16B38 – Powertrain Control Module Reprogramming and Canister Purge Valve Inspection – 2011-2012 Ford Fusion

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October 6, 2016

TO: All U.S. Ford and Lincoln Dealers

SUBJECT:     Customer Satisfaction Program 16B38
Certain 2011-2012 Model Year Fusion Vehicles Equipped with 2.5L or 3.0L Engines
Powertrain Control Module Reprogramming and Canister Purge Valve Inspection

 

PROGRAM TERMS  

This program will be in effect through September 30, 2018.  There is no mileage limit for this program.

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
Fusion 2011-2012 Hermosillo March 5, 2011 through July 29, 2012

 

Affected vehicles are identified in OASIS and FSA VIN Lists.

 

REASON FOR THIS PROGRAM

In some of the affected vehicles, the canister purge valve (CPV) may develop a leak that can cause excessive vacuum to build in the fuel tank. This condition will only occur under certain operating conditions and may result in illumination of the “service engine soon indicator.”

 

SERVICE ACTION

Dealers are to reprogram the powertrain control module (PCM), test the CPV, and repair as needed.  This service must be performed on all affected vehicles at no charge to the vehicle owner.

 

OWNER NOTIFICATION MAILING SCHEDULE

Owner letters are expected to be mailed the week of October 31, 2016.  Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

 

ATTACHMENTS

Attachment I: Administrative Information
Attachment II: Labor Allowances and Parts Ordering Information
Attachment III: Technical Information
Owner Notification Letter

 

QUESTIONS & ASSISTANCE

For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web Contact Site.  The SSSC Web Contact Site can be accessed through the Professional Technician Society (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or listed under the SSSC tab.

Sincerely,

 

Michael A. Berardi

 

ATTACHMENT I

Customer Satisfaction Program 16B38
Certain 2011-2012 Model Year Fusion Vehicles Equipped with 2.5L or 3.0L Engines
Powertrain Control Module Reprogramming and Canister Purge Valve Inspection

 

OASIS ACTIVATION

OASIS will be activated on October 6, 2016.

 

FSA VIN LISTS ACTIVATION

FSA VIN Lists will be available through https://web.fsavinlists.dealerconnection.com on October 6, 2016.  Owner names and addresses will be available by November 18, 2016.

NOTE:  Your FSA VIN Lists may contain owner names and addresses obtained from motor vehicle registration records.  The use of such motor vehicle registration data for any purpose other than in connection with this program is a violation of law in several states, provinces, and countries.  Accordingly, you must limit the use of this listing to the follow-up necessary to complete this service action.

 

STOCK VEHICLES

  • Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

SOLD VEHICLES

  • Owners of affected vehicles will be directed to dealers for repairs.
  • Immediately contact any of your affected customers whose vehicles are not on your VIN list but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and schedule a service date.
  • Correct other affected vehicles identified in OASIS which are brought to your dealership.  

 

TITLE BRANDED / SALVAGED VEHICLES

Affected title branded and salvaged vehicles are eligible for this service action.

 

ADDITIONAL REPAIR (LABOR TIME AND/OR PARTS)

Additional repairs identified as necessary to complete the FSA should be managed as follows:

  • For vehicles within new vehicle bumper-to-bumper warranty coverage, follow existing warranty and policy guidelines for related damage claims. No SSSC approval is required for these vehicles:
    • Ford vehicles – 3 years or 36,000 miles
  • For vehicles outside new vehicle bumper-to-bumper warranty coverage, submit an Approval Request to the SSSC Web Contact Site prior to completing the repair.

 

OWNER REFUNDS

  • Ford Motor Company is offering a refund for owner-paid repairs covered by this program if the repair was performed before the date of the Owner Notification Letter. This refund offer expires March 31, 2017.
  • Dealers are also pre-approved to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the date of the Owner Notification Letter. There is no expiration date for emergency repair refunds.  Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
  • Refunds will only be provided for the cost associated with canister purge valve replacement, vapor canister replacement due to liquid fuel contamination, or fuel tank replacement due to cracks.

 

RENTAL VEHICLES

With proper dealer parts ordering and service appointment scheduling, rental vehicles should not be required.  However, if you have a unique owner circumstance which may require a rental vehicle, please contact the SSSC via the SSSC Web Contact Site.

