Help w/ codes please.

18 - is the SPOUT connector plugged in??

21 - engine needs to be fully warmed up. 150* is not fully warmed up.

94 - part of AIR (smog) system

33 - engine warmed up and at idle, egr vacuum hose disconnected, apply 20' vacuum with vac pump, does vacuum hold?? does engine stutter and/or die??

Code 18 - SPOUT out or wiring fault - look missing SPOUT jumper, short to ground or open circuit in SPOUT wiring going back to the computer. Possible bad TFI.

The SPOUT enables the distributor to advance the timing beyond the base setting. Without a working SPOUT, you are locked down to the timing you set with the timing light.

Checking the SPOUT wiring
Tools needed:
DVM or Ohmmeter
10 MM wrench
Phillips screwdriver.
6 ft 16 or 18 gauge jumper wire with alligator clips on each end.

Anytime you make resistance checks, the circuit under test must not be powered on. If it is powered up during the test, your readings will be wrong and you may damage the meter. Do not touch the probe tips when making resistance measurements. If you do, your readings may be inaccurate.

Remove the SPOUT connector from the ignition harness by the distributor. Remove the passenger side kick panel and loosen the 10 MM bolt that secures the computer wiring connector. Use your DVM to measure the resistance between ground and pin 38 (yellow/lt green wire): you should see and infinite open circuit. Keep the DVM connected to pin 38 (you may need a helper at this point). Insert the DVM lead you previously had connected to the body ground into the computer side of the SPOUT connector. You may need some extra wire to extend the test lead, so have some 16-18 gauge insulated wire handy. If you extend the test lead, remember that the quality of the connections may affect your readings. You should see less than 2.0 Ohms: more than that indicates a wiring problem

The following is a view from the computer side of the computer wiring connector.



Diagrams courtesy of Tmoss & Stang&2birds


See the following website for some help from Tmoss (diagram designer) & Stang&2Birds
(website host) for help on 86-95 5.0 Mustang wiring Mustang FAQ - Engine Information Everyone should bookmark this site.

Ignition switch wiring
http://www.veryuseful.com/mustang/tech/engine/images/IgnitionSwitchWiring.gif

Fuel, alternator, A/C and ignition wiring
http://www.veryuseful.com/mustang/tech/engine/images/fuel-alt-links-ign-ac.gif

Complete computer, actuator & sensor wiring diagram for 88-91 5.0 Mass Air Mustangs
http://www.veryuseful.com/mustang/tech/engine/images/88-91_5.0_EEC_Wiring_Diagram.gif

Complete computer, actuator & sensor wiring diagram for 91-93 5.0 Mass Air Mustangs
http://www.veryuseful.com/mustang/tech/engine/images/91-93_5.0_EEC_Wiring_Diagram.gif

Complete computer, actuator & sensor wiring diagram for 94-95 5.0 Mass Air Mustangs
http://www.veryuseful.com/mustang/tech/engine/images/94-95_5.0_EEC_Wiring_Diagram.gif

Vacuum diagram 89-93 Mustangs
http://www.veryuseful.com/mustang/tech/engine/images/mustangFoxFordVacuumDiagram.jpg

HVAC vacuum diagram
http://www.veryuseful.com/mustang/tech/engine/images/Mustang_AC_heat_vacuum_controls.gif

TFI module differences & pinout
http://www.veryuseful.com/mustang/tech/engine/images/TFI_5.0_comparison.gif

Fuse box layout
http://www.veryuseful.com/mustang/tech/engine/images/MustangFuseBox.gif

Code 21 or 116 – ECT sensor out of range. Broken or damaged wiring, bad ECT sensor.
Note that that if the outside air temp is below 50 degrees F that the test for the
ECT can be in error. This code may go away as the engine warms up, so don't dump the codes
on a cold engine

The ECT sensor has absolutely nothing to do with the temperature gauge. They are
different animals. The ECT sensor is normally located it the RH front of the engine in
the water feed tubes for the heater.

The ACT & ECT have the same thermistor, so the table values are the same

ACT & ECT test data:

Use Pin 46 on the computer for ground for both ECT & ACT to get most accurate
readings.

Pin 7 on the computer - ECT signal in. at 176 degrees F it should be .80 volts

Pin 25 on the computer - ACT signal in. at 50 degrees F it should be 3.5 volts. It is
a good number if the ACT is mounted in the inlet airbox. If it is mounted in the lower
intake manifold, the voltage readings will be lower because of the heat transfer.

