W80 Combo Phase2

Revised February 2021
Dealer Service Instructions for:
Customer Satisfaction Notification W80
Oil Consumption Inspection
NOTE: Added additional information in the repair and parts section.
Remedy Available
2015 - 2018 (BU) Jeep Renegade (FWD)
2016 - 2018 (FB) Fiat 500X (FWD) , (AWD)
2015 - 2018 (VM) Ram Promaster City
NOTE: This recall applies only to the above vehicle equipped with a 2.4L engine
(sales code ED6 or ED8 or EDD or EDE)
NOTE: Some vehicles above may have been identified as not involved in this
campaign and therefore have been excluded from this campaign.
IMPORTANT: Some of the involved vehicles may be in dealer new vehicle
inventory. Dealers should also consider this requirement to apply to used vehicle
inventory and should perform this campaign on vehicles in for service. Involved
vehicles can be determined by using the VIP inquiry process.
Subject
The engines in about 241,000 of the above vehicles may have an engine that
consumes more oil than usual under certain operating conditions like continuous
stop and go driving. The condition results when a combination of components
with certain manufacturing variances are present and the current engine calibration
strategy. While the condition is rare, the vehicles above fall within the population
where such variances could cause an oil consumption issue. If the vehicle is
subjected to a low oil condition, the oil indicator lamp on the instrument panel
 Copyright 2021, FCA US LLC, All Rights Reserved(kka)
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 2
Subject[Continued]
cluster may illuminate or the customer will notice an oil level below the dipstick
crosshatch range markings when checking the vehicle’s oil level as recommended
in the Owner’s Manual. If left unaddressed, a low oil condition can eventually
result in a vehicle stall.
Repair
Initiate an oil consumption test by following section A. Oil Consumption Test.
procedure below. If the oil consumption test fails, please submit a digital imaging
request to the Powertrain Service Center with the oil consumption documentation
and photo of the engine serial number for authorization for a long block
replacement. The request must be submitted as a Claim Type of “W-Warranty”
with the “Actual Cost” field at $0. In the “Repair Issue” section, enter “W80 Oil
Consumption failed” with the mileage at which the vehicle returned, as well as the
amount of oil that was used in the specified mileage. Once the long block
replacement is approved, perform section B. Long Block Removal Procedure
and section C. Long Block Installation Procedure.
The claim that will be later submitted for reimbursement through the claim system
will be “S – Safety” type, but the PTSC request must be submitted as “WWarranty” as there is no S-Safety type available in the pre authorization system
Parts Information
The list of parts below should only be required, if the vehicle fails the oil
consumption test in section A. Oil Consumption Test. Part orders will be
placed for the dealer upon the successful completion of the Powertrain Service
Center approval process. Parts will be blocked from dealer ordering.
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 3
Parts Information [Continued]
Part Number
Description
CCSKW801AA
Part Package
Each package contains the following components:
Quantity
1
1
Description
2.4L Long Block
I-Sheet
Part Number
Description
CCSKW803AA
Part Package (AWD Vehicles Only)
Each package contains the following components:
Quantity
Description
1
Bearing Kit, Drive Shaft
Part Number
Description
CCSKW802AA
Part Package
Each package contains the following components:
Quantity
1
4
2
6
2
1
6
2
2
10
2
2
2
Description
Gasket, Exhaust Manifold
Gasket, Intake Manifold
Nut, Front Axle
Exhaust Hex Head Bolt
Exhaust Hex Head Nut
Gasket, Catalytic Converter
Bolts, Torque Converter
Seal, Banjo Bolt at Gear
Seal, Banjo Bolt at Pump
Strap, Tie
Nut, Lower Control Arm
Bolt, Lower Control Arm
Nut, Tie Rod
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 4
Parts Information [Continued]
Part Number
Description
68163848AB
68088485AB
68523994AA
1 Gallon Bottle, Antifreeze (MSQ 4), MS-12106, MS-90032
1 Pint Bottle, Fluid, Power Steering (MSQ 6) MS-11655
1 Quart Bottle, Oil, Engine SAE 0W-20 (MSQ 6) MS-6395
Bulk Fluid PN’s
68140983AA
55 Gallon Drum, Antifreeze (MSQ 55), MS-12106, MS-90032
68218951AB
5L Bottle, Oil, Engine SAE 0W-20 (MSQ 3) MS-6395
68218952AA
220 Quart Drum, Oil, Engine SAE 0W-20 (MSQ 220) MS6395
NOTE: Dealers are encouraged to use bulk fluids to perform this campaign.
Parts Return
This campaign part will be subject to parts return.
Return the Long Block to the PDC following the standard core return policy.
Dealers will be reimbursed for the core once received by the PDC.
