Recall - Fuel Pressure Regulator
No. 512February, 1992
To: All Dodge and Chrysler-Plymouth Dealers
Subject:
Safety Recall # 512 -- Fuel Pressure Regulator
Models:
1987 Model Year Plymouth Horizon and Turismo, Dodge Omni and Charger (L-Body) Equipped With 2.2L Carbureted Engine Having a Pressure Regulator In The Fuel Supply System
Affected Vehicles Were Built From November, 1986 Through The End of Model Year
The fuel system pressure regulator, installed on involved vehicles during the listed build period, may leak. This could result in an engine compartment fire. The regulator must be replaced with a fuel reservoir, which requires other changes in the fuel supply plumbing system.
Details of this service action are explained in the following sections.
Note:
As an additional service aid, a videotape demonstrating the service procedure will be included in the February, 1992 Master Tech program.
Vehicle List
Each dealer to whom involved vehicles were invoiced (or the current dealer at the same location) will receive with this letter a vehicle list arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles.
Each Dodge or Chrysler-Plymouth dealer without a Vehicle List will receive an information copy of this letter by Compak Mail for use in performing the service on any involved transient vehicles.
Parts
Important:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand.
Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same location), will receive enough Fuel System Reservoir Parts Packages, Recall PN C3940459, at dealer cost to service 25 % of those vehicles.
Each parts package contains a fuel reservoir with mounting bracket, hoses and associated hardware required for installation. Also included in each package is an instruction summary for convenient reference by the servicing technician.
Additional parts may be ordered as needed.
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is included.
Enclosed with each owner notification is an Owner Recall Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.
Service Procedure
1. With the ignition key in the OFF position, disconnect the negative battery cable.
2. Remove the air cleaner assembly.
Refer to Figure 1 for steps 3 through 9:
3. Disconnect the fuel supply hoses from the carburetor and from the fuel tube at the top right of the valve cover.
4. Remove the fuel pressure regulator, hoses and bracket assembly from the carburetor and discard.
5. Disconnect the hose from the vapor return tube at the right (passenger) side shock tower.
6. Disconnect the hose from the fuel supply tube routed from the fuel pump.
7. Release the tubes from the two retaining clips at the front of the valve cover.
8. Remove the fuel filter/vapor separator, tubing and hoses from the vehicle.
9. Remove the 5/16" fuel supply tube from the filter/separator for reuse. Discard the filter/separator and other associated plumbing, including the 1/4" vapor return tube and hose.
10. Attach the supplied 5-1/2" long fuel hose to the end of the fuel supply tube that was previously connected to the filter/separator, using a new clamp from the parts package. Tighten the clamp to 10 in.lbs. (1 N-m) torque.
11. Position the fuel supply tube along the valve cover and attach the other end of the 5-1/2" long hose to the fuel tube from the fuel pump, using a new clamp (FIGURE 2). Tighten the clamp to 10 in.lbs. (1 N-m) torque.
12. Secure the tube in the two retaining clips at the valve cover (FIGURE 2).
13. Attach the supplied reservoir to the new air cleaner gasket/bracket, using the nuts provided in the parts package. Tighten the nuts to 50 in.lbs. (6 N-m) torque. Note: The supplied reservoir contains an internal filter.
14. Install the supplied reservoir, hose and bracket assembly, using the supplied clamps to secure the hoses (FIGURE 3). Tighten the clamps to 10 in.lbs. (1 N-m) torque.
^ Attach the shorter 5/16" diameter fuel hose to the carburetor fuel inlet fitting.
^ Attach the longer 5/16" diameter fuel hose to the fuel supply tube at the top right side of the valve cover.
^ Attach the 1/4" diameter hose to the vapor return tube at the right shock tower.
15. Install the air cleaner assembly.
16. Connect the battery.
17. Start the engine, check for leaks and proper engine operation.
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments.
Use the labor operation number and time allowance (see illustration).
Note:
See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing instructions.
Parts Return
Not required.
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 Recall Notification Form or describe the reason on a postcard and mail to:
Chrysler Corporation 415-03-18
Recall Coordination
P.O. Box 1919
Detroit, Michigan 48231-9986
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your
Zone Service Office.
SAFETY RECALL - FUEL PRESSURE REGULATOR
Dear Chrysler Corporation Vehicle Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1987 model Plymouth Horizon and Turismo, Dodge Omni and Charger vehicles equipped with 2.2L carbureted engines. On these vehicles, fuel leakage could occur at the fuel pressure regulator. In some cases this could result in an engine compartment fire, which could be hazardous to vehicle occupants.
Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange for service to correct the condition without delay. The service and required parts as described in this letter will be provided free of charge.
Your dealer will replace the pressure regulator with a new fuel reservoir. The work will take about one-half hour to complete. However, additional time may be required depending on how dealer appointments are scheduled and processed. To obtain this free service:
^ Contact your dealer as soon as possible to schedule an appointment for the service.
^ Take the enclosed Owner Recall Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and recall for which the service is required.
If you have any problem obtaining the needed repair, please contact the Chrysler Zone Service Office in your area. (It is listed under "Service Assistance" in your Owner's Manual.) A Zone representative will arrange for prompt attention to your vehicle.
We regret any inconvenience which this action may cause you. However, we believe that you understand our concern for motor vehicle safety, and for your continued satisfaction with our products. If your dealer fails or is unable to remedy this defect without charge within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1-800-424-9393. (Washington D.C. area residents may call 366-0123.)
Thank you for your attention to this important matter.