16E02 – Inspect and Replace Fuel System Components – 2015-2016 Ford F-Super Duty

June 30, 2016

TO: All U.S. Ford and Lincoln Dealers

SUBJECT: Emission Recall 16E02
Certain 2015-2016 Model Year F-Super Duty Chassis Cab Vehicles Equipped with a
6.7L Diesel Engine and Serviced with Fuel Injectors or Fuel System Kits
Inspect and Replace Fuel System Components

 

AFFECTED VEHICLES

Certain 2015-2016 Model Year F-Super Duty chassis cab vehicles equipped with a 6.7L diesel engine that were serviced with suspect fuel injectors or fuel system kits on or before April 27, 2016.  Known affected vehicles were identified through ACESII claims, and are activated in OASIS and FSA VIN Lists.

Vehicle	Model Year	Assembly Plant	Build Dates
F-Super Duty	2015-2016	Kentucky	December 16, 2013 through March 07, 2016

 

NOTE:  Not all vehicles serviced with suspect parts will be identified in OASIS.  For vehicles that were serviced with suspect parts, but are not identified in OASIS, dealers will need to contact the Special Service Support Center (SSSC) to have the vehicle added to the recall.

 

REASON FOR THIS EMISSION RECALL

Some of the affected vehicles could have been serviced with fuel system components not intended for use in a chassis cab application, due to a parts catalog error.  The suspect fuel injector kits and fuel system kits are listed below.

 

Part Number	Description
FC3Z-9H529-A	Fuel Injector Kit (for cylinders 1,2,7,8)
FC3Z-9H529-B	Fuel Injector Kit (for cylinders 3,4,5,6)
FC3Z-9B246-A	Fuel System Kit
FC3Z-9B246-B	Fuel System Kit

 

SERVICE ACTION

Dealers are to determine if the VIN is included in Attachment IV, and if so, install a new high pressure pump, all 8 injectors and fuel injector supply tubes.  If the VIN is not included in Attachment IV, the dealer is to inspect for incorrect fuel injector kits and replace, as needed.

If dealership records indicate that an over-the-counter service part sale occurred, or a vehicle was serviced before April 27, 2016, with one of these kits, and the vehicle is not identified in OASIS, dealers should take the following action to complete this emission recall:

• Contact the customer and schedule a service date.
• When the vehicle arrives, give the customer a copy of the Owner Notification Letter.
• Contact the SSSC Web Contact Site, Contact Type: Non-Involved Vehicle to have the vehicle added to the recall. Be prepared to provide the VIN, a copy of the repair order and/or invoice, the suspect kit part number and the date of purchase.
• Proceed with repair once confirmation from the SSSC is received indicating the VIN has been added to the program.

This service must be performed at no charge to the vehicle owner.

NOTE:  The State of California and the Commonwealth of Massachusetts require the completion of emission recall repairs prior to vehicle registration renewal.  For vehicles registered in these states, please provide the owner with a Vehicle Emission Recall Proof of Correction certificate after the repair has been performed.  These certificates may be obtained by contacting your regional office.

 

OWNER NOTIFICATION MAILING SCHEDULE

Pending Agency approval, owner letters are expected to be mailed the week of August 15, 2016.  Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

PLEASE NOTE:     

The sale of uncorrected new vehicles to customers could lead to penalties under applicable state and Federal regulations.  Correct all vehicles in your new vehicle inventory prior to delivery.

 

ATTACHMENTS

Attachment I: Administrative Information
Attachment II: Labor Allowances and Parts Ordering Information
Attachment III: Technical Information
Attachment IV: Table of Known VINs Requiring Fuel System Kit Replacement
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

Emission Recall 16E02
Certain 2015-2016 Model Year F-Super Duty Chassis Cab Vehicles Equipped with a 6.7L Diesel
Engine and Serviced with Fuel Injectors or Fuel System Kits
Inspect and Replace Fuel System Components

 

OASIS ACTIVATION

OASIS will be activated on June 30, 2016.

 

FSA VIN LISTS ACTIVATION

FSA VIN Lists will be available through https://web.fsavinlists.dealerconnection.com by June 30, 2016.  Owner names and addresses will be available by August 26, 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 recall 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 recall.

