Air Intake System - Loss of Performance/hard Restart
Article No.83-3-11
LOSS OF ENGINE PERFORMANCE AND/OR DIFFICULT ENGINE RESTART - SNOW PACKING OF THE ENGINE COMPARTMENT - 1.6L H.O. ENGINE
FORD
1981-82 ESCORT
LINCOLN-MERCURY
1981-82 LYNX
Ambient temperatures substantially below 32°F combined with snow blizzard conditions could result in the accumulation of snow in the engine compartment. Snow in the engine compartment and air intake could result in loss of power or difficult engine restarts. These symptoms can be serviced as follows:
A. Installation of a Manifold Heat Shroud and a revised Air Cleaner Duct Motor Vacuum Hose and delete Secondary Air.
B. Rerouting fresh air intake Zip Tube (includes relocations of hood latch cable and left park lamp wiring).
C. Installation of Distributor Cap Shield.
Figure 14:
A. Heat Shroud and Air Cleaner Duct Motor Vacuum Hose and delete Secondary Air
1. Before performing any rework complete vacuum operated systems check as outlined in Section 24-41-1 Air Cleaner Duct and Valve Assembly Check. Perform functional check of duct door as follows:
a. Apply and maintain 15.0 +/- 1/2" vacuum to the vacuum motor nipple (Figure 14, Location 1).
b. Lower edge of valve at (Figure 14, Location 2) may push off of sealing bead of lower shelf at 15 inches of vacuum to produce a cold air leakage gap.
c. Use approximately a 3/8 x 1/2" wide and 3" to 5" long paper feeler gage made from a 3x5 card or wire tag to determine if blend door gap exceeds requirements. If it slides freely, replace the duct and valve assembly. If it's a tight fit or doesn't fit at all, the duct and valve is within specification.
2. Remove the air cleaner assembly, wing nut (N801368-S36B) grommet (-9697-) and set aside to provide access to the exhaust manifold area.
a. For vehicles with 1.6L HO, the following rework of the air cleaner is required:
Figure 15:
^ Remove primary and secondary zip tubes (shown in Figure 15).
^ Remove four attaching screws from radiator support (primary and secondary zip tubes).
^ Detach primary and secondary zip tubes from duct and valves and discard.
^ Disconnect vacuum hose to secondary duct and valve at tee and cap with 382443-S (Cap).
^ Disconnect -9A624- secondary air tube assembly at air cleaner and discard.
^ Remove the plastic air cleaner duct by drilling the rivet heads using a 3/16" drill bit. Pry the duct loose and remove any burrs with a fine file.
^ Cut a blank 1 - 3/4" x 6" from light gauge sheet metal approximately .020 thick. Form the metal blank to correspond to the inside curvature of the air cleaner tray. Align the blank on the inside of the tray directly over the existing duct hole.
NOTE:
Be sure the blank covers the two outboard existing rivet holes.
^ Mark the four new rivet hole positions as illustrated and drill the new holes using a 1/8" drill bit.
^ Apply a narrow bead of RTV sealer around the surface of the blank contacting the tray.
^ Align the blank with the pre-drilled holes and pop rivet the blank in position.
Figure 16:
3. Remove and discard the existing heat shroud by removing (2) attaching nut and washer assemblies (N621939-S2) from the studs (Figure 16).
4. Remove and discard existing fastener (N801598) from the center hole of the outlet flange to the inlet pipe face.
5. Obtain and position a new service heat shroud (-9A603-) and install (2) attaching nut and washer assemblies removed in Step 3. Torque nut to 15-22 ft.lbs.
6. Prior to reinstallation of the air cleaner, the vacuum source to the bi-metal sensor must be modified as follows:
7. Remove 90° formed rubber hose from red nylon tubing connector (bi-metal vac line).
8. Plug red nylon vacuum line connector with 3/16" cap 382444-S.
9. Bundle inoperative red nylon vacuum line with cap to other vacuum lines away from bi-metal using 95873 bundling strap.
10. Take 90° formed rubber hose back onto air cleaner bi-metal and attach other end of 11" 1/4 OD hose to vacuum manifold source which is located on dash panel, at an open vacuum port. If an open vacuum port isn't available Y-space two hoses to one nipple.