Special Tools
The following special tools are required to perform this repair:
 NPN
wiTECH MicroPod II
 NPN
Laptop Computer
 NPN
wiTECH Software

10288
Pliers, Hose Clamp
 8875A
Cooler Line Disconnect
 6135
Dolly, Power Train or Equivalent
 10287
Tool, Front Hub Staking
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 5
Service Procedure
A. Oil Consumption Test.
1. Verify no external oil leaks are present.
NOTE: A few drops of external oil leakage per mile, can quickly account
for the loss of one quart of oil in a few hundred miles. Ensure no external
engine oil leaks are present.
Oil leakage is not the same as oil consumption and all external
leakage must be eliminated before any action can be taken to verify
and/or correct oil consumption complaints.
2. Ensure the test vehicle has a minimum of 2400 km (1500 miles) until the next
oil change is required. If the vehicle does not have 1500 miles wait until the
scheduled oil change to start the test.
3. Check the oil level at least 5 minutes after a hot shutdown with the vehicle on
a level surface.
4. Ensure the oil level is at the “FULL” mark, if necessary top off the oil to the”
FULL” mark on the dipstick (Figure 1).
1- “FULL”
2- “ADD”
Figure 1 – Oil Dipstick Levels
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 6
Service Procedure [Continued]
5. Tamper proof the oil pan drain plug, oil filter, dipstick and oil fill cap with a
black light marking device (pen), paint pen or touchup paint.
NOTE: The use of a black light marking device is recommended so the
marks can only be seen with an ultraviolet light.
6. Record the vehicle mileage. Note the oil level is at the ‘full’ mark 5 minutes
after hot shutdown and date (Figure 1).
7. Instruct the customer to drive the vehicle as usual.
8. Require the customer to return to the servicing dealer after accumulating
between 2400 - 2700 km (1500 - 1700 miles).
CAUTION! Failure to confirm the oil level between 2400 - 2700 km
(1500 - 1700 miles) voids the test and requires a new test to be
performed.
9. Return the vehicle back to the customer for the 2400 - 2700 km (1500 - 1700
miles) test drive. use LOP (09-W8-0L-81) no further action is needed at this
time.
10. When the vehicle returns for the remaining steps, verify that no evidence
of tampering has occurred.
11. Check the oil level at least 5 minutes after a hot shutdown on a level surface. If
the oil level is at or above the “ADD” mark, the engine is in an acceptable
condition and no further service action required (Figure 1). Use LOP 09-W801-81 to complete the oil consumption inspection.
12. If the oil level is below the “ADD” mark (Figure 1), The vehicle has failed the
oil consumption test, proceed to section B. Long Block Removal Procedure.
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 7
Service Procedure[Continued]
B. Long Block Removal Procedure
1. Perform the fuel pressure release procedure:
a) Loosen the two screws and remove the power distribution center
(PDC) cover (Figure 2).
b) VM Model: Remove F83 20Amp Fuse (Fuel Pump) (Figure 2)
c) BU/FB Model: Remove F21 15Amp Fuse
d) Start and Run the engine until it stalls from fuel starvation.
e) Attempt to start the engine a few times until the engine will no longer
start.
f) Turn the ignition key to the OFF position.
g) Return the fuse back into the fuse box (Figure 2).
F83 FUSE
20Amp(Yellow)
PDC
COVER
SCREWS
NEGATIVE
BATTERY
CABLE
Figure 2 – VM Model - Power Distribution Center
NOTE: VM Model illustrated other models involved are similar.
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 8
Service Procedure [Continued]
2. Disconnect and isolate the negative battery cable. If equipped with an
Intelligent Battery Sensor (IBS), disconnect the IBS connector first before
disconnecting the negative battery cable (Figure 2).
3. Remove the bolt and lift the
engine cover straight up to
disengage the three rubber mount
sockets from the ball (Figure 3).
BALL
STUDS
BOLT
4. VM Model: remove the screw at
the core support securing the air
inlet tube.
Figure 3 – Engine Cover
5. Unlock and disconnect the Inlet
Air Temperature (IAT) sensor
wire harness connector
(Figure 4).
AIR CLEANER
HOUSING
AIR CLEANER
TUBE BOLT
INLET AIR
TEMPERATURE
SENSOR
CONNECTOR
6. Remove the CLIC E® type
clamp at the throttle body inlet
using 10288 Pliers (Figure 4).
7. Remove the make-up air hose
from the valve cover (Figure 4).
8. Remove the bolt that secures the
clean air hose to the cylinder head
cover (Figure 4).
CLIC E CLAMP
MAKE-UP AIR
HOSE
Figure 4 – Air Intake
9. Disengage the clean air hose from
the throttle body inlet and pull straight up to disengage the rubber grommets
from the housing and remove it from the vehicle with the air cleaner hose
attached (Figure 4).
