I'M Back

[wchampmd]

I have been back on the road after replacing numerous parts that I thought would have an adverse effect on passing an auto inspection. I recently completed a complete tune up wires, plugs, distributor , etc. I had my catalytic converter replaced, and 02 sensor. I even changed my air filter and fuel filter. I went to the inspection place and I am running too rich!!I failed HC 235 over 155 (155 being the standard) I failed CO 7.69 over 1.91 being the standard. My levels are way too high. I checcked my code reader and it is telling me codes 23,31,53,63. (23) = Throttle position sensor out of range, (31) = EVAP control system below minimum voltage( What the heck is an EVAP?) Does this have anything to do w/ EGR or Emissions vac controls?????, (53) = Fuel injection pump lever sensor input greater than self test, and (63) = Throtle position circuit below minimum voltage. I knew I would have to probably change the TPS because I had to change the TP sensor in old my 89 Bronco. Does anyone have any suggestions or insight?

Help get an old 86 eddie bauer 5.0 on the road [-o<

 

[miesk5]

I have been back on the road after replacing numerous parts that I thought would have an adverse effect on passing an auto inspection. I recently completed a complete tune up wires, plugs, distributor , etc. I had my catalytic converter replaced, and 02 sensor. I even changed my air filter and fuel filter. I went to the inspection place and I am running too rich!!I failed HC 235 over 155 (155 being the standard) I failed CO 7.69 over 1.91 being the standard. My levels are way too high. I checcked my code reader and it is telling me codes 23,31,53,63. (23) = Throttle position sensor out of range, (31) = EVAP control system below minimum voltage( What the heck is an EVAP?) Does this have anything to do w/ EGR or Emissions vac controls?????, (53) = Fuel injection pump lever sensor input greater than self test, and (63) = Throtle position circuit below minimum voltage. I knew I would have to probably change the TPS because I had to change the TP sensor in old my 89 Bronco. Does anyone have any suggestions or insight? Help get an old 86 eddie bauer 5.0 on the road [-o<

yo,

yeah, replace the TPS, bec DTCs and that both HC & CO are high (less $ and simple fixes first, right?

23 Throttle Position sensor (TP). Voltage out of specification (outside the range of .2 to 4.84 volts).

Sensor, Throttle Position (TPS) Testing & Operational Description & Parameters (click on Sensors) by Ryan M (Fireguy50) at fordfuelinjection.com

53 Throttle Position (TP) sensor voltage is too high.

63 Throttle Position sensor voltage is too low.

btw, saw one Bronco 5 yrs ago w/loose TPS connector...check screws too before pulling it...maybe mark an outline around da sensor on TB so that new TPS is aligned same as old one

EVAP = EVP....

- EGR Valve Position (EVP) Sensor Troubleshooting, Code 31, Ford Source: by Dan J at asashop.org - EGR Valve Position (EVP) Sensor Troubleshooting, Code 31, Ford; If the pintle position sensor (Ford calls it the EVP sensor) is shorted or open, you could have a code set. Source: by Harry G at asashop.org

EGR Valve Position (EVP) Sensor Operation & Testing, Ford Source: by Ryan M (Fireguy50) at fordfuelinjection.com

 

[2NDTOUR89]

I just replaced my TPS for the same issue and I just went through inspection and passed. I would go that route.

 

[wchampmd]

Thanks alot guys I will take all suggestions and put them to work. Hope to report back with good news. >-

 

[miesk5]

also, check TPS connector, blades, wire/strands, etc. for corrosion,,,forgot to mention the simple & <$ checks first!, sorry!!!

 

[wchampmd]

Tkank you guys for the info. I went to change the TPS and EGR sensor and found that the hillbilly who owned the bronco before me cut the EGR exhaust pipe and crimped off the pipe below the EGR and the lower intake. I also found that he disconnected the vaccum line from the EGR to the solenoid. I can't find where the vaccum line from the egr goes to even w/ the diagram on the hood because the only available vaccum line that is not hooked up is the air bypass valve line or abv. I have changed the EGR exhaust pipe, TPS sensor, the EGR sensor, the EGR valve itself does work and hold vaccum or pressure (tested w/ mighty vac) and I have two vaccum lines left that do not go together. HELP! does anyone have a more intensive diagram of vaccum lines? THE BRONCO DOES RUN ALOT BETTER but I am afraid to go and get it inspected w/ vaccum leak. I think it will pass but I really want to find the proper vaccum conncetion. [-o<

 

[miesk5]

Tkank you guys for the info. I went to change the TPS and EGR sensor and found that the hillbilly who owned the bronco before me cut the EGR exhaust pipe and crimped off the pipe below the EGR and the lower intake. I also found that he disconnected the vaccum line from the EGR to the solenoid. I can't find where the vaccum line from the egr goes to even w/ the diagram on the hood because the only available vaccum line that is not hooked up is the air bypass valve line or abv. I have changed the EGR exhaust pipe, TPS sensor, the EGR sensor, the EGR valve itself does work and hold vaccum or pressure (tested w/ mighty vac) and I have two vaccum lines left that do not go together. HELP! does anyone have a more intensive diagram of vaccum lines? THE BRONCO DOES RUN ALOT BETTER but I am afraid to go and get it inspected w/ vaccum leak. I think it will pass but I really want to find the proper vaccum conncetion. [-o<

yo!

