EMISSIONS RECALL
93E45
Exhaust System Catalyst Replacement & Emissions Control
System Modifications on Certain 1986/87 - Model Fed. &
1988/89 - Model Fed. & Can. T'Bird Turbo Coupe/Cougar
XR7 & Merkur XR4Ti Cars Equipped with 2.3L
Turbocharged Engines
To:
All Dealers
Subject:
Emissions Recall 93E45 - Exhaust System Catalyst Replacement and Emissions Control System Modifications
on Certain 1986/87 - Model Federal and 1988/89 - Model Federal and Canadian Thunderbird Turbo
Coupe/Cougar XR7/ and Merkur XR4ti Cars Equipped with 2.3L Turbocharged Engines
Affected Vehicles
1986/87 - Model Federal and 1988/89 - Model Federal and Canadian Thunderbird Turbo Coupe/Cougar XR7
and Merkur XR4ti cars equipped with 2.3L turbocharged engines having calibration codes 6-05R-R00, 6-06ER01 and 7-05E-R00/R10 and 7-06E-R10/R11.
Reasons For Recall
The Environmental Protection Agency (EPA) and Ford have conducted in-use tests on some of the affected
cars and have determined that they may be releasing exhaust emissions which exceed Federal and Canadian
standards.
Service Action
Cars returned for service will have exhaust system catalysts replaced, a vacuum delay valve installed in the
exhaust gas recirculation (EGR) vacuum line and Authorized Modifications and Special Service Information
labels attached at no-charge to owners.
Attachments
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Attachment I
{ Administrative Information
Attachment II
{ Labor Allowances
{ Parts Ordering Information
Attachment IIIA
{ Technical Information for 1986 model Federal Thunderbird Turbo Coupe and Cougar XR7 - 2.3L
Turbo Engines having calibration 6-06E-R01 and Automatic Transmissions
Attachment IIIB
Technical Information for 1987 model Federal and 1988 model Federal and Canadian Thunderbird
Turbo Coupe - 2.3L Turbo Engines having calibration 7-06E-R10 and R11 and Automatic
Transmissions
Attachment IIIC
{ Technical Information for 1987 model Federal and 1988 model Federal and Canadian Thunderbird
Turbo Coupe - 2.3L Turbo Engines having calibration 7-05E-R00 and R10 and Manual
Transmissions
Attachment IIID
{ Technical Information for 1986, 87, 88, 89 - model Federal and 1988 and 1989 model Canadian
Merkur XR4Ti - 2.3L Turbo Engines having calibration 6-05R-R00 and 06-06E-R01 and
Automatic or Manual Transmissions
{
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ATTACHMENT I
Emissions Recall 93E45
OASIS
You must use OASIS to determine if a car is eligible for this recall.
Please Note
Correct all affected dealer stock cars before delivery.
Promptly Correct
Affected cars on the enclosed list and other eligible cars on hand or brought to your dealership.
Dealer-Owner Contact
Immediately contact any owner of an eligible car you know of whose name is not on the list. Give the owner a
copy of the Owner Letter.
District Contact
Advise FCSD district office if:
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an owner cannot be contacted.
an owner does not make a service date.
FCSD Contact
Talk with your FCSD Service Zone Manager about recall concerns.
Reimbursement
Submit claims using the 1864 format on the DWE screen. Refer to your Warranty and Policy Manual Section
6.3. Use Form 1863 or authorized alternative claim form as an internal repair order to support your DWE
entry.
Warranty and Policy Manual
Please read section 6.3 of your Warranty and Policy Manual. This section contains claim processing
information including related damage/refunds and refunds.
ATTACHMENT II
Emissions Recall 93E45
Labor Allowance
OPERATION DESCRIPTION
Replace the Exhaust System Catalyst. Install Vacuum Delay Valve in the EGR
vacuum line. Attach Authorized Modifications and Special Service Information
Labels. Prepare and Return the Removed Exhaust System Catalyst. (Time
included to prepare removed catalysts for return).
LABOR
TIME
0.9 Hrs.
LABOR
CODE
Insert in Box
"B" on Form
1864
Parts Requirements
Parts will not be direct shipped to dealers for this recall. Order your parts requirements through normal order
processing channels.
