small-list-digest Friday, March 26 1999 Volume 03 : Number 067



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Ford Truck Enthusiasts - Ranger, Explorer, Bronco 2 and Aerostar
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In this issue:

FTE Small - Re: '86 BII Tranny Failure
FTE Small - Aerostar Error Codes
RE: FTE Small - re:86 Bronco II
FTE Small - Smog check FAILED
RE: FTE Small - re:86 Bronco II
FTE Small - Rough idle (was Re:Smog check FAILED)
Re: FTE Small - Aerostar Error Codes
FTE Small - re: fuel pump or filter
FTE Small - Re: Bumper Height Bill
FTE Small - Backpressure
Re: FTE Small - unusual sticking problem
Re: FTE Small - Some info if you have it
Re: FTE Small - Smog check FAILED
Re: FTE Small - RE: 98 Ranger Brakes
Re: FTE Small - 86 bronco II
Re: FTE Small - 84 Bronco II 2.8 to 3.0 engine swap
Re: FTE Small - 2.8 L engine help...
FTE Small - Fuel Pump
Re: FTE Small - re: fuel pump or filter

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Date: Thu, 25 Mar 1999 07:02:22 EST
From: BFunk33 aol.com
Subject: FTE Small - Re: '86 BII Tranny Failure

In a message dated 3/25/99 3:41:55 AM US Mountain Standard Time, owner-small-
list-digest ford-trucks.com writes:


From: Dave Slotter
Subject: FTE Small - '86 BII Tranny Failure

My wife's 1986 Ford Bronco II decided to take a turn for the worse on
the PA Turnpike this weekend and I could use some help on diagnosing
the problem and deciding what route to take to solve it.

While I was downshifting from 5th to 4th gear, I felt a large pop
underneath the car and didn't know what happened. I found that 5th,
3rd, 2nd, 1st and reverse gears all had failed, but 4th still worked.
I managed to get us home with just 4th gear (fun when you have to
navigate in the city and make 90 degree turns in a vehicle which is
known for rolling easily). Basically the engine would just rev while
in those gears - no power was transferred. I did not accidentally put
us in 4WD - this was just a failure of the mechanism and not operator
error as far as I can tell. >>

If I remember right, in a 5-speed (overdrive) tranny, all speeds but 4th
operate off a countershaft, while 4th is a straight-through drive. It sounds
like your countershaft is broken (that loud "pop"), or something else so that
the countershaft won't connect to the output shaft.
Good luck.
Bill
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Date: Thu, 25 Mar 1999 07:09:33 PST
From: "H. Lee Purvis"
Subject: FTE Small - Aerostar Error Codes

I've got an '88 Aerostar with the 3.0 liter engine and 148K miles. My
check engine light has been coming on consistantly for the past week. I
bought a code scanner to research the problem and here are my questions.

The first code shows that the cannister purge solenoid is not working.
My Chilton's manual says that the purge solenoid is not required on the
fuel injected engines, but then shows a diagram for the 3.0 liter with a
throttle body and a purge solenoid. What gives?? Its supposedly
somewhere behind the alternator and I haven't had time to tear into it.
Any ideas?

The second code gives a low voltage on the TPS. Is there a way to test
this? The manual shows how to change the TPS, but says nothing about
testing it. Has anyone out there changed the TPS or is this something
better left to the dealer? I do most of my own work and this looks
pretty simple, but I'm worried about adjusting the thing.

Any thoughts or suggestions (other than a .45 to the computer) would be
appreciated.

Lee
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Date: Thu, 25 Mar 1999 11:02:28 -0500
From: Dave Slotter
Subject: RE: FTE Small - re:86 Bronco II

> [] ... Check the EGR Valve. While it is running, wait for it to act up,
>
> []
> What and where is the EGR valve, and what does it do?
>
> JC

A search on the web will give you more details than me, but EGR
stands for Exhaust Gas Recirculation. This valve controls how much
exhaust gas recirculates back into the engine intake so it can be
re-burned, allowing for cleaner exhaust and slightly higher gas
mileage. Replacing mine appears to have gained me 3-5 mpg, but
because of the price of replacement will take 6-12 months to pay for
itself. YMMV. We're getting about 28-30 mpg on our BII now (used to
be 25) - or rather we were until our tranny developed these recent
problems, but I digress. Anyhow, if you replace the EGR valve, be
sure to replace the EGR sensor too.

