Emissions Recall Bulletin

EMISSION RECALL BULLETIN

EMISSION CONTROL MODIFICATIONS - EMISSIONS RECALL 89E79

1986 Ford Crown Victoria, Thunderbird, Mustang (5.0L)
1986 Mercury Grand Marquis, Town Car, Cougar, Capri, Mark VII (5.0L)
1987 Lincoln Mark VII (5.0L)

Recall No. 89E79
Date December, 1989
Number of Affected Vehicles: 44,700

VOLUNTARY EMISSION RECALL CAMPAIGN

1. Description of Subject Vehicles to be Recalled:

All 1986 model year Ford passenger cars equipped with a 5.0 liter engine and calibration 6-21C-R00 (HO), 6-21P-R00 (HO), 6-22L-R00 (HO), 6-22L-R10 (HO), 6-22P-R00 (HO), 6-22Q-R00, 6-22R-R00, 6-22L-R10, 6-22S-R00, 6-22T-R00 or 6-23R-R10 are affected by the recall. The affected vehicle models are Mustang, Capri, Thunderbird, Cougar, Crown Victoria, Grand Marquis, Lincoln Town Car, Continental and Continental Mark VII. In addition, all 1987 model year Continental Mark VII vehicles with a 5.0 liter engine and calibration 6-22L-R10 (HO) are included in the recall. The affected engine families are GFM5.0VSHBC6 and HGFM5.0VSHBC7. Ford records indicate that approximately 44,700 California vehicles are affected by the recall.

2. Description of the Modification:

There are two separate sets of corrective actions, depending on whether a vehicle is equipped with a 5.0 liter base engine or a 5.0 liter high output engine. For vehicles equipped with the high output engine, the idle air control bypass valve will be cleaned and the current catalyst assembly having 28 gm/cu. ft. precious metal loading will be replaced with a catalyst assembly having 40 gm/cu. ft. precious metal loading. Vehicles equipped with the 5.0L base engine will have the fuel injectors replaced, the thermactor air control/bypass valve replaced with one having a five percent upstream air bleed and the idle air control bypass valve will be cleaned. A detailed description of the corrective actions is provided in the draft Dealer Service Recall Bulletin (Attachment I).

3. Identification and Notification of Vehicle Owners:

For the purpose of conducting this recall, owner records contained in Ford’s NAVIS (North American Vehicle Information System) files will be utilized to identify the vehicles to be recalled. The NAVIS is a computerized system containing information on all Ford vehicles produced, including vehicle serial numbers and dealer and owner names and addresses. Current vehicle owner names and addresses will be obtained by utilizing R. L. Polk’s vehicle registration records. A list will be provided to dealerships which identifies involved vehicles reported to be registered in their area. Owner Notification Letters (Attachment III) will be sent to the identified Owners by First Class Mail, including a Form 1864, Customer Notification and Dealer Claim Form (Enclosure III), and a Subsequent Owner Response Card (Enclosure IV).

4. Conditions of Eligibility for Repair under Remedial Plan:

Ford will not condition eligibility for repair under this recall on proper maintenance or use.

5. Procedure to be Followed by Vehicle Owners to Obtain Correction:

The procedure to be followed by vehicle owners to obtain corrective action is described in the draft Owner Notification Letter (Attachment II).

6. Class of Persons other than Dealers who will Remedy the Defect:

Ford will not authorize persons other than Ford authorized dealers to perform the operations necessary for this recall.

7. Owner Letter

See Attachment II below.

8. System to Assure Availability of Adequate Parts Supply:
The parts required for this recall will be readily available to Ford authorized dealers through Ford’s Parts and Service Division prior to the mailing of the Owner Notification Letters. Ford has begun the process of procuring parts for the recall. The ARB will be notified when Ford determines an estimated date by which sufficient quantities of parts should be available to launch the recall. Ford generally considers that having 50% of the anticipated parts requirements on hand is sufficient for launching an emissions recall.

9. Necessary Instructions to Persons who are to Perform Repairs:

A detailed description of the repair action is included in the Dealer Service Recall Bulletin. See Recall Bulletin (Attachment I).

10. Impact of the Proposed Changes on Fuel Consumption, Driveability and Safety:

Fuel consumption, driveability and safety should not be affected by this recall action. The affected 5.0 liter high output engines have a more robust calibration and utilize 19 lbs/hr fuel injectors; whereas, the 5.0 liter base engines utilize 14 lbs/hr fuel injectors. The higher flow injectors utilized in the high output engines were produced by Nippondenso (under license from Bosch), and the base engine injectors were produced by Bosch. Both suppliers utilize their own unique processes during manufacturing. In addition, the Nippondenso injector is of a different design than the Bosch injector.

