owner notification program 01m05 - fuel cross-flow … · 2015. 5. 1. · owner notification...

OWNER NOTIFICATION PROGRAM 01M05 - FUEL CROSS-FLOW EXTENDED

COVERAGE

SERVICE CAMPAIGN BULLETIN

Reference Number(s): 01M05, Date of Issue: June, 2001

FORD: 1990-1993 Model Year F-Series

OWNER NOTIFICATION PROGRAM 01M05

SUBJECT

Owner Notification Program 01M05 - All 1990, 1991, 1992 and 1993 Model Year F-Series

Vehicles equipped with Dual Fuel Tanks and 4.9, 5.0, 5.8 or 7.5 Liter Engine - Fuel Cross-Flow

Extended Coverage

OASIS: Yes

OWNER LIST: Yes

PARTS RETURN: No

PROGRAM TERMS: This additional coverage program extends the coverage for potential fuel

cross-flow to 12 years of service or 150,000 miles from the vehicle's warranty start date,

whichever occurs first. This coverage will automatically transfer to subsequent owners. If a vehicle

already has more than 150,000 miles, this coverage will last until December 31, 2001.

AFFECTED VEHICLES

All 1990, 1991, 1992 and 1993 model year F-Series vehicles equipped with a 4.9, 5.0, 5.8, or 7.5

Liter gasoline fueled engine and dual fuel tanks.

REASONS FOR THIS PROGRAM

A very small number of the affected vehicles may experience a cross tank fuel flow condition due

to a damaged check valve in the fuel pump/sender assembly. Fuel may be supplied from one tank

and some or all of the unused fuel may be returned to the other tank. Should this occur, the

capacity of the receiving tank may be exceeded and fuel may overflow from the filler cap.

SERVICE ACTION

If the customer reports a fuel cross-flow condition:

A. For vehicles with either 93S68 or 00S57 open in OASIS:

A. Perform 93S68 or 00S57 (whichever is open)

B. Release vehicle (No 01M05 action required.)

B. For vehicles which do not have 93S68 or 00S57 open in OASIS:

1993 Ford F-Super Duty 7.5L Eng

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A. Check the fuel pressure and inspect for kinked lines; correct as necessary.

B. A new external check valve will be installed between each fuel supply line

and fuel tank. (On chassis cab vehicles, the rear fuel tank will receive a new

Fuel Delivery Module instead of a new check valve.)

ATTACHMENTS

Attachment I: ............................ Administrative Information and Refund Codes

Attachment II: .............................. Labor Allowances and Parts Ordering Information

Attachment III: ............................. Technical Information

Customer Letter

QUESTIONS?

Claims Information:.......................................................1-800-423-8851

Other (Dealer Only) Program Questions:...........................1-800-325-5621

ATTACHMENT I

Owner Notification Program 01M05:

All 1990, 1991, 1992 and 1993 Model Year F-Series Vehicles Equipped with 4.9, 5.0, 5.8 or 7.5

Liter Engines and Dual Fuel Tanks

Fuel Cross-Flow Extended Coverage

OASIS

You must use OASIS to determine if a vehicle is eligible for this program.

NOTE: When a claim is submitted under an

"M" program the VIN number will remain in

OASIS until the terms of the program expire.

CLAIMS PREPARATION AND SUBMISSION

• Enter claims using DWE.

• Refer to ACESII Manual for claims preparation and submission information.

OWNER REFUNDS

Ford Motor Company will only refund the cost of repairs for the fuel cross-flow condition made

before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair

was made away from the servicing dealer). Refunds only apply to repairs made to correct a

fuel cross-flow condition.



All supporting documentation must be retained in accordance with the Warranty and Policy

Manual.

Refer to ACESII Manual for Refund information. Enter claims using DWE:

Program Code: 01M05

Misc. Expense: REFUND

Misc. Expense: ADMIN

Misc. Expense: 0.2 Hr.

RENTAL VEHICLES

Rental vehicles are not approved for this program.

