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Home >> Mercury >> 1987 >> Merkur Xr4ti L4-140 2.3L SOHC Turbo >> Repair and Diagnosis >> Powertrain Management >> Computers and Control Systems >> Sensors and Switches - Computers and Control Systems >> Air Flow Meter/Sensor >> Technical Service Bulletins >> Customer Interest >> Engine - Stall On Deceleration Or At Idle

Engine - Stall On Deceleration Or At Idle


87ford3

^ IDLE - STALL/ROUGH/ROLL - 2.3L EFI TURBO - Article No.
ENGINES BUILT PRIOR TO 03/25/86 87-11-10

^ STALL ON DECEL - 2.3L EFI TURBO - ENGINES BUILT PRIOR TO 03/25/86

^ LOSS OF POWER/HESITATION/STUMBLE ON ACCELERATION -
2.3L EFI TURBO - ENGINES BUILT PRIOR TO 03/25/86

^ OIL CONSUMPTION - 2.3L EFI TURBO - ENGINES BUILT PRIOR TO 03/25/86

MERKUR: 1985-87 XR4Ti


ISSUE: Idle, deceleration or acceleration driveability concerns may be due to engine oil deposited into the fresh air inlet system through the PCV system closure tube. The oil then gets into the vane air flow meter and the throttle body. The oil gets into these areas due to high crankcase pressures under boost operation.


ACTION: This concern can be serviced by installing a new valve cover, oil separator, and turbo inlet elbow. The new valve cover has a revised baffle and when it is used with the new oil separator is effective in separating oil from the PCV air flow during high crankcase pressures. The new turbo inlet elbow has revised vacuum nipple locations to further minimize the pickup of engine oil in the fresh air inlet system.

If you encounter one of the driveability concerns described above, remove the rubber hose between the vane air flow meter and the turbocharger inlet elbow. Check the hose for presence of oil. If engine oil in the inlet system is verified, the following procedure should be used to correct the concern:

NOTE: Verify that TSB 87-5-18 for oil dipstick calibration has been performed before continuing with this TSB.

1 . Disconnect the negative battery cable.

2. Drain coolant from radiator.

3. Disconnect the air bypass valve electrical connector.

4. Disconnect the throttle position sensor electrical connector.

5. Disconnect the automatic transmission kickdown cable from the throttle linkage (if equipped).

6. Disconnect the accelerator cable from the throttle linkage.

7. Disconnect the metal tube from turbocharger (two bolts), loosen clamp from the throttle body end of the tube and remove the tube. Discard the gasket between the metal tube and the turbocharger assembly.
8. Remove the two (2) upper attaching bolts and two (2) lower attaching nuts and remove the throttle body assembly and gasket. Discard the gasket.

9. Loosen the clamp on the PCV hose at the oil separator and disconnect the hose from the separator.

10. Remove the wires from the spark plugs using spark plug wire removal tool T74P-6666-A or equivalent. Grasp and twist the spark plug boot back and forth, then pull the wire off the plug. Do not pull directly on the spark plug wire. Remove the plug wire holder from the valve cover stud and fold the wires back toward the distributor.

11. Disconnect the coolant line to the oil cooler (connection is located on the right hand side of the engine above the turbocharger assembly. The hose runs up and over the valve cover at the rear).

12. Remove the coolant pipe retaining clip screw from the right front side of the valve cover.

13. Remove the valve cover retaining screws and studs and remove the valve cover and discard.

14. Clean the gasket surfaces of the cylinder head.

15. Coat the gasket surfaces of the new valve cover (E6RY-6582-A) with gasket and seal contact adhesive (D7AZ-19B508-A or equivalent). Allow the adhesive to dry past the wet stage.

16. Install a new gasket (E2ZZ-6584-A) on the valve cover.

17. Place the valve cover onto the cylinder head.

18. Start the retaining studs and bolts and torque to 7 to 11 N-m (5 to 8 ft.lbs.).

19. Reconnect coolant line to oil cooler at the metal to rubber connection (right hand side of engine above turbocharger).