11. Sample of any Label to be Applied to Vehicles or Engines which Participate in the Voluntary Recall Campaign

See Recall Bulletin (Fig. 1).

ATTACHMENT I

RECALL CAMPAIGN BULLETIN - 89E79

Subject: Emissions Recall 89E79 - Recall of Certain 1986 and 1987 Model 5.0 Liter Engine-Equipped Passenger Cars for Emission Control System Modifications

IN CARES/OASIS - Yes

LISTINGS - Yes

REMOVED PARTS - Retain removed injectors (Warranty and Policy Manual Section 7.0) - Scrap all other removed parts.

SPECIAL CLAIM FORM PREPARATION - See Warranty and Policy Manual section 6.3, page 5, 6, 7, and 8 (more than 6 parts).

VEHICLES INVOLVED

Vehicles affected by this recall were manufactered;during the 1986 and 1987-model years and are equipped with 5.0L engines having the following calibration codes:

Model Year	Calibration Code	Repair Code	Vehicle Application
1986	6-22Q-R00 (Base)	A	Crown Victoria/Grand Marquis
	6-22S-R00 (Base)	A	Town Car
	6-23R-R10 (Base)	A
	6-22R-R00/R10 (Base)	A	Continental/Mark VII
	6-22T-R00 (Base)	A	Thunderbird/Cougar
	6-21C-R00 (HO)	B	Mustang/Capri
	6-21P-R00 (HO)	B
	6-22L-R00/R10 (HO)	B	Mark VII
	6-22P-R00 (HO)	B	Mustang/Capri
1987	5-22L-R10 (HO)	B	Mark VII

REASON FOR RECALL

Ford is voluntarily recalling the affected vehicles to help assure acceptable levels of exhaust emissions. This will be achieved by cleaning idle air control bypass valves, replacing 1986-model 5.0L base engine fuel injectors and therm actor air control/bypass valves, and replacing 1986 and 1987 model 5.0L HO engine exhaust system catalysts.

VEHICLE ELIGIBILITY

The enclosed listing identifies involved units reported registered to owners in your dealership’s area. Other eligible vehicles that may be brought to your dealership for this recall service should be corrected as promptly as possible. If the owner of an eligible vehicle does not have a Customer Notification and Dealer Claim Form (FCS-1864), please complete a blank Form 1864. Submit all Forms 1864 via the Direct Warranty Entry (DWE) system for reimbursement.

CARES/OASIS

To determine if a vehicle is eligible, you must utilize "CARES" (Computer Assisted Recall System) or "OASIS" (On-Line Automotive Service Information System).

DEALER OBLIGATION

Dealers are obligated to perform the recall service promptly toll owing tender of the vehicles by the owners. It is important that you promptly report to your FPSD District Office any instance in which an owner will not allow you to complete this recall service because of objections to scheduling or for any other reason.

PARTS ORDERING

Service parts required for this recall may be ordered through normal channels.

CLAIM FORM PREPARATION

Refer to your Warranty and Policy Manual; Section 6.3; pages 5, 6, 7, and 8.

REMOVED PARTS RETURN

Retain removed injectors per instructions in Warranty and Policy Manual, Section 7.0.

REPORTING COMPLETIONS

Use the Form 1864 to report completed vehicles.

TECHNICAL INSTRUCTIONS - Repair Codes A and B

1. Clean the idle air control bypass valve. Refer to 1986 or 1987 Model Car Shop Manual page 24-0 -2.

2. Remove the idle air bypass valve from the throttle body assembly. Remove the electrical solenoid assembly from the mechanical portion of the air bypass valve by removing the two attaching screws. Slide the mechanical portion of the valve away from the solenoid.

3. Soak the mechanical portion of the valve in Ford Carburetor and Combustion Chamber Cleaner (Part Number D9AZ-19579-BA) or equivalent for 2 to 3 minutes. NOTE: Read and observe the cautions printed on the container. Read and observe "Material Safety Data Sheet" TOX #017553 for this cleaner. This sheet was sent to you June 1989.

