Technical Instructions
EXHIBIT I - EMISSIONS RECALL 86E55:
Refer To Exhibit I for the engine Compartment Location of the Parts Before Proceeding With The Following Instructions
1. Remove air cleaner.
2. Remove carburetor.
EXHIBIT II - EMISSIONS RECALL 86E55:
3. Refer to Exhibit II. Locate the combination air bypass and air control valve. Remove and discard the vacuum line, and, elbow assembly and replace with new assembly (Kit Part #1).
EXHIBIT III - EMISSIONS RECALL 86E55:
4. Refer to Exhibit III. Locate the purge control valve purge hose. Remove the "Purple" color-coded tee and replace with new "gray" color coded tee, (Kit Part #7).
EXHIBIT IV-1 - EMISSIONS RECALL 86E55:
EXHIBIT IV-2 - EMISSIONS RECALL 86E55:
5. Refer to Exhibits IV-1 and IV-2. Cut the bundling strap on the purge control valve vacuum lines just below the manifold vacuum thermal vent valve. Disconnect the 1/4-inch hose from the purge control valve. Attach a 4-foot long piece of 1/4-inch vacuum hose and a vacuum connector to the disconnected hose. From the dash panel side of the engine, pull the opposite end of the disconnected 1/4-inch hose far enough to expose the "red" color coded vacuum restrictor.
EXHIBIT IV-3 - EMISSIONS RECALL 86E55:
6. Refer to Exhibit IV-3. Remove the "red" color-coded vacuum restrictor and replace with "green" color-coded restrictor (Kit Part #2).
7. Pull the vacuum hose back to the original position, disconnect the 4-foot long piece of 1/4-inch vacuum hose and vacuum connector and reconnect the 1/4-inch hose to the purge control valve. Install a new bundling strap to replace the strap that was removed.
EXHIBIT V - EMISSIONS RECALL 86E55:
8. Refer to Exhibit V. Remove and discard the existing choke pulldown vacuum hose and delay valve. Install the new assembly (Kit Part #3).
EXHIBIT VI - EMISSIONS RECALL 86E55:
9. Refer to Exhibit VI. Locate the air cleaner cold weather modulator (CWM) valve connector.Remove the "black" color-coded vacuum line from the tee and install connector and cap assembly (Kit Part #4) onto the tee. Pull the "black" colorcoded vacuum line from the plastic convolute protector just rearward of the idle compensator.
EXHIBIT VII - EMISSIONS RECALL 86E55:
10. Refer to Exhibit VII. Locate the air positive crank case ventilation (PCV) valve and disconnect the "yellow" color-coded vacuum line. Connect the "black" color-coded vacuum line disconnected in Step #9 from the cold weather modulator valve to the rubber and plastic connector assembly (Kit Part #5). Route the line behind the nearby vacuum hoses and connect to the "yellow" color-coded vacuum line.
EXHIBIT VIII - EMISSIONS RECALL 86E55:
11. Refer to Exhibit VIII. Obtain the connector and vacuum line assembly (Kit Part #6). Attach the rubber elbow end of the assembly to the positive crankcase ventilation (PCV) valve nipple. Attach the connector end of the assembly to the carburetor exhaust gas recirculation (EGR) white vacuum hose rubber connector. The open end of this assembly will be attached to the carburetor EGR vacuum port (port "E") when the carburetor is installed.
EXHIBIT IX - EMISSIONS RECALL 86E55:
12. Refer to Exhibit IX. Remove and discard the existing 3-port vacuum regulator valve (VRV) located under the intake manifold carburetor pad.
EXHIBIT X - EMISSIONS RECALL 86E55:
Record the port locations on the removed vacuum hoses. Apply masking tape to the hoses and write the hose number on the tape to assure that the hoses are reinstalled as indicated on Exhibit X.
Access to the valve is improved if the 3-port vacuum connector to the "green" color-coded ported vacuum switch (PVS) is disconnected.
13. Refer to Exhibit X. Install new 4-port vacuum regulator valve (VRV) (Kit Parts #8 and #9). Install the vacuum hoses as shown.
14. Drill out the carburetor choke cap retaining rivets. Remove the retaining screw. Remove and discard the existing choke cap indexing spacer.
15. Install new choke cap indexing spacer (Kit Part #10). Install rivets (Kit Part #11) and retaining screw. Assure that the choke cap bimetal tang is engaged into the choke linkage arm slot.
16. Remove existing carburetor part number tag and replace with new tag (Kit Part #12).
17. Reinstall carburetor. Alternately tighten the carburetor flange nuts to 18 N-m (13.5 ft.lbs.). Tighten the fuel line to 16.5 N-m (22 ft.lbs.). Start engine and check for fuel leaks.
18. Reinstall air cleaner.
EXHIBIT XI - EMISSIONS RECALL 86E55:
19. Refer to Exhibit XI. Prepare an Authorized Modifications decal (Form FPS-8262, Kit Part #14) as shown. Affix the decal to a clean, flat surface on the radiator support.
20. Affix a new Vehicle Emission Control Information (VECI) decal (Kit Part #13) over the existing decal.
PARTS REQUIREMENTS
A quantity of service parts kits equivalent to 50% of anticipated requirements will be direct shipped to involved dealerships. Additional requirements may be ordered through normal order processing channels.
Service Part
Number Description Class Dealer Price
E6FZ-9C485-A Kit, Vacuum Supply Assembly RG $12.90
LABOR
Modify Emission Control System . . . . . . . . . . . . . . . . 1.4 Hr. Insert in Box "B" of Form 1864
Administrative Allowance . . . . . . . 0.1 Hr.
The 0.1 Hr. administrative allowance must be added before inserting the total labor time in Box "B" of the Form 1864.
REPORTING OF COMPLETIONS
Only the Form 1864 will be accepted for reimbursement under this program. Upon completion of the required service, the Form 1864 must be completely filled out and signed by authorized dealer personnel. The Forms 1864 must be entered through the Direct Warranty Entry (DWE) system. Dealerships without DWE capability must submit copy number 2 of the Forms 1864 by mail. Should your dealership receive preprinted Forms 1864 with seven digit claim numbers, you must drop the first digit and enter only the last six digits. You must sight verify the claim number for accuracy.
It is important that all claims be submitted promptly for all completed units so that you will be reimbursed and our records will show completion. Any problem encountered with this recall should be discussed with your FPSD Service Zone Manager.