16B35-S1

Michael A. Berardi
Director
Service Engineering Operations
Ford Customer Service Division
Ford Motor Company
P. O. Box 1904
Dearborn, Michigan 48121
September 9, 2016
TO:
All U.S. Ford and Lincoln Dealers
SUBJECT:
DEMONSTRATION / DELIVERY HOLD - Customer Satisfaction Program 16B35 Supplement #1
Certain 2016-2017 Model Year C-MAX and Fusion Energi Vehicles
Reprogram Powertrain Control Module
New! REASON FOR THIS SUPPLEMENT
Technical Instructions: The Technical Instructions have been updated to reduce the risk of module
failure during module reprogramming.
PROGRAM TERMS
This program will be in effect through August 31, 2017. There is no mileage limit for this program.
AFFECTED VEHICLES
Vehicle
Model Year
Assembly Plant
Build Dates
C-MAX
2016
Michigan
April 18, 2016 through July 18, 2016
Fusion Energi
2016-2017
Hermosillo
March 11, 2016 through July 6, 2016
Affected vehicles are identified in OASIS and FSA VIN Lists.
REASON FOR THIS PROGRAM
In some of the affected vehicles, it may be possible for contactors in the high voltage battery junction
box to become temporarily fused closed at ignition off, setting diagnostic trouble code (DTC) P0AA4.
When the next engine start is attempted, the engine will fail to start and will generate a stop safely
now message along with a service engine soon indicator illuminated in the instrument cluster.
SERVICE ACTION
Before demonstrating or delivering any of the new in-stock vehicles involved in this program, dealers
are to reprogram the powertrain control module (PCM) using the Integrated Diagnostic System (IDS)
software 101.02 or higher. The secondary onboard diagnostic module C (SOBDMC) will
automatically update if it is not at the latest calibration level. This service must be performed on all
affected vehicles at no charge to the vehicle owner.
OWNER NOTIFICATION MAILING SCHEDULE
Owner letters are expected to be mailed the week of September 19, 2016. Dealers should repair any
affected vehicles that arrive at their dealerships, whether or not the customer has received a letter.
New! ATTACHMENTS
Attachment I:
Administrative Information
Attachment II:
Labor Allowances and Parts Ordering Information
Attachment III:
Technical Information
Owner Notification Letter
 Copyright 2016 Ford Motor Company
QUESTIONS & ASSISTANCE
For questions and assistance, contact the Special Service Support Center (SSSC) via the SSSC Web
Contact Site. The SSSC Web Contact Site can be accessed through the Professional Technician
Society (PTS) website using the SSSC link listed at the bottom of the OASIS VIN report screen or
listed under the SSSC tab.
Sincerely,
Michael A. Berardi
 Copyright 2016 Ford Motor Company
ATTACHMENT I
Page 1 of 2
DEMONSTRATION / DELIVERY HOLD – Customer Satisfaction Program 16B35 - Supplement #1
Certain 2016-2017 Model Year C-MAX and Fusion Energi Vehicles
Reprogram Powertrain Control Module
OASIS ACTIVATION
OASIS will be activated on August 30, 2016.
FSA VIN LISTS ACTIVATION
FSA VIN Lists will be available through https://web.fsavinlists.dealerconnection.com on August 30,
2016. Owner names and addresses will be available by September 30, 2016.
NOTE: Your FSA VIN Lists may contain owner names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this program is a violation of law in several states, provinces, and countries.
Accordingly, you must limit the use of this listing to the follow-up necessary to complete this service
action.
STOCK VEHICLES
 Correct all affected units in your new vehicle inventory before delivery.
 Use OASIS to identify any affected vehicles in your used vehicle inventory.
SOLD VEHICLES
 Owners of affected vehicles will be directed to dealers for repairs.
 Immediately contact any of your affected customers whose vehicles are not on your VIN list
but are identified in OASIS. Give the customer a copy of the Owner Notification Letter (when
available) and schedule a service date.
 Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this service action.
ADDITIONAL REPAIR (LABOR TIME AND/OR PARTS)
Additional repairs identified as necessary to complete the FSA should be managed as follows:
 For vehicles within new vehicle bumper-to-bumper warranty coverage, follow existing warranty
and policy guidelines for related damage claims. No SSSC approval is required for these
vehicles:
o Ford vehicles – 3 years or 36,000 miles
 For vehicles outside new vehicle bumper-to-bumper warranty coverage, submit an Approval
Request to the SSSC Web Contact Site prior to completing the repair.
OWNER REFUNDS
Refunds are not approved for this program.
RENTAL VEHICLES
The use of rental vehicles is not approved for this program.
 Copyright 2016 Ford Motor Company
ATTACHMENT I
Page 2 of 2
DEMONSTRATION / DELIVERY HOLD – Customer Satisfaction Program 16B35 - Supplement #1
Certain 2016-2017 Model Year C-MAX and Fusion Energi Vehicles
Reprogram Powertrain Control Module
CLAIMS PREPARATION AND SUBMISSION
 Enter claims using Direct Warranty Entry (DWE) or One Warranty Solution (OWS).
o DWE: refer to ACESII manual for claims preparation and submission information.
o OWS: when entering claims in DMS software, select claim type 31: Field Service Action.
The FSA number 16B35 is the sub code.
 Additional labor and/or parts must be claimed as related damage on a separate repair line
from the FSA.
 PROGRAM TERMS: This program will be in effect through August 31, 2017. There is no
mileage limit for this program.
 Copyright 2016 Ford Motor Company
ATTACHMENT II
Page 1 of 1
DEMONSTRATION / DELIVERY HOLD – Customer Satisfaction Program 16B35 - Supplement #1
Certain 2016-2017 Model Year C-MAX and Fusion Energi Vehicles
Reprogram Powertrain Control Module
LABOR ALLOWANCES
Description
Reprogram PCM and SOBDMC using IDS release 101.02
or higher
Labor Operation
Labor Time
16B35B
0.5 Hours
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts are not required to complete this repair.
 Copyright 2016 Ford Motor Company
ATTACHMENT III
PAGE 1 OF 2
CUSTOMER SATISFACTION PROGRAM 16B35-S1
CERTAIN 2016 - 2017 MODEL YEAR C-MAX AND FUSION ENERGI VEHICLES —
POWERTRAIN CONTROL MODULE REPROGRAMMING
OVERVIEW
In some of the affected vehicles, it may be possible for contactors in the high voltage battery junction box
to become temporarily fused closed at ignition off, setting diagnostic trouble code (DTC) P0AA4. When
the next engine start is attempted, the engine will fail to start and will generate a stop safely now message
along with a service engine soon indicator illuminated in the instrument cluster. Dealers are to reprogram
the powertrain control module (PCM) using the Integrated Diagnostic System (IDS) software 101.02 or
higher. The secondary onboard diagnostic module C (SOBDMC) will automatically update if it is not at
the latest calibration level.
SERVICE PROCEDURE
Module Reprogramming
NOTE: Reprogram appropriate vehicle modules before performing diagnostics and clear all DTCs after 		
		 programming. For DTCs generated after reprogramming, follow normal diagnostic service 		
		procedures.
NOTICE: Attempting to reprogram when the high voltage battery charge is less than 50% may 		
		 result in module failure during reprogramming.
1. Connect the 110V or 220V vehicle charger and ensure that the high voltage battery is at least 50% 		
charged before attempting to reprogram.
2. Reprogram the PCM using IDS release 101.02 or higher.
		
