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52SS Page 1
Technical Service Bulletin # 01M05 Date: 010601
You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
When a claim is submitted under an "M" program the VIN number will remain in OASIS until the terms of the program expire.
OWNER REFUNDS
Ford Motor Company will only refund the cost of repairs for the fuel cross-flow condition made before the date of the Owner Letter (or after the date of
the Owner Letter if an emergency repair was made away from the servicing dealer). Refunds only apply to repairs made to correct a fuel cross-flow
condition.
All supporting documentation must be retained in accordance with the Warranty and Policy Manual. Refer to ACESII Manual for Refund information.
Enter claims using DWE:
RENTAL VEHICLES
Labor Allowances
Parts Requirements
Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels as noted.
Dealers will need to call 1-800-325-5621 for emergency orders for 60 days after campaign launch.
NOTE:
ONLY A VERY SMALL PERCENTAGE OF VEHICLES WILL NEED THIS REPAIR BECAUSE IT IS ONLY FOR VEHICLES THAT HAVE
HAD THE ORIGINAL RECALL (93S68 OR 00S57) COMPLETED AND HAVE HAD A SUBSEQUENT CROSS FLOW CONDITION.
The part is used only for 90-91 vehicles requiring repairs. See Attachment III.
(Owner Letters for this vehicle population will be mailed sometime in late July 2001).
1992 Ford Truck F 150 2WD Pickup L6-300 4.9L Copyright © 2013, ALLDATA 10.52SS Page 4
FOR CHASSIS CAB vehicles with 137" WB or 161" WB, ALSO ORDER THE PART BELOW. (only one check valve must be installed on the
forward/mid-ship tank; the check valve will not fit on the rear tank) Dealers MUST install a fuel delivery module on the rear tank.
DOR/COR NUMBER
DOR/COR for this program is 50243. This number identifies parts ordered for this campaign through the Special Service Support Center
(1-800-325-5621).
DEALER PRICE
^ DOES II
Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
FUEL CROSS FLOW WARRANTY EXTENSION
AFFECTED VEHICLES:
ALL 1990, 1991, 1992 AND 1993 MODEL YEAR F-SERIES VEHICLES EQUIPPED WITH 4.9, 5.0, 5.8 OR 7.5 LITER ENGINES AND DUAL
FUEL TANKS
TABLE OF CONTENTS
1992 Ford Truck F 150 2WD Pickup L6-300 4.9L Copyright © 2013, ALLDATA 10.52SS Page 5
FLOWCHART
SERVICE PROCEDURE
EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION - REAR TANK (NON-CHASSIS CAB VEHICLES)
FUEL DELIVERY MODULE REPLACEMENT AND RETURN LINE INSPECTION - REAR TANK (CHASSIS CAB VEHICLES)
NOTE:
Check OASIS to see if either Safety Recall 00S57 or 93S68 is open. If either recall is open, do not continue with this procedure. Instead, perform the
appropriate safety recall and return vehicle to the owner.
SERVICE PROCEDURE
1. Attach an EFI/CFI fuel pressure gauge to the Schrader valve on the engine fuel rail.
1992 Ford Truck F 150 2WD Pickup L6-300 4.9L Copyright © 2013, ALLDATA 10.52SS Page 6
2. WARNING:
FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE, EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE
SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM
PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE
HAZARD.
Start the engine and record the fuel pressure reading. Turn the ignition key to the OFF position. Then relieve the fuel system pressure by slowly
opening the manual valve on the fuel pressure gauge. Remove the gauge from the fuel rail.
6-CYLINDER ENGINES
^ External Check Valve Installation And Return Line Inspection - Rear Tank.
^ External Check Valve Installation And Return Line Inspection - Front Tank.
^ External Check Valve Installation And Return Line Inspection - Rear Tank.
^ External Check Valve Installation And Return Line Inspection - Front Tank.
8-CYLINDER ENGINES
^ External Check Valve Installation And Return Line Inspection - Rear Tank.
^ External Check Valve Installation And Return Line Inspection - Front Tank.
^ External Check Valve Installation And Return Line Inspection - Rear Tank.
^ External Check Valve Installation And Return Line Inspection - Front Tank.
CHASSIS CAB
6-CYLINDER ENGINES
^ Fuel Delivery Module Installation And Return Line Inspection - Rear Tank.
^ External Check Valve Installation And Return Line Inspection - Front Tank.
^ Fuel Delivery Module Installation And Return Line Inspection - Rear Tank. External Check Valve Installation And Return Line Inspection - Front
Tank.
8-CYLINDER ENGINES
^ Fuel Delivery Module Installation And Return Line Inspection - Rear Tank.
1992 Ford Truck F 150 2WD Pickup L6-300 4.9L Copyright © 2013, ALLDATA 10.52SS Page 7
^ External Check Valve Installation And Return Line Inspection - Front Tank.
^ Fuel Delivery Module Installation And Return Line Inspection - Rear Tank.
^ External Check Valve Installation And Return Line Inspection - Front Tank.
NOTE:
Perform only if fuel pressure exceeds levels specified earlier in this procedure.
