the event of unusual or infrequent causes of malfunction.
It is not necessary that any given order be followed, but it makes good sense for the technician
to visually inspect everything that his experience tells him could be the source of the condition
before beginning a m~re involved diagnosis. The effectiv~ness of every service must be validated.
All references, under the REFER~NCE column in each Diagnostic Routine chart, are a~ follows:
• 'Group titles reference specific groups shown in the Powertrain, or Body, Chassis and
Electrical Shop Manuals..
• Section numbers reference sections in the Engine/Emissions Diagnosis manual. •
Special manual publications are referenced in some cases.
• On-line Automotive Service Information System (OASIS) numbers have been included where
applicable. '

ALL RIGHTS RESERVED
2·2
Diagnostic Routine Index

. GASOLINE ENGINES
Diagnostic Routines
OASIS Page
Title Routine Number
Cranks Normally But Won't Start 201 610200 2-3 Starts Normally But Won't Run (Stalls) 202 620100 2-4 Cranks Norl"flally
But Slow to Start 203 610300 2-5 Rough Idle 204 620800 2-6 Misses Under load 205 630300 2·7 low Idle (Stalls on
Deceleration or Quick Stop) 206 630103 2-7 Hesitates or Stalls on Acceleration 207 631900 2-8 Backfire (Induction or
Exhaust) 208 630600 2-9 lack of Power 209 630400 2-10
Surges at Steady Speed 210 630200 2-11 High Idle (Engine Diesels) 211 620700, 640100 2·12 Engine Noise 212 4400 2-13
Poor Fuel Economy 213 640200 2-14 High Oil Consumption 214 4101 2-15 Spark Knock/Pinging 215 632500 2-15 Engine
Vibrates at Normal/High Speeds 216 7210 2-16 Engine Runs Cold 217 4300 2-16
Engine Runs Hot 218 4300 2·16 Exhaust Smoke 219 - 2-17 Gas Smell 220 - 2·18 "CHECK ENGINE" /"SERVICE ENGINE
2-18
SOON" Light Always 221 - On or Never On "CHECK ENGINE"/"CHECK DCl" Message On State Emission Test
Failure 222 - 2-19

Shift Indicator Light and Audible Chimes "ON" 224
Improper Shift 223 5101, 5102 2-21 - 2-21
DIESEL ENGINES
Title Routine Page 6.6l and 7.8l Engines 20-1 7.3l Engine (Engine Induced Faults) 21-1 7.3l Engine (Transmission
Induced Faults)
low Idle (Stalls on Deceleration or Quick Stop) 206 2-7 Hesitates or Stalls on Acceleration 207 2-8 lack of Power 209 2·10
High Idle (Engine Diesels) 211 2-12 Poor Fuel Economy 213 2-14 Improper Shift 223 2·21

ALL RIGHTS RESERVED
Diagnostic Routines
2-3
Diagnostic Routines
201 CRANKS NORMALLY BUT WON'T

START (OASIS #610200)
NOTE: Extended cranking, because of a "No Start" condition, can load the exhaust system with raw
fuel, which can ruin the catalytic converter after the engine starts. After the "No Start" condition has
been repaired, disconnect the thermactor air supply, run the engine until surplus fuel Is used up and
reconnect the thermactor air supply.
System Component Reference EEC Quick Test Section 14

Ignition Electrical Connections
Secondary Ignition Wires
Spark Plugs Fouled
Ignition Switch
OS" and TFI IV: DSII and TFI IV:
Ignition Coil Section 13, Ignition/Engine
Ignition Module Group
Rotor Alignment
Distributor Cap, Adapter, Rotor & Stator
DIS/EDIS: DIS/EDIS:
Single or Dual Hall Crankshaft Sensors Section 14, Section 13,
Hall Camshaft Sensor Ignition/Engine Group
DIS/EDIS Ignition Module
Coil Pack(s)
Fuel Delivery Filter Visual, Section 11, Pump Fuel/Engine Group
Water/Dirt/Rust Contamination in Fuel
Lines
Tank (Fuel Supply)
Dual Tanks (Selector Switch)
Sender Filter
Fuel Pressure Regulators for EFI and CFI
Injectors
Inertia Switch
Fuel Charging Electrical Connections Visual, Section 4, Assy.lThrottle Choke Plate and Linkage
Fuel/Engine Group Body/ External Carburetor Cold Enrichment Rod and Linkage (7200)
Venturi Valve (7200)
Throttle Linkages
Internal Carburetor Float/lnlet Needle and Seat Section 4, Fuel/Engine Group Idle Air Bleeds and Fuel Passages
Basic Engine Camshaft Timing Engine Group Compression
EGA Valve Section 6
MCU Component Diagnostics Special MCU Diagnosis Manual
Exhaust Catalyst Exhaust Visually inspect for blockage.

ALL RIGHTS RESERVED
2-4 Diagnostic Routines
Diagnostic Routines
202 STARTS NORMALLY BUT WON'T
RUN (STALLS)
(OASIS #620100)
System Component Reference
Fuel Charging Curb or Fast Idle Speed Visual, Section 4, Assy/Throttle Electrical and Vacuum
Connections Fuel/Engine Group Body/ External Carburetor Choke Plate and Linkage
Cold Enrichment Rod And Linkage (7200)
Choke Pulldown Adjustment & Diaphragm
Choke Cap Indexing
EEC Quick Test Section 14
Lines
Tank (Fuel Supply)
Sender Filter
Injectors
Inertia Switch
Ignition Electrical Connections
Secondary Ignition Wires
Ignition Switch
DSII and TFI IV: DSII and TFI IV:
Ignition Coil Section 13, Ignition/Engine
Ignition Module Group
Rotor Alignment
Distributor Cap, Adapter, Rotor & Stator
Ballast Resistor
DIS/EDIS: DIS/EDIS:
Single or Dual Hall Crankshaft Sensors Section 14, Ignition/Engine
Hall Camshaft Sensor Group
Coil Pack(s)
Internal Carburetor Float/Inlet Needle and Seat Fuel/Engine Group Idle Air Bleeds and Fuel
Passages
Exhaust Component (Restricted) Section 5 EGR Valve Section 6
Basic Engine Camshaft and Valve Train Engine Group
Induction Intercooler Tube (Air Leaks) Section 8 (Supercharger)

ALL RIGHTS RESERVED
2·5
Diagnostic Routines
Diagnostic Routines
203 CRANKS NORMALLY BUT SLOW TO

START (OASIS # 610300)
NOTE: It is a good practice to confirm that the correct starting procedure was being used by the
customer before proceeding with diagnosis.

Ignition Scope Engine for: Spark Plugs, Coil, Secondary
Ignition Wires
Spark Plugs Fouled
0511 and TFI IV: DSII and TFI IV:
Distributor Cap, Adapter & Rotor Visual, Section 13,
Ignition/Engine Group
DIS/EDIS: DIS/EDIS:
Single or Dual Hall Crankshaft Sensors Section 14, Ignition/Engine
Hall Camshaft Senso Group
Coil Pack(s)
Fuel Delivery Filter Visual, Section 11, Fuel/Engine Pump Group
Lines
Sender Filter
Injectors
Fuel Charging Assy/Throttle Curb or Fast Idle Speeds Visual, Section 4, Fuel/Engine Body/ External Carburetor Electrical
and Vacuum Connections Group
Choke Plate and Linkage
Cold Enrichment Rod and Linkage (7200)
Choke Cap Indexing
Accelerator Pump
Bowl Vents
Internal Carburetor Float/Inlet Needle and Seat Visual, Section 4, Fuel/Engine Stepper Motor (7200) Group
Cold Enrichment System (7200)
Exhaust Component (Restricted) Section 5
Induction and Vacuum Vacuum Leaks Visual, Audible, Engine Group Distribution Air Cleaner Element Restricted
Cooling Electric Fan (Hot Start Only) Cooling/Engine Group EGR Valve Section 6 PCV Valve Section 9 EVAP Components
Section 7, Fuel/Engine Group MCU Component Diagnostics Special MCU Diagnosis Manual

ALL RIGHTS RESERVED
2-6
(OASIS # 620800)
Diagnostic Routines
Diagnostic Routines
204 ROUGH IDLE

System Component Reference Cooling Fan or Electric Fan (Loose or Cracked)
Visual
Ignition Scope Engine For: Spark Plug, Coil, Section 13, Ignition/Engine Secondary Wires, Distributor Cap,
Adapter Group
and Rotor
Ignition Timing
Fuel Charging Curb or Fast Idle Speeds Visual, Section 4, Assy/Throttle Electrical and Vacuum
Connections Fuel/Engine Group Body/External Carburetor Choke Plate and Linkage
Choke Pulldown
Bowl Vent
Fuel Delivery Fuel Pressure Regulators EFI/CFI Section 11, Fuel/Engine Injectors Group
Fuel Rail
Carburetor Idle Mixture Section 4
Internal Carburetor Idle, Air Bleeds or Fuel Passages Visual, Section 3, Section 4, Float/Inlet Needle and
Seat Fuel/Engine Group
Stepper Motor (7200)
Hot Idle Compensator (may be external)
Altitude Compensator "
Vacuum Distribution Vacuum Leaks Visual and Audible
EGR Valve Section 6 Vacuum Regulator
Cooling Thermostat Cooling/Engine Group
Basic Engine Compression Engine Group Valve Train
Camshaft
Intake Manifold Gaskets
PCV Valve Section 9 EVAP Components Section 7, Fuel/Engine Group
Exhaust Pipes, Muffler, Catalyst Section 5 Resonator, Heat Control Valve
Induction Intercooler Tube (Air Leaks) Section 8 (Supercharger)

