Recall - Replace Canister Purge Hoses: Overview
Revised August 2005Dealer Service Instructions for:
EMISSIONS RECALL E07 - CANISTER PURGE HOSES
NOTE:
A hose modification has been added for BR vehicles equipped with 5.9L engine built without Leak Detection Pump (LDP).
Models:
2001-2002 (BR/BE) Dodge Ram 2500/3500 Pick Up Truck
NOTE:
This recall applies only to the above vehicles equipped with a 5.9L heavy duty or 8.0L engine ("5 "or "W" in the 8th VIN position) and a Federal emissions control system (sales code NAA) built after January 31, 2001 (MDH 013123).
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 canister purge hoses on about 7,800 of the above vehicles may develop cracks over time and release evaporative hydrocarbon (HC) which could exceed Federal emission standards.
Repair
The vapor canister purge hoses must be replaced.
Parts Information
A. Canister Purge Hose
Each dealer to whom vehicles in the recall were invoiced will receive enough of each canister purge hose package to service about 10% of those vehicles.
The appropriate canister purge hose package for the vehicle being serviced is displayed on the DealerCONNECT VIP function and may also be determined by using the table.
B. Authorized Modification Label
Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed.
Each vehicle requires application of the following labels:
Part Number Description
04275086AB Authorized Modifications Label
Service Procedure
A: Replace Evaporative Hoses:
1. Open the hood.
2. Remove the air filter housing assembly from the throttle body.
3. Disconnect the vacuum hose located on the front of the throttle body for V-8 engines or on the bottom of the throttle body for V-10 engines (Figure 1).
4. Disconnect the plastic vacuum hose coming from the canister purge solenoid at the rubber hose connector coming from the throttle body (Figure 2).
5. Remove and discard the old throttle body hose assembly.
6. Route the new throttle body hose assembly in the same position as original hose.
7. Connect the new hose to the throttle body fitting.
8. Install the air filter housing assembly to the throttle body.
9. Disconnect the canister purge hoses at the canister purge solenoid (Figure 3).
10. Disconnect the canister purge hose retaining clips.
NOTE:
Vehicles equipped with a V-10 engine, the clips are located behind the coolant recovery bottle.
11. Vehicles equipped with a V-10 engine, pull the canister purge hoses out from behind the coolant bottle (Figure 3).
12. Lift the vehicle on an appropriate hoist.
13. Disconnect the canister purge hoses located on the top side of the vapor canister (Figure 4).
NOTE:
The vapor canisters are mounted to the passenger side frame rail.
14. Disconnect the plastic hose retainer clips on the passenger side frame rail.
15. Remove and discard the canister purge hoses from the vehicle.
16. Loosen the clamps on the canister-to-canister hose located on the top of the vapor canisters (Figure 4).
17. Remove the canister-to-canister vapor hose (Figure 4). Save the hose clamps for reuse and discard the hose.
18. Install the original hose clamps onto the new canister-to-canister hose.
19. Install the canister-to-canister hose and tighten the hose clamps securely (Figure 4).
20. Place the new canister purge hose assembly into position on the vehicle.
21. Clip the plastic hose retainer clips to the passenger side frame rail.
22. Connect the canister purge hoses to the vapor canisters (Figure 4).
23. Lower the vehicle.
24. Vehicles equipped with a V-10 engine, route the new canister purge hoses behind the coolant bottle (Figure 3).
25. BR Vehicles with 5.9L engine, without a Leak Detection Pump (LDP), require the following steps performed to the new canister purge hoses before installation:
a. Remove the white vacuum tee and "J" hose at the canister purge solenoid end of the new canister purge hoses and discard.
b. Transfer the black "L" vacuum fitting from the old canister purge hose to the new canister purge hose, replacing the white vacuum tee previously removed.
c. Remove and save the black canister vent cap from the old canister purge (5/8" diameter) vent hose.
d. Measure down the new 5/8" diameter vent hose 10 inches and cut off the hose.
e. Push the vent cap removed in Step C into the new 5/8" diameter vent hose.
26. Connect the canister purge hoses to the canister purge solenoid (Figure 3).
27. Connect the plastic vacuum hose coming from the canister purge solenoid at the rubber hose connector (located next to the air conditioning pressure switch) to the vacuum hose coming from the throttle body (Figure 2 and 3).
28. Continue to Section B. Install the Authorized Modifications Label.
B. Install the Authorized Modifications Label:
Type or print (with a ballpoint pen) the necessary information shown in Figure 5 onto the Authorized Modifications Label. Then attach the label near the VECI label.
Claims for vehicles that have been serviced must be submitted on DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payment.
Use the labor operation number and time allowance shown.
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
All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on description of this.
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirements by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is shown.
Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable.
Vehicle List 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 list mat 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 completing this action, please contact your Service and Parts District Manager.