January 2002 Dealer Service Instructions for: Safety Recall No. 895 -- Fuel Rail Seals

Models

1996-2000 (NS) Dodge Caravan/Grand Caravan; Plymouth Voyager/Grand Voyager and Chrysler Town & Country NOTE: This recall applies only to the above vehicles equipped with a 3.3L or 3.8L gasoline engine (“R” or “L” in the 8th VIN Position) through Engine Build Date – 102389 (August 26, 1999).

IMPORTANT: Vehicles equipped with a 3.3L Flex Fuel engine (“G” in the 8th VIN Position) are NOT involved in this recall.

IMPORTANT: Vehicles that have already had a fuel rail with the proper O-rings installed, according to Warranty records, have been excluded from this recall.

IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles 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

After extended use, the fuel rail crossover tube O-rings on about 1,136,000 of the above vehicles may leak fuel. Fuel leakage in the presence of an ignition source can result in an engine compartment fire.

Repair

External seals must be installed at both of the fuel rail crossover tube joints. If the crossover tube joints are leaking or red rust exists in the area, the fuel rail assembly must be replaced.

 Copyright 2002, DaimlerChrysler Corporation, All Rights Reserved Safety Recall No. 895 -- Fuel Rail Seals Page 2

Parts Information

A. Fuel Rail Seal Package

Part Number Description CBXJ8951 Fuel Rail Seal Package Each package contains the following components: Quantity Description 2 Fuel Rail Seals 2Clamps 1 Scotch Brite Pad

Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive TWO (2) Fuel Rail Seal Packages. Additional Fuel Rail Seal packages may be ordered as required.

B. Fuel Rail Package

Part Number Description CBXJ8950 Fuel Rail Package Each package contains the following components: Quantity Description 1 Fuel Rail Assembly 6 Injector O-Rings – Upper (Blue) 6 Injector O-Rings – Lower (Black) 1 Intake Manifold Plenum Gasket 1 EGR Tube Gasket Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive FIVE (5) Fuel Rail Packages to service vehicles as required. Additional Fuel Rail packages should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require fuel rail replacement. Safety Recall No. 895 -- Fuel Rail Seals Page 3

Service Procedure

A. Inspect Fuel Rail:

1. Raise hood.

2. Inspect both of the fuel rail crossover tube joints (Figure 1).

3. ! If there are signs of fuel leakage from either of the fuel rail crossover tube joints, the fuel rail assembly must be replaced. Continue with Section C – Replace Fuel Rail Assembly.

! If there are signs of RED rust near either of the fuel rail crossover tube joints, the fuel rail assembly must be replaced. Continue with Section C – Replace Fuel Rail Assembly. ! If there are NO indications of fuel leakage OR RED rust near either of the fuel rail crossover tube joints, continue with Section B – Install Fuel Rail Seals.

Figure 1 Safety Recall No. 895 -- Fuel Rail Seals Page 4

Service Procedure (Continued)

B. Install Fuel Rail Seals:

1. If the engine is equipped with an intake manifold cover (1996 and early-1997 3.8L engines only), remove the cover and set it aside.

2. Using the provided Scotch-Brite pad, clean any dirt or white oxide build-up from the fuel rail area near the crossover tube joints (Figure 2). Clean both of the crossover tube joints with the Scotch-Brite pad and then use compressed air to remove any remaining particles.

3. Install the two provided clamps Figure 2 around the crossover tube. Start the clamps for 1-2 turns to ease seal installation.

4. Lightly lubricate the rubber material of the four fuel rail seal halves with clean engine oil. Be sure to coat the flat ends as well as the two beads.

IMPORTANT: Drain any excess oil from the seals. 5. Install two of the seal halves around the front fuel rail crossover tube joint (Figure 3).

NOTE: Both of the seal halves are identical. Figure 3 Safety Recall No. 895 -- Fuel Rail Seals Page 5

Service Procedure (Continued)

6. Seat the seal halves around the joint INSTALL CLAMP AROUND SEAL and then while holding the two HALVES. seals halves together, install one of TIGHTEN CLAMP the provided clamps around the seal TO 75 IN-LBS halves (Figure 4).

