To: Ford of Canada Dealers in the Atlantic, Eastern, Central, Great Lakes and Pacific Regions (except Yukon Territory)

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Marcia Stevens
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1 SAFETY RECALL 90S through 1989 Merkur XR4Ti for Replacement of the Fuel Filter and Nylon Fuel Lines from the High Pressure Frame-Mounted Fuel Pump to the Engine December 19, 1990 To: Ford of Canada Dealers in the Atlantic, Eastern, Central, Great Lakes and Pacific Regions (except Yukon Territory) Attention: Dealer Principal, Dealer Service Manager, Dealer Parts Manager Subject: Safety Recall 90S through 1989 Merkur XR4Ti for Replacement of the Fuel Filter and Nylon Fuel Lines from the High Pressure Frame-Mounted Fuel Pump to the Engine The attached dealer bulletin is provided for your information only. Perform the recall service if an affected vehicle is presented to you. You should use CARES or OASIS to determine vehicle eligibility.

2 December 19, 1990 To: Ford of Canada Dealers (in Midwestern and Western Regions and the Yukon Territory) Attention: Dealer Principal, Dealer Service Manager, Dealer Parts Manager Subject: Safety Recall 90S through 1989 Merkur XR4Ti for Replacement of the Fuel Filter and Nylon Fuel Lines from the High Pressure Frame-Mounted Fuel Pump to the Engine In CARES/OASIS - Yes Listings - Yes Recal Time Limitation - None Parts Return - No Please read and circulate these instructions to your Service and Parts Personnel. They should become familiar wtih this recall and respond to owner inquiries. Vehicles Affected 1985 through 1989 Model year Merkur XR4Ti cars sold or operated in the Midwestern and Western Regions and the Yukon Territory. Vehicles originally sold or currently identified as operating in the Midwestern and Western Regions and the Yukon Territory will be listed in CARES and OASIS. Vehicles that have been,

3 or are now, in service in the Midwestern and Western Regions and the Yukon Territory, but are not on CARES or OASIS, should also have Recall 90S17 performed. Reason For Recall Pinholes can occur in the nylon fuel line connected to the outlet of the high pressure frame-mounted fuel pump due to electrostatic discharge. This can result in fuel leakage with a potential for a fire under the car. Service Action Dealers will install steel braided, conductive Teflon fuel supply lines. The new lines will replace the non-conductive nylon fuel lines that connect the fuel pump to filter, fuel filter to forward steel line and forward steel line to fuel rail damper. Also, the nipple outlet on the high pressure fuel pump and fuel filter will be replaced. Company Contacts: (For dealer use only) Concern Nature Technical Claiming Procedures Owner Relations Attachments Attachment I Administrative Information Attachment II Labour Allowances Parts Ordering Information Attachment III Technical Information Contact Activity Technical Assistance Hotline for your Region Warranty Claims Hotline for your Region Owner Relations Hotline for your Region General Administrative Brian Moroz - Recall Administrator Telephone (416) Ext 1495 Fax (416)

4 ATTACHMENT I Safety Recall 90S17 Adminstrative Information CARES/OASIS You must use CARES or OASIS to determine if a vehicle is involved in this or another recall. Tell owners of any other recalls that may be uncompleted. Complete all recalls during a single visit by owner. Vehicles originally sold or currently identified as operating in the Midwestern and Western Regions and the Yukon Territory will be listed in CARES and OASIS. Vehicles that have been, or are now, in service in the Midwestern and Western Regions and the Yukon Territory, but are not on CARES or OASIS, should also have Recall 90S17 performed. Promptly Correct В Affected vehicles on the enclosed list. В Other affected vehicles which are brought to your dealership. Correct all affected vehicles in dealer stock before delivery to owners. Dealer-Owner Contact/Action If you are aware of any subject vehicles in your region, and the owner's name does not appear on the enclosed list immediately contact the owner and arrange a service date. Give the owner a copy of the owner letter. Dealership Responsibilities Dealers are responsible to perform this recall service promptly following presentation of the vehicle by owner. It is important that you promptly report to the "National Owner Relations Office" at Oakville any instance in which an owner will not allow you to complete this recall because of objections in scheduling or for any other reason. Reimbursement For Recall Completion And Claims Submission Instructions В Claims must be submitted for all completed units. В Claims reimbursement through the Direct Warranty Entry (DWE) system using the RECALLS screen. Use the RECALLS screen only (PF3 Recall Entry/Retrieval on the DWE Menu Screen). If the claim number contains more that six digits, enter only the last six digits.

