Idle Air Control/Upper Intake Pops

Fanatics -
The smoke must have been antifreeze on the block because it hasn't returned. Moving forward with today's crisis:

IAC unplugged - seems to run fine if a little rough. fires right up and idles well at 725 +/-.
IAC Plugged in - fires up and dies. proper voltage is getting to the IAC. no codes coming in. when started with holding 1/8th throttle she stays alive, but pops through the intake and smells a bit like gas.

IAC seems to be a problem, but why all the sudden? I was working on the upper manifold, but I didn't touch that part. Could it be anything else before I go buy a new part/clean it? Could someone explain what that popping is and why a plugged in but inactive IAC would cause that when an unplugged IAC gives no problems?

You guys are great.
 
The popping back through the intake is a symptom of a lean mixture. When the IAC opens up, it admits more air, which leans out the engine untill it dies. Find the vacuum leak that is admitting the extra air and your problem will be cured.

Dump the codes to insure that there are no hidden problems.

Dumping the computer diagnostic codes on 86-95 Mustangs

Revised 19-May-2009 to update drawing for dumping the codes on 86-88 Mustangs with no check engine light.

Dump the codes and see what the computer says is wrong…Codes may be present in the computer even if the Check Engine light isn’t on.

Here's the way to dump the computer codes with only a jumper wire or paper clip and the check engine light, or test light or voltmeter. I’ve used it for years, and it works great. You watch the flashing test lamp or Check Engine Light and count the flashes.

Be sure to turn off the A/C, and put the transmission in neutral when dumping the codes. Fail to do this and you will generate a code 67 and not be able to dump the Engine Running codes.

Dumping the Engine Running codes: The procedure is the same, you start the engine with the test jumper in place. Be sure the A/C is off and the transmission is in neutral. You'll get an 11, then a 4 and the engine will speed up to do the EGR test. After the engine speed decreases back to idle, it will dump the engine running codes.

Here's the link to dump the computer codes with only a jumper wire or paper clip and the check engine light, or test light or voltmeter. I’ve used it for years, and it works great. You watch the flashing test lamp or Check Engine Light and count the flashes.

See http://www.troublecodes.net/Ford/

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If your car is an 86-88 stang, you'll have to use the test lamp or voltmeter method. There is no functional check engine light on the 86-88's except possibly the Cali Mass Air cars.

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The STI has a gray connector shell and a white/red wire. It comes from the same bundle of wires as the self test connector.

89 through 95 cars have a working Check Engine light. Watch it instead of using a test lamp.

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The STI has a gray connector shell and a white/red wire. It comes from the same bundle of wires as the self test connector.


WARNING!!! There is a single dark brown connector with a black/orange wire. It is the 12 volt power to the under the hood light. Do not jumper it to the computer test connector. If you do, you will damage the computer.

What to expect:
You should get a code 11 (two single flashes in succession). This says that the computer's internal workings are OK, and that the wiring to put the computer into diagnostic mode is good. No code 11 and you have some wiring problems.

Codes have different answers if the engine is running from the answers that it has when the engine isn't running. It helps a lot to know if you had the engine running when you ran the test.

Trouble codes are either 2 digit or 3 digit, there are no cars that use both 2 digit codes and 3 digit codes.

Alternate methods:
For those who are intimidated by all the wires & connections, see Actron® for what a typical hand scanner looks like. Normal retail price is about $30 or so at AutoZone or Wal-Mart.

Or for a nicer scanner see Digital Ford Code Reader (3145) – It has a 3 digit LCD display so that you don’t have to count flashes or beeps.. Cost is $30.
 
how about the EGR as a culprit? I took off the unit and found that the diaphragm doesn't hold the vacuum. So if it lets air pass through it when it isn't supposed to that could be a/the problem right?

The vacuum system looks solid, no cracks, pinches or loose fittings. I also confirmed that it is routed correctly too. I'd love to get a whole new set of hoses, but all I can find are fancy red silicon sets that cost $100.
 
I have a code reader and I pulled code 34 which is something thats been coming up for months. I swapped out the EGR sensor two months ago and today I went ahead and got a new EGR assembly. Still came up with 34 which i'm bummed out about, but not overly concerned with because I haven't been able to run the engine long enough to let it warm up before I test it. (EGR low voltage or something).

I've got a busy weekend, but next week I'll replace all of the pertinent vacuum hoses. Any advice on that job? Should I try to keep it stock with the hard plastic lines and adapters or would it be better if I just got six feet of rubber vacuum hose and started replacing entire sections?
 
Code 34 Or 334 - EGR voltage above closed limit - Failed sensor, carbon between EGR pintle valve and seat holding the valve off its seat or vacuum control problems. Remove the EGR valve and clean it with carbon remover. Prior to re-installing see if you can blow air through the flange side of the EGR by mouth. If it leaks, there is carbon stuck on the pintle valve seat, replace the EGR valve ($85-$95).

If the blow by test passes, and you have replaced the sensor, then you have electrical ground problems. Check the resistance between the black/white wire on the MAP/BARO sensor and then the black/white wire on the EGR and the same wire on the TPS. It should be less than 1.5 ohm. Next check the resistance between the black/white wire and the negative battery post. It should be less than 1.5 ohm.

Note that all resistance tests must be done with power off. Measuring resistance with a circuit powered on will give false readings and possibly damage the meter.

Let’s put on our Inspector Gadget propeller head beanies and think about how this works:
The EGR sensor is a variable resistor with ground on one leg and Vref (5 volts) on the other. Its’ resistance ranges from 4000 to 5500 Ohms measured between Vref & ground, depending on the sensor. The center connection of the variable resistor is the slider that moves in response to the amount of vacuum applied. The slider has some minimum value of resistance greater than 100 ohms so that the computer always sees a voltage present at its’ input. If the value was 0 ohms, there would be no voltage output. Then the computer would not be able to distinguish between a properly functioning sensor and one that had a broken wire or bad connection. The EGR I have in hand reads 700 Ohms between the slider (EPV) and ground (SIG RTN) at rest with no vacuum applied. The EGR valve or sensor may cause the voltage to be above closed limits due to the manufacturing tolerances that cause the EGR sensor to rest at a higher position than it should.

The following sensors are connected to the white 10 pin connector (salt & pepper engine harness connectors)
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Vacuum control problems:
If someone has misrouted the EGR vacuum plumbing or the EVR (Electronic Vacuum Regulator) has failed, you can get this code.
Diagram courtesy of Tmoss & Stang&2birds
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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
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This will affect idle quality by diluting the intake air charge




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 Everyone should bookmark this site.

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the resistance was nominal, but I separated the the upper manifold again and wouldn't you know it? Upon reassembly she fired right up and is running better than ever. Have no clue what it could have been except for maybe a stupid hose not on snug enough. Thanks for your help - I've learned a lot as always.