Safety Recall V76 / NHTSA 19V-498 Fuel Injector Lines – 2019 Ram 2500 & 3500 Trucks, & 3500, 4500, & 5500 Cab Chassis

June 27, 2019 NHTSA CAMPAIGN NUMBER: 19V498000

Fuel Lines May Leak

A fuel leak in the presence of an ignition source increases the risk of a fire.

NHTSA Campaign Number: 19V498

Manufacturer Chrysler (FCA US LLC)

Components FUEL SYSTEM, DIESEL

Potential Number of Units Affected 498

Summary

Chrysler (FCA US LLC) is recalling certain 2019 Ram 2500 and 3500 trucks, and 3500, 4500, and 5500 Cab Chassis vehicles equipped with diesel engines. The fuel lines may leak fuel into the engine compartment.

Remedy

Chrysler will notify owners, and dealers will inspect the fuel lines, replacing them if necessary, free of charge. The recall began July 18, 2019. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler‘s number for this recall is V76.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.----escape_sem_autolink_uri:9c8e025c4aa77f9510aacb39890c86eb----.

Check if your Vehicle has a Recall

July 2019

Dealer Service Instructions for:

Safety Recall V76 / NHTSA 19V-498 Fuel Injector Lines

Remedy Available  

NOTE:  This recall applies only to the above trucks equipped with a 6.7L Cummins diesel engine (Sales Code ETL or ETN or ETM).

NOTE:  Some vehicles above may have been identified as not involved in this recall and therefore have been excluded from this recall.

Subject

The diesel engine on about 560 of the above vehicles may have been manufactured with fuel lines with incorrectly formed end fittings that may not properly seal to other fuel system components. Fuel lines that do not properly seal may lead to a fuel leak in the engine compartment. A fuel leak in the engine compartment may lead to a vehicle fire, which may increase risk of injury to occupants and persons outside the vehicle, as well as property damage.

Repair

Cummins will send a representative to inspect the fuel line date codes. If any of the fuel line date codes are found to be within the suspect build population, the suspect line(s) will be replaced.

Alternate Transportation

Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that fuel tube replacement is required and the vehicle must be held overnight.

Parts Information

Do NOT place an order, parts will be manually allocated by MOPAR.

Parts Return

No parts return required for this campaign.

Special Tools

The following special tools are required to perform this repair:

Service Procedure

Do NOT perform any of these service procedures without prior authorization. A Cummins representative will be dispatched to your dealership to inspect the fuel tube date codes. If any of the fuel tube date codes are found to be within the suspect build population, the Cummins representative will identify which suspect tubes(s) must be replaced. Replacement of any fuel tube without prior authorization will result in forfeit of warranty reimbursement.

A.  Tube Removal Preparation Procedures 

CAUTION: Cleanliness cannot be over emphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel tubes and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary.

1. Disconnect the Intelligent Battery Sensor (IBS) wire   harness connector (1) (Figure 1).

NOTE: Failure to disconnect the IBS wire harness connector can lead to damage of the IBS wire harness connector. 

2. Loosen the ground terminal nut (2) and remove the negative battery cable with IBS from the battery  and isolate it (Figure 1).

Figure 1 – Primary Battery

NOTE: If the vehicle is equipped with an auxiliary battery, when disconnecting and isolating the negative battery cable for the 12volt system, both batteries will need to be disconnected to power down the vehicle.

3. If the vehicle is equipped with an auxiliary battery, Loosen the clamp (1) and remove the clamp from the battery and isolate (Figure 2).

4. Remove the oil dip stick (3) (Figure 3).

5. Remove the bolts (1) and the engine cover (2) (Figure 3).

Figure 2 – Auxiliary Battery

Figure 3 – Engine Cover

6. Cut the cable tie and position aside the bulk head connector (Figure 4).

Figure 4 – Bulk Head Connector

7. Replace only the fuel tubes identified by the Cummins representative which require replacement. Follow the appropriate service procedure depending on which tube(s) must be replaced:

• Section Tube Replacement – Fuel Injection Pump to Fuel Rail 

• Section Tube Replacement – Fuel Rail to Fuel Injector

B.  Tube Replacement – Fuel Injection Pump to Fuel Rail

NOTE: The short upper pump to fuel rail tube may be removed separately without disconnecting the long lower pump to fuel rail tube.  However, the long lower pump to fuel rail tube also requires removal of the short upper pump to fuel rail tube.

