Safety Recall F44 Fuel Pump Module And/Or Reprogram Pcm (F44)

Publication date: 2006-11-01
Reference number: F44

SAFETY RECALL F44 FUEL PUMP MODULE AND/OR REPROGRAM PCM

SERVICE CAMPAIGN BULLETIN

Reference Number(s): F44, Date of Issue: November, 2006

CHRYSLER:

2005 - 2006 (CS) Chrysler Pacifica

NOTE: Effective immediately, all repairs on involved vehicles are to be performed according to this recall. Service Bulletin #18-039-05 is being cancelled.

MODELS

2005 - 2006 (CS) Chrysler Pacifica

NOTE: This recall applies only to the above vehicles built from July 8, 2004 through November 24, 2005 (MDH 070800 through 112400) .

IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall.

IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery . Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.

SUBJECT

The fuel pump module and/or the Powertrain Control Module (PCM) software on about 127,900 of the above vehicles may allow the engine to stall if the vehicle is driven under certain operating conditions. This could cause a crash without warning.

REPAIR

The PCM must be reprogrammed (flashed) on all involved vehicles. The driver's side fuel pump module must also be replaced on vehicles built from August 1, 2004 through September 30, 2004 (MDH 080100 through 093023). Refer to the DealerCONNECT VIP function and/or the Global Recall System (GRS) to determine those VIN's that need a fuel pump and a PCM reprogram vs. those that need a PCM reprogram only.

PARTS INFORMATION

A. Fuel Pump Module Package

PARTS INFORMATION

Part Number	Description
CBB2F440	Fuel Pump Module Package

Each package contains the following components:

PACKAGE COMPONENTS INFORMATION

Quantity	Description
1	Module, Fuel Pump
1	Gasket, Fuel Pump Module

Each dealer to whom vehicles in the recall were assigned will receive one Fuel Pump Module to service only those vehicles built from August 1, 2004 through September 30, 2004 (MDH 080100 through 093023).

NOTE: Only vehicles built within the above two month period require fuel pump modules. Refer to the DealerCONNECT VIP function and/or the Global Recall System (GRS) to determine those VIN's that need a fuel pump and a PCM reprogram vs. those that need a PCM reprogram only.

B. Authorized Modifications Label

Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed.

Each vehicle requires application of the following labels:

MODIFICATIONS LABEL PARTS INFORMATION

Part Number	Description
04275086AB	Authorized Modifications Label

SPECIAL TOOLS

The following special tools are required to perform this repair:

NPN TechCONNECT PC or equivalent
CH2002 General Purpose Interface Bus Cable Assembly
CH6000A DRBIII® Scan Tool
CH7000A / J1962 Cable with red DRBIII connector
NPN TechCONNECT Workstation

SERVICE PROCEDURE

A. Reprogram the Powertrain Control Module

NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII® connection. Use this cable whenever a flash is being performed.

NOTE: Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available.

NOTE: If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool.

Before beginning the flash procedure, remove any old flash files from the DRBIII memory. To clear the memory from the "Main Menu" :
1. Simultaneously press the "MORE" and "YES" keys.
2. A screen will appear requesting a "COLD BOOT" .
3. Follow the on screen instructions by selecting the "F4" key.
4. When the DRBIII reboots to the MAIN MENU, continue with Step 2.
With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII:
1. Select "DRBIII Standalone" .
2. Select "1998 - 2007 Diagnostics" .
3. Select "All (Except Below)" .
4. Select "Engine" .
5. Select "Module Display" .
6. Record the "PCM part #" for later reference.
Connect the DRBIII to TechCONNECT. Open TechTOOLS and verify that the "DRBIII Status: Connected" message is in the upper right corner of the TechTOOLS screen.
Enter the PCM part number recorded in Step 2f in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file.
Select the flash file.
Select the "DRBIII" radio button which is next to the "Download/Update" button.
Select the "Download/Update" button.
Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step 9.
Disconnect the DRBIII from TechCONNECT.
Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process.
Connect the DRBIII to the vehicle.
Download the flash file from the DRBIII to the vehicle. Using the DRBIII:
1. Select "Vehicle Flash" .
2. Follow the directions on the DRBIII screen.
3. When the flash process is complete, proceed to the next step.
Reset the "Pinion Factor" as necessary.
Perform the transmission Quick learn Procedure as necessary.
Due to the PCM programming procedure, a Diagnostic Trouble Code (DTC) may be set in other modules within the vehicle. Some DTC's may cause the Malfunction Indicator Lamp (MIL) to illuminate. Check all modules using "Module Scan", record the DTC's and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased.
Turn off the battery charger and disconnect it from the vehicle.
Type or print (with a ballpoint pen) the recall number, dealer code and date on an Authorized Modifications Label (Figure 1 ).
Attach the Authorized Modifications label near the VECI label.
For vehicles build from August 1, 2004 through September 30, 2004 (MDH 080100 through 093023) continue with Section B. Replace Fuel Pump Module . Vehicles with a build date that is not in the above date range DO NOT require a new fuel pump module.

