Recall # 788

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Models: Dodge Diesel BR/BE 1998 built before 04/29/98  (MDH 0429XX)

Problem:
Chrysler is recalling about 25,000 were built with defective low pressure fuel tubes. The low pressure fuel line may fracture and leak. Notices have been sent by CC to owners and dealers to check unsold stock.

This is the line from the top of the fuel filter to the side of the injection pump. The ends of the tube are made for banjo fittings.

Repair:
"inspect the low pressure fuel line between the fuel filter and the fuel injection pump (fig 1).  If the tube has a compression fitting in the center (just left of the bend) it must be replaced.  If the tube has a short section of rubber hose in the center (just left of the bend) no further action is necessary." Comments within the parenthesis are mine.  If in doubt check with your CC Dodge dealer.

Instruction for those stranded beside the road with a computer and web access (right!).

1. Disconnect both negative battery cables.
2. Disconnect low pressure fuel supply tube from fuel filter assy (fig 1). Save the banjo bolt and washers for reuse.
3. Disconnect low pressure supply tube from fuel injector pump (fig 1). Save the banjo bolt and washers for reuse.
4. Remove and discard fuel tube.
5. Connect new fuel tube assembly to fuel injector pump using the original banjo bolt and washers.
6. Connect new fuel tube assembly to fuel filter assy using the original banjo bolt and washers.
7. Tighten both fuel tube banjo bolts to 18 ft-lbs (24 Nm).
1. NOTE:  HOLD THE FUEL TUBE IN PLACE SO THAT IT DOES NOT ROTATE WHILE THE BOLTS ARE TIGHTENED.
8. Reconnect both negative battery cables.
9. With the ignition key, bump the starter, but do not start the engine, then wait until the fuel transfer pump runs through its 25 second cycle.
10. Bump the starter again and allow the fuel transfer pump to run through another 25 second cycle.
11. Start the engine and run it at 1000-1500 rpm until it runs smoothly.
12. Check the supply tube connections for leaks.

This page was edited on: May 3, 2004