Recall - Non Compliance With FMVSS 301
89Peugeot07BULLETIN NO. 363 ( 1)
DATE: September, 1989
88
SUBJECT: RECALL CAMPAIGN, NON-COMPLIANCE WITH FMVSS 301 - FUEL SYSTEM INTEGRITY
MODELS: ALL 1989MY 405 SEDANS ALL 1990MY 405 SPORTSWAGONS
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Automobiles Peugeot has determined a non-compliance with Federal Motor Vehicle Safety Standard 301 (Fuel System Integrity) which may exist in all 1989 and 1990 model year 405 vehicles as referred to above.
In case of a severe rear crash, the fuel filler pipe may separate at the point where it is connected to the fuel tank hose, resulting in fuel spillage and increasing the risk of fire.
IMPORTANT:
Immediately stop delivery to retail or other purchasers of all 405 Sedans and Sportswagons whether on your inventory or received from the port. Do not sell any of these vehicles until they have been appropriately modified as per the attached instructions.
NOTE:
Due to the nature of the required modification and the absence of the necessary facilities at our port operations, PMA has been unable to make the modification on vehicles at the ports. As a result, dealers receiving cars from the ports must perform this modification prior to retail sale.
OWNER NOTIFICATION:
Retail customers will be notified to bring their vehicles into authorized Peugeot dealers for repair as soon as feasible. You will be informed on a timely basis of the date of the expected owner notification.
PARTS REQUIRED:
Modification Kit P/N 0015.T4, consisting of:
1. Spare tire buffer
2. "U" shaped clamp on buffer
3. Screw HM 6x100-35
4. Flat washer 6-12
5. Nut M 6x100 (for pull rod)
6. Buffer support bracket
7. Buffer mounting flange
8. Lock nut M 6x100 (for buffer support bracket)
9. Flat washer 6-12 (for buffer support bracket)
10. Buffer pull rod
11. Counternut M 6x100 (for pull rod)
12. Caged screw M 6x100-20 (for buffer support bracket)
13. Nut 6x100 (for spare tire buffer)
14. Pop rivet 4.8 diameter, 8.5 mm long
15. Fuel line between pump and filter
16. Fuel line retaining clip
17. 13 mm diameter hose clamp for fuel line between pump and filter
18. 58 mm diameter hose clamp between fuel filler tube and tank
19. 60 mm diameter hose clamp between fuel filler tube and hose (red i.d. paint dot on hose clamp screw housing)
21. "L" shaped bracket for fuel filter
22. Edge protector to be cut to length
23. Sealing washer
24. 70 mm length rubber hose
MODIFICATION PROCEDURE:
IMPORTANT WARNING: THROUGHOUT ALL OPERATION STEPS INDICATED IN THIS PROCEDURE, ANY GRINDING OR WELDING OPERATIONS ARE STRICTLY FORBIDDEN ON OR NEAR THE VEHICLE BEING MODIFIED.
STEP 1:
- Remove:
- spare tire
- ski boot housing on Sedan models if equipped
- trunk carpet and insulator pad
- Place the vehicle on lift
- Remove:
- hose clamps on fuel line between fuel pump and filter
- fuel pump bracket (a) and fuel filter bracket (b) (10 mm retaining nuts)
- fuel line between fuel pump and filter
STEP 2:
- Using two new 13 mm hose clamps (17), install the new fuel line
(15) between fuel pump and filter; the 90~ bend in the line should be installed on the fuel pump side and pointing toward the front of the car
- Temporarily move the fuel pump and filter assembly towards the right of the vehicle
- Install the fuel line retaining clip (16) on the leading edge of rear seat floor where it meets the trunk floor, directly in the center line of vehicle (use spare tire latch as a reference guide for center line of vehicle)
- Attach the fuel line to the retaining clip (16)
- Remove the three caged screws attached to the trunk floor crossmember (previously used to secure the fuel pump and filter brackets)
- Install two new caged screws (12) in the original location of filter bracket screw and front mount of original fuel pump bracket screw
STEP 3:
- Install the buffer support bracket (6) using 2 flat washers
(9) and 2 lock nuts (8) (studs in support bracket facing down)
- Drill two 5 mm (0.20") diameter holes through the trunk floor crossmember using the holes (c) at each end of the buffer support bracket as reference guides
