Vehicle Inspection Vehicle Raised On A Hoist
FIGURE 7 - OEM EXHAUST SYSTEMS:
FIGURE 8 - OEM EXHAUST SHIELD 1985-1/2 - 1987 MODEL YEAR:
NOT 10. Exhaust System for Ford Components and Correct Routing and Retention OK OK [ ] [ ] The Ford exhaust system, as shown in Figure 7, provides the correct routing and flow capacity Non-Ford exhaust components could be less durable and quite often are more flow restrictive than Ford components Table 2 lists Ford Service Part Numbers. If a non-Ford exhaust system or exhaust component is installed. it should be noted on the inspection sheet that such a system or component could be made restrictive and less durable than the Ford system or component. Inspect the exhaust system for leaks or ruptures and inspect the muffler outer wrapper lock seam for separation. For 1985-1/2 to current Ford vehicles it is necessary to remove the muffler heat shield (Figure 8) to inspect the muffler. Reinstall the heat shield if the muffler is found to be OK. Replace the muffler when the seam opening is wide enough to see the inner muffler shell. Replacement Ford Mufflers for 1985-1/2 to 1987 Models have a muffler heat shield included. Note required repairs on the inspection sheet. Contact the FPSO District Office if you have any questions concerning needed corrections.
TABLE 2
ECONOLINE 7.5L EXHAUST SYSTEM PARTS LIST
FIGURE 8 - OEM EXHAUST SHIELD 1985-1/2 - 1987 MODEL YEAR:
NOT 11. Muffler Heat Shield on 1985-1/2 Through 1987 Models for Correct Installation OK OK [ ] [ ] The muffler heat shield, shown in Figure 8, is a part of the 1985-1/2 through 1987 Ford production and service muffler assembly. The shield is provided and required to protect the vehicle underbody and combustible ground materials from the increase in exhaust temperatures resulting from the exhaust emission controls required on these models. Confirm that the muffler heat shield is installed properly and in good condition. Replace any missing parts and note on the inspection sheet. Ford mufflers for use on pre-1985-1/2 vehicles are not equipped with the shield.
NOT 12. Underbody Undercoating for Damage Caused by Exhaust Heat
OK OK
[ ] [ ] Some instances of undercoating smoking and causing fumes have been reported. If added underbody anti-rust undercoating shows signs of heat deterioration in areas exposed to exhaust heat, it should be removed from these areas unless it is already completely hardened. Undercoating that is completely hardened and does not exhibit the potential for dripping on the exhaust does not need to be removed. Indicate the need for corrections on the inspection sheet. Contact the FPSD District Office if you have any questions concerning needed corrections.
NOT 13. Non-Ford Underbody Structures, Body Mounts for Air Flow Restriction
OK OK
[ ] [ ] Shields or structures on top of the frame rails outboard of the fuel tank(s) should permit air flow over and
around the tanks. For example, on E-350 cutaway models, an open space is recommended between the top of the chassis frame rail and the bottom of the patient compartment floor which will allow cross-flow of air over the tank. Indicate the need for corrections on the inspection sheet Contact the FPSD District Office if you have any questions concerning needed corrections.
FIGURE 9:
NOT 14. Fuel Tank Filler Hose and Filler Vent Hose Installation is Free of Liquid Traps, Pinches, Kinks, and
OK OK Exposure to Sharp Edges
[ ] [ ]
The fuel tank filler hose, filler vent hose, and pipes must be routed to avoid having any sections that sag below the tank connections allowing fuel to be trapped in the hose (sink trap). (See Figure 9). Both the filler and vent must be installed with a downhill routing from fuel cap to the tank connection. If the center of either filler opening is less than 10.3 inches above the top of the frame (Figure 9) contact FPSO District Office. The routing of the hoses and pipes must also avoid exposure to sharp edges and be free of holes, pinches, and kinks as shown in Figure 9. If kinked or pinched hoses are found, they must be replaced because they will have already taken a permanent set. Also, each filler pipe and vent hose must be routed only to its proper fuel tank and not inter-connected or separately vented. The filler hoses and pipes must not contact suspension components during full suspension travel. Indicate the need for corrections on the inspection. Contact the FPSO District Office if you have any questions concerning needed corrections.
FIGURE 10:
NOT 15. Fuel Tank Vapor Vent Valves for Damage Caused During Vehicle Manufacture or by Contact with Body
OK OK Components
[ ] [ ] The fuel tank vapor vent valves must be correctly positioned in the grommet at the fuel tank openings as shown in Figure 10. The valves must not contact other components and be free of damage. Note any discrepancies on the inspection sheet and provide repair directions.
NOTE: New valves are installed in Service Kit E3TZ-9000-A or E5UZ-9000-A.
FIGURE 11:
NOT 16. Fuel Tank(s) Vapor Vent Lines OK OK [ ] [ ] E-350 vehicles without carbon canisters (1983-85 49-State Emission) - Tanks are vented to the atmosphere through the fuel tank vapor vent valves and hoses to breather caps clipped to the tank flanges as shown in Figure 11.