 

STOCK VEHICLES

Use OASIS to identify and correct all affected vehicles in your new and 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 recall.

 

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    

Refunds are not approved for this program.

 

RENTAL VEHICLES

Dealers are pre-approved for 2 days of rental vehicle for personal transportation.  A comparable rental vehicle is not authorized.  Follow Extended Service Plan (ESP) guidelines for dollar amounts.  Rentals will only be reimbursed for the day(s) the vehicle is at the dealership for part replacement.  Prior approval for more than 2 rental days is required from 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 16E02 is the sub code.
• Additional labor and/or parts must be claimed as related damage on a separate repair line from the FSA.
• 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.

 

ATTACHMENT II

Emission Recall 16E02
Certain 2015-2016 Model Year F-Super Duty Chassis Cab Vehicles Equipped with a 6.7L Diesel
Engine and Serviced with Fuel Injectors or Fuel System Kits
Inspect and Replace Fuel System Components

 

LABOR ALLOWANCES

Description	Labor Operation	Labor Time
Inspect injectors – no repairs required	16E02A	1.1 Hours
Inspect and replace one injector (left or right bank)	16E02B	1.8 Hours
Inspect and replace two or more injectors (same bank)	16E02C	2.7 Hours
Inspect and replace two injectors (one on each bank)	16E02D	2.3 Hours
Inspect and replace three or more injectors (one or more on each bank)	16E02E	3.9 Hours
Replace high pressure pump, 8 injectors and fuel injector supply tubes – VIN table on Attachment IV	16E02F	8.0 Hours

 

PARTS REQUIREMENTS / ORDERING INFORMATION

Part Number	Description	Order Quantity
FC3Z-9B246-C	Fuel System Kit (only use high pressure pump, 8 injectors and fuel injector supply tubes)	1
BC3Z-9H529-A	Fuel Injector Kit (for cylinders 1,2,7,8)	1 – 4
BC3Z-9H529-B	Fuel Injector Kit (for cylinders 3,4,5,6)	1 – 4

 

The DOR/COR number for this recall is 51049.

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 2015-2016 MODEL YEAR F-SUPER DUTY CHASSIS CAB VEHICLES EQUIPPED WITH A 6.7L DIESEL ENGINE AND SERVICED WITH FUEL INJECTORS OR FUEL SYSTEM KITS — INSPECT AND REPLACE FUEL SYSTEM COMPONENTS

 

OVERVIEW

Some of the affected vehicles could have been serviced with fuel system components not intended for use in a chassis cab application, due to a parts catalog error. Suspect parts are fuel injector kits and fuel system kits. Dealers are to determine if the VIN is included in Attachment IV, and if so, install a new high pressure pump, all 8 injectors and fuel injector supply tubes. All other vehicles will be inspected, and any incorrect injectors will be replaced as needed.

 

INSPECTION AND SERVICE PROCEDURE

1. Reference Attachment IV to determine if a new fuel system kit is required:

NOTE: Repairs covered under this recall are the result of a parts cataloging error rather than fuel system contamination. As a result, some of the components included in the fuel system kit will not be used in the repair.

• If the VIN is on Attachment IV, the vehicle DOES require a new fuel system kit.
  
  Please install only the high pressure pump, all eight fuel injectors and the fuel injector supply tubes following the Workshop Manual (WSM) procedures in Section 303-04C.
• If the VIN is not on Attachment IV, the vehicle DOES NOT require a new fuel system kit.
  
  Proceed to Step 2.

2. Remove the RH and LH fender splash shields. Please follow the WSM procedures in Section 501-02, Fender Splash Shield.
3. Remove the five RH and four LH engine sound shield retainers and the RH and LH engine sound shields from the valve covers.
4. Inspect all fuel injectors for the presence of a gray fuel return port. See Figure 1.
   • Fuel injectors with a gray fuel return port are not correct for the vehicle and must be replaced.
     
     Please follow the WSM procedures in Section 303-04C, Fuel Injectors.
   • Fuel injectors with blue fuel return ports are correct for the vehicle and do not need to be replaced. Proceed to Step 5.

