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Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
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15,330
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Built this last night while watching the Pats beat Buffalo

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Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
39,475
15,330
224
Scored another Recaro headrest that I needed for parts. Was the same price as 3D printing the black bracket I needed, so I figure I get an original one with original intact netting.

This one is black cloth
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Was going to use the insert and mesh with the gray leather pair. For now, just going to dye it black. Lacking the time to track down and vett a vendor to recover these. That’s a project down the road.

White one will get flipped at some point. It’s a trans am Recaro headrest in mint condition. Apparently value on those is going up, so gonna sit on it for a while.
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Pulled the cloth cover off it

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Now to dye the nets
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Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
39,475
15,330
224

Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
39,475
15,330
224
So….found a vacuum leak. Old line to the TAD/TAB . Apparently I tucked it below the pinch weld and then forgot about it. Oops.

Smoke machines….worth it.


Wide open line. Before I even turned on the smoke, I could hear it hissing as I turned on flow to the smoke machine. I would have never thought to check under here.

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Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
39,475
15,330
224
It’s where the blue check valve normally goes. Was tucked under the pinch weld so i forgot about it. Oh well.

Plugged with this bright orange thing for now.
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Once plugged. Two more leaks. Between the IAC motor and body.
4739AEE0-AC55-42BB-9EE5-334256F21FF5.jpeg



And the EGR valve itself. Might be another reason it’s not working. This was a new NOS valve too.
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Also appears the PCV grommet leaks too. Thought this was a brand new seal but The EGR leak makes it difficult to really tell where the leak is. I hope it’s not the rear of the lower intake manifold.

Edit: scratch that. The pcv grommet wasn’t fully seated in the lower intake.
 
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Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
39,475
15,330
224
NOS diaphragm = Old diaphragm

It’s not coming from the diaphragm though. It’s coming through the ports on the EGR into the intake.

Which port is the plunger on? The port down to the heads or the port into the intake track? It’s probably backfeeding out of the intake, meaning I need to block it.

Assuming that’s the case. It looks like the IAC is my only remaining leak.

Gee. I wonder why.

Missing screw
562ACC75-0CE0-4455-9425-1600035BE952.jpeg


No internal o-ring.

75F432A3-4CD6-47FC-80D0-C8E58A5BA2DB.jpeg
 

Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
39,475
15,330
224
Next up. Wiring the new wiper motor in.

Need to convert this to a 5-pin plug.

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I did it. Wiper motor worked for 2 cycles and then made a funky grinding noise and locked up.

Went through it for 2 hours with wiring diagrams and my multimeter. My wiring is fine. Given the mechanical clunking I heard, I think something inside failed.
 

Noobz347

Stangnet Facilities Maint Tech... Er... Janitor
Admin Dude
Jan 4, 1985
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It’s not coming from the diaphragm though. It’s coming through the ports on the EGR into the intake.

Which port is the plunger on? The port down to the heads or the port into the intake track? It’s probably backfeeding out of the intake, meaning I need to block it.

Assuming that’s the case. It looks like the IAC is my only remaining leak.

Gee. I wonder why.

Missing screw
562ACC75-0CE0-4455-9425-1600035BE952.jpeg


No internal o-ring.

75F432A3-4CD6-47FC-80D0-C8E58A5BA2DB.jpeg


:chin Mmmmmmmmmmmmmmmaybe....
 

Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
39,475
15,330
224
Still….it shouldn’t be leaking externally.

It’s late. I’ll worry about it later. I’ll take the IAC to work and sort through our hardware bins for some new screws and an appropriate O-ring to seal it. Then I’ll investigate the EGR leak.


The EGR leak and the unhooked vac line were pretty big leaks. I wonder if this smooths out my idle a tad :shrug:
 
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Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
39,475
15,330
224
So IAC is fixed. A -112 O-ring seals it nicely, and two new M4 x 0.7 x 10mm screws are installed. IAC back on the car.


The egr. I suspect what’s happening is it’s leaking through the plunger from the egr gas side of things.

So I grab my old valve and make a stopper with a hole to seal it up.

E4D2D2C0-A721-4354-A869-3F5777C6DF7D.jpeg


Apply a little smoke, and it leaks easily. I bet my new one leaks this same way. I will smoke test the vaccum port as well just to double check (didn’t think about it until posting this right now.)

F4C0E25F-A195-404B-82D8-5213D6AC0C14.jpeg



I wouldn’t be surprised to find ALL EGR valves leak here. With it being post-combustion, I don’t think it matters one lick.


I did end up ordering an EGR block off plate. I’ll need it eventually, but more importantly I want to install it and smoke test to make sure the PCV is not leaking anymore. With the proximity to the egr, I couldn’t tell if the smoke I saw after reinstalling it was the egr or the pcv. I figure I block it off and do one last check to make sure I got everything. I need to make sure to remember to check the interior to make sure there isn’t any leaks on those small diaphragms that activate the Hvac doors
 
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