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Article No.
02-16-4

08/19/02

^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO
SPEAKER

^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL
PUMP

^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO

FORD:
1990-1994 TEMPO
1990-1997 ESCORT, PROBE, THUNDERBIRD
1990-1998 MUSTANG
1990-1999 TAURUS
1990-2002 CROWN VICTORIA
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD
1990-2002 ECONOLINE, F-150, RANGER
1991-2002 EXPLORER
1995-2002 WINDSTAR
1997-2003 EXPEDITION
1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT
2001-2002 ESCAPE

LINCOLN:
1990-1992 MARK VII
1990-1994 CONTINENTAL
1990-2002 TOWN CAR
1998-2003 NAVIGATOR
2002 BLACKWOOD

MERCURY:
1990-1994 TOPAZ
1990-1997 COUGAR
1990-1999 SABLE
1990-2002 GRAND MARQUIS
1991-1997 TRACER
1997-1999 MYSTIQUE
2001 SABLE
1993-2002 VILLAGER
1997-2002 MOUNTAINEER

TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage.

ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.

ACTION
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details.

NOTE
IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP. ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION.

NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES.

NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS.

TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position).

2. Turn the ignition key to the Run position (do not start the engine).

3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help.

Parts Block
F1PZ-18B925-A - Radio Frequency Interference (RFI) Filter
95873-S101 - Bundling Strap
F5AZ-14A099-AA - Heat Shrink Tubing

OTHER APPLICABLE ARTICLES: NONE

SUPERSEDES: 01-7-3

WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage

OPERATION: 021604YA
DESCRIPTION: Diagnose And Install RFI Filter 2001-2002 Escape
TIME: 0.8 Hr.

DEALER CODING
BASIC PART NO.: 18B925
CONDITION CODE: 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300

Service Procedure
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure.

2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING
(ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN
THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND
PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON
ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING.


3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING
(ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK
APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN
THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND
PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON
ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING.


4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2.

5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER
APPLICATIONS.

6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump.

7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual.

 

[Squishy]

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09-001/03

1991-2002 Navajo, B-Series, Tribute - WHINING BUZZING NOISE FROM RADIO SPEAKERS

Note:
This bulletin supersedes the following TSB(s): 09-015/01. Please update your records accordingly.

BULLETIN NOTE:
This bulletin supersedes 09-015/01, issued 12/21/01. The APPLICABLE MODEL(S)/VINs and PART(S) INFORMATION have been changed.

APPLICABLE MODEL(S)/VINs
All 1991-94 Navajo
All 1994-02 B-Series (excludes all Flexible Fuel (FFV) B-3000).
2001-2002 Tribute

DESCRIPTION
A whining or buzzing noise can be heard coming from the audio system speakers. This may be caused by an electrical noise coming from the in-tank fuel pump or its ground wire. A Radio Frequency Filter (RFI) is available to correct this concern. Customers having this concern should have their vehicle repaired using the following procedure.

NOTE:
^ Do not perform the following procedure on FFV B-3000 vehicles, this procedure does not apply. To verify if vehicle is FFV, check 8th digit of VIN.
^ If 8th digit is V then vehicle is FFV.
^ If 8th digit is U then vehicle is not FFV.
^ Fuel pump audio noise is relatively constant and changes only slightly with engine RPMs. If the audio noise constantly changes with the engine RPMs, the fuel pump is not the cause of the problem and the RFI filter will not effectively reduce the noise.

Customers having this concern should have their vehicle repaired using the following procedure.

REPAIR PROCEDURE
1. Verify customer concern.
a. Turn the key to the "ACCESSORY" position and turn ON the audio unit, tune the radio to a station with clear reception.
b. Turn the ignition to the "RUN" position (do not start the engine).
c. The fuel pump should run for about 1 second with the key in the "RUN" position with the engine not running. Listen for electrical noise in the speakers of the audio system.
^ If noise is present while the pump is running and stops when the pump stops, then the fuel pump is generating the noise. Proceed to STEP 2.
^ If noise is not present when the pump is running, or is constant even when the fuel pump quits running, then the noise source may not be the fuel pump. Refer to PINPOINT TEST 2: NOISY RECEPTION of the applicable Workshop Manual for additional troubleshooting and repair procedures.

