Engine - Hard Start/Hesitation/ Stumble
NOVEMBER 7,1985Article No. 85-22-23
HARD START/HESITATION/ STUMBLE - HOT (5.8L-4V) UNDER 8500 LBS. GVW
LIGHT TRUCK 1984-85 E, F SERIES, BRONCO
CALIBRATIONS: All with 5.8L-4V H.O. Engine
WARNING: This modification is authorized only for the listed engines. Performing this modification on other engine calibrations is unauthorized and could create liability under applicable federal or local laws.
This article supersedes TSB Article 85-18-9. It is being republished to correct the part number in Step 7 from E5TE-9B963-BA to E5TE-9B963-BB and add alternate part D9AE-9B963-BA.
Figure 23 - Vacuum Schematic Routing:
The subject vehicles may experience difficulty restarting after a hot soak and hesitation/stumble during stabilized drive. To resolve this concern, a 5.8L-4V Hot Start Kit has been released to modify the canister purge control system. The following procedure will be included in the kit as an instruction sheet. See Figure 23 for vacuum schematic routing.
1. Remove carburetor air cleaner assembly and drain engine coolant.
2. Remove upper radiator hose from the thermostat housing to gain access to the yellow PVS.
3. Remove hose from PCV fitting in right rear valve cover. Install the 3/8 x 3/8 crankcase vent elbow, part number E1EE-6853-HA, and Hot Idle Compensator valve (HIC), part number D7BE-9E890- AA (tail of bi-metal extended towards firewall). Cut original PCV hose on steel tube to 2.5 inches overall length and attach to open nipple of HIC valve.
4. Replace production purge valves (two) with new purge valves, part number E5UE-9B963-AA, which have a 0.030 inch diameter constant purge bleed orifice.
5. Replace existing yellow (160~F) purge PVS (vertically mounted in thermostat housing) with a red (225~F) PVS, part number E1SE-12A091 -AA. Leave the molded rubber connector disconnected and reconnect the radiator hose.
6. Disconnect vacuum line (which originates at the bottom of the 3-port PVS vacuum connector of the PVS replaced in Step 5) from four-way tee connector at the two port PVS (black).
7. Install fuel tank vapor control valve, part number E5TE-9B963-BB (some kits may have part D9AE- 9B963-BA which is equivalent to E5TE-9B963- BB), using (3) 2-inch pieces of 5/32" diameter vacuum tube in the fuel tank(s) to canister's vapor return line as follows:
a. Cut 5/32" diameter vapor line between the steel vapor return line and the plastic three-way connector ("Y" on F Series/Bronco and "T" connector on E Series) leading to the vapor storage canisters.
b. Connect* large diameter ports on the bottom side of fuel tank vapor control valve using two (2) plastic reducing elbows, part number 387980-S as follows:
^ Large diameter "centered" port of valve connects to the vapor line going to the canisters through the plastic "Y" or "T" connector.
^ Large diameter "off-centered" port of valve connects to the vapor line coming from the fuel tank(s).
*NOTE: Caution must be used to correctly connect these ports for proper function. Caution must also be used in routing vacuum hose to avoid possible abrasion/burns from contact with engine or sheet metal during operation.
c. Connect single, small diameter port on top of the valve, using a 3/16 straight plastic connector, part number 383003-S. Measure and cut 24 inches of 5/32 diameter vacuum tube for F Series/Bronco or 3/16 plastic elbow, part number 387065-S, pointed forward along with 56 inches of 5/32 diameter hose for E Series. Route hose to the engine vacuum harness and connect to the now available nipple of the four-way tee of Step 6. Strap vacuum hose to large "evap" hose from the canister using an 11 inch long bundling strap, part number 95874-S.
8. Remove connector at top port of 2-port PVS and install a three-way tee, part number 373846-S.
9. Connect 5/32 diameter by 2 inch length vacuum hose on the open nipple of the three-way tee installed in Step 8. Install a three-way tee, part number 373846-S, in open end of vacuum hose just installed.
10. Remove filter from top port of 3-port red PVS vacuum connector of PVS changed in Step 5. Install plastic connector elbow, part number 387065-S.
