Emissions Recall 05E15 - 6.0L Diesel - Exhaust Pressure Sensor Replacement, On-Board Diagnostic System And Engine Control Modules RECALIBRATION (05E15)

Publication date: 2006-01-01
Reference number: 05E15

EMISSIONS RECALL 05E15 - 6.0L DIESEL - EXHAUST PRESSURE SENSOR REPLACEMENT, ON-BOARD DIAGNOSTIC SYSTEM AND ENGINE CONTROL MODULES RECALIBRATION

SERVICE CAMPAIGN BULLETIN

Reference Number(s): 05E15 Supplement #3, Date of Issue: January 2006

FORD:

2004-2005 F250/350/450/550, Excursion, and E350/450

EMISSIONS RECALL 05E15

SUBJECT

Voluntary Emission Recall 05E15: Supplement #3

Certain 2004-2005 Model Year F250/350/450/550, Excursion, and E350/450 Vehicles Equipped with 6.0L Diesel Engines

Exhaust Pressure Sensor Replacement, On-Board Diagnostic System and Engine Control Modules Recalibration

REF

Voluntary Emission Recall 05E15: Supplement #2 Dated August 18, 2005

AFFECTED VEHICLES

Attachment III addresses certain 2004 model year E350/450 vehicles built from 12/9/2003 through 5/31/2004 for Exhaust Pressure (EP) sensor and (EP) connector replacement, and recalibration.
Attachment IV addresses certain 2004 model year F-250/350/450/550 and Excursion built from 12/1/2003 through 5/31/04 for Exhaust Pressure (EP) sensor, and (EP) connector replacement, and recalibration.
Attachment V addresses certain 2004 model year F-250/350/450/550 and Excursion built from 9/29/2003 through 11/30/2003 for Exhaust Pressure (EP) sensor replacement, and recalibration.
Attachment VI addresses certain 2004-2005 model year F-250/350/450/550 and Excursion built from 6/1/2004 through 1/18/2005, and 2004-2005 model year E350/450 vehicles built from 6/1/2004 through 3/3/2005 for Exhaust Pressure (EP) sensor replacement, and recalibration.

Affected vehicles are identified in OASIS. In addition, for a list of vehicles assigned to your dealership, visit https://web.fsavinlists.dealerconnection.com . This information will be available on January 9, 2006.

NOTE: A small number of vehicles that were repaired between July 5, 2005 and July 18, 2005, prior to the suspension of Voluntary Emissions Recall 05E15 will be included in Voluntary Emissions Recall 05E16 .

REASON FOR THIS SUPPLEMENT #3

Expand the affected vehicle coverage to include late build 2004 model vehicles and certain 2005 model vehicles.
Revise existing Technical Instructions and add Attachment VI.
Add labor operations and labor times for additional vehicles.

Affected VINs have been listed in OASIS. It is important that Dealers check OASIS to verify program eligibility. Dealers should ensure that all engine recalibration repairs are completed utilizing the latest calibration (refer to Service Action).

The Customer Assurance Test Drive includes the additional model years, and should continue to be claimed as part of Voluntary Emission Recall 05E15.

REASON FOR THIS VOLUNTARY EMISSION RECALL

On some of the affected vehicles, corrosion may exist at the electrode surface on the Exhaust Pressure (EP) sensor; fuel delivery timing during cold weather may not be optimal; and/or Exhaust Gas Recirculation (EGR) system operation at idle may not be optimal. These conditions may cause "Check Engine" light illumination, lack of power, hard starting, and/or rough engine operation. In addition, the on-board diagnostic (OBD) system on F-250/350, Excursion, and E350/450 vehicles may not properly monitor the performance of the emission control systems.

SERVICE ACTION

At no charge to the vehicle owner, dealers will perform repairs on the affected vehicles as outlined in the Technical Instructions (Attachments III, IV, V, and VI). Dealers will also recalibrate (reflash) the engine control modules with the latest level software. This must be performed on all of the affected vehicles in your inventory prior to delivery.

