Recall - Fuel Pump Module Seal and Lock Nut
NO845
DATE
January, 2000
Safety Recall No. 845 Fuel Pump Module Seal and Lock Nut
MODELS
1996 (NS) Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth Voyager/Grand Voyager
IMPORTANT
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on this vehicle before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the dial VIP system.
SUBJECT
The fuel pump module seal and lock nut on about 640,000 of the above vehicles may allow fuel leakage to occur. Fuel leakage in the presence of an ignition source could result in an underbody fire.
REPAIR
The fuel pump module seal must be replaced. in addition, the fuel tank lock nut replaced if necessary.
PARTS INFORMATION
Part Number Description
CBXG845O Fuel Tank Lock Nut Package
Each package contains a lock nut and a lock nut seal.
Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough fuel tank lock nut packages to service about 25% of those vehicles.
SPECIAL TOOL REQUIREMENTS
Miller Special Tools No.8269 and No.8585 are required for this service. All Chrysler/Plymouth and Dodge dealers received one (1) each of these special tools in January 2000 free of charge. Additional special tools may be purchased from Miller Tool. Additional tools are not reimbursable by DaimlerChrysler.
SERVICE PROCEDURE
1. Remove the fuel filler cap.
2. Insert a siphon hose into the fuel filler tube and drain the fuel into an approved gasoline holding tank until the fuel level in the tank is at or below � full.
3. Remove the cover from the power distribution center (PDC).
4. Remove the fuel pump relay from the PDC.
5. Start the vehicle and run it until it runs out of fuel then crank the engine for an additional 10 seconds. Turn the key to the OFF position.
6. Install the fuel pump relay and PDC cover.
7. With the ignition key in the OFF position, disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.
8. Raise the vehicle on an appropriate hoist.
9. Support the fuel tank using a transmission jack.
10. Remove the two (2) inboard fuel tank strap bolts.
11. Lower the inboard side of the fuel tank about 3" to allow access to the fuel pump module.
12. Using a shop rag, clean any dirt and debris from around the fuel pump module area.
Figure 1:
Figure 2:
13. Slide the fuel pump module electrical connector lock to the unlocked position (Figure 1). Push down on the connector retainer and then pull the connector from the module (Figure 2).
14. Disconnect both fuel line quick connects from the fuel pump module (Figure 1).
15. Clean any excess gasoline and/or dirt from the fuel pump module flange.
Figure 3:
16. Using Miller Tool No.8269, remove the lock nut (Figure 3).
17. Clean any excess gasoline and/or dirt from the fuel pump module flange.
18. Slightly raise the fuel pump module and then remove and discard the fuel pump module seal.
NOTE:
It is not necessary to remove the fuel pump module from the fuel tank to remove or install the fuel pump module seal.
19. Check the outer diameter of the fuel tank pump module mounting boss threads using the provided Go/No-Go gauge (Miller Tool #8585) (Figure 4).
> If the Go/No-Go gauge fits over the threads (Go) and can be moved to the tank surface, a NEW lock nut MUST be installed.
> If the Go/No-Go gauge does NOT fit over the threads (No-Go), the ORIGINAL lock nut must be reinstalled.
Figure 4:
IMPORTANT:
The Go/No-Go gauge must easily fit over the mounting boss threads. Do NOT use excessive force when attempting to install the gauge.
20. Install the new or original lock nut as determined above. Make sure that the locating tab on the fuel pump module is aligned with the notch in the fuel tank.
IMPORTANT:
Do NOT install the new lock nut SEAL at this time.
NOTE:
The NEW lock nut I.D. is smaller than the old lock nut and therefore will have a much tighter fit to the fuel tank. Be careful not to cross thread the lock nut.
21. Using Miller Special Tool No.8269, tighten the fuel pump module lock nut to 20 ft-lbs (27 N.m) (Figure 3).
IMPORTANT:
The lock nut MUST be tightened using Miller Special Tool No.8269. Do not over tighten the lock nut. To ensure a correct torque measurement, the torque wrench must be installed in line with the special tool handle.
Figure 5:
22. With a paint marker or similar tool, mark the top of the fuel pump module and the lock nut to indicate the location of the arrow on the lock nut after the lock nut has been tightened without having the seal installed (Figure 5).
