August 26, 2021 NHTSA CAMPAIGN NUMBER: 21V665000

Fuel Supply Line Connector May Leak

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

 

NHTSA Campaign Number: 21V665

Manufacturer Chrysler (FCA US, LLC)

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 14,410

 

Summary

Chrysler (FCA US, LLC) is recalling certain 2020 Jeep Wrangler vehicles equipped with the 2.0 Liter engine. A cracked fuel supply line connector may leak fuel into the engine compartment.

 

Remedy

Dealers will inspect and replace the fuel supply line as needed, free of charge. Owner notification letters were mailed on September 10, 2021. Owners may contact FCA US LLC customer service at 1-800-853-140. FCA US LLC’s number for this recall is Y10.

 

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.nhtsa.gov.

 

Check if your Vehicle has a Recall

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New Safety Recall Advanced Communication – Y10

 

FCA US LLC (FCA US) has announced a safety recall on certain 2020 Model Year (JL) Jeep_® Wrangler vehicles equipped with a 2.0L engine (sales codes EC1 and EC3).  

 

REASON FOR THIS SAFETY RECALL

Some of the above vehicles may have been built with a cracked fuel supply line connector which may leak gasoline into the engine compartment. Uncontained gasoline in the engine compartment can result in a vehicle fire which increases the risk of injury to occupants and persons outside the vehicle, as well as property damage.

 

SERVICE ACTION

FCA US will conduct a voluntary safety recall on all affected vehicles to inspect and replace the fuel supply line as needed. 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.  This recall is estimated to launch in 3rd Quarter of 2021.

 

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September 2021

Dealer Service Instructions for:

Safety Recall Y10 / NHTSA 21V-665 Fuel Supply Line

 

Remedy Available

2020 (JL) Jeep Wrangler

 

NOTE:  This campaign applies only to the above vehicles equipped with a 2.0L engine (sales codes EC1 and EC3).

 

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

 

IMPORTANT:  Some of the involved vehicles may be in dealer new vehicle inventory.  Federal law requires you to complete this recall service on these  vehicles before retail delivery.  Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service.  Involved vehicles can be determined by using the VIP inquiry process.

 

Subject

The fuel supply line connector on about 14,400 of the above vehicles may crack.

Uncontained gasoline in the engine compartment can result in a vehicle fire which increases the risk of injury to occupants and persons outside the vehicle, as well as property damage.

 

Repair

Locate the fuel supply line that feeds into the high pressure fuel pump on the engine. Inspect the date code on the fuel line tag. If the date falls within the specified range, replace the line.

If the tag is missing, replace the line.

 

Alternate Transportation

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

 

Parts Information

 

Two Door Wrangler

 

Four Door Wrangler

 

Parts Return

No parts return required for this campaign.

 

Special Tools

No special tools are required to perform this service procedure.

 

Service Procedure

WARNING: Observe the following precautions when working on fuel systems: No sparks, open flames or smoking. Avoid inhaling and swallowing fuel. Avoid eye and skin contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing. Failure to observe these precautions may result in fire, explosion, property damage, and serious or fatal injury.

 

WARNING: The fuel system is under constant pressure even with engine off. Before servicing the fuel rail, fuel system pressure must be released.

 

NOTE: The “Fuel Adaptive Parameter Reset” and “Fuel Feed System Component Replacement” scan tool procedures should always be run after a PCM, fuel injector, fuel rail, high pressure pump or fuel pressure sensor is replaced. The procedures should be in the “Miscellaneous Functions” tab in the PCM. Failure to run the procedures may cause DTCs to set in the PCM.

 

Service Procedure

 

A.  Fuel Supply Line Inspection Procedure

 

1. Raise the vehicle. Locate the fuel supply line that feeds into the high pressure fuel pump on the engine. Inspect the parts tag on the fuel line (Figures 1 and 2). If the tag is missing, replace the line.

 

NOTE: The fuel supply line to the high pressure pump is located on the back of the engine, behind the cylinder head, and above the transmission bellhousing.

 

2. Compare the date code on the tag (Figure 3) to the table (Figure 4). If the date code falls within the ranges shown, replace the line. If it does not, return the vehicle to the customer.

 

B.  Fuel Supply Line Removal Procedure

 

1. Lower the vehicle.

 

2. Remove the fuel fill cap.

 

3. Remove the fuel pump fuse from the Power Distribution Center (PDC). For location of the fuel pump fuse, refer to label on the underside of the PDC cover.

 

4. Start and run the engine until it stalls.

 

5. Attempt restarting the engine until it will no longer run.

 

6. Turn the ignition key to the OFF position.

 

7. Return the fuel pump fuse to the PDC.

 

8. Disconnect and isolate the negative battery cable(s). If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable.

 

9. Raise and support the vehicle.

 

10. Support the powertrain with a suitable jack.

 

11. Remove the front reinforcement crossmember bolts (2 and 3) (Figure 5).

 

12. Remove the two bolts attaching the Power Pack Unit (PPU) skid plate to the transfer case skid plate (models with eTorque only) (Figure 6).