Be sure that your Worldwide Diagnostic System (WDS) is updated using WDS release B40.7 and higher or B41.1 and higher. THIS NEW CALIBRATION IS NOT INCLUDED IN THE B41 CD. Calibration files may also be obtained at www.motorcraft.com. (refer to Attachment III, IV, V, or VI for software levels).

For 2005 Model Year F-Series Vehicles Operated in Cold Weather

NOTE: After the update, 2005 model year F-Series vehicles operated in cold weather may experience a small reduction in acceleration during the first few minutes of cold engine operation. Customers in this category will be notified of this condition in their owner letter.

NOTE: The State of California and the Commonwealth of Massachusetts require the completion of emission recall repairs prior to vehicle registration renewal. For vehicles registered in these states, please provide the owner with a Vehicle Emission Recall Proof of Correction certificate after the repair has been performed. These certificates may be obtained by contacting your regional office.

PLEASE NOTE: The sale of uncorrected new vehicles to customers could lead to penalties under applicable state and Federal regulations. Correct all vehicles in your new vehicle inventory prior to delivery.

CUSTOMER VEHICLES AFFECTED BY OTHER FIELD SERVICE ACTIONS

PLEASE NOTE: It is possible that a vehicle affected by this program may also be affected by other programs. Affected owners will receive one mailing explaining all applicable programs. The owner letter sample posted with this bulletin, however, will reflect only program 05E15. PLEASE CONSULT OASIS TO BE SURE YOU ARE ADMINISTERING THE CORRECT PROGRAM(S) AND, IF POSSIBLE, COMPLETE ALL OPEN PROGRAMS IN ONE CUSTOMER VISIT.

CUSTOMER ASSURANCE TEST DRIVE

A special allowance for a test drive is provided for customer owned vehicles after all open Field Service Actions have been completed. The test drive is to identify whether the vehicle has any other engine performance issues. See Attachment II for claiming instructions. Consult OASIS to assure that all open programs have been completed.

To address any customer vehicles that are out of warranty and exhibit engine performance issues after the completion of all open programs, please follow the guidelines in the Warranty & Policy Manual.

NOTE: THIS TEST DRIVE CAN ONLY BE CLAIMED ONCE; IT SHOULD BE PERFORMED AFTER ALL OPEN FIELD SERVICE ACTIONS HAVE BEEN COMPLETED; AND CLAIMED ON PROGRAM 05E15.

TECHNICIAN REQUIREMENTS

The repairs required under this program can be performed by any technician trained in electrical, driveability, or diesel repairs. Therefore, a diesel certified technician is not required to perform the repairs specified under this program. However, if any additional engine performance issues are noted after completion of the repairs specified in this program and the Customer Assurance Test Drive, the vehicle should be turned over to a diesel certified technician for normal diagnosis and repair.

ATTACHMENTS

Attachment I: Administrative Information
Attachment II: Labor Allowances and Parts Ordering Information
Attachment III: Technical Information
Attachment IV: Technical Information
Attachment V: Technical Information
Attachment VI: Technical Information
Customer Notification Letter(s)

QUESTIONS?

Claims Information ... 1-800-423-8851
Special Service Support Center
- Parts (Dealer Only) ... 1-800-207-2444
- Technical and All Other (Dealer Only) ... 1-800-325-5621

ATTACHMENT I

Voluntary Emission Recall 05E15: Supplement #3

Certain 2004-2005 Model Year F250/350/450/550, Excursion, and E350/450 Vehicles Equipped with 6.0L Diesel Engines

Exhaust Pressure Sensor Replacement, On-Board Diagnostic System and Engine Control Modules Recalibration

OASIS ACTIVATED?

Yes. OASIS will be activated for the additional vehicles by January 9, 2006.

FSA VIN LIST ACTIVATED?

Yes.