Voltages may be measured across the ECT/ACT by probing the connector from
the rear. A pair of safety pins may be helpful in doing this. Use care in doing it
so that you don't damage the wiring or connector.

Here's the table :

50 degrees F = 3.52 v
68 degrees F = 3.02 v
86 degrees F = 2.62 v
104 degrees F = 2.16 v
122 degrees F = 1.72 v
140 degrees F = 1.35 v
158 degrees F = 1.04 v
176 degrees F = .80 v
194 degrees F = .61
212 degrees F = .47 v
230 degrees F = .36 v
248 degrees F = .28 v

Ohms measures at the computer with the computer disconnected, or at the sensor with the sensor disconnected.

50 degrees F = 58.75 K ohms
68 degrees F = 37.30 K ohms
86 degrees F = 27.27 K ohms
104 degrees F = 16.15 K ohms
122 degrees F = 10.97 K ohms
140 degrees F = 7.60 K ohms
158 degrees F = 5.37 K ohms
176 degrees F = 3.84 K ohms
194 degrees F = 2.80 K ohms
212 degrees F = 2.07 K ohms
230 degrees F = 1.55 K ohms
248 degrees F = 1.18 k ohms

Diagram courtesy of Tmoss & Stang&2birds



See the following website for some help from Tmoss (diagram designer) & Stang&2Birds
(website host) for help on 88-95 wiring Mustang FAQ - Engine Information

Ignition switch wiring
http://www.veryuseful.com/mustang/tech/engine/images/IgnitionSwitchWiring.gif

Fuel, alternator, A/C and ignition wiring
http://www.veryuseful.com/mustang/tech/engine/images/fuel-alt-links-ign-ac.gif

Complete computer, actuator & sensor wiring diagram for 88-91 Mass Air Mustangs
http://www.veryuseful.com/mustang/tech/engine/images/88-91_5.0_EEC_Wiring_Diagram.gif

Vacuum diagram 89-93 Mustangs
http://www.veryuseful.com/mustang/tech/engine/images/mustangFoxFordVacuumDiagram.jpg

Code 33 - Insufficient EGR flow detected.
Look for vacuum leaks, cracked vacuum lines, failed EGR vacuum regulator. Check to see if you have 10” of vacuum at the EGR vacuum connection coming from the intake manifold. Look for electrical signal at the vacuum regulator solenoid valves located on the rear of the passenger side wheel well. Using a test light across the electrical connector, it should flicker as the electrical signal flickers. Remember that the computer does not source any power, but provides the ground necessary to complete the circuit. That means one side of the circuit will always be hot, and the other side will go to ground or below 1 volt as the computer switches on that circuit.
Check for resistance between the brown/lt green wire on the EGR sensor and pin 27 on the computer: you should have less than 1.5 ohm.

See the following website for some help from Tmoss (diagram designer) & Stang&2Birds (website host)

http://www.veryuseful.com/mustang/tech/engine/images/fuel-alt-links-ign-ac.gif

http://www.veryuseful.com/mustang/tech/engine/images/88-91eecPinout.gif


EGR test procedure courtesy of cjones

to check the EGR valve:
bring the engine to normal temp.

connect a vacuum pump to the EGR Valve or see the EGR test jig drawing below. Connnect the test jig or to directly to manifold vacuum.

Do not connect the EGR test jig to the EVR (Electronic Vacuum Regulator).

apply 5in vacuum to the valve. Using the test jig, use your finger to vary the vacuum

if engine stumbled or died then EGR Valve and passage(there is a passageway through the heads and intake) are good.

if engine did NOT stumble or die then either the EGR Valve is bad and/or the passage is blocked.

if engine stumbled, connect EGR test jig to the hose coming off of the EGR Valve.
Use your finger to cap the open port on the vacuum tee.
snap throttle to 2500 RPM (remember snap the throttle don't hold it there).
did the vacuum gauge show about 2-5 in vacuum?
if not the EVR has failed

EGR test jig


The operation of the EGR vacuum regulator can be checked by using a test light applied across the wiring connector. Jumper the computer into self test mode and turn the key on but do not start the engine. You will hear all the actuators (including the EVR vacuum regulator) cycle. Watch for the light to flicker: that means the computer has signaled the EGR vacuum regulator successfully.

