24S16 – PCM Programming and Drain Tube Installation – 2022-2023 Ford Bronco Sport & 2022 Escape

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March 8, 2024 NHTSA CAMPAIGN NUMBER: 24V187000

Cracked Fuel Injector May Leak and Cause a Fire

A fuel leak in the presence of an ignition source such as hot engine or exhaust components, can increase the risk of a fire.

 

NHTSA Campaign Number: 24V187000

Manufacturer Ford Motor Company

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 42,652

 

Summary

Ford Motor Company (Ford) is recalling certain 2022-2023 Bronco Sport and 2022 Escape vehicles equipped with 1.5L engines. A fuel injector may crack and leak fuel inside the engine compartment.

 

Remedy

Dealers will update the engine control software to include fuel injector leak detection and install a drain tube, free of charge. Owner notification letters are expected to be mailed in April 2024. Owners may contact Ford customer service at 1-866-436-7332. Ford’s number for this recall is 24S16. This recall is an expansion of previous recall number 22V-859.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


March 11, 2024

NEW VEHICLE DEMONSTRATION / DELIVERY HOLD
Safety Recall 24S16
Certain 2022-2023 Model Year Bronco Sport and 2022 Model Year Escape with a  3-cylinder 1.5L Engine
PCM Programming and Drain Tube Installation

 

AFFECTED VEHICLES

Vehicle Model Year Assembly Plant Build Dates
Bronco Sport 2022-2023 Hermosillo October 17, 2022 through January 13, 2023
Escape 2022 Louisville October 17, 2022 through December 15, 2022

US population of affected vehicles: 41,057. Affected vehicles are identified in OASIS and FSA VIN Lists.

Note: Some vehicles may be in the process of being repaired at the plant. Monitor OASIS before opening an RO and/or beginning a repair. Parts purchased for an FSA can be returned for credit if required. See the EXCESS STOCK RETURN details in Labor Allowances and Parts Ordering Information for more information.

 

REASON FOR THIS SAFETY RECALL

In some of the affected vehicles there is a possibility that a high-pressure fuel injector may crack, which may result in fuel accumulating on the top of the engine. Liquid fuel and/or fuel vapor that accumulates near a sufficiently hot surface may ignite resulting in an underhood fire, increasing the risk of injury.

NOTE: When FSA 24S16 is completed and claimed, customer satisfaction program 22N18 will be automatically activated on the VIN, which will provide a one-time repair to replace the high-pressure fuel injectors in the event of a cracked high-pressure injector (see 22N18 for coverage details).

 

SERVICE ACTION

Before demonstrating or delivering any new in-stock vehicles involved in this recall, dealers are to install a drain tube into the engine cylinder head and reprogram the PCM, using the Ford Diagnostic and Repair System (FDRS). This service must be performed on all affected vehicles at no charge to the vehicle owner.

NOTE: Integrated Diagnostic Software (IDS) cannot be used for programming on the affected vehicles in this program.

For new vehicle storage guidelines, refer to EFC13033, Storage Guidelines for New Vehicles.

To assist vehicle owners to have this repair completed when parts are available, dealers should:

  • Arrange to pick up the owner’s vehicle and drive it to the dealership for repairs o Re-deliver the owner’s vehicle after repairs have been completed.
  • Pick-Up & Delivery should be made available for all customers. Refer to the Rental and Claiming sections for further details.

 

OWNER NOTIFICATION AND MAILING SCHEDULE

Owner letters are expected to be mailed the week of April 1, 2024. Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

PLEASE NOTE:

Federal law requires dealers to complete this recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $27,168 per vehicle. Correct all vehicles in your new vehicle inventory before delivery.

 

MOBILE SERVICE REPAIR ASSESSMENT LEVEL

  • All repairs in this program have the following assessment level:

– Not a Mobile Service Repair

OASIS ACTIVATION

OASIS will be activated on March 11, 2024.

 

SOLD VEHICLES

  • Ford has not issued instructions to stop selling/delivering or driving used vehicles under this safety recall. Owners should contact their dealer for an appointment to have their vehicles remedied as soon as practicable, once they’ve been notified of part and software availability.
  • When parts and software are available, 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.
  • Dealers are to prioritize repairs of customer vehicles over repairs of new and used vehicle inventory.

 

STOCK VEHICLES

  • Correct all affected units in your new vehicle inventory before delivery.
  • Use OASIS to identify any affected vehicles in your used vehicle inventory.

