Customer Satisfaction Notification F19

Roll-Over Valve Vent Hoses

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Date: June 2006

Effective immediately, all repairs on involved vehicles are to be performed
according to this notification. Rapid Response Transmittal (RRT) #06–015 is
cancelled.

Models: 2006 (DH) Dodge Ram 2500 Pick-Up and Cab-Chassis Truck
                 2006 (D1) Dodge Ram 3500 Pick Up and Cab-Chassis Truck

NOTE: This notification applies only to the above vehicles equipped with a 5.9L
diesel engine (“C” in the 8th VIN position) built through February 1, 2006
(MDH 020108).

Important: Many of the above vehicles have already been repaired and, therefore,
have been excluded from this notification.

IMPORTANT: Some of the involved vehicles may be in distributor/dealer vehicle inventory.
Distributor/Dealers should complete this repair on these vehicles before retail delivery.
Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles
can be determined by using the VIP inquiry process.

Subject:

The roll over valves on about 69,300 of the above vehicles (978 in International
markets) may allow water to enter into the fuel tank. Excessive water in the fuel
can damage the injection pump and/or injectors if the engine is off for an extended
period of time.

Repair:

A vent hose must be installed at the each fuel tank roll-over valve (ROV). The fuel
system must be inspected for excessive water content. If excessive water is found,
the water must be removed and the fuel filter must be replaced.

Parts Information:

The following parts are required for each vehicle:

  Each package contains 2 hoses.

  Each package contains 1 filter.

Special Tools:

The following essential tool is required to perform this repair:

  * Part of CH9400 kit.

Service Procedure:

A. Inspect Fuel For Water
	1.	Open the hood.
	2.	Clean the area around the engine fuel filter drain valve and the entire length of the drain hose.
	3.	Place the drain hose into a clean and dry translucent 1/2 gallon diesel fuel compatible container (such as a milk jug or equivalent). See Figure 1.
	4.	Drain about one pint of fuel by opening the engine fuel filter drain valve.
	5.	Allow the fuel to sit for at least two minutes (the fuel may be cloudy). Tilt the container so that the water (if any) can collect in one spot. Inspect the liquid.
	»If three drops of water or less is found at the bottom of the container, continue with Section C - Installation of ROV Hose.
	»If more than three drops of water are found at the bottom of the container of diesel fuel, continue with Section B - Water Removal and Fuel Filter Replacement.
	NOTE: Dispose of petroleum based products in a manner consistent with all applicable Local, State, and Federal environmental regulations.
B. Water Removal and Fuel Filter Replacement
	1.	Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle.
	2.	Place the Ignition in the “RUN” position and Power “ON” the StarSCAN.
	3.	Place the StarSCAN in a suitable underhood area nearby the fuel filter.
	4.	On the StarSCAN screen, select “ECU View”.
	5.	On the StarSCAN screen, select “PCM”.
	6.	On the StarSCAN screen, select “ACTUATORS”.
	7.	On the StarSCAN screen, select “LIFT PUMP RELAY”.
	8.	On the StarSCAN screen, select “START ACTUATOR”.
	9.	Empty and clean the fuel container.
	10.	Place the engine fuel filter drain hose into the container.
	11.	Open the fuel filter drain valve (Figure 1).
	12.	On the StarSCAN screen, select “TOGGLE” to turn ON fuel tank lift pump.
	13.	Drain 1/2 gallon of diesel fuel into the container.
	14.	On the StarSCAN screen, select “STOP ACTUATOR” to turn OFF fuel tank lift pump.
	15.	Close the fuel filter drain valve.
	16.	Let the fuel container sit for at least two minutes. Tilt the fuel container so that any water in the fuel can collect in one spot.
	»If three drops of water or less is found at the bottom of the container, continue with Step 17.
	»If more than three drops of water are found at the bottom of the container of diesel fuel, repeat Step 9 through 15 until there are no more than three drops of water in the fuel
		1-   ENGINE 2-  FUEL HEATER 3-  FUEL FILTER HOUSING NUT 4-  FUEL FILTER HOUSING 5-  WATER IN FUEL SENSOR 6-  INPUT SHAFT TO STEERING GEAR BOX 7-  FUEL FILTER DRAIN HOSE 8-  FUEL FILTER DRAIN VALVE
	NOTE: Very few vehicles will require the removal of more than 2 gallons of diesel fuel to be extracted from the fuel tank. Dispose of petroleum based products in a manner consistent with all applicable Local, State, and Federal environmental regulations.
	17.	Turn the Ignition to the “OFF” position.
	18.	Clean all debris from the outside of the fuel filter housing.
	19.	Using a 1 1/8” hex head socket wrench, remove the fuel filter cap and element assembly.
	20.	Remove the old filter element from the cap by pulling loose the filter element from the retainer pegs on the filter cap.
	NOTE: Check if the gasket on the bottom of the filter element is attached to the element. If not, you must remove it from the filter cap.
	21.	Remove and discard the o-ring on the cap. Carefully clean the mating surfaces.
	22.	Gently wipe the water-in-fuel (WIF) sensor probes inside of the filter housing with a soft cloth to remove any debris.
	23.	Apply a coat of diesel fuel onto the new o-ring and gasket of the new fuel filter element.
	24.	Install the new o-ring on to the filter cap.
	25.	Install the new filter element onto the filter cap.
	26.	Install and slowly tighten the filter element and cap assembly cap bolt. Tighten the cap bolt to 25 ft.lbs. (34 Nm). Do not overtighten.
	27.	Check to assure the fuel filter drain valve is closed.
	28.	Turn the ignition to the “RUN” position.
	29.	On the StarSCAN screen, select “TOGGLE” to turn ON fuel tank lift pump.
	30.	Wait for about 30 seconds. This will purge the air from the fuel line and filter.
	31.	On the StarSCAN screen, select “STOP ACTUATOR” to turn OFF fuel tank lift pump.
	32.	Turn the Ignition to the “OFF” position.
	33.	Turn the StarSCAN power “OFF” and disconnect the StarSCAN from the vehicle.
	34.	Start the engine and let it run for a few minutes.
	35.	Add an equivalent amount of fresh #2 diesel fuel as was removed from the fuel system.
	36.	Continue with Section C - Installation of ROV Hoses.
C. Installation of ROV Hose:
	1.	Raise the vehicle on a suitable hoist.
	2.	From the left side of the frame rail near the front of the fuel tank, locate the front roll-over valve. (Figure 2).
	3.	Push the hose onto the roll-over valve nipple (rear ROV hose shown in Figure 3). Let the open end of the hose drape over the side of the fuel tank so it vents to the atmosphere (Figure 4).
	4.	From the center of the vehicle near the rear of the fuel tank, locate the rear roll-over valve (Figure 2).
	5.	Push the hose onto the roll-over valve nipple until seated. Let the open end of the hose drape over the side of the fuel tank so it vents to the atmosphere (Figure 5).
	6.	Clean the suspension components of any spilled diesel fuel.
	7.	Lower the vehicle and return the vehicle to the customer.