ATTACHMENT II

Owner Notification Program 01M05:

All 1990, 1991, 1992 and 1993 Model Year F-Series Vehicles Equipped with Dual Fuel Tanks and

4.9, 5.0, 5.8 or 7.5 Liter Engine - Fuel Cross-Flow Extended Coverage

LABOR ALLOWANCES

LABOR ALLOWANCES

Description: Check fuel pressure and inspect for kinked fuel lines.

Install two check valves (or install one check valve and one FDM

on Chassis Cab vehicles)

Labor

Operation

Labor

Time

1990/91 4.9L, 5.0L, 5.8L, and 7.5L Engine (Except Chassis

Cab)

01M05B 1.5

Hour

1992/93 4.9L Engine 01M05C 1.9

Hour

1992/93 5.0L, 5.8L, and 7.5L Engine 01M05D 1.8

Hour

1990/91 Chassis Cab 4.9L Engine 01M05E 2.4

Hour

1990/91 Chassis Cab 5.0L, 5.8L, and 7.5L 01M05F 2.3

Hour

When additional time is required due to the conditions described below, this must

be claimed as actual time. Use "MT01M05" as the labor operation for the

additional time.

◦ Trucks equipped with fuel tank skid plates

◦ Trucks over 8,500 lbs. GVW and equipped with a 5.8L engine

(1)

(1)



LABOR ALLOWANCES

Description: Check fuel pressure and inspect for kinked fuel lines.

Install new fuel pressure regulator and two check valves (or fuel

pressure regulator, one check valve, and one FDM on Chassis

Cab vehicles)

Labor

Operation

Labor

Time

1990/91 4.9L, 5.0L, 5.8L, and 7.5L Engine (Except Chassis Cab) 01M05G 1.6

Hour

1992/93 4.9L Engine 01M05H 2.0

Hour

1992/93 5.0L, 5.8L, and 7.5L Engine 01M05J 1.9

Hour

1990/91 Chassis Cab 4.9L Engine 01M05M 2.5

Hour

1990/91 Chassis Cab 5.0L, 5.8L, and 7.5L Engine 01M05N 2.4

Hour

When additional time is required due to the conditions described below, this must

be claimed as actual time. Use "MT01M05" as the labor operation for the

additional time.

◦ Trucks equipped with fuel tank skid plates

◦ Trucks over 8,500 lbs. GVW and equipped with a 5.8L engine

PARTS REQUIREMENTS

Parts Ordering Information

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

order processing channels as noted below:

Stock Orders - Effective immediately - Normal order process

Interim Orders - Effective immediately - Normal order process

Emergency Orders - First 60 days after launch - Call 1-800-325-5621

Emergency Orders - 61 days after launch - Normal order process

Dealers will need to call 1-800-325-5621 for emergency orders for 60 days after campaign launch.

NOTE: ONLY A VERY SMALL

PERCENTAGE OF VEHICLES WILL NEED

THIS REPAIR BECAUSE IT IS ONLY FOR

VEHICLES THAT HAVE HAD THE ORIGINAL

RECALL (93S68 OR 00S57) COMPLETED AND

(1)

(1)



HAVE HAD A SUBSEQUENT CROSS FLOW

CONDITION.

PARTS REQUIREMENTS

Part

Number Description Quantity

1L3Z-

9J274-BA

Check Valve for 1990/91 4.9L/5.0L/5.8L/7.5L

Engines (Also used for Chassis Cab Vehicles)

1 package per

vehicle (2 per pkg.)

1L3Z-

9J274-AA

Check Valve for 1992/93 4.9L/5.0L/5.8L/7.5L

Engines

1 package per

vehicle (2 per pkg.)

The following part is used only for 90-91 vehicles requiring repairs. See Attachment III.

(Owner Letters for this vehicle population will be mailed sometime in late July 2001).

PARTS REQUIREMENTS

N806190-

S1901

Black Hairpin Clip (Retainer-Push Connect) 90-

91 vehicles only

2 per vehicle (4 per

pkg.)

FOR CHASSIS CAB vehicles with 137" WB or 161" WB , ALSO ORDER THE PART BELOW.