On my wife's '86 BII, the EGR valve is located on the driver side of
the throttle body and is in front of the EGR sensor. They are hooked
directly together with a hose.

Replacement is easily performed by a DIY-er.

- -Dave
- --

ICQ# 16458879 AOL/AIM ID: "Mac XR"
1986 Ford Bronco II Gray Manual 2.9 V6 123K Pittsburgh PA

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Date: Thu, 25 Mar 1999 09:45:07 -0800
From: "Tim J. Clevenger"
Subject: FTE Small - Smog check FAILED

Hi all,

I know I've posted this message before, but I've searched all my old =
messages and can't find where I saved the reply.

I have an '86 Ranger, 2WD, 2.3L with the 5 speed, 183,000 miles. I =
failed the California smog check (BIG time), so it's time to put some =
money into her.


Here are the symptoms:

1. When engine drops to idle, sometimes it drops past idle and I have =
to give it some gas or it will die. (Used to do it just when cold, now =
even when warm.)

2. Rough idle (light sputtering from the exhaust pipe.)

3. Lack of power. (Of course, it was only 90 hp when new, so I don't =
know how close I am to normal. I guess I should find another 2.3L =
Ranger and compare notes.)

4. Rapidly diminishing fuel economy. (23 mpg last year, down to 15-17 =
mpg now, with approximately the same driving habits, tire pressure, =
etc.)


Here are the changes I've made:

1. New wires and plugs. I used regular wires and plugs recommended by =
the local Carquest. I also bought a bunch of hangers in a vain attempt =
to keep the wires off the metal. I think it's much better than it's =
been.

2. New cap and rotor. I'm getting really bad carbon tracking, and the =
cap and rotor need to be replaced about every 10,000 now.

3. New air cleaner. Old one was still fairly decent, but these are =
desperate times.

4. Fuel injector cleaner. This is the aerosol stuff that you spray =
into the throttle body while revving the engine. Other than probably =
knocking 20,000 miles off the life of the engine, it had no effect.

5. Oil change. (Needed it anyway.)


Any suggestions? I know there are various valves and filters (EGR, PCV, =
MAF, fuel filter, etc.) Should I just start replacing them until =
something works? Also, anybody have a trusted mechanic in the Bay Area =
or Sacramento/Stockton area? Thanks!

Regards,

Tim Clevenger
Fremont, CA

'83 Ranger 2WD, 166k (parts truck)
'86 Ranger 2WD, "Ol' Roy", 183k (daily crawler)=20


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Date: Thu, 25 Mar 1999 09:48:33 -0800 (PST)
From: Bill Ciocco
Subject: RE: FTE Small - re:86 Bronco II

[] What and where is the EGR valve, and what does it do?

The EGR valve is an emmision componant the allows some of the exhaust
gasses to be recirculated through the engine during certain conditions.
It connects the exhaust to the intake by way of a tube that attaches to
the base of the valve (on a Ford, a GM uses ports on the intake
manifold, but let's not go there).
It is located on the left front corner of the engine right by the
throttle cables. There is a vacuum hose attached to a disc shaped
actuator. This disc is approximately 2-3.5" in diameter and 3/4" high (I
am not sure of the metric conversions)
When the EGR valve gets stuck in the open position, it will allow these
gasses to enter the intake all of the time, creating a lean/vacuum leak
situation.

