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Article No.
01-4-3

03/05/01
^ FUEL - FUEL ODOR - FUEL SMELL FROM
PASSENGER COMPARTMENT - VEHICLES
EQUIPPED WITH 3.0L 4 - VALVE DURATEC ENGINE
ONLY - UPDATED LOWER INTAKE MANIFOLD
GASKETS

^ CLIMATE CONTROL - ODOR - FUEL SMELL FROM
PASSENGER COMPARTMENT THROUGH VENTS -
VEHICLES EQUIPPED WITH 3.0L 4 - VALVE
DURATEC ENGINE ONLY - UPDATED LOWER
INTAKE MANIFOLD GASKETS

^ ENGINE - FUEL ODOR - FUEL SMELL FROM
PASSENGER COMPARTMENT THROUGH VENTS -
VEHICLES EQUIPPED WITH 3.0L 4-VALVE
DURATEC ENGINE ONLY - UPDATED LOWER
INTAKE MANIFOLD GASKETS

FORD:
2000-2001 TAURUS 2001 ESCAPE

MERCURY:
2000-2001 SABLE

This article applies to 2000-2001 Taurus/Sable vehicles with 3.0L 4V Duratec engine built through 4/1/2001 and 2001 Escape vehicles with 3.0L 4V Duratec engine built through 6/1/2001 only.

ISSUE
Some vehicles may exhibit a fuel odor noticed through the vents inside the vehicle. The odor may be noticed upon initial startup after "Hot Soak". This condition produces a fuel odor only and does not involve visible fuel or include the presence of a combustible mixture. This may be caused by the lower intake manifold gaskets.

ACTION
If fuel odor condition is verified and no fuel leaks or mechanical problems are found, replace the lower intake gaskets with revised gaskets. Refer to the following Service Procedure.

PART NUMBER: YF1Z-9439-AC
PART NAME: Gasket Set - Lower Intake Manifold

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208999, 404000, 499000

Remove and Replace Gaskets
Remove and replace the production YF1Z-9439-AB silicone lower intake manifold gaskets with new YF1Z-9439-AC Fluorocarbon Gaskets.

NOTE
THIS PROCEDURE ONLY APPLIES TO THE 3.0L 4V DURATEC ENGINE.

NOTE
DO NOT REUSE ORIGINAL GASKETS.

2001 Escape Lower Intake Manifold Removal
1. Relieve fuel system pressure (refer to Section 310-00 of the Escape Workshop Manual).

2. Disconnect the fuel line spring lock (Section 310-00).

3. Remove the upper intake manifold (Section 303-01B).

4. Disconnect the fuel injection supply manifold.
a. Disconnect the fuel injector electrical connectors (Figure 1, View A).
b. Disconnect the fuel pressure damper line (Figure 1, View B).


5. Remove the bolts in the sequence shown (Figure 2), and remove the lower intake manifold assembly.


6. Remove and discard the six (6) silicone gaskets from the lower intake manifold assembly.

2001 Escape Lower Intake Manifold Installation
1. Install the six (6) new fluorocarbon gaskets in the tower intake manifold assembly.

2. Install the lower intake manifold assembly and tighten the bolts in the sequence shown (Figure 3).


3. Connect the fuel injection supply manifold.
a. Connect the six (6) fuel injector electrical connectors (Figure 1 View A).
b. Connect the fuel pressure damper vacuum line (Figure 1, View B).

4. Connect the fuel line spring lock coupling (Section 310-00).

5. Install the upper intake manifold (Section 303-01B).

 

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Bulletin No: 01-001/01

Last Issued: 02/28/2001

Subject:
FUEL ODOR INSIDE PASSENGER COMPARTMENT

APPLICABLE MODEL(S)/VINs
All 2001 Tributes with 3.0L Duratec engine.

DESCRIPTION
Some vehicles may exhibit a fuel odor coming from the vents inside the vehicle. The odor is most noticeable after starting the vehicle after a "hot soak." This condition produces only a fuel odor and does not involve visible fuel or include the presence of a combustible mixture. This may be caused by the lower intake manifold silicone gaskets. Modified fluorocarbon gaskets are available to resolve this concern.

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

REPAIR PROCEDURE
1. Verify customer concern.

2. Relieve fuel system pressure (section 01-14 FUEL SYSTEM PRESSURE RELEASE).

3. Disconnect fuel line spring lock (section 01-14 SPRING LOCK COUPLINGS).

4. Remove upper intake manifold (section 01-13B UPPER INTAKE MANIFOLD REMOVAL).

5. Disconnect fuel injection supply manifold using the following steps:
A. Disconnect fuel injector electrical connectors.
B. Disconnect fuel pressure damper line.


6. Remove the bolts in the sequence shown and remove lower intake manifold assembly.


7. Remove and discard the six silicone gaskets from lower intake manifold assembly.

8. Install six new fluorocarbon gaskets in the lower intake manifold assembly.
Caution:
DO NOT reuse original gaskets.

9. Install lower intake manifold assembly and tighten bolts in sequence shown.


10. Connect the fuel injection supply manifold.
A. Connect six fuel injector electrical connectors.
B. Connect fuel pressure damper vacuum line.

11. Connect fuel line spring lock coupling (section 01-14 SPRING LOCK COUPLINGS - CONNECT).

12. Install upper intake manifold (section 01-13B UPPER INTAKE MANIFOLD INSTALLATION).

13. Verify repair.

PART(S) INFORMATION
AJ03-13-111A - Intake Manifold Gasket - Qty. 6

WARRANTY INFORMATION
Warranty Type: A
Symptom Code: 84
Damage Code: 9E
Part Number Main Cause: SEE PART(S) INFORMATION
Quantity: 6
Operation Number / Labor Hours: YY247XRX / 1.5

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