Available through FMCDealer.com or at https://web.fsavinlists.dealerconnection.com January 11, 2006. Owner names and addresses for the additional vehicles will be available by January 26, 2006.

NOTE: Your FSA VIN list may contain owner names and addresses obtained from motor vehicle registration records. The use of such motor vehicle registration data for any purpose other than in connection with this recall is a violation of law in several states, provinces, and countries. Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall action.

STOCK VEHICLES

Correct all affected units in your new vehicle inventory before sale and delivery.

SOLD VEHICLES

Owners of affected vehicles will be directed to dealers for repairs.
Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are identified in OASIS. Give the owner a copy of the Customer Notification Letter and schedule a service date.
Correct other affected vehicles identified in OASIS which are brought to your dealership.

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this service.

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.
If you encounter aftermarket equipment or modifications to the vehicle which would cause the technician to expend additional labor time to complete the repair, actual time (MT05E15) may be used. (See Claims "Preparation and Submission"). No approval is required.

OWNER REFUNDS

Ford Motor Company will only refund owner-paid repairs covered by this recall that were performed prior to 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).
This recall must still be performed, even if the customer has paid for a previous repair. Claiming a refund will not close out the VIN for this recall.
Refund Claiming Information. (Submit on separate repair line.)
1. - Program Code: 05E15
2. - Misc. Expense: REFUND
3. - Misc. Expense: ADMIN
4. - Misc. Expense: 0.2 Hrs.

RENTAL VEHICLES

Ford Motor Company will pay for a rental vehicle up to $50/day, except for fuel and insurance, which will be at the owner's expense. Enter the word "RENTAL", the number of days the vehicle was used, and the dollar amount in the Miscellaneous Expense area of the claim form.

CLAIMS PREPARATION AND SUBMISSION

Enter claims using Direct Warranty Entry (DWE).
Related damage must be claimed on a repair line that is separate from the repair line on which the FSA is claimed.
"MT" labor should be submitted on a separate repair line with the related damage flag checked.
The use of actual time (MT05E15) must comply with warranty and policy guidelines as outlined in the Warranty and Policy Manual. "Actual time" repairs require technician time stamps on the repair order. (See "Time Recording Procedure" in Section 1, page 14 of the Warranty and Policy Manual.)
Claims for the "59B01A" labor operation for the Customer Assurance Test Drive should be claimed using program code 59B01.
Refer to ACESII manual for claims preparation and submission information.
See Attachment II for claim instructions for the Customer Assurance Test Drive.

ATTACHMENT II

Voluntary Emission Recall 05E15: Supplement #3

Certain 2004-2005 Model Year F250/350/450/550, Excursion, and E350/450 Vehicles Equipped with 6.0L Diesel Engines

Exhaust Pressure Sensor Replacement, On-Board Diagnostic System and Engine Control Modules Recalibration

LABOR ALLOWANCES

Description	Labor Operation	Labor Time
2004 E350/450 (built from 12/9/2003 through 5/28/2004) Exhaust Pressure (EP) sensor and (EP) connector replacement, and recalibrate control modules.	05E15E	1.4 Hours
2004 F-250/350/450/550 and Excursion (built from 12/1/2003 through 5/31/04) Exhaust Pressure (EP) sensor, and (EP) connector replacement, and recalibrate control modules.	05E15G	1.3 Hours
2004 F-250/350/450/550 and Excursion (built from 9/29/2003 through 11/30/2003) Exhaust Pressure (EP) sensor replacement, and recalibrate control modules.	05E15F	1.0 Hour
2004-2005 F-250/350/450/550 and Excursion (built from 6/1/2004 through 1/18/2005) Exhaust Pressure (EP) sensor replacement, and recalibrate control modules.	05E15M	1.0 Hour
2004-2005 E350/450 (built from 6/1/2004 through 3/3/2005) Exhaust Pressure (EP) sensor replacement, and recalibrate control modules.	05E15N	0.9 Hour
* CUSTOMER ASSURANCE TEST DRIVE (May only be claimed once per vehicle)	59B01A	0.3 Hour
*NOTE: This test drive is to verify that there are no other engine related concerns with the vehicle before returning it to the customer. Because it is possible that a vehicle affected by this program may also be affected by other programs, the post-repair test drive labor operation and labor time may only be claimed once, after completing all field service actions including Voluntary Emission Recall 05E15.

