Extended Coverage Program 04N02 - Fuel Delivery Module - New Design (04N02)

SUBJECT

Extended Coverage Program 04N02: Supplement #1

Certain 1999 through 2002 Model Year Cougar Vehicles

Fuel Delivery Module - New Design

REF

Extended Coverage Program 04N02: Dated April 2004

Certain 1999 through 2002 Model Year Cougar Vehicles

Fuel Delivery Module

PURPOSE OF THIS SUPPLEMENT

• Notify dealers of the availability of the new design fuel delivery module.
• Revised technical instructions for the new design fuel delivery module.
• Revised labor times and part information.
• Special required cutting tool - (same cutting tool supplied and used for 03N01 ).

PROGRAM TERMS

This program extends the coverage of the fuel delivery module (FDM) to 10 years from the original warranty start date of the vehicle, with no limit on the number of miles that the vehicle has been driven. This program provides one-time replacement coverage, and is automatically transferred to subsequent owners.

VEHICLES COVERED BY THIS PROGRAM

Certain 1999 through 2002 model year Cougar vehicles built at the Flat Rock Assembly Plant from May 25, 1999 through November 30, 2001. Affected vehicles are identified in OASIS.

REASON FOR PROVIDING ADDITIONAL COVERAGE

Some of the affected vehicles may experience engine hesitation, loss of power, surging, and other similar symptoms as a result of contamination of the fuel pump. Because the contamination of the fuel pump is progressive, it may ultimately become sufficiently blocked to cause the engine to stall completely. Although the symptoms noted above can occur under a variety of driving conditions, they are most likely to occur when there is less than one-quarter tank of fuel and/or when the driver is attempting to accelerate while making a turning maneuver (such as entering a highway through a cloverleaf) or while driving uphill.

SERVICE ACTION

If the customer informs you that their vehicle exhibits stalling, engine hesitation, loss of power, surging, or other similar symptoms, replace the FDM. There is no need for further diagnostics prior to FDM replacement. Owners are not to be charged for any diagnostics or repairs related to the FDM replacement.

Prior to performing service, tell the customer:

• Ford will replace the FDM at no cost based upon the customer's description of the condition without performing any diagnostics.
• That without performing diagnostics other conditions that may affect driveability, if any, would not be addressed by an FDM replacement.
• That diagnosis and correction of any remaining driveability issues, if any, are the responsibility of the customer unless the vehicle still has remaining Basic Vehicle Warranty coverage.
• That after FDM replacement, a road test will be conducted at no charge to determine if the driveability concern has been corrected.
• This Customer Satisfaction program only covers replacement of the FDM.
• Please note: It is not necessary to replace the in-line fuel filter due to this issue. Fuel filters should continue to be replaced at normal maintenance scheduled intervals.

EFFECTIVE IMMEDIATELY, ONLY THE NEW DESIGN FDM IS TO BE INSTALLED

With the release of the new XS2Z-9H307-CA level FDM, dealers are to replace the FDM if the customer describes the above symptoms; no additional diagnostics are required.

Detailed Technical Instructions and revised labor times to install the new design FDM are included with this 04N02 Supplement #1.

SPECIAL CUTTING TOOL (ALREADY SUPPLIED)

Each dealer received a special cutting tool used to install the new design FDM for the 03N01 Focus concern.

This same cutting tool will be needed to install the new design FDM for the 04N02-S1 on Cougar vehicles. One cutting tool along with a replacement-cutting blade was supplied (free of charge) to each dealership. Additional cutting tools are available for purchase. See Attachment II for further information on tool ordering and Attachment III for tool usage.

ATTACHMENTS

1. Attachment I: Administrative Information
2. Attachment II: Labor Allowances and Parts Ordering Information
3. Attachment III: Technical Information
4. Customer Notification Letter (previously mailed to all customers under 04N02)

QUESTIONS?

1. Claims Information: ............................................................ 1-800-423-8851
2. Special Service Support Center (Dealer Only) Questions: .......... 1-800-325-5621

OASIS ACTIVATED?

Yes

You must use OASIS to determine if a vehicle is eligible for this program.

FSA VIN LIST ACTIVATED?

No

STOCK VEHICLES

Do not perform this program unless the affected vehicle exhibits the symptoms described earlier in this letter.

SOLD VEHICLES

Only owners with affected vehicles that exhibit the stated symptoms will be directed to dealers for service action.

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this Field Service Action.

