84-85 Excessive HC emissions RECALL 90E94

[Vitas]

Does anyone have any information about this recall? A modification decal is required to be added to the vehicle. Does anyone have, or not have, the decal? What does it say?

From a summary: "High level of tailpipe emissions." "Catalytic converters will be replaced."

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1984 and 1985 Federal Ford Thunderbird, Mustang, LTD and Crown Victoria; Lincoln-Mercury Cougar, Capri, Continental, Grand Marquis, Mark VII and Town Car, and 1984 California Mark VII with 5.0L fuel injected engine. 1985 engine families consist of carryover calibrations from 1984 only
(EFM5.0V5HBF7 [84] FFM5.0V5HBF8 [85])


http://www.epa.gov/otaq/cert/recall/91recall.htm

[pro-five-oh]

Our 1985 Tbird had it done, I think. I vaguely remember a sticker on the fan shroud. The car is sitting in storage but you've finally given me the best reason to pull it out of mothballs and take it out for another spin.

I'll get back to ya in a couple of days. I bet it was something EGR related.

[Vitas]

...The car is sitting in storage but you've finally given me the best reason to pull it out of mothballs and take it out for another spin.

I'll get back to ya in a couple of days. I bet it was something EGR related.

Happy to oblige. -g-

One reference says the recall replaced the catalytic converters. In the meantime the '85 Valentino is throwing a "31" EGR blah blah blah code.

[Nick]

My '86 Mark VII had the H pipe replaced I believe to service the cats. I am not sure why though. It does have a Ford sticker with handwritten notes for an emissions system modification. JSev22 had something similar done to one of his Marks.

[Fordace]

Note, TSB was to big, so I only included cars I deemed necessary....Rich


Attachment IIIC
Town Car, Crown Victoria / Grand Marquis
Attachment IIID

Continental / Mark VII
Attachment IV

Important Information



ATTACHMENT IIIC
Emissions Recall 90E94
Catalyst Assembly Replacement Kit "C"
Installation Instructions
SERVICE PART NUMBER E4AZ-5E212-C KIT CONTENTS COMPONENT PART NUMBER PART NAME QUANTITY F1AC-5E212-AA Catalyst Assembly-Right 1 F1AC-5E214-AA Catalyst Assembly-Left 1 CATALYST ATTACHING PARTS: D50A-5B266-AA Gasket, Rear Flanges 2 389089-S2 Bolt (LH), Rear Flange 2 388516-S2 Nut, Rear Flanges 4 N800408-S Air Tube Clamp (at valve) 1 388635-S2 Bolt (RH), Rear Flange 2 388718-S2 Stud (RH), Front Flange 2 E0AC-5F234-BC Air Tube Right 1 E4AC-5F243-AA Air Tube Left 1 E0AC-5F235-BE Air Tube Center 1 N802597-S Clamp, Air Tube 4 D9AC-5F248-AA Clip (RH), Air Tube 1 F0AC-5F249-AA Clip (LH), Air Tube 1 55738-S2 Nut, Air Tube 1 E8DE-9A487-AA Check Valve 1 TVAA-22252-AA Clamp, Air Tube (at valve) 1 390150-S2 Stud (LH), Front Flange 2 387039-S7 Nut, Front Flanges 4 56720-S2 Screw, Heat Shield 8 Form FPS-8262 Authorized Modifications Decal (Preprinted) 1 Catalyst Return Container 1 I.S. #8018 1 Affected Vehicles

1984-85 Model Lincoln Town Car, Crown Victoria / Grand Marquis — 49 states 5.0L engines with calibrations codes 4-22B-R00, 4-22C-R00 or 4-22H-R00. Catalytic Converter
Removal

Raise the vehicle.
Remove the air injection tube and check valve.
Remove the attaching bolts at each converter to Y-pipe flange.
Remove the converter flange attaching nuts holding the converter(s) to the exhaust manifold.
Slide the pipe rearward until the catalytic converter(s) can be removed. It may be necessary to obtain sufficient clearance to separate the converter at manifold connection(s).
Discard gasket(s) and any damaged parts.
Remove exhaust shield(s), if so equipped, from the catalytic converters.Installation

Remove gasket material from Y-pipe flanges. Transfer heat shields to new catalyst.
Install the exhaust shield(s) to the catalytic converter(s). Tighten screw to 5.5-8.0 N-m (50-70 Lb-In).
Position the catalytic converter(s) to the exhaust manifold. Loosely install the attaching nuts.
Install new gaskets between the inlet y-pipe converter flat flanges. Position the inlet y-pipe flange to the converter outlet flange connections and insert new attaching bolts.
Alternately tighten the converter to the inlet y-pipe flange connection(s) to 27-41 N-m (20-30 Lb-Ft).
Align the system to proper clearance.
Alternately tighten the manifold nuts to 21.7-32.5 N-m (16-24 Lb-Ft).
Install the air injection tube and check valve.
Check the system for leaks.

