Safety Recall R07 / NHTSA 15V-114 Fuel Rail Crossover Hose – 2015 Dodge Challenger SRT & Charger SRT

NHTSA Campaign Number: 15V114
Manufacturer Chrysler (FCA US LLC)
Components ENGINE AND ENGINE COOLING, FUEL SYSTEM, GASOLINE
Potential Number of Units Affected 1,875

 

Damaged Fuel Rail Hose Connection

A fuel leak in the presence of an ignition source such as hot engine or exhaust components increases the risk of a vehicle fire.

 

Summary

Chrysler (FCA US LLC) is recalling certain model year 2015 Dodge Challenger SRT and Dodge Charger SRT vehicles manufactured September 18, 2014, to February 5, 2015, and equipped with a 6.2L supercharged engine.

O-ring seal and fuel rail crossover hose damage may result in the fuel rail hose connection leaking fuel.

 

Remedy

Chrysler will notify owners and dealers will replace the engine fuel rail injector crossover hose, free of charge. The recall began April 23, 2015.

Owners may contact Chrysler customer service at 1-800-853-1403.

Chrysler’s number for this recall is R07.

 

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

 

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April 2015

Dealer Service Instructions for:

Safety Recall R07 / NHTSA 15V-114 Fuel Rail Crossover Hose

 

Models

2015	(LA)	Dodge Challenger SRT
	(LD)	Dodge Charger SRT

 

NOTE: This recall applies only to the above vehicles equipped with a 6.2L supercharged engine (sales code ESD) built through February 05, 2015 (MDH 020514).

IMPORTANT:  Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall.

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 rail crossover hose on about 2,000 of the above vehicles may leak fuel.  The fuel rail crossover hose may have been damaged during the manufacturing process.  The damage cannot be reliably detected and may cause a fuel leak without warning.  A leaking engine fuel rail crossover hose, in the presence of an ignition source, could cause an underhood fire.

 

Repair

The left fuel rail and crossover hose must be replaced.

 

Parts Information

Part Number	Description
CBA0R071AA	Rail Assembly, Fuel Injector
Each package contains the following components:
Quantity	Description
1	Rail, Left Side Fuel (with crossover hose, fuel injectors and O-rings)

 

Each dealer to whom vehicles in the recall were assigned will receive enough Fuel Injector Rails to service about 20% of those vehicles.

 

Parts Return

No parts return required for this campaign.

 

Special Tools

The following special tools are required to perform this repair:

NPN	wiTECH VCI Pod Kit
NPN	Laptop Computer
NPN	wiTECH Software

 

Service Procedure

WARNING: THE FUEL SYSTEM IS UNDER CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING THE FUEL INJECTOR RAIL, THE FUEL SYSTEM PRESSURE MUST BE RELEASED.  FAILURE TO FOLLOW THIS WARNING MAY RESULT IN SERIOUS OR FATAL INJURY.

1. Use the following procedure to release the fuel pressure from the fuel injection fuel rail:

a. Remove the fuel pump relay from the Power Distribution Center (PDC).

NOTE:  The fuel pump relay is located in cavity number 72 of the PDC located next to the battery in the trunk (Figure 1). 

b. With the fuel pump relay removed, start and run the engine until it stalls.

c. Attempt restarting engine until it will no longer run.

d. Turn the ignition to the “OFF” position.

e. Install the fuel pump relay into cavity number 72 of the PDC (Figure 1).

NOTE: Removing the fuel pump relay and releasing the fuel pressure from the fuel system may generate Diagnostic Trouble Codes (DTC’s). Use the wiTECH scan tool to erase DTC’s after the repairs are complete.

Figure 1 – Fuel Pump Relay Location

 

2. Disconnect and isolate the negative battery cable (Figure 1).
3. Remove and save both engine fuel injector covers (Figure 2).
4. Using compressed air, blow air around each injector on the left fuel rail to remove any debris that may have collected around the fuel injectors, supercharger  and/or intake manifold area (Figure 3).

Figure 2 – Fuel Injector Covers

 

CAUTION:  Failure to clean the injector area with compressed air could allow debris to enter the engine when the fuel injectors are removed.