CLAIMS PREPARATION AND SUBMISSION - CUSTOMER ASSURANCE TEST DRIVE

Verify eligibility in OASIS. If eligible, "59B01" will display under "Outstanding Field Service Actions".
Program Code: 59B01
Submit on a Recall Type Form
Can only be claimed one time per vehicle and only if all open field service actions are completed.
Labor only, no parts or miscellaneous expense cost.

IF UNABLE TO REPROGRAM PCM, TCM, or FICM

PCM and/or FICM replacement will not be covered under this program.
Prior to disconnecting WDS from the vehicle and closing the session, call the Special Service Support Center at 1-800-325-5621.

PARTS REQUIREMENTS / ORDERING INFORMATION

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

PARTS INFORMATION

Part Number	Description	Qty.
4C3Z-9J460-A	Exhaust Pressure Sensor - Straight (pipe) Thread Fitting - 2004-05 F-250/350/450/550 - built through 11/3/2004 - 2004-05 Excursion - built through 1/9/2005	1
5C3Z-9J460-A	Exhaust Pressure Sensor - Tapered/Flared Thread - 2004-05 E350/450 - 2005 F-250/350/450/550 - built 11/4/2004 and later - 2005 Excursion - built 1/10/2005 and later	1
5C3Z-12224-A	ICP/EP Connector Kit - 2004 E350/450 - built 12/9/2003 through 5/28/2004 - 2004 F-SD & Excursion - built from 12/1/2003 through 5/31/2004 Note: The ICP/EP connector kit is not required on any 2005 MY vehicles. Note: This connector is also used in Safety Recall 05S34 .	1
FPS-8262	Authorized Modifications Label Note: Labels are in packages of 25 and are provided to dealers at no charge.	1
*Note: Exhaust Pressure Sensors (EPS) date ranges for the F-SD and Excursion above are approximate. Both models switched during the 2005 model year build from straight (4C3Z-9J460-A) to flared (5C3Z-9J460-A) thread fittings.

Parts Support Center

To contact the Parts Support Center for questions or for ordering assistance regarding recall parts:

E-mail: Ford@Renkim.com
FAX: 1-734-374-1030
Phone number: 1-800-207-2444 (Parts Support Center)

When contacting the Parts Support Center please provide:

Dealer Name and P & A code
Contact Name
Phone number and E-mail address
FSA # 05E15
Part number and QTY being requested or question / concern regarding part

The DOR/COR for this program is 50356. This number identifies parts ordered for this recall through the Parts Support Center (1-800-207-2444). Continue to contact the Special Service Support Center for related damage, technical, or other repair issues (1-800-325-5621).

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.

VEHICLE EMISSION RECALL PROOF OF CORRECTION CERTIFICATE

Describe the modification completed, your P & A code, date of repair, etc. Provide the owners of vehicles registered in California and Massachusetts with a completed Vehicle Emission Recall Proof of Correction Certificate. This certificate can be obtained through your Regional Office.

ATTACHMENT III

Emissions Recall 05E15 Supplement #3

Certain 2004 Model Year E-Series Vehicles Equipped with 6.0L Diesel Engine Built From 12/09/03 Through 5/31/04

EP Sensor And Connector Replacement And Recalibration

OVERVIEW

The 2004 model year program involves replacing the exhaust pressure (EP) sensor and connector and recalibrating the powertrain control module (PCM), transmission control module (TCM) and the fuel injection control module (FICM) with the latest software.

