Attachment I - Technical and Administrative Instructions
Owner Notification Program M60Revised Technical and Administrative Instructions
PLEASE READ THESE INSTRUCTIONS. CIRCULATE THEM TO YOUR PARTS AND SERVICE PERSONNEL. QUESTIONS SHOULD BE DIRECTED TO YOUR SERVICE ZONE MANAGER
VEHICLE IDENTIFICATION
Vehicles affected by this program are 1986 and 1987-model Taurus and Sable cars manufactured from start of 1986-model production through June, 1987 that are equipped with 3.0L engines.
SUMMARY OF SERVICE
All vehicles will require the following fuel system modifications:
1) Installation of a dual-purpose fuel tank vapor pressure relief valve in the fuel tank.
2) Replacement of fuel pump filter socks.
3) Replacement of fuel tank spacers, insulators and attaching hardware.
4) Replacement of existing fuel filler caps.
TECHNICAL INSTRUCTIONS
Before Starting This Procedure Refer to Taurus/Sable Shop Manual Sections 24-03 and 24-50 For Fuel System Pressure Relief and Removal/Installation of Fuel Tanks
1. Relieve fuel system pressure and drain fuel tank.
2. Lower tank onto a stand.
3. Remove fuel pump/sender. Discard the pump/sender "O" ring seal.
4. Remove and discard the existing tank vent valve and grommet.
5. Refer to Exhibit 1. Remove old filter sock as follows:
a. Note the orientation of the filter relative to the pump assembly.
b. Without cutting or grasping the brass retention ring inside the filter housing, cut or tear-off the filter cloth, stuffer material and the plastic filter housing itself using side cutters and pliers at the corners opposite the fuel return tube. The retention ring will remain attached to the pump inlet.
c. Using side cutters, cut the brass retention ring in one or two locations, and remove with pliers. Be careful not to scratch the outside diameter of the pump inlet with the cutters.
6. Install new fuel pump filter sock as follows:
a. Inspect the new filter for any dirt or debris. Do not use a filter which contains dirt or debris.
b. Lay the filter on a clean flat surface.
c. Remember the orientation of the filter relative to the pump assembly from Step 5a.
d. Grasp the pump assembly in one hand and hold the assembly such that the pump is in a horizontal position with the fuel return tube on the top side of the pump.
e. Insert the lower portion of the pump inlet (the side of the pump inlet opposite the fuel return tube) into the plastic filter housing maintaining the proper orientation of the filter.
f. To insert the remaining portion of the pump inlet, rock the pump assembly into an upright position applying a downward force throughout the rocking motion. Apply the minimum force necessary to push the filter completely on, to avoid damage to the filter and the plastic filter housing. This is necessary to create a tight seal around the pump inlet.
7. Install the pump/sender with the new filter sock into the tank, using a new O-ring seal. Be careful not to bend the float rod during installation.
8. Refer to Exhibit 1. Install the following new spacers and insulators (adhesive side down) to the top of fuel tank.
Description
Spacer, Black Foam 1/2" thick
Insulator, Grey Foam 1" thick
Spacer, Hard Rubber 1/4" thick,
Foam Backed, 2 Req'd.
9. Install new fuel tank vapor pressure relief valve assembly and grommet in the tank. (Lubricate center hole with a thin film of engine oil).
CAUTION: Do not use silicone lube on this or any other fuel system component as damage will result to other parts of the fuel system.
10. Insert the small diameter nipple on the new vapor pressure relief valve into the existing small diameter vent line on the vehicle. Tape the new larger diameter vent line on top of the existing fuel line. Bundle the lines about eighteen-inches from the valve centerline.
11. Hold the new vent line against the fuel line bundle and tape together at the convoluted split-tube cover near the fuel line filter.
12. Reconnect fuel (use new fuel line connector retainers) and electrical connectors. Assure that the new vapor valve is pushed completely into grommet with ports toward sender unit and that the original bundle of three fuel lines is placed into the fuel tank top clip. Use body-tape to secure the new line to the recess on the tank just beyond the open-end of the clip to prevent pinching against the floorpan.
NOTE: Make sure the nylon fuel and vapor lines on top of fuel tank are not kinked or blocked.
13. Reinstall the fuel tank by positioning the tank as far forward as possible, leaving a 1/2" maximum gap forward of the seam weld flange. Using two (2) new, fuel tank strap-attaching bolts and two (2) new nuts, reinstall fuel tank straps, first the left side then the right side. Torque bolts to 20-29 ft.lbs. (28-40 N-m).
14. To prevent underbody dirt from entering the fuel filler pipe, place a clean rag into the fuel filler pipe. Install the fuel filler pipe. Remove the rag from the pipe.
15. Replace existing fuel filler cap with new cap.
NOTE: When returning vehicle to customer, explain that a new style "Pre-Vent" cap has been installed. Demonstrate "Free Play" feature for bleeding off pressure when removing the cap. Also show how to tighten the cap properly (at least three -3- loud clicks of the ratchet. Emphasize that fuel filler caps should be correctly installed to permit proper cap operation.
16. Replace fuel removed. Start engine and check for leaks.
PARTS ORDERING INSTRUCTIONS
Service Parts required for this program may be ordered through normal order processing channels.
Service Part
Number Description Class Dealer Price
E6DZ-9000-A Kit, Fuel Venting BG $24.50
LABOR OPERATIONS
SCHEDULED LABOR
TIME (HOURS) OPERATION
Replace Fuel Tank Vapor Pressure
Relief Valve, Insulators, Spacers,
Fuel Pump/Sender Filter, Fuel Tank
Mounting Bolts and Nuts and Fuel
Filler Cap 1.3 M60
CLAIM PREPARATION INSTRUCTIONS (A copy of these instructions should be filed in Subject 5.5 or 9.0 of your Warranty and Policy Manual).
Repairs performed under Owner Notification Program M60 are to be submitted on warranty claim Forms 1863, which are to include the information shown below. Enter Program Number M60 in the Program Code box in the upper left of the form. Repair claims should be submitted through the Direct Warranty Entry (DWE) System.
Causal Basic Part Number - 9002
Condition Code - 53
Labor Operations - M60
Scheduled Time - 1.3 Hours
Program Code - M60
REFUNDS Refund requests submitted under Owner Notification Program M60 are governed by the following guidelines:
^ Owners (in states other than Michigan, Ohio and California) seeking refund for repairs covered by this program, which were performed at their expense prior to the receipt of notice of this program must present their paid repair orders or invoices to any Ford or LincolnMercury dealership by December 31, 1989.
^ Refunds include parts, labor and any deductible amount owners may have paid.
^ A copy of the paid repair orders or parts purchase receipts must be retained in your service file for at least one year following the date of Company notification of payment.
^ Owner refund requests must be submitted on separate warranty claim Forms 1863 by December 31, 1989. Claims submitted after that date will not be paid. In addition to the information shown for the special preparation of Owner Refund claims (Reference: Warranty and
Policy Manual - Subject 6.1, Page 15), please enter the information shown below:
Causal Basic Part Number - 9002
Condition Code - 53
Labor Operation - REFUND
Administrative Allowance - 0.2 Hr.
Program Code - M60
^ An administrative allowance of 0.2 hours will be allowed for processing each eligible owner refund request. To claim the allowance, enter ALLOW in the Labor Operation No. column and 0.2 in the Scheduled Time column. Extend the 0.2 hours at your authorized warranty labor rate and enter the result in the Amount column.