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
Total Page：16
File Type：pdf, Size：1020Kb
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.