Five Hundred AWD V6-3.0L VIN 1 (2005)
Fuel Filler Cap: All Technical Service Bulletins
Fuel System - Fuel Filler Cap Binds/Lamp ON/DTC P0457
TSB 07-16-9
08/20/07
FUEL FILLER CAP BINDING, FUEL CAP LIGHT /
WARNING MESSAGE AND/OR DTC P0457
FORD:
2005-2007 Five Hundred, Freestyle
MERCURY:
2005-2007 Montego
This article supersedes TSB 07-6-6 to update the Service Labor Time Standards (SLTS) and Service Part numbers.
ISSUE
Some 2005-2007 Freestyle, Five Hundred, and Montego vehicles built before 8/15/2006 may exhibit a fuel filler cap that binds when reinstalling after
fueling. Improperly installed fuel cap may cause Fuel Cap Lamp illumination in the instrument cluster, a Check Fuel Cap warning message in message
center (if equipped) and/or diagnostic trouble code (DTC) P0457. P0455 may also be present.
ACTION
Refer to the following Service Procedure to replace the fuel filler cap, and relocate the cap tether mounting position.
SERVICE PROCEDURE
^
2005 vehicles, perform Service Procedure A below
^
2006 vehicles, perform Service Procedure B below
^
2007 vehicles, perform Service Procedure C below
Service Procedure A
NOTE
LEAVE THE FUEL FILLER CAP IN PLACE WHEN PERFORMING STEPS 1, 2, AND 3.
1.
On the filler door housing mark the center point for a hole located approximately at the 10 o'clock position relative to the filler pipe as defined in
Figure 1. The 9/16" (14 mm) dimension is downward from the base of the embossment and the 3/4" (19 mm) dimension is inboard from the edge
of the opening in the vehicle body.
2.
Drill hole with a 5/16" (8 mm) diameter drill bit. Tape the bit 1/2" (13 mm) from the end to be used as a drill depth guide.
NOTE
WHEN DRILLING, USE LIGHT PRESSURE TO PREVENT FORMATION OF EXCESSIVE BURRS.
3.
Remove chips from the filler housing.
