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ok, here we go for now;
TSB 91-12-11 Catalytic Converter Diagnosis
Publication Date: JUNE 12, 1991
LIGHT TRUCK: 1986-91 BRONCO, ECONOLINE, F-150-350 SERIES
1988-91 F SUPER DUTY, F47
ISSUE: Lack of power or a no start condition may be diagnosed as an exhaust restriction caused by a plugged catalytic converter. A plugged catalytic converter (internal deterioration) is usually caused by abnormal engine operation.
ACTION: Diagnose the catalytic converter to confirm internal failure. Refer to the Catalyst and Exhaust System Diagnostic Section, in the Engine/Emissions Diagnostic Shop Manual and the following procedures for service details.
SERVICE PROCEDURE
1. Lack of proper HEGO operation may cause, or be the result of a rich or lean fuel condition, which could cause additional heat in the catalyst. Perform self test KOEO and KOER, service any codes.
NOTE: IF TWO DIGIT CODES 41, 42, 85 OR THREE DIGIT CODES 171, 172, 173, 179, 181, 182, 183 AND
565 ARE RECIEVED,
CHECK FOR PROPER HEGO GROUND.
If the HEGO ground is good, the following areas may be at fault:
Ignition Coil
Distributor Cap & Rotor
Fouled Spark Plug
Spark Plug Wires
Air Filter
Stuck Open Injector
Fuel Contamination Engine OIL
Manifold Leaks Intake/Exhaust
Fuel Pressure
Poor Power
Ground * Engine Not At Normal Operating Temperature
HEGO Sensor 2. Spark timing that is retarded from specification may increase exhaust gas temperature and shorten catalyst life. Refer to the following procedure for service details.
a. Check spark timing. Check base timing with spout disconnected. Set base timing to the specification on the vehicle emission decal.
b. Check computed timing with spout connected.
NOTE: COMPUTED TIMING IS EQUAL TO BASE TIMING PLUS 20° BTDC ± 3°.
3. Misfiring spark plugs may cause an unburned fuel air mixture to pass through the catalyst, which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details. Check secondary ignition, hook the vehicle up to an engine analyzer and check for a secondary ignition misfire.
NOTE: SERVICE ANY ITEM THAT IS NOT PERFORMING AT PROPER SPECIFICATIONS BEFORE CONTINUING.
4. Fuel pressure that is too high may cause rich air fuel mixtures to pass through the catalyst which could cause higher than normal catalyst temperatures. Refer to the following procedure for service details.
a. Check fuel pressure, install fuel pressure gauge, start and run the engine at idle. Fuel pressures between 28 and 34 PSI are typical (4.9L typically is 15 PSI higher).
b. Disconnect the vacuum line going to the fuel pressure regulator. Fuel pressure typically jumps to 40 PSI ± 3 PSI (4.9L typically is 15 PSI higher). Visually inspect vacuum line for raw fuel.
NOTE: FUEL PRESSURES ABOVE THESE VALUES SHOULD BE CORRECTED. HOWEVER, THIS MAY NOT BE THE CAUSE OF THE CONCERN. SERVICE AS NECESSARY.
5. Throttle plates in the throttle body not returning to the proper closed position may cause excessive catalyst temperatures during downhill grades. Refer to the following procedure for service details. Visually inspect the throttle body and linkage for:
* Binding or sticking throttle linkage.
* Tight speed control linkage or cable.
* Vacuum line interference.
* Electrical harness interference.
NOTE: AFTERMARKET GOVERNORS, THROTTLE LINKAGE AND CABLES ASSOCIATED WITH POWER TAKE-OFF UNITS, MAY ALSO INTERFERE WITH PROPER THROTTLE RETURN. SERVICE AS NECESSARY.
6. It is extremely important that all systems related to the engine and emission systems operate properly.
a. Visually inspect the engine compartment to make sure all vacuum hoses and spark plug wires are properly routed and securely connected.
b. Inspect all wiring harnesses and connectors for insulation damage, burned, overheated, loose or broken conditions.
c. Verify proper operation of the thermactor system. Thermactor systems that fail to dump thermactor air to the atmosphere properly or at the correct time can cause high catalyst temperatures.
d. Visually inspect thermactor system for damaged or kinked hoses and perform a function test on following components: air control valve, check valve, silencer, filter and the air bypass solenoid.
e. Verify proper operation of the engine cooling system thermostat.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
911211A Diagnostics - Perform KOEO And KOER Self Tests 0.5 Hrs.
