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Distributor & EGR System Modification: Service Kit (91-16-7)

Publication date: 1991-08-07
Reference number: 91-16-7

DISTRIBUTOR & EGR SYSTEM MODIFICATION: SERVICE KIT

DISTRIBUTOR & EGR SYSTEM MODIFICATION: SERVICE KIT

TECHNICAL SERVICE BULLETIN

Reference Number(s): 91-16-7, Date of Issue:  August 7, 1991
Superceded Bulletin(s): 88-10-8 , Date of Issue:  May 11, 1988, 89-25-5 , Date of Issue:  December 13, 1989, 90-2-3 , Date of Issue:  January 17, 1990

CONDITIONS

HESITATION - 1.3L - NOT ENOUGH DISTRIBUTOR ADVANCE - CARBURETED ENGINES BUILT BEFORE 11/15/88

SURGE - 1.3L - NOT ENOUGH DISTRIBUTOR ADVANCE - CARBURETED ENGINES BUILT BEFORE 11/11/88

APPLICATION

Model(s): FORD: 1988-89 FESTIVA

Group: Body

Bulletin No.: 91-16-7

Date: August 7, 1991

Symptom: Hesitation/Surge

SERVICE INFORMATION

This bulletin supersedes the following Technical Service Bulletins:

TSB 88-10-8 dated May 11, 1988

TSB 89-25-5 dated December 13, 1989

TSB 90-2-3 dated January 17, 1990

ISSUE

Hesitation during acceleration or a surge while driving at a steady speed may be caused by insufficient distributor spark advance, excessive EGR flow and fuel getting into the distributor vacuum advance manifold port.

ACTION

Modify the distributor and EGR system by installing the applicable special service kits identified in the parts block. Refer to the service procedure that applies to the vehicle application. Check to see if the procedure outlined in TSB 88-10-8 has been done for 1988 vehicles. FOR THOSE VEHICLES THAT HAVE BEEN RETURNED FOR SERVICE WITH THE EGR NON-FUNCTIONAL AFTER APPLICATION OF A PRIOR VERSION OF THIS TSB (TSB'S 88-10-8, 89-25-5, 90-2-3), UPDATE THE MODIFICATION DECAL WITH THE FOLLOWING NOTE: PER TSB 91-16-7 THE EGR WILL NO LONGER FUNCTION AND EGR GAS WILL NOT FLOW. 

NOTE: California vehicles have an EGR valve position (EVP) sensor mounted to the top of the EGR valve and the Vehicle Emission Certification Information Label is noted for California Emissions Certification.
NOTE: Verify the build date of the vehicle by referring to the build date stamped on the Vehicle Certification Label on the driver's side "B" pillar face. All 1988 and 1989 carbureted units built before November 15, 1988 are affected.

1988 - 49 STATE AND CALIFORNIA VEHICLES WITH TSB 88-10-8 COMPLETED

Inspect the vehicle and review the service file to determine if TSB 88-10-8 has been done to the car. Look for the following:

If any or all of these indicators are found, the car has had TSB 88-10-8 done and needs only a new distributor vacuum advance and a fuel migration kit installed.

  1. Obtain special service kit (E9PZ-12370-A) for a 49 state calibration vehicle or (E9PZ-12370-B) for a California vehicle. Obtain a distributor vacuum advance unit (E9BZ-12370-C).
  2. Open kit (E9PZ-12370-A) or (E9PZ-12370-B) and remove the contents.
    1. Determine if the vehicle is a 49 state or California calibration by referring to the information covered in the note above.
    2. Look at the part number in the lower left corner of the new VECI label in the kit. (The 1988 49 state VECI label is identified by a DX03 code and the 1988 California VECI label is identified by a DX07 code.)
    3. Throw away the extra label. (1989 49 state -DX01G) (1989 California - DX08)
  3. Clean the surface of the existing VECI label with alcohol. Install the new VECI label over the existing label. Use a squeegee to work out any bubbles and make sure there is adequate adhesion to the old label.
  4. Remove the distributor vacuum advance manifold port hose from the intake manifold port. Cap the open intake manifold port with the vacuum cap provided in the special service kit. See Figure 1.
  5. Cut the manifold vacuum hose that goes to the map sensor just to the carburetor side of the routing bracket as shown in Fig 1 .
  6. Insert the "T" provided in the kit into the vacuum hose and install the distributor vacuum advance hose, removed from the intake manifold port in step 5, to the open port on "T".
  7. Remove and throw away the distributor vacuum advance.
  8. Install the new distributor vacuum advance (E9BZ-12370-C).
  9. Remove and plug the vacuum advance hoses at the distributor vacuum advance. Set the initial ignition timing to 2° BTDC.
  10. Unplug and reconnect the distributor vacuum advance hoses.
Fig 1: Map Sensor Vacuum Line Re-work
G93I50300

Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. See Fig 2 .