 

CLAIMS PREPARATION AND SUBMISSION

  • Enter claims using Direct Warranty Entry (DWE) or One Warranty Solution (OWS).
    • DWE: refer to ACESII manual for claims preparation and submission information.
    • OWS: when entering claims in DMS software, select claim type 31: Field Service Action. The FSA number (16B38) is the sub code.
  • Additional labor and/or parts must be claimed as related damage on a separate repair line from the FSA.
  • Submit refunds on a separate repair line.
    • Program Code:  16B38                   –  Misc. Expense:  ADMIN
    • Misc. Expense:  REFUND             –  Misc. Expense:  0.2 Hrs.
  • Multiple refunds should be submitted on one repair line and the invoice details for each repair should be detailed in the comments section of the claim.
  • For rental vehicle claiming, follow Extended Service Plan (ESP) guidelines for dollar amounts. Enter the total amount of the rental expense under Miscellaneous Expense code RENTAL.
  • PROGRAM TERMS: This program will be in effect through September 30, 2018.  There is no mileage limit for this program.

 

ATTACHMENT II

Customer Satisfaction Program 16B38
Certain 2011-2012 Model Year Fusion Vehicles Equipped with 2.5L or 3.0L Engines
Powertrain Control Module Reprogramming and Canister Purge Valve Inspection

 

LABOR ALLOWANCES

Description Drive Type Labor Operation Labor Time
Reprogram PCM (IDS release 99.05 or later) Test CPV – pass FWD and  AWD 16B38B 0.5 Hours
Reprogram PCM (IDS release 99.05 or later)

Test CPV – fail (replace CPV)

Inspect and replace vapor canister if needed  Inspect fuel tank

FWD 16B38C 1.3 Hours
AWD 16B38D 1.0 Hours
Additional time to replace fuel tank if inspection fails (claim with labor operations 16B38C or 16B38D) FWD 16B38CC 1.8 Hours
AWD 16B38DD 2.2 Hours

 

PARTS REQUIREMENTS / ORDERING INFORMATION

Part Number Description Order Quantity
9U5Z-9C915-H 16B38 - Powertrain Control Module Reprogramming and Canister Purge Valve Inspection - 2011-2012 Ford Fusion | small light Canister purge valve 1
9E5Z-9D653-C 16B38 - Powertrain Control Module Reprogramming and Canister Purge Valve Inspection - 2011-2012 Ford Fusion | small light Vapor canister 1
4L3Z-9276-AA 16B38 - Powertrain Control Module Reprogramming and Canister Purge Valve Inspection - 2011-2012 Ford Fusion | small light Fuel pump module seal 1
CE5Z-9002-BR Fuel tank – 2.5L vehicles only 1
CE5Z-9002-CR Fuel tank – 3.0L FWD vehicles only 1
AE5Z-9002-CR Fuel tank – 3.0L AWD vehicles only 1

 

The DOR/COR number for this program is 51059.

Order your parts requirements through normal order processing channels.  To guarantee the shortest delivery time, an emergency order for parts must be placed.

 

DEALER PRICE  

For latest prices, refer to DOES II.

 

PARTS RETENTION AND RETURN

Follow the provisions of the Warranty and Policy Manual, Section 1 – WARRANTY PARTS RETENTION AND RETURN POLICIES.

 

EXCESS STOCK RETURN

Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000.

 

ATTACHMENT III

CERTAIN 2011-2012 MODEL YEAR FUSION VEHICLES EQUIPPED WITH 2.5L OR 3.0L ENGINES — POWERTRAIN CONTRO L MODULE REPROGRAMMING AND CANISTER PURGE VA LVE INSPECTION

 

OVERVIEW

In some of the affected vehicles, the canister purge valve (CPV) may develop a leak that can cause excessive vacuum to build in the fuel tank. This condition will only occur under certain operating conditions and may result in illumination of the “service engine soon indicator”. Dealers are to reprogram the powertrain control module (PCM), test the CPV, and repair as needed.

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

 

Module Reprogramming

Important Information for Module Programming

NOTE: When programming or reprogramming a module, use the following basic checks to ensure programming completes without errors.