ok:

Vacuum Line Routing Diagram for 86 5.0 Source: by Ford via Steve83 (Steve, That dirty old truck)

Looks as if the air bypass valve line or abv is hooked to the TAB

Fig. 4: Thermactor system on 302 V8 engine by Chilton via AutoZone Click on daigram to view full size

find where the vaccum line from the egr goes to -

- VRESER vacuum resorvoir; stores excess vacuum to prevent rapid fluctuations and sudden drops in a vacuum signal, such as during acceleration

Vacuum Line Routing Diagram for 78-86 Bronco/Ford truck Source: by AutoZone.com (under license from Delmar Publishers, comb of Chilton/Nichols/Delmar & Haynes); some may be incorrect, as reported by Seabronc, thanks Seabronc!

Thermactor (Smog air pump)

This pumps fresh air into the exhaust system, to burn left over hydrocarbons, lowering emissions. The computer uses 2 air valves (TAB & TAD) to control where the air flows depending on engine operation.

Thermactor Air Bypass (TAB) shunts air to the atmosphere, when no air is needed. When air is needed it sends air to the second valve TAD; by Ryan M

also by Ryan; The EGR Vacuum Regulator (EVR) controls the opening and closing of the EGR valve. The EVR is an electromagnetic solenoid and should have between 20-70 ohms resistance between the pins. +12volts should be constant on one side from the EEC Relay, the computer controls the ground signal when EGR flow is needed.When the EGR Vacuum Regulator (EVR) is off, both ports vent slowly to atsmophere.To test it mechanically check to see if vacuum is present at the EGR valve with the electrical connector unplugged from the EVR. The top port should not have vacuum! Because that would open the EGR at the wrong times.With everything connected and the engine running ground out the pin 33 side. The EGR vavle should open and the engine RPM should change.

Ford EGR valves will open 50% at 4 inHg of vacuum, and 100% at 8 inHg of vacuum. See the depiction for vacuum line source and "to EGR Valve"

Sensor Locations, MAP, IAC, TPS, ACT, ECT, ISC, TAB-TAD, TFI, EEC Relay, Fuel Pump Relay & EGR Position Sensor in a 85 302 Source: by Chris B (Blue, bronco boy) at telus.net

TAB solenoid- (mounted next to the coil)

TAD solenoid- (mounted next to the coil)

EGR solenoid- (mounted in front of the coil)

what did I forget; will be back in a day or 2...am rushed here...GL!

 

[miesk5]

ok, forgot this;

The Thermactor Air Bypass solenoid is controlled by the EEC-IV computer and provides vacuum to the Air Bypass/Air Control Valve. With vacuum present, air flows through the secondary air injection system. With no vacuum, the air from the air pump is dumped to the atmosphere. Essentially, this turns the secondary air injection system on or off. The secondary air injection system adds air to the catalytic converter to improve the burning of NOx gases. This reduces emissions.

Based on vacuum input from the Thermactor Air Bypass Solenoid, and the Thermactor Air Diverter Solenoid, this valve controls the flow of air from the air pump to the exhaust manifold and the catalyst.

& some abbreviations/acronyms..

VCV = Vacuum Control Valve

AIR BPV = AIR ByPass Valve

CPRV = Canister PuRge Valve

CARBON CAN = CARBON CANister

EVR = Egr solenoid Vacuum Regulator valve assembly

EGR = Exhaust Gas Recirculation valve

VCV = Vacuum Control Valve

SOLV = Solenoid vacuum Valve assembly

MAP = Manifold Absolute Pressure sensor

VRESER = Vacuum Reservoir or VRES = Vacuum Reservoir

MAN VAC = Manifold Vacuum

DIV = air DIverter Valve

FPR = Fuel Pressure Regulator

PCV = Positive Crankcase ventilation Valve

TAB = Thermactor Air Bypass vacuum solenoid valve

TAD = Thermactor Air Diverter vacuum solenoid valve

more here

Seabronc has a lot of info on this///he'll jump in w/better info I'm sure1

 

[chuckles1856]

The emissions people were telling me CO was high or the truck is running too rich.

According to the shop my '91 wouldn't pass simply because the emission people were not turning off the Over Drive. The OD unit comes on automatically when started in the '91, but in an '86 I'm not too sure. Emissions are a pain. Good Luck with it!

 

[ilystbronco]

i say u just slip ur local inspection station a 20$ bill or something and hook the truck exhaust senser up to another car while it is dynoed, that would work in my shop,lol we do it all the time cuz we are just too busy and want to get the p.o.s. out of the shop,****

 

[wchampmd]

I want thank all of the guys who gave all the great advice. I finally passed inspection and carbon levels & hc levels were very low. I am legal and the Ole Bronco is back on the road! THANKS AGAIN. >