FIGURE 1

 

5. Install the RH and LH engine sound shields onto the valve covers and install the five RH and four LH engine sound shield retainers.
6. Install the RH and LH fender splash shields. Please follow the WSM procedures in Section 501-02, Fender Splash Shield.

 

ATTACHMENT IV

Emission Recall 16E02
Certain 2015-2016 Model Year F-Super Duty Chassis Cab Vehicles Equipped with a 6.7L
Diesel Engine and Serviced with Fuel Injectors or Fuel System Kits
Inspect and Replace Fuel System Components

 

Use the following chart to identify if a vehicle requires a fuel system kit replacement.

 

To search for a VIN:

• In Adobe Reader menu, click “EDIT”, then click “FIND”, then insert the VIN, then press ENTER, Or
• Press Ctrl and F simultaneously, then insert the VIN, then press ENTER.

 

VIN	VIN	VIN	VIN
1FDUF5GT2FEC18283	1FDUF4GT4FEA27135	1FDUF4HT6FEA60121	1FD0W4GT6GEA84498
1FDRF3GT3GEA44977	1FD0W5HT7FEA28699	1FD0X5HT0FEB26678	1FD8W3HT1FEA12991
1FDUF5GT3FEC93042	1FDUF4GT9FEA30998	1FDUF5GT0FEB83520	1FDRF3GT5FEA61195
1FD0W4HT0FEB83900	1FD0W5HT7FEB62547	1FD0X5HT0FEC32175	1FD8W3HT1FEA42105
1FDUF5GT0FEC73444	1FDUF5GT0FEB26265	1FDUF5GT2FEA23283	1FDRF3GT7FEC08004
1FD0W4HT5FEB64808	1FD0W5HT8FEA58634	1FD0X5HT0FED71268	1FD8W3HT1FEA69191
1FDUF5GT3FEB08195	1FDUF5GT2FEB64581	1FDUF5GT2FEC18638	1FDRF3GT8FEB62697
1FDUF5HT1FEC91952	1FD0W5HT8FEB56465	1FD0X5HT2FEB62758	1FD8W3HT2FEB33318
1FDUF5HT5FEB82507	1FD0W4GT3FEB96402	1FDUF5GT3FEA51271	1FDRF3GTXFEA73682
1FDUF5GT5FEC91924	1FD0W5HT8FEB83147	1FD0X5HT5FEB05616	1FD8W3HT3FEA61691
1FDUF4GT3FEA42905	1FDUF5GTXFEA90035	1FDUF5GT3FED26850	1FDRF3HT6FEA83740
1FD0W4GT5FEB99995	1FD0W5HT9FEA42989	1FD0X5HT6FEB32162	1FD8W3HT3FEB51438
1FDUF5GT2FED18013	1FDUF5HT1FED10936	1FD0W4HT8GEA24088	1FDRF3HT9FED29938
1FD0W4HTXGEB98700	1FD0W5HT9FEC46529	1FD0X5HT6FED07445	1FD8W3HT3FEC47747
1FDRF3GT3FEA61194	1FDUF5HT4FEC38713	1FDUF5HT0FEA41604	1FDUF4GT2FED31774
1FD0W5GT2FEC16886	1FD0W5HT9FED31743	1FD0X5HT8FEC25992	1FD8W3HT3FED06280
1FDUF4HT4FEC86688	1FDUF5HT6GEA67559	1FD0W4GT3GEB78872	1FDUF4GT3FEB57231
1FD0W5GT4FEB82630	1FD0W5HTXFEB26254	1FD0X5HT9FEA28586	1FD8W3HT3GEA37196
1FDUF5HT0GEA56573	1FDUF5HT9FED09436	1FDUF5HT2FEB88975	1FDUF4GT3FED34585
1FD0W5GT5GEC43422	1FD0X4GT0FEC71540	1FD0X5HTXFEB26011	1FD8W3HT4FEA26254
1FDRF3ETXFEB79973	1FDRF3GT0FEA16780	1FDUF5HT3FEC39707	1FDUF4GT4FEA42587
1FD0W5GT8FEA15588	1FD0X4GT3FEC57230	1FD7W2BT9FEA35112	1FD8W3HT5FEA84230
1FDRF3GT9FEA98637	1FDRF3GT1FEC23517	1FDUF5HT5FEB05359	1FDUF4GT4FEC64045
1FD0W5HT0FEC37038	1FD0X4GT4FEA29396	1FD7W2BTXFEA35099	1FD8W3HT5FEB49707
1FDUF4GT5FEA65134	1FDRF3GT4FEA01280	1FDUF5HT6FEA40862	1FDUF4GT6FEA53770
1FD0W5HT0FED31744	1FD0X4GT7FEB34045	1FD7X2BTXGEA72345	1FD8W3HT6FEB83767
1FDUF5GT1FEB62207	1FDRF3GT7FEC66579	1FDUF5HT8FEA83891	1FDUF4GT8GEB06695
1FD0W5HT1FEA98439	1FD0X4HT4GEA30905	1FD7X3FT6EEB81009	1FD8W3HT6FEC02690
1FDUF5GT4FEB62041	1FDRF3HT5FEC95383	1FDUF5HT8GEA67207	1FDUF4GT9FEB24606
1FD0W5HT1FEB33562	1FD0X5GT0FEA04467	1FD8W3GT3FEA10046	1FD8W3HT7FEA73844
1FDUF5HT3FEA00528	1FDUF4GT2FEA00094	1FD0W4GT0FEA62253	1FDUF4GTXFEA64545

