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Safety Recall No. 895 -- Fuel Rail Seals

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Safety Recall No. 895 -- Fuel Rail Seals 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.
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