ALL RIGHTS RESERVED
Diagnostic Routines
2·7
Diagnostic Routines
205 MISSES UNDER LOAD

(OASIS # 630300)
Ignition Scope Engine For: Spark Plug, Coil, Secondary Section 13, Ignition/Engine Wires, Distributor Cap,
Adapter and Rotor Group
Timing
EEC
, Quick Test Section 14
MCU
Component Diagnostics Special MCU Diagnosis Manual
Fuel Delivery Filter Visual, Section 4, Section 11, Pump Fuel/Engine Group
Lines . Fuel Pressure Regulators EFI/CFI
Sender Filter
Injectors
Fuel Charging Electrical and Vacuum Connections Visual, Section 4, Fuel/E~gine Assy/Throttle Choke and Linkage
Group Body/External Carburetor Cold Enrichment Rod and Linkage (7200)
Venturi Valves (7200)
Internal Carburetor Basic: Idle, Main, and Accelerator Pump Visual, Section 3, Fuel/Engine Float/Inlet Needle and
Seat Group
Main Metering
Fuel Enrichment
EGR Valve Section 6
206 LOW IDLE

(STALLS ON DECEL OR QU'ICK STOP)
(OASIS #630103)
Fuel Charging Curb or Fast Idle Speed Visual, Section 4,· Fuel/Engine Assy/Throttle Electrical and Vacuum
Connections Group Body/ ExternalCarburetor Throttle Devices
Internal Carburetor Idle Airbleeds or Fuel Passages Visual, Section· 4, Fuel/Engine Stepper Motor (7200) Group .
Hot Idle Compensator (may be external)
Float/Inlet Needle and Seat
EEC Quick Test Section 14 MCU Component Diagnostics Special MCU Diagnosis Manual EGR Valve Section 6
Base Transmission (E40D Transmission Oil Level Transmission Group Only) Converter Clutch Control
Solenoid

ALL RIGHTS RESERVED
Diagnostic Routines
207
HESITATES OR STALLS ON ACCELERATION
(OASIS #631900)
Ignition Scope Engine For: Spark Plug, Coil, Section 13, Ignition/Engine Secondary Wires, Distributor Cap,
Adapter Group
and Rotor
Ignition Timing
Fuel Charging Choke Plat and Linkage Visual, and Section 4 Assy/Throttle Electrical & Vacuum
Connections
Body/ External Carburetor Cold Enrichment Rod and Linkage (7200)
Accelerator Pump
Curb or Fast Idle Speeds
Lines
Sender Filter
Injectors
Internal Carburetor VV Diaphragm (7200) Section 4, Fuel/Engine Group Power Valve
Main System
Vacuum Distribution Vacuum Leaks Visual and Audible
Induction Air Cleaner Duct, Stove Pipe, and Valve Section 8 Inter-Cooler Tube (Air Leaks)
EGR Valve Section 6 PCV Valve Section 9
Exhaust (Restriction) With Backpressure EGR System Section 5
Base Transmission Converter Clutch Control Solenoid Transmission Group (E40D and A4LD)
Converter Clutch Override
Converter Clutch

ALL RIGHTS RESERVED
Diagnostic Routines
2-9
Diagnostic Routines
I
208 BACKFIRE (INDUCTION OR EXHAUST)
(OASIS IF 630600)

Ignition Scope Engine For: Spark Plug, Coil, Section 13 Secondary Wires, Distributor
Cap and Rotor,
Crossed Wires
Ignition Timing
Vacuum Distribution Vacuum Hoses, or Connections Leak(s) Visual and Audible EEC Quick Test
Section 14 Thermactor Thermactor System Components Section 10 Pulse Air Pulse Air System
Components Section 10
Basic Engine Intake Manifold Gaskets Engine Group Compression Check
Camshaft
Valves
Exhaust Components (Restricted) Section 5
Water, Dirt, Rust, Contamination in Fuel
Lines
Fuel Pressure Regulators EFI/CFI
Injectors
Sender Filter
External Carburetor Choke Plate and Linkage Visual and Section 4

ALL RIGHTS RESERVED
2·10
Diagnostic Routines
(OASIS # 630400)
Diagnostic Routines
209 LACK OF POWER
System Component Reference Ignition Timing Section 13 EEC Quick Test

Section 14
Lines
Fuel Pressure Regulator EFI/CFI
Sender Filter
Injectors
Fuel Charging Electrical and Vacuum Connections Visual, Section 4, Assy/Throttle Choke Plate
and Linkage Fuel/Engine Group Body/ External Carburetor Accelerator Pump
Curb or Fast Idle Speed
Internal Carburetor Float Inlet/Needle and Seat Visual, Section 4, Accelerator Pump Fuel/Engine
Group
Main Metering System
Fuel Enrichment
Altitude Compensator
Pullover Rod Sticking (1949)
Ignition Scope Engine For: Spark Plugs, Coil, etc. Visual, Section 13, Ignition/Engine Group
Exhaust Components (Restricted) Section 5 Cooling Thermostat Cooling/Engine Group Vacuum
Distribution Vacuum Leaks Visual/Audible Induction Air Cleaner Duct and Valve and Element Section
8 EGR Valve Section 6
Basic Engine Compression Check Fuel/Engine Group Camshaft
Valves
Drive Train Clutch, Automatic Transmission, Brakes Transmission Group, Driveline Group
Supercharger Assembly Fuel/Engine Group

ALL RIGHTS RESERVED
Diagnostic Routines
2·11
Diagnostic Routines
210 SURGE AT STEADY SPEED

(OASIS # 630200)
Lines·
Sender Filter
Fuel Charging Choke Plate and Linkage Visual, Section 4, Assy/Throttle Electrical & Vacuum
Connections Fuel/Engine Group Body/ External Carburetor Venturi Valves (7200)
Curb or Fast Idle Speeds
Internal Carburetor Idle, Main Systems Visual, Section 4, Float/Inlet Needle and Seat Fuel/Engine
Group
Fuel Enrichment Systems
Altitude Compensator .
Ignition Scope Engin~ For: Spark Plugs, Coil, Section 13 Secondary Ignition Wires, etc.,
Timing
Vacuum Distribution Vacuum Leaks Visual, Audible EGR Valve Section 6 Induction Air Cleaner
Duct and Element Visual, Section 8
EVAP Components Section 7, Fuel/Engine Group
Basic Engine Valve Train and Camshaft Engine Group Intake Manifold Gaskets
Thermactor Thermactor System Components Section 10 Supercharger Assembly Fuel/Engine
Group

ALL RIGHTS RESERVED
2·12
Diagnostic Routines
211 HIGH IDLE (ENGINE
DIESELS) (OASIS #620700, 640100)
Diagnostic Routines
NOTE: If
engine
idles
smoothly
after key
is turned
off,
trouble is
likely to
be in the
ignition
switch,
ignition
harness,
starter
solenoid
"IGN"
tap, or
EEC
relay.
System
Component
Reference
Fuel Charging Curb or Fast Idle Speeds Visual, Section 4, AssyIThrottle Electrical and Vacuum
Connections Fuel/Engine Group BodyI External Carburetor Throttle Positioner or Dashpot
Throttle Plate and Linkage
Choke Plate and Linkage
Fast Idle Linkage
Speed Control Chain
Vacuum Distribution Vacuum Leaks Visual and Audible EEC Quick Test Section 14 Induction
Vacuum Leaks Engine Group Cooling Overheating Routine 218
ALL RIGHTS RESERVED
Diagnostic Routines
2-13
Diagnostic Routines
212 ENGINE NOISE

(OASIS # 4400)
Squeal, Click, or Chirp .Oil Level (low) Visual, Audible, Engine Valve Train Group, Cooling Group
Drive' Belts (loose),
Belt Driven Components
EEC Solenoids
Rumble, Grind Belt Driven Components

Rattle Component (loose) Exhaust Group
Hiss Thermactor System (leak) Visual, Audible, Section 10, Vacuum Distribution System (leak) Engine Group
Induction System (leak):
Spark Plug (loose)
Cooling System (leak) Visual and Audible
EVAP System (leak) Section 7
Snap Secondary Ignition Visual and Audible
Rap, Roar Exhaust System (leak) Visual, Audible, Section 1O, Pulse Air System (air cleaner) Exhaust Group
Knock Connecting Rod Bearing (worn) Engine Group Main Bearing (worn)
Piston Pin (loose)
Piston to Bore Clearance (cold engine)
Mechanical Fuel Pump Fuel/Engine Group
Detonation Routine 215