7. Tighten the clamp to 75 in-lbs (8.5 N"m).

8. Install the remaining two seal halves around the rear fuel rail crossover tube joint (Figure 3).

9. Seat the seal halves around the joint and then while holding the two seals halves together, install the other clamp around the seal halves (Figure 4). Figure 4

10. Tighten the clamp to 75 in-lbs (8.5 N"m).

11. If the engine was equipped with an intake manifold cover (1996 and early-1997 3.8L only), the cover must be modified as follows: a. Remove the spring clip from the cover that was attached to the fuel rail near the crossover tube joint (Figure 5). Discard the clip. b. Using a small cut-off wheel, saw or similar tool, remove the plastic cover material inside of the mold line on the end of the cover (Figure 5). Figure 5 c. Reinstall the cover onto the intake manifold. Tighten the cover bolt securely. 12. No further action is necessary. Return the vehicle to the customer. Safety Recall No. 895 -- Fuel Rail Seals Page 6

Service Procedure (Continued)

C. Replace Fuel Rail Assembly:

NOTE: Only fuel rails with fuel leakage or RED rust at the crossover tube joint, as determined by the inspection in Section A, require replacement. Very few vehicles are expected to require fuel rail replacement.

WARNING: The fuel system is under constant fuel pressure even with the engine off. Fuel pressure must be released before replacing the fuel rail. 1. 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. 2. Remove and reinstall the fuel tank filler cap to release the fuel tank pressure.

3. Remove the protective cap from the pressure test port on the fuel rail (Figure 6).

WARNING: Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel when Figure 6 pressure is released from the rail. 4. Obtain the hose from the fuel pressure gauge tool set #C-4799-1. Position one end of the hose into an approved gasoline container, then attach the hose to the fuel rail test port to release the fuel pressure.

5. Remove the hose from the fuel rail and reinstall the test port cap.

6. Remove the plastic intake manifold cover, if equipped.

7. Remove the air inlet resonator. Safety Recall No. 895 -- Fuel Rail Seals Page 7

Service Procedure (Continued)

8. Remove the throttle cable and speed control cable (if equipped) from the throttle lever and bracket (Figure 7).

Figure 7 9. Disconnect the idle air control motor and Throttle Position Sensor (TPS) electrical connectors (Figure 8).

Figure 8 10. Disconnect the vacuum hoses from the throttle body and intake manifold (Figure 9).

Figure 9 Safety Recall No. 895 -- Fuel Rail Seals Page 8

Service Procedure (Continued)

11. Disconnect the EGR tube from the intake manifold flange (Figure 10).

12. Disconnect the cylinder head-to- intake plenum strut from the cylinder head.

Figure 10 13. Disconnect the MAP sensor electrical connector (Figure 11).

FRONT

Figure 11 14. Disconnect the fuel hose quick connect fitting from the chassis fuel tube (Figure 12).

WARNING: Wrap a shop towel around the hoses to catch any gasoline spillage.

Figure 12 Safety Recall No. 895 -- Fuel Rail Seals Page 9

Service Procedure (Continued)

15. Remove the Direct Ignition System (DIS) coil pack (Figure 13).

16. Remove the generator support bracket.

Figure 13 17. Remove the intake plenum ROTATE mounting bolts and rotate the BACK plenum back over the rear valve cover (Figure 14).

NOTE: It is not necessary to completely remove the intake plenum from the vehicle. 18. Cover the intake manifold openings.

Figure 14 19. Remove the fuel rail attaching bolts (Figure 15).

Figure 15 Safety Recall No. 895 -- Fuel Rail Seals Page 10

Service Procedure (Continued)

20. Disconnect the engine coolant FRONT temperature sensor and camshaft position sensor or coil pack electrical connectors (Figure 16).

21. Disconnect the fuel rail wiring harness from the main engine harness.

22. Remove the fuel rail assembly.

23. Position the fuel rail on a clean bench or other suitable work surface so that the fuel injectors are Figure 16 easily accessible.

24. Disconnect the injector wiring connectors from the fuel injectors and then remove the wiring harness from the fuel rail.

25. Rotate the injectors and then pull them out of the fuel rail. The injector clip will stay on the injector (Figure 17).

26. Remove the upper and lower injector O-rings from the injectors.

27. Lubricate the new upper O-rings (BLUE) with a drop of clean engine oil. Figure 17 28. Install the new upper O-rings (BLUE) on the top of the injectors.

CAUTION: Do NOT install the black O-rings in the upper O-ring position or fuel leakage may result. Safety Recall No. 895 -- Fuel Rail Seals Page 11

Service Procedure (Continued)

29. Lubricate the new lower O-rings (BLACK) with a drop of clean engine oil.

30. Install the new lower O-rings (BLACK) on the bottom of the injectors.

31. Install the injector clips onto the injectors, if necessary, by sliding the open end into the top slot of the injector.

32. Install the injectors into the new fuel rail (Figure 17). Make sure that the injector clips are fully seated. Use care so that the upper O-ring is not damaged during installation.