Fig 2: Authorized Modifications Label (1 of 3)
G93J50301

1988 - 49 STATE CALIBRATED VEHICLES

  1. Obtain special service kits E8PZ-12370-A and E9PZ-12370-A.
  2. Open kit E8PZ-12370-A and remove the contents. Throw the VECI label and instruction sheet away. The number in the lower left corner of the VECI label is DX02.
  3. Remove and throw away the green and black EGR delay valve from the EGR valve vacuum hose. See Fig 3 .
  4. Install the new red and black EGR delay valve included in the kit. Install the red side toward the EGR valve and the black side toward the No. 1 EGR solenoid.
  5. Install the new pulse air orifice, included in the kit in the upstream pulse air hose that runs from the air cleaner to the exhaust manifold. See Fig 4 .
  6. Remove and throw away the distributor vacuum advance.
  7. Install the new distributor vacuum advance included in the kit.
  8. Open kit E9PZ-12370-A and remove the contents. The VECI label to be used on this vehicle has the ID number DX03 (1988 - 49 State) in the lower left corner. The other VECI label (DXO1G) should be discarded.
  9. Clean the surface of the existing VECI label with alcohol. Install the new VECI label over the existing label. Use a squeegee to work out any bubbles and make sure there is adequate adhesion to the old label.
  10. Remove the distributor vacuum advance manifold port hose from the intake manifold port. Cap the open intake manifold port with the vacuum cap provided in the special service kit. See Fig 1 .
  11. Cut the manifold vacuum hose that goes to the map sensor just to the carburetor side of the routing bracket as shown in Fig 1 .
  12. Insert the "T" provided in the kit into the vacuum hose and install the distributor vacuum advance hose, removed from the intake manifold port in step 10, to the open port on the "T".
  13. Remove and plug the vacuum advance hoses at the distributor vacuum advance. Set the initial ignition timing to 2° BTDC.
  14. Unplug and reconnect the distributor vacuum advance hoses.
  15. Check and. if necessary, reset the curb idle and fast idle speeds.

Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. See Fig 5 .

Fig 3: EGR Vacuum Delay Valve Location
G93A50302

1989 - 49 STATE CALIBRATED VEHICLES

  1. Obtain special service kits E8PZ-12370-A and E9PZ-12370-A.
  2. Open kit E8PZ-12370-A and remove the contents. Throw away the VECI label and instruction sheet. The number in the lower left corner of the VECI label is DX02.
  3. Remove and throw away the green and black EGR delay valve from the EGR valve vacuum hose. See Fig 3 .
  4. Install the new red and black EGR delay valve included in the kit. Install the red side toward the EGR valve and the black side toward the No. 1 EGR solenoid.
  5. Install the new pulse air orifice, included in the kit, in the upstream pulse air hosg that runs from the air cleaner to the exhaust manifold. See Fig 4 .
  6. Remove and throw away the distributor vacuum advance.
  7. Install the new distributor vacuum advance included in the kit.
  8. Open kit E9PZ-12370-A and remove the contents. The VECI label to be used on this vehicle has the ID number DXO1G (1989 49 State) in the lower left corner. The other VECI label (DX03) and all other parts included in the kit should be discarded.
  9. Clean the surface of the existing VECI label with alcohol. Install the new VECI label over the existing label. Use a squeegee to work out any bubbles and make sure there is adequate adhesion to the old label.
  10. Remove and plug the vacuum advance hoses at the distributor vacuum advance. Set the initial ignition timing to 2° BTDC.
  11. Unplug and reconnect the distributor vacuum advance hoses.
  12. Check and, if necessary, re-set the curb idle and fast idle speeds.

Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. See Fig 5 .

