Attachment II - Technical and Administrative Instructions
Attachment IIOWNER NOTIFICATION PROGRAM M41
TECHNICAL AND ADMINISTRATIVE INSTRUCTIONS
PLEASE CIRCULATE THESE INSTRUCTIONS TO YOUR PARTS AND SERVICE PERSONNEL. ANY QUESTIONS REGARDING THESE INSTRUCTIONS SHOULD BE DIRECTED TO YOUR SERVICE ZONE MANAGER.
VEHICLES INVOLVED
^ All 1984-model Tempo/Topaz and Escort/Lynx vehicles equipped with 2.0 liter diesel engines.
^ 1985-model Tempo/Topaz and Escort/Lynx vehicles equipped with 2.0 liter diesel engines and built from start of 1985-model production through April 21, 1985 (Tempo/Topaz) and March 29, 1985 (Escort/Lynx).
TECHNICAL INSTRUCTIONS
Inspection
Before you proceed with the replacement of the engine cylinder head gasket on vehicles involved in Owner Notification Program M41, verify that the engine oil leakage is a result of a prematurely-failed engine cylinder head gasket. This can be achieved as follows:
1. Ask the owner if there has been engine oil leakage on the surface beneath the vehicle when it is parked. Leakage would occur under the forward part of the engine on the passenger side of the vehicle.
2. Refer to Exhibit I. Use a mirror to inspect the outboard corner (passenger side) of the engine where the engine cylinder head mates with the engine block. There should be oil leakage in this area.
3. Refer to Exhibit I. Inspect the front corner (passenger side) of the engine where the engine cylinder head mates with the engine block. There should be oil leakage in this area.
4. Open the cap of the coolant recovery bottle located on the passenger side of the engine compartment and inspect for the presence of engine oil in the coolant.
If you detect engine oil leakage at either or both of the areas described above, the vehicle's engine is eligible for the service provided by this program. The presence of engine oil in the coolant recovery bottle will further confirm that the oil leakage condition exists.
Repair
IMPORTANT NOTE:
TO PREVENT WARPING OF THE ALUMINUM ENGINE CYLINDER HEADS, ENGINES MUST BE AT AMBIENT TEMPERATURE BEFORE THE HEADS ARE REMOVED. REMOVAL, CLEANING, AND REINSTALLATION OF THE CYLINDER HEAD PRE-COMBUSTION CHAMBER CUPS IS NOT REQUIRED FOR THIS PROCEDURE.
1. Remove the engine cylinder head according to the procedures described in the 1984 or 1985 Car Shop Manual-Volume E, pages 22-06-22 and 22-06-23.
2. Inspect the cylinder head and components according to the procedures described in the 1984 or 1985 Car Shop Manual-Volume E, page 22-06-29.
When the Cylinder Head is Reusable:
3. Install a new engine cylinder head gasket and reinstall the head according to the procedures described in the 1984 or 1985 Car Shop Manual-Volume E, pages 22-06-22 and 22-06-23.
When the Cylinder Head is not Reusable:
4. If the inspection in Step 2 reveals that the cylinder head is not reusable, install a new engine cylinder head and head gasket according to the procedures described in the 1984 and 1985 Car Shop Manual-Volume E, pages 22-06-22 and 22-06-23.
IMPORTANT NOTE:
NEW ENGINE CYLINDER HEAD BOLTS MUST BE INSTALLED WHEN REINSTALLING THE CYLINDER HEAD. DISCARD THE REMOVED BOLTS.
PARTS ORDERING INFORMATION
All parts required for this program may be ordered through normal order processing channels.
PARTS TO BE REPLACED WHEN CYLINDER HEAD IS REUSABLE
PARTS TO BE REPLACED (IN ADDITION TO ABOVE PARTS) WHEN THE CYLINDER HEAD IS NOT REUSABLE
Reminder:
^ You must retain replaced cylinder heads in accordance with the provisions of the Warranty and Policy Manual (Subject 4.1).
^ All replaced cylinder head gaskets must be retained for recall by the Warranty Parts Return Center.
COMPLETE ENGINE ASSEMBLIES (WHEN ENGINE REPLACEMENT IS REQUIRED)
REPLACEMENT OF ENGINES REQUIRES FPSD DISTRICT OFFICE AUTHORIZATION
RETURN OF DEALER SERVICE STOCK
All cylinder head gaskets with service part numbers E43Z-6051-A, B and C in dealer service stock must be returned immediately to Ford for credit.
Return all unused service stock through your normal order processing channel. Form FPS-340, "Customer Request for Credit or Return of Parts and Accessories" Reason Code "L" (Campaign Parts Return) must accompany the returned parts. To obtain full credit to your parts account, the form should be annotated, "RETURNED PER INSTRUCTIONS IN OWNER NOTIFICATION PROGRAM M41". Credit to your parts account will cover normal return freight and parts costs.
LABOR OPERATIONS
The inspection operation is the base labor operation for this program. All other operations are to be performed in combination with the base operation.
CLAIMS PREPARATION INSTRUCTIONS (A copy of these instructions should be filed in Subject 13.0 of your Warranty and Policy Manual).
Repairs
Repairs provided under this program will be performed on eligible vehicles at no charge to owners for five years from the vehicles' in-service date or 60,000 miles of operation, whichever comes first.
The claim forms for repairs performed under Owner Notification Program M41 must include standard claim preparation procedures and the information shown. Program number M41 must be entered in the Program Code box in the upper left of the forms. All repairs performed under this program must be coded M41.
OWNER REIMBURSEMENT
Owner reimbursement requests submitted under Owner Notification Program M41 are governed by the following guidelines:
Owners seeking reimbursement for cylinder head gasket replacements or engine repairs covered by this program, which were performed at their expense prior to the announcement of this program, must present their paid repair orders or over-the-counter parts purchase receipts to any Ford or Lincoln-Mercury dealership by March 31, 1986.
Reimbursement includes the deductible amount owners may have paid under Ford Motor Company's 24-month/24,000-mile powertrain warranty, Ford's Extended Service Plan or any similar plan in effect on their vehicles.
A copy of the paid repair orders showing the date and vehicle mileage at the time of repair or over-the-counter parts purchase receipts must be retained in your service file for at least one year following the date of Company notification of payment.
Owner reimbursement requests must be submitted on separate warranty claim Forms 1863 by May 30, 1986. Claims submitted after May 30, 1986 will not be paid. In addition to the information shown for the special preparation of Owner Refund claims (Reference: Warranty and Policy Manual - Subject 9.3, Page 3), please enter the information shown below:
Causal Basic Part Number - 6051
Condition Code - 77
Labor Operation - REFUND
Administrative Allowance - 0.2 Hr.
Program Code - M41
^ An administrative allowance of 0.2 hours will be allowed for processing each eligible owner reimbursement request. To claim the allowance, enter ALLOW in the Labor Operation No. column and 0.2 in the Scheduled Time column. Extend the 0.2 hours at your authorized warranty labor rate and enter the result in the Amount column.
^ You are requested to provide prompt reimbursement to all eligible owners who respond to this program with proper repair documentation regardless of the source of the original repair (your dealership, another Ford or Lincoln-Mercury dealership, or a repair location other than a Ford or Lincoln-Mercury dealership).