(only one check valve must be installed on the forward/mid-ship tank; the check valve will not fit

on the rear tank) Dealers MUST install a fuel delivery module on the rear tank.

PARTS REQUIREMENTS

F6TZ-

9A407-EA

Fuel Delivery Module (rear plastic tank for

Chassis Cab only)MUST CALL 1-800-325-

5621 FOR ALL ORDER TYPES

1 per vehicle (ONLY FOR

CHASSIS CAB

VEHICLES)

DOR/COR NUMBER

DOR/COR for this program is 50243 . This number identifies parts ordered for this campaign

through the Special Service Support Center (1-800-325-5621).

DEALER PRICE

For latest prices, check or call your:

• DOES II

• Updated Price Book

EXCESS STOCK RETURN

Excess stock returned for credit must have been purchased from Ford Customer Service Division

in accordance with Policy Procedure Bulletin 4000.

ATTACHMENT III



OWNER NOTIFICATION PROGRAM 01M05

FUEL CROSS FLOW WARRANTY EXTENSION

AFFECTED VEHICLES: ALL 1990, 1991, 1992 AND 1993 MODEL YEAR F-SERIES VEHICLES

EQUIPPED WITH 4.9, 5.0, 5.8 OR 7.5 LITER ENGINES AND DUAL FUEL TANKS

NOTE: Check OASIS to see if either Safety

Recall 00S57 or 93S68 is open. If either recall is

open, do not continue with this procedure.

Instead, perform the appropriate safety recall

and return vehicle to the owner.

SERVICE PROCEDURE

1. Attach an EFI/CFI fuel pressure gauge to the Schrader valve on the engine fuel rail.

2. WARNING: FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE,

EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR

DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS,

THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL

SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD.

Start the engine and record the fuel pressure reading. Turn the ignition key to the OFF

position. Then relieve the fuel system pressure by slowly opening the manual valve on

the fuel pressure gauge. Remove the gauge from the fuel rail.

ALL EXCEPT CHASSIS CAB

6-CYLINDER ENGINES

• If the fuel pressure is 55 PSI or less, perform all of the following:



• External Check Valve Installation And Return Line Inspection - Rear Tank.

• External Check Valve Installation And Return Line Inspection - Front Tank.

• If the fuel pressure exceeds 55 PSI, perform all of the following:

• Fuel Pressure Regulator Replacement.



8-CYLINDER ENGINES








CHASSIS CAB

6-CYLINDER ENGINES


• Fuel Delivery Module Installation And Return Line Inspection - Rear Tank.






8-CYLINDER ENGINES










FUEL PRESSURE REGULATOR REPLACEMENT

NOTE: Perform only if fuel pressure

exceeds levels specified earlier in this

procedure.

1. Install a memory saver, then disconnect the battery negative cable.

2. Disconnect the vacuum line from the fuel pressure regulator, which is located on the fuel

rail.

3. Remove the retaining screws from the fuel pressure regulator.

4. Remove and discard the fuel pressure regulator, gasket and O-ring seal from the fuel

rail manifold.

5. Lubricate the new fuel pressure regulator O-ring with light oil (10W30 oil WSE-M2C903-

A2 or equivalent). Install the new O-ring and the new gasket on the new regulator.

6. Position the new fuel pressure regulator with O-ring and gasket onto the fuel rail and

install the retaining screws. Tighten the screws to 4 Nm (35 lb-in).

7. Connect the vacuum line to the new fuel pressure regulator.

EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION - REAR TANK

(NON-CHASSIS CAB VEHICLES)


2. Drain the rear fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or

equivalent.

3. Raise the vehicle on a hoist.

4. Position the spare tire out of the way.

5. Loosen the hose clamp at the fuel filler hose connection to the rear fuel tank.

6. Position a safety stand under the rear fuel tank.

7. Remove the fuel tank support straps.

8. Access the fuel delivery module (FDM) at the top of the tank by lowering the tank while

guiding the fuel filler hose from the tank.

9. NOTE: For vehicles equipped with

stainless steel braided flex lines, proceed to

the next step.



