Safety Recall V62 – Fuel Pump Relay – 2011-2013 Dodge Durango & Jeep Grand Cherokee

November 14, 2019 NHTSA CAMPAIGN NUMBER: 19V813000

Fuel Pump Relay May Fail Resulting In a Stall

A vehicle stall increases the risk of a crash.

 

NHTSA Campaign Number: 19V813

Manufacturer Chrysler (FCA US LLC)

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 528,594

 

Summary

Chrysler (FCA US LLC) is recalling certain 2011-2013 Dodge Durango and Jeep Grand Cherokee vehicles equipped with a 3.6, 5.7, or 6.4 liter engine and previously recalled under NHTSA Recall 14V530 or 15V115. The fuel pump relay inside the Totally Integrated Power Module (TIPM-7) may fail, causing the vehicle to stall without warning.

 

Remedy

Chrysler (FCA US LLC) will replace the affected fuel pump relay and related wire harness. Interim notices informing owners of the safety risk were mailed beginning December 19, 2019. Vehicles that experience a fuel pump failure will receive an interim repair. Owners will receive a second notice when the final remedy becomes available. Owner notification letters were mailed on December 10, 2020. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler’s number for this recall is V62.

 

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.safercar.gov.

 

Check if your Vehicle has a Recall

 


New Safety Recall Advanced Communication – V62

 

FCA US LLC (FCA US) has announced a safety recall on certain 2011 through 2013 Model Year (WD) Dodge Durango and 2011 through 2013 Model Year (WK) Jeep® Grand Cherokee vehicles.  

 

VINs identified as being involved in this campaign are currently live and searchable. Stop sale is in effect for the above-identified vehicles.

 

Vehicles impacted by a stop sale are eligible for reimbursement allowance through the Recall Floorplan Reimbursement Policy (RFPRP), which can be requested upon recall claim submission.

 

REASON FOR THIS SAFETY RECALL

Some of the above vehicles may have had a fuel pump relay installed as a recall remedy during the completion of Safety Recall P54 (NHTSA 14V-530) or Safety Recall R09 (NHTSA 15V-115). The installed relay has been determined to be susceptible to silicon contamination on the relay contacts, which can cause the relay to fail.A fuel pump relay failure can result in a no-start condition or an engine stall condition if the vehicle is running. A vehicle engine stall while driving can cause a vehicle crash without prior warning.

 

SERVICE ACTION

The remedy for this condition is not currently available.  Dealers will be notified of the launch of this safety recall by way of established communication methods.

 


Safety Recall V62 / NHTSA 19V-813 Fuel Pump Relay

 

Remedy Available

2011 – 2013 (WD) Dodge Durango
(WK) Jeep Grand Cherokee

 

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

 

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

 

Subject

The fuel pump relay on about 582,000 of the above vehicles may have had a fuel pump relay installed as a recall remedy that is susceptible to silicon contamination of the relay contacts, that can cause the relay to fail. A fuel pump relay failure can result in a no-start condition or an engine stall condition if the vehicle is running. A vehicle engine stall while driving can cause a vehicle crash without prior warning

 

Repair

Inspect for an external fuel pump relay and replace the fuel pump relay and harness connector and mount relay on bracket near the PCM, if there is no external fuel pump relay modify the TIPM to accept an external relay.

 

Parts Information

Part Number Description
CSZDV621AA Part Package
Each package contains the following components:
Quantity Description
1 Harness, Fuel Pump Relay
1 Relay, Fuel Pump
3 Crimp, Brass
3 Strap, Plastic Tie
3 Tube, Shrink

 

Part Number Description
CSZDV622AA Part Package
Each package contains the following components:
Quantity Description
1 Nut
1 Bracket
1 Bolt

 

Special Tools

The following special tools are required to perform this repair:

➢ 10042 Wire splice crimp tool
➢ 6680-2PA Pick, Terminal

 

Service Procedure

A. Inspect for External Fuel Pump Relay

 

  1. Open hood.

 

  1. Inspect for an external fuel pump relay (Figure 1):

 

 

 

  1. Position the passenger seat fully forward.

 

  1. Open the battery access cover located under the passenger front seat and disconnect the negative battery cable (Figure 2).