 

VIN	VIN	VIN	VIN
1FD0W5HT2FEA03841	1FD0X5GT0FEB96828	1FD8W3GT8FEA89682	1FD8W3HT7FEB17275
1FDUF5HT8FEC42375	1FDUF4GT3FEC73240	1FDRF3GT0FEA16777	1FDUF4HT5FEB82386
1FD0W5HT2FEA57317	1FD0X5GT1FEA90047	1FD8W3GTXFEB97527	1FD8W3HT7FEB31032
1FDRF3GT1FEA53983	1FDUF4GT4FEA72088	1FDRF3GT1DEA81702	1FDUF4HT8FEB57062
1FD0W5HT2FEA72223	1FD0X5GT4FEA13513	1FD8W3HT0FEA38000	1FD8W3HT8FEA95304
1FDRF3GT6FEA47211	1FDUF4GT7FEA46200	1FDRF3GT1FEA61193	1FDUF5GT0FEB26752
1FD0W5HT4FEA43418	1FD0X5GT6FED58073	1FD8W3HT0FEA87116	1FD8W3HT8FEC37179
1FDRF3HT9FEA26240	1FDUF4GT9GEA45339	1FDRF3GT2FEA16778	1FD0W4GT1FEA60267
1FD0W5HT7FEA05018	1FD0X5GT7FEA62754	1FD8W3HT0FEA95796	1FD8W3HT8FEC98418
1FDUF5GT9FEA17089	1FD8W3HT9FEB60211	1FDUF5HT2FEC90941	1FDUF5HT5FEB37261
1FD8W3HTXFEC60883	1FDUF5GT3FEA04824	1FDAF5GT4GEA45211	1FDGF5GT4FEA99536
1FDUF5GT9FEB82981	1FDUF5GT5FEB62775	1FDUF5HT3FEA61362	1FDUF5HT5FED10325
1FD8X3FT3FEA71234	1FDUF5GT3FEA60472	1FDAF5GT6FED59182	1FDGF5GT5FEA42522
1FDUF5GTXFEA16694	1FDUF5GT6FED68610	1FDUF5HT4FEA21923	1FDUF5HT6FEC91946
1FD8X3GT8FEC23510	1FD0W4HT7FEB72506	1FDGF5GT0FEA42525	1FDGF5GT5FEA42794
1FDUF5GTXFED43483	1FDUF5GT7FEB82056	1FDUF5HT5FEA53490	1FDUF5HT7FEA99726
1FD8X3HT2FEA35824	1FDUF5GT4FEA04833	1FDGF5GT2FEA65692	1FDGF5GT6FEA42528
1FDUF5HT0FEA53820	1FDUF5GT8FEC04890	1FDUF5GT1FEC42655	1FDUF5HT8FEB56788
1FD8X3HT5FEB68903	1FDUF5GT5EEB82152	1FD8W3HT9FEA62540	1FDGF5GT7FEA42523
1FDUF5HT1FEA14170	1FDUF5GT9FEA65787	1FDUF5GT2FEA53285	1FDUF5HT8GEA61276
1FD8X3HT6FEC10883	1FDUF5GTXFEA14153	1FD8W3HT9FEB31033	1FDGF5GT9FEA42524
1FDUF5HT1FED09253	1FD8W3HT9FEB61214	1FD0W4HT3GEA65793	1FDUF5HT9FEA35834
1FD8X3HT8FEC88419	1FDUF5GT7FEB31463	1FD8W3HT9FEB51461	1FDGF5GTXFEA17387
1FDUF5HT2FEB72744	1FD8W3HT9FEC22562	1FDUF5GT2FEC83277	1FDUF5HT9FED19190
1FD8X3HTXFEA36008	1FDUF5GT7FEC91942	1FD8W3HTXFEA84403	1FDNF6DC6GDA00241
1FDRF3BT4FEA83230