2. Disconnect the vacuum line from the fuel pressure regulator, which is located on the fuel rail.
4. Remove and discard the fuel pressure regulator, gasket and 0-ring seal from the fuel rail manifold.
5. Lubricate the new fuel pressure regulator 0-ring with light oil (10W30 oil WSE-M2C903-A2 or equivalent). Install the new o-ring and the new
gasket on the new regulator.
6. Position the new fuel pressure regulator with 0-ring and gasket onto the fuel rail and install the retaining screws. Tighten the screws to 4 Nm (35
lb-in).
EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION - REAR TANK (NON-CHASSIS CAB VEHICLES)
2. Drain the rear fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or equivalent.
5. Loosen the hose clamp at the fuel filler hose connection to the rear fuel tank.
8. Access the fuel delivery module (FDM) at the top of the tank by lowering the tank while guiding the fuel filler hose from the tank.
9. NOTE: For vehicles equipped with stainless steel braided flex lines, proceed to the next step. Inspect the nylon fuel return lines for kinking.
^ If the nylon fuel return line is not kinked or the vehicle is equipped with stainless steel braided flex lines, proceed to the next step.
^ If the nylon return line is kinked, repair the line as necessary using Rotunda Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool),
before continuing this procedure.
10. NOTE: Remove and discard the black hairpin clip on 1990 and 1991 model year vehicles. A new clip will be used when reconnecting the fuel
supply line.
11. If equipped, remove and discard the old external check valve.
1992 Ford Truck F 150 2WD Pickup L6-300 4.9L Copyright © 2013, ALLDATA 10.52SS Page 8
12. Install the external check valve to the supply tube of the FDM. Install the fuel line clip onto the external check valve. See Figure 1.
13. Connect the fuel supply line to the external check valve. Install a new black hairpin clip on 1990 and 1991 model year vehicles. See Figure 1.
14. Raise the rear fuel tank back into position while guiding the fuel filler hose onto the fuel tank.
15. Install the fuel tank straps. Tighten bolts to 38 Nm (28 lb-ft).
EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION - FRONT TANK (ALL VEHICLES)
1. Drain the front fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or equivalent.
4. Loosen the hose clamp at the fuel filler hose connection to the front tank.
7. Access the FDM at the top of the tank by lowering the tank while guiding the fuel filler hose from the tank.
8. NOTE: For vehicles equipped with stainless steel braided flex lines, proceed to the next step. Inspect the nylon fuel return line for kinking.
^ If the nylon fuel return line is not kinked or the vehicle is equipped with stainless steel braided flex lines, proceed to the next step.
^ If the nylon return line is kinked, repair the line as necessary using Rotunda Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool),
before continuing this procedure.
9. NOTE: Remove and discard the black hairpin clip on 1990 and 1991 model year vehicles. A new clip will be used when reconnecting the fuel
supply line.
Disconnect the fuel supply line at the fuel delivery module. See Figure 2.
10. If equipped, remove and discard the old external check valve.
11. Install the external check valve to the supply tube of the fuel delivery module. Install the fuel line clip onto the external check valve. See Figure 2.
12. Connect the fuel supply line to the external check valve. Install a new black hairpin clip on 1990 and 1991 model year vehicles.
16. Connect the battery negative cable, then remove the memory saver.
17. Without starting the engine, turn the ignition key on and off several times to pressurize the fuel system and check for leaks.
FUEL DELIVERY MODULE REPLACEMENT AND RETURN LINE INSPECTION - REAR TANK (CHASSIS CAB VEHICLES)
2. Drain the rear fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or equivalent.
5. Loosen the hose clamp at the fuel filler hose connection to the rear fuel tank.
8. Access the fuel delivery module (FDM) at the top of the tank by lowering the tank while guiding the fuel filler hose from the tank.
9. NOTE: Remove and discard the black hairpin clip. A new clip will be used when reconnecting the fuel supply line.
Disconnect the fuel supply line, fuel return line and the electrical connector (not shown) from the FDM See Figure 3.
10. Disconnect the vapor line from the fuel tank. See Figure 3.
11. Lower the fuel tank while guiding the fuel filler hose out of the tank.
12. NOTE: For vehicles equipped with stainless steel braided flex lines, proceed to the next step. Inspect the nylon fuel return line for kinking.
^ If the nylon fuel return line is not kinked or the vehicle is equipped with stainless steel braided flex lines, proceed to the next step.
^ If the nylon return line is kinked, repair the line as necessary, using Rotunda Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool)
before continuing this procedure.
13. Clean any dirt from the top of the tank around the FDM.
15. Remove the FDM, then remove and discard the gasket.
16. Clean the FDM mounting flange on the fuel tank, then install a new gasket onto the flange.
1992 Ford Truck F 150 2WD Pickup L6-300 4.9L Copyright © 2013, ALLDATA 10.52SS Page 11
17. Install the new FDM, then install the locking ring. Tighten the locking ring to 62 Nm (46 lb-ft).
18. Raise the tank up into the vehicle, leaving enough mom to make the connections on the top of the tank.
20. Connect the fuel supply, fuel return and electrical connector to the FDM. Install a new black hairpin clip on the fuel supply line connection.
21. Raise the rear fuel tank into position while guiding the fuel filler hose into the tank.
22. Install the fuel tank support skid plate bolts. Tighten bolts 44 Nm (32 lb-ft).