5 Claim Form 1864 will no longer be mailed to owners. Use a Form or an authorized computer generated claim form as an internal repair order to support DWE Entry through the RECALLS screen. Ensure that only the RECALLS screen is used when inputting completion and reimbursement information. В Dealers without DWE capability must mail the second copy of a completed Form 1864 to Warranty Claims Processing at Oakville for reimbursement. Forms submitted must show all parts used and their cost, the parts handling allowance, and be imprinted, dated and signed by authorized dealership personnel. В All claims must show 90S17 in the recall box. ATTACHMENT II Safety Recall 90S17 Labour Allowances OPERATION DESCRIPTION LABOUR TIME LABOUR CODE Install New Fuel Filter and Fuel Lines 0.8 Hrs. B Administrative Allowance 0.1 Hrs. The 0.1 hour Adminstrative Allowance must be added to the total labour time before inputting. Parts Ordering Information Parts will not be direct shipped for this recall. Order requirements through your Servicing Parts Distribution Centre. PART NUMBER F1DZ-9155-A В Fuel Lines and Filter Kit Kit Contains: DESCRIPTION One "PUMP-TO-FILTER" Fuel Line One "SUPPLY-TO-ENGINE" Fuel Line One "FILTER-TO-SUPPLY-LINE" Fuel Line Three tie straps (95874-S) One copper washer (E6TZ-9374-A) One fuel pump nipple (E6TZ-9416-A) One fuel filter (FG-872) Instruction Sheet ATTACHMENT III Safety Recall 90S17

6 Technical Instructions The new stainless steel reinforced TeflonВ fuel lines replace the three nylon fuel lines that connect the fuel pump to filter, fuel filter to forward steel line and forward steel line to fuel rail damper. The existing in-line fuel filter and high pressure fuel pump outlet fitting will also be replaced. Fuel System Pressure Relief - EFI Engines CAUTION Fuel supply lines on EFI engines will remain pressurized for some period of time after the engine is shut off. This pressure must be relieved before servicing of the fuel system. Before opening the fuel supply system, relieve fuel pressure as follows: 1. Remove fuel tank cap. 2. Disconnect the vacuum hose from the fuel pressure regulator located on the engine fuel rail. 3. Using a hand vacuum pump, apply about 84.2kPa (25 in Hg) of vacuum to the pressure regulator. Refer to Figure 1. Figure 1 Fuel pressure will be released into the fuel tank through the fuel return hose. When using a vacuum pump to relieve system pressure, it may take up to 3 minutes, to bleed system pressure. 4. After the fuel pressure has been released, disconnect the vacuum pump and reconnect the vacuum hose disconnected in step 2 above.

7 5. Install and tighten fuel tank cap after pressure is relieved. 6. Disconnect battery ground cable. 7. Raise vehicle on hoist. Refer to the Shop Manual, Section 50-04, Hoisting, Jacking and Towing. High Pressure Fuel Lines And High Pressure Fuel Pump Filter Replacement CAUTION Fuel lines may still contain fuel. Use caution when disconnecting. 1. Disconnect the "Push Connect" fittings at: the high-pressure pump outlet nipple the filter inlet the filter outlet the steel fuel line to which the filter outlet line connects by removing the hairpin clip and twisting the line while pulling on it. 2. Remove the filter cover attaching screws (2 screws). 3. Remove the filter cover and filter. 4. Remove the filter. Remove both end seals from the filter. Discard the filter. 5. Position the two end seals, removed from the old filter, on each end of the new fuel filter (FG- 872) and install the filter in the cover observing the direction of fuel flow. (Outlet will be through open end of cover.) 6. Position the cover on the filter and pump mounting bracket. Install and hand tighten securely the two attaching screws (removed in step 2). The attaching screws tighten into plastic. Do not over-tighten. 7. Using a 16 mm wrench for the fitting and a 14 mm wrench (on the boss of the fuel pump) for backup, unscrew outlet nipple from the front of the high pressure fuel pump. Discard nipple and copper sealing washer. 8. Install new copper washer (E6TZ-9374-A) on the new fuel pump nipple (E6TZ-9416-A). Screw this new nipple into the pump. Using a deepwell socket torque to N-m (9-12 lbs.ft.), while keeping a 14 mm wrench (on the boss of the fuel pump) for backup. 9. Remove the topmost pump mounting bracket attaching screw. 10. Remove the shipping plug on fuel pump nipple. 11. Select the fuel line assembly labelled "PUMP-TO-FILTER". Remove shipping plugs if present. Install one end of the fuel line to the fuel pump outlet nipple. CAUTION Push firmly onto nipple until distinct click is heard or felt. Firmly pull on line to test for and confirm retention (see Figure 2).

