Fuel System - Fuel Filler Cap Binds/Lamp ON/DTC P0457
TSB 07-16-908/20/07
FUEL FILLER CAP BINDING, FUEL CAP LIGHT /
WARNING MESSAGE AND/OR DTC P0457
FORD:
2005-2007 Five Hundred, Freestyle
MERCURY:
2005-2007 Montego
This article supersedes TSB 07-6-6 to update the Service Labor Time Standards (SLTS) and Service Part numbers.
ISSUE
Some 2005-2007 Freestyle, Five Hundred, and Montego vehicles built before 8/15/2006 may exhibit a fuel filler cap that binds when reinstalling after fueling. Improperly installed fuel cap may cause Fuel Cap Lamp illumination in the instrument cluster, a Check Fuel Cap warning message in message center (if equipped) and/or diagnostic trouble code (DTC) P0457. P0455 may also be present.
ACTION
Refer to the following Service Procedure to replace the fuel filler cap, and relocate the cap tether mounting position.
SERVICE PROCEDURE
^ 2005 vehicles, perform Service Procedure A below
^ 2006 vehicles, perform Service Procedure B below
^ 2007 vehicles, perform Service Procedure C below
Service Procedure A
NOTE
LEAVE THE FUEL FILLER CAP IN PLACE WHEN PERFORMING STEPS 1, 2, AND 3.
1. On the filler door housing mark the center point for a hole located approximately at the 10 o'clock position relative to the filler pipe as defined in Figure 1. The 9/16" (14 mm) dimension is downward from the base of the embossment and the 3/4" (19 mm) dimension is inboard from the edge of the opening in the vehicle body.
2. Drill hole with a 5/16" (8 mm) diameter drill bit. Tape the bit 1/2" (13 mm) from the end to be used as a drill depth guide.
NOTE
WHEN DRILLING, USE LIGHT PRESSURE TO PREVENT FORMATION OF EXCESSIVE BURRS.
3. Remove chips from the filler housing.
4. Remove the fuel cap from the filler pipe and the tether end from the attachment screw on the filler pipe flange.
5. Reinstall the screw to the filler pipe flange.
NOTE
REPLACE ONLY NON-LOCKING WITH NON-LOCKING CAPS AND LOCKING WITH LOCKING CAPS.
6. Install the revised fuel cap into the filler pipe.
7. Attach tether in counterclockwise direction from attachment point on vehicle by inserting the push pin into the drilled hole. This is the opposite direction from cap being removed. (Figure 1)
Service Procedure B
Install revised fuel cap (hole already in correct position - 3 o'clock) following Steps 6 and 7 of Service Procedure A.
Service Procedure C
Install revised fuel cap by attaching to existing hole in fuel door hinge, not the original fuel filler pipe location.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
071609A 2005 Five Hundred, 0.5 Hr.
Freestyle, Montego: Check
For DTC, Replace The
Fuel Filler Cap Includes
Time To Drill Hole To
Relocate Tether And Clear
Codes (Do Not Use With
9030A, 12650D)
071609B 2006-2007 Five Hundred, 0.3 Hr.
Freestyle, Montego: Check
For DTC, Replace The
Fuel Filler Cap, Includes
Time To Clear Codes (Do
Not Use With 9030A,
12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9030 69
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