B. Replace Fuel Pump Module

NOTE: Fuel pump module replacement is only required on vehicles built from August 1, 2004 through September 30, 2004 (MDH 080100 through 093023).

Release the fuel pressure from the fuel system using the following procedure:
1. Open the Power Distribution Center (PDC) cover located next to the battery (Figure 2 ).
2. Remove the fuel pump relay (Figure 2 ).
  NOTE: Refer to the PDC cover for fuel pump relay location.
3. Start the engine and allow it to run until the engine stalls.
Disconnect the negative battery cable.
Remove the fuel tank using the following procedure:
1. Drain the fuel from the fuel tank into a properly labeled GASOLINE safety container.
2. Raise vehicle on an appropriate hoist.
3. Loosen the exhaust pipe clamp and separate the exhaust system between the catalytic converter and the muffler.
4. Support the exhaust system with jack stands.
5. Remove muffler hanger rubber grommets.
6. Remove the center exhaust hanger rubber grommets.
7. With the help of an assistant, remove the rear portion of the exhaust system and set it on the floor.
8. Disconnect the fuel tank electrical connector located at the rear of the tank (Figure 3 ).
9. Disconnect the fuel line, EVAP line, and vapor recirculation tube located at the right front corner of the fuel tank (Figure 4 ).
10. For vehicles with all wheel drive, place alignment marks on the driveshaft where it attaches to the PTU and the rear axle.
11. For vehicles with all wheel drive, remove the front muffler heat shield.
12. For vehicles with all wheel drive, support driveshaft using jack stands.
13. For vehicles with all wheel drive, disconnect the rear end of the driveshaft.
14. For vehicles with all wheel drive, remove the center and rear driveshaft support/bearing bolts.
15. For vehicles with all wheel drive, disconnect the front end of the driveshaft.
16. For vehicles with all wheel drive, with the help of an assistant, lower the driveshaft assembly and set it aside.
17. Remove the left rear tire and wheel well plastic splash shield.
18. Remove the fuel filler tube from the rubber hose on the fuel tank.
19. Support the fuel tank with a transmission jack.
20. Remove the two fuel tank straps.
21. Lower the fuel tank.
Place the fuel tank on the floor.
Using a vacuum cleaner, remove any debris from the area around the driver's side fuel pump module lock ring (Figure 5 ).
Disconnect the vapor line and the electrical connector on the driver's side fuel pump module (Figure 5 ).
Using a brass punch and hammer, remove the driver's side fuel pump module lock ring (Figure 6 ).
NOTE: Use a brass punch to rotate the lock ring 1/4 turn. Make contact only at the points shown in Figure 6 .
Lift the fuel pump module top and disconnect the wire connector inside of the tank for the passenger side level sensor.
Remove the internal tank return fuel line from pump module. Use a small screwdriver to pry the lock tab back and tilt the hose to one side. Pry the lock tab back on other side to release the hose (Figure 7 ).
CAUTION: Care should be taken to not crack/break the locking tabs or supply line fitting.
Remove the internal tank supply fuel line from top of the pump module. Use a small screwdriver to pry the lock tab back and tilt the hose to one side. Pry the lock tab back on other side to release the hose (Figure 8 ).
Tip the fuel pump module on its side to remove fuel from the reservoir.
Remove and discard the fuel pump module assembly and gasket.
Place the new fuel pump module gasket into position.
Install the new fuel pump module assembly into the fuel tank.
NOTE: The lower part of the fuel pump module is off-set from the upper part when correctly installed into the tank (Figure 8 ).
Connect the return fuel line first and then connect the supply fuel line to the new fuel pump module (Figure 7 ).
Connect the wires from the passenger side level sensor to the new pump module.
Install the fuel pump module top to fuel tank and then install the fuel pump module lock ring.
NOTE: Use a brass punch to install the lock ring 1/4 turn.
Connect the vapor line and the electrical connector onto the driver's side fuel module (Figure 5 ).
Place the fuel tank back onto the transmission jack.
Raise the fuel tank into position and install the fuel tank straps. Tighten the mounting strap bolts to 40 ft. lbs. (54 N.m).
Install the fuel filler tube onto the rubber fuel tank fill hose and tighten the screw clamp securely.
Install the left rear wheel well plastic splash shield.
Install the tire/wheel assembly. Tighten the lug nuts to 100 ft. lbs. (135 N.m) and in the sequence shown in Figure 9 .
For vehicles with all wheel drive, place the driveshaft in position with jack stands.
For vehicles with all wheel drive, align the marks made in Step j and install the front driveshaft onto the PTU. Install the front driveshaft bolts and tighten to 22 ft. lbs. (30 N.m).
For vehicles with all wheel drive, install the driveshaft center and rear support/bearing mounts. Tighten the support-to-body bolts to 40 ft. lbs. (54 N.m).
For vehicles with all wheel drive, align the marks made in Step j and install the driveshaft onto the rear axle. Then tighten the bolts to 40 ft. lbs (54 N.m).
Connect the fuel line, EVAP line and vapor recirculation tube located at the right front corner of the fuel tank (Figure 4 ).
Connect the fuel tank electrical connector located at the rear of the tank (Figure 3 ).
With the help of an assistant, place the rear portion of the exhaust system into position and support the exhaust system with jack stands.
Connect the inlet pipe of the front muffler to the outlet pipe of the catalytic converter. Tighten the exhaust pipe clamp to 40 ft. lbs. (54 N.m)
Install the center exhaust hanger rubber grommets.
Install the rear muffler rubber grommets onto the hangers (Figure 10 ).
Lower the vehicle from the hoist.
Fill the fuel tank with the fuel removed in Step a.
Install the fuel pump relay into the PDC and then close and latch the PDC cover.
Connect the negative battery cable.
Using the DRBIII scan tool to pressurize the fuel system, check for any fuel leaks.
Disconnect and remove the DRBIII from the vehicle.