ALL RIGHTS RESERVED
2·14
ECONOMY (OASIS # 640200)
Diagnostic Routines
Diagnostic Routines
213 POOR FUEL
NOTE: Since fuel consumption is drastically increased for city driving, short-run operation, stop and
go driving, trailer towing, extended winter warm-up periods, etc., as opposed to "trip" mileage,
an attempt should be made to determine these factors when confronted with "poor mileage"
conditions. However, since the operator Is not always at fault, the following is appended:

Fuel Charging Choke Plate and Linkage Visual, Section 4 Assy/Throttle Cold Enrichment Rod and
Linkage (7200)
Body/ External Carburetor Electrical & Vacuum Connections
Fuel Delivery Fuel Return Line Blocked Section 11, Fuel/Engine Fuel Pressure Regulators EFI/CFI Group
Induction Air Cleaner Duct and Valve Visual, Section 8 Air Cleaner Element (Restricted)
Ignition Scope Engine For: Spark Plug, Coil, Section 13 Secondary Wires, Distributor Cap,
Adapter
and Rotor
Ignition Timing
Internal Carburetor Idle, Main Systems Section 4, Fuel/Engine Group Enrichment Systems
Float/Inlet Needle and Seat
Factors External to the Tire Pressure & Type Manual and Visual Engine Clutch Operation
I
Converter Clutch Override

Automatic Transmission Shift Pattern and
Fluid Level
Brake Drag
Exhaust System
Speedometer/Odometer Gear Ratio
Axle Ratio
Vehicle Load
Road & Weather Conditions
Aftermarket Add-Ons
Base Transmission Converter Clutch Control Solenoid Transmission Group (E40D Only)

ALL RIGHTS RESERVED
Diagnostic Routines
CONSUMPTION (OASIS #4101)
2·15
Diagnostic Routines
214 HIGH OIL

NOTE: If the condition cannot be verified, clean engine, if necessary, change oil and filter (at
customer's expense), seal and have customer drive 500 miles (804.5 Kmlor enough distance
to consume two quarts before returning for re-examination.
System CompQnent Reference

External Leaks Rocker Cover Gasket, Crankshaft Seals, Engine Visual Assembly
Proper Dipstick Overfilling (sometimes accomplished by the Manual and Visual "short stick" gas station
procedure).
Induction Air Cleaner Element (Sealing) Visual, Fuel/Engine Group pcv Valve Section 9
Internal Leaks (blue smoke Valve Guides Engine Group from tailpipe) Valve Stem Seals
Intake Manifold and Gasket
Cylinder Head Drain Passages
Piston Rings
215 SPARK KNOCK/PINGING
(OASIS # 632500)
NOTE: If the above fails to correct the condition, it is recommended that the owner change his
source of fuel and use higher octane fuel. .
System Component Reference Ignition Timing Section 13 EEC Quick Test Section 14
Vacuum Distribution Vacuum Leaks Visual, Audible, and Section 3 Spark Delay Valve
PVS
Cooling Overheating Visual, Routine 218
Basic Engine Oil Level Engine Group Compression Check
Intake Manifold Gasket
Fuel Delivery Injectors Section 11 PCV Valve Section 9 EGR Verity correct application, then
diagnose. Section 6 Induction Air Cleaner Duct and Valve Assembly Section 8 Thermactor
Thermactor System Components Section 10
Base Transmission (E40D Transmission Controls Transmission Group Non-Diesel Only)

ALL RIGHTS RESERVED
Diagnostic Routines
216
ENGINE VIBRATES AT NORMAL SPEEDS
(OASIS #7210)
Engine Accessories Fan Manual and Visual Belt Driven Components
Engine Mounts
Engine Vibration Damper
Otherwise Non-Engine Components: Drive Line, Tires, Manual and Visual Wheel Balance
3.8L Supercharged Shift Indicator Light and Audible Chime Routine 224 "ON"
217 ENGINE RUNS COLD

(OASIS # 4300)
System Component Reference Gauge System Gauge, Sender Instruments/Gauge
218 ENGINE RUNS HOT

(OASIS # 4300)
Cooling Thermostat Visual, Cooling/Engine Group Coolant Level
Radiator or A/C Condenser
Pressure Cap and Overflow System
External Leaks
Belts and Belt Tension
Fan and Fan Clutch
Electric Fan (If So Equipped)
Gauge System Gauge, Sender Instruments/Gauge Group Vacuum Distribution Spark Delay Valve
Section 3 EEC Quick Test Section 14 Ignition Timing Section 13
Basic Engine Oil Level Engine Group Internal Leak(s)
Core Sand in Head/Block
Water Pump
Brake Brakes (dragging) Brake Group

ALL RIGHTS RESERVED
Diagnostic Routines
2-17
Diagnostic Routines
219 EXHAUST SMOKE

NOTE: White Smoke is normal during warm-up.

Black Smoke (rich Choke Plate and Linkage Section 4, Fuel Group mixture) Cold Enrichment Rod
and Linkage (7200)
Air Cleaner Element (Restricted) Visual
Internal Carburetor Components: Visual, Section 4,
Basic: Idle, Main and Accelerator - Pump Fuel/Engine Group
Metering Systems
Enrichment Systems
Fuel Inlet Needle/Seat
Float
Fuel Pressure Regulator EFI/CFI Section 11, Fuel/Engine
Injectors Group
EEC Components Section 14
MCU Components Special MCU Diagnosis
Manual
Blue Smoke (burning oil) PCV Valve Section 9
Valve Guides/Stems/Seals Engine Group
.Oil Drain Passages in Head
Rings (not seated, seized, gummed up, worn) Engine Group
Cylinder bores (scuffed)
White Smoke (coolant in Thermactor Vacuum Delay Valve (restricted) Section 6, Engine. Group
combustion) EGR Cooler
Intake Manifold (cracked/porous)
Cylinder Head/Gasket (leaks)
Block (cracked/porous)

ALL RIGHTS RESERVED
2·18
Diagnostic Routines
Diagnostic Routines
220 GAS SMEll
System
Component Reference
Fuel Delivery Fuel Filter (leaks) Visual, Section 11, Fuel Line to Carburetor (leaks) Fuel/Engine
Group
Injectors (leaking)
Fuel Pump (leaks)
Fuel Line, Pump to Tank (leaks)
Fuel Tank (leaks)
Fuel Tank Filler Neck/Cap (leaks)
Fuel Return Line (Blocked)
Internal Carburetor Float/Inlet Needle (stuck) Section 4, Fuel/Engine Group
EVAP Carbon Canister, Solenoid, Hoses (leaks) Section 7, Section 14, Fuel/Engine Group
221 "CHECK ENGINE" /"SERVICE ENGINE

SOON" liGHT ALWAYS ON OR NEVER ON
"CHECK ENGINE" /"SERVICE ENGINE
SOON" /"CHECK DCl" MESSAGE ON
NON-EEC 6.1 L/7.0L Heavy Duty Truck Check Engine Section 12 Light

ALL RIGHTS RESERVED
Diagnostic Routines
2-19
Diagnostic Routines
222 STATE EMISSION TEST FAILURE

NOTE: Canada and some states or metropolitan areas in the United States require periodic Idle
Emission Tests. All Ford products have. been designed to pass these tests. If a Ford
product fails an Idle Emission Test, it is probable that 1) The engine temperature was not
warm and stabilized prior to the test. 2) The vehicle had idled excessively long prior to
the test.
Prior to starting any repairs, complaints of Idle Emission Test failure should be verified.
The following example encompasses most of the emissions measurement modes of the current state
idle test procedures:
• Ensure that the engine is at normal operating temperature and that all accessories are turned
off.
• Read emissions at idle.
• Run engine at 2500 ± 300 rpm.
• Read emissions within 30 seconds.
• Return engine speed to idle.
• Read emissions within 30 seconds.
If any emission components are replaced, Keep Alive Memory (KAM) should be cleared before
repeating State Emission Test procedure. Refer to Quick Test Appendix.