 

  1. Remove the fuel pump relay from the core support (Figure 1).

 

  1. Remove the TIPM cover and remove the B+ terminal retaining nut, cable and the orange 12V relay wire (Figure 3).

 

  1. Push the four TIPM retaining tabs and separate the TIPM from the TIPM support bracket (Figure 3).

 

  1. Carefully rotate the TIPM on its side to expose the fuel pump relay wire harness connections (Figure 4).

 

  1. Cut the pink, brown and blue wires from the Fuel Pump Relay wire harness assuring to leave sufficient lengths to reconnect all 3 wires and DISCARD the relay and wire harness (Figure 5).

 

  1. Remove the relay housing from the repair package (Figure 6).

 

  1. Lift up on both sides of the fuel relay housing cover tabs and remove the cover from the housing (Figure 7).

 

  1. Align the fuel pump relay male terminals to the female terminals in the electrical housing connector and firmly insert until fully seated into the housing (Figure 8).

 

  1. Align the cover keys to the fuel pump relay housing cover assuring the tabs are fully locked (Figure 9 and Figure 10).

 

  1. Slide the relay bracket into the relay housing opening assuring it is fully seated (Figure 11).

 

  1. Strip approximately ½ inch (13 mm) of insulation from the ends of the brown wire, pink wire and blue wire on the NEW fuel pump relay wire and the original brown wire, pink wire and blue wire.

 

  1. Place a piece of black shrink tube, provided in the repair kit, over the cut brown, blue wire and pink wire (Figure 12).

 

  1. Using the supplied brass splice band clamp and crimp tool 10042, crimp the wires on the wire harness side (brown wire, pink wire and blue wire) to the NEW fuel pump relay harness (brown wire, pink wire and blue wire) (Figure 12).

 

  1. Solder the brass splice band clamp with rosin core solder.

 

  1. Slide the shrink tube evenly over the soldered brass splice and apply heat to the shrink tube until glue comes out of both ends of the shrink tube.

 

  1. Route the NEW Fuel Pump Relay wiring harness along the main TIPM harness and secure the NEW harness using tie straps as shown in (Figure 13).

 

  1. Cut off the excess tie strap material.

 

  1. Align and install the TIPM in housing assuring all four of the release tabs are fully locked (Figure 14).

 

  1. Attached the NEW external fuel pump relay bracket on to the back of the existing hole on the PCM mounting bracket and tighten the nut and bolt to 6N·m (53in. lbs.) (Figure 15).

 

  1. Connect the original B+ cable terminal to the TIPM B+ stud (Figure 15).

 

  1. Connect the wire eyelet on the orange wire of the NEW fuel pump relay wire harness to the TIPM B+ stud (Figure 15).

 

  1. Install the B+ cable terminal retaining nut and tighten the nut to 19 N·m (14 ft. lbs.) (Figure 15).

 

  1. Connect the negative battery cable to the negative battery terminal on the battery and close the battery access cover.

 

  1. Return the passenger seat to its original location.

 

  1. Return the vehicle to the customer.

 

A.  Install External Fuel Pump Relay

  1. Remove the relay housing from the repair package (Figure 16).

 

  1. Lift up on both sides of the fuel relay housing cover tabs and remove the cover from the housing (Figure 17).

 

  1. Align the fuel pump relay male terminals to the female terminals in the electrical housing connector and firmly insert until fully seated into the housing (Figure 18).

 

  1. Align the cover keys to the fuel pump relay housing cover assuring the tabs are fully locked (Figure 19 and Figure 20).

 

  1. Slide the relay bracket into the relay housing opening assuring it is fully seated (Figure 21).

 

  1. Position the passenger seat fully forward.

 

  1. Open the battery access cover located under the passenger front seat and disconnect the negative battery cable (Figure 22).