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 9
Service Procedure [Continued]
10. Recover the refrigerant from the air conditioning system.
11. Remove the battery and battery tray:
a) Disconnect the starter cable from the power distribution center.
b) Disconnect the generator cable from the power distribution enter.
c) Disconnect the positive battery clamp.
a) Remove the battery.
b) Disconnect the Powertrain Control Module(PCM) electrical connectors and
the ground wire from the mount.
c) Remove any wiring harness retainers from the battery tray.
d) Remove the battery tray bolts.
e) Remove the battery tray from the vehicle.
BATTERY TRAY
BOLTS
Figure 5 – Battery Tray
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 10
Service Procedure [Continued]
12. VM Model: Remove the Transmission Control Module (TCM) and mounting
bracket nuts and the ground wires nuts (Figure 6).
13. FB AWD Model: Disconnect the TCM module electrical connector.
GROUND
WIRE NUTS
TCM MOUNTING BRACKET
NUTS
TCM
Figure 6 – VM Model Transmission Control Module Mounting Bracket
14. Disconnect the
vacuum hose
quick-connect
fitting from the
vacuum pump and
disengage the
vacuum hose from
the support
bracket (Figure 7).
VACUUM HOSE
QUICK-CONNECT
Figure 7 – Vacuum Pump Hose
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 11
Service Procedure [Continued]
15. VM Model: Remove
the banjo bolt at the
power steering pump
(Figure 8).
16. VM Model:
Disconnect the power
steering return line at
the power steering
pump (Figure 8).
POWER STEERING
RETURN LINE
BANJO BOLT
Figure 8 – Power Steering Pump
17. VM Model : Disengage
the power steering hose
retainer from the support
bracket at the rear of the
cylinder head cover and
reposition the power
steering pump
(Figure 9).
SUPPORT
BRACKET
HOSE
RETAINER
Figure 9 – Power Steering Retainer
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 12
Service Procedure [Continued]
18. Position a drain pan under the lower radiator hose.
19. Disengage the quick-connect coupling and carefully remove the lower radiator
inlet hose from the radiator (Figure 10).
NOTE: DO NOT
WASTE reusable
coolant. If the solution
is clean, drain the
coolant into a clean
container for reuse.
LOWER
RADIATOR
HOSE QUICKCONNECT
Figure 10 – Lower Radiator Hose
20. Remove the coolant pressurized coolant reservoir bolts (Figure 11).
NOTE: VM model
illustrated others
are similar.
COOLANT RESERVOIR
BOLTS
Figure 11 – VM Model - Pressurized Coolant Reservoir
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 13
Service Procedure [Continued]
21. Remove the bolt and
the A/C discharge
line/suction line
manifold from the A/C
compressor (Figure
12).
22. Install plugs in, or tape
over, the opened
refrigerant line fittings
and A/C compressor
ports.
BOLT
DISCHARGE/SUCTION
LINE
AC COMPRESSOR
Figure 12 – AC Lines
23. From inside the
vehicle remove the
bolt and separate the
universal joint
(Figure 13).
UNIVERSAL JOINT
Figure 13 – Steering Shaft Joint
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 14
Service Procedure [Continued]
24. Disconnect the purge vapor line from the purge solenoid (Figure 14).
25. Disconnect the fuel line from the fuel rail (Figure 14).
FUEL
PRESSURE
SENSOR
FUEL LINE
PURGE VAPOR LINE
Figure 14 – Fuel Line
26. If equipped: Disconnect the electrical connector at the fuel pressure sensor
(Figure 14).
27. Disconnect the quick-connect
coupling and remove the upper
radiator inlet hose from the
radiator (Figure 15).
28. FB AWD Model: Disconnect
the power transfer unit actuator
wire harness connector.
29. FB AWD Model: Open the
retaining clip and disconnect
the Transmission Control
Module (TCM) wire harness
connector.
UPPER RADIATOR
HOSE
Figure 15 – Upper Radiator Hose
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 15
Service Procedure [Continued]
30. Disengage
the
wire
harness retainer from the
upper radiator inlet hose at
the thermostat housing
(Figure 16).
UPPER RADIATOR
TO THERMOSTAT
HOSE
ENGINE BLOCK
HEATER
31. If equipped: Disconnect
the block heater wire
harness connector
(Figure 16).
Figure 16 – Thermostat Housing
32. Loosen the CLIC E® type clamp using the Pliers, Hose Clamp 10288 and
remove the engine oil cooler inlet and outlet hoses (Figure 17).
OIL COOLER
INLET HOSE
OIL COOLER
OUTLET HOSE
Figure 17 – Oil Cooler Hoses
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 16
Service Procedure [Continued]
33. Disengage the heater core hose
retainer at the rear of the
transmission (Figure 18).
HEATER CORE
RETAINER
34. Loosen the CLIC E® type
clamp using the Pliers, Hose
Clamp 10288 and remove the
heater core outlet hose from
the coolant return pipe
(Figure 18).