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 numbers and time allowances:

LABOR OPERATION NUMBER AND TIME ALLOWANCE

	Labor Operation Number	Time Allowance
PCM update previously performed	18-F4-41-81	0.2 hours
Reprogram the PCM	18-F4-41-82	0.7 hours
Replace fuel pump module (MDH 080100 through 093023) & PCM update previously performed	14-F4-41-82	1.3 hours
Replace fuel pump module (MDH 080100 through 093023) & reprogram the PCM	14-F4-41-83	2.0 hours
Optional Equipment:
All Wheel Drive	14-F4-41-60	0.6 hours

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

NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

DEALER NOTIFICATION

All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification.

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.

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.

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.

ADDITIONAL INFORMATION

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

Customer Services Field Operations

DaimlerChrysler Corporation

SAFETY RECALL F44 - FUEL PUMP MODULE AND/OR REPROGRAM PCM

Dear: (Name)

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

DaimlerChrysler Corporation has decided that a defect, which relates to motor vehicle safety, exists in some 2005 and 2006 model year Chrysler Pacifica vehicles .

The problem is... The fuel pump module and/or the Powertrain Control Module (PCM) software on your vehicle (VIN: xxxxxxxxxxxxxxxxx) may allow the engine to stall if the vehicle is driven under certain operating conditions. This could cause a crash without warning.

What your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor) . To do this, your dealer will reprogram your vehicle's PCM. Some vehicles built within a certain time frame must also have the fuel pump module replaced. This work will require up to two hours to complete. However, additional time may be necessary depending on how dealer appointments are scheduled and processed.

What you must do to ensure your safety... Simply contact your dealer right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. Remember to bring this letter with you to your dealer.

If you need help... If you have questions or concerns which your dealer is unable to resolve, please contact DaimlerChrysler at 1-800-853-1403.

Please help us update our records, by filling out the attached prepaid postcard, if any of the conditions listed on the card apply to you or your vehicle.

If you have already experienced this condition and have paid to have it repaired, you may send your original receipts and/or other adequate proof of payment to the following address for reimbursement: DaimlerChrysler P.O. Box 4639 Oak Ridge, TN 37831, Attention: Reimbursement.

If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov.

We're sorry for any inconvenience, but we are sincerely concerned about your safety. Thank you for your attention to this important matter.

Customer Services Field Operations

DaimlerChrysler Corporation

Notification Code F44

Note to lessors receiving this recall: Federal regulation requires that you forward this recall notice to the lessee within 10 days.