8 Figure 2 - Fuel Line Installation/Removal In the event the new fuel line has to be removed, ease the fuel fitting onto the fuel tube until it bottoms. Fully depress the plastic release collar into the fitting end. While maintaining pressure on the release collar slightly twist the fitting and pull it off the tube (refer to Figure 2), 12. Route the tube rearward above the high pressure fuel pump behind the mounting bracket above the foam. 13. Install the other end to the fuel filter (inlet end).

9 CAUTION Push firmly onto nipple until distinct click is heard or felt. Firmly pull on line to test for and confirm retention (see Figure 2). 14. Ensure the fuel line is routed so it will not contact body sheet metal and that it is seated between the foam and pump mounting bracket (see Figure 3). Install and tighten the pump mounting bracket attaching screw (previously removed in step 9). Figure 3 - Fuel Line Routing From Fuel Pump To Filter Line, Filter To Supply Line (Steel Frame Line) And Strap Location 15. Select the fuel line assembly labeled "FILTER-TO-SUPPLY LINE". 16. Install one end to the fuel filter outlet and the other end to the steel supply line (see Figure 3). 17. Tightly strap (using one S strap) the pump outlet and filter outlet lines to ensure free gentle routing and that lines do not contact body sheet metal. Cut off excess tie strap length (see Figure3). 18. Lower vehicle. 19. Disconnect both "Push Connect" fittings on the forward nylon fuel line that connects the steel supply line to the Fuel Rail Pulse Damper by removing the hairpin clips. Remove by twisting the line at each connection point while pulling on it. 20. Select the fuel line assembly labelled "SUPPLY-TO-ENGINE". 21. Install the fuel line to the steel supply line and engine Fuel Rail Pulse Damper. Ensure the fuel line routed clear of brake lines, etc. and is located behind the wiring for the master cylinder sensor and adjacent to the large vacuum hose (see Figure 4).

10 Figure 4 - Fuel Line Routing And Strapping Of Fuel Line To Large Engine Vacuum Line CAUTION Push firmly onto nipple until distinct click is heard of felt. Firmly pull on line to test for and confirm retention (see Figure 2). 22. Tie strap the fuel line to the large vacuum hose (see Figure 4). 23. Reconnect battery ground cable. 24. Cycle ignition to "ON" position 5 times at 2 second intervals to prime the fuel system. Inspect all fuel line connections for leaks (correct as required). 25. Start engine and while engine is running reinspect the fuel system for leaks (correct as required). 26. Mutilate and scrap all removed parts.

11 December 1990 Serial Number: XXXXXXXXXXXXXX 90S17 Customer Name 123 Main Street City PR ANA NAN This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act of Canada. Ford Motor Company of Canada, Limited (Ford) has determined that certain Merkur XR4Ti cars in areas of Canada in which severe low temperature, low humidity winter weather is experienced may develop leaks in a fuel line. Our records indicate you own the 198X Merkur XR4Ti bearing the serial number shown above your name. Reason For Recall A short fuel supply tube, located beneath the vehicle on the driver's side, could develop a pin hole in the tubing wall. If this condition occurs, fuel will leak and a fire could result. Repairs At no cost to you, your dealer will replace this fuel supply tube with one of a different material. A new fuel filter and some adjoining fuel line parts will also be installed. How Long Will It Take? The time needed to repair your vehicle is less than one hour. However, due to service scheduling times, your dealer may need your vehicle for a full day. Call Your Dealer Call your dealer without delay and ask for a service date. Also ask your dealer to check the CARES / OASIS systems for any outstanding recalls. Your dealer has the service and parts ordering information needed to repair your vehicle. If parts are not in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your vehicle in, show the dealer this letter. If you lose the letter, your dealer will still do the work, free of charge. Changed Name, Address, Or Sold The Vehicle? If you have changed your name or address, or have sold the vehicle, please fill out the enclosed prepaid postcard and mail it to Ford. If you cannot get the recall service performed, contact the "National Owner Relations Office" or the nearest Ford of Canada Regional Office. The addresses and telephone numbers for these offices are shown in your vehicle's Owner Guide. Your Ford or Lincoln Mercury dealer can also give you this information. Please identify your vehicle's serial number in any correspondence. We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your vehicle.

12 SAFETY RECALL 90S17 CPR В 1990 FORD MOTOR COMPANY Published By: Recall/Service Programs Department Ford Customer Service Division

This Field Service Action expired on January 31, 2001.

This Field Service Action expired on January 31, 2001. OWNER NOTIFICATION PROGRAM 99B28 Certain 1999 & 2000 Model Year F-250 Super Duty Through F-550 Super Duty, 1999 F-Super Duty Stripped Chassis & 1999