 

DEALER-OPERATED RENTAL VEHICLES

The Fixing America’s Surface Transportation (FAST) Act law effective June 2016 prohibits a rental company from selling, renting, or leasing vehicles subject to a safety or compliance recall. Please consult your legal counsel for legal advice.

 

BRANDED / SALVAGED TITLE VEHICLES

Affected branded / salvaged title vehicles are eligible for this recall.

 

OWNER REFUNDS

  • This safety recall must still be performed, even if the owner has paid for a previous repair. Claiming a refund will not close the recall on the vehicle.
  • Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair was performed before the date indicated in the reimbursement plan, which is posted with this bulletin. Owners are directed to seek reimbursement through authorized dealers or, at their option, directly through Ford Motor Company at PO Box 6251, Dearborn, MI 48121-6251.
  • Dealers are also pre-approved to refund owner-paid emergency repairs that were performed away from an authorized servicing dealer after the end date specified in the reimbursement plan. 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 fuel leaks caused by a cracked fuel injector(s).

 

RENTAL VEHICLES 

Rentals are not approved for this program.

 

PICK-UP & DELIVERY- Participating Dealers

Dealers participating in the Remote Experience Program:

  • Ford Dealers – Refer to EFC14125, 2024 Remote Experience Program, Pick-Up & Delivery Offset section for additional details.

 

PICK-UP & DELIVERY- Non-participating Dealers

Ford Dealers not participating in the 2024 Remote Experience Program for Pick-Up & Delivery are authorized to claim unique services for completing this program.

  • Dealers are authorized to claim one-half labor hour per repair for vehicle Pick-Up & Delivery services. Refer to Labor Allowances for details.
  • Dealers must retain a Vehicle Pick-Up & Delivery Record with the repair order documentation.

 

PARTS REQUIREMENTS

Part Number  Description Order Quantity
NX6Z-8A507-A Water outlet drain tube 1
Loctite® (SF) 7649™ Surface primer

(liquid or aerosol acceptable)

obtain locally or purchase online
Loctite® 638™ Retaining compound

 


CERTAIN 2022-2023 MODEL YEAR BRONCO SPORT AND 2022 MODEL YEAR ESCAPE VEHICLES WITH A 3-CYLINDER 1.5L ENGINEPCM PROGRAMMING AND DRAIN TUBE INSTALLATION

SERVICE PROCEDURE

NOTE: Make sure to order and have on hand, the outlet drain tube prior to starting the repair.
WARNING: When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the parking brake if the rear wheels will remain on the ground. These actions help prevent unintended vehicle movement. Failure to follow these instructions may result in serious personal injury.

WARNING: Never get underneath a vehicle that is supported only by a jack. The jack could unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions may result in serious personal injury.

WARNING: Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand. Failure to follow this instruction may result in serious personal injury.

WARNING: Turn off (disable) the power running boards (if equipped) before jacking, lifting or placing any object under the vehicle. Never place your hand between the power running board and the vehicle. Extended power running boards will retract when doors are closed. Failure to follow these instructions may result in serious personal injury.

NOTICE: When raising a vehicle on a hoist, use care when positioning the hoist adapters prior to lifting the vehicle so that hoist arms do not interfere with the surrounding suspension or steering linkage components.

1. Inspect vehicle for the presence of a fuel smell. Is there a fuel smell present?

Yes – Is the fuel smell coming from the high pressure fuel injectors?

Yes – Contact the Special Service Support Center (SSSC).

No – Repair this vehicle outside of this FSA.

No – Proceed to Step 2.

2. Connect a battery charger to the 12-volt (12V) battery.

NOTE: Verify that the negative cable of the charger is installed on a chassis or engine ground, and not the 12 volt battery negative terminal to prevent the battery saver mode from activating on the vehicle.

NOTE: If the diagnostic software does not load or if the vehicle cannot be identified properly, make sure there is a good internet connection and the Vehicle Communication Module II (VCM IIeBay) is properly connected to the Data Link Connector (DLC).

NOTE: Make sure the Ford Diagnostic and Repair System (FDRS) does not enter sleep mode during module configuration.

3. Launch Ford Diagnostic and Repair System (FDRS).

NOTE: Vehicle information is automatically retrieved by the diagnostic software and a Network Test is run. Vehicle identification data appears on the screen when this is complete.

4. Click ‘Read VIN from Vehicle’ or manually enter the Vehicle Identification Number (VIN).

NOTE: Available modules are shown on the left hand (LH) side of the screen, and available procedures are listed on the right hand (RH) side of the screen. Modules that are communicating are highlighted in green.