- Check the hoses for restrictions and freedom from kinks or pinches.
- Check the breather cap at the end of the hose to be sure it is open and clear of dirt, etc.
E-350 vehicles with carbon canisters (1985-1/2 through 1987 49-State and 1983-87 California Emission)
FIGURE 12 - DUAL CARBON CANISTER VAPOR VENTING SYSTEM:
- Tanks are vented to canisters through the fuel tank vapor vent valves and hoses as shown in Figure 12.
- Check the hoses and tubes to be sure they are correctly routed and clipped without kinks or pinches throughout their entire length from fuel tanks to canisters as shown in Figure 12.
- Check and confirm that there is at least 1/2 inch clearance between the top of the vent line and the bottom of the floor (7/8 inch total minimum distance between the vehicle frame and any added floor structures including floor sills, braces, and floor) especially in the areas where these vent lines are routed above the Ford mid-ship fuel tank crossmember and the rear fuel tank frame crossmember or cutaway models as shown in Figure 12. At least 1/2 inch clearance is required to allow for deflections which can occur during vehicle operation. In areas that are obstructed from view, use your fingers and wiggle the tubes to confirm at least 1/2 inch vertical movement is possible.
Indicate the need for corrections on the inspection sheet. Contact the FPSD District Office if you have any Questions concerning needed corrections.
NOT 17. Flow of Fuel Tank Vapor Vent Lines for Free Unobstructed Flow OK OK
[ ] [ ] On vehicles equipped with carbon canisters, a vapor line flow check must be made using a hand powered
vacuum pump or pressure pump.
VACUUM METHOD
- With the engine off, remove the fuel caps. Disconnect each vapor vent line at the interconnecting point on the right frame rail. Dual tank vehicles will have a "T" or "Y" fitting at this point.
CAUTION: Because these lines may contain drops of liquid fuel, use a long clear jumper tube to avoid entry of liquid into the vacuum pump or onto your clothing.
FIGURE 14:
- Using a hand operated vacuum pump in turn, apply vacuum to the vapor vent lines to each tank as shown in Figure 14.
- If no vacuum can be developed, the lines are not kinked or pinched. If any vacuum is developed the lines are restricted and the cause must be found and eliminated. Indicate the need for corrections on the inspection sheet. Contact the FPSD District Office if you have any questions concerning needed corrections.
FIGURE 13 - HAND PRESSURE PUMP CONNECTION:
PRESSURE METHOD:
- Alter a radiator pressure tester as shown in Figure 13.
FIGURE 14:
- With the engine off, remove the fuel caps. Disconnect each vapor vent line at the interconnecting point on the right frame rail, as shown in Figure 14. Dual tank vehicles will have a "T" or "Y" fitting at this point.
CAUTION: Because these lines may contain drops of liquid fuel, avoid spilling it onto your clothing.
- Using the hand operated pressure pump, apply pressure (one full stroke) to the vapor lines to each tank as shown in Figure 14.
- If no pressure (1/2 psi maximum) can be developed and held longer than 0.5 seconds, the lines are not pinched or kinked. If it holds pressure longer than 0.8 seconds, the lines are restricted and the cause must be found and eliminated. Indicate the need for corrections on the inspection sheet. Contact the FPSD District Office if you have any questions concerning needed corrections.
FIGURE 15:
NOT 18. Fuel Lines, Tank to Engine Supply and Return, for Correct Material, Pinches, Kinks, Adequate Retention
OK OK or Other Damage and Signs of Leaks
[ ] [ ] Leaks are evidenced by streaking of undercoating and/or damp appearing surfaces. The engine fuel supply and return line, as shown in Figure 15, on 1983-85 model vehicles are composed of steel with composition rubber hose connections. The lines on 1986-87 model vehicles are composed of nylon, steel, and composition rubber hoses. Indicate the need for corrections on the inspection sheet. Contact the FPSD District Office if you have any questions concerning needed corrections.
NOTE: Composition (black rubber) hoses must only be serviced with fluro elastomer material.
NOT 19. Non-Ford Fuel Pumps
OK OK
[ ] [ ] The fuel system must not have an auxiliary booster type fuel pump installed. If one is installed, it must be
removed and the fuel supply system restored to Ford condition including all lines, clamps, and proper selector valve location. Note on the inspection sheet the need for removal of such a booster pump.
FIGURE 16:
NOT 20. Air Cleaner Air Temperature Control System for Correct and Complete Installation of Ford Ducts, Heat
OK OK
[ ] [ ] Valve, and Air Cleaner Inlet
The air cleaner air temperature control system, shown in Figure 16, provides warmed air to the engine induction system during the engine warm-up period and then converts to cooler outside air when the engine is at operating temperature. The cooler and denser outside air is required for correct air fuel ratios and combustion characteristics. If the air temperature control system is missing, non-functional, blocked, or not connected to the air cleaner, elevated temperature, driveability and detonation concerns can be experienced. Note on the inspection sheet any missing, incorrect, or damaged parts that need to be replaced.