 

13. Remove the crossmember bolts (2) (Figure 7).

 

14. Remove the fuel tank strap nuts (3) (Figure 7).

 

15. Remove the frame bolts (4) and remove the transfer case skid plate (1) (Figure 7).

 

16. Remove the nut and bolt and remove the shield deflector at front of fuel tank (Figure 8).

 

17. Support the transmission with a suitable lifting device.

 

18. Remove the nuts (5) attaching the transmission mount to the crossmember (Figure 9).

 

19. Remove the bolt (6) through the fuel tank skid plate (Figure 9).

 

20. Remove the frame bolts (1) (Figure 9).

 

21. Remove the bracket bolts (4) and nuts (3) (Figure 9).

 

22. Remove the bolts and separate the exhaust hanger from the crossmember, if equipped (Figure 10).

 

23. Remove the crossmember.

 

24. Remove the fasteners from four locations securing the PPU wiring harness to the transfer case and transmission (models with eTorque only) (Figures 11- 14).

 

25. Mark an installation reference line across the front driveshaft flange and the axle pinion flange.

 

26. Remove and DISCARD the front axle flange to front driveshaft bolts (1) and remove the driveshaft (Figure 15).

 

27. Hang front of driveshaft to transmission.

 

28. Disconnect the Fuel Pressure Sensor wire harness connector (Figure 16).

 

29. Remove fuel line from mounting clips (Figures 17 and 18).

 

30. Disconnect the fuel supply line clip at the tank (Figures 19 and 20).

 

31. Disconnect the fuel supply lines at the tank (Figure 21).

 

32. Lower the rear of the transmission to create access to reach the high pressure fuel pump.

 

33. Release the blue connector clip on the fuel supply line connector at the high pressure pump (Figure 22).

 

34. Using an appropriate tool, release the locking tab on the fuel line, and remove it from the vehicle (Figure 23).

 

C.  Install

 

1. Connect the fuel supply line to the fuel injection pump (Figure 22).

 

2. Install the fuel tank supply line at the front of fuel tank (Figure 21).

 

3. Install the fuel line into the mounting clips (Figure 17 – 20).

 

4. Connect the Fuel Pressure Sensor wire harness connector (Figure 16).

 

NOTE: Drive shaft bolts must be replaced with NEW. If NEW bolts are not available clean the old bolts and apply Mopar® Lock and Seal Adhesive or equivalent.

 

5. Install the front drive shaft with new bolts (Figure 15). Tighten bolts to 121 N·m (89 ft. lbs.).

 

6. Install the fasteners from four locations securing the PPU wiring harness to the transfer case and transmission (models with eTorque only) (Figures 11-14). Tighten the bolts to 9 N·m (80 in. lbs.).

 

7. Install the transmission crossmember (Figure 9).

 

8. Install the crossmember bolts (4) and nuts (3) to the bracket on the frame, and tighten to 175 N·m (129 ft. lbs.) (Figure 9).

 

9. Install the crossmember bolts (1) through the frame and tighten to 70 N·m (52 ft. lbs.) (Figure 9).

 

10. Install the bolt (6) through the fuel tank skid plate and tighten to 65 N·m (48 ft. lbs.) (Figure 9).

 

11. Install the nuts (5) attaching the transmission mount to the crossmember and tighten to 175 N·m (129 ft. lbs.) (Figure 9).

 

12. Install the bolts attaching the exhaust hanger to the crossmember, if equipped and tighten to 22 N·m (16 ft. lbs.) (Figure 10).

 

13. Remove the support from the transmission.

 

14. Install the shield deflector at the front of the fuel tank. Tighten the bolt to 9 N·m (80 in. lbs.), and the nut to 8 N·m (71 in. lbs.).

 

15. Install the frame bolts (4) and install the transfer case skid plate (1) (Figure 7). Tighten the bolts to 75 N·m (55 ft. lbs.).

 

16. Install the fuel tank strap nuts (3) (Figure 7). Tighten the nuts to 17 N·m (13 ft. lbs.).

 

17. Install the transmission crossmember to transfer case skid plate bolts (2) (Figure 7). Tighten the nuts to 75 N·m (55 ft. lbs.).

 

18. Install the two bolts attaching the Power Pack Unit (PPU) skid plate to the transfer case skid plate (models with eTorque only) (Figure 6). Tighten the bolts to 9 N·m (80 in. lbs.).

 

19. Install the front reinforcement crossmember and bolts (2 and 3) (Figure 5).

Tighten the bolts (2) to 75 N·m (55 ft. lbs.), and bolts (3) to 65 N·m (48 ft. lbs.).

 

20. Lower the vehicle.

 

21. Connect the negative battery cable.

 

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1 Affected Product

Vehicle

 

 

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10 Associated Documents

Recall Quarterly Report #1, 2021-3

RCLQRT-21V665-5647.PDF 211.143KB

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Defect Notice 573 Report

RCLRPT-21V665-4028.PDF 214.359KB

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Recall Acknowledgement

RCAK-21V665-6670.pdf 645.174KB

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Recall Quarterly Report #2, 2021-4

RCLQRT-21V665-0293.PDF 211.25KB

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Remedy Instructions and TSB

RCRIT-21V665-9176.pdf 1394.985KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V665-3886.pdf 58.141KB

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Manufacturer Notices(to Dealers,etc) – Software Update Screen Shot

RCMN-21V665-0600.pdf 97.189KB

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ISSUED Renotification Notice

RCRN-21V665-9753.pdf 138.857KB

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Renotification Notice

RCRN-21V665-1000.pdf 1537.491KB

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Recall Quarterly Report #3, 2022-1

RCLQRT-21V665-2555.PDF 211.339KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V665&docType=RCL

 

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