NOTE: Calibration files may also be obtained at www.motorcraftservice.com.
NOTE:
		
		
		
		
A coordinated reflash is required when reprogramming the PCM. When PCM reprogramming is
initiated, the IDS will check for software updates on certain onboard modules (anti-lock brake
system (ABS) module, secondary onboard diagnostic module C (SOBDMC), etc.). The IDS will 		
automatically install updates in these modules if they are not at the latest level. If the coordinated 		
reflash is interrupted, undesired vehicle operation may result.
NOTE: Follow the IDS on-screen instructions to complete the reprogramming procedure.
3. Disconnect the battery charger from the vehicle once the reprogramming has completed.
CPR © 2016 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
9/2016
ATTACHMENT III
PAGE 2 OF 2
CUSTOMER SATISFACTION PROGRAM 16B35-S1
Important Information for Module Programming
														
NOTE: When programming or reprogramming a module, use the following basic checks to ensure
programming completes without errors.
• Make sure the high voltage battery is at least 50% charged before carrying out the programming steps
and connect IDS/scan tool to a power source.
• Inspect Vehicle Communication Module (VCM) and cables for any damage. Make sure scan tool
connections are not interrupted during programming.
• A hardwired connection is strongly recommended.
• Turn off all unnecessary accessories (radio, heated/cooled seats, headlamps, interior lamps, HVAC
system, etc.) and close doors.
• Disconnect/depower any aftermarket accessories (remote start, alarm, power inverter, CB radio,
etc.).
• Follow all scan tool on-screen instructions carefully.
• Disable IDS/scan tool sleep mode, screensaver, hibernation modes.						
• Create all sessions key on engine off (KOEO). Starting the vehicle before creating a session will 		
cause errors within the programming inhale process.
NOTE: If a module becomes unresponsive or does not operate properly following a module programming
		 procedure, attempt a battery disconnect and reconnect.
Recovering a module when programming has resulted in a blank module:
NEVER DELETE THE ORIGINAL SESSION!
a. Obtain the original IDS that was used when the programming error occurred during module
reprogramming (MR) or programmable module installation (PMI).
b. Disconnect the VCM from the data link connector (DLC) and the IDS.
c. Reconnect the VCM to IDS and then connect to the DLC. Once reconnected, the VCM icon should
appear in the corner of the IDS screen. If it does not, troubleshoot the IDS to VCM connection.
		
d. Locate the original vehicle session when programming failed. This should be the last session used
in most cases. If not, use the session created on the date that the programming failed.
NOTE: If the original session is not listed in the previous session list, click the Recycle Bin icon at the 		
		 lower right of the previous session screen. This loads any deleted sessions and allows you to 		
		 look through them. Double-click the session to restore it.
e. Once the session is loaded, the failed process should resume automatically.
f. If programming does not resume automatically, proceed to the Module Programming menu and select
the previously attempted process, PMI or MR.
g. Follow all on-screen prompts/instructions.
h. The last screen on the IDS may list additional steps required to complete the programming process.
Make sure all applicable steps listed on the screen are followed in order.
CPR © 2016 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
9/2016