Codes 44 & 94 - AIR system inoperative - Air Injection. Check vacuum lines for leaks, & cracks.

The computer uses the change in the O2 sensor readings to detect operation of the Thermactor control valves. When the dump valve opens, it reduces the O2 readings in the exhaust system. Then it closes the dump valve and the O2 readings increase. By toggling the dump valve (TAB) and switching the diverter valve (TAD) flow from the back of the heads to the air pipe, the computer tests for the 44/94 codes.

Testing the system:
Disconnect the big hose from smog pump: with the engine running you should feel air output. Reconnect
the smog pump hose & apply vacuum to the first vacuum controlled valve: Its purpose is to either dump
the pump's output to the atmosphere or pass it to the next valve.

The next vacuum controlled valve directs the air to either the cylinder heads when the engine is cold or
to the catalytic converter when the engine is warm. Disconnect the big hoses from the back side of the
vacuum controlled valve and start the engine. Apply vacuum to the valve and see if the airflow changes
from one hose to the next.

The two electrical controlled vacuum valves mounted on the rear of the passenger side wheel well turn the
vacuum on & off under computer control. Check to see that both valves have +12 volts on the red wire.
Then ground the white/red wire and the first solenoid should open and pass vacuum. Do the same thing to
the light green/black wire on the second solenoid and it should open and pass vacuum.

Remember that the computer does not source power for any actuator or relay, but provides the ground
necessary to complete the circuit. That means one side of the circuit will always be hot, and the other side
will go to ground or below 1 volt as the computer switches on that circuit.

The computer provides the ground to complete the circuit to power the solenoid valve that turns the
vacuum on or off. The computer is located under the passenger side kick panel. Remove the kick panel &
the cover over the computer wiring connector pins. Check Pin 38 Solenoid valve #1 that provides vacuum
to the first Thermactor control valve for a switch from 12-14 volts to 1 volt or less. Do the same with pin
32 solenoid valve #2 that provides vacuum to the second Thermactor control valve. Starting the engine
with the computer jumpered to self test mode will cause all the actuators to toggle on and off. If after
doing this and you see no switching of the voltage on and off, you can start testing the wiring for shorts to
ground and broken wiring. An Ohm check to ground with the computer connector disconnected & the
solenoid valves disconnected should show open circuit between the pin 32 and ground and again on pin 38
and ground. In like manner, there should be less than 1 ohm between pin 32 and solenoid valve #2 and pin
38 & Solenoid valve #1.

If after checking the resistance of the wiring & you are sure that there are no wiring faults, start looking at the
solenoid valves. If you disconnect them, you can jumper power & ground to them to verify operation. Power &
ground supplied should turn on the vacuum flow, remove either one and the vacuum should stop flowing.

See the following website for some help from Tmoss (diagram designer) & Stang&2Birds (website host)

http://www.veryuseful.com/mustang/tech/engine/images/fuel-alt-links-ign-ac.gif

http://www.veryuseful.com/mustang/tech/engine/images/88-91eecPinout.gif

See Mustang Forums at StangNet for a very nice drawing of the Thermactor Air System (smog pump) plumbing

If you have a catalytic converter H pipe, you need to fix these codes. If you don't, then don't worry about them


Some basic theory to clarify how things work is in order…

EGR System theory and testing

The EGR shuts off at Wide Open Throttle (WOT), so it has minimal effect on performance. The addition of exhaust gas drops
combustion temperature, increases gas mileage and reduces the tendency of the engine to ping. It can also reduce HC emissions
by reducing fuel consumption. The primary result of EGR usage is a reduction in NOx emissions.

The EGR system has a vacuum source (line from the intake manifold) that goes to the EVR, computer operated electronic vacuum
regulator. The EVR is located on the back of the passenger side shock strut tower. The computer uses RPM, Load. and some other
factors to tell the EVR to pass vacuum to open the EGR valve. The EGR valve and the passages in the heads and intake manifold
route exhaust gas to the EGR spacer (throttle body spacer). The EGR sensor tells the computer how far the EGR valve is open.
Then computer adjusts the signal sent to the EVR to hold, increase or decrease the vacuum. The computer adds spark advance to
compensate for the recirculated gases and the slower rate they burn at.




Troubleshooting:
There should be no vacuum at the EGR valve when at idle. If there is, the EVR (electronic vacuum regulator) mounted on the
backside of the passenger side wheelwell is suspect. Check the vacuum line plumbing to make sure the previous owner didn’t
cross the vacuum lines.