  • Make sure the 12V battery is fully charged before carrying out the programming steps and connect IDS/scan tool to a power source.
  • Inspect Vehicle Communication Module (VCM) and cables for any damage. Make sure scan tool connections are not interrupted during programming.
  • A hardwired connection is strongly recommended.
  • Turn off all unnecessary accessories (radio, heated/cooled seats, headlamps, interior lamps, HVAC system, etc.) and close doors.
  • Disconnect/depower any aftermarket accessories (remote start, alarm, power inverter, CB radio, etc.).
  • Follow all scan tool on-screen instructions carefully.
  • Disable IDS/scan tool sleep mode, screensaver, hibernation modes.
  • Create all sessions Key On Engine Off (KOEO). Starting the vehicle before creating a session will cause errors within the programming inhale process.

 

NOTE: Reprogram appropriate vehicle modules before performing diagnostics and clear all Diagnostic Trouble Codes (DTCs) after programming. For DTCs generated after reprogramming, follow normal diagnostic service procedures.

  1. Connect a battery charger to the 12V battery.
  2. Reprogram the Powertain Control Module (PCM) using IDS release 99.05 or higher.

NOTE: Calibration files may also be obtained at www.motorcraftservice.com.

NOTE: Follow the IDS on-screen instructions to complete the reprogramming procedure.

NOTE: If programming results in a blank module, refer to module recovery instructions on Page 10.

  1. Disconnect the battery charger from the 12V battery, once the reprogramming has completed.
  2. Proceed to Canister Purge Valve (CPV) Testing on Page 3.

 

Canister Purge Valve (CPV) Testing

NOTE: Ensure that the VACUTEC Smoke Machine or equivalent is properly calibrated for a 0.020″ leak test following the manufacturer’s instructions.

  1. Disconnect the vapor tube-to-CPV quick connect coupling. Please follow the WSM procedures in Section 310-00. See Figure 1.

NOTE: 2.5L shown, 3.0L similar.

vapor tube-to-CPV quick connect couplingFIGURE 1

 

  1. Using suitable adapters, connect the VACUTEC Smoke Machine Fuel Evaporative Emission System Tester or equivalent to the port on the CPV. See Figure 2.

NOTE: 2.5L shown, 3.0L similar.

port on the CPVFIGURE 2

 

  1. With the ignition in the “OFF” position, test the CPV for leaks by applying pressure from the tester and monitoring for air flow on the gauge. A good CPV will register a leak rate of less than 0.020″.
  2. Is CPV leak rate less than 0.020″?
    • YES – Reconnect the vapor tube-to-CPV quick connect coupling. No further repairs needed.
    • NO – Replace the CPV following the WSM procedures in Section 303-13, then proceed to Vapor Canister Inspection on Page 5.

 

Vapor Canister Inspection

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

IMPORTANT: Liquid fuel may be present inside of the vapor canister. Ensure you are using proper precautions while servicing.

  1. Remove the vapor canister from the vehicle. Please follow the WSM procedures in Section 303-13.
  2. While holding the vapor canister, tip the EVAP hose ports downward to determine if there is any liquid fuel within the canister.
  3. Is there any liquid fuel in the canister?
    • YES – Install a new vapor canister following the WSM procedures in Section 303-13.
    • NO – Reinstall the vapor canister following the WSM procedures in Section 303-13.
  4. Proceed to Module Reprogramming on Page 6.

 

INSPECTION PROCEDURE

Fuel Tank Inspection

  1. Inspect the fuel tank for any signs of fuel staining on the bottom of the fuel tank. See Figure 3.

NOTE: AWD Vehicles OnlyFuel tanks come equipped with a plastic shield covering the tank. See Figure 4.

a. Remove the fuel tank strap bolts and strap from the RH side of the fuel tank.

b. Remove the two push pins and bend the plastic shield downward to inspect the RH side of the fuel tank.

c. Reinstall the fuel tank strap, bolts and shield push pins. Perform the same inspection steps for the LH side of the fuel tank (Steps a-c).

d. If fuel tank replacement is not required, tighten the fuel tank strap bolts to 40 Nm (30 lb-ft).