Inspect the nylon fuel return lines for kinking.

1. If the nylon fuel return line is not kinked or the vehicle is equipped with

stainless steel braided flex lines, proceed to the next step.

2. If the nylon return line is kinked, repair the line as necessary using Rotunda

Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool), before continuing

this procedure.

10. NOTE: Remove and discard the black

hairpin clip on 1990 and 1991 model year

vehicles.

A new clip will be used when reconnecting the fuel supply line.

Disconnect the fuel supply line at the FDM. See Figure 1.

11. If equipped, remove and discard the old external check valve.

12. Install the external check valve to the supply tube of the FDM. Install the fuel line clip

onto the external check valve. See Figure 1.

13. Connect the fuel supply line to the external check valve. Install a new black hairpin clip

on 1990 and 1991 model year vehicles. See Figure 1.

14. Raise the rear fuel tank back into position while guiding the fuel filler hose onto the fuel

tank.

15. Install the fuel tank straps. Tighten bolts to 38 Nm (28 lb-ft).

16. Tighten the fuel filler hose clamp to 4 Nm (35 lb-in).

17. Remove the safety stand.



18. Reposition the spare tire.

19. Lower the vehicle.

EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION - FRONT

TANK (ALL VEHICLES)

1. Drain the front fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or

equivalent.


3. Remove the skid plate if equipped.

4. Loosen the hose clamp at the fuel filler hose connection to the front tank.

5. Position a safety stand under the fuel tank.

6. Remove the fuel tank support strap bolts.

7. Access the FDM at the top of the tank by lowering the tank while guiding the fuel filler

hose from the tank.



the next step.

Inspect the nylon fuel return line for kinking.



2. If the nylon return line is kinked, repair the line as necessary using Rotunda

Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool), before continuing

this procedure.


hairpin clip on 1990 and 1991 model year

vehicles.

A new clip will be used when reconnecting the fuel supply line.

Disconnect the fuel supply line at the fuel delivery module. See Figure 2.

10. If equipped, remove and discard the old external check valve.

11. Install the external check valve to the supply tube of the fuel delivery module. Install the

fuel line clip onto the external check valve. See Figure 2.



12. Connect the fuel supply line to the external check valve. Install a new black hairpin clip

on 1990 and 1991 model year vehicles.

13. Reinstall the skid plate if removed.


15. Fill the fuel tanks.

16. Connect the battery negative cable, then remove the memory saver.

17. Without starting the engine, turn the ignition key on and off several times to pressurize

the fuel system and check for leaks.

FUEL DELIVERY MODULE REPLACEMENT AND RETURN LINE INSPECTION - REAR TANK

(CHASSIS CAB VEHICLES)


2. Drain the rear fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or

equivalent.


4. Position the spare tire out of the way.

5. Loosen the hose clamp at the fuel filler hose connection to the rear fuel tank.

6. Position a safety stand under the rear fuel tank.

7. Remove the fuel tank support skid plate bolts.

8. Access the fuel delivery module (FDM) at the top of the tank by lowering the tank while

guiding the fuel filler hose from the tank.




hairpin clip. A new clip will be used when

reconnecting the fuel supply line.

Disconnect the fuel supply line, fuel return line and the electrical connector (not shown)

from the FDM. See Figure 3.

10. Disconnect the vapor line from the fuel tank. See Figure 3.

11. Lower the fuel tank while guiding the fuel filler hose out of the tank.



the next step.

Inspect the nylon fuel return line for kinking.



2. If the nylon return line is kinked, repair the line as necessary, using Rotunda

Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool) before continuing

this procedure.

13. Clean any dirt from the top of the tank around the FDM.

14. Remove the locking ring from the FDM.

15. Remove the FDM, then remove and discard the gasket.

16. Clean the FDM mounting flange on the fuel tank, then install a new gasket onto the

flange.

17. Install the new FDM, then install the locking ring. Tighten the locking ring to 62 Nm (46

lb-ft).

18. Raise the tank up into the vehicle, leaving enough room to make the connections on the

top of the tank.

