Vehicles Involved: Freightliner S2G and C2 Chassis with the 8.0L PIthon Engine
and Propane Fuel System
Concern: 15 Amp Fuel Pump Fuse Intermittently Opens Resulting in a Stall/Crank
No Start Condition
Cause: Certain Operational Conditions can result in Circuit Amperage Exceeding
the 15 Amp Limit of the Fuse
Correction: Replace Fuel Pump Relay with New 5 Pin Relay, Modify Relay Box
Wiring and Replace 15 Amp Fuse with 20 Amp Fuse and install new sticker
Parts Information: Parts must be obtained by calling Cleanfuel USA at 877-2341722 or the PI Help Line at 844-747-6937 and choosing 8.0 Liter and Fuel System
Tech Assist. Part number ECO-6016-X-01 will be supplied at no charge for
approved claims on vehicles under Warranty. Parts are sent UPS
Ground
Vehicles exhibiting the condition outlined above will require the following service
procedure to be performed.
Disconnect the Vehicle Battery using the documented Service Procedure
Locate the Fuse/Relay panel that holds the Fuel Pump Relay and Fuel Pump Fuse
and remove the cover. The Fuse/Relay panel is located under the hood on the
driver’s side. The panel closest to the cowl (inboard) is the one you need to
access.
Fuel Pump Relay & Fuse
Front
of
Vehicle
D
isengage tabs to remove Fuse/Relay Panel from Metal Bracket and move it
forward (box moves up to disengage then feed it back through the bottom to gain access)
Tab
Location
Remove the original 4 Pin Fuel Pump Relay and discard. Locate the terminals in
location A4 and B4. These wire terminals must be moved to location A5 and B5 to
accommodate the new 5 Pin Relay.
A4
B4
Remove the terminals from location A4 & B4 (one at a time) using the appropriate
terminal tool, also remove the sealing plugs in the empty locations of A5 & B5 and
save them for reuse. Move the terminal removed from A4 to A5 (shown). Move
the terminal removed from B4 to B5. Install the Sealing Plugs into the now vacant
cavities of A4 and B4
Removing terminal using terminal tool
Removing sealing plugs from vacant cavities
Install new 5 pin relay and replace original 15 Amp fuel pump fuse with new 20
Amp fuse. Reinstall Fuse/Relay Panel into metal bracket. Reinstall cover and
install Sticker “Fuel Pump 20 Amp” over the original Fuel Pump Fuse location.
Reconnect Battery per documented procedures. Start the vehicle using normal
starting procedures and verify normal vehicle operation.
Sealing Plug Removed
Terminal Tool Example
Labor Time: Relocate Fuel Pump Relay Pins, Replace Relay and Fuse, Install
Sticker - 0.3 hrs
Invoices must be made out to Cleanfuel USA, PO Box 1609, Georgetown, TX,
78627. Only preapproved invoices will be paid. Email Invoices to
[email protected]