4. With the mechanical portion of the valve completely submerged in the cleaner shake the valve in all directions to assure thorough cleaning of the valve. NOTE: Do not soak the valve more than three minutes. Use only the cleaner specified as deterioration of an internal "O" ring may result. Assure that a rod that mates with the solenoid assembly is pushed in as far as possible when shaking the valve while it is submerged in the cleaner.

5. Remove the valve from the cleaner and dry the valve using compressed air. Re-assemble the valve using new gasket (Part Number E7SZ-9F670-A) and re-install on the throttle body.

ALTERNATE CLEANING METHOD FOR DEALERS HAVING ROTUNDA FUEL INJECTOR TESTER/CLEANER - ROTUNDA TOOL NUMBER 113-00001 AND ADAPTER 113-00009

* REFER TO THE INSTRUCTIONS FOR CLEANING VALVES PROVIDED WITH THE ADAPTER.

* OBSERVE SAFETY AND PERSONNEL PROTECTION CAUTIONS WHEN HANDLING CLEANER SPECIFIED FOR THIS METHOD OF CLEANING.

7. Refer to Fig. 1. Prepare and attach Authorized Modifications Decal as shown.

FOR 1986 MODEL VEHICLES EQUIPPED WITH 5.0L BASE ENGINES REPAIR CODE A

1. Remove the existing fuel injectors. Replace with new injectors (Part Number E6SZ-9F593-A). Retain removed fuel injectors per instructions contained in Warranty and Policy Manual Section 7.0. Refer to Exhibit 2. Assure that fuel line retainers/clips are properly engaged.

2. Remove the existing thermactor air control/bypass valve. Replace with new valve (Part Number E3SZ-9F491-A).

FOR 1986 AND 1987-MODEL VEHICLES EQUIPPED WITH 5.0L HO ENGINES - REPAIR CODE B

1. Remove the existing catalyst assembly. Replace with new catalyst (P/N FOLY-5F250-A Mark VII or F0Z-5F250-A Mustang/Capri).

2. Use the appropriate catalyst attaching parts as outlined in the "Parts" section of this bulletin (not included on this site). Mutilate and scrap removed catalyst assemblies.

LABOR TIMES

Base Labor Time

Clean the Idle Air Bypass Valve and
Attach Authorized Modifications Decal .................... 0.7 Hrs.
Insert in Box "B" of Form 1864

Additive to Above:

Replace Fuel Injectors and Thermactor Air Control/Bypass Valve
(Repair Code "A" Vehicles) ............................... 2.4 Hrs.

Replace Catalyst Assemblies
(Repair Code "B" Vehicles) ............................... 1.0 Hrs.

The above allowances must be added before inserting the total labor time in Box "B" of the Form 1864.

FPSD ASSISTANCE

Any problems encountered with this recall should be discussed with your FPSD Service Zone Manager.

ATTACHMENT II

OWNER NOTIFICATION LETTER
December, 1989
Dear Owner:

REASON FOR THIS LETTER
Ford Motor Company is voluntarily recalling some 1986 and 1987 model cars equipped with certain 5.0L engines (Emissions Recall 89E79). Our records show that you own one of these cars. Your car’s engine may be releasing air pollutants which exceed California or Federal standards.

WHAT YOU SHOULD DO
Please telephone your Ford or Lincoln-Mercury dealer to arrange for this recall service.

WHAT THE DEALER WILL DO
The dealer will modify your car’s emissions control system at no extra charge to you. This service should have little or no effect on your car except to reduce the air pollutants released by the emissions control system. The time required for this service is between two and three hours.

WHY SERVICE SHOULD BE DONE
If you do not have this service done your emissions warranty may be reduced. Also your car may not pass emissions tests that may be required in your area.

ASK YOUR DEALER
When you call your dealer for this service ask for a computer check on the "CARES" or the OASIS" systems to see if your car needs other recall work. If it does the dealer can tell you about the required service.

FORM ENCLOSED
Your car’s identification number is shown on the enclosed form. Please detach the postcard on the cover sheet of the form. Complete any of the sections that may apply to you and mail the postcard to us. Please give the rest of the form to your dealer at the time of service. If you lose the form the dealer will still service your car at no charge to you.

ASSISTANCE
If the dealer cannot answer any questions you have regarding this recall service you may contact the nearest Ford Parts and Service Division District Office whose address is shown in your Owner Guide.

We regret any inconvenience this recall may cause you. We are doing this so that you will be satisfied with your car. We urge you to have your car serviced promptly to maintain full coverage under the emission warranties.

Sincerely,

J. P. King
Manager
Parts and Service Engineering

Enclosure
89E79