2.5L ('98-'01) 2000 2.5 mystery plug (IAT?)

[racsan]

Whatcha wanna bet someone had the pulleys off at some point (probably when painting random stuff neon green?) and swapped them...

Throw a potato at it, call it a red breasted sap sucker then have a pickle... then threaten it with a sack of feathers and it might cooperate... lol

thats a good point!

 

[Snoranger]

How about the EVR solenoid?

 

[Dirtman]

How about the EVR solenoid?

View attachment 56544

This may be the only thing yet to NOT piss me off today.

 

[Dirtman]

And BTW i found A SECOND MARK ON THE FREAKING CAM GEAR!!!!!!!!!!!!!!!!! so tomorrow i go back to see if that fu#^$@ing mark works.

This engine is in amazing shape inside, but I simply cant go any further until im 100% on the timing because there's so much crap that can't go on until then. I refuse to do it wrong and then spend half a day pulling all this bullshit back off.

 

[racsan]

thats the only good thing about a non-power steering lima engine, the timing cover can go off & on without the hassle of unbolting the pump bracket from the block.

 

[MikeG]

So would this help:

Ignore the marks. Turn the cam over till you are SURE (by looking at the valve train) that it is about to start the intake cycle on #1 (exhaust closing, intake about to open). I'm assuming this is a non-interference engine and you can do that. Might take a couple of turns to be sure.

Then, a dial indicator with a long enough probe down the spark plug hole will tell you when the piston is exactly at TDC. Probably have to have one on a magnetic base, or rig up something else to hold it.

Then you put the crank at it's 0 degree mark - presto.

Thoughts?

 

[racsan]

yes, the best thing about a lima is its a non-interference engine

 

[RonD]

Oh I don't know about that, it reads like its giving Dirtman PLENTY of INTERFERENCE

 

[Roert42]

Buh dum tiss

 

[Dirtman]

Im still ignoring the timing belt while I work on other stuff since I can assemble everything except the AC/PS bracket and still be able to work on that.

BUT!!!!!!!


I FOUND THE MYSTERY PLUG!!!!!!!

It goes to whatever the hell this thing is that bolts to the side of the alternator bracket. Some kinda vacuum solenoid for the HVAC? No idea why I even took it off.

 

[RonD]

That's the EGR Valve solenoid, computer use vacuum to open EGR valve a little or alot by pulsing the ground side of the circuit on this vacuum valve

I have Brown/pink and light blue/orange wires as connection for that

 

[Dirtman]

That's the EGR Valve solenoid, computer use vacuum to open EGR valve a little or alot by pulsing the ground side of the circuit on this vacuum valve

I have Brown/pink and light blue/orange wires as connection for that

So @snoranger was right. Kudos man. It just made no sense for the egr solenoid to be in that weird location...

Damn confusing egr system. They seem to have just scatter shot the parts everywhere. The EGR and vacuum diaphragm is up on the top on the upper intake, the DPFE is way down by the exhaust manifold, and this thing is all the way up front by the alternator. Seems like it would be easier to just put all these things together in one spot.

Anyway now I guess I gotta get the vacuum diagram since the spider web of nonsense is insane. And before you say anything.... there is a vacuum diagram under the hood, but like the belt routing guide, for some reason it's for a 3.0.

I talked to the kid I got it from and he believes it was in a wreck and they used a rad support off a 3.0 truck and just never bothered to worry about the stickers being wrong.

All i have left to do is the upper intake, vac line mess, set the timing, and then install the giant AC/PS bracket mess. Bunch of stuff is mickey moused but im not putting money into this thing. It just needs to run.

I gotta say, I've worked on old limas and they are stupid simple. This thing is a disaster as far as wires and hoses. Even my duratec which is a far more complex engine is just 1000% cleaner and neater when it comes to how all the wiring and hoses are done. You really need to try hard to screw up anything electrical or vacuum related on the duratec. Everything just fits nice and neatly.

 

[RonD]

The EGR solenoid "might" be T'ed off the vacuum reservoir hose that runs to the cab for the Vent control
As this is a steady vacuum source vs intake vacuum
The other port would run to EGR valve, of course

BUT...........on some years Ford used a check valve between intake and vacuum reservoir(I think you ran into something like that on your Duratec brake booster)

If they did then T for EGR solenoid's vacuum source could be on the hose between check valve and reservoir since that would hold same stable vacuum as the reservoir itself

 

[Dirtman]

The EGR solenoid "might" be T'ed off the vacuum reservoir hose that runs to the cab for the Vent control
As this is a steady vacuum source vs intake vacuum
The other port would run to EGR valve, of course

BUT...........on some years Ford used a check valve between intake and vacuum reservoir(I think you ran into something like that on your Duratec brake booster)

If they did then T for EGR solenoid's vacuum source could be on the hose between check valve and reservoir since that would hold same stable vacuum as the reservoir itself

On my duratec the brake booster has a valve where one vacuum line is coming direct from the intake manifold, and then one is coming from in front of the throttle plate connected to the intake tube. The valve splits that into the one hose going to the booster.

I have yet to fully understand the concept but from my understanding it's designed to be able to switch between post and pre throttle plate vacuum so if you're at high RPM with little intake vacuum, the booster can still pull vacuum from the side before the throttle plate and you wont loose brake assist.

Yea i had an issue figuring out how that connected lol. I had it backwards for a while.

That was this nonsense...

 

[Dirtman]

But notice there is only 3 other vac lines on that engine. Pcv, evap, and one to the hvac resivoir. Egr is full electric, no dpfe or diaphragm. All individual lines that fit nicely with no splices. Very clean setup compared to the crap on this 2.5. Even the wiring on the duratec is cleaner and simpler.