PART NUMBER
DESCRIPTION
PRICE
E6PZ-5E212-A
Kit, Catalyst (Kit "A" - I.S. #8127) $79.40
E7PZ-5E212-B
Kit, Catalyst (Kit "B" - I.S. #8128) 79.29
E7PZ-5E212-D
Kit, Catalyst (Kit "C" - I.S. #8129) 71.07
E6PZ-5E212-B
Kit, Catalyst (Kit "D" - I.S. #8130) 79.29
Part price is current until the next issue of the Master Price Book. For the latest price, call or check the
following:
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Order Processing Center
Updated Master Price Book
DOES II.
Removed Catalysts
Removed catalysts must be returned. Prepare catalysts by removing excess weight. Cut and discard
pipes/flanges as close to the catalyst shell as practical.
An FPS-700 Parts Disposition Tag will be issued to recall the removed catalysts. Return of removed catalysts
with the FPS-700 tag attached must be shipped prepaid freight via United Parcel Service (UPS) to the address
on the reverse side of the tag.
Refer to the part return shipping procedure in Section 7.0, of the Warranty and Policy Manual.
Any Questions regarding the handling of special situations regarding removed catalysts should be resolved
with your Service Zone Manager.
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 IIIA
Emissions Recall 93E45
Exhaust System Catalyst Replacement
and Emissions Control System Modification
SERVICE PART NUMBER E6PZ-5E212-A
KIT CONTENTS
COMPONENT PART NUMBER
F4SC-5E212-CA
PART NAME
QUANTITY
Catalyst Assembly
1
387255-S2
Nut
2
388690-S2
Stud
2
45358-S7G/S2
Nut
2
N800064-S2
Stud
2
387039-S7
Nut
2
E3SC-5F229-CB
Catalyst Heat Shield Upper
1
E4DC-5K282-BA
Catalyst Heat Shield Lower
1
Screw
4
CATALYST REPLACEMENT:
56721-S2
EMISSIONS SYSTEM MODIFICATIONS:
F4PE-9E455-AA
Valve and Hose Assembly
1
Tie Strap
1
Form FPS-8262-PP
Authorized Modifications Label (Preprinted)
1
E9AE-9C485-BLD
Special Information - Revised EGR Vacuum Circuit 1
F4PE-12A661-BA
Special Information - Test Connector
1
Instruction
1
95874-S
LABELS
I.S. 8127
Affected Vehicles:
1986 model Federal Thunderbird Turbo Coupe and Cougar XR7 - 2.3L Turbo Engines having calibration 606E-R01 and Automatic Transmissions
Catalytic Converter
Removal
1. Raise vehicle on hoist.
2. Remove converter outlet nuts and studs.
3. Remove nuts and studs at exhaust manifold.
4. Remove converter from vehicle.
Installation
1.
2.
3.
4.
Attach heat shields to catalyst. Install and tighten attaching hardware as indicated below.
Position catalyst assembly in vehicle.
Align exhaust system and tighten attaching hardware as indicated below.
Lower vehicle and open hood.
Emissions System Modification
1. Refer to Figure 1. Remove the vacuum line from exhaust gas recirculation (EGR) valve.
2. Install valve and hose assembly as shown.
3. Use tie strap to position assembly.
Figure 1 - EGR Location - Thunderbird
Labels
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Preprinted Authorized Modifications Label
Authorized Modifications preprinted label is provided in the parts kit.
{ Insert your P & A Code and service date on the authorized modifications label. Attach label to the
radiator support or the plastic pocket attached to the underside of the hood.
{ Place the clear overlay on the label.
Special Information Label - Test Connector
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Locate the test connector.
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Wrap the label around the connector so the label attaches to the wiring and to the label.
Special Information Label - Revised EGR Vacuum Circuit
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Attach near the Vehicle Emissions Control Information (VECI) label.
ATTACHMENT IIIB
Emissions Recall 93E45
System Catalyst Replacement
and Emissions Control System Modification
SERVICE PART NUMBER E7PZ-5E212-B
KIT CONTENTS
COMPONENT PART NUMBER
E8SC-5E212-BA
PART NAME
QUANTITY
Catalyst Assembly
1
387255-S2
Nut
2
388690-S2
Stud
2
45358-S7G/S2
Nut
2
N800064-S2
Stud
2
387039-S7
Nut
2
E7SC-5F229-DA
Catalyst Heat Shield Upper
1
E7SC-5K282-AA
Catalyst Heat Shield Lower
1
Screw
4
CATALYST REPLACEMENT:
56721-S2
EMISSIONS SYSTEM MODIFICATIONS:
F4PE-9E455-AA
Valve and Hose Assembly
1
Tie Strap
1
Form FPS-8262-PP
Authorized Modifications Label (Preprinted)
1
E9AE-9C485-BLD
Special Information - Revised EGR Vacuum Circuit 1
F4PE-12A661-BA
Special Information - Test Connector
95874-S
LABELS
1
I.S. 8128
Instruction
1
Affected Vehicles:
1987 model Federal and 1988 model Federal and Canadian Thunderbird Turbo Coupe - 2.3L Turbo Engines
having calibrations 7-06E-R10 and R11 and Automatic Transmissions
Catalytic Converter
Removal
1.
2.
3.
4.
Raise vehicle on hoist.
Remove converter outlet nuts and studs.
Remove nuts and studs at exhaust manifold.
Remove converter from vehicle.
Installation
1.
2.
3.
4.
Attach heat shields to catalyst. Install and tighten attaching hardware as indicated below.
Position catalyst assembly in vehicle.
Align exhaust system and tighten attaching hardware as indicated below.
Lower vehicle and open hood.
Emissions System Modification
1. Refer to Figure 1. Remove the vacuum line from exhaust gas recirculation (EGR) valve.
2. Install valve and hose assembly as shown.
3. Use tie strap to position assembly.
Figure 1 - EGR Location - Thunderbird
Labels
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Preprinted Authorized Modifications Label
Authorized Modifications preprinted label is provided in the parts kit.
{ Insert your P & A Code and service date on the authorized modifications label. Attach label to the
radiator support or the plastic pocket attached to the underside of the hood.
{ Place the clear overlay on the label.
Special Information Label - Test Connector
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Locate the test connector.
Wrap the label around the connector so the label attaches to the wiring and to the label.
Special Information Label - Revised EGR Vacuum Circuit
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Attach near the Vehicle Emissions Control Information (VECI) label.
ATTACHMENT IIIC
Emissions Recall 93E45
Exhaust System Catalyst Replacement
and Emissions Control System Modification
SERVICE PART NUMBER E7PZ-5E212-D
KIT CONTENTS
COMPONENT PART NUMBER
E8SC-5E212-BA
PART NAME
QUANTITY
Catalyst Assembly
1
387255-S2
Nut
2
388690-S2
Stud
2
45358-S7G/S2
Nut
2
N800064-S2
Stud
2
387039-S7
Nut
2
E7SC-5F229-CA
Catalyst Heat Shield Upper
1
E7SC-5K282-AA
Catalyst Heat Shield Lower
1
Screw
4
CATALYST REPLACEMENT:
56721-S2
EMISSIONS SYSTEM MODIFICATIONS:
F4PE-9E455-AA
Valve and Hose Assembly
1
Tie Strap
1
Form FPS-8262-PP
Authorized Modifications Label (Preprinted)
1
E9AE-9C485-BLD
Special Information - Revised EGR Vacuum Circuit 1
F4PE-12A661-BA
Special Information - Test Connector
1
Instruction
1
95874-S
LABELS
I.S. 8129
Affected Vehicles:
1987 model Federal and 1988 model Federal and Canadian Thunderbird Turbo Coupe - 2.3L Turbo Engines
having calibrations 7-05E-R00 and R10 and Automatic Transmissions
Catalytic Converter
Removal
1.
2.
3.
4.
Raise vehicle on hoist.
Remove converter outlet nuts and studs.
Remove nuts and studs at exhaust manifold.
Remove converter from vehicle.
Installation
1.
2.
3.
4.
Attach heat shields to catalyst. Install and tighten attaching hardware as indicated below.
Position catalyst assembly in vehicle.
Align exhaust system and tighten attaching hardware as indicated below.
Lower vehicle and open hood.
Emissions System Modification
1. Refer to Figure 1. Remove the vacuum line from exhaust gas recirculation (EGR) valve.
2. Install valve and hose assembly as shown.
3. Use tie strap to position assembly.
Figure 1 - EGR Location - Thunderbird
Labels
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Preprinted Authorized Modifications Label
Authorized Modifications preprinted label is provided in the parts kit.
{ Insert your P & A Code and service date on the authorized modifications label. Attach label to the
radiator support or the plastic pocket attached to the underside of the hood.
{ Place the clear overlay on the label.
Special Information Label - Test Connector
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Locate the test connector.
Wrap the label around the connector so the label attaches to the wiring and to the label.
Special Information Label - Revised EGR Vacuum Circuit
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Attach near the Vehicle Emissions Control Information (VECI) label.