The map sensor is a possibility, but it usually creates the opposite
condition. It creates a rich condition that may even show as an oxygen
sensor code. It will not neccesarily affect idle as much as cruising.
This is not to say that it will not effect idle, as it is a rich mixture
and prolonged idle will cause loading up and is solved by stepping on
the gas pedal.
To check for a map sensor, disconnect the vacuum line from the sensor
and see if the engine straightens out. I may be mistaken on this, it has
been a while since I have had a MAP sensor problem, and it was when I
had an Escort, so it may be different.
_________________________________________________________
Do You Yahoo!?

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Date: Thu, 25 Mar 1999 13:34:37 -0500 (EST)
From: fss altavista.net
Subject: FTE Small - Rough idle (was Re:Smog check FAILED)

>-----Original Message-----
>From:tclevenger paypros.com
>Sent:Thursday, March 25, 1999 1:01 PM
>Subject:FTE Small - Smog check FAILED
>
[snip]
>
>1. When engine drops to idle, sometimes it drops past
>idle and I have to give it some gas or it will die.
>(Used to do it just when cold, now even when warm.)
>
>2. Rough idle (light sputtering from the exhaust
>pipe.)
[snip, snip]

My '98 2.5L was recently in the shop for these same intermitent symptoms. They ran a diagnostic and didn't find anything, but the tech said that Ford had released a notice (not a TSB) on rough idling. They replaced the Mass Air Flow sensor. It seems to have helped and I have a much steadier idle now.

HTH,


+-----------------------------------------------+
Rick Sapir fss altavista.net
Raleigh, NC USA ricks99 netzero.net
http://www.ford-trucks.com//lc/lc.php?action=do&link=http://www.geocities.com/Heartland/Cottage/4654
+-----------------------------------------------+

- ----------------------------------------------------------------
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Date: Thu, 25 Mar 1999 19:39:30 +0100 (CET)
From: Thomas_Ucen kirchgruppe.de (Thomas Ucen)
Subject: Re: FTE Small - Aerostar Error Codes

The TPS is easy to change, just watch out for the lower screw. You have to
remove the water hose. I ruined the screw by trying to get around this.
Although the manuals were writing about adjustment, there is just one way to
insert it and it can't go anywhere. Just remove the TPS and you'll see it.
As for the Chilton manual: I have it too. It's not bad but is full of
mistakes since it covers all years and models. Try to get the Ford books,
they are more accurate.

Good luck!
Tom Ucen
1993 Aerostar Ext. 3.0L
Munich, Germany
thomas_ucen kirchgruppe.de


>I've got an '88 Aerostar with the 3.0 liter engine and 148K miles. My
>check engine light has been coming on consistantly for the past week. I
>bought a code scanner to research the problem and here are my questions.
>
>The first code shows that the cannister purge solenoid is not working.
>My Chilton's manual says that the purge solenoid is not required on the
>fuel injected engines, but then shows a diagram for the 3.0 liter with a
>throttle body and a purge solenoid. What gives?? Its supposedly
>somewhere behind the alternator and I haven't had time to tear into it.
>Any ideas?
>
>The second code gives a low voltage on the TPS. Is there a way to test
>this? The manual shows how to change the TPS, but says nothing about
>testing it. Has anyone out there changed the TPS or is this something
>better left to the dealer? I do most of my own work and this looks
>pretty simple, but I'm worried about adjusting the thing.
>
>Any thoughts or suggestions (other than a .45 to the computer) would be
>appreciated.
>
>Lee
> >== FTE: Uns*bscribe and posting info http://www.ford-trucks.com/faq.html
>
>

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Date: Thu, 25 Mar 1999 18:21:27 -0500
From: Robert Craven Jr (nospam)
Subject: FTE Small - re: fuel pump or filter

My fuel pump will not cut off even though I turn off the ignition. It
will behave for a while If I put on a new fuel pump relay but the relay
goes bad in a couple of weeks and I have to bang on the fuse block under
the hood to get the fuel pump to shut off.

Where can you get one of those tools to undo the gas line from the fuel
filter? Could my pressure sensor on top of the engine be bad and not
shutting off the pump when sufficient fuel pressure has been reached.
Once again the fuel line connections require a special tool.

