Attachment V - Certain 2004 MY F-Series and Excursion
OVERVIEW
This program involves inspecting the exhaust pressure (EP) sensor and replacing it when it is not of the latest design level. Also, the powertrain control module (PCM), transmission control module (TCM) and fuel injector control module (FICM) will be recalibrated in all affected vehicles.
EP SENSOR REPLACEMENT
NOTE:
The EP sensor is located on a bracket directly in front of the left cylinder head between the front lifting bracket and the charge air cooler (CAC) tube. See Figure 1.
1. Remove the air filter cartridge and the outlet tube assembly.
2. Remove the CAC outlet tube (driver side of vehicle).
3. Disconnect the EP sensor.
4. Remove the EP sensor.
5. Locate and inspect the EP sensor part number located on the black connector end.
NOTE:
The part number on the sensor shows the International� part number. It differs from Ford Motor Company part numbers. The part number on the sensor is two (2) strings of numbers.
See Figure 2.
^ The first string of numbers must be 1850353.
^ The second string of numbers must begin with C1. The remaining numbers are inconsequential.
- If the part number is anything but 1850353/C1 or if the part number is illegible and cannot be read, install a new sensor, (Ford PN - 4C3Z-9J460-A) and tighten to 10 Nm (89 lb-in), then proceed with the next step of this procedure.
- If the part number is 1850353/C1 reinstall it and tighten to 10 Nm (89 lb-in), then proceed with the next step of this procedure.
6. Verify that the weather seal is in place in the harness connector, then connect to the EP sensor.
7. NOTE: If there is any oil residue, use Motorcraft Metal Brake Parts Cleaner, PM-4, to clean both connecting ports and the inside surface of the charge air cooler tube to prevent the tube from blowing off.
Install the CAC outlet tube. Tighten the clamps to 12 Nm (9 lb-ft).
8. Install the air filter and outlet tube assembly. Tighten the clamps to 4 Nm (35 lb-in).
9. Proceed to Module Reprogramming in this Attachment V.
MODULE RECALIBRATION
NOTE:
This recalibration, using WDS software Version B40.7 or higher, or B41.1 or higher, will update the PCM, TCM and FICM. This new calibration is not included in the B41 CD. Calibration files may also be obtained at the website.
1. Connect a battery charger to the vehicle.
2. Using Worldwide Diagnostic System (WDS), recalibrate the modules to the latest level calibration.
3. VERIFY THE WDS IS LOADED WITH SOFTWARE VERSION B40.7 OR HIGHER, ORB41.1 OR HIGHER.
4. Select Module Configuration Programming (MCP) and follow the WDS display instructions.
^ If unable to recalibrate the modules:
- module replacement will not be covered underthis program.
- prior to disconnecting the WDS from the vehicle and closing the session, call the Special Service Support Center.
5. Perform a self-test to verify there are no further concerns.
6. Proceed to Road Test Procedure in this Attachment V.
ROAD TEST PROCEDURE
Check OASIS to verify there are no other Field Service Actions applicable to this vehicle prior to performing the Road Test Procedure.
Test drive the vehicle to make sure no drivability concerns exist prior to returning the vehicle to the owner.
NOTE:
To address any customer concerns for vehicles that are out of warranty and exhibit engine performance issues after the road test, please follow the guidelines in the Warranty and Policy Manual.
AUTHORIZED MODIFICATIONS LABEL INSTALLATION
1. Obtain and prepare the Authorized Modifications Label. Describe the modification performed, and enter your P&A Code, date of repair and the program type and program number. See Figure 3.
PROOF OF CORRECTION CERTIFICATE
1. Provide the owners of vehicles registered in California and Massachusetts with a completed "Vehicle Emissions Recall - Proof of Correction" certificate. See Figure 4.