5. Select Toolbox tab.

6. From the list on the LH side of the screen, select the PCM.

7. Is there an update for the PCM available?

Yes – Continue to Step 8.

No – Continue to Step 13.

8. From the list on the RH side of the screen, select PCMPowertrain Control Module (PCM) Software Update.

9. From the list on the RH side of the screen, select Self-Test and click RUN.

10. Click the Run Selected Tests button in the lower right.

11. Click the Clear & Retest button at the top of the screen to clear Diagnostic Trouble Codes (DTC’s) in all modules.

12. Disconnect the battery charger from the 12V battery once the programming has completed. Continue to Step 13.

 

Important Information for Module Programming

NOTE: When programming 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 FDRS/scan tool to a power source.

NOTE: A good internet connection is necessary to identify the vehicle and to load the diagnostic software.

  • Inspect the Vehicle Communication Module II (VCM IIeBay)/Vehicle Communication Module III (VCM III) or the Vehicle Communication and Measurement Module (VCMM) and the 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.
  • Turn the accessories back on after programming has completed.
  • Disconnect/depower any aftermarket accessories (remote start, alarm, power inverter, CB radio,etc.).
  • Follow all scan tool on-screen instructions carefully.
  • Disable FDRS/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.

 

Recovering a module when programming has resulted in a blank module

a. Disconnect the VCM IIeBay/VCM III or the VCMM from the data link connector (DLC) and your computer.

b. After ten seconds, reconnect the VCMII/VCMIII or the VCMM to the DLC and the PC. Launch FDRS.
The VCMII/VCMIII or the VCMM icon should turn green in the bottom right corner of the screen. If it does not, troubleshoot the FDRS to VCM connection.

c. If you are using the same FDRS as the initial programming attempt, select the appropriate VIN from the Vehicle Identification menu. If you are using a different FDRS, select “Read VIN from Vehicle” and proceed through the Network Test.

d. In the Toolbox menu, navigate to the failed module and Download/Run Programmable Module Installation (PMI). Follow the on-screen prompts. When asked if the original module is installed, select “No” and continue through the installation application.

e. Once programming has completed, a screen may list additional steps required to complete the programming process. Make sure all applicable steps are followed in order.

 

13. Is there a drain tube present? See Figure 1.

Yes – Field Service Action (FSA) is complete.

No – Install drain tube. Continue to Step 14.

14. Turn steering wheel all the way to the left.

15. Remove Battery Tray. Follow the Workshop Manual (WSM) procedures in Section 414-01.

16. Remove air cleaner outlet pipe. Use a clean shop towel to cover the opening left behind. See Figure 2.

17. Clean area with Motorcraft Brake Cleaner. See Figure 3.

18. Inspect the part label on the drain tube. Is the suffix of the part an AA or AB? See Figure 4.

If the suffix is AA continue to Step 19.

If the suffix is AB Continue to Step 23.

19. Remove the fir tree fastener highlighted in the figure below. See Figure 5.

20. Cut the tip from fir tree fastener at the end of the tube. Trim the sides of the top 2 barbs at a 45-degree angle on the fir tree fastener to more easily allow fitment through the subframe hole.
See Figure 6.

21. Feed the rubber hose end through the engine compartment and down into the wheel well.
See Figure 7.

22. Attach hose to subframe. Position fir tree fastener and push in as far as possible. If needed you can use groove joint pliers to secure fir tree fastener fully into the hole in the subframe. See Figure 8.
Continue to Step 27.

NOTE: Wheel removed for clarity.

23. Cut the tip from fir tree fastener at the end of the tube. Trim the sides of the top 2 barbs at a 45-degree angle on the fir tree fastener to more easily allow fitment through the subframe hole.
See Figure 9.

24. Feed the rubber hose end through the engine compartment and down into the wheel well.
See Figure 10.

25. Attach hose to subframe. Position fir tree fastener and push in as far as possible. If needed you can use groove joint pliers to secure fir tree fastener fully into the hole in the subframe. See Figure 11.

NOTE: Wheel removed for clarity.

 

26. With the steering wheel turned to the left install the christmas tree connector as shown in the figure below. See Figure 12.

NOTE: Wheel removed for clarity.

 

27. Apply Loctite® (SF) 7649™ Primer to the metal tube, as shown in the blue highlighted area. Allow one minute for primer to cure. See Figure 13.

 

28. Apply Loctite® 638™ to the metal tube, in the area shown in Figure 14.

NOTE: When applying the Loctite® 638™, ensure that a full bead of the Loctite® 638™ is applied to the circumference of the metal tube in the area shown in Figure 14.

