Safety Recall D31 - Fuel Pump Module (RC-D31-04)

SAFETY RECALL D31 - FUEL PUMP MODULE

SERVICE CAMPAIGN BULLETIN

Models

2004 (ST) Chrysler Sebring Coupe and Dodge Stratus Coupe 

Subject

The fuel pump module on about 8,900 of the above vehicles may have an improperly molded fuel return port. This can cause the fuel return port to fracture and leak fuel. Fuel leakage in the presence of an ignition source can result in an underbody fire.

Repair

The fuel pump module must be replaced.

Parts Information

Each dealer  to whom vehicles in the recall were invoiced will receive enough of each fuel pump module package to service about 10%  of those vehicles.

The appropriate fuel pump module for the vehicle being serviced is displayed on the DealerCONNECT VIP function and may also be determined by using the table below.

Engine	8th VIN Character	VIN List Part Type Code	Part Number (Shown on VIP)
2.4L - 4-Cylinder	G	1	MR990817
3.0L - 6-Cylinder	H	2	MR990818

Special Tools

The following existing special tool may be required to perform this service procedure:

• #6856 Fuel Pump Module Lock Ring Tool

Service Procedure

1. Remove the instrument panel driver side end cap.
2. Remove the fuel pump relay from the fuse panel (Fig 1 ).
Fig 1: Removing Fuel Pump Relay From Fuse Panel

3. Start the engine and let it run until it runs out of fuel. Attempt to start the engine three more times and then turn the ignition key to the LOCK position.
4. Install the fuel pump relay (Fig 1 ).
5. Install the instrument panel end cap.
6. Pull the two (2) rear seat cushion catches to release the rear seat cushion and then remove the rear seat cushion (Fig 2 ).
   Fig 2: Removing Rear Seat Cushion

   
7. Remove the passenger (right) side fuel pump module wiring harness clip fastener and then remove the clip from the floorpan.
8. Remove the four (4) fuel pump module access panel screws and then remove the access panel (Fig 3 ).
Fig 3: Removing Fuel Pump Module Access Panel

9. Disconnect the fuel pump module and wiring harness electrical connectors and disconnect the harness support from the fuel pump module return port.
10. Disconnect the small diameter return hose from the fuel pump module.
11. Disconnect the fuel supply hose from the fuel pump module.
    IMPORTANT: If the fuel tank is over 3/4 full, drain enough fuel through the return port to lower the fuel to the 3/4 full level.
12. Using Special Tool #6856, remove the fuel pump module lock ring (Fig 4 ).
    Fig 4: Removing Fuel Pump Module Lock Ring

    
13. Remove the fuel pump module and seal from the fuel tank and discard.
14. Install the provided pump module seal into the fuel tank opening.
    CAUTION: Do not install the seal onto the pump module prior to installing the module into the tank or damage to the seal could occur.
15. Lubricate the pump module seal with soapy water and then install the new fuel pump module into the fuel tank and align the mating marks (Fig 5 ).
    Fig 5: Installing Fuel Pump Module Lock Ring

    
16. Using Special Tool #6856, install the fuel pump module lock ring (Fig 5 ).

    Tighten the lock ring to 59 ft-lbs (80 N.m).

    CAUTION: When tightening the lock ring, do not allow the fuel pump module to turn. Make sure that the mating marks remain aligned.
17. Connect the fuel supply hose to the fuel pump module.
18. Connect the fuel return hose to the fuel pump module.
19. Connect the fuel pump module and wiring harness electrical connectors.

    Connect the harness support to the fuel pump module return port.

20. Start the engine and check to make sure that it runs smoothly and that there are no fuel leaks.
21. Install the fuel pump module access cover (Fig 3 ). Tighten the access cover screws securely.
22. Install the fuel pump module wiring harness clip and secure it with the screw.
23. Install the rear seat cushion (Fig 2 ). Be sure to insert the seat belt buckle assemblies through the cushion openings. Pull up on the front of the cushion to ensure that the catches are fastened.

Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. 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 Number	Time Allowance
Replace fuel pump module	14-D3-11-82	0.4 hours

Add the cost of the parts package plus applicable dealer allowance to your claim.

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. DealerCONNECT will be updated to include this recall in the near future.

Vehicle Lists, Global Recall System, VIP and Dealer Follow Up

All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter.

GRS provides involved dealers with an updated  VIN list of their incomplete  vehicles. The owner's name, address and phone number are listed if known.

Completed vehicles are removed from GRS within several days of repair claim submission.

To use this system, click on the "Service"  tab and then click on "Global Recall System."  Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence.

Dealers must  perform this repair on all unsold vehicles before  retail delivery.

Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair.

Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. 

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 generic copy of the owner letter is attached.

Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable.

Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair.

Additional Information

If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager.

1. Customer Services Field Operations
2. DaimlerChrysler Corporation