2021 Chrysler Pacifica Fuel System Problems

High pressure fuel leak with large fan spray pattern in fuel line part number 68492134AA where it sits and rubs against a sharp corner of another component, (appears to be ignition coil) above the rear passenger side of the engine. Searched online and found another owner had posted an image of the exact same leak! https://www.reddit.com/r/ChryslerPacifica/comments/1amcdp9/2021_pacifica_hybrid_fuel_leak/Their photo and mine are identical and in comments on their thread, Two other owners that responded to that thread also said they've also had exactly the same leak. The cause appears to be how this line is routed by the factory. it is resting against the coil and not secured in a way to prevent chafing. Result is extremely dangerous with fuel spraying down towards the exhaust. The part is available for inspection. Safety of my family was put at risk by fuel spraying towards hot exhaust while my wife was driving. She was unaware of problem until fuel smell just prior to arriving at home. Problem is easily reproduced. I spoke with Olympia Chrysler Jeep and the service advisor Corey, said he had seen this issue before as well. He also said because car is not under warranty and I don't have roadside assistance, towing would be at my expense. I have ordered replacement part and will install and secure it to prevent chafing. I will keep part to be availalbe for examination. There were no warning lamps, messages or other symptoms prior to the fuel smell.

While driving my children home from an evening activity, there was a strong odor of gas inside the cabin. I had the vehicle towed to the dealership the next morning for diagnostics and repairs. The dealership 's technician was able to reproduce the issue and upon further inspection discovered a small leak in the fuel line. It was determined that the fuel line had been rubbing against the coil pack, which created a small hole. The fuel was leaking onto the coil pack. This puts both the driver and the passengers at risk because the coil pack is in close proximity to the spark plugs. When there is a spark and gasoline, fires and/or explosions tend to be the result. The technician stated that there had been no tampering with the components and that the gap between the fuel line and the coil pack is very small. I believe that the gap is too small because normal operation of a vehicle should never cause a hole to be rubbed into a fuel line due to it's proximity to the coil pack. Prior to the smell of fuel, there were no other warnings. I have included pictures of the faulty part.

Van had a smell of gasoline inside the cabin and out. Upon inspection, the fuel line going from the hard line to the nylon line in the engine bay was leaking. The nylon line between the fuel pressure sensor and the hard line had rubbed against a coil pack and was leaking fuel. Any fuel leak, especially in the engine bay, poses a safety risk as it can combust and cause a fire inside the engine bay. Other owners have posted about this exact problem on forums, hence why I knew where to look for the issue. I have ordered the new fuel line through the dealership, however, if the fuel line has the same bend in it as the original, the same thing will happen in the future.

I went to start my van and out of nowhere I got an error message saying to “service hybrid electric system” and a check engine light came on. I am not sure if there are any safety hazards related to this, but am no longer able to charge the vehicle. When I plug it in the charging lights flash and the “service charging system” error pops up.

Van has 70K miles. After a long road trip. last stop noticed a gas smell from the front of van. When opening the hood noticed gas had been leaking over top of the motor by spraying fuel. Moving the fuel line running over the top of the motor, showed it was rubbing against top of the coil pack on engine. The rubbing over time caused a small cut in the fuel line allowing for fuel leak. The fuel line seam to be malformed or is unsported causing the rubbing.

High pressure fuel line leaking due to tube rubbing against hard plastic clip. Smelled gasoline fumes from outside the vehicle. Narrowed it down to the passenger side of the engine compartment but couldn't isolate it. Read some forums from similar cases and identified a high pressure fuel line that could wear a hole due to a design flaw. Sure enough I wigged it just slightly and upon starting the vehicle it started spraying gasoline all over the engine at an alarming rate. I drove my children to daycare the previous day, this could have started a fire or caused the engine area to explode. Crazy unsafe and glad I caught it quickly.

