Recall - Fuel Rail Replacement

VOLUME
3

GROUP
Campaign

NUMBER
036 (Revised)

MODEL
Rio/Rio Cinco

DATE
June 2004

SUBJECT
Safety Recall: Rio/Rio Cinco Fuel Distributor Replacement

This bulletin provides information relating to a recall campaign to replace the fuel distributor and flexible fuel line on certain 2001-2004MY Rio/Rio Cinco models.





Some Rio vehicles produced from 5/4/00 through 3/31/04 may develop a crack in the fuel inlet fitting on the fuel distributor resulting in a fuel leak. To prevent possible leakage a new fuel distributor has been made available with a steel inlet fitting and an improved flexible fuel line.

* NOTICE

There is no charge to the customer for this repair. Under applicable law, you may not sell or otherwise deliver any affected 2001-2004MY Rio or Rio Cinco until it has been repaired, pursuant to the procedures set forth in this bulletin.

INSPECTION PROCEDURE:





1. Open hood and check for SC036 Campaign Completion Label on bulkhead above master cylinder.

^ If label exists, NO FURTHER ACTION IS REQUIRED.

^ If label DOES NOT EXIST, continue on to REPLACEMENT PROCEDURE.

REPLACEMENT PROCEDURE:





1. Open hood, remove fuse box cover and remove fuel pump fuse. Attempt to start engine, crank engine for an additional 10 seconds to remove fuel pressure.

2. Turn ignition key off, reinstall fuse and fuse box cover.





3. Remove two nuts and two bolts securing engine cover, remove engine cover.





4. Disconnect MAF sensor connector, loosen clamp at air intake hose and remove hose from air cleaner.

5. Disconnect crankcase vent hose from head cover.

6. Remove four bolts securing air cleaner.





7. Loosen clamp at throttle body hose.

8. Remove air cleaner.





9. Remove flexible fuel line at bulkhead end by pushing line toward bulkhead and installing fuel line removal tool (see TSB Fuel 005, Quick Connect Fuel Line Tool). Pull gently on tool and flexible line to remove from steel line. (Use a shop towel to catch any residual fuel.)





10. Remove two bolts securing fuel distributor to intake manifold.

11. Gently pry injectors loose from intake manifold.

12. Disconnect injector connectors and detach injector harness retainers from fuel distributor.





13. Drain fuel from fuel distributor into an approved container.

14. Remove injector retaining clips from fuel distributor and remove fuel injectors.

15. Install new upper "0" rings (included in kit) onto fuel injectors, reinstall fuel injector retaining clips.

16. Lubricate upper "0" rings with clean engine oil and install injectors into new fuel distributor.

Note:
Use only clean engine oil to lubricate injector "0" rings, the use of grease may plug injector screen resulting in a misfire.

17. Lubricate lower "0" rings (NOT included in kit) with clean engine oil, reconnect injector electrical connectors before installing fuel distributor onto intake manifold.

18. Install fuel distributor retaining bolts, torque to 15-17 lb.ft. (20-23 Nm).

19. Reattach injector harness retainers.

20. Install new flexible fuel line by pushing onto fittings until a click is heard, pull gently to test.

Note:
End of line with colored dots goes toward fuel distributor.

21. Reinstall air cleaner and engine cover in reverse order of removal.

22. Turn ignition key on to cycle fuel pump, check fuel distributor for leaks, start engine and check again for leaks.

23. Install SC036 Campaign Completion Label onto bulkhead above master cylinder.

Note:
The fuel pressure test port was intentionally left off the new fuel distributor. Use fuel pressure test adapter "D" to test fuel pressure at the quick disconnect located at the bulkhead end of the new flexible fuel line.

FOR CALIFORNIA, MASSACHUSETTS, VERMONT; AND MAINE DEALERS:

VEHICLE EMISSION RECALL - PROOF OF CORRECTION CARD

A Vehicle Emission Recall - Proof of Correction card must be filled out for all vehicles registered in California, Massachusetts, Vermont, and Maine.

California, Massachusetts, Vermont, and Maine residents who own an affected vehicle will be required to possess a Vehicle Emission Recall - Proof of Correction card as evidence of voluntary service campaign completion when they apply for vehicle registration renewal.

WHAT TO DO WITH THE CARD:

Each customer whose vehicle is registered in California, Massachusetts, Vermont, and Maine must be given a completed Vehicle Emission Recall - Proof of Correction card after the voluntary service campaign has been completed.

Note:
This card MUST be completed by the Dealership's Service Manager using a permanent ink pen. A fine point pen is recommended. When filling in the information, copy the information directly from the vehicle, NOT the repair order. ALL INFORMATION MUST BE PRINTED AND NEAT.

DO NOT COMPLETE THE CARD UNLESS THE SERVICE CAMPAIGN WORK IS COMPLETED!





The copy of the card shown indicates the areas to be filled in.

AFFECTED PRODUCTION RANGE:

Some 2001-2004MY Rio/Rio Cinco vehicles with production dates 5/4/00 through 3/31/04.





PART NUMBER INFORMATION:

Note:
An initial inventory of the Fuel Distributor Kits will be shipped to all dealers to coincide with the recall announcement.





WARRANTY INFORMATION: