Note: Before Attempting This Recall, Review Vip Or Vehicle History Tab to Verify That the Recall Applies to This Vehicle and Has Not Been Completed

NOTE: BEFORE ATTEMPTING THIS RECALL, REVIEW VIP OR VEHICLE HISTORY TAB TO VERIFY THAT THE RECALL APPLIES TO THIS VEHICLE AND HAS NOT BEEN COMPLETED.

January, 1999

Dealer Service Instructions For:

Federal Emissions Recall No. 7971 (Vehicles w/Sales Code NAA)

California Emissions Recall No. 7972 (Vehicles w/Sales Code NAE)

Methanol Concentration Sensor

Models

1993-1994 (AA) Dodge Spirit and Plymouth Acclaim

Note: This recall applies to the above vehicles equipped with a 2.5L Flex Fuel Engine ("V" in the 8th VIN position).

1994-1995 (LH) Dodge Intrepid, Chrysler Concorde, and Eagle Vision

Note: This recall applies to the above vehicles equipped with a 3.3L Flex Fuel Engine ("U" in the 8th VIN position).

Subject

The methanol concentration sensor on about 10,000 of the above listed vehicles may fail. This can affect the ability of the engine to adapt to various concentrations of methanol in the fuel and cause hard starting, poor driveability and illumination of the "Check Engine" light.

Repair

The methanol concentration sensor must be replaced and a wiring jumper must be installed.

Parts Information

Each dealer , to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Methanol Concentration Sensor Packages to service about 25% of those vehicles. Vehicle Part Number Description (AA) Spirit/Acclaim CLAS7971 Methanol Concentration Sensor Package (LH) Intrepid/Concord/Vision CLAR7972 Methanol Concentration Sensor Package

Each package contains one methanol concentration sensor, one wiring jumper harness, and three pieces of heat shrink tubing.

For vehicles involved in Recall No. 7972, dealers must order the required Authorized Modifications Label, PN 4275086, as necessary to support scheduled repairs.

Service Procedure

1. Replace Methanol Concentration Sensor and Install Wiring Jumper:

WARNING: Wear methanol resistant gloves, eye protection and avoid breathing fumes. Do not allow the methanol/gasoline mixture to contact skin. Service the vehicle in a well- ventilated area and avoid all ignition sources.

1. With the ignition key in the "OFF" position, disconnect the battery.

Note: To enhance customer satisfaction, record all of the radio settings before disconnecting the battery and 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 located on the fuel rail. 4. Obtain the hose from the fuel pressure gauge tool set #C-4799-A. Position one end of the hose into an approved gasoline container. Then attach the other end of the hose to the fuel rail test port to release the fuel pressure.

WARNING: Do not allow the fuel to spill onto the intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel when the pressure is released from the rail.

5. Remove the hose from the fuel rail and reinstall the test port cap. 6. Raise the vehicle on an appropriate hoist. 7. For LH vehicles: Use an appropriate jack stand to support the front of the fuel tank. 8. For LH vehicles: Remove the four fuel tank mounting strap bolts and then carefully remove the fuel tank strap and sway bar brackets (Figure 1). 9. For LH vehicles: Remove the left side fuel tank heat shield. Save the shield for later installation. 10. Disconnect the methanol sensor wiring connector (Figure 2 and Figure 3). 11. Remove the brown locking tab from the rear of the original wiring connector and then remove the three wire terminals from the connector using a small screw driver, Miller Special Tool 8197 or equivalent. 12. Slip one piece of heat shrink tubing (three pieces provided) over each of the terminals on the new wiring jumper harness. 13. Connect the three jumper harness wire terminals to the three original methanol sensor wiring terminals. Be sure to match the appropriate wire color on both harnesses. NOTE: On LH vehicles only, the YELLOW with WHITE tracer wire on the original sensor wiring must be connected to the BLACK with RED tracer wire on the new jumper harness.

14. Slide the three pieces of heat shrink tubing over the three terminal connections. Heat the tubing until sealant comes out of both ends of each piece of heat shrink tubing. 15. Disconnect the fuel inlet and outlet hose quick connect fittings from the methanol concentration sensor (Figure 2 and Figure 3).

WARNING: Residual fuel may remain in the fuel lines even though the fuel pressure has been released. Use extreme care when disconnecting the quick connect fittings and have an approved gasoline container available to catch any residual fuel.

16. For LH vehicles: Remove the methanol concentration sensor mounting nuts. Remove and discard the old sensor.

IMPORTANT: Avoid the use of excessive force when removing the methanol sensor retaining nuts. If a sensor retaining screw breaks replace it with PN 06502841.