 

  1. Remove and save the Totally Integrated Power Module (TIPM) access cover.

 

  1. Remove and save the B+ cable terminal retaining nut.

 

  1. Carefully separate the B+ cable terminal from the B+ TIPM stud (Figure 23).

 

  1. Push the four TIPM retaining tabs and separate the TIPM from the TIPM support bracket (Figure 24).

 

  1. Unplug the 50-way electrical connector from the bottom of the TIPM (Cavity “A”) (Figure 25).

 

  1. Locate the brown wire in cavity number 40 of the 50-way electrical connector (Figure 27).

 

  1. Cut the brown wire one inch (25 mm) from the 50-way electrical connector (Figure 27).

 

  1. Install shrink tube to the connector side brown wire to insulate the wire end. This wire will no longer be used (Figure 28).

 

  1. Using the following procedure, splice the brown wire on the wire harness to the brown wire on the new fuel pump relay harness:

a. Strip approximately ½ inch (13 mm) of insulation from the end of the brown wire on the new fuel pump relay wire and the original brown wire.

b. Place a piece of black shrink tube, provided in the repair kit, over the cut brown wire.

c. Using the supplied brass splice band clamp and crimp tool 10042, crimp the brown wire on the wire harness side to the brown wire on the new fuel pump relay harness (Figure 29).

d. Solder the brass splice band clamp with rosin core solder.

e. Slide the shrink tube evenly over the soldered brass splice and apply heat to the shrink tube until glue comes out of both ends of the shrink tube.

 

  1. Carefully plug the 50-way electrical connector into the bottom of the TIPM.

 

CAUTION: Be sure that the 50-way connector lock bar is fully engaged.

 

  1. Unplug the 40-way electrical connector located on the bottom side of the TIPM (Figure 30).

 

  1. Carefully remove and save the 40-way electrical connector wire cover located on the wire side of the connector (Figure 31).

 

NOTE: The plastic tie strap that holds the wire harness to the wire cover must be cut off and discarded (Figure 31).

 

  1. Locate the blue (with an orange trace) wire in the 40-way electrical connector (Figure 32).

 

  1. Cut the blue (with an orange trace) wire one inch (25 mm) from the 40-way electrical connector (Figure 33).

 

  1. Install shrink tube to the connector side blue (with an orange trace) wire to insulate the wire end. This wire will no longer be used (Figure 33).

 

  1. Using the following procedure, splice the blue (with an orange trace) wire on the wire harness to the blue wire on the new fuel pump relay harness:

a. Strip approximately ½ inch (13 mm) of insulation from the end of the blue wire on the new fuel pump relay wire and the original blue (with an orange trace) wire (Figure 34).

b. Place the black shrink tube provided in the repair kit over the cut wire (Figure 34).

c. Using the supplied brass splice band clamps and crimp tool 10042, crimp the blue wire (with orange trace) on the wire harness side to the blue wire on the fuel pump relay wire harness (Figure 35).

d. Solder the brass splice band clamp with rosin core solder (Figure 35).

e. Slide the shrink tube evenly over the soldered brass splice band clamp and apply heat to the shrink tube until glue comes out of both ends of the shrink tube.

 

  1. Remove and save the 40-way electrical connector green plastic terminal lock (Figure 36).

 

  1. Locate the pink (with green trace) wire in cavity 38 of the 40-way electrical connector (Figure 37).

 

  1. Carefully remove the pink (with a green trace) from the 40-way connector (Figure 38).

 

NOTE: Use Miller Tool 6680-2PA terminal pick, or equivalent, to remove the wire terminal from the 40-way electrical connector.

 

  1. Strip approximately ½ inch (13 mm) of insulation off the pink (with green trace) wire without cutting the wire (Figure 39).