HEATER CORE
OUTLET HOSE
Figure 18 – Heater Hoses
35. Remove the shifter cable from the manual lever by pushing down on release
button while pulling up on cable end (Figure 19).
36. Slide the gear shift cable collar back and pull the cable out of the cable bracket
(Figure 20).
SHIFT CABLE
COLLAR
RELEASE
BUTTON
SHIFT
CABLE
END
SHIFT
CABLE
LEVER
Figure 20 – Shift Cable
Figure 19 – Shift Cable Release
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 17
Service Procedure [Continued]
37. Disconnect the transmission
wire harness connector from
the transmission by rotating
the lock lever
counterclockwise
(Figure 21).
TRANSMISSION
WIRE HARNESS
CONNECTOR
38. FB (AWD Models):
Disconnect the power
transfer unit actuator wire
harness connector.
39. Remove the two bolts and
separate the wire harness
bracket from the
transmission (Figure 22).
LOCK
LEVER
Figure 21 – Harness Connector
40. Unlock and disconnect the engine wire harness connector. Reposition the main
wire harness away from the engine (Figure 22).
BOLTS
ENGINE WIRE
HARNESS
CONNECTOR
BRACKET
Figure 22 – Wire Harness Bracket
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 18
Service Procedure [Continued]
41. BU/FB Model: Disengage the hood latch cable and the retainer from the hood
latch.
42. Raise and support the vehicle.
43. Remove the front tire and wheel assemblies,
44. If equipped: Remove the front belly pan.
45. Remove the screws from the outer side of the fascia on both sides.
46. Remove the screws securing the front wheel splash shields to the fascia
(Figure 23).
47. BU/FB Model: Partially release the fender molding retainers (Figure 24).
48. FB Model: Release the fascia from the retainers, along the side profile, then
slightly separate it from the body.
SPLASH SHIELD
PLASTIC SCREW
Figure 23 - VM Model Wheelhouse Splash Shield
FENDER
RETAINERS
NOTE: BU model illustrated, FB
model is similar.
Figure 24 – BU Fender Retainers
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 19
Service Procedure [Continued]
49. Remove the upper fascia screws VM Model Illustrated other models similar.
(Figure 25).
FASCIA SCREWS
Figure 25 – Upper Fascia Screws
50. Remove the lower fascia screws VM Model Illustrated other models similar
(Figure 26).
FASCIA SCREWS
Figure 26 – Lower Fascia Screws
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 20
Service Procedure [Continued]
51. If equipped: Disconnect the fog light electrical connectors.
52. Release the side ends from the fascia seats.
53. Remove the front fascia.
54. VM Model: Remove the
screws and the right lower
splash shield (Figure 27).
SPLASH
SHIELD
55. FB Model: Remove the
right and left frame bolts
and the frame braces.
Figure 27 – Lower Splash Shield
56. VM Model: Remove the
four bolts crossmember
bolts (Figure 28).
CROSSMEMBER
BOLTS
Figure 28 – Crossmember Bracket
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 21
Service Procedure [Continued]
57. Remove the exhaust pipe:
a) Remove the 2 nuts at the
Catalytic Converter
(Figure 29).
NOTE: Nuts may require
to be cut off to remove.
b) Loosen the exhaust band
clamp at the rear and
remove the bolt at the
front support bracket.
c) Disconnect the rubber
isolators.
SUPPORT
BRACKET
BOLT
CATALYTIC
CONVERTER
NUTS
Figure 29 – Exhaust Pipe
58. Remove the bolt holding the ground cable to the transmission and reposition the
cable (Figure 30).
59. FB (AWD) Models: Position
a suitable hydraulic lift under
the powertrain.
60. FB (AWD) Models: Using
the hydraulic lift, move the
powertrain up and forward as
much as permitted by the
right and left engine mounts.
61. FB (AWD) Models: Pull
back the dust cover.
GROUND CABLE BOLT
TRANSMISSION
Figure 30 – Ground Cable
62. FB (AWD) Models: For NAFTA market, use commercially available snap ring
pliers to open the snap ring. For EMEA market, using tool 2019500030
Retractor, open the snap ring.
63. FB (AWD) Models Pull back the driveshaft to disengage it from the PTU and
reposition the shaft on the crossmember.
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 22
Service Procedure [Continued]
64. Separate the cooler lines from the transmission, install suitable cap-plugs in the
male and female ends of the cooler lines to prevent leakage (Figure 31).
65. Remove the four bolts
holding the front of the right
and left load beams to the
radiator support. Do not
remove the nut (Figure 32).
NOTE: FB model remove
the left side impact block.
COOLER LINES
Figure 31 – Cooler Lines
NOTE: Right side shown,
left side similar.
