Five Hundred AWD V6-3.0L VIN 1 (2005)
Fuel Filler Hose: Customer Interest
Fuel System - Premature Nozzle Shut-OFF/Slow Fuel Fill
TSB 07-11-15
06/11/07
SLOW FUEL FILL/PREMATURE SHUT OFF
FORD:
2005-2007 Five Hundred, Freestyle
MERCURY:
2005-2007 Montego
ISSUE
Some 2005-2007 Five Hundred, Montego and Freestyle vehicles may experience premature automatic shut off of the fuel fill nozzle. Several variables,
including variations in fuel pump nozzles, fuel flow rates, and fuel flow pressure may result in the premature automatic shut off of the fuel fill nozzle
making it more difficult to fill the fuel tank.
ACTION
Follow the Service Procedure steps to correct the condition.
NOTE
THIS CONDITION MAY STILL OCCUR EVEN AFTER THE REPAIR BELOW IS COMPLETE. SOME FILLING STATION PUMPS MAY
DELIVER FUEL AT A RATE GREATER THAN THE DEPARTMENT OF TRANSPORTATION (DOT) SPECIFICATION, OR MAY USE
NOZZLE DESIGNS THAT ARE OVERLY SENSITIVE AND TEND TO SHUT OFF PREMATURELY. THIS IS NORMAL.
SERVICE PROCEDURE
It is not necessary to complete all steps listed.
Repair is complete when concern is found.
1.
Drain fuel tank to 1/2.
2.
Install IDS and check for diagnostic trouble code (DTC) P1450. Is DTC present?
a.
Yes - Go to Step 4 to repair Evaporative Emissions (EVAP) restriction.
b.
No - Go to Step 3.
3.
Monitor the fuel tank pressure PID (FTP) on IDS and start refueling, stopping at 7/8 tank or less (add less than 2.5 gallons). Did voltage go over
3.8?
a.
Yes - Go to Step 4 to repair EVAP restriction.
b.
No - Go to Step 5 to inspect fill pipe/tank for blockage.
4.
Remove fresh air line at fuel vapor separator (line goes from fuel filler housing to fuel vapor separator near carbon canister). Blow shop air
through the lower end of the line and capture contaminants in a clear plastic bag in the top end. Was a blockage or appreciable amount of debris
(spider nest/web) present?
a.
Yes - Follow procedure I to install new filler housing kit that contains new spider trap to prevent spiders from building a nest/web in fresh
air line. Repair complete.
b.
No - Go to Step 6.
5.
Inspect the fill hose for any evidence of a kink. Remove the clamp at the tank spout and pull off the hose. Check the spout for any evidence that it
may have been crushed under the clamp. Push check valve in tank with finger, the plunger in the tank should move freely down with light pressure
and return to the top with a light spring force. If the spout is crushed or the valve does not move freely - remove and replace the fuel tank. Was
concern found?
a.
Yes - Repair/replace line or tank as necessary. Repair complete.
b.
No - Go to Step 7.