20. Reinstall the spark plug wire holder onto the valve cover stud and reconnect wires to proper spark plugs.

21. Reinstall the coolant pipe retaining clip and screw at the right front of the valve cover.

22. Make sure that the throttle body and upper intake manifold gasket surfaces are clean.

23. Install a new throttle body gasket (E5TZ-9E936- B) on the two (2) studs of the upper intake and install the throttle body. Secure the throttle body with two (2) retaining nuts and two (2) bolts. Torque to 16-20 N-m (12-15 ft.lbs.).

24. Reconnect the rubber air intake hose and clamp to the throttle body.

25. Insert a new gasket (E3ZZ-9F703-A) between the turbocharger and metal air intake tube. Reinstall the tube and the two (2) retaining bolts and torque to 19-29 N-m (14-21 ft.lbs.). Tighten clamps on the rubber air intake hose.

26. Install the new oil separator (E6ZZ-6A785-A) in the rubber grommet in the new valve cover and connect the PCV closure tube to the separator and clamp.

27. Reconnect the accelerator cable and automatic transmission kickdown linkage (if equipped).

28. Reconnect the throttle position sensor and air bypass valve electrical connectors.

Figure 11 - Article 87-11-10:




Figure 12 - Article 87-11-10:




29. Locate the turbocharger air inlet elbow and disconnect the crankcase vent tube (PCV) from the tube connector, Figure 11.

30. Disconnect the vacuum hoses from the tube connector and then remove the tube connector from the turbocharger inlet elbow. Save the tube connector for installation in the new turbocharger inlet elbow.
31. Remove the air inlet hose from the inlet elbow.

32. Remove "EGO" ground wire from the stud on the air inlet elbow, Figure 12.

33. Remove both the hex head bolts and the stud holding the inlet elbow to the turbocharger assembly and remove the inlet elbow. Discard the gasket.

34. Install the new turbocharger inlet elbow (E6SZ- 9C674-A). Use a new gasket (E3ZZ-9D634-A). Torque the bolts to 19-29 N-m (14-21 ft.lbs.) and reconnect "EGO" ground wire.

35. Inspect inlet hose for oil and clean before reinstalling. Install the air inlet hose to the new inlet elbow and vane air meter. Torque the hose clamps to 1.7-2.3 N-m (1.2-1.6 ft.lbs.).

36. Install the tube connector to the inlet elbow and reconnect the crankcase vent (PCV) tube, Figure 11.

37. Reconnect the vacuum lines to the new nipples on the turbocharger inlet elbow. If only one connection is needed (non-speed control) block off or cap the other nipple with a 7/32" rubber cap (382443-S). Also block off the old nipple connections on the PCV tube connector with one or two 7/32" rubber caps depending on whether the vehicle is speed control or nonspeed control (see Figure 11).

38. Refill cooling system.

39. Reconnect the negative battery cable.

40. Start engine and check for oil and coolant leaks.

41. Run the engine for a few minutes and recheck coolant level.

PART NUMBER PART NAME CLASS

E6RY-6582-A Valve Cover C
E7AZ-6A892-A Grommet A
E6ZZ-6A785-A Separator C
E2ZZ-6584-A Valve Cover Gasket AG
E5TZ-9E936-B Throttle Body Gasket B
E3ZZ-9F703-A Gasket - Turbo To Air BM
Tube
E6SZ-9C674-A Inlet Elbow - BM
Turbocharger
E3ZZ-9D634-A Inlet Elbow - Gasket B
382443-S Rubber Vacuum Cap BS
D7AZ-19B508-A Contact Adhesive AM

OTHER APPLICABLE ARTICLES: 87-5-18
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual
OPERATION: SP871110A
TIME: 1.9 Hrs.
DLR. CODING: Basic Part No. 6A785 - Code: 40
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