Recall - Fuel Pump Return Line Restriction
No: SR-03-003DATE: December, 2003
MODEL: See below
SUBJECT:
FUEL PUMP RETURN LINE RESTRICTION
- SAFETY RECALL CAMPAIGN
PURPOSE
The fuel return line hose fitting on the fuel pump may be restricted, causing excessive fuel pressure to build up in the fuel injection system. Excessive fuel pressure may result in the fuel return hose becoming dislodged from the fitting, resulting in fuel leakage. Fuel leakage in the presence of an ignition source could result in a fire. If there is a restriction in the fuel return hose fitting, a new fuel pump must be installed.
AFFECTED VEHICLES
2003 Galant models produced between 6/16/03 - 9/11/03
2003-04 Eclipse and Eclipse Spyder models produced between 6/16/03 - 9/11/03
CUSTOMER NOTIFICATION
A letter will be sent to all owners of affected vehicles. The letter tells the owner to bring their vehicle to a Mitsubishi Motors dealer to have the fuel return system inspected. A sample copy of the customer notification letter appears in Attachment A of this bulletin.
REQUIRED OPERATIONS
Before starting this campaign procedure, CHECK ON THE WARRANTY SUPERSCREEN to verify that the vehicle is an affected VIN for this campaign and that this campaign procedure has not already been completed.
CAUTION
The pressure that is used to test the fuel return system is limited to 5 psi. If you apply pressure over this amount, serious damage to the fuel tank will result.
Use only a hand pressure pump (such as MITYVAC-II or equivalent) with a vacuum/pressure gauge attached. Do not use shop air.
1. Remove the hose clamp from the fuel return hose on the fuel pressure regulator. Remove the hose from the fitting.
Cover the hose connection with shop towels, to prevent fuel splashing.
Wrap a shop towel around the hose end. If the fuel return port is blocked, pressure will be trapped in the return hose.
2. Using a hand pressure pump, apply 5 psi into the open end of the fuel return hose.
a. If the fuel return hose holds this pressure, this indicates that the return line is 1restricted. Continue with Step 3 to determine whether the restriction is at the fuel pump.
b. If the fuel return hose does not hold this pressure, continue with Step 3 to verify that the fuel return hose is securely connected.
c. Reinstall the fuel return hose securely to the fuel pressure regulator, and reinstall the hose clamp.
3. To minimize gasoline fumes building up in the passenger compartment, open the rear doors and trunk lid (Galant), open the doors and hatch (Eclipse), and lower the convertible top on Eclipse Spyder models.
4. Remove the rear seat cushion and remove the fuel pump access cover.
5. If the fuel return hose did not hold pressure in Step 2, visually inspect the fuel return fitting on the fuel pump to verify that it is securely connected. If it is securely connected, this campaign procedure is completed. Reinstall the fuel pump access cover and the rear seat cushion.
If the fuel return hose held pressure in Step 2, continue with Step 6.
6. Remove the fuel return hose from the return fitting on the fuel pump. Apply 5 psi pressure to the fitting. Pressure should drop immediately.
CAUTION
Cover the hose connection with shop towels, to prevent fuel splashing.
a. If the pressure remains in the fuel return fitting, it is restricted and the fuel pump must be replaced. Go to Step 7 for fuel pump replacement.
b. If it is not able to hold pressure, check the fuel return line for kinks or other damage. Repair as necessary.
7. Replace the fuel pump as follows:
a. Disconnect the hose and connector connections. Use special tool MB991480 to remove the fuel pump.
Note the manufacturing code number on the original fuel pump, stamped on the part number decal under the part number. Record this code on the repair order.
b. Replace the fuel pump, using the new, improved pump listed in the PARTS INFORMATION section of this bulletin. Refer to Group 13C of the appropriate service manual.
c. For ease of installation, install the new gasket to the fuel tank, lubricate the gasket inside diameter with soapy water, and then install the fuel pump. Torque the nut to 57 +/- 7 ft/lbs (77 +/- 10 Nm).
CAUTION
Do not tilt the fuel pump module when installing.
Ensure that the alignment mark on the fuel pump module is lined up with the mark on the tank.
Do not allow the fuel pump module to turn when tightening the nut.
Be sure that the gasket does not fold over.
8. Reinstall the fuel pump access cover and the rear seat cushion.
PARTS INFORMATION
Use the Genuine Mitsubishi Parts listed below:
WARRANTY INFORMATION - Use campaign labor operation C0304AXX
Claims for this campaign must be entered as Recall type "C" claims. Sample claim screens are shown on the next two pages. Check the repair process(es) performed. You may only claim the repairs actually made associated with the specific vehicle condition found.