On certain vehicles equipped with diesel engines, a temporary fuel tank breather tube cap may not have removed during assembly, and the tube may not have been correctly affixed to the bed rail. As a result, the fuel tank may not receive proper ventilation through the fuel tank breather tube and, in some instances, may deform. This condition could result in the fuel gauge, and the separate “distance to empty” meter, to both display inaccurately. If this occurs, the vehicle could possibly run out of fuel, which would cause the engine to stall without warning to the driver. Engine stalling could increase the risk of a crash causing injury and/or property damage.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the fuel tank breather tube for proper routing and inspect for the absence of the temporary fuel tank breather tube cap to determine if a vehicle is affected. The temporary fuel tank breather tube cap will be removed and fuel tank, fuel sending unit, and/or fuel tank breather tube will be replaced as necessary.
On certain Amerivan 10 wheelchair accessible vehicles built on Dodge Grand Caravan and Chrysler Town and Country platforms, the crimp fasteners used to retain fittings in the fuel line may not be fully crimped or compressed. This could result in a fuel leak. Leaking fuel, in the presence of an ignition source, could lead to a fire causing injury and/or damage to property.
Safety Risk
No risk description available.
Remedy
Dealers will inspect fasteners and crimp the fasteners further to ensure they are fully compressed and seated.
On certain vehicles, the fuel pump sealing rings may deteriorate from being exposed to heat from the engine and exhaust pipe. Over time, this could cause the fuel pump rings to crack, which could result in a fuel leak. A fuel leak in the presence of an ignition source could result in a fire causing injury and/or property damage.
Safety Risk
No risk description available.
Remedy
Dealers will replace the fuel pump rings with new parts and add additional insulation to the fuel tank.
On certain vehicles equipped with certain 3.6L V6 gasoline engines, the fuel rail crossover tube may be damaged. Over time this could result in a fuel leak, which in the presence of an ignition source could increase the risk of a vehicle fire causing injury and/or property damage.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the fuel rail crossover tube for damage. The fuel rail assembly and the lower intake manifold will be replaced on vehicles found to have the damage.
On certain motorcycles, the wiring sealing material of the fuel pump mounting plate could become damaged. This could allow for fuel to escape from the fuel tank and travel along the wiring toward the sub harness to the main harness connector, possibly resulting in an electrical short. This could lead to a fire, which could increase the risk of injury and/or damage to property.
On certain vehicles, the fuel delivery line may not have sufficient clearance between the underfloor and the under shield. This could cause the fuel line to chafe against the underfloor and the under shield which could result in a fuel leak. A fuel leak in the presence of an ignition source could result in a fire causing injury and/or damage to property.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the fuel delivery line for chaffing and replace it as necessary. Additional clips will be added to prevent chafing.
On certain vehicles, the thickness of the port wall of the Fuel Delivery Module (FDM) may be below specification and could result in the supply port cracking. If a crack were to develop in the vertical portion of the FDM fuel supply port, a fuel leak could occur. A fuel leak in the presence of an ignition source could result in a fire causing injury and/or property damage.
Safety Risk
No risk description available.
Remedy
Dealers will replace the FDM flange with a flange that has a redesigned fuel supply port.
On certain vehicles equipped with a 6.7L diesel engine and a middle position fuel tank, there could be inadequate adhesion between the protective shield and the fuel conditioning module. This could allow for the the shield to be dislodged by road debris or water spray, which could force open the drain valve on the module. If the drain valve were to be forced open, this could result in substantial fuel leak. It could also allow for air ingress into the fuel system, which may cause the engine to stumble. A substantial fuel leak on a road surface could increase the risk of a crash, and a fuel leak in the presence of an ignition source could result in a fire causing injury and/or property damage.
Safety Risk
No risk description available.
Remedy
Dealers will replace the adhesive mounted protective shield on the fuel conditioning module with a bolt-on metallic protective shield.