11. Install air cleaner assembly using care to ensure proper seating of hot air tube to shroud. Locate new air cleaner cover gasket (-9E608-) over stud and install grommet and wing nut (torque to 20-30 in.lbs.).
B. Fresh Air Intake Zip Tube Rerouting (Includes Relocation of Hood Latch cable and Left Park Lamp Wiring)
The next modification required is to the zip tube assembly. The steps which follow require battery removal and relocation of the hood latch control cable and relocation of left hand park lamp socket wiring.
1. Remove battery.
2. Remove and discard zip tube inlet from radiator support bracket - done in A (section 2-a).
Figure 17:
3. Remove the (4) screws that retain the left hand headlamp door. Pull the headlamp door forward and remove the parking lamp bulb socket from the lamp assembly.
NOTE:
Refer to Figure 17. On some vehicles, the hood latch control cable may be routed through the "zip tube" opening. If this is the existing condition, it must be rerouted as shown in the illustration. If the cable is not currently routed through the "zip tube" opening, omit Steps 4 through 7.
4. To reroute the cable, remove the cable from the retainer clip at the hood latch lever.
5. Remove cable bushing from hood plate.
6. Remove cable from cable clip in radiator support.
7. Reroute the cable as shown in the illustration and reconnect the hood latch lever.
8. Close the hood and check release cable for proper operation.
FIGURE 18:
9. Refer to Figure 18 for the following procedure.
10. Procure one -13234- replacement socket and wire assembly and 7 inches of -14A099- convolute protective tubing.
11. Cut the wires of the existing left hand parking lamp socket as close to the socket as possible.
12. Place the convolute protective tubing (-14A099-) around the wires of the replacement socket assembly.
13. Route the wires of the replacement socket through the new opening as shown.
14. Strip 3/8" of insulation from the previously cut wires, insert into ends of bun splice connectors (part of replacement socket assembly) and crimp firmly with D81L-17018-A crimp tool.
NOTE:
Be sure to observe color codes of wires when connecting wires to bun splice connectors.
15. Cut the three butt splice connectors and the ends of the convolute tubing with ESB-M3G5-A electrical tape.
16. Install the parking lamp socket to the parking lamp and the headlamp door to the vehicle.
17. Reconnect the battery and test the park/turn signal lamps for proper operation.
Figure 19:
18. Air Intake (Zip) Tube Assembly Rework, (Figure 19), install -9C675- zip tube by:
^ Drill 4.30" holes in the left side fastener apron to match zip tube.
^ Install 4 388930-S push pins to retain zip tube to fender apron.
^ Attach elbow to duct and valve.
^ Drill 1/4 diameter access hole thru fan shroud (or strap to radiator support) and strap -9A624- tube to left/top side radiator using 95873-S bundling strap to prevent zip tube duct from contacting fan.
Figure 20:
C. Distributor Shield (Boot) Installation
1. Remove and scrap ignition coil suppressor wire.
2. Clean cap towers and grease suppressor insulators with silicone grease compound D7PE-19A331-CA.
3. Spark plug wires should be positioned on cap as shown in Figure 20. Any insulators required to be removed should be regreased and the cap tower should be wiped clean prior to installation.
Figure 21:
Figure 22:
4. Install new suppressor as shown in Figure 21.
5. Position the distributor cap shield as shown in Figure 22. Snap shield together so that the spark plug wires and suppressor exit through the opening provided. Adjust slack in spark plug wires as required.
NOTE:
Two suppressors are provided in the kit. Use the appropriate wire for the type of coil being used (Figure 21).
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.
PART NUMBER PART NAME CLASS
E1FZ-9E635-A Snow Pack Kit CG
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: SP 9600-A-82
TIME: 1.9 Hrs. DLR. CODING: Basic Part No. 9600 Code: 53
NOTE:
If vehicle is operated in ambients below 0~F in the presence of blowing snow, the customer may wish to purchase a grille cover E1FZ-8K104-B, available at Ford and LincolnMercury dealerships through the Motorcraft accessory line.