 

  1. Using the following procedure, splice the pink (with a green trace) wire to the pink wire on the new fuel pump relay harness:

a. Strip approximately ¾ inch (20 mm) of insulation from the end of the pink wire on the new fuel pump relay wire.

b. Wrap the pink wire from the new fuel pump relay wire harness around the pink (with green trace) wire at the location the insulation was removed (Figure 40).

c. Using the supplied brass splice band clamp and crimp tool 10042, crimp the fuel pump wire harness pink wire to the pink (with a green trace) wire on the vehicle wire harness (Figure 40).

d. Solder the brass splice band clamp with rosin core solder.

e. Slide the shrink tube evenly over the soldered brass splice band clamp and apply heat to the shrink tube until glue comes out of both ends of the shrink tube (Figure 41).

 

  1. Carefully install the wire terminal for the pink (with green trace) wire back into the same cavity (cavity 38) in the 40-way electrical connector that it was removed from (Figure 42).

 

  1. Install the 40-way electrical connector green plastic terminal lock (Figure 42).

 

  1. Install the 40-way electrical connector wire cover.

 

  1. Install a plastic tie strap to hold the wire harness in place on the back side of the 40-way electrical connector (Figure 43).

 

  1. Plug the 40-way electrical connector into the bottom of the TIPM assembly.

 

CAUTION: Be sure the 40-way electrical connector lock bar is fully engaged.

 

  1. Snap the TIPM assembly back into the TIPM support bracket.

 

Figure 42 – Install Pink (with Green Trace) Wire Terminal into the same cavity on the 40-Way Connector from which it was removed

 

  1. Route the NEW Fuel Pump Relay wiring harness along the main TIPM harness and secure the NEW harness using tie straps as shown in (Figure 44).

 

  1. Cut off the excess tie strap material.

 

  1. Align and install the TIPM in housing assuring all four of the release tabs are fully locked (Figure 45).

 

  1. Attached the NEW external fuel pump relay bracket to the existing hole on the PCM mounting bracket and tighten the nut and bolt to 6N·m (53in. lbs.) (Figure 46).

 

  1. Connect the original B+ cable terminal to the TIPM B+ stud (Figure 47).

 

  1. Connect the wire eyelet on the orange wire of the new fuel pump relay wire harness to the TIPM B+ stud (Figure 47).

 

  1. Install the B+ cable terminal retaining Tighten the nut to 14 ft. lbs. (19 N·m) (Figure 47).

 

  1. Push down on all the relays and fuses in the TIPM to ensure that they are all fully engaged.

 

CAUTION: Be sure that the new fuel pump relay wire harness does not contact any sharp edges that may damage the new fuel pump relay wire harness.

 

  1. Carefully install the TIPM access cover (Figure 48).

 

  1. Connect the negative battery cable to the negative battery terminal on the battery and close the battery access cover.

 

  1. Return the passenger seat to its original location.

 

  1. Return the vehicle to the customer.

 


FCA US LLC Chronology
2011-2013 Dodge Durango and Jeep Grand Cherokee Fuel Pump Relay
Submitted on November 14, 2019

 

  • In November 2018, FCA US LLC (“FCA US”) Vehicle Safety Regulatory Compliance (“VSRC”) Product Investigation team was notified by the FCA US Recall Administration team of dealers requesting NHTSA Recall 14V-150 or 15V-115 parts due to the original campaign parts failing. FCA US VSRC Product Investigation team requested six dealers to return a failed relay and relay harness to FCA US for analysis.

 

  • In December 2018, FCA US VSRC sent six relays to FCA US Electrical Engineering for testing and analysis. Initial test results indicated that the relay coil was capable of closing and opening the relay contacts and appeared to be operational.

 

  • Between December 2018 and January 2019, FCA US sent the same six relays and harness kits to the relay supplier for additional intrusive testing.

 

  • Between January 2019 and February 2019, FCA US VSRC, FCA US engineering, and the relay supplier held meetings to discuss test results. The relay supplier test results indicated relay contacts had silicon present on the contact surfaces, preventing current flow through contacts. Additional testing was performed on the relay weather protection seals. Both seals were found to be made of silicone.