Diagram courtesy of Tmoss & Stang&2birds. (the diagram says 88 GT, but the EGR part is the same for 86-93 Mustangs)


The EGR sensor is basically a variable resistor, like the volume control on a radio. One end is 5 volt VREF power from the
computer (red/orange wire). One end is computer signal ground (black/white), and the middle wire (brown/lt green) is the signal
output from the EGR sensor. It is designed to always have some small voltage output from it anytime the ignition switch is the
Run position. That way the computer knows the sensor & the wiring is OK. No voltage on computer pin 27 (brown/lt green wire)
and the computer thinks the sensor is bad or the wire is broken and sets code 31. The voltage output can range from approximately
.6-.85 volt.

The EVR regulates vacuum to the EGR valve to maintain the correct amount of vacuum. The solenoid coil should measure 20-70
Ohms resistance. The regulator has a vacuum feed on the bottom which draws from the intake manifold. The other vacuum line is
regulated vacuum going to the EGR valve. One side of the EVR electrical circuit is +12 volts anytime the ignition switch is in the
run position. The other side of the electrical circuit is the ground path and is controlled by the computer. The computer switches
the ground on and off to control the regulator solenoid.



EGR test procedure courtesy of cjones

EGR test procedure courtesy of cjones

to check the EGR valve:
bring the engine to normal temp.

connect a vacuum pump to the EGR Valve or see the EGR test jig drawing below. Connnect the test jig or to directly to manifold vacuum.

Do not connect the EGR test jig to the EVR (Electronic Vacuum Regulator).

apply 5in vacuum to the valve. Using the test jig, use your finger to vary the vacuum

if engine stumbled or died then EGR Valve and passage(there is a passageway through the heads and intake) are good.

if engine did NOT stumble or die then either the EGR Valve is bad and/or the passage is blocked.

if engine stumbled, connect EGR test jig to the hose coming off of the EGR Valve.
Use your finger to cap the open port on the vacuum tee.
snap throttle to 2500 RPM (remember snap the throttle don't hold it there).
did the vacuum gauge show about 2-5 in vacuum?
if not the EVR has failed

EGR test jig


To test the computer, you can use a test light across the EVR wiring connectors and dump the codes. When you dump the codes,
the computer does a self test that toggles every relay/actuator/solenoid on and off. When this happens, the test light will flicker.

Late Model Restoration has the Ford Racing M-12071-N302 kit with the EGR valve & sensor along with the ACT & ECT sensors for
$45. See http://www.latemodelrestoration.com/iwwida.pvx?;item?item_no=M12071N302 1&comp=LRS for
more details



Thermactor Air System
Some review of how it works...

The Thermactor air pump (smog pump) supplies air to the heads or catalytic converters. This air helps break down the excess HC (hydrocarbons) and CO (carbon monoxide). The air supplied to the catalytic converters helps create the catalytic reaction that changes the HC & CO into CO2 and water vapor. Catalytic converters on 5.0 Mustangs are designed to use the extra air provided by the smog pump. Without the extra air, the catalytic converters will clog and fail.

The Thermactor air pump draws air from an inlet filter in the front of the pump. The smog pump puts air into the heads when the engine is cold and then into the catalytic converters when it is warm. The Thermactor control valves serve to direct the flow. The first valve, TAB (Thermactor Air Bypass) or AM1 valve) either dumps air to the atmosphere or passes it on to the second valve. The second valve, TAD (Thermactor Air Diverter valve or AM2 valve) directs it to the heads or the catalytic converters. Check valves located after the TAB & TAD solenoids prevent hot exhaust gases from damaging the control valves or pump in case of a backfire. The air serves to help consume any unburned hydrocarbons by supplying extra oxygen to the catalytic process. The computer tells the Thermactor Air System to open the Bypass valve at WOT (wide open throttle) minimizing engine drag. This dumps the pump's output to the atmosphere, and reduces the parasitic drag caused by the smog pump to about 2-4 HP at WOT. The Bypass valve also opens during deceleration to reduce or prevent backfires.

The computer uses the change in the O2 sensor readings to detect operation of the Thermactor control valves. When the dump valve opens, it reduces the O2 readings in the exhaust system. Then it closes the dump valve and the O2 readings increase. By toggling the dump valve (TAB) and switching the diverter valve (TAD) flow from the back of the heads to the air pipe, the computer tests for the 44/94 codes.