RELATED DAMAGE

If a related damage condition exists that you believe to be caused by the covered condition, call the Special Service Support Center to request approval prior  to the repair of any related damage.

Requests for approval after completion of the repair will not be granted.

ADDITIONAL LABOR TIME

• If a condition exists that requires additional labor to complete the repair, call the Special Service Support Center to request approval prior  to performing any additional labor. Requests for approval after completion of the repair will not be granted.
• If you encounter aftermarket equipment or modifications to the vehicle which might prevent the repair of the covered condition, call the Special Service Support Center.

OWNER REFUNDS

Ford Motor Company will only refund owner-paid repairs made before the date of the Customer Notification Letter (or after the date of the letter if an emergency  repair was made away from the servicing dealer). Refund claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be accepted for reimbursement.

Refund Claiming Information. (Submit on separate repair line.)

1. - Program Code: 04N02
2. - Misc. Expense: ADMIN
3. - Misc. Expense: REFUND
4. - Misc. Expense: 0.2 Hr.

RENTAL VEHICLES

The use of rental vehicles is not authorized for this program.

CLAIMS PREPARATION AND SUBMISSION

• Enter claims using Direct Warranty Entry (DWE).
• Related damage or refunds must be claimed on a repair line that is separate from the FSA's repair line.
• "MT" labor should be submitted on a separate repair line with the related damage flag checked.
• Refer to ACESII manual for claims preparation and submission information.

LABOR ALLOWANCES

PARTS REQUIREMENTS / ORDERING INFORMATION

The new design FDM is now available, and must be used to service vehicles that experience the condition. EFFECTIVE IMMEDIATELY, DO NOT USE ANY PREVIOUS DESIGN FDMS TO SERVICE THE AFFECTED VEHICLES. See claim handling procedure for returning old level FDM's.

Parts will not be direct shipped for this program. Order your parts requirements through normal ordering processing channels.

All order types - Follow normal dealer order processes.

Please note: This program does not  cover parts or procedures other than the part described below. It is not  necessary to replace the fuel filter due to this issue. Fuel filters should continue to be replaced at normal scheduled maintenance intervals. The fuel delivery module replacement will be performed at no charge to the customer.

SPECIAL CUTTING TOOL (Already supplied)

Each dealer received a special cutting tool used to install the new design FDM for the 03N01 Focus concern.

This same cutting tool will be needed to install the new design FDM for the 04N02-S1 on Cougar vehicles. One cutting tool along with a replacement-cutting blade was supplied (free of charge) to each dealership. Additional cutting tools are available for purchase. See Attachment III for tool usage.

DEALER PRICE

For latest prices, refer to DOES II.

PARTS RETENTION AND RETURN

Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures."

EXCESS STOCK RETURN

Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000.

CLAIM HANDLING PROCEDURE FOR RETURNING OLD LEVEL FDMS

• Prepare and submit a PCS claim as described below.
• DO NOT ship the parts until Return Authorization is granted.
• The return authorizations will include shipping addresses.

PCS CLAIM INSTRUCTIONS

When you create your PCS claim, use the following information for the REASON CODE, SHIPPER NBR, and LINE EXPLANATION fields:

REASON CODE: GB

SHIPPER NBR: 04N02

LINE EXPLANATION: Design Revision

• When preparing your PCS claim, list the part number being returned on the claim, and indicate the quantity of that part number being returned.
• Your PCS claim must be submitted by July 1, 2004.  Claims filed after this date will be denied.

OVERVIEW

This program involves replacing the fuel delivery module (FDM) with a new  , redesigned module. The new  module is top-mounted in the tank and requires the removal of the retaining ring that attaches the original FDM to the floor of the tank. Cut-off tool 310-133 has been designed to cut the tabs of the retaining ring without damaging the fuel tank vapor barrier (inside surface of the tank).

FUEL SYSTEM PRESSURE RELEASE AND FUEL TANK DRAINING

1. Record the radio stations and disconnect the battery ground cable.
2. Remove the fuel filler cap.
3. CAUTION:  The fuel tanker used to store the removed fuel must be equipped with a filtering system. Rotunda Fuel Tankers, such as model 034-00014 or 034-00004, are equipped with the necessary filtering systems.
   NOTE: Use an appropriate length hose attached to the end of the fuel tanker drain hose to drain the vehicle fuel tank. To enable the adapter hose to enter the tank, a 40-mm long taper may need to be cut in the end of the hose.

