Customer Satisfaction Program 16B38

SUBJECT

Certain 2011-2012 Model Year Fusion Vehicles Equipped with 2.5L or 3.0L Engines

Powertrain Control Module Reprogramming and Canister Purge Valve Inspection

PROGRAM TERMS

This program will be in effect through September 30, 2018. There is no mileage limit for this program.

AFFECTED VEHICLES

Vehicle	Model Year	Assembly Plant	Build Dates
Fusion	2011-2012	Hermosillo	March 5, 2011 through July 29, 2012

Affected vehicles are identified in OASIS and FSA VIN Lists.

REASON FOR THIS PROGRAM

In some of the affected vehicles, the canister purge valve (CPV) may develop a leak that can cause excessive vacuum to build in the fuel tank. This condition will only occur under certain operating conditions and may result in illumination of the "service engine soon indicator."

SERVICE ACTION

Dealers are to reprogram the powertrain control module (PCM), test the CPV, and repair as needed. This service must be performed on all affected vehicles at no charge to the vehicle owner.

OWNER NOTIFICATION MAILING SCHEDULE

Owner letters are expected to be mailed the week of October 31, 2016. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

ATTACHMENTS

Attachment I: Administrative Information
Attachment II: Labor Allowances and Parts Ordering Information
Attachment III: Technical Information
Owner Notification Letter

QUESTIONS & ASSISTANCE

For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site. The SSSC Web Contact Site can be accessed through the Professional Technician Society (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or listed under the SSSC tab.

OASIS ACTIVATION

OASIS will be activated on October 6, 2016.

FSA VIN LISTS ACTIVATION

FSA VIN Lists will be available through https://web.fsavinlists.dealerconnection.com on October 6, 2016. Owner names and addresses will be available by November 18, 2016.

NOTE: Your FSA VIN Lists 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 program 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 service action.

STOCK VEHICLES

Use OASIS to identify any affected vehicles in your used vehicle inventory.

SOLD VEHICLES

Owners of affected vehicles will be directed to dealers for repairs.
Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) 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 action.

ADDITIONAL REPAIR (LABOR TIME AND/OR PARTS)

Additional repairs identified as necessary to complete the FSA should be managed as follows:

For vehicles within new vehicle bumper-to-bumper warranty coverage, follow existing warranty and policy guidelines for related damage claims. No SSSC approval is required for these vehicles:
- Ford vehicles - 3 years or 36,000 miles
For vehicles outside new vehicle bumper-to-bumper warranty coverage, submit an Approval Request to the SSSC Web Contact Site prior to completing the repair.

OWNER REFUNDS

Ford Motor Company is offering a refund for owner-paid repairs covered by this program if the repair was performed before the date of the Owner Notification Letter. This refund offer expires March 31, 2017.
Dealers are also pre-approved to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the date of the Owner Notification Letter. There is no expiration date for emergency repair refunds. Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
Refunds will only be provided for the cost associated with canister purge valve replacement, vapor canister replacement due to liquid fuel contamination, or fuel tank replacement due to cracks.

RENTAL VEHICLES

With proper dealer parts ordering and service appointment scheduling, rental vehicles should not be required. However, if you have a unique owner circumstance which may require a rental vehicle, please contact the SSSC via the SSSC Web Contact Site.

CLAIMS PREPARATION AND SUBMISSION

Enter claims using Direct Warranty Entry (DWE) or One Warranty Solution (OWS).
- DWE: refer to ACESII manual for claims preparation and submission information.
- OWS: when entering claims in DMS software, select claim type 31: Field Service Action. The FSA number (16B38) is the sub code.
Additional labor and/or parts must be claimed as related damage on a separate repair line from the FSA.
Submit refunds on a separate repair line.
1. - Program Code: 16B38
2. - Misc. Expense: ADMIN
3. - Misc. Expense: REFUND
4. - Misc. Expense: 0.2 Hrs.
Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim.
For rental vehicle claiming, follow Extended Service Plan (ESP) guidelines for dollar amounts. Enter the total amount of the rental expense under Miscellaneous Expense code RENTAL.
PROGRAM TERMS: This program will be in effect through September 30, 2018. There is no mileage limit for this program.