Figure 3 – Clean Injector Area with Compressed Air

 

5. For LA vehicles, continue with Step 6 of this procedure.

For LD vehicles only, use the following procedure to remove the cowl panel and cross-car beam:

a. Remove and save the windshield wiper arms (Figure 4).

b. Remove and save the plastic cowl panel (Figure 4).

Figure 4 – Cowl Panel

 

Figure 5 – Windshield Wiper Module

 

c. Remove and save the windshield wiper module (Figure 5).

d. Disconnect the electrical connect from the right side of the cross-car beam (Figure 6).

Figure 6 – Electrical Connector

 

e. Remove and save the right and left side cross-car beam mounting bolts (Figure 7).

f. Remove and save the cross-car beam (Figure 7).

g. Remove and save the windshield wiper module plastic tub (Figure 8).

h. Continue with Step 6.

Figure 7 – Cross-Car Beam Bolts (right side shown)

 

Figure 8 – Windshield Wiper Module Plastic Tub

 

Figure 9 – Crossover Hose Quick Connect Fitting Location
(LA Vehicle Shown)

 

6. Disconnect the fuel pressure sensor wire harness connector located next to the left fuel rail crossover hose quick connect fitting (Figure 9).

NOTE: To access the fuel pressure sensor wire harness connector, reach behind the supercharger from the left side of the vehicle.

7. Disconnect the left fuel rail crossover hose quick connect fitting from right fuel rail (Figure 9).

NOTE: To access the left fuel rail crossover hose quick connect, reach behind the supercharger from the left side of the vehicle.

Figure 10 – Fuel Injector Wire Harness Connectors

 

8. Disconnect the left side fuel injector wire harness connectors for each fuel injector and position the wire harness aside (Figure 10).
9. Remove and save the left fuel rail retaining bolts (Figure 10).
10. Gently rock and lift the left fuel rail until the fuel injectors just start to clear the machined holes in the supercharger (Figure 11).

Figure 11 – Rock and Lift Fuel Injector Fuel Rail

 

11. Remove the left fuel rail, with fuel injectors attached, from the engine (Figure 12).

CAUTION: Note the routing of the crossover hose before removing the fuel rail and crossover hose assembly.

12. Using a 11/32 nut driver (or equivalent) and a lint free cloth, apply a small amount of brake cleaner to the lint free cloth and clean out each of the fuel injector machined bores in the supercharger (Figure 13).

Figure 12 – Left Fuel Rail and Crossover Hose

 

Figure 13 – Clean Fuel Injector Machined Bores

 

13. Apply a light coat of engine oil to the green fuel injector O-rings (Figure 14).
14. Loosely place the new fuel injector rail into position on the engine.
15. Position the fuel injector nozzles into the machined bores of the supercharger and correctly route the fuel rail crossover hose between the supercharger and coolant hoses.

Figure 14 – Apply a light Coat of Motor Oil onto

 

16. Push the fuel rail down until the Green Fuel Injector O-Rings fuel injectors have bottomed on intake manifold shoulders.

CAUTION: Use care not to damage the fuel injector O-ring.

17. Install the left fuel rail retaining bolts and tighten to 89 in. lbs. (10 N·m) (Figure 10).
18. Connect the left side fuel injector wire harness connectors to each fuel injector (Figure 10).
19. Connect the left fuel rail cross-over to the right fuel rail (Figure 9).
20. For LD vehicles only, use the following procedure to install the cowl panel and cross-car beam:

a. Install the windshield wiper module plastic tub.

b. Install the cross-car beam. Tighten the four mounting bolts to 9 ft. lbs. (12 N·m).

c. Install the windshield wiper module. Tighten the retaining bolts to 71 in. lbs. (8 N·m).

d. Secure the electrical connector to the cross-car beam.

e. Install the plastic cowl panel.

f. Install the right and left wiper arms. Tighten the arm nuts to 13 ft. lbs. (18 N·m).

NOTE: Be sure that the wiper blades line up between the two alignment dots on the windshield before tightening the wiper arm retaining nuts.

21. Connect the fuel pressure sensor wire harness connector.
22. Install both engine fuel injector covers (Figure 2).
23. Connect the negative battery cable (Figure 1).
24. Start the engine and check for fuel leaks at the fuel injector rail and fittings.
25. Connect the wiTECH scan tool to the vehicle and clear all Diagnostic Trouble Codes (DTC’s).
26. Remove the wiTECH and return the vehicle to the customer.

