Extended Coverage Program 03N01 - Fuel Delivery Module - New Design (03N01)

SUBJECT

Extended Coverage Program 03N01: Supplement #2

Certain 2000 and 2001 Model Year Focus Vehicles

Fuel Delivery Module - New Design

REF

Extended Coverage Program 03N01: Supplement #1 Dated January 2004

Certain 2000 and 2001 Model Year Focus Vehicles

Fuel Delivery Module - New Design

Extended Coverage Program 03N01: Dated November 2003

Certain 2000 and 2001 Model Year Focus Vehicles

Fuel Delivery Module

PURPOSE OF THIS SUPPLEMENT

• Reinstate 0.3 Hour road test labor times
• Revised technical instructions which include a road test to be performed after FDM replacement to determine if the driveability concern has been corrected.

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 replacement coverage, and is automatically transferred to subsequent owners.

VEHICLES COVERED BY THIS PROGRAM

Certain 2000 and 2001 model year Focus vehicles built at the Wayne and Hermosillo Assembly Plants from Job #1, 1999 through June 13, 2001. Affected vehicles are identified in OASIS.

REASON FOR PROVIDING ADDITIONAL COVERAGE

Some of the affected vehicles may experience stalling, engine hesitation, loss of power, surging, and other similar symptoms as a result of contamination of the fuel pump filters. Because the contamination of the filters is progressive, they 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 right turn 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 after FDM replacement, a road test will be conducted at no charge to determine if the driveability concern has been corrected.
• That diagnosis and correction of any remaining driveability issues are the responsibility of the customer unless the vehicle still has remaining Basic Vehicle Warranty coverage.
• This Customer Satisfaction program only covers replacement of the FDM.

Obtain customer approval before conducting any further diagnostics.

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

Detailed Technical Instructions and revised labor times to install the new design FDM are included with this 03N01 Supplement #2.

SPECIAL CUTTING TOOL

A special cutting tool will be needed to install the new design fuel pump. One cutting tool along with a replacement-cutting blade will be supplied (free of charge) to each dealership. Additional cutting tools will be available for purchase. See Attachment II for further information on tool ordering and Attachment III for tool usage.

AN OPPORTUNITY TO BUILD CUSTOMER LOYALTY

With increased service capacity, use the resulting service traffic to acquire new retail service customers, or become re-acquainted with current ones. Take this opportunity to make a lifetime customer by demonstrating:

• Care  by using the Quality Care Report Card every time to identify additional service needs that may require attention.
• Convenience  by offering convenient payment terms, by scheduling service appointments, and by providing convenient hours and days of operation.
• Competitive Pricing  by promoting national, regional, and your individual dealer service specials.

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 03N01)

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. See "SERVICE ACTION" above for specific direction.

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

• This repair will require no additional labor time  to complete. Claims submitted with "MT" labor will not be accepted for reimbursement.
• 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.)

• Program Code: 03N01
• Misc. Expense: REFUND
• Misc. Expense: ADMIN
• 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).
• Refer to ACESII manual for claims preparation and submission information.
• Refunds must be claimed on a repair line that is separate from the FSA's repair line.

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.

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.

SPECIAL CUTTING TOOL

A special cutting tool will be needed to install the new design fuel pump. One cutting tool, (part number 310-133) along with a replacement-cutting blade (part number 310-133/1), will be supplied free of charge to each dealership. Additional cutting tools and/or cutting blades will be available for purchase by calling 1-800-ROTUNDA (1-800-768-8632). 

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:

1. REASON CODE: GB
2. SHIPPER NBR: 03N01
3. 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 February 23, 2004.  Claims filed after this date will be denied.

OVERVIEW

This program involves replacing the fuel delivery module (FDM) with a new  , redesigned module. A redesigned fuel filter inlet tube is also being installed due to the FDM design changes.

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.

A special 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). Each dealer will receive one special cut-off tool and two sample retaining rings. The rings are provided so the technicians can practice fitting the tool and cutting the tabs before performing the repair on a customer's vehicle.

FUEL TANK AND FUEL DELIVERY MODULE REMOVAL

1. Remove and discard the fuel delivery module from the fuel tank. Refer to Section 310-01 of either the 2000 or 2001 model year Workshop Manual for removal instructions, including depressurizing the fuel system and draining the tank.
   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 (shown in the illustration) are equipped with the necessary filtering systems.
   NOTE: Use Rotunda 5' Adapter Hose, 034-R0077, 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 must be cut in the end of the hose.

CUT-OFF TOOL INFORMATION

FDM RETAINING RING REMOVAL

IMPORTANT NOTE 

When all four (4) tabs are fully cut, the ring will then be detached and easily removed. If the ring cannot be easily removed, the tool was not positioned properly.

Check the tool position and recut.

Do not rock, twist, pull or pry the tool under any circumstances!!! 

FUEL DELIVERY MODULE (FDM) INSTALLATION

1. Install the new  gasket onto the new  FDM. Be sure it sits flat on the underside of the flange and that it is not rolled or twisted.
2. NOTE:  The new  FDM has a spring-loaded upper plate which must be pushed and held downward to install the locking ring.
   • Position the new  FDM into the fuel tank.
   • Place the locking ring over one hand (like a bracelet).
   • With that same hand, push the FDM upper plate down while aligning the two locating tabs on the FDM with the two (2) notches on the fuel tank.
   • While holding the upper plate in place, use your other hand to install and tighten the FDM locking ring.
   • Using Fuel Tank Wrench 310-069, tighten the FDM locking ring to 80 Nm (59 lb-ft).
3. Install the new  fuel filter inlet tube assembly onto the FDM.
   NOTE: The new  FDM will be shipped with either a shipping plug or tape covering the red connector. This is to prevent dirt or contaminants from entering the FDM prior to installation. Remove only the shipping plug or tape. DO NOT REMOVE THE RED CONNECTOR!!! 

FUEL TANK INSTALLATION

1. Reinstall the fuel tank as outlined in the appropriate workshop manual.
2. Replace the drained and filtered fuel.
3. 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 H₂ O).
   4. Monitor the system for two (2) minutes. If pressure falls below 2.0 kPa (8 inches H₂ O), the system has failed the leak test.
   5. Repair any leaks 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 H₂ O) after the last test period.
4. Perform a post-repair road test to determine that the driveability concern has been corrected.

BACKGROUND SUMMARY