2.2L Turbo Intermittent Malfunction Indicator Light (95-3-5)

Publication date: 1995-02-13
Reference number: 95-3-5
Supersedes refnos: 93-22-5

2.2L TURBO INTERMITTENT MALFUNCTION INDICATOR LIGHT

TECHNICAL SERVICE BULLETIN

Reference Number(s): 95-3-5, Date of Issue: February 13, 1995
Superceded Bulletin(s): 93-22-5, Date of Issue: October 27, 1993

LAMP - MALFUNCTION INDICATOR LIGHT (MIL) - INTERMITTENT ACTIVATION - GT MODELS WITH 2.2L TURBO ENGINES

APPLICATION

Model(s): Ford: 1990-92 Probe

Bulletin No.: 95-3-5

Date: February 13, 1995

This bulletin supersedes Technical Service Bulletin No. 93-22-5, dated October 27, 1993.

This TSB is being republished in its entirety to correct the Pin numbers for the Pinpoint tests.

ISSUE

The Malfunction Indicator Light (MIL) may illuminate intermittently. This may be caused by output voltage variations from the EGR Valve Position Sensor (EVP) as a result of carbon deposits on the Exhaust Gas Recirculation (EGR) valve.

ACTION

Install a EGR Valve Plate Set which includes a spacer plate and O-ring to move the EVP away from the EGR. Refer to the following procedure for service details.

SERVICE PROCEDURE

Remove the vacuum hose from the EGR valve. See Fig 1 .

Fig 1: Removing Vacuum Hose From EGR Valve
It the MIL is on, install the break out box and turn the ignition switch to the RUN position.
1. Using a voltmeter, check the voltage between Pins 26 and 46. Verify that the voltage is between 4.5-5.5 volts.
2. Check the voltage between Pins 27 and 46. If the MIL is on and/or the voltage between Pins 27 and 46 is greater than 1.1 volts, proceed with the repair procedure.
Remove the EGR valve from the engine by removing the three (3) 10 mm bolts. Disconnect the vacuum line and disconnect the EVP sensor connector.
Loosen the two (2) screws on the position sensor of the EGR valve. See Fig 2 .

Fig 2: Screws On Position Sensor

NOTE: Be careful not to damage the slots of the screws while removing them.
Remove the O-ring (brown) between the position sensor and the diaphragm case.
Remove any dirt between the position sensor and the diaphragm case. See Fig 3 .

Fig 3: Area Of Dirt Removal
Install the new O-ring from the EGR Valve Plate Set by sliding it down to the groove on the flange part. See Fig 4 .

Fig 4: Installing O-Ring

NOTE: When installing the o-ring, be careful not to twist or otherwise damage it.
Install the new plate from the EGR Valve Plate Set (F2PZ-9D475-J) and reinstall the position sensor on the EGR valve. See Fig 5 .

Fig 5: Reassembly Of Position Sensor
Install the EVP harness. Check the voltage values of the new EVP installation (Step 2). The voltage between Pins 27 and 46 should be between 0.3-0.8 volts.
Disconnect the break out box and reconnect the harness to the PCM.
Apply 19" Hg of vacuum to the EGR valve with a vacuum tester. Confirm that the valve holds more than 15" Hg for at least one (1) minute. See Fig 6 .

Fig 6: Applying Vacuum To EGR Valve
Reinstall the EGR valve on the engine.
Reconnect the vacuum hose.

PARTS INFORMATION

Part Number	Part Name
F2PZ-9D475-J	EGR Valve Plate Set

WARRANTY INFORMATION

WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper

Warranty Coverage For 1992 Models, Basic Warranty

Coverage For 1990/91 Models, And Emission

Coverage For All Model Years.

OPERATION: 950305A

DESCRIPTION: Check And Install EGR Valve Position Sensor Spacer Plate

TIME: 0.6 Hr.

DEALER CODING: BASIC PART NO.: 9D475

CONDITION CODE: 41

OASIS CODES: 20600, 403000, 698298