I am getting tired of "slapping the motor" when I stop and worry about
wearing out the fuel pump if it is running too much.

Bobby Craven
Denton, NC
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Date: Thu, 25 Mar 1999 15:57:26 -0800
From: Thom Cheney
Subject: FTE Small - Re: Bumper Height Bill

I read a post this morning by someone about some senate bills in NY and
Oregon that will affect some 4X4's. The law will deny highway access to
any vehicle whose bumper is 3" higher or lower than the stock height.
I followed up on the Oregon bill (since I live in OR). This bill is
still in the Transportation Committee & has not gone to vote yet. We
are mobilizing an e-mail campaign to inform Senator Lim that we do not
agree with his idea of how our vehicles should look and perform on or
off the road. If any of you would care to drop Mr. Lim an e-mail, his
address is: Lim.sen state.or.us

If you would like to see the text of the proposed bill (and a bunch of
Ford related stuff)... please visit www.EarlyBroncoEnt.com

thanks for your help!
- --
Thom Cheney
tcgrafx... among other things
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Date: Thu, 25 Mar 1999 15:30:29 -0500
From: J Cope
Subject: FTE Small - Backpressure

I drive an 88 BII, and I recently changed the exhaust system, as mine was
rusted out a bit. BTW, here's a tip: If your exhaust system is at all
like mine, the muffler and the resonator are slightly tilted, which tends
to cause water to sit at the low end, rusting it out. A few correctly
placed 1/8" holes let it drain nicely. Anyway, while I had the whole
exhaust system off, I turned the truck on to see what it sounded like
completely unmuffled. I must admit, it sounded pretty darn good for a 6
cyl. My immediate thoughts were of a straightpipe exhaust to take
advantage of this sound, but then I remembered a friend of mine telling me
about backpressure and fuel injection and how I needed a muffler for the
whole thing to work right. Any input confirming or denying this would be
greatly appreciated!
Thanks!

JC

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Date: Thu, 25 Mar 1999 21:06:11 -0500
From: Tim Turner
Subject: Re: FTE Small - unusual sticking problem

Richard Salitra wrote:
>

> it was cold & sleeting (we had a good time anyway) & if i
> recall correctly, the previous times it was also cold. when the truck
> finally unstuck itself, it seemed to clunk forward & then it was fine.

Did it seem like the rear brakes were still on? I had an Opel that the
parking brake would freeze if left on cold. (Cables?) That's all the
suggestion I have. :-(

Tim
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Date: Thu, 25 Mar 1999 21:21:23 -0500
From: Tim Turner
Subject: Re: FTE Small - Some info if you have it

Matt Baldwin wrote:
>
> Hello,
>
> I drive a 85 Ranger 4x4 reg. cab on a daily basis. The truck is set to roll
> 280,000 Km soon, and the body is in such good shape that I don't want to even
> consider a trade-in, or upgrade.

I feel the same way about my 85 B-II :-)

> What I am wanting to do is get a more
> comfortable seat. I have the standard Ford bench, and was wondering if anyone
> out there had any experience in swapping this for a bucket type? Can I use
> the same mounting points?

No real knowledge, but since the Ranger & B-II are basically identical I
suspect pre 88 B-II buckets would swap in. There was some interior
changes around 88, but I dont know if the actual seat changed. Maybe
give us a rough description of how your seat mounts and some of us B-II
people could look at our own seats to see what sounds compatible. ;-)

> How late a model seat can I get before I find that
> the mounting points are no longer congruent.

Of course if you dont mind making shims and/or drilling then anything
will work.. I put 68 Riviera buckets in a 71 Satellite Sebring with
some 'rigging'

Tim Turner/Manic Mechanic
Custer Auto Repair
Wilmington NC
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Date: Thu, 25 Mar 1999 21:38:32 -0500
From: Tim Turner
Subject: Re: FTE Small - Smog check FAILED

"Tim J. Clevenger" wrote:
>

>
> Here are the changes I've made:
>

> 4. Fuel injector cleaner. This is the aerosol stuff that you spray into the throttle body while revving the engine. Other than probably knocking 20,000 miles off the life of the engine, it had no effect.