EP SENSOR AND CONNECTOR REPLACEMENT

NOTE: All splices are to be made using tools provided in the Rotunda Wire Splice Tool Kit 164-R5903. The repair kit contains the connector and pigtails, butt splice connectors and heat shrink tubing. The EP sensor is located on a bracket above the left valve cover in front of the glow plug relay. See Fig 1.

Remove the engine cover from inside the passenger compartment.
Disconnect the EP sensor.

Fig 1: EP Sensor Location - E-Series Built From 12/09/03 Through 5/31/04

While holding the tube nut, remove the EP sensor.
Install the new EP sensor and tighten to 10 Nm (89 lb-in).
Remove the tape from the vehicle harness back to the original take-out location.
CAUTION: The replacement connector has only one color wire, so location identification is crucial for a proper repair.
Label the wires identifying the cavity in which they are located. Place identifying tags at least a few inches away from the connector to be cut off.
Cut the wires about 25 mm (1 inch) behind the connector on the vehicle harness MAKING SURE TO LEAVE THE IDENTIFYING TAGS ON THE HARNESS and discard the old connector. See Fig 2.

Fig 2: Location To Cut Vehicle Harness

Strip about 7 mm (1/4 inch) of insulation from the wires on the new pigtail.
Using the crimp tool provided in the Rotunda Tool Kit, install the butt splice connectors provided in the service kit onto the replacement connector pigtail.
Strip about 7 mm (1/4 inch) of insulation from the wires on the vehicle harness.
Position the heat shrink over the wires on the new connector.
Matching the wires on the pigtail to the identifying tags on the vehicle harness, crimp the new butt splice connectors to the vehicle harness. Lightly tug on the wires to make sure of quality connections.
Position the heat shrink tubing over the butt splice connectors, then using the provided Flameless Heat Gun and deflector, heat the tubes on the vehicle harness until they shrink and adhesive flows from the ends, indicating a water-tight seal.
Fold the repaired harness to mirror the original harness length and tape the harness.
Install a length of convolute over the spliced section of harness and secure with tape.
Apply electrical grease to the face of the connector, forcing a small amount into all three (3) terminals.
Connect the EP harness connector.
Install the engine cover.
Proceed to Module Recalibration in this Attachment III.

MODULE RECALIBRATION

NOTE: This recalibration, using WDS software Version B40.7 or higher, or B41.1 or higher, will update the PCM, TCM and FICM. This new calibration is not included in the B41 CD. Calibration files may also be obtained at www.motorcraft.com.

Connect a battery charger to the vehicle.
Using Worldwide Diagnostic System (WDS), recalibrate the modules to the latest level calibration.
VERIFY THE WDS IS LOADED WITH SOFTWARE VERSION B40.7 OR HIGHER, OR B41.1 OR HIGHER.
Select Module Configuration Programming (MCP) and follow the WDS display instructions.
- If unable to recalibrate the modules:
  1. - module replacement will not be covered under this program.
  2. - prior to disconnecting the WDS from the vehicle and closing the session, call the Special Service Support Center at 1-800-325-5621.
Perform a self-test to verify there are no further concerns.
Proceed to Road Test Procedure in this Attachment III.

ROAD TEST PROCEDURE

Check OASIS to verify there are no other Field Service Actions applicable to this vehicle prior to performing the Road Test Procedure.

Test drive the vehicle to make sure no driveability concerns exist prior to returning the vehicle to the owner.

NOTE: To address any customer concerns for vehicles that are out of warranty and exhibit engine performance issues after the road test, please follow the guidelines in the Warranty and Policy Manual.

AUTHORIZED MODIFICATIONS LABEL INSTALLATION

Obtain and prepare the Authorized Modifications Label. Describe the modification performed, and enter your P & A Code, date of repair and the program type and program number. See Fig 3.

Fig 3: Authorized Modifications Label

PROOF OF CORRECTION CERTIFICATE

Provide the owners of vehicles registered in California and Massachusetts with a completed "Vehicle Emissions Recall - Proof of Correction" certificate. See Fig 4.

Fig 4: Proof Of Correction Certificate