Computer operation & control for the Thermactor Air System
Automobile computers use current sink technology. They do not source power to any relay, solenoid or actuator like the IAC, fuel pump relay, or fuel injectors. Instead the computer provides a ground path for the positive battery voltage to get back to the battery negative terminal. That flow of power from positive to negative is what provides the energy to make the IAC, fuel pump relay, or fuel injectors work. No ground provided by the computer, then the actuators and relays don't operate.

One side of the any relay/actuator/solenoid in the engine compartment will be connected to a red wire that has 12-14 volts anytime the ignition switch is in the run position. The other side will have 12-14 volts when the relay/actuator/solenoid isn't turned on. Once the computer turns on the clamp side, the voltage on the computer side of the wire will drop down to 1 volt or less.

In order to test the TAD/TAB solenoids, you need to ground the white/red wire on the TAB solenoid or the light green/black wire on the TAD solenoid.

For 94-95 cars: the colors are different. The White/Red wire (TAB control) is White/Orange (Pin 31 on the PCM). The Green/Black wire (TAD control) should be Brown (pin 34 at the PCM). Thanks to HISSIN50 for this tip.

To test the computer, you can use a test light across the TAB or TAD wiring connectors and dump the codes. When you dump the codes, the computer does a self test that toggles every relay/actuator/solenoid on and off. When this happens, the test light will flicker.

Theory of operation:
Catalytic converters consist of two different types of catalysts: Reduction and Oxidation.
The Reduction catalyst is the first converter in a 5.0 Mustang, and the Oxidation converter is the second converter. The Oxidation converter uses the extra air from the smog pump to burn the excess HC. Aftermarket converters that use the smog pump often combine both types of catalysts in one housing.

Now for the Chemistry...
"The reduction catalyst is the first stage of the catalytic converter. It uses platinum and rhodium to help reduce the NOx emissions. When an NO or NO2 molecule contacts the catalyst, the catalyst rips the nitrogen atom out of the molecule and holds on to it, freeing the oxygen in the form of O2. The nitrogen atoms bond with other nitrogen atoms that are also stuck to the catalyst, forming N2. For example:

2NO => N2 + O2 or 2NO2 => N2 + 2O2

The oxidation catalyst is the second stage of the catalytic converter. It reduces the unburned hydrocarbons and carbon monoxide by burning (oxidizing) them over a platinum and palladium catalyst. This catalyst aids the reaction of the CO and hydrocarbons with the remaining oxygen in the exhaust gas. For example:

2CO + O2 => 2CO2

There are two main types of structures used in catalytic converters -- honeycomb and ceramic beads. Most cars today use a honeycomb structure." Quote courtesy of How Stuff Works (HowStuffWorks "Catalysts")

What happens when there is no extra air from the smog pump...
As engines age, the quality of tune decreases and wear causes them to burn oil. We have all seem cars that go down the road puffing blue or black smoke from the tailpipe. Oil consumption and poor tune increase the amount of HC the oxidation catalyst has to deal with. The excess HC that the converters cannot oxidize due to lack of extra air becomes a crusty coating inside the honeycomb structure. This effectively reduces the size of the honeycomb passageways and builds up thicker over time and mileage. Continuous usage under such conditions will cause the converter to fail and clog. The extra air provided by the Thermactor Air System (smog pump) is essential for the oxidation process. It oxidizes the added HC from oil consumption and poor tune and keeps the HC levels within acceptable limits.

Newer catalytic converters do not use the Thermactor Air System (smog pump) because they are designed to work with an improved computer system that runs leaner and cleaner
They add an extra set of O2 sensors after the catalytic converters to monitor the oxygen and HC levels. Using this additional information, the improved computer system adjusts the air/fuel mixture for cleaner combustion and reduced emissions. If the computer cannot compensate for the added load of emissions due to wear and poor tune, the catalytic converters will eventually fail and clog. The periodic checks (smog inspections) are supposed to help owners keep track of problems and get them repaired.


Idle problems:
See the "Surging Idle Checklist for help with all your idle/stall problems. Everything you need to find and fix idle problems is in there.

The first two posts contain all the updates to the fixes. At last count there were 24 possible causes and fixes for surging idle/stall problems. I continue to update it as more people post fixes or ask questions.