2. Remove the fuel pump sending unit from the fuel tank. Refer to Workshop Manual (section F or 01) for removal procedure.


3. Remove the black (negative) and red (positive) connectors from the fuel pump.

4. Cut the black and red wires to the fuel pump 3 inches (76 mm) below the flange of the fuel pump.


5. Solder both the red and black wires of the RFI Filter to the red and black wires below the flange. Use heat shrink tubing over the solder connectors.
NOTE:
Heat shrink tubing must be used over all solder connections; covering the entire soldered area to prevent exposure.
WARNING:
All soldering and heat shrinking steps should be performed AWAY from the fuel tank area.

6. Connect the RFI filter connectors to the spade terminals on the fuel pump.
NOTE:
If RFI connectors do not fit to spade connectors on fuel pump; cut the connectors from the RFI filter and cut the fuel pump wires 1" (25 mm) above the pump wire connectors. Solder both the red and black wires from the RFI Filter to the red and black fuel pump wires.

7. Secure the RFI filter to the fuel pump assembly with a plastic tie-wrap to prevent rattling.

8. Install fuel pump assembly into fuel tank. Refer to Section 01-14 for installation procedures.
NOTE:
Do not reuse the fuel pump gasket, replace with a new gasket prior to reassembly.

9. Verify that the noise is reduced by using the testing procedure in (STEP 1).
^ If noise has been reduced, return vehicle to the customer.
^ If noise has not been reduced, proceed to (STEP 10).

10. Locate fuel pump ground wire (black) in the wiring harness on the left frame rail.

11. Locate one (1) unused 12 mm hole in the left side frame rail between the fuel pump and the fuel filter.


12. Clean and remove some of the finish in this area to ensure a good metal-to-metal electrical connection.

13. Cut the fuel pump ground wire to prevent it from acting as an antenna.
^ 1991-94 Navajo and 1994 B-Series-) Cut the fuel pump ground as close to the 12 mm frame rail hole as possible.
^ 1995 -) 97 B-Series-) Cut the fuel pump ground wire just before the X1007 connector. Seal the back of the X1007 connector with silicone sealant to prevent water from entering.
^ 1998-99 B-Series -) Cut the fuel pump ground wire just before the X-304 connector. Seal the back of the X304 connector with silicone sealant to prevent water from entering.

14. Attach an eyelet connector to the fuel pump side of the ground wire and secure the wire to the frame rail with a bolt, nut and washer, at the 12 mm hole.

15. Cover the ground with rust-proofing paint to prevent corrosion.
NOTE:
Corrosion protection is important since this wire is the operating ground for the fuel pump.

16. Verify repair.

PART(S) INFORMATION
ZZL0-66-950 - RFI Filter - Qty. 1
9X09-58-73A1 - Tie-Wrap - Qty. 1
AJ03-13-VT8 - Heat Shrink Tubing - as needed - 25 ft. roll (non-warrantable) shop supply
ZZL0-13-449 - Fuel Pump Gasket - Qty. 1 - 1990-97 B-Series w/steel fuel pump ring (T=3mm)
ZZM0-13-449 - Fuel Pump Gasket - Qty. 1 - 1993-97 B-Series w/plastic fuel pump ring (T=4mm)
ZZP0-13-449 - Fuel Pump Gasket - Qty. 1 - 1998-99 B-Series (T=3.5mm)
EC01-42-166 - Fuel Pump Gasket - Qty. 1 - 2001-2002 Tribute
Obtain Locally - Eyelet Connector - Qty. 1 - As needed

WARRANTY INFORMATION
Warranty Type: A
Symptom Code: 57
Damage Code: 9Q
Part Number Main Cause: SEE PART(S) INFORMATION
Quantity: 1
Operation Number / Labor Hours: YY269XRX / 0.8 (Tribute)

NOTE:
This information applies to verified customer complaints on vehicles covered under normal warranty. Refer to the SRT microfiche for warranty term information.