Emission Recall 15E06

SUBJECT

Emission Recall 15E06 - Supplement #1

Certain 2004 E-Series Vehicles with 5.4L Engine

Powertrain Control Module Reprogramming

REASON FOR THIS SUPPLEMENT

Affected Vehicles: The population has been expanded to include additional vehicles.
Service Action: IDS release 99.04 or higher is required to repair vehicles in the expanded population.

AFFECTED VEHICLES

Vehicle	Model Year	Assembly Plant	Build Dates
E-Series	2004	Lorain	June 24, 2003 through July 30, 2004

Affected vehicles are identified in OASIS and FSA VIN Lists.

REASON FOR THIS EMISSION RECALL

In all of the affected vehicles, a powertrain calibration flaw is present that may prevent the Catalyst Monitor from achieving a "Ready" condition. There is no perceivable impact on vehicle operation. However, the vehicle may not be able to complete emissions certification requirements in some states. Without completed emissions certification, certain states may not renew vehicle registrations.

SERVICE ACTION

Dealers are to reprogram the Powertrain Control Module (PCM) using Integrated Diagnostic System (IDS) release 99.04 or higher. This service must be performed at no charge to the vehicle owner.

NOTE: No additional action is required for vehicles previously repaired under this program.

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 this emission recall has been performed. These certificates may be obtained by contacting your regional office.

OWNER NOTIFICATION MAILING SCHEDULE

Owner Letters were mailed the week of November 19, 2015. Owner letters for the additional vehicles are expected to be mailed the week of March 28, 2016 . Dealers should repair any affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.

ATTACHMENTS

Attachment I: Administrative Information
Attachment II: Labor Allowances and Parts Ordering Information
Attachment III: Technical Information

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.

OASIS ACTIVATION

OASIS was activated on October 8, 2015. OASIS will be activated for the additional vehicles on March 17, 2016.

FSA VIN LISTS ACTIVATION

FSA VIN lists became available through https://web.fsavinlists.dealerconnection.com on October 8, 2015. Revised FSA VIN Lists will be available by March 17, 2016. Owner names and addresses for the additional vehicles will be available by April 8, 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 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 LABOR TIME AND/OR PARTS

Submit a request to the SSSC Web Contact Site prior to the repair if you have any of the following:

Damage that you believe was caused by the covered condition.
A condition that requires additional labor and/or parts to complete the repair.
Aftermarket equipment or non-Ford modifications to the vehicle which might prevent the repair of the covered condition.

Requests for approval after completion of the repair may not be granted. Ford Motor Company reserves the right to deny coverage for related damage in cases where the vehicle owner has not had this recall performed on a timely basis. Additional related damage parts are subject to random selection for return to the Ford Warranty Parts Analysis Center (WPAC).

OWNER REFUNDS

Refunds are not approved for this program.

RENTAL VEHICLES

The use of rental vehicles is not approved for this program.

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 15E06 is the sub code.
Additional labor and/or parts must be claimed as related damage on a repair line that is separate from the repair line on which the FSA is claimed. Additional labor and/or parts require prior approval from the SSSC via the SSSC Web Contact Site.

NOTE: Maintain supporting documentation for all Miscellaneous Expenses according to procedure as identified in the Warranty and Policy Manual.

LABOR ALLOWANCES

Description	Labor Operation	Labor Time
Reprogram the PCM using IDS release 99.04 or higher	15E06B	0.3 Hours

PARTS REQUIREMENTS / ORDERING INFORMATION

Parts are not required to complete this repair.

OVERVIEW

In all of the affected vehicles, a powertrain calibration flaw is present that may prevent the Catalyst Monitor from achieving a "Ready" condition. There is no perceivable impact on vehicle operation. However, the vehicle may not be able to complete emissions certification requirements in some states. Without completed emissions certification, certain states may not renew vehicle registrations. Dealers are to reprogram the Powertrain Control Module (PCM) using the following procedure.

SERVICE PROCEDURE

Module Reprogramming

NOTE: Reprogram appropriate vehicle modules before performing diagnostics and clear all Diagnostic Trouble Codes (DTCs) after programming. For DTCs generated after reprogramming, follow normal diagnostic service procedures.

Connect a battery charger to the 12V battery.
Reprogram the PCM using IDS release 99.04 or higher .
NOTE: Calibration files may also be obtained at www.motorcraftservice.com.

NOTE: Follow the IDS on-screen instructions to complete the reprogramming procedure.
Disconnect the battery charger from the 12V battery, once the reprogramming has completed.

Important Information for Module Programming

NOTE: When programming or reprogramming 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 IDS/scan tool to a power source.
Inspect Vehicle Communication Module (VCM) and 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.
Disconnect/depower any aftermarket accessories (remote start, alarm, power inverter, CB radio, etc.).
Follow all scan tool on-screen instructions carefully.
Disable IDS/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: NEVER DELETE THE ORIGINAL SESSION!

Obtain the original IDS that was used when the programming error occurred during Module Reprogramming (MR) or Programmable Module Installation (PMI).
Disconnect the VCM from the Data Link Connector (DLC) and the IDS.
Reconnect the VCM to IDS and then connect to the DLC. Once reconnected, the VCM icon should appear in the corner of the IDS screen. If it does not, troubleshoot the IDS to VCM connection.
Locate the ORIGINAL vehicle session when programming failed. This should be the last session used in most cases. If not, use the session created on the date that the programming failed.
NOTE: If the original session is not listed in the previous session list, click the "Recycle Bin" icon at the lower right of the previous session screen. This loads any deleted sessions and allows you to look through them. Double-click the session to restore it.
Once the session is loaded, the failed process should resume automatically.
If programming does not resume automatically, proceed to the MODULE PROGRAMMING menu and select the previously attempted process, PMI or MR.
Follow all on-screen prompts/instructions.
The last screen on the IDS may list additional steps required to complete the programming process. Make sure all applicable steps listed on the screen are followed in order.

Emission Recall 15E06 - 5.4L Engine Powertrain Control Module Reprogramming (15E06)