FRONT LOAD BEAM
BOLTS
Figure 32 – Load Beam Support
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 23
Service Procedure [Continued]
66. Remove the two lower load beam to cradle bolts and both left and right lower
load beams (Figure 33).
REAR LOAD BEAM BOLTS
Figure 33 – Load Beams
67. VM Model: Remove
the two lower bolts
and the lower radiator
core support
(Figure 34).
RADIATOR CORE SUPPORT
BOLT
Figure 34 – Radiator Core Support
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 24
Service Procedure [Continued]
68. Remove the rear engine mount insulator bolt (Figure 35).
69. Remove the nuts from
the outer tie rod ends
(Figure 36).
REAR ENGINE MOUNT
BOLT
Figure 35 – Rear Engine Mount
70. Remove the nuts and separate the sway bar links (Figure 36).
SWAY BAR LINK
TIE ROD END
Figure 36 – Front Suspension
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 25
Service Procedure [Continued]
71. Using a suitable punch, lift the two staked areas in the hub nut to avoid
damaging the halfshaft.
72. While a helper applies the brakes to keep the hub from rotating, remove the hub
nut from the halfshaft and DISCARD. The used hub nut is not reusable.
73. Remove and DISCARD the lower ball joint pinch bolt and nut.
74. If Equipped with Intermediate Shaft.
Remove bolts holding the support bearing to the engine bracket.
NOTE: Use care when separating the ball joint stud from the knuckle so
the ball joint boot does not get cut.
b) Insert a pry bar in the opening between the control arm front mounting bolt
and the front fascia support beam.
c) Pry down on the control arm until the ball joint stud is clear of the knuckle.
Position the knuckle assembly to the side until it is clear of the ball joint
stud. Slowly release the control arm.
d) Swing the steering knuckle outward and off the halfshaft end.
e) Place a drain pan under the transmission to catch fluid that may spill from
the transmission when the halfshaft is removed.
75. VM Model: Remove the
retaining bolt at the Power
Steering gear (Figure 37).
Retaining Bolt
POWER
STEERING
RETURN LINE
76. VM Model: Disconnect the
power steering return line
(Figure 37).
77. VM Model: Disconnect the
power steering supply line
(Figure 37)
POWER STEERING
SUPPLY LINE
Figure 37 – Power Steering Lines
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 26
Service Procedure [Continued]
78. VM Model: Remove the
power steering support
bracket bolt (Figure 38).
POWER STEERING
SUPPORT
BRACKET BOLT
79. Support the crossmember
with a suitable lifting
device.
80. Remove the bolts and
separate the crossmember
assembly from the frame
rails (Figure 39).
81. Lower the crossmember
and set aside.
NOTE: There are 2
additional bolts that are not
illustrated to remove
Figure 38 – Support Bracket Bolt
CROSSMEMBER BOLTS
Figure 39 - Crossmember
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 27
Service Procedure [Continued]
82. Position the vehicle height to allow the Dolly, Power Train 6135 and Cradle,
Engine Support 6710A or equivalent to be installed under the
engine/transmission assembly.
83. Loosen the cradle engine mounts to allow movement for positioning onto the
engine locating holes on the engine block and oil pan rail. Align the powertain
to the engine support cradle. Position/adjust as necessary. Tighten the posts to
the cradle frame.
Secure the
engine/transaxle
assembly to the
dolly/cradle with
safety straps.
LEFT ENGINE
MOUNT BOLTS (3)
84. Remove the 3 left
engine mount
insulator bolts
(Figure 40).
85. Remove the 3 right
engine mount
insulator bolts
(Figure 41).
Figure 40 – Left Engine Mount
RIGHT ENGINE MOUNT
BOLTS (3)
Figure 41 – Right Engine Mount
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 28
Service Procedure [Continued]
86. Slowly raise the vehicle to allow it to clear the powertrain assembly.
CAUTION: Make sure that all components are clear of obstructions while
raising the vehicle off the powertrain assembly.
87. Remove the bolt
supporting the catalytic
converter to the engine
block, loosen the other 2
bolts on the support
bracket (Figure 42).
CATALYTIC
CONVERTER
BOLTS
Figure 42 – Support Bracket
88. Remove the catalytic
converter heat shields from
the exhaust manifold
(Figure 43).
Figure 43 – Heat Shields
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 29
Service Procedure [Continued]
89. Remove the exhaust manifold bolts and remove the exhaust manifold gasket
and DISCARD.
90. Remove the bolt retaining the
torque converter bolt access
cover (Figure 44).
ACCESS COVER
NOTE: There are three pairs
of bolts 120° apart attaching
the flexplate to the torque
converter.
ACCESS
COVER BOLT
Figure 44 – Access Cover
91. Through the access door opening, remove the bolts holding the flexplate to the
torque converter. Rotate the crankshaft to bring each set of bolts into view
through the access door (Figure 45).