 

  • Between March 2019 and June 2019, meetings were conducted between FCA US VSRC and FCA US engineering to review the issue and understand customer consequence and scope of the issue.

 

  • Between June 2019 and November 2019, additional failed fuel pump relays were returned to FCA US for testing. FCA US materials engineering performed intrusive testing on faulty relays returned from the field, and two new relays that had never been installed on a vehicle. Meetings were conducted between FCA US VSRC and FCA US engineering to review the test results.

 

  • As of October 31, 2019, FCA US has identified 170 CAIRs reported related to this issue.

 

  • As of October 31, 2019, FCA US has identified 49 c/1000 warranty related to this issue.

 

  • As of October 31, 2019, FCA US is not aware of any accidents or injuries potentially related to the issue.

 

  • On November 7, 2019, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles.

 


6 Affected Products

Vehicles

MAKE MODEL YEAR
DODGE DURANGO 2011-2013
JEEP GRAND CHEROKEE 2011-2013

 


20 Associated Documents

Recall 573 Report – Amendment 1

RCLRPT-19V813-7419.PDF 214.97KB

RCLRPT-19V813-7419

 


Recall 573 Report – Amendment 2

RCLRPT-19V813-8433.PDF 215.144KB

RCLRPT-19V813-8433

 


Chronology

RMISC-19V813-5694.pdf 21.57KB

RMISC-19V813-5694

 


Manufacturer Notices(to Dealers,etc) – 11/15/2019 New Safety Recall Advanced Communication V62

RCMN-19V813-2121.pdf 98.292KB

RCMN-19V813-2121

 


Recall Acknowledgement

RCAK-19V813-6065.pdf 301.592KB

RCAK-19V813-6065

 


Defect Notice 573 Report

RCLRPT-19V813-3634.PDF 214.039KB

RCLRPT-19V813-3634

 


Manufacturer Notices(to Dealers,etc) – December 2019 62 Interim Parts Communication FINAL

RCMN-19V813-0088.pdf 103.938KB

RCMN-19V813-0088

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-19V813-5404.pdf 56.142KB

RIONL-19V813-5404

 


Manufacturer Notices(to Dealers,etc) – 11/21/2019 New Safety Recall Advanced Communication V62

RCMN-19V813-0756.pdf 100.456KB

RCMN-19V813-0756

 


Recall Quarterly Report #1, 2020-4

RCLQRT-19V813-0761.PDF 211.157KB

RCLQRT-19V813-0761

 


Recall Quarterly Report #3, 2021-2

RCLQRT-19V813-8533.PDF 211.365KB

RCLQRT-19V813-8533

 


Owner Notification Letter(Part 577)

RCONL-19V813-7823.pdf 516.905KB

RCONL-19V813-7823

 


Recall Quarterly Report #2, 2021-1

RCLQRT-19V813-4802.PDF 211.265KB

RCLQRT-19V813-4802

 


ISSUED Renotification Notice

RCRN-19V813-6930.pdf 138.312KB

RCRN-19V813-6930

 


Remedy Instructions and TSB

RCRIT-19V813-0002.pdf 5109.685KB

RCRIT-19V813-0002

 


Remedy Instructions and TSB

RCRIT-19V813-2805.pdf 5303.911KB

RCRIT-19V813-2805

 


Recall 573 Report

RCLRPT-19V813-2449.PDF 215.174KB

RCLRPT-19V813-2449

 


Recall Quarterly Report #4, 2021-3

RCLQRT-19V813-8478.PDF 211.48KB

RCLQRT-19V813-8478

 


Recall Quarterly Report #5, 2021-4

RCLQRT-19V813-8330.PDF 211.604KB

RCLQRT-19V813-8330

 


Renotification Notice

RCRN-19V813-1000.pdf 1537.491KB

RCRN-19V813-1000

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V813&docType=RCL

 


 

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