ALL RIGHTS RESERVED
2·20
TEST FAILURE
Diagnostic Routines (CONTINUED)
Diagnostic Routines
222 STATE EMISSION
System Component Reference EEC Quick Test Section 14 MCU Componen~ Diagnostics Special MCU
Diagnosis Manual
Ignition Scope Engine For: Spark Plug, Coil, Secondary Section 13, Ignition/Engine Wires, Distributor Cap, Adapter
and Rotor Group
Timing
Vacuum Distribution Vacuum Leaks/Blockage Visual and Audible Carburetor Idle Mixture Section 4
Fuel Charging Assy/Throttle Curb or Fast Idle Speeds Visual, Section 4, Section 11, Body/ External Carburetor
Electrical and Vacuum Connections Fuel/Engine Group Choke Plate and Linkage
Choke Pulldown
Bowl Vent
Internal Carburetors Idle, Air Bleeds or Fuel Passages Visual, Section 4, Fuel/Engine Float/Inlet Needle and Seat
Group
Fuel Delivery Injectors Section 11, Fuel/Engine Group Fuel Rail
EGR Valve Section 6 Vacuum Regulator
PCV Valve Section 9 EVAP Carbon Canister, Purge Solenoid Section 7, Fuel/Engine Group Thermactor Thermactor
Air Dump Section 10
Exhaust Pipes, Muffler, Catalyst Section 5 Resonator, Heat Control Valve
Cooling Unstabilized Engine Temperature Visual, Routine 218
Basic Engine Scheduled Maintenance Engine Group Compression
Valve Train
Camshaft
Intake Manifold Gaskets

ALL RIGHTS RESERVED
Diagnostic Routines
2·21
Diagnostic Routines
223 IMPROPER SHIFT

(OASIS #5101, 5102)
Base Converter Clutch Control Solenoid Transmission Group Transmission Converter Clutch
(E40D, A4LD, AXOD Electronic Pressure Control Solenoid
Only) Shift Solenoid # 1
Shift Solenoid # 2
4 X 4 Low Switch
EEC Quick Test Section 14 (E40D, A4LD Only)
224 SHIFT INDICATOR LIGHT AND

AUDIBLE CHIMES "ON"
NOTE: VERIFY THAT THE CUSTOMER HAS READ THE OWNERS MANUAL ON THE NEW 3.8L
SC OVERHEAT PROTECTION FEATURE.
The 3.8L SC is equipped with a Shift Indicator Light and Audible Chime that warns the customer
when the engine oil or coolant overheats while the vehicle is operated at high speeds (above 100
mph) for extended periods of time. The Shift Indicator Light and Chime will also warn the customer
when the engine has reached too high an rpm for that gear. The EEC·IV processor will reduce
vehicle speed by limiting fuel to the engine when one of these overheat conditions has been
reached. The customer may then notice a loss of power and/or a slight vibration. The Shift Indicator
Light will "light" and the Audible Chime will produce a "steady tone" to alert the customer to upshift at
this time. Full power will be restored and the Shift Indicator Light and Chimes will turn off when the
vehicle returns to normal operating temperatures.

EEC Shift Indicator Light Bulb Section 14 "SIL" Dimmer Relay
Top Gear Switch
3.8L SC Only Audible Chime System Thunderbird/Cougar Shop Manual Section
33-50 - Warning Chimes

ALL RIGHTS RESERVED
SECTION 3
Emission Related
Components
Contents
PART
NAME NUMBER PAGE Air Charge Temperature Sensor 12A697 3-1 Air Cleaner Cold
Weather Modulator 9E862 3-2 Air Cleaner Temperature Sensor 9E607 3-3 Air Cleaner
Vacuum Motor 90604 3-4 Barometric Absolute Pressure Sensor 9F479 3-5 Carbon
Canister 90653 3-6 EGR Valve and Transducer Assembly 9H495 3-7 EGR Valve-Electronic
9F483 3-8 EGR Valve-Integral Back Pressure Transducer 90448 3-9 EGR Valve-Ported
90475 3-10 EGR Valve Position Sensor 9G428 3-11
Electronic Control Assembly (FBC/CFI/EFIISEFI) 12A650 3-12 EGR Vacuum Regulator
9J459 3-13 Engine Coolant Temperature Sensor 12A648 3-14 Exhaust Heat Control Valve
9A427 .. .. .. ... .. ... .. .. .. 3-15 Feedback Carburetor Actuator Motor 9C908 .. .. .. ..... .. .. .. ..
3-16 Filter Assembly-Vacuum Vent 9F474 3-17 Fuel-Vapor Separator 9C369 3-18 Heated
Exhaust Gas Oxygen Sensor 9F472 3-19 Ignition Barometric Pressure Switch 12A243 3-20
Emission Maintenance Warning (EMW) Module 12B514 3-21 Integral Relay Control Module
12B577 3-22 Knock Sensor 12A699 3-23 Manifold Absolute Pressure Sensor 9F479 3-24
Mass Air Flow Sensor ' 128579 3-25
(Continued)

ALL RIGHTS RESERVED
SECTION 3
Emission Related
Components
Contents
PART
NAME NUMBER PAGE
Pressure Feedback Electronic EGR Valve 90460 3-26 Pressure Feedback Electronic EGR
Transducer 9J640 3-27 Relay Assembly EEC (Power) Time Delay 12A646 3-28 Diode
Assembly (Blade Type) 14A604 3-29 EEC Power Relay Location 12A646 3-30 Vacuum
Check Valve 12A197 3-31
Vacuum Control Valve 8A564 3-32 Vacuum Delay Valves 9E897 3-34 Vacuum Harness
Assembly-Nylon ; 9E498 3-36 Vacuum Regulator (2-Port) 9F490 3-38 Vacuum Regulator (3
& 4 Port) 9F490 3-39 Vacuum Reservoir. 9E453 3-40 Vacuum Restrictor 12A225 3-41
Vane Air Flow Meter 12B259 3-80

ALL RIGHTS RESERVED
Emission Related Components DESCRIPTION
SYMBOL
TITLE
Air Charge
Temperature Se~sor BASIC PART NO. 12A697 I
3·1
The sensor provides the Electronic Fuel Injection System with mixture (fuel and air) temperature
information. The ACT is used both as a density corrector· for airflow calculation and to proportion
the cold enrichment fuel flow. This sensor is similar in construction to the Engine Coolant
Temperature (ECT) sensor, except it is packaged to improve sensor response time.
The sensor is threaded into a.cylinder runn~r of the intake manifold and provides the fuel strategy
with mixture temperature inforr~ation. The sensor input is used as a density corrector for airflow
flow.
calculations and to proportion the cold enrichment f~el ..
4.9U5.0U5.8L TRUCK'
3.8L THUNDERBIRD/COUGAR
5.0L CAR APPLICATIONS
2.9L TRUCK APPLICATIONS
3.8L TAURUs/SABLE AND
CONTINENTAL AND
SUPERCHARGED
2.5L HSC CAR APPLICATIONS
(AT REAR OF INTAKE MANIFOLD)
3.0L CAR AND TRUCK
APPLICATIONS LOCATED IN THE
SIDE OF THROTTLE BODY
(UPPER INTAKE MANIFOLD)
1.9L ENGINE APPLICATIONS
IS LOCATED IN THE N1
INTAKE MANIFOLD
RUNNER
THREADED INTO INTAKE

MANIFOLD
A5783-H
Figure 1 Air Charge Temperature Sensor

(ACt)

ALL RIGHTS RESERVED
3·2 SYMBOL
TITLE
9E862
Air Cleaner Cold
BASIC PART NO.
I~CWM_
Weather Modulator
Emission Related Components
DESCRIPTION
A
cold weather modulator is sometimes used in addition to the air cleaner temperature control
(bimetal) sensor to control the inlet air temperature.
The cold weather modulator traps vacuum in the system, so the door will not switch to cold air when
the vacuum drops during acceleration. The cold weather modulator only works when the outside air
is cold, (refer to the chart below).
TO DUCT VALVE
VACUUM MOTOR
A5918-B
Figure 1 Cold Weather Modulator
Functional Check
A 54 kPa (16 in-Hg) vacuum applied to motor side of the modulator holds or leaks as follows:
COLOR TYPE HOLDS LEAKS Black N/O Below -6.7°C (20°F) Above 1.7°C (35°F) Blue N/O
Below 4.4°C (40°F) Above 12.8°C (55°F) Green N/O Below 10°C (50°F) Above 24.4°C (76°F) Yellow
N/C Above 18.3°C (65°F) Below 10°C (50°F)

ALL RIGHTS RESERVED
Emission Related Components SYMBOL
TITLE
BASIC PART NO. 9E607 I0 AICl
Air Cleaner Temperat~re SIMET
Sensor
3·3
DESCRIPTION
--
The sensor is installed in the cleaner tray or air cleaner line. and is subject to temperature
changes within the air cleaner. At a given increase in temperature, the sensor bleeds off vacuum,
permitting the vacuum motor to open the duct door to allow fresh air in while shutting off full heat.
BIMETAL SENSOR
VACUUM MOTOR
FRESH AIR
IN
TO VACUUM SOURCE
Figure 1 Air Clea!1er Temperature Sensor
Functional Check
At an ambient temperature of less than 24°C (75°F), the sensor will allow vacuum to close the
duct door to fresh air. The sensor will bleed off vacuum to allow the duct door to open and let in
fresh air at or above the following temperatures:
Brown 24°C (75°F)

Pink, black, or red 32.2°C H~O°F)
Blue,. yellow or green 40.6°C (105°F)

ALL RIGHTS RESERVED
3-4 Emission Related Components
TITLE BASIC PART NO.

SYMBOL
@
Air Cleaner '--
.....V_a_c_u_u_ DESCRIPTION
..I...- ----'
m_M_o_t_o_r
90604 I ~_~_L ___'
The air. cleaner vacuum motor operates the door within the duct. which allows either warm or cold
air to enter the engine. depending upon the temperature within the air cleaner.
_n
:({( 0
~II I
I•
A5921-8
Figure 1 Air Cleaner

Vacuum Motor
I
Functional Check
When a vacuum of 27 kPa (8 in-Hg) or greater is applied to the vacuum motor. the door stem should
pUll up and stay as long as vacuum is applied to the vacuum motor.