NOTE:
Alternate tightening of the joint fastener is required to provide uniform clamping. This will prevent joint distortion, a major cause of system leaks and misadjustment.
Lower the vehicle.Authorized Modifications Decal

The preprinted Authorized Modifications Decal shown below is provided in the parts kit.

Insert your P & A Code and date and attach the Authorized Modifications Decal to a clean surface on the fan shroud.
Place the clear overlay on the decal.
Preprinted Authorized Modifications Decal



ATTACHMENT IIID
Emissions Recall 90E94
Catalyst And Y-Pipe Assembly Replacement Kit "D"
Installation Instructions
SERVICE PART NUMBER E45Y-5F250-B KIT CONTENTS COMPONENT PART NUMBER PART NAME QUANTITY E45C-5F250-BC Catalyst & Y-Pipe Assembly 1 CATALYST ATTACHING PARTS: E9AC-5E241-AA Gasket, Front Flange 2 389763-S2 Bolt, Front Flange 4 388516-S2 Nut, Rear Flange 6 N802597-S Air Tube Clamp (at cat.) 1 E1EC-5F264-AB Spring, Front Flange 4 E5LC-5F235-DA Air Tube 1 N800408-S Air Tube Clamp (at valve) 1 382802-S191 Nut, Air Tube 1 E8DE-9A487-AA Check Valve 1 TVAA-22252-A4 Clamp, Air Tube (at valve) 1 388690-S2 Stud, Rear Flange 2 45358-S2 Nut, Rear Flange 2 56720-S2 Screw, Heat Shield 8 Form FPS-8262 Authorized Modifications Decal (Preprinted) 1 Catalyst Return Container 1 I.S. #8019 1 Affected Vehicles

1984-85 Model Continental / Mark VII — 49 states 5.0L engines with calibration code 4-22D-R10. Catalytic Converter
Underbody and Double Converter System

Mark VII / Continental - 5.0L Engine Removal

Raise vehicle.
Remove air injection tube and check valve.
Remove bolts attaching catalytic converter to inlet pipes.
Remove nuts attaching muffler inlet pipe to converter outlet flange.
Remove converter.
Replace any damaged parts.Catalytic Converter
Installation

Position spacers above and below converter.
Attach the heat shields.
Insert converter hanger rods into the hanger brackets.
Position converter to inlet pipes using new gaskets and install attaching bolts. Do not tighten bolts.
Align exhaust system, refer to appropriate illustration.
With exhaust system aligned:
Tighten converter to inlet pipe bolts to 27-41 N-m (20-30 Lb-Ft).
Tighten muffler inlet pipe to converter outlet flange attaching nuts to 27-41 N-m (20-30 Lb-Ft).
Install the new air tube and check valve.
Check system for leaks and lower vehicle.Authorized Modifications Decal

The preprinted Authorized Modifications Decal shown below is provided in the parts kit.

Insert your P & A Code and date and attach the Authorized Modifications Decal to a clean surface on the fan shroud.
Place the clear overlay on the decal.
Preprinted Authorized Modifications Decal



EMISSIONS RECALL
90E94

http://img495.imageshack.us/img495/186/label7en.png

[Vitas]

Emissions Recall 90E94

Rich,

Thanks for taking the time to post the TSB!

Vitas

[Fordace]

email sent Vitas.......Rich

[pro-five-oh]

Are LoL moderators the BEST or what?;)

[Fordace]

Vitas, PICS sent too......

PRO......thanks:o

[gadget73]

Our 1985 Tbird had it done, I think. I vaguely remember a sticker on the fan shroud. The car is sitting in storage but you've finally given me the best reason to pull it out of mothballs and take it out for another spin.

I'll get back to ya in a couple of days. I bet it was something EGR related.

The EGR mod you're thinking of was the removal of that cooler thing that some of them had. It got clogged with carbon all the time and would make the pintle stick open. Essentially unbolt the EGR valve, remove the spacer, chuck it, and re-install the EGR valve. Least I think thats what you're thinking of.