911211B Timing - Check Or Adjust Spark Timing, Check Computed Timing And Check Secondary Ignition System With Engine Analyzer 0.5 Hrs.
911211C Check - Fuel Pressure And Inspect Vacuum Line For Raw Fuel 0.2 Hrs.
911211D Inspect - Throttle Body And Linkage 0.1 Hrs.
911211E Inspect - Vacuum Hoses, Electrical Harnesses, Connectors And Spark Plug Wires For Routing Damage 0.1 Hrs.
911211F Thermactor System - Inspect For Proper Operation And Damaged Component. Includes Function Check Of Air Control Valve, Thermactor Air Bypass Solenoid, Check Valves, Silencer And Filter 0.3 Hrs.
911211G Thermostat - Check For Proper Operation 0.2 Hrs.
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DTC 211; Hesitation, Stumble, Stall, Miss, No Start, No Spark and/or Diagnostic Trouble Code (DTC) 211 TSB 95-15-11 in 93-95 (Shorts in Profile Ignition Pickup (PIP) & Spark Output (SPOUT)
Source: by Ford via Chilton summary; engines may exhibit various driveability symptoms, such as no start, no spark, hesitation/stumble/stall/miss and/or Diagnostic Trouble Code (DTC) 211. The symptoms may occur during any drive mode or at idle. These concerns may be caused by the shielding drain wire (Circuit 48.) cutting through the insulation of, and shorting to, the Profile Ignition Pickup (PIP) wire (Circuit 395) or the spark output (SPOUT) wire (Circuit 929) near the Powertrain Control Module (PCM) 60-pin connector. A protruding wire from Splice 145 may also cause the same concern as the wire strand shorts to the PIP, SPOUT, or the foil wrap surrounding the drain wire.
ACTION: Inspect PIP - Circuit 395 (GY/O), Ignition Ground (IGN GND) - Circuit 259 (O/R), and SPOUT - Circuit 929 (PK) for possible cut insulation from Circuit 48. Also, inspect Splice 145 - Circuit 395 (GY/O) for stray wire strands. If wire insulation is cut, exposing copper wire, repair cut insulation with 3M Mastic Tape. Refer to the following procedure for service details
READ MORE
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DTC 332; "...indicates the EGR valve did not open with the engine stabilized and the EVR solenoid duty cycle present sometime during vehicle operation. Possible causes: "...Obstructed or cracked hose to EGR valve, Icing, Damaged EGR valve, Damaged EVR solenoid harness..."
Source: by Ford via SigEpBlue (Steve) at FSB
.......
DTC 332, P1407 and P1408 or detonation ;"...We have run into many situations where a code for insufficient flow has been set and the system is functioning correctly. Then it is time to check the EGR passages. There is a Ford Technical Service Bulletin (TSB 96-23-4) that addresses this for some vehicles. This TSB includes: 1992-1995 Crown Victoria 1994-1995 Thunderbird 1991-1995 Town Car 1992-1995 Grand Marquis 1994-1995 Cougar The concerns have to do with intermittent MILs; DTCs 332, P1407 and P1408; or detonation. If exercising the EGR valve does not result in a change in rpm, then the passages may be clogged. There are “U” shaped passages (Fig. 6) under the throttle body adapter that get clogged with carbon. Remove the adapter, clean the passages and reinstall with a new gasket. Just because the vehicle you are working on is not listed in the TSB doesn’t mean you may not have a clogging problem. Make sure you check the passages and be sure they are clean. Just a slight restriction can cause a flow code to be set, and you may still have an rpm drop that can mislead you..."
Source: by tomco-inc.com
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E4OD Controls Overview, Sensors, DTC (s) & Diagram; Vehicle Speed Sensor (VSS) 9E731: "... The vehicle speed sensor is a variable reluctance sensor that sends an AC/frequency signal to the powertrain control module. The vehicle speed sensor signal is used by the powertrain control module to calculate vehicle speed in mph.
Used as an input in determining shift scheduling and electronic pressure control.
DTC 452, P0500, P1500, P1501, P0503..."