Fig 4: Pulse Air Orifice Installation
G93B50303
Fig 5: Authorized Modifications Label (2 of 3)
G93C50304

1988 - CALIFORNIA CALIBRATED VEHICLES

  1. Obtain special service kits E8PZ-12370-B and E9PZ-12370-B.
  2. Open kit E8PZ-12370-B and remove the contents. Throw the VECI label and instruction sheet away. The number in the lower left corner of the VECI label is DX05.
  3. Remove the EGR valve and throw away the steel gasket between the EGR valve and the intake manifold.
  4. Install the new blind EGR gasket included in the special service kit between the EGR valve and the intake manifold.
  5. Remove and throw away the vacuum hoses and the green and black EGR delay valve between the EGR valve and the No.1 EGR solenoid. See Fig 3 .
  6. Install one of the vacuum caps included in the kit on the No. 1 EGR solenoid nipple.
  7. Remove the carburetor vacuum port hose from the orange No. 1 port of the EGR vacuum modulator. Connect the hose removed from the modulator to the EGR valve nipple. See Fig 3 .
  8. Install the second vacuum cap included in the kit on the EGR vacuum modulator orange No. 1 port nipple.
  9. Remove and throw away the distributor vacuum Install the new distributor vacuum advance.
  10. Install the new distributor vacuum advance included in the kit.
  11. Open kit E9PZ-12370-B and remove the contents. The VECI label to be used on this vehicle has the ID number DX07 (1988 California) in the lower left corner. The other VECI label (DX08) included in the kit should be discarded.
  12. Clean the surface of the existing VECI label with alcohol. Install the new VECI label over the existing label. Use a squeegee to work out any bubbles and make sure there is adequate adhesion to the old label.
  13. Remove the distributor vacuum advance manifold port hose from the intake manifold port. Cap the open intake manifold port with the vacuum cap provided in the special service kit. See Figure 1.
  14. Cut the manifold vacuum hose that goes to the map sensor just to the carburetor side of the routing bracket as shown in Fig 1 .
  15. Insert the "T" provided in the kit into the vacuum hose and install the distributor vacuum advance hose, removed from the intake manifold port in step 13, to the open port on the "T".
  16. Remove and plug the vacuum advance hoses at the distributor vacuum advance. Set the initial ignition timing to 2° BTDC.
  17. Unplug and reconnect the distributor vacuum advance hoses.
  18. Check and, if necessary, re-set the curb idle and fast idle speeds.

Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. See Fig 6 .

Fig 6: Authorized Modifications Label (3 of 3)
G93D50305

1989 - CALIFORNIA CALIBRATED VEHICLES

  1. Obtain special service kits E8PZ-12370-B and E9PZ-12370-B.
  2. Open kit E8PZ-12370-B and remove the contents. Throw away the VECI label and instruction sheet. The number in the lower left corner of the VECI label is DX05.
  3. Remove the EGR valve and throw away the steel gasket between the EGR valve and the intake manifold.
  4. Install the new blind EGR gasket included in the special service kit between the EGR valve and the intake manifold.
  5. Remove and throw away the vacuum hoses and the green and black EGR delay valve between the EGR valve and No. 1 EGR solenoid. See Fig 3 .
  6. Install one of the vacuum caps included in the kit on the No. 1 EGR solenoid nipple.
  7. Remove the carburetor vacuum port hose from the orange No. 1 port of the EGR vacuum modulator. Connect the hose removed from the modulator to the EGR valve nipple. See Fig 3 .
  8. Install the second vacuum cap included in the kit on the EGR vacuum modulator orange No. 1 port nipple.
  9. Remove and throw away the distributor vacuum 10 Install the new distributor vacuum advance.
  10. Install the new distributor vacuum advance included in the kit.
  11. Open kit E9PZ-12370-B and remove the contents. The VECI label to be used on this vehicle has the ID number DX08 (1989 California) in the lower left corner. The other VECI label (DX07) and all other parts included in the kit should be discarded.
  12. Clean the surface of the existing VECI label with alcohol. Install the new VECI label over the existing label. Use a squeegee to work out any bubbles and make sure there is adequate adhesion to the old label.
  13. Remove and plug the vacuum advance hoses at the distributor vacuum advance. Set the initial ignition timing to 2° BTDC.
  14. Unplug and reconnect the distributor vacuum advance hoses.

Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with clear plastic decal shield. See Fig 6 .

PARTS INFORMATION

Part Number Part Name Class
E8PZ-12370-A Special Service Kit - 1988 - 49 States BG
E8PZ-12370-B Special Service Kit - 1989 - California WG
E9PZ-12370-A Special Service Kit - 1989 - 49 States B
E9PZ-12370-B Special Service Kit - 1989 - California B
E9BZ-12370-C Vacuum Advance Unit B
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