Print CUSTOMER SATISFACTION PROGRAM 02M01 - TUBE-MOUNTED EGR PRESSURE SENSOR (9J460) REPLACEMENT SERVICE CAMPAIGN BULLETIN Reference Number(s): 02M01 Supplement # 6, Date of Issue: June 2004 FORD/LINCOLN/MERCURY: Certain vehicles equipped with a tube-mounted EGR Pressure Sensor Superceded Bulletin(s): 02M01 Supplement # 5, Date of Issue: April 2004 CUSTOMER SATISFACTION PROGRAM 02M01 SUBJECT Customer Satisfaction Program 02M01 Supplement # 6: Certain vehicles equipped with a tube-mounted EGR Pressure Sensor - Additional EGR Pressure Sensor Warranty Coverage REF Customer Satisfaction Program 02M01 Supplement # 5 dated April 2004 - Certain vehicles equipped with a tube-mounted EGR Pressure Sensor - Additional EGR Pressure Sensor Warranty Coverage OASIS Yes OWNER LIST No PROGRAM TERMS This additional coverage program will add 2 years or 24,000 miles, whichever occurs first, to the base warranty coverage for the tube-mounted EGR Pressure Sensor. This coverage will automatically transfer to subsequent owners. REASON FOR THIS SUPPLEMENT
This bulletin is being re-issued to provide additional information on 2002 2.0L Zetec Focus vehicles. Some of these vehicles, which are equipped with a dash mounted EGR pressure sensor (vs. the tube mounted EGR pressure sensor), were inadvertently included in this program. Ford will honor the warranty extension on the dash mounted EGR pressure sensors for these vehicles. If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. VEHICLES COVERED BY THIS PROGRAM Certain 2000 through 2003 model year vehicles equipped with a tube-mounted EGR Pressure Sensor (9J460). Refer to Reason For This Supplement section above for additional vehicles covered by this program. TIME AND MILEAGE LIMITS TIME AND MILEAGE LIMITS Warranty Type Current Warranty Coverage Total (9J460) Warranty Coverage Federal 3 Years/36,000 Miles 5 years/60,000 Miles California Emissions 3 Years/50,000 Miles 5 Years/74,000 Miles Lincoln 4 Years/50,000 Miles 6 Years/74,000 Miles (1) California emissions include vehicles certified for sale in California and registered in California, Maine, Massachusetts, New York or Vermont. REASON FOR PROVIDING ADDITIONAL COVERAGE Vehicles experiencing a problem with the tube-mounted EGR Pressure Sensor may exhibit a Malfunction Indicator Light (MIL) along with one or more of Diagnostic Trouble Codes (DTC) P0401, P0402, P1400, or P1401. A very small percentage of vehicles may also exhibit a MIL with the following symptoms: Hesitation/Surge Stall with restart None of these conditions will cause engine damage or failure, but they may decrease the customer's satisfaction with their vehicle. SERVICE ACTION It is recommended for vehicles exhibiting any of the conditions listed above and equipped with a tube mounted EGR Pressure Sensor, that the dealer retrieve continuous DTCs prior to performing any other diagnostics. Dealers are to install a new tube-mounted EGR Pressure Sensor at no charge to the owner of the vehicle, ONLY if one or more of these continuous DTCs are present: P1400 - DPF EGR Sensor Circuit Low Voltage Detected P1401 - DPF EGR Sensor Circuit High Voltage Detected P0401 - EGR Flow Insufficient Detected P0402 - EGR Flow Excessive Detected
A failed DPFE will only exhibit one or more of the DTCs listed above. This program will not cover any other continuous DTCs, if present. ATTACHMENTS Attachment I: Administrative Information Attachment II: Labor Allowances and Parts Ordering Information Attachment III: Technical Information Customer Notification Letters QUESTIONS? Claims Information:...1-800-423-8851 Other (Dealer Only) Program Questions:...1-800-325-5621 ATTACHMENT I Customer Satisfaction Program 02M01-S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage OASIS You must use OASIS to determine if a vehicle is eligible for this program. NOTE: Submission of an "M" program claim will not remove the vehicle from OASIS because the affected vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended warranty time/mileage period. CLAIMS PREPARATION AND SUBMISSION Enter claims using Direct Warranty Entry (DWE). Refer to ACESII manual for claims preparation and submission information. Refunds must be claimed on a repair line that is separate from the repair line that the FSA is claimed on. CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03 Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for this repair under the 02M01 program.