I wouldn't go *that* far. :-) make sure all the crud is off the edges
of the throttle plate as that affects the idle the most. Old tooth
brushes can be handy for TP cleaning.

> Any suggestions? I know there are various valves and filters (EGR, PCV, MAF, fuel filter, etc.)

I would suspect the EGR system, and possibly the MAP or TPS, but follow
the instructions for retrieving trouble codes available form the FTE
site (I think) and post what code(s) you get.

> Should I just start replacing them until something works? Also, anybody have a trusted mechanic in the Bay Area or Sacramento/Stockton area? Thanks!

Try searching the iATN webtv for a member near you.
http://www.ford-trucks.com//lc/lc.php?action=do&link=http://www.iatn.net/dir/ will get you there. The iATN is 19,000+
technicians in a mail list similar to this one. It's no guarantee of
quality work but just like ASE certification it at least shows good
intent. ;-)


Tim Turner/Manic Mechanic
Custer Auto Repair
Wilmington NC
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Date: Thu, 25 Mar 1999 21:47:32 -0500
From: Tim Turner
Subject: Re: FTE Small - RE: 98 Ranger Brakes

JJ Thomas wrote:
>
> I do like the Ranger,
> especially when shopping and going by gas stations. If I could just get
> a bigger tank installed...

Check with JC Whitney; they've got a pretty good selection of extra
capacity tanks. (pricey though!)

Tim
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Date: Thu, 25 Mar 1999 22:30:50 -0500
From: Tim Turner
Subject: Re: FTE Small - 86 bronco II

Dave Slotter wrote:
>

> Your vehicle looks like another candidate for running a computer
> diagnostic. See my post in the archives.

Anything 84 up is a candidate! ;-)

>
> If my memory serves correct, the '85 BII was the last vehicle with a
> carbureted engine, and from '86 through the end of production, the
> BII used EFI and a computer.

Quite correct; I'd add that the 84/85 B-II/Ranger were also
computerized, just using a solenoid to change the mixture. (Picture an
electrically controlled metering rod.. not actually correct, but gets
the idea across.) No check engine light in the earlier models so
there's no clue of a malfunction until there's enough wrong that the
computer cant compensate by interpretations from other sensors.. My own
85 B-II usually reveals a minimum of 5 codes any time I check it!

> The computer knows way more about the
> "real-time" operation of the engine than anyone else - including a
> mechanic,

!!! Depends on the meaning.. certainly it's zooming along making
adjustments every milliSecond that I couldn't do, but it's diagnostic
capability is only what's programmed into it. A burnt valve causing
major swings in the vacuum pretty much gets ignored (other than doing
odd things to the mixture), but even a rookie can see it on a vacuum
gauge and call it.

> and it's safe to use its codes as a starting point.

After ruling out all basic engine/ignition/fuel supply problems of
course.

> However, the knowledge and experience of a mechanic (shadetree or
> otherwise) is essential to using these codes to provide the proper
> maintenance.

Even ones on e-mail lists.

>
> It is important to remember that the computer doesn't know
> everything. You could have problems that the computer can't sense
> directly and replacing sensors won't alleviate the problem (and will
> lighten your wallet unnecessarily).

*VERY* true had a S-10 that had been through several O2 sensors due to
a lean O2 code, but the actual problem was a leaking gasket under the
EGR valve, a rich running carb will throw a code for a rich O2 and on
the 96 up vehicles a poorly tightened gas cap will set a code for the
evaporative emissions system. Also the computer is programmed to
recognize *gross* faults, so a sensor that is 'off' but not failed will
not set a code. (e.g. a TPS that has a 'drop' in voltage at 1/3
throttle is seen as on the gas, off the gas, on the gas and the vehicle
stumbles at that point; without a quick responding meter or ideally a
'scope you cant pinpoint the failure.)