The contact owns a 2021 Chrysler Pacifica. The contact stated while refueling the vehicle, the pump handle was set to pump automatically. The contact stated the pump handle was ejected from the filler neck when the fuel tank was full, causing a fuel spill onto the ground. The contact was able to prevent further spilling. The vehicle was not diagnosed or repaired. The manufacturer was contacted and notified of the failure. The failure mileage was 63,000.

I was driving my kids to school this morning on the interstate, traveling at roughly 70 MPH when my Pacifica just died on me. I wasn't able to get the vehicle moving again and I coasted to a stop on the shoulder. The vehicle reported a "Service Charging System" fault and would not restart afterwards. I am waiting (2 weeks) for an opening at the dealership and will have the vehicle towed. I was lucky the interstate had a wide shoulder and traffic was light otherwise it could have been incredibly dangerous.

On 3 separate occasions while driving the dashboard has flashed the error message "Shift to P, Service Charging System". As soon as this occurs, the car begins to lose power and is no longer driveable. Once the car is shifted to "Park" it is temporarily stuck in that position with the car "On" but no power to the engine. For somewhere between 30-90s the car can't be turned off or shifted out of "Park". At some point after a short period - sometimes opening the door seems to help - the car will turn off and can then be re-started. The check engine light is on, but the car can be driven. Within a couple of hours the check engine light goes off and the car seems to behave normally. This has happened to us 3 times over ~2 months now. The car has actually stopped in the middle of the road forcing us to turn on hazard lights while trying to restart. It is extremely dangerous and seemingly common problem. Our local Chrysler service center was only able to book an appointment a month out due to limited technicians qualified to work on the hybrid vehicles. We described the problem in detail but they are not aware of the problem or solutions. We are trying to contact Chrysler Corporate directly to find out what their solution is.

While driving on the highway, the vehicle abruptly lost propulsion, flashed error lights, and indicated an issue with the EV battery and charger, and would not charge when plugged in. Error codes flashed related to the Power train control module, Hybrid control processor, and Aux hybrid control processor. The CJDR Fairfax dealer would only provide software updates and would not perform other repairs per Chrysler's recommendations.

Service Charging Error flashed on instrument panel Power cut and car had no power Unable to restart for 5-10 minutes Power comes back on with check engine light Power cut on the freeway. SUPER dangerous.

*Please note: this is the second incident of this kind with my van (see NHTSA #11468554). The dealer checked our car after the first incident, saying it needed a repair to the transmission. They said they checked with Chrysler engineers who said it was a known issue, but were confident the issue would not occur again for at least another 1,000 miles. They assured us we could drive it the 4 hours home with no problem. However, the same problem occurred about 3.5 hours (~240 miles) into the trip. I am including documentation from the dealer after the first incident.* Today, the van suddenly lost power on the highway going 65mph. The car gave a “service charging system” error. We started to quickly decelerate amid high speed traffic. Pushing on the gas pedal did not make the car accelerate - we were coasting. Luckily, I was able to cross two lanes of traffic and coast up an exit to get to safety. We could have easily been unable to change lanes and stopped cold in a lane on the highway. This is highly dangerous.

Nov 23, 2021. Check Engine Light Illuminated. Dealer service diagnosed the problem as the battery pack coolant heater “A” control circuit performance. Dealer replaced part. Jan 12, 2022. Check engine light illuminated again. Dealer, again, diagnosed the same problem and replaced the same part.

While in EV mode, driving 75 mph on the freeway for at least five minutes, the vehicle suddenly loses power and the accelerator pedal becomes completely unresponsive. My vehicle was slowing down in the carpool lane and I had to carefully find my way to the shoulder to be able to turn the vehicle EV motor back on. There are no warning signs. It is very sudden. This has happened 8 times so far. Dealership service center has inspected and tested the vehicle twice for a few weeks and has not been able to reproduce. My vehicle is available for more inspection but I just initiated a buy back process with Chrysler Customer Care.