1. Vehicles within New Vehicle Warranty Coverage - Claims are to be submitted as a normal warranty claim in accordance with TSB. 2. Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles) - Claims are to be submitted following program 02M01 guidelines. 3. Future Warranty Extension Customer Satisfaction Programs (CSP) - Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside the New Vehicle Warranty Coverage will be submitted as a CSP type repair. OWNER REFUNDS Ford Motor Company will only refund owner-paid repairs made on or before the last day of the month of 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). Failure of the EGR Pressure Sensor (9J460) will not have an impact on any other component of the vehicle. Therefore, refunds will only be granted for the replacement of the EGR Pressure Sensor (9J460). All supporting documentation must be retained in accordance with the Warranty and Policy Manual. 1. Program Code: 02M01 2. Misc. Expense: REFUND 3. Misc. Expense: ADMIN 4. Misc. Expense: 0.2 Hr. Refer to ACESII manual for refund information. RENTAL VEHICLES The use of rental vehicles is not authorized for this program. ATTACHMENT II Customer Satisfaction Program 02M01- S6 Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure Sensor Warranty Coverage LABOR ALLOWANCES LABOR ALLOWANCES Labor Labor Description Operation Time Retrieve one or more of the following Continuous DTCs, P1400, P1401, P0401 or P0402, clear codes and replace tube-mounted EGR Pressure Sensor, perform KOEO & KOER self test. 02M01C 0.4 hr. NOTE: 0.6 hr. labor time will be paid for Econoline and Town Car, and 0.5 hr. labor time will be paid for Crown Vic/Grand Marquis, Expedition, and 4.6L Explorer/Mountaineer. NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. Special Notes:
02M01C labor operation is in effect for repairs performed on or after 10/27/03. Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program. Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor time has been adjusted accordingly. Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs. There will be no related damage claims allowed for this program. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirement through normal order processing. PARTS REQUIREMENTS / ORDERING INFORMATION PARTS REQUIREMENTS / ORDERING INFORMATION Part Number Description Quantity 4U7Z- 9J460- AA Tube- Mounted EGR Pressure Sensor Affected Vehicles 1 2000-2002 3.0L 4V Taurus/Sable2001-2002 2.0L (Zetec) Escape2001-2002 2.5L Cougar2001-2002 3.0L 2V (OHV & FFV) Taurus/Sable*2001-2002 3.8L Mustang2001-2002 4.2L F-Series2001-2002 4.2L Econoline2001-2002 4.6L Crown Vic/Grand Marquis2001-2002 4.6L Town Car2001-2002 2.0L (Zetec) Focus* (See Note)2001-2002 3.0L 4V Escape*2001-2002 3.8L Windstar*2001-2002 4.0L Ranger*2001-2002 4.0L Explorer Sport*2001-2002 4.0L Explorer Sport Trac*2002 4.0L Explorer/Mountaineer2001 Explorer Stripped Postal Chassis*2001-2002 4.6L F-Series*2002-2003 4.6L Explorer/Mountaineer2001-2002 4.6L Expedition*2001-2002 4.6L Econoline**2M5Z-9J460-AA Tube Mounted EGR Pressure Sensor Kit may be used, while supplies last, for these vehicle applications. NOTE: If service is requested on a dash mounted EGR pressure sensor (during the extended warranty coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service Support Center. DEALER PRICE For latest prices, check DOES II or updated price book. PARTS RETENTION Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return Procedures." 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
CUSTOMER SATISFACTION PROGRAM 02M01-S6 TUBE-MOUNTED EGR PRESSURE SENSOR (9J460) REPLACEMENT AFFECTED VEHICLES CERTAIN 2000 THROUGH 2003 MODEL YEAR VEHICLES EQUIPPED WITH TUBE-MOUNTED EGR PRESSURE SENSOR SERVICE PROCEDURE NOTE: If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is encountered, call the Special Service Support Center. 1. Retrieve continuous DTCs. NOTE: Replace the EGR pressure sensor only if one or more of the following continuous DTCs are present: 1. P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED 2. P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED 3. P0401 - EGR FLOW INSUFFICIENT DETECTED 4. P0402 - EGR FLOW EXCESSIVE DETECTED 5. Any other DTC present is not covered by this program. 2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as follows: 1. Key off. 2. Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube. 3. Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector. NOTE: Refer to Section 303-08 of the appropriate workshop manual if additional information is required. 3. Clear continuous DTCs. 4. Perform KOEO and KOER self tests. CUSTOMER NOTIFICATION LETTER