TORQUE
CONVERTER
BOLTS
Figure 45 – Torque Converter Bolts
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 30
Service Procedure [Continued]
92. FB AWD Model:
a) Remove the fasteners and remove the lower intake manifold support bracket.
b) Remove the bolts and remove the Power Transfer Unit (PTU) support racket.
c) Remove the bolts and remove the PTU from the transmission.
93. Remove the three oil pan to
transmission bolts (Figure 46).
94. Affix a chain to the
transmission mount bracket to
be used as a lifting point.
TRANSMISSION
BOLTS
Figure 46 – Transmission Bolts
95. Remove the left upper transmission to engine bolt and bracket (Figure 47).
BRACKET
UPPER
TRANSMISSION
BOLT
Figure 47 – Left Upper Transmission Bolt
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 31
Service Procedure [Continued]
96. Remove the left lower bolt holding the transmission to the engine block.
97. Remove the right upper transmission to engine bolt.
98. Remove the upper
starter bolt.
99. Remove the lower
starter bolt and the
starter from the
transmission
bellhousing (Figure 48).
STARTER
100. Remove the left engine
to transmission bolt and
bracket.
LOWER
STARTER
BOLT
101. Using a suitable prying
tool, pry the bell
housing away from the
engine block.
102. VM Model: Remove
the bolt securing the top
of the belt cover and the
three nuts (Figure 49).
Figure 48 - Starter
BELT
COVER
BELT
COVER
NUTS
Figure 49 – Accessory Belt Cover
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 32
Service Procedure [Continued]
103. Decrease the belt tension by rotating the center bolt of the tensioner pulley
counterclockwise, lift the belt off one of the pulleys and slowly release the
tensioner of the fully extended position (Figure 50).
TENSIONER
PULLEY
104. The following components
will have to be transferred
to the NEW engine:
 Intake manifold.
 Exhaust manifold/Cat.
Figure 50 – Belt Tensioner
Conv.
 A/C compressor and
mounting bracket.
 Generator and mounting bracket.
 Accessory drive belt tensioner.
 Accessory drive belt.
 Power steering pump and mounting bracket.
 If equipped: Intermediate drive shaft bearing housing.
 Engine wire harness.
 If equipped: Block heater.
 Engine cover mounting post and the power steering hose support bracket.
 If equipped: Accessory belt cover.
NOTE: Please reference Instructions Sheet (I-Sheet) K6855974AD for
additional information.
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 33
Service Procedure [Continued]
NOTE: VM model is equipped with a power steering pump, please remove the
two front bolts on the NEW engine and DISCARD use the original bolts
(Figure 51).
POWER
STEERING
BRACKET
MOUNTING
BOLTS
Figure 51 – 2.4L Engine Assy. (VM Model)
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 34
Service Procedure [Continued]
C. Long Block Installation Procedure
1. Place the NEW engine on the Dolly, Power Train 6135 or equivalent and the
Cradle, Engine Support:
 Loosen the cradle engine mounts to allow movement for positioning
to the engine locating holes on the engine block and oil pan rail.
 Lower the engine until it is resting on the posts.
 Tighten the post mounts to the cradle frame.
 Secure the engine to the dolly/cradle with safety straps.
NOTE: Perform the following steps to install the transmission to the
engine.
2. Lightly grease the torque converter hub pocket in the end of the crankshaft.
NOTE: The close tolerance torque converter bolt hole is oval shaped, and
will aid in aligning the flexplate to the torque converter if the torque
converter bolt is installed in this location first.
3. Rotate the flexplate so the close tolerance bolt hole is at the six o’clock
position.
4. Push the bell housing against the engine block and engage the guide pins.
5. Align the wire harness bracket and install the engine block to transmission bolt
hand tight.
6. Install the starter and the lower starter bolt hand tight.
7. Install the three bolts to hold the oil pan to the transmission hand tight.
8. Install the transmission to engine bolt hand tight.
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 35
Service Procedure [Continued]
9. Install the left upper transmission to engine bolt through the wiring harness
bracket hand tight.
10. Install the right upper transmission to engine bolt hand tight.
11. Install the upper starter bolt and tighten all nine installed bolts to 36N·m
(27ft. lbs.).
CAUTION: It is essential that correct length bolts be used to attach the
converter to the flexplate. Failure to follow this caution may result in
transmission damage.
12. Through the access door opening, install NEW bolts to hold the flexplate to the
torque converter hand tight. Rotate the crankshaft to bring each set of bolts into
view through the access door.
NOTE: There are three pairs of bolts 120° apart attaching the flexplate to
the torque converter.
13. Tighten all the torque converter bolts to 40N·m (30ft. lbs.) (Figure 44).
14. Install the torque converter bolt access door and tighten the bolt to 9N·m (80In.
lbs.) (Figure 43).