For AA vehicles: Remove the methanol concentration sensor bracket screws. Remove and discard the old sensor and bracket assembly. 17. Install the new methanol concentration sensor. For LH vehicles: Tighten the sensor mounting nuts to 20 in-lbs (2.3 N•m). For AA vehicles: Tighten the bracket-to-crossmember mounting screws to 40 in- lbs (4.5 N•m). 18. Install the fuel inlet and outlet hose quick connects onto the methanol sensor as outlined below: a. Wipe the sensor tube ends which will be inserted into the quick connects with a clean lint free cloth. b. Check the tube surfaces for burrs. Remove any burrs as necessary. c. Prior to connecting the fittings to the sensor tube, lightly coat the exterior surface of the sensor tube nipples with clean 30-weight engine oil. d. Push the quick connects onto the sensor tubes until the retainers seat and a click is heard for each connection. Pull back on the quick connects to ensure that the quick connects are firmly locked in place. Do not rely only on the audible click to confirm that secure connections have been made.

WARNING: It is extremely important that the fuel tube and quick connect seating is checked as described in Step D. If the tube and quick connect are not fully secured, normal fuel pressure could eventually unseat the joint, resulting in fuel leakage.

19. Connect the new wiring jumper harness connector to the new methanol sensor. 20. For LH vehicles: Reinstall the fuel tank heat shield that was removed in Step 9. 21. For LH vehicles: Position the fuel tank strap and the sway bar mounting brackets into place. Install and tighten the bolts to 44 ft-lbs (60 N•m) torque. 22. Lower the vehicle. 23. Reconnect the battery. 24. Start the vehicle and check the fuel system for leaks. 2. Install an Authorized Modifications Label: For vehicles involved in Recall #7972 located in California only: Type or print (with a ballpoint pen) the following information on an Authorized Modifications Label (PN 4275086) and attach the label near the VECI label (Figure 4).

3. Complete Proof of Correction Form:

For vehicles involved in Recall #7972 located in California only: Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner.

Completion Reporting and Reimbursement

Claims for vehicles, which 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:

Description Labor Op. No. Time Replace methanol sensor - AA Body 14797182 0.4 hours Replace methanol sensor - LH Body 14797182 0.8 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 & 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 CMMS and the "TIL" 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 will be entered to DIAL System Functions 53 and VIP at the time of recall implementation 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 is 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 "ORD7971" (Federal emission vehicles) or "ORD7972" (California emission vehicles). 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.

California Registration Renewal Program

IMPORTANT: This recall (#7972) is subject to theState of CaliforniaRegistration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal.

The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each California vehicle owner upon completion of the Recall #7972 service for use as proof in renewal of the vehicle registration.

Vehicle Not Available

If a vehicle is not available for service for a known reason, let us know by filling out the pre- addressed Vehicle Disposition Form portion of the 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.

Customer Services Field Operations DaimlerChrysler Corporation

EMISSIONS RECALL TO REPLACE YOUR VEHICLE’S METHANOL FUEL SENSOR

Dear DaimlerChrysler Vehicle Owner:

DaimlerChrysler has determined that some 1993-1994 Dodge Spirit and Plymouth Acclaim; and 1994-1995 Dodge Intrepid, Chrysler Concorde and Eagle Vision vehicles equipped with a flexible fuel engine may be in violation of Federal Emissions Standards.

The problem is... The methanol fuel sensor on your vehicle (identified on the enclosed form) may fail and affect the ability of the engine to adapt to the amount of methanol contained in the fuel. This may cause hard starting, poor driveability and illumination of the "Check Engine" light. This could also result in hydrocarbon (HC), carbon monoxide (CO) and oxides of nitrogen (NOx) levels above the allowable limits which were established to protect the public from the dangers of air pollution. What DaimlerChrysler will repair your vehicle free of charge (parts and DaimlerChrysler and labor). To do this, your dealer will replace the methanol fuel sensor. your dealer will do... 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... • Simply contact your dealer 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 your dealer. If you need help... If you have trouble getting your vehicle repaired, please call the DaimlerChrysler Customer Center, toll free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Vehicle Programs and Compliance Division of the Environmental Protection Agency (6405J), 401 M Street, S.W., Washington, DC 20460.

In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair,your vehicle may fail a state or local emission inspection test.

We are sorry for any inconvenience but trust that you understand our interest in clean air and your continuing satisfaction with our product. Thank you for your attention to this important matter.

Customer Services Field Operations DaimlerChrysler Corporation 7971

EMISSIONS RECALL TO REPLACE YOUR VEHICLE’S

METHANOL FUEL SENSOR

Dear DaimlerChrysler Vehicle Owner:

HC emissions consist of unburned fuel that is released into the atmosphere. HC in combination with NOx in the presence of sunlight can cause the formation of ozone. CO emissions are formed by the incomplete combustion of fuel. These pollutants are the primary components of smog. What DaimlerChrysler will repair your vehicle free of charge (parts and DaimlerChrysler and labor). To do this, your dealer will replace the methanol fuel sensor. your dealer will do... 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... • Simply contact your dealer 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 your dealer. If you don't get this The State of California requires the completion of emission recall done... repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs.

Further, in order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle.

We are sorry for any inconvenience but trust you understand our interest in clean air and in your continued satisfaction with our products. Thank you for your attention to this important matter.

Customer Services Field Operations DaimlerChrysler Corporation 7972