LABOR ALLOWANCES

Description	Drive Type	Labor Operation	Labor Time
Reprogram PCM (IDS release 99.05 or later) Test CPV - pass	FWD and AWD	16B38B	0.5 Hours
Reprogram PCM (IDS release 99.05 or later) Test CPV - fail (replace CPV) Inspect and replace vapor canister if needed Inspect fuel tank	FWD	16B38C	1.3 Hours
	AWD	16B38D	1.0 Hours
Additional time to replace fuel tank if inspection fails (claim with labor operations 16B38C or 16B38D)	FWD	16B38CC	1.8 Hours
	AWD	16B38DD	2.2 Hours

PARTS REQUIREMENTS / ORDERING INFORMATION

PARTS INFORMATION

Part Number	Description	Order Quantity
9U5Z-9C915-H	Canister purge valve	1
9E5Z-9D653-C	Vapor canister	1
4L3Z-9276-AA	Fuel pump module seal	1
CE5Z-9002-BR	Fuel tank - 2.5L vehicles only	1
CE5Z-9002-CR	Fuel tank - 3.0L FWD vehicles only	1
AE5Z-9002-CR	Fuel tank - 3.0L AWD vehicles only	1

The DOR/COR number for this program is 51059.

Order your parts requirements through normal order processing channels. To guarantee the shortest delivery time, an emergency order for parts must be placed.

DEALER PRICE

For latest prices, refer to DOES II.

PARTS RETENTION AND RETURN

Follow the provisions of the Warranty and Policy Manual, Section 1 - WARRANTY PARTS RETENTION AND RETURN POLICIES.

EXCESS STOCK RETURN

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

OVERVIEW

In some of the affected vehicles, the canister purge valve (CPV) may develop a leak that can cause excessive vacuum to build in the fuel tank. This condition will only occur under certain operating conditions and may result in illumination of the "service engine soon indicator". Dealers are to reprogram the powertrain control module (PCM), test the CPV, and repair as needed.

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

Module Reprogramming

Important Information for Module Programming

NOTE: When programming or reprogramming a module, use the following basic checks to ensure programming completes without errors.

Make sure the 12V battery is fully charged before carrying out the programming steps and connect IDS/scan tool to a power source.
Inspect Vehicle Communication Module (VCM) and cables for any damage. Make sure scan tool connections are not interrupted during programming.
A hardwired connection is strongly recommended.
Turn off all unnecessary accessories (radio, heated/cooled seats, headlamps, interior lamps, HVAC system, etc.) and close doors.
Disconnect/depower any aftermarket accessories (remote start, alarm, power inverter, CB radio, etc.).
Follow all scan tool on-screen instructions carefully.
Disable IDS/scan tool sleep mode, screensaver, hibernation modes.
Create all sessions Key On Engine Off (KOEO). Starting the vehicle before creating a session will cause errors within the programming inhale process.

NOTE: Reprogram appropriate vehicle modules before performing diagnostics and clear all Diagnostic Trouble Codes (DTCs) after programming. For DTCs generated after reprogramming, follow normal diagnostic service procedures.

Connect a battery charger to the 12V battery.
Reprogram the Powertain Control Module (PCM) using IDS release 99.05 or higher.
NOTE: Calibration files may also be obtained at www.motorcraftservice.com.

NOTE: Follow the IDS on-screen instructions to complete the reprogramming procedure.

NOTE: If programming results in a blank module, refer to module recovery instructions below.
Disconnect the battery charger from the 12V battery, once the reprogramming has completed.
Proceed to Canister Purge Valve (CPV) Testing below.

Canister Purge Valve (CPV) Testing

NOTE: Ensure that the VACUTEC® Smoke Machine or equivalent is properly calibrated for a 0.020" leak test following the manufacturer's instructions.

Disconnect the vapor tube-to-CPV quick connect coupling. Please follow the WSM procedures in Section 310-00. See Figure 1.
NOTE: 2.5L shown, 3.0L similar.
Using suitable adapters, connect the VACUTEC® Smoke Machine Fuel Evaporative Emission System Tester or equivalent to the port on the CPV. See Figure 2.
NOTE: 2.5L shown, 3.0L similar.
With the ignition in the "OFF" position, test the CPV for leaks by applying pressure from the tester and monitoring for air flow on the gauge. A good CPV will register a leak rate of less than 0.020".
Is CPV leak rate less than 0.020"?
YES - Reconnect the vapor tube-to-CPV quick connect coupling. No further repairs needed.

NO - Replace the CPV following the WSM procedures in Section 303-13, then proceed to Vapor Canister Inspection below.