Tim Turner/Manic Mechanic
Custer Auto Repair
Wilmington NC
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Date: Thu, 25 Mar 1999 22:48:45 -0500
From: Tim Turner
Subject: Re: FTE Small - 84 Bronco II 2.8 to 3.0 engine swap

CBadgerJr aol.com wrote:
>
> I have an 84 Bronco II with the 2.8L engine that has seen better days. I am
> considering swapping it out for a 3.0L engine as they are much easier to find,
> plus fuel injected.

3.0? Do you mean the 2.9 that was stock in later years, the 4.0 from an
Explorer or a 3.0 from a FWD Taurus? I'm assuming the 2.9.. The exhaust
ports are different on the 2.8/2.9 so you'll need the manifolds along
with the wiring harness, computer, fuel pump, fuel hoses, patience and
ingenuity.. I was looking into swaps for my 85 B-II a while back but
due to regulations in my county/state I'll settle for a stock 2.8 long
block swap. If your area isn't so anal about engine swaps try
posting in the performance list as there's been several good threads
about the 4.0 swap as well as the 5.0. If I had the $$ and the legal
ability to do it I'd use Advance Adaptors stuff and put a FI 5.0 in my
horse. ($1400 for everything but the power train..) I've seen pictures
on the net (including kit!) for a 428 CJ in a ranger as well, but that's
pretty intense! :-)

Tim Turner/Manic Mechanic
Custer Auto Repair
Wilmington NC
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Date: Thu, 25 Mar 1999 22:56:51 -0500
From: Tim Turner
Subject: Re: FTE Small - 2.8 L engine help...

"Thomas E. Francis" wrote:
>
> My son purchased a '85 Bronci II with the 2.8 L V6.

>
> The engine is a little tired, as in low oil pressure,
> low compression on a couple of cylinders and needs
> a carb rebuild.

Sounds just like my poor 85! :-)

> I figured as long as we were at this point, we might
> as well "hot rod" the engine a little.

Just be sure to check your local laws for what you can do. (or keep old
parts handy for re-installation every year at inspection time!)

>
> Are there performance parts available for this engine
> and where might I find them?

Racer Walsh (racerwalsh.com I think) has some nice cams and 4 bbl
manifold/carb & headers, I think James Duff has some good things as well
but I forget the URL. Walsh doesn't list the 2.8 goodies on-line, but
the catalog shows 'em.

Let us know how it does when it gets together!

Tim
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Date: Thu, 25 Mar 1999 22:05:06 -0600
From: Matthew Banevich
Subject: FTE Small - Fuel Pump

I have an 89' BII, and the fuel pump is making quite a bit of noise, is
it the fuel filter, and if it is, where is the uel filter, this is my
first fuel injected vehicle...
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Date: Thu, 25 Mar 1999 23:36:03 -0500
From: Tim Turner
Subject: Re: FTE Small - re: fuel pump or filter

"Robert Craven Jr (nospam)" wrote:
>
> My fuel pump will not cut off even though I turn off the ignition.

What type of truck? I'll assume 86-95 small Ford and keep it general
for now.

> will behave for a while If I put on a new fuel pump relay but the relay
> goes bad in a couple of weeks and I have to bang on the fuse block under
> the hood to get the fuel pump to shut off.

*Normal* operation is that the computer energizes the relay at key on
and stops it if no RPM/cranking seen within 2 seconds. Likely culprits
would be (in no order)

1) Bad computer (not switching off the relay)
2) bad wiring (grounded lead to the relay or short to key off power)
3) bad fuel pump (drawing too much current and 'welding' the relay
contacts closed)


>
> Where can you get one of those tools to undo the gas line from the fuel filter?

Which type of fitting? Should be able to get one from NAPA or a DIY
type store though.

> Could my pressure sensor on top of the engine be bad and not
> shutting off the pump when sufficient fuel pressure has been reached.

Assuming you mean the pressure regulator all it does is pass gas back to....


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