On certain vehicles, the software within the Central Electronic Module (CEM) may not send a signal to the fuel Pump Electronic Module (PEM). This missing signal to the PEM inhibits the start of the fuel pump. The driver may be able to start the engine in spite of the fuel pump not being activated due to residual pressure in the fuel system. In some cases, the driver may be able to drive the vehicle a short distance at idle. However, the engine will eventually stall. Engine stalling would result in lost propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash.
On certain vehicles, one of the two rollover valves fitted to the top of the fuel tank may have been installed incorrectly during vehicle assembly. This could result in illumination of the malfunction indicator lamp (MIL), a fuel odour, or a fuel leak. Fuel leakage, in the presence of an ignition source, could result in a fire.
Safety Risk
No risk description available.
Remedy
All vehicles will be held at the port of entry where replacement fuel tanks will be fitted. No vehicles have been distributed to dealerships or owners.
On certain vehicles, the fuel pump nipple may develop cracks and leak. Fuel leakage, in the presence of an ignition source, could result in a fire causing property damage, personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will replace the fuel pump bracket (including nipple) with an update version.
On certain E-350 and E-450 cutaway vehicles with school bus prep packages and some Econoline E-350 vans, certain frame rail tank guard brackets may have been omitted during vehicle assembly. These brackets are intended to prevent frame edge to fuel tank contact during a vehicle crash. As these vehicles were not evaluated for compliance without the use of brackets, their performance during a vehicle crash is thereby unknown. Should the tank be damaged enough to cause a fuel leak a vehicle fire could ensue, which may result in personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if missing, install the brackets.
On certain motorcycles, a plastic fitting between the fuel injector and hose can warp or break. This may cause a fuel leak which, in the presence of an ignition source, could result in a fire causing property damage, personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if necessary, replace the fuel injector hose assembly.
On certain vehicles, the fuel system control module may be subject to water intrusion. This could cause a short or open circuit, illumination of the Service Engine Soon lamp, setting diagnostic trouble codes, or the engine may be hard to start, may not start or may stall. Engine stalling would result in lost propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash.
Safety Risk
No risk description available.
Remedy
Dealers will replace the fuel system control module.
On certain Econoline chassis/cab school bus prep package vehicles, the upper fuel tank protection bracket was not assembled in the intended position on the frame rail. The unintended position of the bracket may allow the frame-edge to contact the fuel tank during a vehicle crash. Fuel tank damage may cause fuel leakage which, in the presence of an ignition source, could result in a fire causing property damage, personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will reposition the fuel tank protection bracket.
On certain vehicles, the fuel tank front support strap may fracture. Continued use of the vehicle may eventually fracture the rear support strap and stone shield fasteners, which could allow the fuel tank to separate. The errant tank assembly could strike a vehicle, property, or a bystander, which could result in property damage, personal injury or death. Fuel leakage, in the presence of an ignition source, could result in a fire.
Safety Risk
No risk description available.
Remedy
Dealers will replace the fuel tank front support strap with an update version.
On certain vehicles, the use of selected ethanol fuels may cause the aluminium fuel rails to corrode. This could result in plugged fuel injector(s), causing a rough engine idle and/or the illumination of the engine warning lamp. Corrosion may also cause a pinhole to develop on the fuel rail, which could result in fuel leakage. Fuel leakage, in the presence of an ignition source, could result in a vehicle fire.
On certain vehicles, the fuel tank inlet check valve may not fully close after refueling. This could allow some fuel to escape from the fuel tank filler tube. Fuel, in the presence of an ignition source, can result in a fire.
Safety Risk
No risk description available.
Remedy
Dealers will inspect the check valve and, if required, replace the fuel tank assembly.
On certain motorcycles, the fuel tank vent tube assembly may have been manufactured incorrectly. If the anti-slosh valve separates, and the motorcycle is tipped over, fuel spillage may occur. Fuel leakage, in the presence of an ignition source, could result in a fire.
On certain vehicles, an incorrect dimensional characteristic of the fuel pumps upper body can result in a misalignment of the armature shaft, which may cause some fuel pumps to experience poor brush-to-commutator contact conditions. In addition use of a 10 percent ethanol blend fuel can cause a film built-up that creates a high resistance between the brush and the commutator. The misaligned armature shaft prevents the brush and the commutator from making sufficient contact to overcome the high resistance film build-up between the brush and commutator. As a result the fuel pump may produce less pumping pressure than required to supply the fuel injection system resulting in poor starting or hesitation. Loss of propulstion, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash.
On certain vehicles, the fuel pump may fail. Engine stalling would result in lost propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash.
On certain trucks equipped with diesel engines, a fuel pump outlet check plug may crack and cause fuel to spray and leak from the fuel pump, which could create a fire hazard.
Safety Risk
No risk description available.
Remedy
Caterpillar dealers will replace the fuel pump plugs.
On certain motorcycles, the fuel filter shell may crack, leading to a loss of fuel pressure. This could cause diminished performance, engine stalling or a no-start condition. This may lead to a crash which could cause personal injuries or death.
On certain vehicles, the fuel tank may contain a manufacturing flaw - a dimple in the bottom, at a spot weld. This dimple could result in fuel weepage or a fuel drip from the tank. A fuel leak in the presence of an ignition source could result in a fire, causing property damage, personal injury, or death.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if a dimple is found, will replace the fuel tank.
On certain trucks, the fuel pump may develop a diesel fuel leak as a result of improper assembly process at the factory. Fuel leakage, in the presence of an ignition source, could result in a vehicle fire, causing property damage, personal injury, or death.
Safety Risk
No risk description available.
Remedy
Dealers will inspect and, if no seepage or leakage is detected, the fuel pipe fittings will be tightened to specifications. However, should seepage or leakage be discovered, the fuel supply pump would be replaced.
On certain vehicles, the outer surface of the fuel filter may corrode prematurely. This may cause the filter housing to become porous and develop a leak. Fuel leakage in the presence of an ignition source could result in a vehicle fire, possibly causing personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will replace the fuel filter and reposition the retaining clip.
On certain scooters, wire terminals in the fuel pump wire coupler may corrode due to water infiltration into the main wire harness. This could cause the engine to stall which, in conjunction with traffic and road conditions, and the rider's reactions, could increase the risk of a crash, causing personal injury or death.
Safety Risk
No risk description available.
Remedy
Dealers will install a sub-harness assembly designed to allow any water between the wire harness and the fuel pump to drain out before reaching the pump. If either the main wire harness connector or the fuel pump connector is already corroded, the corresponding assembly(ies) will be replaced.