NOTE: To minimize poor adhesion risk, ensure tube is inserted into the head within 15 minutes of applying Loctite® 638™ to tube.

 

29. Route hose as shown in Figure 15.

NOTE: Route the metal end of the hose between the two battery positive leads and make sure the hose does not interfere with the transmission shift cable(s), and that it runs under the engine hoses.

 

30. Insert tube into the cylinder head drain hole until fully seated against the larger diameter flange section, as shown. See Figure 16.

 

31. Remove shop towel and reinstall air cleaner outlet pipe.
Torque: 42 lb.in (4.8 Nm)

32. Reinstall Battery Tray, Battery, and Air Cleaner. Please follow WSM procedures in Section 414-01.

IMPORTANT NOTE: Federal law prohibits selling motor vehicle parts or components that are under safety, compliance, or emissions recall. Unless a part is requested to be returned to Ford, all parts replaced under this FSA must be scrapped in accordance with all applicable local, state and federal environmental protection and hazardous material regulations. Refer to the Parts Retention, Return, & Scrapping section of the FSA dealer bulletin for further information.

 

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Date of Submission: 3/8/2024

FSA 24S16 – Certain 2022 – 2023 Ford Bronco Sport And 2022 Ford Escape – 1.5l Engine Underhood Fire

Chronology

On February 6, 2024, an issue pertaining to underhood fires on Bronco Sport and Escape vehicles produced after Safety Recall 22S73 (NHTSA Recall No. 22V-859) clean point was brought to Ford’s Critical Concern Review Group (CCRG) for review.  Ford’s Internal Combustion Engines Propulsion Thermal Systems Engineering (IPTSE) team had identified leaks during component-level injector flow testing on fuel injectors recovered from two Bronco Sport vehicles that had experienced underhood fires.

Ford determined that the two vehicles were produced on November 23, 2022, and December 13, 2022, with HX7G-9F597-BC fuel injectors.  These injectors have a reduced knurl diameter relative to the HX7G-9F597-BB injector that the Recall 22S73 population of vehicles was originally produced with.  This change was introduced to provide improved robustness against stresses leading to cracking.  Ford did not include the updated engine control software developed as part of the Recall 22S73 remedy for Escape vehicles produced from October 17, 2022, to December 15, 2022, and Bronco Sport vehicles produced from October 17, 2022, to January 13, 2023, at Hermosillo Assembly Plant.  This software will detect a pressure drop in the fuel rail, provide instrument cluster messaging to the customer to seek service, invoke a strategy to disable the high-pressure fuel pump, derate engine power output and reduce temperatures of possible ignition sources in the engine compartment. Ford’s decision not to include the updated engine control software on these vehicles was based on Ford’s assessment of the new injectors’ improved robustness.

Ford is aware of 5 underhood fires on 1.5L Escape and Bronco Sport vehicles built during this window of production. Ford is aware of 2 related VOQs during this production window, describing 2 of the 5 underhood fires.  Ford is also aware of 14 warranty replacements of BClevel injectors on 1.5L vehicles due to suspected cracking during this production window.

Ford is not aware of any reports of accident or injury related to this condition.

On March 1, 2024, Ford’s Field Review Committee reviewed the concern and approved a field action.

 


3 Affected Products

Vehicles

MAKE MODEL YEAR
FORD BRONCO SPORT 2022-2023
FORD ESCAPE 2022

 


5 Associated Documents

Manufacturer Notices(to Dealers,etc)

RCMN-24V187-9655.pdf 2898.842KB

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Chronology

RMISC-24V187-6053.pdf 13.497KB

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Defect Notice 573 Report

RCLRPT-24V187-8517.PDF 215.782KB

 


Recall Acknowledgement

RCAK-24V187-1027.pdf 645.455KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-24V187-9005.pdf 52.695KB

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Latest Recalls Documents

For the Latest and Most recent Recall Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=24V187&docType=RCL

 


 

Reprogramming

Service Information & Reprogramming

 

Module Reprogramming

Diagnostic Software Interface Device Complete Vehicle Diagnostics Module Programming
1996-2017
Model Year
2018-Present
Model Year
1996-2017
Model Year
2018-Present
Model Year
IDS/FDRS VCM, VCM IIeBay, VCMM X X X X
FJDS/FDRS Compatible J2534 Devices
(Including VCM IIeBay and VCMM)
  X X X

Detailed system requirements, installation, and support information for each product is located under the diagnostics tool support tab for each product.