15. Install a new exhaust manifold gasket DO NOT APPLY SEALER.
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 36
Service Procedure [Continued]
16. Set the manifold into position
and install the manifold bolts.
17. Tighten the bolts following the
sequence shown to 34N·m
(25ft. lbs.) (Figure 52).
18. Install the catalytic converter
heat shields to the exhaust
manifold and tighten the bolts to
12N·m (9ft. lbs.).
19. Install the catalytic converter
lower support bracket and
tighten the bolts to 20N·m
(15ft. lbs.).
Figure 52 – Manifold Torque Sequence
20. FB AWD Model:
a) Install the PTU to the transmission and tighten the bolts to 55N·m (41ft.
lbs.).
b) Install and tighten the stud to the intake manifold.
c) Install the PTU support bracket and tighten the bolts to 55N·m (41ft.
lbs.).
d) Install the lower intake manifold support bracket and tighten the
fasteners to 24N·m (18ft. lbs.).
21. Position the vehicle height to allow the power train dolly, cradle and engine to
be installed into the engine compartment. Slowly lower the vehicle to allow it to
clear the powertrain assembly.
22. Install the right engine mount insulator bolts and tighten to 113N·m (83 ft. lbs.)
23. Install the left engine mount insulator bolts and tighten to 125N·m (92ft. lbs.).
24. Remove the strap and the power train dolly.
25. Raise and support the vehicle.
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 37
Service Procedure [Continued]
26. FB AWD Model: Install a NEW driveshaft cover, snap ring and install the
driveshaft into the transfer unit and engage the snap ring.
27. Install the muffler and exhaust pipe as an assembly. Temporarily attach the
exhaust pipe to the catalytic converter.
27. Support the crossmember on a suitable lifting device and position back onto the
vehicle frame rails.
28. Center the steering gear back in place.
29. Install the crossmember bolts and hand tighten only.
30. Remove the support device.
31. Install the load beams and install the front load beam bolts and hand tighten
only.
32. Position the halfshaft under the vehicle and over the lower control arm.
NOTE: Apply a light coat of grease to the splines prior to installation.
NOTE: If equipped with an intermediate shaft: The intermediate shaft
bearing isolator must be installed on the intermediate bearing for proper
half shaft installation.
NOTE: Never handle the halfshaft assembly by the inner or outer boots.
This can cause damage to the boot, which will allow contaminants to enter
the Constant Velocity (CV) joint.
NOTE: The inner tripod joint is designed with a retention feature that
prevents the tripod rollers from coming out of the inner joint housing up to
a specific load. If this feature is overcome and the rollers are pulled past
the retention feature the joint will lock up and no longer function properly.
The entire halfshaft assembly must be replaced if this occurs.
33. Slip the halfshaft shaft into the differential seal and lightly twist until
intermediate shaft slides all the way into the differential.
34. Swing the steering knuckle outward and engage the halfshaft end into the hub
bearing spline.
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 38
Service Procedure [Continued]
35. Position the lower ball joints back into the steering knuckles and install NEW
bolt and nut and hand tighten only.
36. If equipped: Position the intermediate bearing bracket onto the engine support
bracket and align the bolt holes.
37. If equipped: Install the bolts to hold intermediate support bearing to the engine
bracket and tighten to 10N·m (89in. lbs.).
38. Install a NEW hub nut and while a helper applies the brakes, tighten the nut
using the following procedure;
 tighten the nut to 150 N·m (111ft. lbs.)
 loosen the nut 90°
 tighten the nut to 70 N·m (52ft. lbs.)
 tighten the nut an additional 63°
39. Using the Tool, Front Hub Staking 10287 , align the leading cutting edge of
Tool, Front Hub Staking 10287 with the top left side channel on axle as shown
(Figure 54). Tighten fastener on Tool, Front Hub Staking 10287 with hand tools
until the threads bottom out completely.
NOTE: The hub nut must be
staked so that it looks similar to
Figure 53. Both edges must be
split and bent into the shape
shown (3). The staking must be
opposite of the direction to
tighten the nut.
Figure 53 – Axle Nut Staking
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 39
Service Procedure [Continued]
40. Connect the sway bar link and install the nut and hand tighten only.
41. Connect the outer tie rod ends to the knuckles and install the nuts and hand
tighten only.
42. Tighten the crossmember bolts to 125N·M (92ft. lbs.).
43. Tighten the front load beam bolts to 38N·M (28ft. lbs.).
44. Tighten the rear load beam bolts to 38N·M (28ft. lbs.).
45. Install the four bolts to hold the front of the right and left load beams to the
radiator support panel and tighten all the installed bolts to 50N·m (37ft.lbs.).