ATTACHMENT IIID
Emissions Recall 93E45
System Catalyst Replacement
and Emissions Control System Modification
SERVICE PART NUMBER E6PZ-5E212-B
KIT CONTENTS
COMPONENT PART NUMBER
E5RD-5E212-AC
PART NAME
QUANTITY
Catalyst Assembly
1
N801509-S
Bolt
4
N802641-S2
Nut
4
CATALYST REPLACEMENT:
E1EC-5F264-AB
Spring
4
E5RD-E241-AA
Gasket
2
D9AE-5F215-AA
Pad/Spacer
2
E5RD-5F229-AB
Catalyst Heat Shield Upper
1
E4DC-5K282-BA
Catalyst Heat Shield Lower
1
Screw
4
56721-S2
EMISSIONS SYSTEM MODIFICATIONS:
F4PE-9E455-AA
Valve and Hose Assembly
1
Tie Strap
1
Form FPS-8262-PP
Authorized Modifications Label (Preprinted)
1
E9AE-9C485-BLD
Special Information - Revised EGR Vacuum Circuit 1
F4PE-19A661-BA
Special Information - Test Connector
1
Instruction
1
95874-S
LABELS
I.S. 8130
Affected Vehicles:
1986, 87, 88, 89 - model Federal and 1988 and 1989 model Canadian Merkur XR4ti - 2.3L Turbo engines
having calibrations 6-05R-R00 and 6-06E-R01 and automatic or manual transmissions.
Catalytic Converter
Removal
1.
2.
3.
4.
Raise vehicle on hoist.
Remove grounding strap.
Remove converter nuts, bolts and springs from front and rear flange joints.
Remove catalyst from vehicle.
Installation
1.
2.
3.
4.
5.
Use water to wet the converter pad/spacers.
Place the pad/spacers on the converter and install the converter shields.
Position catalyst in vehicle.
Align exhaust system and tighten attaching hardware as indicated below.
Lower vehicle and open hood.
Emissions System Modification
1. Refer to Figure 1. Remove the vacuum line from exhaust gas recirculation (EGR) valve.
2. Install valve and hose assembly as shown.
3. Use tie strap to position assembly.
Figure 1 - EGR Location - XR4Ti
Labels
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Preprinted Authorized Modifications Label
Authorized Modifications preprinted label is provided in the parts kit.
{ Insert your P & A Code and service date on the authorized modifications label. Attach label to the
radiator support or the plastic pocket attached to the underside of the hood.
{ Place the clear overlay on the label.
Figure 1 - EGR Location - Thunderbird
Special Information Label - Test Connector
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Locate the test connector.
Wrap the label around the connector so the label attaches to the wiring and to the label.
Special Information Label - Revised EGR Vacuum Circuit
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Attach near the Vehicle Emissions Control Information (VECI) label.
Date, here
Serial Number: 12345678901234567 93E45
Mr. John Sample
123 Main Street
Anywhere, USA 12345
Ford Motor Company is voluntarily recalling (Emissions Recall 93E45) certain 1986 through 1989 - model
Thunderbird, Cougar and Merkur XR4ti cars equipped with 2.3L turbocharged engines. Your car's engine may
be releasing air pollutants which exceed Federal standards.
What The Dealer Will Do
At no cost to you the exhaust system catalyst will be replaced and the exhaust gas recirculation system will be
modified according to the instructions provided by Ford.
This service should have little or no effect on your car except to reduce air pollutants.
How Long Will It Take?
The time needed to repair your car is about one hour. However, due to service scheduling times, your dealer
may need your vehicle for one full working day.
Call Your Dealer
Call your dealer without delay. Ask for a service date and if parts are in stock.
If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts
would be expected to arrive within a week.
When you bring your car in, give the dealer this letter.
If you misplace this letter, your dealer will still do the work, free of charge.
Changed Address Or Sold The Car?
If you have, please fill out the enclosed prepaid postcard and mail it to us.
If the repair offered by this recall is not made promptly and without charge, talk to the dealer service manager.
You may also contact the Ford Customer Assistance Center at 300 Renaissance Center, P.O. Box 43360,
Detroit, Michigan 48243.
We regret the inconvenience this recall may cause you. We are doing this so that you will be satisfied with
your Ford-built car. Please have your car serviced promptly to maintain full emission warranty coverage.
EMISSIONS RECALL
93E45
CPR В© 1994 FORD MOTOR COMPANY
Published By: Recall/Service Programs Department
Ford Customer Service Division