 

Integrated Diagnostic Software (IDS) / Ford Diagnosis & Repair System (FDRS)

For use with VCM I, VCM IIeBay, VMM and VCMM hardware devices only. The complete factory Ford Motor Company vehicle diagnostic tool that provides complete dealership level vehicle diagnostic coverage for all 1996 to present Ford, Lincoln and Mercury vehicles. The IDS software includes time based access to the IDS software, software updates and calibration files.

 

Ford J2534 Diagnostic Software (FJDS) / Ford Diagnosis & Repair System (FDRS)

For use with compatible J2534 hardware devices. FJDS software provides Ford Module Programming functionality that covers 1996 to present Ford, Lincoln and Mercury module reprogramming functions, plus complete dealership level vehicle diagnostic software for all 2018 to present Ford and Lincoln vehicles. The FJDS software license includes time based access to the FJDS software, software updates and calibration files.

24S16 - PCM Programming and Drain Tube Installation - 2022-2023 Ford Bronco Sport & 2022 Escape | small light CarDAQ-Plus 3 All Makes J2534 Reprogramming Tool
24S16 - PCM Programming and Drain Tube Installation - 2022-2023 Ford Bronco Sport & 2022 Escape | small light CarDAQ-Plus 2 Diagnostic Code Reader and J2534 Programming Tool
24S16 - PCM Programming and Drain Tube Installation - 2022-2023 Ford Bronco Sport & 2022 Escape | small light CarDAQ-Plus
24S16 - PCM Programming and Drain Tube Installation - 2022-2023 Ford Bronco Sport & 2022 Escape | small light CarDAQ-M
24S16 - PCM Programming and Drain Tube Installation - 2022-2023 Ford Bronco Sport & 2022 Escape | small light VSI J2534 ECU Reprogrammer
24S16 - PCM Programming and Drain Tube Installation - 2022-2023 Ford Bronco Sport & 2022 Escape | small light

Mongoose-Plus J2534

24S16 - PCM Programming and Drain Tube Installation - 2022-2023 Ford Bronco Sport & 2022 Escape | small light

Bosch Automotive Tools MTECH2 Mastertech II J2534 VCI with Wired/Wireless Capability for OEM Reprogramming and Diagnostics on GM, Ford, FCA, Nissan/Infiniti, Honda/Acura, and Toyota/Lexus Vehicles

24S16 - PCM Programming and Drain Tube Installation - 2022-2023 Ford Bronco Sport & 2022 Escape | small light

RAP2 OEM J2534 Remote Reprogramming Tool

24S16 - PCM Programming and Drain Tube Installation - 2022-2023 Ford Bronco Sport & 2022 Escape | small light

BOSCH Automotive Tools MTECH2 Mastertech II J2534 VCI

24S16 - PCM Programming and Drain Tube Installation - 2022-2023 Ford Bronco Sport & 2022 Escape | small light

Autel MaxiFlash VCI Vehicle Communication Interface J2534 PassThru ECU Programming Device Bluetooth Connection Internet Update Support CAN FD, 4 CAN Channels, DoIP, D-PDU Works with PC or Autel MS909

24S16 - PCM Programming and Drain Tube Installation - 2022-2023 Ford Bronco Sport & 2022 Escape | small light

GODIAG J2534

 


Latest Calibration Information

Module Build Data (As-Built)

Use VIN to obtain As-Built data

www.motorcraftservice.com

 


 

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  • 🚗[Functional] ●USB vehicle-to-PC connectivity●Supports Windows,XP●Supports Windows 7● CE and FCC compliance for hardware●Firmware Updatable. 【SPS】Service Programming System: ◎Passthrough programming on GM past model and Global A vehicles◎Increase reprogramming speed 20-70% and get ready to service new models.
  • 🚗[GDS] Global Diagnostic System: ◎New Diagnostic Application Software required for all GM Global Architecture (Global A) Vehicles. ◎GDS & GDS2 is software which runs on a specific PC. Updates received via TIS2Web.
  • 🚗[Efficient&Convenience] Quick access to vehicle data for maintenance or management reports.Quickly attaches to vehicle's diagnostic connector. Mixed fleet capabilities with broad protocol support.May be used with desktop PC or laptop. make sure your computer at least 4GB.Tech2win software only installed on 7 32bit computer and on physical system.Please download the latest vxmanager from vxdiag official website.

Last update on 2024-05-17 / Affiliate links / Images from Amazon Product Advertising API

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