Fuel Tank InspectionFIGURE 3

 

FUEL TANK SHIELD (IF EQUIPPED)FIGURE 4

 

  1. Is there fuel staining on the bottom of the fuel tank?
    • YES – Replace the fuel tank. Please follow the WSM procedures in Section 310-01. Repair is complete after fuel tank replacement has occurred.
      NOTE: When replacing the fuel tank, position the exhaust muffler and tailpipe assembly aside as outlined in Step 3 below. Full removal of the exhaust muffler and tailpipe assembly is not required.
    • NO – FWD Vehicles – Proceed to Step 3.
      AWD Vehicles – No repairs are needed at this time.

NOTE: Some fuel staining may be present on the top of the fuel tank if the fuel pump has been replaced previously. Fuel staining on the top of the fuel tank caused by prior fuel pump service is not an indication of a fuel tank leak.

 

FWD Vehicles Only

NOTICE: When lowering the fuel tank, do not exceed the stated distance. Lowering the fuel tank too far can cause damage to fuel lines and other components.

  1. Partially lower the fuel tank to inspect the top of the fuel tank for any signs of fuel staining. See Figures 5 and 6.
    1. Detach the exhaust isolators. Position aside and support the exhaust assembly.
    2. Remove the fuel tank heat shield.
    3. Use a suitable powertrain lift to support the fuel tank.
    4. Remove the four fuel tank bolts and lower the fuel tank approximately 1.75 in (44.45 mm). See Figure 6 on Page 8.

NOTE: 2.5L shown, 3.0L similar.

Partially lower the fuel tankFIGURE 5

 

  1. Check the top RH side of the fuel tank for signs of cracks. See Figures 6 and 7. Is cracking present?
    • YES – Replace the fuel tank. Please follow the WSM procedures in Section 310-01.
      NOTE: When replacing the fuel tank, position the exhaust muffler and tailpipe assembly aside as outlined in Step 3 on the previous page. Full removal of the exhaust muffler and tailpipe assembly is not required.
    • NO – Reassemble the vehicle. No repairs are needed at this time.

RH SIDE OF FUEL TANK (INSPECT IN THIS AREA)FIGURE 6

NOTE:  Fuel tank removed for clarity.

RH SIDE OF FUEL TANK (INSPECT IN THIS AREA)FIGURE 7

 

Recovering a module when programming has resulted in a blank module:
NEVER DELETE THE ORIGINAL SESSION!

a. Obtain the original IDS that was used when the programming error occurred during Module Reprogramming (MR) or Programmable Module Installation (PMI).

b. Disconnect the VCM from the Data Link Connector (DLC) and the IDS.

c. Reconnect the VCM to IDS and then connect to the DLC. Once reconnected, the VCM icon should appear in the corner of the IDS screen. If it does not, troubleshoot the IDS to VCM connection.

d. Locate the ORIGINAL vehicle session when programming failed. This should be the last session used in most cases. If not, use the session created on the date that the programming failed.

NOTE: If the original session is not listed in the previous session list, click the ”Recycle Bin” icon at the lower right of the previous session screen. This loads any deleted sessions and allows you to look through them. Double-click the session to restore it.

e. Once the session is loaded, the failed process should resume automatically.

f. If programming does not resume automatically, proceed to the Module Programming menu and select the previously attempted process, PMI or MR.

g. Follow all on-screen prompts/instructions.

h. The last screen on the IDS may list additional steps required to complete the programming process. Make sure all applicable steps listed on the screen are followed in order.

 

October 2016

Customer Satisfaction Program 16B38
Programa de satisfacción del cliente 16B38

 

Mr. John Sample
123 Main Street
Anywhere, USA 12345

 

Your Vehicle Identification Number (VIN):  12345678901234567

At Ford Motor Company, we are committed not only to building high quality, dependable products, but also to building a community of happy, satisfied customers. To demonstrate that commitment, we are providing a no-charge Customer Satisfaction Program for your vehicle with the VIN shown above.

Why are you receiving this  notice? In your vehicle, the canister purge valve (CPV) may develop a leak that can cause excessive vacuum to build in the fuel tank. This condition will only occur under certain operating conditions and may result in illumination of the “service engine soon indicator.”
What will Ford and your dealer do? In the interest of customer satisfaction, Ford Motor Company has authorized your dealer to update your vehicle’s powertrain control module calibration and test your vehicle’s CPV free of charge (parts and labor) under the terms of this program.

This Customer Satisfaction Program will be in effect until September 30, 2018 regardless of mileage.  Coverage is automatically transferred to subsequent owners.