33. Connect the injector wiring harness to the injectors.

34. Put the tip of each injector into its port in the intake manifold and then gently push the fuel rail assembly into place until all injectors are seated in their port.

35. Install the fuel rail mounting bolts (Figure 15). Tighten the mounting bolts to 200 in-lbs (22 N⋅m).

36. Connect the fuel injector wiring harness to the main engine wiring harness.

37. Connect the fuel rail hose quick connect fitting to the chassis fuel tube (Figure 12). Push the connector on until it clicks and then pull back to ensure a complete connection.

38. Connect the coolant temperature sensor and camshaft position sensor or coil pack electrical connectors (Figure 16).

39. Remove the covering from the intake manifold openings. Clean the intake manifold and intake plenum gasket surfaces.

40. Place the provided intake plenum gasket on the intake manifold.

41. Install the intake plenum onto the intake manifold (Figure 14). Loosely install the intake plenum bolts. Do NOT tighten.

42. Install the generator bracket. Loosely install the bracket bolts. Do NOT tighten. Safety Recall No. 895 -- Fuel Rail Seals Page 12

Service Procedure (Continued)

43. Install the cylinder head-to-intake plenum strut. Loosely install the strut mounting bolt. Do NOT tighten.

44. Using the supplied gasket, connect the EGR tube to the intake plenum (Figure 10). Loosely install the mounting bolts. Do NOT tighten.

45. Following the tightening sequence in Figure 14, tighten the intake plenum bolts to 250 in-lbs (28 N⋅m).

46. Tighten the generator bracket bolts to 40 ft-lbs (54 N⋅m).

47. Tighten the cylinder head-to-intake plenum strut bolt to 40 ft-lbs (54 N⋅m).

48. Tighten the EGR tube bolts to 200 in-lbs (22 N⋅m) (Figure 10).

49. Install the DIS coil pack (Figure 13). Tighten the bolts to 105 in-lbs (12 N⋅m).

50. Connect the MAP sensor electrical connector (Figure 11).

51. Connect the vacuum hoses to the intake plenum (Figure 9).

52. Connect the TPS and idle air control motor electrical connectors (Figure 8).

53. Connect the throttle body vacuum connectors (Figure 9).

54. Connect the throttle cable and speed control cable (if equipped) (Figure 7).

55. Install the intake manifold cover (if equipped).

56. Install the air inlet resonator.

57. Connect the negative battery cable.

58. Start the engine and check for any fuel leakage. Safety Recall No. 895 -- Fuel Rail Seals Page 13

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 one of the following labor operation numbers and time allowances: Labor Operation Time Number Allowance ! Install fuel rail seals 14-89-51-82 0.2 hours ! Install fuel rail seals and modify intake manifold 14-89-51-83 0.3 hours cover (1996 and early-1997 3.8L engines only) ! Replace fuel rail assembly 14-89-51-84 1.0 hours Add the cost of the appropriate 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

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. Safety Recall No. 895 -- Fuel Rail Seals Page 14

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 “ORD895”.

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 letter is attached. Enclosed with each owner letter 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 describing 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.

Customer Services Field Operations DaimlerChrysler Corporation SAFETY RECALL TO INSTALL SEALS ON YOUR MINIVAN’S FUEL RAIL

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 through 2000 model year Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country minivans equipped with a 3.3L or 3.8L gasoline engine. The problem is... After extended use, the fuel rail crossover tube O-rings on your minivan may leak fuel. Fuel leakage in the presence of an ignition source can result in an engine compartment fire. What DaimlerChrysler DaimlerChrysler will repair your minivan free of charge (parts and your dealer will and labor). To do this, your dealer will inspect the fuel rail do... assembly. If the fuel rail is NOT leaking fuel, your dealer will install external fuel rail seals. If your fuel rail is leaking fuel, it will be replaced. Fuel rail seal installation will take less than ½ hour to complete. Fuel rail replacement, if necessary, will take about 1½ hours to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed. What you must do to ! Simply contact your dealer right away to schedule a service ensure your safety... appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. ! Bring the enclosed form with you to your dealer. It identifies the required service to the dealer. If you need help... If you have questions or concerns which the dealer is unable to resolve, please contact the DaimlerChrysler Customer Assistance Center at 1-800-853-1403. A representative will assist you. If you have already experienced the problem described above and have paid to have it repaired, you may send your original receipts and/or other adequate proof of payment to the following address for reimbursement: DaimlerChrysler Customer Assistance Center, P.O. Box 1040, St. Charles, MO 63302-1040, Attention: Reimbursement. 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 1-888-327-4236. We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your attention to this important matter. Customer Services Field Operations DaimlerChrysler Corporation Buckle 895 up