ALL RIGHTS RESERVED
Emission Related Components 3-5 !ressure L...-B_a_r_o_m_e_t_ri_C_A_b_S_O_lu_t_e

a-.-...9_F_4_7_9---'
I----n---
Sensor .
TITLE BASIC PART NO. SYMBOL·
DESCRIPTION
The SAP Sensor measures barometric pressure using a frequency. This gives the EGA
information on engine load.
It is used as a barometric sensor for altitude compensation, updating the EGA during Key On,
Engine Off and every wide-open throttle.
The EGA uses SAP for:
• Spark advance
• EGR flow
• Air/fuel ratio
)
VENT
A9387·A
Figure 1 Barometric Absolute Pressure (BAP)

Sensor
ALL RIGHTS RESERVED
3-6
TITLE BASIC PART NO. SYMBOL I~C_U_bo_n_c_~_~_~_r
I~~II~~-O-la~o~o-~-_O~0-'1
DESCRIPTION
The fuel vapors from the fuel tank and carburetor fuel bowl are stored in the carbon canister until
the vehicle is operated. at which time. the vapors will purge from the canister into the engine for
consumption. There are two canister sizes. 925 ml and 1400 ml carbon. Canisters
~APORPUAGE
f ~CONNECTOAS
are sometimes used in pairs when the vehicle has a large fuel tank or dual fuel tanks or dual
carburetor bowls.
TYPICAL - OTHER
CONFIGURATIONS
ARE AVAILABLE
OUST CAP
OUST CAP VAPOR/PURGE NIPPLE FOAM FILTER
VAPOR NIPPLE \
RETAINING \
\ SCREEN
AND
RETAINING SCREEN AND SPRING
"SONICALLY
1400 ml CARBON CANISTER WELDED COVER
Functional Check
925 ml CARBON CANISTER
Figure 1 Carbon Canisters A6836·F
• There are no moving parts and nothing to wear in the canister. • Check
for loose. missing. cracked or broken connections and parts. • There

should be no liquid in the canister.
NOTE: The Evaporative Emission System Is outlined In Section 7.

ALL RIGHTS RESERVED
TITLE BASIC PART NO. SYMBOL
_A_s_~_m_b_~~~~~~~~~9_H_4_95~ :
DESCRIPTION
The Valve and Transducer Assembly (9H495) which consists of a modified ported EGR valve and a
remote transducer, is used on selected engines (Figure 1). This· assembly operates the same as
the Integral Back Pressure Transducer EGR Valve (90448) and is diagnosed and serviced as an
assembly only. Valve function checks are the same as those for the Integral Back Pressure
Transducer EGR Valve.
When servicing the assembly or any related vacuum harness, it is important to ensure proper
orientation of the transducer. The nipple 'of the transducer attached to the metal tube from the EGR
valve base must point straight down after installation. This allows drainage of exhaust gas'
condensation that ·may accumulate.
FROM CARBURETOR
Figure 1 EGR Valve and Transducer

Assembly
NOTE: Refer to Section 6, Exhaust Gas Recirculation (EGR) System.:

ALL RIGHTS RESERVED
3-8
TITLE
EGR Valve-Electronic SYMBOL
9F483
I~
BASIC PART NO.
DESCRIPTION
The
Electronic EGR Valve (Figure 1) is required in EEC systems where EGR flow is controlled according
to computer demands by means of an EGR valve' position (EVP) sensor attached to the valve.
The valve is operated by a vacuum signal from the dual EGR Solenoid Valves (90474) or the
electronic vacuum regulator (9J459) which actuates the valve diaphragm.
As supply vacuum overcomes the spring load, the diaphragm is actuated. This lifts the pintle off its
seat allowing exhaust gas to recirculate (flow). The amount of flow is proportional to the pintle
position. The EVP sensor mounted on the valve sends an electrical signal of its position to the
Electronic Control Assembly (12A650).
The Electronic EGR Valve Assembly (9F483) is not serviceable. The EVP sensor (9G428) and EGR
valve (9H473) must be serviced separately.
EVP SENSOA~~-e--.......
9G428
EGR VALVE
AND SENSOR
ASSEMBLY
9F483
EGR VALVE
AND SENSOR
EXHAUST GAS INLET
BASE ENTRY TYPE A7192-e SIDE (EXTERNAL) ENTRY TYPE A71910C
ASSEMBLY
9F483
Figure 1 Electronic EGR Valves
NOTE: Verify vacuum routing per the vehicle decal before proceeding to EEC-IV Quick Test,
Section 14.

ALL RIGHTS RESERVED
TITLE
EGR Valve-Integral
Back Pressure
Transducer
BASIC PART NO. 9D448
Ie 3-9
SYMBOL
DESCRIPTION
The Integral Back Pressure Transducer EGA valve combines inputs of back pressure and EGA port
vacuum into one unit. The valve requires BOTH inputs to operate. The valve will not operate on
vacuum alone. The back pressure valve has two types; poppet and tapered pintle (Figure 1).
VACUUM CHAMBER
~S~~~~!~~~ f"""V-A-CU-U-M-B-'-L-EE-D-H-O-L-E--VE-N-T""""'S
VACUUM TO ATMOSPHERE
~=1~~UNTILCLOSED BY EXHAUST
BACK PRESSURE WORKING
ON INNER DIAPHRAGM
~~--__ OPEN TO
EXHAUST
BACK PRESSURE CHAMBER
ATMOSPHERIC
PRESSURE
ORIFICE
A7178-B
Figure 1 Integral Back Pressure Transducer EGR Valve (9D448)

.. NOTE:
Refer to Section 6, Exhaust Gas Recirculation (EGR) System.

ALL RIGHTS RESERVED
3-10
TITLE BASIC PART NO. SYMBOL _E_G_R_V_a_lv_e_-p_o_rt_e_d
~9_D__.4~7-5-11--@-E-GR---
DESCRIPTION
The Ported EGR Valve is operated by a vacuum signal (only) from the carburetor EGR port signal
which actuates the valve diaphragm. As the vacuum increases sufficiently to overcome the power
spring, the valve is opened allowing EGR flow. The amount of flow is dependent on the tapered pintle
or the poppet position which is a direct result of vacuum signal (Figure 1).
OUTLET
VALVE INLET
(VALVE HAS TAPERED PINTLE ALSO)
BASE ENTRY, POPPET TYPE SIDE ENTRY, TAPERED PINTlE A5978-C
Figure 1 Ported EGR Valve (90475)
NOTE: Refer to Section 6, Exhaust Gas Recirculation (EGR) System.

ALL RIGHTS RESERVED
Emission Related Components 3·11
L.-E_G_R_V_81_v_e_P_OS_i_ti_o_D_S_eD_S_O_r_--I-..-"_9_G_4_2_S-----lI~--~
-E-G-R
---I
DESCRIPTION
The EVP Sensor provides EEC System with a signal indicating position of "the EGR valve.
EVP SENSOR
(REMOVABLE)
TYPICAL
LOCATION
ASSEMBLY
A5932·D
Figure 1 EGR Valve Position (EVP) Sensor
NOTE: Refer to the EEC·IV Quick Test, Section 1~.

ALL RIGHTS RESERVED
3-12
TITLE BASIC PART NO. SYMBOL Electronic Control Assembly

12A650 I
L.-(F_B_C_/_C_FI_/E_F_I/_S_EF_I_> ""'-- _
DESCRIPTION
The center of the EEC-IV system is a microprocessor called the Electronic Control Assembly (ECA).
The ECA (Figure 1) receives data from a number of sensors and other electronic components
(switches, relays, etc.). The ECA contains a specific calibration for optimizing emissions, fuel
economy, and driveability. Based on information received and programmed into its memory, the
ECA generates output signals to control various relays, solenoids and other actuators.
The ECA in the EEC-IV system is a microprocessor like the one in the other EEC systems. One
significant difference is that this ECA has the calibration module located inside the ECA assembly,
unlike the EEC-III system.
The ECA is found in different locations, depending on the model. Refer to the chart for
locations.
PROCESSOR
ASSEMBLY - 12A650
Figure 1 Electronic Control Assembly (EGA)
Vehicle Location
RH dash panel behind kick panel

Mark VII/Continental, Thunderbird/Cougar, Mustang, XR4Ti,
Ranger/Bronco II
Tempo/Topaz, Escort Under instrument panel left of steering column Taurus/Sable Ahead of glove
compartment
LH side dash panel in passenger

Lincoln Town Car, Ford Crown Victoria/Mercury
compartment
Grand Marquis, Aerostar F-Series/Bronco LH dash panel behind kick panel
Econoline RH dash panel under heater blower motor