   Drain the fuel tank using a tanker and hose as specified.

4. WARNING:  MAKE SURE THE TAP ON THE FUEL PRESSURE GAUGE 310-012 (T80L-9974-B) IS TURNED FULLY CLOCKWISE BEFORE CONNECTING IT TO THE SCHRADER VALVE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

   While the fuel tank is draining, relieve the fuel system pressure as follows:

   1. Remove the air cleaner outlet tube.
   2. Remove the cap from the Schrader valve on the fuel manifold.
   3. Connect the Fuel Pressure Gauge 310-012 or equivalent to the Schrader valve.
   4. With the end of the gauge hose in a suitable container, turn the tap fully counterclockwise to relieve the fuel pressure.
   5. Remove the gauge from the Schrader valve and reinstall the valve cap and air cleaner outlet tube.

FUEL TANK AND FUEL DELIVERY MODULE REMOVAL

1. Raise and support the vehicle on a hoist.
2. CAUTION:  Support the exhaust system as described to prevent any damage from occurring.

   Support the exhaust system using either a tall jack stand or a bungee strap at the tailpipe, then disconnect the four (4) exhaust system rubber hangers.

3. Remove the two (2) stamped nuts and carefully position the heat shield aside to allow access to the left-side fuel tank support strap bolt.
4. Place a suitable drain pan under the fuel filter.
5. Disconnect the fuel filter outlet tube by first removing the retaining clip, then pulling the connector off the filter. Discard the retaining clip  .
6. Remove the stabilizer bar clamps and allow the bar to hang by the links. This will provide added access for fuel tank removal and installation.
7. Support the fuel tank using an appropriate lift table or equivalent.
8. Remove the filler pipe lower bolt from the subframe.
9. Remove the fuel tank support strap bolts and position the straps down.
10. CAUTION:  When lowering the fuel tank, make sure that excessive strain is not placed on the hoses or electrical harness and connectors.

    Partially  lower the fuel tank.

11. WARNING:  EYE AND EAR PROTECTION IS REQUIRED WHEN USING COMPRESSED AIR TO CLEAN THE FUEL TANK DEBRIS.

    Using compressed air, clean the debris from around and inside the filler pipe area to help eliminate any contaminants from entering the fuel tank.

12. CAUTION:  When lowering the fuel tank, make sure that excessive strain is not placed on the hoses or electrical harness and connectors.

    Disconnect the fuel tank filler pipe from the tank as follows:

    1. Push the locking collar down.
    2. Turn the locking collar approximately 45 degrees either right or left.
    3. Using a small pry bar, work the locking collar up out of the gray filler pipe connector, at the same time lowering the fuel tank to allow the filler pipe to exit the tank. Keep the filler neck opening as parallel as possible with the filler pipe so the pipe does not become wedged in the tank and hinder tank removal.
13. With the tank partially lowered, disconnect the fuel delivery module electrical connector (at the FDM) and the two (2) fuel vent hoses and the vapor tube (near the rear of the tank). Discard the clamps. Disconnect the pressure sensor electrical connector (applicable to early 1999 models only).
14. Lower the tank and place on a suitable workbench.
15. Disconnect the fuel outlet tube from the FDM.
16. Using suitable tools, remove the fuel delivery module locking ring. Discard the locking ring  .
17. Unlock the FDM from the retaining ring in the tank by rotating it counterclockwise, then lift the pump from the tank.
18. Remove and discard the FDM O-ring seal  .
19. Using Cut-Off Tool 310-133, remove the FDM retaining ring from the floor of the fuel tank. Refer to the following instructions for proper tool usage. Be sure to follow all notes and cautions regarding tool usage or damage to the fuel tank may occur.

CUT-OFF TOOL INFORMATION

FDM RETAINING RING REMOVAL

FUEL TANK FILLER NECK GROMMET, FLAPPER VALVE AND LOCKING COLLAR REPLACEMENT

1. CAUTION:  Use caution when removing the filler neck grommet. Do not damage the filler neck flange when removing the grommet.

   Using a suitable tool, carefully remove the filler neck grommet from the fuel tank filler neck flange. Discard the grommet  .

2. Clean any fuel or dirt present in the grommet seating area.
3. CAUTION: Do not lubricate the outside of the grommet or the filler neck flange  . It may cause the grommet to be dislodged during fuel tank filler pipe installation.

