Recall - Thermactor Air Bypass Kit Installation: Overview
89ford29At Dealers By Order as req'd -0- % of Parts Direct
At PDC BY Now Shipped to Dealers
Date in Owner Letter Same
RECALL NUMBER 89E77
Date August, 1989
To: All Ford and Lincoln-Mercury Dealers
Subject: Emissions Recall 89E77-Recall of Certain 49-States 1985 and 1986-Model 3.8 Liter Engine-Equipped Passenger Cars for Emission Control System Modifications
In CARES/OASIS - Yes LISTINGS - Yes RETURN REMOVED PARTS - NO - SCRAP REMOVED PARTS DIAGNOSTIC PROCEDURE DECALS ENCLOSED
VEHICLES INVOLVED
All 1985 and 1986-Model 49-States Mustang, Capri, Thunderbird, Cougar, LTD and Marquis manufactured at the Dearborn, Lorain, Atlanta and Chicago Assembly Plants equipped with the following 3.8L engine calibration codes:
Calibration Codes
1985-Model 1986-Model
4-16A-R10 5-16B-R05/R06/R07/R11 5-16A-R10
4-16B-R10 5-16F-R00/R06/R07 5-16B-R11
5-16A-R05/R10
REASON FOR RECALL
Ford is voluntarily recalling the affected vehicles to help assure acceptable levels of exhaust emissions. This will be achieved by modifying the emission control system.
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 and submit it 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 following tender of the vehicles by the owners. It is important that you promptly report to your FPSD District Office any instance in which an owlier will not allow you to complete this recall service because of objections to scheduling or for any other reason.
TECHNICAL Refer to Attachment I
INSTRUCTIONS
OWNER Refer to Attachment II
NOTIFICATION
PARTS ORDERING
Service parts required for this recall may be ordered through normal channels.
Service Part
Number Description Class Dealer Price
E4DZ-9F491-B Kit Thermactor Air CG $28.12
Control/Bypass Mod.
FPS-8262 Decal, Authorized
Modification - No Charge
E9PE-12A661-AA Decal, Diagnostic Procedure - Provided with Bulletin.
Obtain additional decals from District Office.
REMOVED PARTS RETURN
LABOR TIMES
It is not necessary to return the removed parts. Retain the removed parts under the provisions of the Warranty and Policy Manual.
Base Labor Time
Replace the Air Control/Bypass Valve, hoses and clamps, Attach Diagnostic Procedure Information and Authorized Modifications Decals . . . . . . . . . . . . . . 0.5 His. Insert in Box "B" of Form 1864
Administrative Allowance (Additive to Above)
Administrative Allowance . . . . . . . . 0.1 Hr.
The 0.1 hour administrative allowance must be added before inserting the total labor time in Box "B" of the Form 1864.
REPORTING COMPLETIONS
Only the Form 1864 will be accepted for reimbursement under this program. Upon completion of the required service, the Form 1864 must be completely filled out and signed by authorized dealer personnel.
CLAIM SUBMISSION
The claims must be entered through the Direct Warranty Entry (DWE) system. Dealers without DWE capability must mail the second copy of the Form 1864 for reimbursement. Should your dealership receive pre-printed Forms 1864 with a seven digit claim number, you must drop the first digit and enter only the last six digits. You must sight verify the claim number for accuracy. It is important that all claims be filed for all completed units so that you will be reimbursed and our records will show completion.
FPSD ASSISTANCE
Any problems encountered with this recall should be discussed with your FPSD Service Zone Manager.
Attachment I
TECHNICAL INSTRUCTIONS FOR RECALL 89E77
1) Locate the thermactor system air control/bypass valve. Disconnect the two vacuum hoses from the valve.
2) Loosen the hose clamps connecting the air control/bypass valve hoses to the air pump outlet and the upstream and downstream air distribution tubes. Remove the air control/bypass valve and hoses as a unit.
3) Using the old air control/bypass valve and hoses as a guide, assemble the new hoses to the replacement valve in the same orientation as the old hoses. Use a hose clamp at each connection, and tighten the clamps securely.
4) Install the new air control/bypass valve and hose assembly to the air pump outlet and air distribution tubes, using a hose clamp at each connection. Tighten the clamps securely.
5) Reconnect the vacuum lines (from Step 1) to the air control/bypass valve.
6) Locate the self-test connector in the engine compartment. Install the diagnostic procedures information decal Part Number E9PE-12A661-AA) around the connector wire near the connector. Decal is provided with this bulletin.
7) Refer to Exhibit 1. Prepare and attach an Authorized Modifications decal as shown.
Authorized Modifications Decal For All Vehicles
PREPARE THE DECAL AS SHOWN. AFFIX THE DECAL TO A FLAT, CLEAN SURFACE ON THE RADIATOR SUPPORT. ORDER DECALS AS YOU WOULD ORDER ANY OTHER SERVICE PART. PART NUMBER FPS-8262.
Emissions Recall 88E77 Exhibit 1