Engine Purge Revision

1. Disconnect the battery ground cables, if not previously done.

2. Remove distributor cap and wires, adapter, and rotor.

3. Remove the interior engine cover for accessibility to the engine.

4. Remove the air cleaner.

5. Remove the carburetor and discard gasket, leaving the EGR spacer in place. Cover manifold openings and remove any gasket material which may have adhered to the EGR spacer and base of carburetor.

FIGURE 14:

FIGURE 15:

FIGURE 16:

6. a. Remove 14289 wiring harness, as shown in Figures 14, 15, and 16.

b. Install the new 14289 (Item 14) wiring harness, routed in the same manner as the one removed. The new harness will have male connectors for the electric carburetor bowl vent solenoids. These connectors are to be routed along the choke side of the carburetor passing in front of the carburetor location. See Figures 14, 15, and 16.

7. Replace any wiring harness tie straps that were removed in Step "6".
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FIGURE 17:

8. Remove the PCV vacuum hose and tube which connects the PCV valve to front of carburetor throttle body and discard. (See Figure 17).
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FIGURE 18:

9. Remove the primary and secondary vacuum thermal bowl vent valves and discard. Save rubber hose(s) for later installation of solenoid bowl vent valves and cap vacuum sources with caps (Item 7) and plastic in-line connectors (item 10) provided. (See Figure 18).

FIGURE 19:

10. Fabricate a new PCV line from bulk 3/8" hose (Item 6) by cutting hose lengths necessary to install the hot idle compensator (HIC) and Tee assembly (D7BE-9E890-AA) (Item 4) and a 3/8" plastic Tee (part number 388131-S) (Item 13) in the PCV line. Position the 3/8" plastic Tee between the HIC valve and the end of the PCV hose that will connect to the fitting on the carburetor base. (See Figure 19). The open port on the Tee will be used later.

Route the new PCV hose with the HIC valve assembly and the plastic "Tee" under the spark plug wires along the right rocker arm cover to the front of the carburetor throttle body.
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FIGURE 20:

11. Remove the large canister purge lines from the manifold vacuum fittings. Install caps (Item 8) over open vacuum fittings. (See Figure 20).

FIGURE 21:

Both purge lines run to the rear of the intake manifold and come together in a "Y" connector. (See Figure 20). Connect the purge line "Y" fitting to the external port of the PCV line "T" fitting (from Step "10") using a piece of 3/8" hose (Item 6). (See Figure 21).

Trim or shorten the ends of the large purge lines if necessary for proper installation.
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FIGURE 22:

12. Disconnect the carburetor fuel supply line from the vapor separator. (See Figure 22).

13. Separate the supply and return lines from the vapor separator and discard the vapor separator.
14. Remove the clip that holds the supply and return lines together. This is located above the block mounted retention clip. Discard this clip; it is an assembly aid.

15. Cut two pieces of insulation sleeving (Item 27). Cut one piece about 15 inches long and the other about 12 inches long.

NOTE: Tape or cap the open end of the fuel lines before installing the sleeves. A spray of silicone lubricant inside the sleeve will ease the installation.

16. Slide the shorter piece over the supply line (larger diameter) down to the engine block clip.

17. Slide the longer piece over the return line (smaller diameter) down to the engine block clip.

18. Connect the supply and return lines to the new vapor separator (Item 31) and tighten to 20 to 24 N-m (15 to 18 lb. ft.).

19. Cut a 6 inch piece of sleeving (Item 27) and slide it over the carburetor supply line.

20. Attach the carburetor supply line to the vapor separator. Do not tighten it.
NOTE: If this vehcile is equipped with an electric auxiliary throttle "kicker", install High Idle Thermactor Air By-pass Kit E3TZ-9000-B (Kit D) per the instructions provided with that kit. If this vehicle is equipped with a mechanical throttle "kicker", it must be changed to the electric type first and then install this kit. Contact the vehicle owner to arrange installation.