ALL RIGHTS RESERVED
TITLE BASIC PART NO. SYMBOL I~E_G_R_v_a_c_u_u_m_R_eg_U_I_a_to_r
__.-..I--_9_J_4_5_9_11--~-,-~ ---
DESCRIPTION
The· EGR Vacuum Regulator (EVR) is an electromagnetic device which controls vacuum output to
the EGR valve. The EVR replaces the EGR Solenoid Vacuum Vent Valve Assembly (9D474). An
electric current in the coil induces a magnetic field in the armature. The magnetic field pulls the disk
closed, closing the vent and increasing the vacuum level. The vacuum source is manifold vacuum.
As the duty cycle is increased, an increased vacuum signal goes to the EGR valve.
A9359-A
Figure 1 EGR Vacuum Regulator

ALL RIGHTS RESERVED
3-14
Engine Coolant Temperature Sensor
TITLE
DESCRIPTION Emission Related Components
SYMBOL
BASIC PART NO. 12A648

1_______
The Engine Coolant Temperature (ECT) Sensor (Figure 1) detects the temperature of engine
coolant and supplies the information to Electronic Control Assembly (ECA).
The ECT sensor is threaded into the heater outlet fitting or cooling passage on the engine. For
engine control applications, the ECT signal is used to modify ignition timing, EGR flow, and air to
fuel ratio as a function of engine coolant temperature. On electronic instrument cluster
applications, the ECT output is used to control a coolant temperature indicator.
3.8L TAURUS/SABLE
AND CONTINENTAL
-lA-----,~~'--_ 4.9U5.0U5.8L TRUCK

3.8L THUNDERBIRD/COUGAR/
SUPERCHARGED
(AT REAR OF CYLINDER HEAD)
(AT CENTER OF INTAKE MANIFOLD)
3.0L TRUCK INTAKE MANIFOLD
ADJACENT TO WATER OUTLET
(FRONT OF ENGINE) 3.0L CAR
REAR OF ENGINE
2.3L IS LOCATED IN THE WATER
OUTLET CONNECTOR AT
THE REAR OF THE
CYLINDER HEAD
THREADED INTO COOLING SYSTEM

A5937-G
Figure 1 Engine Coolant Temperature (ECT)

Sensor

ALL RIGHTS RESERVED
io-E_x_h_a_u_st_H_e_at_C_O_n_tr_o_I_V_a_lv_e_~9_A_4_2_7---,
I~.--():[J-· -.,---
DESCRIPTION
The purpose of the Exhaust Heat Control Valve (Figure 1) is to divert hot gases from the exhaust
manifold to the intake manifold riser pad. Heat is transferred from the exhaust gas to the riser pad,
which in turn heats the incoming fuel!air charge. There are two types currently available; the bimetal
spring type and the vacuum actuated type.
Bimetal Type
Refer to Section 5 for a complete description.
Vacuum Operated
The vacuum operated heat valve functions as follows:
• When the engine is started, the valve is closed by intake manifold vacuum acting on the
vacuum motor. .
• The valve will stay closed until one of two conditions occurs:
1. When the engine coolant temperature reaches a predetermined value, the vacuum supply to
the heat valve is shut off by a temperature sensing vacuum switch and the heat valve opens.
2. When the engine speed/load condition causes a drop in intake manifold vacuum below a
specific value, the heat valve opens.
A691008
Figure 1 Exhaust Heat Control Valve
Functional Check
Apply 33.77-67.54 kPa (10-15 in-Hg) vacuum to the vacuum motor using a hand vacuum pump,
Rotunda 021-00014 or equivalent, and trap for 60 seconds. The valve must close and not leak more
than 6.75 kPa (2 in-Hg) and open when the vacuum is released. If it does not operate in this
manner, replace the valve.

ALL RIGHTS RESERVED
1--
TITLE
Feedback Carburetor
Actuator Motor
DESCRIPTION
BASIC PART NO. 9C908
SYMBOL
The Actuator (Figure 1) is part of the Carburetor Feedback Control System, used on 7200 model
carburetors. The actuator is threaded into the carburetor body and its actuator shaft moves a fuel
metering pintle valve to produce a richer or leaner air/fuel mixture at the carburetor. In response to
an electronic signal coming from the Exhaust Gas Oxygen (EGO) sensor and conditioned by the
EEC (or MCU) System, the actuator shaft moves in and out.
PINTLE THREADED INTO
~URnoo
A6839-8
Figure 1 Feedback Carburetor Actuator Motor
Functional Check
1. Remove the FBCA motor from carburetor. Connect wiring harness to FBCA motor; turn ignition
switch to RUN to extend shaft. Turn ignition switch to OFF. If FBCA shaft does not extend,
replace FBCA motor and retest.
2. Push FBCA motor shaft back in by hand. If shaft will not push in, replace FBCA motor and
retest.
3. Remove and clean pintle valve, spring and carburetor passage with choke cleaner and a small
brush.
4. Reinstall pintle, spring a FBCA motor. Tighten FBCA motor to 8-10 Ib-ft. 5.
Retest according to appropriate Quick Test. Refer to Section 14.
6. Check/reset curb idle, if necessary.
NOTE: FBCA motor Is partly diagnosed as a part of the 5.8l MCU electronic system. Refer to the
5.8l FBC Police and Canadian Trailer Tow MCU Diagnosis Manual.
ALL RIGHTS RESERVED
Emission Related Components SYMBOL
TITLE'
BASIC PART NO. 9F474 VREST FLTR
Filter Assembly
Vacuum Vent
3-17
DESCRIPTION
--
The Vacuum Vent Filter (Figure .1) is used to filter air being drawn into the vacuum system when a
vacuum bleed is required. It is a nylon tee with a restrictor and an open cell foam on one leg.
RESTRICT';" { BLUE .015" (E~E-9F4~4-AA)

. _ RED _.... (E3EE-9F<74-8A)
. . OPEN CELL FOAM .
A7117-8
Figure 1 Vacuum Vent Filter Assembly
NOTE: If the filter appears to be dirty, wash ·it in an appropriate solvent.

ALL RIGHTS RESERVED
3·18
Emission Related Components TITLE BASIC PART NO. SYMBOL
I_F_u_e_I-_v_a_p_o_r_S_e_p_a_ra_t_o_r -""--_9_C_3_6_9--l11 ~_SA_.FA
______'
DESCRIPTION
The Fuel-Vapor Separator (Figure 1) is used in vacuum systems to prevent fuel migration to a vacuum
operated device.
WHlTE--••
.
l.
J -.
~-:
. -.-
..
e-
~t:::=:;-il
TO VACUUM DELAY
VALVE OR
DISTRIBUTOR
(HIGH SIDE)
AS285-C
Figure 1 Fuel-Vapor Separator
Functional Check
NOTE: Separator requires positive orientation to ensure that any fuel collected will drain
back to the carburetor.
If separator becomes cracked or clogged, replace the separator.

ALL RIGHTS RESERVED

3-19
Heated Exhaust Gas Oxygen

Sensor
9F472
DESCRIPTION
The 'Heated Exhaust Gas Oxygen Sensor (HEGO) (Figure 1) supplies the ECA with a signal which
indicates a rich or lean condition during. engine operation.
THREADED INTO LH
~{L==;;=~--EXHAUST PIPE ON
LOCATIONS
3.8l
TAURUS/SABLE
AND
CONTINENTAL
TYPICAL
THREADED INTO EXHAUST MANIFOLD ON 2.3l, 3.8L SUPERCHARGED,
5.0L SEFI (BOTH SIDES)
THREADED INTO CROSSOVER BOSS TUBULAR RUNNER ON 1.9L EFI
THREADED INTO EXHAUST MANIFOLD ON 1.9L CAR. 49U5.0U58L
TRUCK -
THREADED INTO CENTER REAR OF EXHAUST MANIFOLD ON 2.3L HSCI
2.5L HSC
THREADED·INTO V-PIPE JUNCTURE OF CATALYST INLET ON 3.0l EFI
A7752-E
Figure 1 Typical Heated Exhaust Gas

Oxygen Sensor (HEGO)
ALL RIGHTS RESERVED
3·20 SYMBOL
TITLE
Ignition Barometric
Pressure Switch
1---
DESCRIPTION

The Ignition Barometric Pressure Switch (Figure 1) is used to control spark timing and/or other
electrical devices in response to changes in barometric pressure (Le., altitude). When controlling
spark timing, the ignition module (12A244) is made to vary the spark timing by an amount determined
by calibration resistors in the switch assembly. In normal operation, spark timing is increased for
vehicle operation above the switching point (increasing altitude) and retarded for vehicle operation
below the switching point (decreasing altitude). When controlling other electrical devices, only On/Off
control is provided; with On (switch closed) above the switching point and Off (switch open) below the
switching point. Some switch assemblies control both spark timing and another device (dual switch
assembly) and other switch assemblies control only one or the other (single switch assembly).
A7757-8
Figure 1 Ignition Barometric Pressure Switch
• Dual switch assembly shown.
• Attaching brackets vary according to installation requirements.
• Connectors may vary.
Resistance (Ohms) Resistance (Ohms)

Part Number Below 3,000 Feet Above 4,600 Feet E2AE-12A243-AA Greater than 200,000 Less
than 1 E43E-12A243-AA 2,820-2,920 1,750-1,850 E4DE-12A243-AB 2,560·2,660 1,960-2,060
E4EE-12A243-AA Greater than 200,000 Less than 1
Either resistance value is correct if altitude is between 3,000 and 4,600 feet.