Source: by Ford via Steve83 (Steve, That dirty old truck) at SuperMotors.net
DTC 452 Erratic Harsh Shift; Short Circuits, Common Locations TSB 95-02-11 on 94-95 Bronco & Trucks
Source: by Ford via Chilton - See
D. then;
Driver's side A pillar trim screws may pinch the wire assy; Dome light grnd screw may pinch the wire assy/mtg screw may be too long & short the ckt to roof panel; Scuff plate screws may pinch the 14A504 wire assy; 14401 wire assy may be pinched between Half car beam & instrument panel attachment (repeated as the wire harness may be pinched/shorted behind the dash where the 14401 wire assy may come in contact w/a sharp edge on dash panel wall.; Chaffing may occur above the brake pedal-to-dash panel wall weld.; E4OD shift cable assy near tranny may chaf the wire harness; the wire harness may be chaffing against the clutch pedal; See Repairs for each condition
and the location diagram
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DTC 27, 29, 452, P0502, P0503, PO716, PO718; Insufficient input from VSS.; "...A more difficult problem to identify is a VSS that works, but sends out the wrong signal for a given vehicle speed. In some cases, a wrong reading from the VSS may still cause a code to be set. For example, if the VSS signal tells the computer the vehicle is traveling 60 miles an hour, but the throttle position sensor and MAP sensor tell the computer that the engine is idling, the computer will be confused. And a confused computer should set any of the following codes: Ford 27, 29, 452. On a vehicle that uses the VSS as a safety device, a defective sensor may send out a wrong "too fast" signal, shutting down fuel flow at the wrong time. Although this doesn’t happen often, it can be a difficult problem to identify. The customer will probably describe it as a random or intermittent sudden loss of power and poor performance, onlyto have the engine resume normal operation. Routine diagnostic checks of the engine in the shop won’t show any problem because there isn’t a problem with the engine or the ECM..." read more
Source: by wellsmfgcorp.com
DTC 624, 625, P1746, P1747 The Electronic Pressure Control solenoid is a variable force solenoid. The variable-force type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. It supplies electronic pressure control which regulates transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and the line modulator circuits. These two pressures control clutch application pressures. Failed off — maximum electronic pressure control pressure, harsh engagements and shifts. May flash transmission control indicator lamp. CAUTION: The electronic pressure control pressure output from the variable force solenoid is NOT adjustable. Any modification to the electronic pressure control solenoid will affect the transmission warranty. (*Output circuit check, generated only by electrical condition.) Possible causes, Damaged harness connector. Damaged EPC solenoid. Damaged MLP sensor. Intermittent harness continuity. Damaged PCM connector pins. Pin Point testing; Source: by Ford via miesk5 at
http://www.fullsizebronco.com/forum/showthread.php?p=2452835
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DTC 311 - Thermactor air system inoperable; "...because of the possibility that (following is an excerpt of a condensed discussion of how a
bad TAB/TAD/vac line DTC 311 ... and so-on problem could cause the rich aroma; Your smog pump... blows fresh clean air up through a hose to the diverter valve. The solenoid next to the diverter valve which has a .... pink little hose plugged into ... it, creates a vacuum (sucking) that opens up the valve, and allows the fresh air to pass through the valve and make it's way to the exhaust, where the cats burn the unburnt gas more efficiently since this all happens during "open loop mode". Open loop mode happens when you turn on your car and it revs at 1200rpms for the first 15-20 seconds. During this process, your ECU feeds more gas to the engine to warm up the car quickly before driving. (also known as choke on older cars). During this open loop procedure, the extra unburnt gasoline will usually cause your exhaust to smell very rich, and the air that this diverter valve sends to the cats, causes it to burn the extra unburnt gas more efficiently like I mentoined above...thus eliminating the rich gasoline smell that us older mustangs sometimes suffer from..."
DTC 311, 312, 313 & 314; "...311 and 314 indicate the Secondary Air Injection system is inoperative. DTC 312 indicates that Secondary Air is misdirected. DTC 313 indicates that Secondary Air is not being bypassed when requested. Possible causes: Visually inspect vacuum lines for disconnects in the AIR system. Visually inspect for proper vacuum line routing. Refer to VECI decal. Visually inspect Air Pump for broken or loose Air Pump Belt. Refer to Section 13A for adjustment/replacement..." MORE
Source: by Jim
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DTC 213 Spout Circuit Open; "...EZ check first; Ck to see if the SPOUT (Spark Output) connector is missing. da connector is a little "jumper" that fits into two wire connector; located near da distributor (it is removed to adjust timing). Check to see if it is in-place, if connector/wiring is damaged or corrosion is in conn or wiring..."
Source: by miesk5 at FSB
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DTC 332; "...Continuous Memory DTC 332 indicates the EGR valve did not open with the engine stabilized and the EVR solenoid duty cycle present sometime during vehicle operation. Possible causes: "...Obstructed or cracked hose to EGR valve,Icing, Damaged EGR valve, Damaged EVR solenoid harness..."
Source: by Ford via SigEpBlue (Steve) at FSB
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