Recall - Fuel Pump Relay Inspection/Replacement: Overview

07-017

March 14, 2007

Applies To:
SEE VEHICLES AFFECTED

Safety Recall: Fuel Pump Relay May Cause Engine No-Start or Stalling

BACKGROUND

A manufacturing fault with the fuel pump relay (PGM-FI Main Relay 2) could cause a coil wire inside the relay to break. If this happens, the fuel pump will not operate and the engine may not start. If the relay fails while driving, the engine may stall without warning and a crash could occur.





VEHICLES AFFECTED

CLIENT NOTIFICATION

All owners of affected vehicles will be sent a notification of this campaign. An example of the client notification is at the end of this service bulletin.

To verify vehicle eligibility, check at least one of these items:

^ The client has a notification letter.

^ The vehicle is shown on your campaign responsibility report.

^ The vehicle is shown as eligible on a VIN status inquiry.

In addition to the bulleted verification items, check for a punch mark above the third character of the engine compartment VIN. A punch mark in that location means this campaign has already been completed.

Some vehicles affected by this campaign may be in your used vehicle inventory. According to federal law, these vehicles cannot be sold or leased until they are repaired. To see if a vehicle is affected by this campaign, do a VIN status inquiry before selling it.

CORRECTIVE ACTION

Check the name printed on the fuel pump relay

(PGM-FI Main Relay 2) in the under-dash fuse/relay box.

^ If the name on the relay is DENSO, it does not need to be replaced.

^ If the name on the relay is MITSUBA, and the vehicle is shown as eligible on a VIN status inquiry, replace the relay.

PARTS INFORMATION

PGM-FI Main Relay 2: P/N 39794-SDA-305





WARRANTY CLAIM INFORMATION

Failed Part: 39794-SDA-003

Defect Code: 5RL00

Symptom Code: Q3800

Skill Level: Repair Technician

REPAIR PROCEDURE

1. Turn the ignition switch to LOCK (0).

2. Remove the left front door sill trim and the left kick panel:

^ Refer to section 20 of the appropriate service manual, or

^ Online, enter keyword TRIM and select Interior Trim Removal/Installation - Door Areas or Front Door Sill Area from the list.





3. Locate PGM-FI Main Relay 2 (Fuel Pump) in the under-dash fuse/relay box. Look at the name printed on the relay.





^ If the name is DENSO, the relay is OK. Go to step 6.





^ If the name is MITSUBA, and the vehicle is not shown as eligible on a VIN status inquiry, go to step 6.

^ If the name is MITSUBA, and the vehicle is shown as eligible on a VIN status inquiry, go to step 4.

NOTE:
MITSUBA may be printed upside down.

4. Remove the relay.

NOTE:
Since the relay will not be reused, it's OK to remove it with pliers.

5. Press the new relay into place on the fuse/relay box.

6. Reinstall the left kick panel and the left front door sill trim.





7. Center-punch a completion mark above the third character of the engine compartment VIN.





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