23. Using Miller Tool No.8269, remove the lock nut (Figure 3).
24. Slightly raise the fuel pump module and carefully install the NEW fuel pump module seal (Figure 6). Use care to not stretch the new seal when installing it over the module.
CAUTION:
Make sure that the new seal is fully seated on the fuel pump module sealing surface.
Figure 6:
25. Install the new or original lock nut as determined in Step 19. Make sure that the locating tab on the fuel pump module is aligned with the notch in the fuel tank (Figure 6).
26. Using Miller Special Tool No.8269, tighten the lock nut to 35 ft-lbs (47.5 N.m) (Figure 3).
IMPORTANT:
The lock nut MUST be tightened using Miller Special Tool No.8269. Do not over tighten the lock nut. To ensure a correct torque measurement, the torque wrench must be installed in line with the special tool handle.
27. Check the position of the arrow on the lock nut relative to the mark made on the fuel pump module in Step 22 above.
> If the lock nut has been tightened such that the arrow is at or beyond the mark on the fuel pump module, continue with Step 28.
> If the lock nut has been tightened such that the arrow has not reached the mark on the fuel pump module, tighten the lock nut further until the arrow is aligned with the mark.
28. Connect both fuel lines to the fuel pump module (Figure 1). Push the connectors on to the nipples until they are seated and then pull back and push on again to assure that the connectors are secure.
NOTE:
Wipe any excess fuel from the fuel pump module.
29. Connect the fuel pump module electrical connector. Be sure to slide the retainer into the locked position (Figure 1).
30. Raise the fuel tank into position and install the inboard fuel tank strap bolts. Torque the strap bolts to 40 ft-lbs (54 N.m).
31. Remove the tank support and lower the vehicle.
32. Refill the fuel tank.
33. Connect the negative battery cable.
34. Start the engine and check for any fuel leaks.
COMPLETION REPORTING AND REIMBURSEMENT
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments.
Use the following labor operation number and time allowance:
Labor Operation Time
Number Allowance
Replace fuel tank seal and/or lock nut 14845182 0.6 hours
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.
PARTS RETURN
Not required.
DEALER NOTIFICATION and VEHICLE LIST
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.
DIAL SYSTEM FUNCTIONS 53 AND VIP
All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as needed. Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The customer name, address and phone number are listed if known. Completed vehicles are removed from Function 53 within several days of repair claim submission. To use this system, type "53" at the "ENTER FUNCTION" prompt, then type "0RD845".
OWNER NOTIFICATION AND SERVICE SCHEDULING
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner notification letter is attached.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.
Vehicle Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation
CIMS 482-00-85
800 Chrysler Drive East
Auburn Hills, Michigan 48326-2757
ADDITIONAL INFORMATION
If you have any questions or need assistance in completing this action, please contact your Zone Service Office.
SAFETY RECALL TO REPLACE YOUR MINIVAN'S FUEL PUMP MODULE SEAL
Dear DaimlerChrysler Minivan Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
DaimlerChrysler Corporation has determined that a defect, which relates to motor vehicle safety, exists in some 1996 model year Chrysler Town & Country, Dodge Caravan/Grand Caravan and Plymouth Voyager/Grand Voyager minivans.
The problem is...
The fuel pump module seal and lock nut on your Minivans (identified on the enclosed form) may allow fuel leakage to occur. Fuel leakage in the presence of an ignition source could result in an underbody fire.
What DaimlerChrysler and your dealer will do...
DaimlerChrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the fuel pump seal, and if necessary, the fuel pump module lock nut. The work will take about one hour to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed.
what you must do t0 ensure your safety...
> Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment.
> Bring the enclosed Owner Notification Form with you to your dealer. It identifies the required service to the dealer.
If you need help...
If, after contacting your local dealership, you have questions or concerns which the dealership is unable to resolve, please contact the DaimlerChrysler Customer Assistance Center at 1-800-992-1997. A representative will assist you. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590, or call the Toll Free Auto Safety Hotline at 1-800424-9393. Washington, DC area residents may call 1-202-366-0123.