[Vitas]

Are LoL moderators the BEST or what?;)

YES! http://www.lincolnsonline.com/forum/images/icons/icon10.gifhttp://www.lincolnsonline.com/forum/images/icons/icon10.gifhttp://www.lincolnsonline.com/forum/images/icons/icon10.gif

Rich, thanks again!

The service manager at the Lincoln dealer thinks that the catalytic converter 90E94 recall does not apply to 1985 Continentals.

"1985 engine families consist of carryover calibrations from 1984 only."

"1984-85 Model Continental / Mark VII — 49 states 5.0L engines with calibration code 4-22D-R10. Catalytic Converter Underbody and Double Converter System."

So we looked at the calibration code on my car, and it looks like 522?R10, starts with a 5, not a 4.

What do any of you 1985 Continental owners have for a 49 states, non high altitude calibration code?

He suggested checking the PFE hose connected to the EGR, as it can "jelly up" blocking flow, and/or cleaning the EGR.

The TSB I posted a few months ago dealt with a carbon trap, but the chart does not seem to show it as applicable to 1985 Continentals:

http://www.geocities.com/vitas00/LINCOLNS/egr.html

but it does refer to TSB 86-2-22 (which I don't have) "if carbon-buildup is not excessive (carbon chunks not larger than 1/8."

In the meantime I spoke to the original owner this evening and he says that he never changed the sparkplugs, that they are the original plugs.

A KOEO code test this evening shows a 31, and then what appears to be a continuous memory code of 18.

After clearing continuous memory it shows 31, followed by 11.

The symptoms are a very slight stumbling at drive idle only when hot, and high emissions.

All suggestions are welcome.

[Vitas]

FMC_Passenger_1985

Engine Liters/ CID/ Type
5.0L/302/V8 (NON HO)

{18}—On models with calibration codes 4-22B, 4-22C, 4-22F, 4-22H, 4-22Q, 4-22T, 5-22B, 5-22Q & 5-22T which experience engine stall at idle, EGR valve stuck open, a service modification can be performed. For additional information, refer to Powertrain Management in Diagnostic & Repair for the applicable model.

2}—Electronic EGR valve (sonic-cooler). For complete EGR system testing, refer to Powertrain Management in Diagnostic & Repair for the applicable model.


http://library.motoralldata.com/techRef/WebHelp/Emission_Control_System_Application_Chart/FMC_Passenger_1985.htm

[Vitas]

The latest word from reggie bird:

1. Check EVR to EGR vacuum hose for blockage

2. Check MAP sensor vacuum hoses - can plug due to contamination from leaking silicone gel in the MAP sensor.

3. Remove EGR. Block hole where EGR bolted to. If idle stuble goes away problem is the EGR valve.

4. Inspect EGR 1/8" tube/hole for carbon. Pick it out with a screwdriver and or vacuum it. Do NOT spray any solvents in as the sensor may get damaged. Install a new EGR gasket.

5. Check EVR bleed hole for blockage.

6. Also check the throttle body plate for deposits that prevent it from closing properly, and clean as necessary.

BTW, if found what should be the key to the calibration code, a green sticker with "ML" on the trunk lid hinge. It should reference to ECA and Calibration Assy part numbers and show the calibration.

[Fordace]

who's Reggie Bird?

I've seen a ton of those clogged map sensor lines.....new map, new hose.....:)

[Vitas]

who's Reggie Bird?

I've seen a ton of those clogged map sensor lines.....new map, new hose.....:)

An engineer friend in Dearborn. He said that it was not necessary to replace the map sensor, just replace the affected vacuum lines.

$60 for an EEC-IV map isn't bad, for a Mark VI EEC-III it is at least $250 and something like $500 from Ford. I had what looked like a new plastic map in the Mark VI, and after I replaced it with the original steel map from a junkyard the car ran much better.

[Vitas]

Service Bulletin Number: 86-2-22
Bulletin Sequence Number: 003
Date of Bulletin: 8601
NHTSA Item Number: 83421
Make: LINCOLN
Model: MARK VII
Year: 1985
Component: EXHAUST GAS RECIRCULATION VALVE (EGR VALVE)
Summary: IDLE STALLS-5.0L EEC III AND IV-EGR VALVE STUCK OPEN-CARBON BUILD-UP IN PINTLE A REA OF EGR
VALVE-PROCEDURE TO TEST/REPLACE EGR VALVE, REMOVE EGR COOLER, INSTALL NEW MOUNTING STUDS,
GASKET AND CLAMP-ALL 1983-85 LINCOLN CONTINENTAL, MARK VII, TOWN CAR SO EQUIPPED

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The carbon trap bulletin:

Service Bulletin Number: 87-1-15
Bulletin Sequence Number: 006
Date of Bulletin: 8701
NHTSA Item Number: 89227
Make: LINCOLN
Model: MARK VII
Year: 1985
Component: EXHAUST GAS RECIRCULATION VALVE (EGR VALVE)
Summary: ENGINE SERIAL NUMBER-LOCATION-1.9L,3.0L AND 3.8L-INFORMATION CONTENT ON DECALS F OR
ENGINES-ALL LINCOLN 1983 MARK VI 1983 TO 1985 CONTINENTAL MARK VII AND TOWN C AR WITH 5.0L WITH EEC III
AND EEC IV CALIBRATION

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Service Bulletin Number: 89-14-7
Bulletin Sequence Number: 037
Date of Bulletin: 8907
NHTSA Item Number: SB008006
Make: LINCOLN
Model: MARK VII
Year: 1985
Component: FUEL:THROTTLE LINKAGES AND CONTROL
Summary: THROTTLE POSITION SENSOR MOUNTING SCREWS HARD TO REMOVE SERVICE TIP-ALL THROTTLE
POSITION SENSOR (TPS) MOUNTING SCREWS HAVE "POZIDRIVE" HEAD-TO PREVENT ROUNDED O R DAMAGES
SCREW HEADS WHEN SERVICING THE TPS MOUNTING SCREWS, ALWAYS USE #2 "POZ IDRIVE" SCREWDRIVER-ALL
1983-89 LINCOLN MARK VII/ TOWN CAR/AND CONTINENTALS TLH

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Service Bulletin Number: 89-16-4
Bulletin Sequence Number: 041
Date of Bulletin: 8908
NHTSA Item Number: SB008629
Make: LINCOLN
Model: MARK VII
Year: 1985
Component: FUEL:THROTTLE LINKAGES AND CONTROL
Summary: EEC-IV THROTTLE POSITION SENSOR-APPLICATION CHART-SERVICE TIP-TO ASSIST TECHNICI ANS IN
CORRECT PART USAGE, IF WRONG TPS INSTALLED IT COULD FAIL PREMATURELY-ALL 1984 TO 1988 LINCOLN MARK
VII AND TOWN CARS DG



http://lsc.netherealm.net/1985.html

[Vitas]

Took the EGR valve off, pressed the pintle - plunger a dozen times, wiped some carbon in the area off with a rag.

Blew through the nipple, diaphragm held air.

Blew through a hose with a red stripe that was attached to the EGR, heard air come out at the throttle body.

Could not find the map sensor.

Changed the distributor cap and rotor for good luck.

Drives fine, code test returns "11" system pass.

[Vitas]

Beforehttp://www.geocities.com/vitas00/LINCOLNS/egrc1.jpg


After

http://www.geocities.com/vitas00/LINCOLNS/egrc2.jpg

[peppermrj]

Could not find the map sensor.

For future reference it is located behind the coolant overflow bottle. You have to unbolt the bottle from the fenderwell to get to the vacuum lines. Also note that there are a lot of electrical components (relays and such) underneath the coolant bottle.

[Nick]

I should probably clean out the EGR in my Continental. I bet it looks 100x worse.

[Vitas]

For future reference it is located behind the coolant overflow bottle. You have to unbolt the bottle from the fenderwell to get to the vacuum lines. Also note that there are a lot of electrical components (relays and such) underneath the coolant bottle.

Thanks!

[Vitas]

I should probably clean out the EGR in my Continental. I bet it looks 100x worse.

I am amazed that it was that easy. Two bolts, a little cleaning. It is even more incredible that the code reader recognized the problem, which I think was a problem of the pintle not seating properly, not being stuck, and that then it recognized that that problem was gone.

I am trying to find out what the purpose of the EGR cooler removal and the carbon trap TSB's are all about. I did not touch that aspect of it on my car.

[dallaswreckerdude]

The 84 Crown Vic I owned had the modification sticker on it. NTSA site has info on recalls, I owned a 1980 Tbird that was recalled simply because I visited the site and printed out the recall and took it to the dealer, who then replaced the defective parts, at that time the car was 15 years old, but FoMoCo, seems to stand behind their products, guess thats why I continue to buy and drive them.

[Vitas]

dallaswreckerdude,
Welcome to the board!

It is an interesting issue, whether, today, they would honor a 20 year old emissions recall.

[Vitas]

Passed the Massachusetts emissions test today with flying colors.:cheer: :dance: :drink: :gears: :cheer:

No more worrying about:

:cop:

I can't believe that cleaning the EGR was all there was to it.