Vapor Canister Inspection

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

IMPORTANT: Liquid fuel may be present inside of the vapor canister. Ensure you are using proper precautions while servicing.

Remove the vapor canister from the vehicle. Please follow the WSM procedures in Section 303-13.
While holding the vapor canister, tip the EVAP hose ports downward to determine if there is any liquid fuel within the canister.
Is there any liquid fuel in the canister?
YES - Install a new vapor canister following the WSM procedures in Section 303-13.

NO - Reinstall the vapor canister following the WSM procedures in Section 303-13.
Proceed to Fuel Tank Inspection below.

INSPECTION PROCEDURE

Fuel Tank Inspection

Inspect the fuel tank for any signs of fuel staining on the bottom of the fuel tank. See Figure 3.

NOTE: AWD Vehicles Only - Fuel tanks come equipped with a plastic shield covering the tank. See Figure 4.

Remove the fuel tank strap bolts and strap from the RH side of the fuel tank.
Remove the two push pins and bend the plastic shield downward to inspect the RH side of the fuel tank.
Reinstall the fuel tank strap, bolts and shield push pins. Perform the same inspection steps for the LH side of the fuel tank (Steps a - c).

If fuel tank replacement is not required, tighten the fuel tank strap bolts to 40 Nm (30 lb-ft).

Is there fuel staining on the bottom of the fuel tank?
YES - Replace the fuel tank. Please follow the WSM procedures in Section 310-01. Repair is complete after fuel tank replacement has occurred.

NOTE: When replacing the fuel tank, position the exhaust muffler and tailpipe assembly aside as outlined in Step 3 below. Full removal of the exhaust muffler and tailpipe assembly is not required.

NO - FWD Vehicles - Proceed to Step 3.

AWD Vehicles - No repairs are needed at this time.

NOTE: Some fuel staining may be present on the top of the fuel tank if the fuel pump has been replaced previously. Fuel staining on the top of the fuel tank caused by prior fuel pump service is not an indication of a fuel tank leak.

FWD Vehicles Only

NOTE: When lowering the fuel tank, do not exceed the stated distance. Lowering the fuel tank too far can cause damage to fuel lines and other components.

Partially lower the fuel tank to allow for inspection. See Figures 5 and 6.

Detach the exhaust isolators. Position aside and support the exhaust assembly.
Remove the fuel tank heat shield.
Use a suitable powertrain lift to support the fuel tank.

Remove the four fuel tank bolts and lower the fuel tank approximately 1.75 in (44.45 mm). See Figure 6.

NOTE: 2.5L shown, 3.0L similar.

Check the top RH side of the fuel tank for signs of cracks. See Figures 6 and 7. Is cracking present?

YES - Replace the fuel tank. Please follow the WSM procedures in Section 310-01.

NOTE: When replacing the fuel tank, position the exhaust muffler and tailpipe assembly aside as outlined in Step 3 above. Full removal of the exhaust muffler and tailpipe assembly is not required.

NO - Reassemble the vehicle. No repairs are needed at this time.

When reinstalling the fuel tank strap bolts, tighten to 40 Nm (30 lb-ft).

NOTE: Fuel tank removed for clarity.

Recovering a module when programming has resulted in a blank module:

NEVER DELETE THE ORIGINAL SESSION!

Obtain the original IDS that was used when the programming error occurred during Module Reprogramming (MR) or Programmable Module Installation (PMI).
Disconnect the VCM from the Data Link Connector (DLC) and the IDS.
Reconnect the VCM to IDS and then connect to the DLC. Once reconnected, the VCM icon should appear in the corner of the IDS screen. If it does not, troubleshoot the IDS to VCM connection.
Locate the ORIGINAL vehicle session when programming failed. This should be the last session used in most cases. If not, use the session created on the date that the programming failed.
NOTE: If the original session is not listed in the previous session list, click the "Recycle Bin" icon at the lower right of the previous session screen. This loads any deleted sessions and allows you to look through them. Double-click the session to restore it.
Once the session is loaded, the failed process should resume automatically.
If programming does not resume automatically, proceed to the Module Programming menu and select the previously attempted process, PMI or MR.
Follow all on-screen prompts/instructions.
The last screen on the IDS may list additional steps required to complete the programming process. Make sure all applicable steps listed on the screen are followed in order.

Customer Satisfaction Program 16B38 - 2.5L Or 3.0L Engines - Powertrain Control Module Reprogramming And Canister Purge Valve Inspection (16B38)