1. Remove the nut (1) securing the high pressure pump to rail tubes (16 and 17) (Figure 5).

2. Only if removing the long lower pump to fuel rail tube: Remove the bolt (7) securing the high pressure pump to rail tube (17) (Figure 5).

Figure 5 – Fuel Tubes

3. Place a clean shop towels around fuel tubes being disconnected. If possible, do not allow fuel to drip down side of engine.

NOTE: If only replacing the short upper pump to fuel rail tube, it is not necessary to loosen the long lower pump to fuel rail tube.  If replacing the long lower pump to fuel rail tube, both short upper and long lower pump to fuel rail tubes must be removed.

4. Loosen the union nuts and carefully remove the fuel tube(s) (16 and 17) from the engine. Note position of tube(s) while removing (Figure 5).

NOTE: Use care not to bend fuel tubes when removing or installing.

5. Carefully install the fuel tube(s) (16 and 17) to the engine. Tighten the high-pressure fuel injection pump-to-fuel rail fuel tube(s) at the pump first and then at the rail. Tighten the union nuts to 40 N·m (30 ft. lbs.) (Figure 5).

6. Remove the shop towels from around fuel tubes that were disconnected.

7. If previously removed: Install the bolt (7) securing the high pressure pump to rail tube (17). Tighten the bolt to 24 N·m (18 ft. lbs.) (Figure 5).

8. Install the nut (1) securing the high pressure pump to rail tubes (16 and 17). Tighten the nut to 20 N·m (15 ft. lbs.) (Figure 5).

9. Proceed to Section Reassembly and Fuel System Priming Procedures.

C.  Tube Replacement – Fuel Rail to Fuel Injector

1. Disconnect the exhaust pressure sensor wire harness connector (Figure 6).

2. Disconnect the EGR cooler bypass valve wire harness connector (Figure 6).

3. Disconnect the crankcase pressure sensor 2 wire harness connector (Figure 6).

4. Release the wire harness retainers (Figure 6).

5. Disconnect crankcase pressure sensor 1 wire harness connector (Figure 6).

6. Disconnect the three Crank Case Ventilation (CCV) hoses from the crank case breather cover and cylinder head cover (Figure 6).

Figure 6 – Electrical Connectors and CCV Hoses

7. Disconnect the fuel pressure sensor wire harness connector (1) (Figure 7).

8. Disconnect both fuel injector harness connectors (Figure 8).

9. Position the engine harness to the side to allow clear access to the fuel rail noise silencer.

10. Remove the fuel rail noise silencer (Figure 8).

11. Thoroughly clean any dirt from fuel tubes and fuel tube nuts to minimize exposure to dirt/debris.

Figure 7 – Fuel Pressure Sensor

Figure 8 – Fuel Injector Harness and Nose Silencer

12. Remove eight fasteners and the crank case breather cover (Figure 9).

Figure 9 – Crank Case Breather Cover

13. Remove the crank case breather element (Figure 10).

Figure 10 – Crank Case Breather Element

14. Remove six bolts and remove the cylinder head cover (Figure 11).

15. Loosen the fuel injector wire harness nuts on the cylinder head cover gasket. Remove the cylinder head cover gasket (Figure 12).

Figure 11 – Cylinder Head Cover

Figure 12 – Cylinder Head Cover Gasket

16. Remove the bolts and the rocker housing (Figure 13).

17. Place clean shop towels around any fuel tube fittings that will be disconnected. If possible, do not allow fuel to drip down side of engine.

NOTE: Rail-to-cylinder head fuel tubes are marked on the cylinder head side nut with cylinder number identification.

NOTE: Cylinder No. 3 fuel tube (12) is equipped with two vibration isolators (18). Do not remove or change the position of vibration isolators (18) (Figure 14).

Figure 13 – Rocker Housing

CAUTION: When loosening high-pressure tube fittings attached to a separate fitting (5), use a back-up wrench on fitting (5). Do not allow fittings (5) to rotate. Damage to both fuel tube and fitting will result (Figure 14).

18. Loosen the union nuts then carefully remove the suspect fuel tube from engine.

NOTE: Use care not to bend fuel tubes when removing or installing.

CAUTION: Anytime a high-pressure fuel tube is removed from the engine, its fuel connector retaining nut (5) at the cylinder head must first be retorqued to prevent a leak between the high pressure connector and fuel injector inside the cylinder head (Figure 14).

