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Home >> Mercury >> 1982 >> Cougar/XR7 V6-232 3.8L >> Repair and Diagnosis >> Powertrain Management >> Fuel Delivery and Air Induction >> Altitude Compensator >> Technical Service Bulletins >> All Technical Service Bulletins >> Recall - Altitude Compensator Adjustment >> Dealership Obligations & Technical & Administrative Instructions Information

Dealership Obligations & Technical & Administrative Instructions Information


Dealership Obligations

Dealers are obligated to perform the recall service promptly following tender of the vehicles by the owners. It is important that you promptly report to your FPSD District Office any instance in which an owner will not allow you to complete this recall because of objections to scheduling or for any other reason.

Technical and Administrative Instructions

Note: These instructions supersede those previously provided in the referenced TechnicalService Bulletin.

PERFORM THE FOLLOWING SERVICE (STEPS 1 THROUGH 12) FOR ALL INVOLVED VEHICLES

Repair

1. Open the hood and locate the altitude compensator located forward of the shock tower on the driver side front fender apron.

2. Carefully disconnect the individual vacuum lines from the compensator. Avoid side loading.

3. Remove the compensator from the vehicle. Retain the two attaching screws. Heat the 5/32-inch brass Allen adjusting screw with a soldering iron until the adhesive bond is broken. Holding the compensator with the adjusting screw facing you, turn the screw counterclockwise three full turns.

4. The action of the compensator is such that the three ports do not always open simultaneously. It is necessary, therefore, to adjust the compensator until the last port begins to open before the final adjustment is made. Using a hand vacuum pump, apply vacuum individually to each of the three ports. Holding the compensator with the adjusting screw facing you, turn the screw clockwise until the last port begins to leak vacuum. With all three ports open, and based on your altitude, further turn the adjusting screw clockwise as shown in the following chart:

Additional Screw Adjustment Based on Altitude
Altitude (Feet) Turns

3,500 - 4,000 0
4,001 - 6,000 1 and 1/2
Above 6,000 1 and 3/4

5. Before performing this step, please read carefully and observe the following caution when using the following adhesive (Part No. E0AZ-19554-B; Ford Specification No. ESE-M4G167-A2):

CAUTION! MAY IRRITATE SENSITIVE SKIN. CONTAINS METHACRYLIC ESTER. AVOID PROLONGED OR REPEATED CONTACT WITH SKIN. IN CASE OF SKIN CONTACT, WASH THOROUGHLY WITH WATER. KEEP OUT OF THE REACH OF CHILDREN.

6. Apply one drop of the adhesive between the compensator body and the adjusting screw to secure the final adjustment.

7. Reinstall the compensator to the vehicle using the two attaching screws previously removed in Step 3.

8. Carefully reconnect the individual vacuum lines to the compensator.

EXHIBIT I - EMISSIONS RECALL U-7B:





9. (Refer to Exhibit I, Figure 1). Remove the 3/8-inch vacuum line from the upper carburetor port and place a 3/8-inch cap (part number C9AZ-9C492-A) over the port.

EXHIBIT I - EMISSIONS RECALL U-7B:





10. (Refer to Exhibit I, Figure 2). Cut the opposite end of the 3/8-inch vacuum line (from Step 9) two inches from the altitude compensator and install a 3/8-inch air filter (part number E2AZ-6A768-A) in the end of the line. Secure the filter to the adjoining vacuum lines with a bundling strap (part number 95874-S).

11. Remove and discard the 1/4-inch cap on the altitude compensator and install a 45 inch length of 7/32-inch vacuum line (part number D0PZ-12226-C). Install a 1/4-inch vacuum "T" (part number 383009-S) on the other end of this line.

EXHIBIT I - EMISSIONS RECALL U-7B:





12. (Refer to Exhibit I, Figure 1). Cut the vacuum line which is routed from the lower carburetor port (main idle port) to the altitude compensator, and install the open ends of the vacuum "T" to this line. Install a bundling strap (part number 95874-S) around the vacuum lines in two places to hold the lines in position.

IF THE VEHICLE YOU ARE SERVICING IS A GRANADA OR COUGAR, DO NOT PERFORM THE NEXT FIVE STEPS. INSTEAD, PROCEED TO STEPS 1 THROUGH 11 SHOWN FOR GRANADA AND COUGAR VEHICLES.




13. If the vehicle you are servicing is a Thunderbird or XR-7, prepare an "Authorized Modifications" decal (Form FPS-8262, available on your stock order pad) as shown below.


14. Attach the "Authorized Modifications" decal to the rocker arm cover.

15. Attach the new Vehicle Emission Control Information (VECI) decal (part number E2AE-9C485-BKC) over the existing VECI decal.

16. Check and set fast and curb idle speeds to the specifications shown on the Vehicle Emission Control Information (VECI) decal. Follow the idle speed setting procedures described on pages 4-15 and 4-16 of the 1982 Car/Truck Shop Manual - Engine/Emissions Diagnosis.

17. Close the hood.

EXHIBIT I - EMISSIONS RECALL U-7B:





PERFORM THIS SERVICE FOR GRANADA/COUGAR VEHICLES ONLY

1. (Refer to Exhibit I, Figure 3). Cut in the middle the vacuum line running from the carburetor power valve to the manifold vacuum source fitting. Discard the half of the vacuum line which is connected to the carburetor power valve.

2. Install the vacuum vent valve (part number E4SZ-12A226-A) to an existing hole on the driver side of the air cleaner. Remove and discard the existing plug in the air cleaner.

3. Install vacuum connector (part number 383004-S) in the vacuum line that was left in the manifold vacuum fitting in Step 1.

4. Install a 12 inch length of 5/32-inch vacuum line (part number D0PZ-12226-B) between the vacuum connector installed in Step 3, and the vacuum source port (marked as "VAC") of the vacuum vent valve.

5. Install a 12 inch length of 5/32-inch vacuum line (part number D0PZ-12226-B) to the remaining open port of the vacuum vent valve. Install the other end to the white port of the vacuum delay valve (part number E3AZ-12A208-D).

6. Install a six inch length of 7/32-inch vacuum line (part number D0PZ-12226-C) from the carburetor power valve to the brown end of the vacuum delay valve.




7. Prepare an "Authorized Modifications" decal (Form FPS-8262, available on your stock order pad) as shown below.

8. Attach the "Authorized Modifications" decal to the rocker arm cover.

9. Attach the new Vehicle Emission Control Information (VECI) decal (part number E2AE-9C485-BKB) over the existing VECI decal.

10. Check and set fast and curb idle speeds to the specifications shown on the Vehicle Emission Control Information (VECI) decal. Follow the idle speed setting procedures described on pages 4-15 and 4-16 of the 1982 Car/Truck Shop Manual - Engine/Emissions Diagnosis.

11. Close the hood.
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