ALL RIGHTS RESERVED
Emission Related Components TITLE
Emission Maintenance Warning
(EMW) Module
DESCRIPTION
·1------ BASIC
PART NO. SYMBOL

·128514
The Emission Maintenance Warning (EMW) Module (Figure 1) is mounted in the instrument panel.
The EMW function activates the Check Engine Light {CELl .on the instrument panel at 2,000 hours
(60,000 miles). The light indicates the emission maintenance should be performed.
3 PIN MODULE
...----
Testing. APPLICATIONS:
'" U0
A11623·A
Figure 1 Emission Maintenance Warning (EMWj
Module NOTE: Refer to Section 12 for Pinpoint
E5TF·128514-AA
ENGINE 6.1 L, 7.0L
VEHICLE
F, B, Series Heavy Truck
MODULE EMW
PART NUMBER
ALL RIGHTS RESERVED
3-22
128577
TITLE
Integral Relay Control Module

1------ BASIC
DESCRIPTION PART NO. SYMBOL

The Integral Relay Control Module (IRCM) (Figure 1) interfaces with the EEC-IV to provide control
of the cooling fan, A/C clutch and the fuel pump. The module also incorporates the EEC power
relay to provide power to the EEC-IV system.
The module is designed specifically for underhood application. The limits of operation are as
follows:
Operating Temperature - 30°C to 100°C Storage Temperature - 40°C to

125°C Operating Voltage 7 to 17 volts
o
o
A9861-B
Figure 1 Integral Relay Control Module
8racket and
Powertraln Model Control Assembly
Application Controller -128577- -128581- Vehicle Location
2.5L HSC A/T
Taurus/Sable E9DF-BB E9DF-BB Radiator Support
3.0L A/T
Taurus/Sable E9DF-DB E9DF-DB Radiator Support 3.0L SHO E9DF-AB E9DF-DB Radiator Support
3.8L Supercharged E9SF-AB E9SF-AB Radiator Support
3.8L A/T
Taurus/Sable E9DF-EB E9DF-EB Radiator Support

ALL RIGHTS RESERVED
TITLE
IKnock Sensor DESCRIPTION

12A699 11---'
BASIC PART NO. SYMBOL
3-23
The Knock Sensor (Figure 1) is a piezoelectric accelerometer with the sensor designed to
resonate at approximately the same frequency as the engine knock frequency. The sensor uses
the resonant frequency to mechanically amplify the vibrations. This method allows relatively large
signals to be achieved without electrical amplification and with small package size.
The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal
diaphragm. Electrical connections are made through a two pin integral connector.
A7188-8
Figure 1 Knock Sensor
Part Resonant
Number Frequency Color Planned Usage Thread E3AF-AA 5.4K Black 5.8L Ford/Mercury
1/2-13 UNC E6TF-AA 6.45K Black 2.9L Ranger/Bronco II M10 X 1.5mm-6g E5TF-BA 6.0K Black
3.0L Taurus/Sable, Aerostar M10 X 1.5mm-6g E9TF-AA 9.5K White 4.9L 5.0L/5.8L
Econoline/Bronco M12 X 1.5mm-6g E9SF-AA 5.7K Gray 3.8L Supercharged T-Bird/Cougar M10 X
1.5mm-6g E3SF-AA 5.7K Gray 2.3L OHC Mustang - M12 X 1.5mm-6g E5TF-AA 6.0K Black 3.0L
SHO Taurus M10 X 1.5mm-6g

ALL RIGHTS RESERVED
3·24 Emission Related Components
L..-M_aO_i_f_OI_d_A_b_S_O_lu_t_e_p_r_e_s_s_u_re_--,--_9_F_4_7_9----1
n
Ir----- ---- _Sensor . Y
DESCRIPTION
The MAP sensor (Figure 1) measures manifold vacuum using a frequency. This gives the EGA
information on engine load.
It is used as a barometric sensor for altitude compensation, updating the EGA during Key On,
Engine Off and every wide-open throttle.
The EGA uses MAP for:
• Spark advance
• EGR flow
• Air/fuel ratio
MAP SENSOR
INTAKE
MANIFOLD
VENT
A9384-A
Figure 1 Manifold Absolute Pressure Sensor

ALL RIGHTS RESERVED
Emission .Related Components
TITLE
128579
IMass Air Flow Sensor

11-----------
DESCRIPTION
BASIC PART NO. SYMBOL
3·25
The sensor directly measures the mass of the air flowing into the engine. The sensor output is a D.C.
(Analog) signal ranging from about 0.5 volts to 5.0 volts used by the ECA to calculate the injector
pulse width for stoichiometry. The sensing element" is a thin platinum wire wound on a ceramic bobbin
and coated with glass. This "hot wire" is maintained at 200°C above ambient temperature'as measu~ed by
a constant "cold wire".
MASS AIR FLOW

SENSOR
HOT WIRE
SENSOR
COLD WIRE
SENSOR
.......
AIR
. FLOW
A9389-B
Figure 1 Mass Airflow Sensor Assembly

ALL RIGHTS RESERVED
3·26 Emission
Related
Components
TITLE
BASIC PART NO. SYMBOL Pressure Feedback Electronic Ir----~------,
",-E_G_R_V_al_v_e ---'-_9.D_4_6_0----'
DESCRIPTION
The Pressure Feedback Electronic (PFE) EGR valve is a conventional ported EGR valve. The valve
is used in conjunction with a pressure transducer (9J460) which supplies pressure feedback to the
EEC-IV processor. The EGR flow rate is proportional to the pressure drop across a remotely
located sharp edged orifice.
.\9362·.\
Figure 1 Typical Pressure Feedback

Electronic EGR Valve

ALL RIGHTS RESERVED
Emission Related Components 3-27

p_r_e_s_su_r_e_F_ee_d_b_a_c_k_E_le_c_tr_o_D_i_C __9_J_4_6_0---,
I~--- m P
----
EF EGR Transducer o-W .....
DESCRIPTION
The Pressure Feedback Electronic (PFE) EGR transducer converts a varying exhaust pressure
flow. ,',
signal into a proportional analog voltage wh~ch is digitized by the EEC-IV processor. The EEC IV
processor uses the signal received from the PFE transducer to complete the optimum EGR
Af363.A
Figure 1 Pressure Feedback Electronic EGR

Transducer

ALL RIGHTS RESERVED
3-28
TITLE
DESCRIPTION
SYMBOL
Relay Assembly EEC
(Power) EEC (Power)
Time Delay BASIC PART NO. 12A646 1_
There are three types of relays: the STO Power Relay, the Time Delay Power (TOP) Relay and ISO
Power Relay. The TOP has a delay of 5 to 10 seconds and is used with an actuator assembly throttle
control. STO Power Relay and TOP relay types consist of a movable contact in the normally open
position (SPST). Where as ISO Power Relay is SPOT. All STO power relays (except time delay) have
the same design with a different bracket attachment. ISO Power Relay is the same as fuel pump and
WAC Relays and have different base part numbers.
Function
EEC power relays are in parallel with the ignition switch and provides power to the EEC, STO and
Time Oelay module. TOP relays also provide reverse battery protection with internal diode and
increased load handling to improve ignition switch reliability, where as ISO Power Relay is connected
in series with separate stand alone diode, which provides reverse battery protection.
Time Delay Power STD .Power Relay ISO Power Relay

Specifications Relay Pull-in Voltage 9V DC
max 8.5V DC max 5-9V DC max Millivolt Drop 15 my/amp 10 my/amp 5 my/amp Coil Current 220 rna @
14.4V DC 220 rna @ 12.8V DC 220 rna @ 12.8V DC Drop-out Voltage 4.5V DC 1-4V DC 1.2V-4V DC
87 t:=::::::l
1. KEY POWER (RUN AND CRANK)

D~D
2. TO BATIERY NEG. POST
3. V POWER TO EEC MODULE
4. TO BATIERY POS. POST

86 0
30
85
ISO RELAY
Figure 1 Relay Assembly

EEC POWER (TIME OELAY) RELAY
1. TO BATIERY NEG. POST 87. V POWER TO EEC MODULE
2. KEY POWER (RUN AND CRANK) 30. BATIERY POSITIVE POST
86. TO DIODE CATHODE

3. V POWER TO EEC MODULE
85. BATIERY NEGATIVE POST
4. TO BATIERY POS. POST
87A. NOT CONNECTED
An58~E
STO EEC POWER RELAY

ALL RIGHTS RESERVED
Emission Related. Components 3-29
TITLE BASIC PART NO. SYMBOL __D_i_O_de_A_s_se_m_bl_Y --&....-1_4_A_6_0_4---'
1------kJ------ (Blade Type) .