21. With the carburetor on the bench, install the primary and secondary electric bowl vent solenoids (D8TE- 9B982-B1A) (Item 1) on the carburetor, using the hoses removed in Step 7. Use minimum hose lengths on the front solenoid bowl vent installation. The word CARB and an arrow appear on the plastic outlet in raised letters. The arrow should be pointed toward the carburetor.
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FIGURE 23:

22. Install a cap on the spark port (Item 7) located on the front of the carburetor throttle body (See Figure 23). Using a new carburetor gasket (E5HE-9C477-BA) (Item 3), install the carburetor (do not tighten down), fuel supply line, attach the throttle linkage, transmission kick/down lever, hoses, choke wire, and solenoid bowl vent ground wires.
23. Tighten the carburetor mounting nuts to their proper torque (19 to 27 N-m or 14 to 20 ft. lb.).

24. Tighten the vapor separator and carburetor fuel supply line to 20 to 24 N-m (15 to 18 ft. lb.).

25. Inspect the hoses between the frame mounted fuel lines and the engine mounted lines. Be certain that they are oriented away from the exhaust manifold and any other hot, sharp or abrasive surface.

FIGURE 24:

26. Install the thermal vent valve (D8TE-9E589-B1A)(Item 2) in the primary bowl vent line immediately after the bowl vent solenoid with the colored side facing toward the carburetor (See Figure 24). Use the 90~ formed hose originally removed from the rear bowl vent. It will be necessary to cut 1/2" off of each end of this hose.

FIGURE 23:

27. Connect the PV hose to the 3/8" tube on the front of the carburetor throttle body. (See Figure 23).

28. Install distributor, adapter, rotor, cap and wires.
29. PRESSURE TEST FUEL SYSTEM

Step A - Pressure test both fuel tanks. Use the Rotunda Fuel Tank Assembly Leak Tester Number 134-00003 to be sure the reinstalled fuel tank, filler system, fuel lines, and vent system are leak free. Checking instructions are provided with the tester. Be sure to retest the system after repairing the leak.

Step B - Remove pressure test equipment and temporary plugs and reattach vent lines.

30. Refill the fuel tanks

NOTE: WARNING - Before turning the key, make sure the parking brake has been set fully. On vehicles with automatic transmission, place the gearshift selector in P (PARK). Check routing of hoses for clearance, cap any lines which may allow vacuum passage. DO NOT idle vehicle in closed area for any extended time unless tailpipe is externally vented out of the area.
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31. Reconnect the battery ground cable and start vehicle. Check for fuel and vacuum leaks and installation. Check for choke wire power. The choke wire should have approximately 7 to 8 volts with the engine running.

NOTE: Some ambulance builders run a separate wire to the choke in place of the existing wire included in the Ford wiring harness.

If the thermactor system has been deactivated by the removal of the air pump drive belt, the system must be reactivated. However, before installing a new pump drive belt, several procedures must be followed to determine the condition of the system components. These procedures are out fined in the 1987 Engine/Emissions -Diagnosis Shop Manual, Volume H, pages 3-3, 3-5, 3-8, 3-15, and 3-16. The procedures on pages 3-15 or 3-16 should be performed first. Perform any corrective action required.

NOTE: Long term deactivation of the thermactor system by removal of the air pump drive belt will lead to component deterioration due to heat.

32. If Kit E3TZ-9000-B was installed, check for proper operation of the thermactor air-bypass. When the auxiliary throttle kicker is actuated, thermactor air should "dump" to the air cleaner hoses. This test must be performed at normal operating temperature. It is normal for the thermactor air to "dump" to the air cleaner during engine warm up regardless of whether the auxiliary throttle kicker is actuated.

33. Shut the vehicle off.

34. The function of the electric bowl vent solenoids can be felt by touching each solenoid while the ignition key is being switched to the "ON" and "OFF" position. The solenoids will be in the closed position when the key is in the "ON" position.

35. Install the air cleaner. Connect the vacuum (front and rear) lines, zip tube, and hot air stove. Also install the thermactor air-bypass hoses.

36. Replace the interior engine cover over the engine access in the vehicle.

37. Important - On Automatic Transmission Vehicles, the engine manifold vacuum line to the transmission shift modulator may be inadvertently disconnected during kit installation. Double-check all of the manifold vacuum line connections to the transmission shift modulator for proper and secure engagement.

38. Road test vehicle after modification kits are installed to verify proper vehicle operation.
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