How long will it take? The time needed for this repair is less than one-half day.  However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.
What should you do? Please call your dealer without delay and request a service date for Customer Satisfaction Program 16B38.  Provide the dealer with the VIN of your vehicle.  The VIN is printed near your name at the beginning of this letter.

If you do not already have a servicing dealer, you can access www.Fordowner.com for dealer addresses, maps, and driving instructions.      Ford Motor Company wants you to have this service action completed on your vehicle.  The vehicle owner is responsible for making arrangements to have the work completed.

Your vehicle may be equipped with a diagnostic feature called the Vehicle Health Report which can inform you about all available recalls, as well as other key vehicle health information. Please see https://owner.ford.com/vehicle-health for more information.

 

Have you previously paid for this repair? If you have previously paid for a repair that addresses the issue described in this letter, you still need to have this service action performed to ensure the correct parts and procedures were used.

If the previously paid for repair was performed before the date of this letter, you may be eligible for a refund.  Refunds will only be provided for service related to canister purge valve replacement, vapor canister replacement due to liquid fuel contamination, or fuel tank replacement due to cracks.  To verify eligibility and expedite reimbursement, give your paid original receipt to your dealer before March 31, 2017.  To avoid delays, do not send receipts to Ford Motor Company.

 

What if you no longer own this vehicle? If you no longer own this vehicle, and have an address for the current owner, please forward this letter to the new owner.

You received this notice because our records, which are based primarily on state registration and title data, indicate that you are the current owner.

 

Can we assist you further? If you have difficulties getting your vehicle repaired promptly and without charge, please contact your dealership’s Service Manager for assistance.

RETAIL OWNERS:  If you have questions or concerns, please contact our Ford Customer Relationship Center at 1-866-436-7332 and one of our representatives will be happy to assist you.  If you wish to contact us through the Internet, our address is:  www.Fordowner.com.

For the hearing impaired call 1-800-232-5952 (TDD).  Representatives are available Monday through Friday:  8:00AM – 8:00PM (Eastern Time).

FLEET OWNERS:  If you have questions or concerns, please contact our Fleet Customer Information Center at 1-800-34-FLEET, choose Option #3, and one of our representatives will be happy to assist you.  If you wish to contact us through the Internet, our address is:  www.fleet.ford.com.

Representatives are available Monday through Friday:  8:00AM – 8:00PM(Eastern Time).

Para asistencia en Español Visite nuestro sitio web para ver este anuncio en Español al siguiente dirección: https://es.owner.ford.com/recall.

Si necesita ayuda o tiene alguna pregunta, por favor llame al Centro de Relación con Clientes al 1-866-436-7332 y presione 2 para Español.

 

Thank you for your attention to this important matter.

Ford Customer Service Division

 

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Service Information & Reprogramming

Software necessary to program electronic modules to the latest calibration level, perform module initialization (PATS), and set Programmable Parameters on Ford, Lincoln and Mercury vehicles.

Ford Module Programming (FMP) is a software application that allows subscribers to program electronic modules on Ford, Lincoln and Mercury vehicles. It can be used for:

  • Reprogramming emission-related (OBDII) modules on some vehicles manufactured in 1995 and all vehicles manufactured from 1996 to the present
  • Reprogramming or reconfiguring non-emission-related modules on many vehicles (UBP and MS-CAN not supported)

In addition, module initialization (PATS) functions such as Keycode Erase/Reprogram and PCM Parameter Reset can be done using this application.

J2534 Device 16B38 - Powertrain Control Module Reprogramming and Canister Purge Valve Inspection - 2011-2012 Ford Fusion | small light 16B38 - Powertrain Control Module Reprogramming and Canister Purge Valve Inspection - 2011-2012 Ford Fusion | small light 16B38 - Powertrain Control Module Reprogramming and Canister Purge Valve Inspection - 2011-2012 Ford Fusion | small light 16B38 - Powertrain Control Module Reprogramming and Canister Purge Valve Inspection - 2011-2012 Ford Fusion | small light using Ford Module Programming (FMP) can Reprogram and Configure most Modules.

Latest Calibration Information

Module Build Data (As-Built)
Use VIN to obtain As-Built data

www.motorcraftservice.com

 

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