11. Install black and green vacuum delay valve, part number E3AE-12A189-HA, between bottom port of red PVS and three-way tee of Step 9 with the green side of the delay valve towards red PVS as follows:
a. Cut existing hose coming from bottom port of PVS connector 4 inches from straight end. Install straight plastic connector, part number 383003- S, in open end of shortened line. Next, install rubber reducing connector, part number E0BE- 12226-AA, (7/32 to 5/32) on green side of delay valve and connect to straight plastic connector in hose coming from bottom port of red PVS connector. Connect black side of delay valve to three-way vacuum tee with appropriate length of 5/32 diameter vacuum hose.
12. Install black and brown vacuum delay valve, part number E3AE-12A189-DA, between top port of red PVS and three-way tee of Step 9 with brown side of delay valve towards red PVS as follows:
a. Connect 3 inch length of 5/32 diameter vacuum hose removed in Step 11a. to plastic elbow connector installed in Step 10. Install a straight plastic connector, part number 383003-S, in open end of 3 inch length of vacuum hose just installed. Next, install rubber reducing connector, part number E0BE-12226-AA, (7/32 to 5/32) on brown side of delay valve and connect to 3/16 straight plastic connector in hose coming from top port of PVS connector. Connect black side of delay valve to three-way vacuum tee with appropriate length of 5/32 diameter vacuum hose, Reconnect the three-way molded rubber connector to the red 3-port PVS.
13. On A/C equipped vehicles, disconnect for removal in Step 17, vacuum hose at throttle kicker.
14. Disconnect existing pick striped vacuum tube from air control valve at the nylon "Y" in vacuum harness. (Leave connected at air control valve.)
15. Connect a 28 inch length of 5/32 vacuum tubing to open port of plastic "Y" disconnected in Step 14. Route under and behind ACV to prevent kinking and connect to vacuum throttle kicker.
16. Electrically disconnect thermactor solenoid valve by removing plug in connector, (identified with red and black wires), cover connector and vacuum solenoid valve electrical openings with electrical tape.
17. On A/C equipped vehicles, disconnect the front and rear vacuum hose connectors at the vacuum solenoids. Remove plastic "T" from the bottom vacuum tube of the rear connector and replace with a 3/16 straight plastic connector, part number 383003-S. Reconnect the rear vacuum hose connector to the front vacuum solenoid and remove the unused front vacuum connector and hose assembly from the harness. Retape harness securely.
18. Connect WOT valve, part number D6AE-9F424- AA as follows:
a. Insert a three-way plastic "T", part number 373846-S, in EGR vacuum hose between EGR valve and PVS, 8 inches from the EGR valve.
b. Connect single vertical port of WOT valve to available port of tee installed in Step 18a. with a 2 inch long piece of 5/32 vacuum hose.
c. Connect the pink striped tube from air control valve, disconnected in Step 14 to the rear port of the two opposing ports on the WOT valve.
d. Locate vacuum hose that supplies air cleaner. Cut this hose 6 inches from the air cleaner connection and insert a vacuum plastic tee, part number 373846-S.
e. Install a 4-1/2 inch long piece of 5/32 vacuum hose on the open port of the tee installed in Step 18d.
f. Install black/blue vacuum delay valve, part number E3AE-12A189-GA, with black side of the delay valve installed in open end of the 4-1/2 inch long hose installed in Step 18e.
g. Connect blue end of vacuum delay valve, using 7/32 to 5/32 reducing nipple, part number E0BE-12226-AA, to remaining open port on WOT valve.
Figure 23 - Vacuum Schematic Routing:
19. Check system over for proper routing per schematic (Figure 23) and integrity of connections.
a. Refill cooling system.
20. Check and adjust curb idle speed as follows:
With engine warm and accessories off, disconnect and plug purge flow hose (1/4" diameter) at purge valve harness tee connector.
a. Set curb idle speed in drive to 650 rpm.
b. Disconnect vacuum hose from throttle kicker and connect a manifold vacuum source to kicker (vacuum line for air cleaner is appropriate).
c. Adjust throttle kicker to provide 800 rpm in drive (vacuum applied).
d. Remove plug from purge flow hose. Reconnect the flow hose and vacuum hoses to the kicker.
e. Reinstall air cleaner assembly.
Authorized Modifications Decal:
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
E4TZ-12000-A Hot Start Kit - 5.8L-4V CG
OTHER APPLICABLE ARTICLES: Supersedes 85-18-9
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: SP12000A85 - Non A/C
TIME: 1.6 Hrs.
OPERATION: SP12000B85 - With A/C
TIME: 1.7 Hrs. DLR. CODING: Basic Part No. 9B963 - Code: H5 or H8