Attachment III - Technical Information

OVERVIEW

This is a one-time warranty extension program for vehicles that exhibit a driveability concern related to a loose or disconnected PCV hose assembly on the affected 2003 through 2005 Lincoln LS vehicles. Vehicle symptoms indicating a loose or disconnected PCV hose assembly include rough running engine, engine not starting, stalling at start-up or at idle, or malfunction indicator lamp (MIL) on with DTCs P0171, P0174, P0173, P2195, P2197, P0420, P0301, P0302, P0303, P0304, P0305, and/or P0306. If any of the original PCV hose assembly connections/fittings are loose or disconnected, install a new PCV hose assembly as described below. If no problems are found with the PCV hose assembly, the repair is not covered underthis program.

NOTE:
The PCV valve is not covered under this program.

SERVICE PROCEDURE

1. NOTE: One retention clip is located at the RH side of the upper intake manifold and the second clip is behind the upper intake manifold.

Disconnect the retention clip holding the throttle body coolant hose to the PCV hose assembly.





2. Remove the PCV hose assembly pushpin retainer from the flange at the right rear corner of the upper intake manifold. See Figure 1.





3. Disconnect PCV hose connector from the upper intake manifold at the rear of the throttle body. See Figure 2.





4. Disconnect the PCV hose from the PCV valve elbow, at left rear of the LH valve cover. See Figure 3.





5. Remove and discard the old PCV hose assembly.

NOTE:
The new PCV hose assembly comes with spring clamps already in place. Do not remove the plastic clips from the spring clamps prior to installation. The plastic clips hold the spring clamps open.

NOTE:
When installing the new PCV hose assembly, the following order must be followed to prevent damage.

6. Install the new PCV hose assembly by sliding it rearward over the intake manifold toward the cowl. Position the PCV hose assembly above the coolant hose. Attach and fully seat the PCV hose assembly connector at intake manifold. See Figure 4.





7. Position the spring clamp tabs away from the coolant hose by rotating the hose. Do not attempt to rotate the spring clamp on the hose. While holding and fully seating the PCV hose on the intake manifold hose nipple, remove the plastic clip from the spring clamp by pulling the clip straight up. See Figure 5.





8. Attach the PCV hose assembly to the PCV valve elbow at the left rear of the LH valve cover. While holding the PCV hose in place on the PCV elbow, remove the plastic clip from spring clamp by pulling the clip straight up. See Figure 6.





9. Attach the PCV hose assembly pushpin to the flange on right rear corner of the upper intake manifold. See Figure 7.





10. Position the coolant hose rearward so that it does not contact the edge of the flange on the right rear corner of the upper intake manifold and attach the coolant line retention clip to the PCV hose assembly. See Figure 8.

11. Clear all DTCs.