On certain vehicles, the wires going to the in-tank fuel pump may not have been crimped correctly. An incorrect crimp could increase the resistance of the circuit which could cause the contact pin to heat and melt the surrounding plastic. This could potentially cause the fuel pump to stop working causing the vehicle to stall without warning, increasing the risk of a crash causing injury and/or damage to property. Also, in a very rare case, a fuel leak combined with an external ignition source, could increase the risk of fire causing injury and/or damage to property.
On certain vehicles. the fuel tank may contain a defect which could allow a weld to break, potentially resulting in a fuel leak. A fuel leak in the presence of an ignition source could result in a fire causing injury and/or property damage.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the fuel tank and replace if necessary.
On certain vehicles. the fuel tank may contain a defect which could allow a weld to break, potentially resulting in a fuel leak. A fuel leak in the presence of an ignition source could result in a fire causing injury and/or property damage.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the fuel tank and replace if necessary.
On certain Amerivan 10 wheelchair accessible vehicles built on Dodge Grand Caravan platforms, a fuel line on the vehicle underbody may be routed incorrectly and could contact underbody components, potentially resulting in a fuel leak. Leaking fuel, in the presence of an ignition source, could lead to a fire causing injury and/or damage to property.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and reposition the fuel line.
On certain motorcycles, the resin inlet cover of the fuel pump may swell abnormally and interfere with the rotation of the impeller which may cause the fuel pump to stop working properly. While parked, this can prevent the engine from starting. If this occurs while riding, it may cause the engine to stall and possibly not restart. Engine stalling, in conjunction with traffic, road conditions, and driver's reactions, could increase the risk of a crash causing injury and/or property damage.
Safety Risk
No risk description available.
Remedy
Dealers will replace the original fuel pump with an updated pump.
On certain vehicles, the fuel pump flange may develop fine cracks or fissures, which could result in a fuel leak. Leaking fuel, in the presence of an ignition source, could lead to a fire causing injury and/or damage to property.
Safety Risk
No risk description available.
Remedy
Dealers will apply a butyl protective film to the fuel pump flange. If cracks are present, the fuel pump flange will be replaced.
On certain vehicles, the under hood fuel hose may degrade, which could result in a fuel leak. Leaking fuel, in the presence of an ignition source, could lead to a fire causing injury and/or damage to property.
Safety Risk
No risk description available.
Remedy
Dealers will replace the under hood fuel hose and the in-tank fuel pump.
On certain vehicles, the suction pump inside the fuel tank designed to purge fuel from the evaporative emissions (EVAP) system may be compromised. This could cause fuel to flow directly into the EVAP system which could, over time, accumulate and cause a leak through the charcoal canister filter element. Leaking fuel, in the presence of an ignition source, could lead to a fire causing injury and/or damage to property.
Safety Risk
No risk description available.
Remedy
Dealers will replace the suction pump inside the fuel tank.
On certain vehicles equipped with a 3.2L diesel engine, defects in the high pressure fuel pump could result in excessive wear, leading to metallic wear particles. These particles could clog fuel volume control valves and/or fuel injectors, potentially resulting in the engine stalling or failing to start. A loss of motive power could increase the risk of a crash causing injury and/or damage to property.
Safety Risk
No risk description available.
Remedy
Dealers will replace the fuel injection pump and inspect the fuel system for metallic contamination. If metallic contamination is present, dealers will also clean/flush the fuel system and replace the fuel filter and fuel injectors.
On certain vehicles equipped with a 2.0 litre turbocharged engine, the fuel line assembly may not have been routed properly due to a manufacturing error. This could cause the fuel lines to contact hot surfaces which could, over time, degrade the fuel lines and cause a leak. A fuel leak in the presence of an ignition source could result in a fire causing injury and/or damage to property.
On certain vehicles, the fuel tank may have received insufficient welds during manufacturing. Over time, the insufficient welds may separate and allow for fuel leakage. A fuel leak in the presence of an ignition source could result in a fire causing injury and/or property damage.
On a certain vehicles, the fuel rail may detach from the cylinder head, allowing fuel to leak into the engine compartment during engine operation. Leaking fuel, in the presence of an ignition source, could lead to a fire causing injury and/or damage to property.
Safety Risk
No risk description available.
Remedy
Dealers will replace the cylinder head with a new part.