CAUTION: When tightening high-pressure tube fittings attached to a separate fitting (5), use a back-up wrench on fitting (5). Do not allow fittings (5) to rotate. Damage to both fuel tube and fitting will result (Figure 14).

Figure 14 – Fuel Tubes

19. Install the new fuel tube to the injector and fuel rail. Tighten the fittings hand tight at both ends of tube (Figure 14).

20. Tighten fuel tube nut at the cylinder head to 55 N·m (41 ft. lbs.) (Figure 14).

21. Tighten fuel tube nuts at the fuel rail to 45 N·m (33 ft. lbs.) (Figure 14).

NOTE: Ensure proper clearance between each fuel tube after torqueing both the fuel tube nut at the cylinder head and the fuel rail.  The fuel tubes should have minimum clearance of 1.25mm between one another.

22. Remove the shop towels around any fuel tube that was replaced.

23. Clean all the gasket sealing surfaces and inspect the rocker housing gasket (3) for damage and replace if necessary (Figure 15).

NOTE: If the rocker housing gasket (3) has been removed from the groove in the rocker housing (2), a NEW gasket must be installed (Figure 15).

Figure 15 – Rocker Housing Gasket

CAUTION: When installing rocker housing onto cylinder head, do not slide housing from side to side, the gasket could fall out or be damaged.

24. Install the rocker housing and tighten the bolts finger tight. Working from center out, tighten bolts to 24 N·m (18 ft. lbs.) (Figure 13).

25. Inspect the cylinder head cover gasket for tears, or splits. Replace if necessary (Figure 12).

26. Install the cylinder head cover gasket on the rocker housing. Tighten the fuel injector wire harness nuts to 1.5 N·m (13 in. lbs.) (Figure 12).

27. Install the cylinder head cover then install the six bolts fastening the cover. Tighten the bolts to 24 N·m (18 ft. lbs.) (Figure 11).

28. Install the crank case breather element (Figure 10).

29. Install the crank case breather cover and the eight fasteners securing the cover. Tighten the fasteners to 10 N·m (89 in. lbs.) (Figure 9).

30. Install the fuel rail noise silencer (Figure 8).

31. Connect both fuel injector harness connectors (Figure 8).

32. Connect the fuel pressure sensor wire harness connector (1) (Figure 7).

33. Connect the three CCV hoses to the cylinder head cover and crank case breather cover (Figure 6).

34. Connect crankcase pressure sensor 1 wire harness connector (Figure 6).

35. Attach the wire harness retainers (Figure 6).

36. Connect the crankcase pressure sensor 2 wire harness connector (Figure 6).

37. Connect the EGR cooler bypass valve wire harness connector (Figure 6).

38. Connect the exhaust pressure sensor wire harness connector (Figure 6).

39. Proceed to Section Reassembly and Fuel System Priming Procedures.

D. Reassembly and Fuel System Priming Procedures. 

1. Attach the bulk head connector (Figure 4).

2. Install the engine cover (2) and the bolts (1) securing the cover. Tighten the bolts to 10 N·m (89 in. lbs.) (Figure 3).

3. Install the oil dip stick (3) (Figure 3).

4. If the vehicle is equipped with an auxiliary battery, install the clamp (1) to the negative post and tighten to 6 N·m (53 in. lbs.) (Figure 2).

4. Install the negative battery cable with IBS to the negative post and tighten to 6 N·m (53 in. lbs.) (Figure 1).

5. Connect the IBS wire harness connector (Figure 1).

6. Be sure there is fuel in the fuel tank.

7. Turn ignition switch to the RUN position. This will operate fuel transfer pump for a minimum of 30 seconds.

8. Turn the ignition switch to the OFF position, and leave it off for at least 5 seconds.

NOTE: A certain amount of air becomes trapped in the fuel system when fuel system components on the supply and/or high-pressure side are serviced or replaced. Fuel system priming is accomplished using the electric fuel transfer (lift) pump.

The fuel transfer (lift) pump is self-priming: When the ignition switch is turned to the run position (without cranking engine), the pump operates for a minimum of 30 second. In cold temperatures, the lift pump operates for up to 35 seconds. Two priming cycles (each with a duration of 30 seconds) must be performed any time the fuel system is serviced

9. Turn the ignition switch to the RUN position. This will complete an additional priming cycle and operate the fuel transfer pump for a minimum of 30 seconds.

10. Start the engine. If the engine does not start after 25 seconds, turn the ignition switch to the OFF position, and leave it off for at least 5 seconds. Repeat the previous step until the engine starts. When engine does start, allow the engine to idle for a minimum of 30 seconds. The engine may run erratically and be noisy for a few minutes. This is a normal condition.