DESCRIPTION
The Device is 1 amp, 400V min. glass passivated metalurgically brazed, low leakage rectifier
diode.
Function
in series with ,EEC power relay coil and provides reverse battery protection.
The diode' is · - ..
Specifications
Forward Volt~ge V
• F O.BOV @ IF = 10ma; 1.15V @ IF = 1.0 A
• -Reverse Current "-.I R
100ma-@ V == 400V; 20ma @ V = 10V
R R
. • Reverse Breakdown Voltage
VR 400 @ IR = 10.0nA
..
OP
. ~lOAELAYCOIL VIEW
BOTTOM 0 KEY PWA (RUN

DIODE
A13533-A
&CRANK) V~W .
Figure 1 Diode Assy
.. 'Part Number System Locat,lon(s) Location(s) • FOVF-14AG04-AA Ford/Mercury 5.0L SFI Engine
Compartment Relay Box, " Lincoln -Town Car 5.gL SFI ~ttached to vacuum reservoir. -.

ALL RIGHTS RESERVED
3-30
TITLE
EEC Power
BASIC PART NO. 12A646 I~-
Relay Locations
Emis"sion Related Components
SYMBOL
EEC POWER
RELAY
LOCATION
AND
APPLICATIONS
PART NUMBER AND RELAY SYSTEM APPLICATION(S) LOCATION(S)

TYPE (Power or Time Delay)
• E6EF-12A646-B1A/B2A Escort/Lynx EXP 1.9L EFI Passenger compartment under Power Relay (Std.) dash on
m0dule bracket.
• E3UF-12A646-B1A/B2A Mustang 2.3L OHC/5.0L SFI Passenger compartment on module Power Relay (Std.)
bracke! in right cowl area.
• E3EF-12A646-B1A/B2A Tempo/Topaz 2.3L HSC EFI Passenger compartment under Power Relay (Std.) 2.3L HO
dash behind glove compartment
• E3AF-12A646-B1A/B2A Thunderbird/Cougar 3.8L EFI Engine compartment fuse/relay Power Relay (Std.) box
Ford/Mercury 5.0L SFI Engine compartment doghouse.
Lincoln Town Car 5.0L SFI
Mark VIII 5.0L SFI
Ranger/Bronco II 2.3L/2.9L
Aerostar 3.0L EFI
Econo/F-Series/Bronco
4.9L/5.0L/5.8L
F-Series/Bronco 7.0L
Econoline/F-Series/Heavy
Truck 7.5L/7.3L
• E7EF-12A646-A1A Power Escort/Lynx/EXP 1.9L CFI Passe.nger compartment under Relay (Time Delay) dash
on module bracket.
• FOVB-9345-AA Power Relay Ford/Mercury 5.0L SFI Engine compartment relay box; (ISO) Lincoln Town Car
5.0L SFI attached to vacuum reservoir.

ALL RIGHTS RESERVED
Emission Related Components 3-31 TITLE BASIC PART NO. SYMBOL
I_v_a_c_uu_m_·_"C_h_e_C_k_v_a_l_ve_" ....Io..-l_2_A_l_9_7
__~_vc_K-_v _
11""'--
DESCRIPTION
A Vacuum Check Valve (Figure 1) blocks airflow in one direction. It allows free airflow in the other
direction. The check side of this valve will hold the highest vacuum seen on the vacuum side. If not,
replace it.
----DIRECTION OF FREE AIRFLOW
~*~ VACUUM SIDE
- BLACK
AIOI7oC
Figure 1 Vacuum Check Valve
Functional Check
Apply 54 kPa (16 in-Hg) vacuum to "check" side of valve and trap. If vacuum remains above 50.6
kPa (15 in-Hg) for 10 seconds, the valve is acceptable.

ALL RIGHTS RESERVED

Control Valve 9D473
TITLE 9F454 ogv vCv
12A091
Vacuum DESCRIPTION SYMBOL 2·PORT

3PORT '01]
The VCV controls vacuum to other emission devices during engine warm-up: the 2-port types simply
open when engine coolant reaches their pre-determined calibration temperatures; the 4-port types
open likewise, since they are nothing more than two 2-port types in one housing; and the 3-port types
switch the vacuum source to the center port from the top or the bottom ports. Electrical switches can
be either open or closed until the VCV is fully cycled. Most VCV's respond to a sensing bulb
immersed in engine coolant by utilizing a wax pellet principle. The only exception is the 9F454 which
operates on a bimetal principle. Vacuum is usually sourced as illustrated in Figure 1.
r--~- A
8AS64
OR
12A091
0 A, EGR VALVE
A
M 8, VACUUM
SOURCE
A
A CONNECTS TO VACUUM DEVICE
B CONNECTS TO VACUUM SOURCE
Figure 1 2-, 3-, and 4-Port Vacuum Valves

8
B
EA B
2 CARBON CANISTER
9F4S4
PURGE VALVE
8
S 2 VACUUM SOURCE A6064-D
90473

ALL RIGHTS RESERVED

3..33
8A564
Vacuum Control 9D473

9F454
12A091
Valve Functional Vacuum Check
1. With a cold engine, passag~. A to B should be closed and passage A to C should be open.
2. With engine" at normal operating temperature, the VCV should be open between A an'd B and
closed betWeen A and C. '. . " .'" For the 4-port valve, check A 1 to B1 and A 2 to B2 separately.
3. If these conditions are not met, replace the VCV Valve.
Electrical Vacuum· S'witch
The electrical vacuum switch (Figure 2) could be either opened or closed at room temperature. It will
be reversed (opened to closed or closed to opened) with the engine at full operating, temperature.
C (SPARK PORT VACUUM)
--;:? NOAMALLY OPEN

/ A COMMON PORT
"-.. (DISTRIBUTOR)
NORMALLY CLOSED
B (INTAKE MANIFOLD) .
A615O-C
Figure 2 Electrical Vacuum Switch - 8A564
Functional Electrical Check
1. While the engine is cold,' measure the continuity across the switch. Compare with
specifications.
2. Warm the engine to normal operating temperature.
3. Measure the continuity across the switch. Compare '!"lith specifications. 4.
The vacuum function is checked as previously described.

ALL RIGHTS RESERVED

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APpropriate service methods and proper repair procedures are essential

Notes, cautions, and warnings

The descriptions and

Copyright © 1989, Ford Motor Company

DAVE GRAHAM INC. 2012

NAAO car & Truck Models

Body, Chassis, Electrical,

Body, Chassis, "Electrical,

Body, Chassis, Electrical,

Body, Chassis, Electrical,

DAVE GRAHAM INC. 2012

Aerostar. Ranger, Bronco II (2 Of 2)

Econonne, F-Serles, Bronco NAAO car and Truck Models

Medium/Heavy Duty B-, C·, F-600 content

Body/ Chassis/ Electrical!Engine pre-Delivery (Volume F)

Engine/ Emissions Diagnosis

DAVE GRAHAM INC. 2012

New or Modified Applications

Modified Manual sections

~ew or Modified Pinpoint Tests

DAVE GRAHAM INC. 2012

section Title section Number How to use This Manual .1

How TO use This Manual

• Refer to Section 1, Emission Control

DAVE GRAHAM INC. 2012

1990 EngineI Emissions Diagnosis

t----------.~--- ------ Manuals Repair List of Probable

I Verify Repair 1 Supplement-Passenger

DAVE GRAHAM INC. 2012

BATT: Battery Back Pressure Variable Transducer.

DAVE GRAHAM INC. 2012

"CHECK ENGINE" OR "SERVICE ENGINE DV: Delay Valve.

CLUTCH: Clutch engagement switch or its E40D: Electronic 4-Speed Overdrive

COC: Conventional Oxidation Catalyst. ECA: Electronic Control Assembly.

DCl: Data Communications Link. EEGR: Electronic EGR Valve (Sonic).

DAVE GRAHAM INC. 2012

FBC: Feedback Carburetor. An MCU GND or GRND: A common ground circuit

FTO: Filtered Tach Output. An output from

DAVE GRAHAM INC. 2012

IBP: Integral Back Pressure.

IRCM: Integrated Relay Control Module. MIL: (Malfunction Indicator Light) An

KOEO: Key On Engine Off Self-Test. OASIS: On-line Automobile Service

DAVE GRAHAM INC. 2012

PFE: Pressure Feedback EGR sensor or its

PIP: Profile Ignition Pickup. A "hall effect"

PROCESSOR: EEC-IV Electronic Control

PSPS: Power Steering Pressure Switch. An

PULSE AIR SYSTEM: Part of the emission

PVS: Ported Vacuum Switch..

PWR GND: Power Ground. '

QUICK TEST: A functional diagnostic test of

RECORDER: An optional EEC-IV test device

RELAY: A switching device operated by a

RELIEF VALVE: A pressure limiting valve

DAVE GRAHAM INC. 2012

TIV: Thermactor Idle Vacuum Valve. VR/S: Vacuum Regulator/Solenoid.

TP: Throttle Position sensor or its signal

DAVE GRAHAM INC. 2012

Vehicle Emission Control Information Decal Location 1-2

Emission Control Application:

Light Truck 1-4

Medium/Heavy Truck 1-5

DAVE GRAHAM INC. 2012

Vehicle Emission Control Information Decal