 

Complete Proof of Correction Form for California Residents

This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program.  Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration.

 

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 FCA to record recall service completions and provide dealer payments.

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

	Labor Operation Number	Time Allowance
Replace left fuel rail and crossover hose (LA Models)	14-R0-71-82	0.5 hours
Replace left fuel rail and crossover hose (LD Models)	14-R0-71-83	1.1 hours

 

Add the cost of the recall parts package plus applicable dealer allowance to your claim.

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

 

Dealer Notification

To view this notification on DealerCONNECT, select “Global Recall System” on the Service tab, then click on the description of this notification.

 

Owner Notification and Service Scheduling

All involved vehicle owners known to FCA are being notified of the service requirement by first class mail.  They are requested to schedule appointments for this service with their dealers.  A generic copy of the owner letter is attached.

Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable.

 

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

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

GRS provides involved dealers with an updated VIN list of their incomplete vehicles.  The owner’s name, address and phone number are listed if known.  Completed vehicles are removed from GRS within several days of repair claim submission.

To use this system, click on the “Service” tab and then click on “Global Recall System.”  Your dealer’s VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence.

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

Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states.  Use of this information is permitted for this recall only and is strictly prohibited from all other use.

 

Additional Information

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

Customer Services / Field Operations

FCA US LLC

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FUEL RAIL CROSSOVER HOSE

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IMPORTANT SAFETY RECALL
R07 / NHTSA 15V-114

 

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

 

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.

Dear: (Name)

FCA has decided that a defect, which relates to motor vehicle safety, exists in certain 2015 model year Dodge Challenger SRT and Dodge Charger SRT vehicles equipped with a 6.2L supercharged engine.

The problem is…	The fuel rail crossover hose on your vehicle may leak fuel.   The fuel rail crossover hose may have been damaged during the manufacturing process.  The damage cannot be reliably detected and may cause a fuel leak without warning.  A leaking engine fuel injector rail crossover hose, in the presence of an ignition source, could cause an underhood fire.
What your dealer will do…	FCA will repair your vehicle free of charge.  To do this, your dealer will replace the left fuel rail and crossover hose assembly.  The work will take about one hours to complete. However, additional time may be necessary depending on service schedules.
What you must do to ensure your safety…	Simply contact your Chrysler, Jeep, Dodge or RAM 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.  Please bring this letter with you to your dealer.
If you need help…   California residents…	If you have questions or concerns which your dealer is unable to resolve, please contact the FCA Group Recall Assistance Center at either recalls.mopar.com or 1-800-853-1403. The State of California requires the completion of emission recall repairs prior to vehicle registration renewal.  Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is performed.  Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof that the recall has been performed.

 

Please help us update our records by filling out the attached prepaid postcard if any of the conditions listed on the card apply to you or your vehicle.  If you have further questions go to recalls.mopar.com.

If you have already experienced this specific condition and have paid to have it repaired, you may mail your original receipts and proof of payment to the following address for reimbursement consideration: FCA US Customer Assistance, P.O. Box 21-8004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.  Once we receive and validate the required documents, reimbursement will be sent to you within 60 days.  If you’ve had previous repairs and/or reimbursement you may still need to have the recall repair performed on your vehicle.

 

If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC  20590, or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to https://www.safercar.gov.

We’re sorry for any inconvenience, but we are sincerely concerned about your safety.  Thank you for your attention to this important matter.

Customer Services / Field Operations

FCA US LLC

 

Note to lessors receiving this recall: Federal regulation requires that you forward this recall notice to the lessee within 10 days.

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https://static.nhtsa.gov/odi/rcl/2015/RCRIT-15V114-9386.pdf

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https://static.nhtsa.gov/odi/rcl/2015/RCONL-15V114-5286.pdf

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https://static.nhtsa.gov/odi/rcl/2015/RCORRD-15V114-3016.pdf

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https://static.nhtsa.gov/odi/rcl/2015/RCMN-15V114-0901.pdf

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https://static.nhtsa.gov/odi/rcl/2015/RCAK-15V114-3083.pdf

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Latest Recalls Documents

For the Latest and Most recent Recall Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=15V114&docType=RCL

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