11. Fuel system priming is now completed.

CAUTION: Do not engage the starter motor for more than 30 seconds at a time. Allow two minutes between cranking intervals.

WARNING: The fuel injection pump supplies extremely high fuel pressure to each individual injector through the high-pressure tubes. Fuel under this amount of pressure can penetrate the skin and cause personal injury. Wear safety goggles and adequate protective clothing. Do not loosen fuel fittings while engine is running.

WARNING: Engine may start while cranking starter motor

12. Start engine and check for leaks.

13. Validation Run Fuel System Leak Test for Diesel ECM Controller Modules (Fuel Pressure Override Test)

14. Install a battery charger and verify that the charging rate provides 13.2 to 13.5 volts. Do not allow the charger to time out during the flash process.  Set the battery charger timer (if so equipped) to continuous charge.

NOTE:  Use an accurate stand-alone voltmeter.  The battery charger volt meter may not be sufficiently accurate.  If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage.

15. Connect the wiTECH MicroPod II to the vehicle Data Link Connector (DLC).

16. Place the ignition in the “RUN” position.

17. Open the wiTECH 2.0 website.

18. Enter your “User id” and “Password” and your “Dealer Code”, then select “Sign In” at the bottom of the screen.  Click “Accept”.

19. From the “Vehicle Selection” screen, select the appropriate vehicle.

20. From the vehicle “Topology” screen, select the “PCM” icon.

21. From the “PCM” screen select the “System Tests” tab.

22. From the “System Tests” tab perform the “Fuel Pressure Overide” test.

23. Place the ignition in the “OFF” position the remove the wiTECH MicroPod II from the vehicle DLC.

24. Remove the battery changer.

25. Close the hood.

26. Complete the Proof of Correction form for California residents.

27. Return the vehicle to customer or vehicle inventory.

FUEL INJECTOR LINES

IMPORTANT SAFETY RECALL INFORMATION

V76 / NHTSA 19V-498

This notice applies to your vehicle (VIN: xxxxxxxxxxxxxxxxx).      

Dear: (Name)

FCA has decided that a defect, which relates to motor vehicle safety, exists in certain [2019 Model Year (DJ) RAM 2500 Pickup, (D2) RAM 3500 Pickup, (DD) RAM 3500 Cab Chassis, (DP) RAM 4500/5500 Cab Chassis] trucks equipped with a 6.7L Cummins diesel engine.

FCA US LLC records indicate that your RAM truck was manufactured with this defect.  However, your truck has already been repaired under service action RRT 19-047.

This notification is provided for your records only. There is nothing more that you need to do.

If you have additional questions or concerns about this issue, please contact the FCA US Recall Information Center at 1-800-853-1403. An FCA representative will be glad to answer any further questions you may have regarding this issue.

We apologize for any inconvenience this issue may have caused. Thank you for your attention to this important matter.

Customer Services / Field Operations
FCA US LLC

4 Affected Products

Vehicles

12 Associated Documents

Owner Notification Letter(Part 577)

RCONL-19V498-8370.pdf 517.04KB

ISSUED Renotification Notice

RCRN-19V498-9112.pdf 135.203KB

V76 Owner Letter for Vehicles Already Remedied

RMISC-19V498-1054.pdf 36.698KB

Recall Quarterly Report #2, 2019-4

RCLQRT-19V498-7544.PDF 211.221KB

Recall 573 Report-Amendment 1

RCLRPT-19V498-1820.PDF 217.496KB

Manufacturer Notices(to Dealers,etc) – 07/05/2019 New Safety Recall Advanced Communication – V76

RCMN-19V498-7701.pdf 101.463KB

Remedy Instructions and TSB

RCRIT-19V498-9451.pdf 1693.091KB

Defect Notice 573 Report

RCLRPT-19V498-5736.PDF 217.643KB

Manufacturer Notices(to Dealers,etc) – 06/28/2019 New Safety Recall Advanced Communication – V76

RCMN-19V498-9627.pdf 97.898KB

Recall Quarterly Report #1, 2019-3

RCLQRT-19V498-3565.PDF 211.122KB

Recall Acknowledgement

RCAK-19V498-3458.pdf 244.104KB

Recall Quarterly Report #3, 2020-1

RCLQRT-19V498-3634.PDF 211.305KB

Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V498&docType=RCL

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