I had a CEL in the 96 last summer; it was an IAC DTC; I did the test and the IAC came up good; so...
TSB 91-25-07 IAC Sludge; Poor Idle
Publication Date: DECEMBER 13, 1991
FORD: 1983-87 EXP
1983-91 ******
1984-90 MUSTANG, THUNDERBIRD
1986-90 TAURUS
1986-91 CROWN VICTORIA
1988-90 TEMPO
LINCOLN-MERCURY: 1983-85 LN7
1983-87 LYNX
1984-88 CAPRI
1984-90 COUGAR
1986-90 CONTINENTAL, MARK VII, SABLE
1986-91 GRAND MARQUIS, TOWN CAR
1988-90 TOPAZ
1991 TRACER
LIGHT TRUCK: 1985-90 BRONCO II, BRONCO
1985-91 ECONOLINE, F-150-350 SERIES
1985-92 RANGER
1986-91 AEROSTAR
1991 EXPLORER
ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions.
Hard Cold Start
Stall On Initial Start-Up
Stall During Idle
Stall During Decel
Rough Idle
Rolling Idle
Hesitation During Acceleration
ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years.
Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article.
The idle air by-pass service kit (F2PZ-9F939-A) includes the following items.
One (1) Idle Adjust Spacer
Two (2) Gaskets
Two (2) Attaching Bolts
One (1) "Attention" Sticker
One (1) Instruction Sheet
Refer to the figure for the kit's components.
NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED.
The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required.
CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION
Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation.
Contamination within the idle air by-pass solenoid
Lack of fuel system control (excessively rich or lean)
Ignition timing change
Incorrect or malfunctioning EGR system
Incorrect or malfunctioning cooling system
Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable).
EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared.
If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation.
IDLE SPEED ADJUSTMENT
WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY.
The transmission is in PARK or Neutral.
The parking brake is applied.
The wheels are properly blocked.
The engine is at operating temperature.
The heater. A/C, cooling fan and other accessories are OFF.
The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation.
THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE
Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN #/engine displacement/vehicle application and model year are shown. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used.
SERVICE CLEANING PROCEDURES
The following items should be noted prior to beginning the service cleaning procedure.
Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being serviced.
Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER.
Use a 1" (25.4mm) to 1 1/2" (38.1mm) wire stemmed horse hair or nylon bottle cleaner type brush.
Use rubber gloves and eye protection.
Do not clean throttle bodies identified with a yellow/black "ATTENTION" label.
Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details.
Do not run vehicles with air flow meters when the air duct is removed.
Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA).
PROCEDURE #1
THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING
CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE #2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY.
Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009.
Remove the air duct to the throttle body inlet.
Disconnect the idle air by-pass valve signal lead.
Attach the actuator harness plug to the idle air by-pass valve.
Start the actuator and then start the engine. Do not start engines that have air flow meters.
Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate.
Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating.
Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open.
NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING.
Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall.
Start the actuator and the start the engine. Do not start engines that have air flow meters.
Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running.
Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running.
Stop actuator and stop engine, if running.
NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY.
Reinstall the air duct.
Start and run the engine for about one (1) minute to dry out the solvent residue.
Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
Disconnect the actuator from the idle air by-pass valve.
Reattach the control signal lead to the air by-pass valve.
Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.)
PROCEDURE #2
IDLE AIR BY-PASS VALVE CLEANING ONLY
CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE.
Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent.
Remove the air duct to the throttle body inlet.
Disconnect the idle air by-pass valve signal lead.
Attach the actuator harness plug to the idle air by-pass valve.
Start the actuator and then start the engine.
NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating.
CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA
Stop the engine and actuator. Let everything soak for fifteen (15) minutes.
Start the actuator and the start the engine.
CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS.
Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute.
CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING.
Stop actuator and stop engine if running.
Reinstall the air duct.
Start and run the engine for about one (1) minute to dry out the solvent residue.
Operate the actuator to make sure the solvent is purged from the idle by-pass valve.
Disconnect the actuator from the idle air by-pass valve.
Reattach the control signal lead to the air by-pass valve.
Check engine for normal operation.
NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE
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