Customer Satisfaction Program 07N11 - Throttle Body Cleaning (07N11)

SUBJECT

Customer Satisfaction Program 07N11: 

Certain 1999 and 2000 Model Year Villager Vehicles

Throttle Body Cleaning

REF

Awareness Communication: Upcoming Customer Satisfaction Program 07N11 Dated May 15, 2008 

Certain 1999 and 2000 Model Year Villager Vehicles

Throttle Body Cleaning

PROGRAM TERMS

This program extends the warranty coverage for a one-time throttle body cleaning to December 31, 2010 regardless of warranty start date or vehicle mileage.

VEHICLES COVERED BY THIS PROGRAM

Certain 1999 and 2000 model year Villager vehicles registered in the state of Ohio. Affected vehicles are identified in OASIS.

BACKGROUND

Pursuant to the settlement of a class action lawsuit, certain Villager owners in the state of Ohio were given the opportunity to submit a request to Ford Motor Company to have a one-time cleaning of the vehicle throttle body at no charge. Customers who properly responded by the deadline of June 27, 2008, will receive a postcard notifying them that their claim was approved. These are the only VINs that will be activated in OASIS.

REASON FOR PROVIDING ADDITIONAL COVERAGE

In some of the affected vehicles, the throttle body plate may be difficult to open due to carbon buildup in the throttle body bore. The customer may complain that the accelerator pedal requires excessive force upon initial acceleration.

SERVICE ACTION

Dealers are to follow the throttle body cleaning procedure in Attachment III. This one time only service will be performed on affected vehicles at no charge to the vehicle owner. The vehicle does not need to exhibit a stuck closed throttle symptom to have this service performed.

OWNER NOTIFICATION MAILING SCHEDULE

Approved customers will be mailed notification post cards to obtain the no charge throttle body cleaning beginning July 31, 2008. Affected vehicles will be identified in OASIS.

ATTACHMENTS

1. Attachment I: Administrative Information
2. Attachment II: Labor Allowances and Parts Ordering Information
3. Attachment III: Technical Information
4. Customer Notification Letter

QUESTIONS & ASSISTANCE

Special Service Support Center (Dealer Only) ................ 1-800-325-5621

OASIS ACTIVATED?

Yes, OASIS will be activated by July 31, 2008.

FSA VIN LIST ACTIVATED?

No

SOLD VEHICLES

Only owners of affected vehicles that received approved notification post cards will be directed to dealers for repairs.

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

Eligible owners have been identified and refunds are currently in process. Dealerships will not process these refund claims.

RENTAL VEHICLES

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

CLAIMS PREPARATION AND SUBMISSION

• Enter claims using Direct Warranty Entry (DWE).
• "MT" labor should be submitted on a separate repair line with the related damage flag checked. "MT" labor requires approval from Special Service Support Center.
• Refer to ACESII manual for claims preparation and submission information.
• Claiming information for Motorcraft Choke and Linkage Cleaner PM-14 or equivalent (Submit on same repair line as repair).
  • Program Code: 07N11
  • Misc. Expense: OTHER
  • Misc. Expense: $2.00

LABOR ALLOWANCES

PARTS REQUIREMENTS / ORDERING INFORMATION

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

Questions regarding parts should be directed to the Special Support Center (800-325-5621) or Emailed to: Ford@Renkim.com.

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."

REQUIRED SHOP SUPPLIES

A quantity of Motorcraft Choke and Linkage Cleaner PM-14 or equivalent should be claimed under MISC. EXPENSE (See Attachment I).

OVERVIEW

This program involves cleaning the Throttle Body (TB) plate and bore. Install a new TB gasket.

SERVICE PROCEDURE

1. Disconnect the battery ground cable.
2. Disconnect the vacuum hose from the lower air intake duct. See Fig 1.
Fig 1: Vacuum Hose On Lower Air Intake Duct

3. Loosen the TB clamp and the air box clamp. Open the breather tube inlet hose clamp and the bypass air inlet hose clamp to remove both hoses from air intake duct. See Fig 2.
Fig 2: Clamps And Hoses On Air Intake Duct

4. Disconnect the transaxle vent tube from the air intake housing clip. Remove the center air intake duct.
5. NOTE:  The Throttle Position (TP) electrical connector is held with 3 hold-down pushpins.

   Disconnect the TP sensor harness connector, TP electrical connector and the Idle Air Control (IAC) harness connector from the TB. See Fig 3.

Fig 3: TP Sensor Harness Connector, TP Electrical Connector And Idle Air Control (IAC) Harness Connector

6. Remove the upper TB electrical harness and vacuum hose to allow for more clearance to move the TB away from the intake. See Fig 4.
Fig 4: TB Electrical Harness And Vacuum Hose

7. Disconnect the accelerator and speed control cables from the throttle linkage. See Fig 5.
Fig 5: Accelerator And Speed Control Cables On Throttle Linkage

8. Remove 4 TB bolts and move the TB away from the intake to gain access to the inside of the TB bore. See Fig 6.
Fig 6: TB Positioned Away From Intake

9. NOTE:  For proper operation of the TB, it will be necessary to clean the entire ID of the throttle plate-to-TB bore mating surfaces.

   With the TB positioned to the side, open the throttle plate. Using Motorcraft Choke and Linkage Cleaner PM-14 or equivalent, spray the TB Plate And Bore. Using a suitable soft bristle brush, clean the edges of the throttle plate and the mating surface of the TB bore to remove all carbon build up. Re-apply Motorcraft Choke and Linkage Cleaner PM-14 or equivalent and wipe clean with a lint-free cloth. See Fig 7.

Fig 7: Cleaning TB Plate And Bore

10. Remove and install a new TB gasket.
11. Reposition the TB to the intake and install the 4 TB bolts. Tighten the bolts in 2 stages. First, tighten to 10 Nm (89 lb-in) and then tighten to 20 Nm (15 lb-ft). See Fig 6.
12. Connect the accelerator and speed cables to the TB linkage. See Fig 5.
13. Connect the upper TB electrical harness and vacuum hose. See Fig 4.
14. Connect the TP sensor harness connector and the IAC harness connector to the TB and attach the TP electrical connector. See Fig 3.
15. Install the center air intake duct. Tighten the air box clamp to 2 Nm (18 lb-in) and the TB clamp to 3 Nm (27 lb-in). Reinstall and secure the breather tube inlet hose and the bypass air inlet hose clamps. See Fig 2.
16. Connect the transaxle vent tube to the lower air intake duct.
17. Connect the vacuum hose to the lower air intake duct. See Fig 1.
18. Connect the battery ground cable.
19. Using the appropriate Workshop Manual, Section 303-04, recheck the idle speed setting. If necessary, adjust the idle speed setting.