- Apply a coating of rustproofing compound to the drilled holes
- Install 4.8 mm diameter pop rivets
(14) to secure each end of the buffer support bracket to the trunk floor crossmember
STEP 4:
Locating Center of 6.5 mm Hole to be Drilled:
- Scribe a line 127 mm (5") forward of the front edge of trunk floor crossmember
- Scribe a line 50 mm (2") to the right of the center rib of trunk floor; this should be located directly in the center of the rib on the right side of the center rib of the vehicle as determined by the spare tire latch
- Drill a 6.5 mm (0.25") diameter hole where the two lines meet
- Apply a coating of rustproofing compound to the drilled hole
STEP 5:
- Install the pull rods (10) in the threaded holes in the support bracket (6); tighten until they come in contact with the trunk floor crossmember
- Install the counternuts (11) with flat washer part facing support bracket (6)
- Tighten counternuts (11)
- Install the spare tire buffer (1) onto the pull rods (10) and through the 6.5 mm hole drilled in Step 4
- Install the buffer flange (7) onto the pull rods (10) using new retaining nuts (5)
- Tighten until approximately 20 mm (0.78") of stud protrude through the nuts. A slight deformation of the buffer flange (7) is normal.
- Check that the fuel line (15) is properly routed behind the buffer (1)
- Reinstall:
- fuel filter using the new "L" shaped bracket (21)
- fuel pump on studs in support bracket (6), making sure to reinstall the fuel pump wire bracket at the same time
- Align the brake line (d) to prevent contact and possible pinching of the fuel pump inlet hole
STEP 6:
IMPORTANT WARNING: DO NOT DISCONNECT THE FUEL FILLER HOSE FROM THE TANK OR FILLER TUBE. OPEN THE HOSE CLAMPS IN ORDER TO FIT THEM ON THE FUEL FILLER TUBE AND HOSE.
- Remove the two original fuel tank filler hose clamps (18) and (19) by releasing the lock tabs with a flat-blade screwdriver
- Install hose clamp (19) (red i.d. paint dot manufactured by "Awas") between filler tube and hose and tighten to a torque of 0.450 mdaN (40 in.lbs.)
- Install hose clamp (18) between filler hose and tank; position clamp screw housing 30~ from center line shown on drawing. Tighten to a torque of 0.20 mdaN (18 in.lbs.)
STEP 7:
- Cut the lower corner of the right side inner fender lip (e) (shaded area of drawing)
- Apply a coating of rustproofing compound to the exposed edge of inner fender lip
- Based on model type, cut and install the edge protector strips
(22) as shown below and on next page
SEDAN: (Fig. 1)
1 piece 220 mm (8.7") long
1 piece 120 mm (4.7") long
2 pieces 40 mm (1.6") long
- Install the 120 mm protector along the lower right side inner fender lip, taking care to cover the area cut-out in Step 7
- Install the 220 mm long protector along the side and bottom edge of the right side bumper mounting bracket
- Install the two short 40 mm protector's on the leading edges of the right side bumper mounting bracket above and below the
SPORTSWAGON: (Fig. 2)
2 pieces 220 mm (8.7") long 2 pieces 60 mm (2.4") long
- Install the two 220 mm long pieces along the lower right side inner fender lip. The trailing edge of the first protector should first be installed against the plastic filler panel (mud flap), then press into place along the fender lip. To install the second piece, first install the leading edge against the rear of the plastic filler panel, then press into place along the fender lip
- Install the two 60 mm long pieces on the upper and lower leading edges of the bumper shock mounting frame as shown (22)
ALL MODELS:
- Install the split rubber hose (24) on the filler tube vent hose to prevent direct contact with fuel pump
- Reinstall the spare tire
- From inside the trunk area, install sealing washer (23) on the stud protruding from the buffer and tighten using a new retaining nut (13)
- Reinstall ski boot housing
- Reinstall trunk insulating pad and carpet
- Tighten spare tire carrier
WARRANTY INFORMATION:
Allocation Code: XL7
Damage Code: 0099L7
Operation Number: 990112
Time Allowance: 2.00 hours