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 Customer Satisfaction Notification
service completions and provide dealer payments.

Use one of the following labor operation numbers and time allowance:

Add the cost of the parts plus applicable dealer allowance to your claim. If water
was found in the fuel, enter “DSLFUELS” in the Part Number section of your
claim.

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

Distributor/ Dealer Notification and Vehicle List

Regional offices will receive an electronic list of involved vehicles. The Vehicle
List is arranged by Distributor/Dealer code and in Vehicle Identification Number
(VIN) sequence. The lists are for Distributor/Dealer reference in arranging for
service of involved vehicles.

Enclosed with each owner letter is an Owner Notification Form. The involved
vehicle and notification are identified on the form for owner or dealer reference as
needed.

Owner Notification and Service Scheduling

All involved vehicle owners should be notified of the service requirement by their
Distributor/Dealer. Owners are requested to schedule appointments for this service.
A sample copy of the owner notification letter is attached

Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow Up

All involved vehicles have been entered into the Global Recall System (GRS) and
Vehicle Information Plus (VIP) for Distributor/Dealer inquiry as needed.

Distributors/Dealers must perform this repair on all unsold vehicles before
retail delivery. Distributors/Dealers should also use the VIN list to follow up with
all owners to schedule appointments for this repair.

Additional Information

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

International Service and Parts
DaimlerChrysler Corporation

CUSTOMER SATISFACTION NOTIFICATION F19 -
ROLL-OVER VALVE VENT HOSES

Dear: (Name)

Customer satisfaction is very important to DaimlerChrysler. Accordingly, we are recommending
the following service on some 2006 model year Dodge Ram 2500 and 3500 pick up trucks
equipped with a Cummins Diesel engine.

The problem is...
The roll-over valves on your truck (VIN: xxxxxxxxxxxxxxxxx) may allow
water to enter into the fuel tank. Excessive water in the fuel can
damage the injection pump and/or injectors if the engine is off for an
extended period of time.

What your dealer will do...
DaimlerChrysler will repair your vehicle free of charge (parts and
labor). To do this, your dealer will install a hose on each roll-over valve
and if necessary remove any water in found in the fuel and install a new
fuel filter. The work will take about 1 hour to complete. However,
additional time may be necessary depending on how dealer appointments
are scheduled and processed.

What you must do...
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 trouble getting your vehicle serviced, please contact the
DaimlerChrysler Distributor nearest your location. A representative will
assist you in getting your vehicle serviced. This information can be found
in the Customer Assistance section of your Owner’s Manual.

If you have already experienced the problem described above and have paid to have it repaired,
contact the DaimlerChrysler Distributor nearest your location for reimbursement procedures.
We’re sorry for any inconvenience, but we believe that this service will help to ensure your
continuing satisfaction with your vehicle. Thank you for your attention to this important matter.

International Service and Parts
DaimlerChrysler Corporation
Notification Code F19

This page was edited on: May 3, 2004