 

August, 2016

 

Emission Recall 16E02
Programa de Emisiones 16E02

 

Mr. John Sample
123 Main Street
Anywhere, USA 12345

 

Your Vehicle Identification Number (VIN):  12345678901234567

Ford Motor Company values you as a customer and is committed to vehicle quality and preserving the environment.  Therefore, we are voluntarily recalling your vehicle, with the VIN shown above. Your vehicle may be releasing air pollutants that exceed applicable emission standards due to the installation of an incorrect service part.

What is the issue?	Your vehicle may have been previously repaired with fuel injectors and a high pressure fuel pump that do not meet emission certification requirements for your vehicle application.
What will Ford and your dealer do?	Ford Motor Company has authorized your dealer to inspect, and if necessary, replace the fuel injectors and high pressure fuel pump.  This service will be provided free of charge (parts and labor).
How long will it take?	The time needed for this repair is less than two days.  However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.  In addition, your vehicle may require an inspection to determine if parts need to be ordered.
What should you do?	Please call your dealer without delay and request a service date for Emission Recall 16E02.  Provide the dealer with the VIN, which 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 recall completed on your vehicle.  The vehicle owner is responsible for making arrangements to have the work completed.
Do you need a rental vehicle?	Your dealer is authorized to provide a rental vehicle for your personal transportation at no charge (except for fuel and insurance) while your vehicle is at the dealership for repairs.  Please see your dealer for guidelines and limitations.
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 government regulations require that notification be sent to the last known owner of record. Our records are based primarily on state registration and title data, which 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). MOTORHOME OWNERS:  If you have questions or concerns, please contact our Motorhome Customer Assistance Center toll free at 1-866-906-9811.  Representatives are available 24 hours a day.
Para asistencia en Español	Visite nuestro sitio web para ver este anuncio en Español al siguiente dirección: https://es.owner.ford.com/tools/account/maintenance/recalls.html 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.
California and Massachusetts Registration Requirements	The State of California and the Commonwealth of Massachusetts require the completion of emission recall repairs prior to vehicle registration renewal.  If your vehicle is registered in California or Massachusetts, it is subject to these requirements. When your dealer completes this emission recall repair, you will receive a Vehicle Emission Recall Proof of Correction certificate.  Please make sure that you receive a certificate from your dealer and that you have it with you when you renew your vehicle registration. It is also important for you to know that the certificate should be returned to the Department of Motor Vehicles (DMV) only if it is requested by the DMV.  Otherwise, this certificate is to be held by you for your records. In order to ensure your full protection under emissions warranty provisions, and to avoid any inconvenience when renewing your registration, it is recommended that you have your vehicle serviced as soon as possible.  Failure to do so could be determined as lack of proper maintenance of your vehicle.

 

Thank you for your attention to this important matter.

Ford Customer Service Division