On certain vehicles equipped with a 2.5L engine, the crank angle sensor can malfunction causing the engine to stall. Engine stalling would result in lost propulsion which, in conjunction with traffic and road conditions, and the driver's reactions, could increase the risk of a crash. Correction: Dealers will reprogram the Electronic Control Module (ECM) to prevent stalling.
On certain vehicles, the circuit board for the crank position sensor may have an improper solder joint. This could cause the Service Engine Soon warning light to come on, create a no start condition, cause reduced engine power, or cause the engine to stop running without warning during vehicle operation. Correction: Dealers will replace the crankshaft position sensor and both camshaft position sensors.
On certain vehicles at extremely cold temperatures, moisture in the fuel tank may freeze and form ice crystals. These ice crystals may obstruct the suction opening of the fuel pump which can prevent the supply of fuel to the engine and cause the engine to stop. Correction: Dealer will install a screen at the suction opening of the fuel pump.
On certain vehicles equipped with the 2.5 liter engine, the exhaust pipe hanger pin may catch debris from the road which could be ignited by contact with the main catalyst. Correction: Dealer will remove the protruding portion of the exhaust pipe hanger pin.
Also, certain operating conditions may cause the pre-catalyst to overheat and damage the catalyst substrate. If substrate particles enter the combustion chamber, they may score the cylinder walls, resulting in increased oil consumption. If the engine oil level is not checked on a periodic basis, engine damage may occur which could result in fire. Correction: Dealer will reprogram the engine control unit to prevent the possibility of the pre-catalyst overheating. If the conversion efficiency of the pre-catalyst has deteriorated, then the catalyst will be replaced. The original pre-catalyst will then be inspected for evidence of damage to the catalyst substrate. If damage is present, the vehicle engine will be replaced.
On certain vehicles, the clockspring electrical connector may not be fully secured to the driver side air bag module squib pin connector due to the retaining groove in the module not having sufficient depth to hold the connector in the assembled position. If the connector comes loose, the supplemental air bag warning light will come on. However, the driver side air bag will not deploy in the event of a crash. Correction: Dealer will install a retaining clip on the clockspring electrical connector.