   Install a new  grommet, making sure it is fully seated.

4. Using suitable pliers, remove the flapper valve from the filler pipe by twisting it until the hinge pins shear. Then remove the valve housing using a 3/8-inch center punch to carefully punch out the housing retaining tabs through the retaining tab windows. Be sure to remove any remaining plastic debris from the filler pipe.
5. Position the new  flapper valve on the end of the filler pipe and align the retaining tabs with the windows in the filler pipe.
6. Using a light-weight hammer, and with a block of wood placed between the flapper valve and the hammer, gently tap the flapper valve into place. Be sure both flapper valve retaining tabs are seated firmly in the filler pipe windows once the valve is in place.
7. Confirm proper flapper valve operation. The valve must open and close under its own weight. If it does not, check for proper flapper valve retaining tab alignment or fuel filler pipe distortion.
8. Remove the white locking collar from the filler pipe and discard  .
9. Install the new  locking collar.

FUEL DELIVERY MODULE INSTALLATION

1. Make sure the O-ring groove is clean and the area around the FDM opening is free of loose dirt and debris, then install a new  O-ring seal onto the fuel tank.
2. NOTE:  Make sure the legs supporting the FDM upper plate are fully extended prior to FDM installation.

   Position the new  FDM in the tank.

3. Using suitable tools, install and tighten the new  fuel delivery module locking ring.
4. NOTE:  The new  FDM is constructed with the outlet tube and electrical connector reversed as compared to the original FDM.

   Connect the FDM fuel outlet tube.

5. Position the protective foam pad aside and install the supplied convolute over the FDM outlet tube as shown in the following illustration with the slit facing up. Use vinyl tape to secure the convolute in place by taping both ends to the outlet tube.

FUEL TANK INSTALLATION

1. CAUTION:  Do not use silicone to lubricate any fuel system component. Damage to certain components may occur.
   NOTE: Lightly lubricating the grommet and the fuel filler pipe with petroleum jelly will help ease filler pipe reinstallation and prevent dislodging the grommet during tank installation.

   Using petroleum jelly, lightly lubricate the filler pipe and the INSIDE of the grommet.

2. Position tank on suitable lift table and partially raise the tank into position and guide the filler pipe only part way into the tank. DO NOT attempt to fully seat the filler pipe at this time.
3. Position the new  clamps on the fuel vent hoses. Connect the vent hoses and the vapor tube, then tighten the vent hose clamps.
4. Connect the FDM electrical connector and the pressure sensor electrical connector, if applicable.
5. Continue to raise the tank into position, making sure the filler pipe is properly entering the grommet. Then engage the white filler pipe locking collar into the filler neck flange once the tank is fully in position.
6. Position and secure the fuel tank support straps. Tighten the retaining bolts to 24 Nm (18 lb-ft).
7. Install the filler pipe lower bolt.
8. Install the new  retaining clip onto the fuel filter outlet tube connector, then connect the tube to the fuel filter outlet. Tug on the line to make sure of proper connection.
9. Position the stabilizer bar and install the clamps and bolts. Tighten the bolts to 23 Nm (17 lb-ft).
10. Position the heat shield and install the stamped nuts.
11. Reconnect the exhaust system rubber hangers.
12. Lower the hoist.
13. Return the drained and filtered fuel back into the vehicle fuel tank.
14. Connect the battery negative cable and reset the radio stations.
15. Perform an Evaporative Emissions System Leak Test as follows:
    CAUTION: The evaporative emission system must not be pressurized to more than 3.48 kPa (14 inches H2O) or damage to the evaporative emission system may occur.
    1. Connect the Evaporative Emission System Leak Tester 310-F007 (134-00056 or equivalent) to the evaporative test port.
    2. NOTE:  The ignition switch must be in the Key ON/Engine OFF position. Using WDS, NGS or equivalent, apply 12 volts to the canister vent solenoid.
    3. Pressurize the evaporative emissions system to 3.48 kPa (14 inches H2O).
    4. Monitor the system for two (2) minutes. If pressure falls below 2.0 kPa (8 inches H2O), the system has failed the leak test.
    5. Repair any leaks as necessary. (NOTE: Any repairs not related directly to the FDM replacement are not covered by this program.)
    6. Repeat the Evaporative Emissions System Leak Test until the system remains above 2.0 kPa (8 inches H2O) after the last test period.
16. Perform a post-repair road test to determine that the driveability concern has been corrected.