19. Connect the vapor line to the fuel tank.



20. Connect the fuel supply, fuel return and electrical connector to the FDM. Install a new

black hairpin clip on the fuel supply line connection.

21. Raise the rear fuel tank into position while guiding the fuel filler hose into the tank.

22. Install the fuel tank support skid plate bolts. Tighten bolts 44 Nm (32 lb-ft).

23. Tighten the fuel filler hose clamp to 4 Nm (35 lb-in).

24. Remove the safety stand.

25. Reposition the spare tire.


CUSTOMER NOTIFICATION LETTER

ADDITIONAL INFORMATION



RELATED NEWSLETTER ARTICLES

93S68 / 00S57 /01M05 1990-1993 F-Series Dual Fuel Tanks Cross Flow

10/08/2001

A summary is provided below of the field actions concerning 1990-1993 F-Series regarding fuel

cross-flow.

FIELD

ACTION

NO.

PURPOSEVEHICLES

AFFECTEDSERVICE PERFORMED

TERMS OF

COVERAGE

93S68

To

correct a

potential

fuel

cross-

flow

condition

between

fuel

tanks.

All 1990,

1991, 1992

and certain

early-build

1993

Model Year

F-Series

Vehicles

equipped

with 4.9,

5.0, 5.8 or

7.5 Liter

Engines

and Dual

Fuel Tanks

(Published:

September

1993)

Replace fuel pressure

regulator and install a

check valve between

each fuel supply line and

fuel tank.

No time or mileage

limit.

00S57

To

correct a

concern

that could

lead to a

fuel

cross-

flow

condition.

Certain

later-build

1993

Model Year

F-Series

Vehicles

Equipped

with Dual

Fuel Tanks

and 4.9,

5.0, 5.8 or

7.5 Liter

Engines -

Fuel

Pressure

Regulator

(Published:

June 2001)

Replace fuel pressure

regulator.

No time or mileage

limit.

01M05



To

correct a

reported

fuel

cross-

flow

condition

between

fuel

tanks.

All vehicles

covered by

the above

two

programs.

(Published:

June 2001)

Follow flow chart on page

1 of Tech Instructions:

• Replace fuel

pressure

regulator if fuel

pressure is out

of spec.

• Repair/Replace

fuel lines if

restricted or

kinked.

• Install new

check valves.

NOTE:

Call 1-800-

325-5621 if

the customer

still has

cross-flow

after

performing

above steps.

• 12 years

of service

or -

150,000

miles from

the

vehicle's

warranty

start date,

whichever

occurs

first.

• If a

vehicle

already

has more

than

150,000

miles, this

coverage

will last

until

December

31, 2001.

01M05 F-Series Fuel Cross Flow

10/01/2001

Please note that program 01M05 provides extended coverage against the crossflow condition

after performing Safety Recall 00S57 .

If the customer reports that cross flow has still not been corrected even after performing both

00S57and 01M05, please call the Special Service Support Center at 1-800-325-5621 for further

direction. Please see the chart on page 2 of Attachment III for details.

In addition please note that program 01M05 terms provide coverage even for a vehicle which

already has more than 150,000 miles until December 31, 2001.

01M05 F-Series Fuel Cross Flow

08/06/2001

Jumper harness F8PZ-9A213-AA is required for initial retrofit of any affected Chassis Cab vehicle

using fuel delivery module part number F6TZ-9A407-EA.



If you are removing F4TZ-9A407-S from the rear fuel tank, you will need to replace it with F6TZ-

9A407-EA (replacement FDM) and F8PZ-9A213-AA (Jumper Harness). If the vehicle already has

an F6TZ-9A407-EA installed, you can reuse the jumper harness, F8PZ-9A213-AA.

F8PZ-9A213-AA Jumper Harness

F6TZ-9A407-EA Fuel Delivery Module (Replacement FDM)

F4TZ-9A407-S Fuel Delivery Module (Original/Obsolete FDM)



owner notification program 01m05 - fuel cross-flow … · 2015. 5. 1. · owner notification...

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