46. Install the rear engine mount insulator tighten the bolts to 210N·m
(155ft. lbs.).
47. Connect the exhaust pipe complete with a NEW gasket to the catalytic
converter and tighten the new nuts to 25N·m (18ft. lbs.).
48. Install the exhaust support bolt and tighten to 25N·m (18ft. lbs.).
49. VM Model: Connect the power steering supply line and tighten the bolt to
40N·m (30ft. lbs.).
50. VM Model: Connect the return line and tighten to 30N·m (22ft. lbs.).
51. VM Model: Install the power steering line support bracket bolt.
52. Tighten the lower ball joint nuts to 168N·m (124ft. lbs.).
53. Tighten the sway bar link nut to 63N·m (46ft. lbs.).
54. Tighten the outer tie rod end nuts to 90N·m (66ft. lbs.).
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 40
Service Procedure [Continued]
55. VM Model: Position the lower radiator core support, while aligning the radiator
to the bushings and install the two lower bolts hand tight.
56. Place the ground cable in position on the transmission and tighten the bolt to
22N·m (16ft. lbs.).
57. Install the front crossmember bracket and tighten the bolts to 20N·m (15ft. lbs.).
58. Remove the tape or plugs from the opened refrigerant line fittings and the A/C
compressor ports.
59. Lubricate the O-ring seals with clean refrigerant oil and install them onto the
refrigerant line fittings. Use only the specified O-ring seals as they are made of
a special material for the system. Use only refrigerant oil of the type
recommended for the A/C compressor in the vehicle.
60. Install the A/C discharge line/suction line manifold to the A/C compressor and
tighten the nut to 20N·m (15ft. lbs.).
61. Connect the transmission cooler lines to the transmission.
62. If equipped: Install the right and left frame brace and tighten the bolts to
20N·m (15ft. lbs.).
63. Install the right lower splash shield with four bolts and screws tightened to
50N·m (37ft. lbs.).
64. Install the wire harness routing bracket with two bolts and tighten to10N·m
(88In. lbs.).
65. Connect and lock the engine wire harness connector.
66. Connect the transmission wire harness connector to the transmission and rotate
the locking lever clockwise.
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 41
Service Procedure [Continued]
67. Hold down the release button down while attaching the shifter cable end to the
manual lever.
68. Install the heater core outlet hose to the coolant return pipe with the CLIC E®
type clamp using the Pliers, Hose Clamp 10288 .
69. Install the heater core inlet hose to the thermostat housing and engage the
quick-connect coupling.
70. Secure the heater core hoses in the retainer at the rear of the transmission.
71. Install the engine oil cooler inlet and outlet hoses with the CLIC E® type
clamp using the Pliers, Hose Clamp 10288 .
72. Install the upper radiator inlet and lower radiator outlet hoses with the CLIC
E® type clamp using the Pliers, Hose Clamp 10288.
73. If equipped: Connect the block heater wire harness connector.
74. Engage the wire harness retainer to the upper radiator inlet hose at the
thermostat housing.
75. Install the upper radiator inlet hose to the radiator and engage the quick-connect
coupling.
76. Install the lower radiator outlet hose to the radiator and engage the quickconnect coupling.
77. Install the degas hose to the pressurized coolant bottle with the CLIC E® type
clamp using the Pliers, Hose Clamp 10288.
78. Connect the vacuum hose quick-connect fitting to the vacuum pump and secure
the vacuum hose to the support bracket.
79. Connect the starter cable to the power distribution center and tighten the nut
to10N·m (90In. lbs.).
80. Connect the generator cable to the power distribution center and tighten the nut
to 4N·m (36In. lbs.).
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 42
Service Procedure [Continued]
81. Connect fuel line to the fuel rail.
82. Connect the purge vapor line to the purge solenoid.
83. If equipped: Connect the Power Takeoff Unit (PTU) wire harness connector
84. From inside the vehicle position the steering shaft back and install the bolt and
tighten to 25N·m (18ft. lbs.).
85. BU/FB Models: Engage the hood latch release cable to the hood latch and
retainers.
86. Install the front fascia.
a) Position the fascia back onto the vehicle.
b) Secure the side ends in their housings.
c) Install the upper screws.
d) Install the lower screws.
e) If equipped, connect the fog light electrical connectors.
f) Install the plastic fender screw.
g) Position the wheelhouse splash shield back and install the screws.
87. BU/FB Models: Reattach the fender molding retainers to fender.
88. Install the battery tray and battery tighten the bolts securely.
89. Install the air cleaner body.
a) If required, recover the rubber mount socket from the bottom of the air
cleaner body and reinstall it to the right engine mount.
b) Lubricate the three rubber mount sockets with Mopar® Rubber Bushing
Installation Lube.
c) Align the air cleaner body to the rubber mount sockets and press firmly
downwards.
d) Engage the air inlet duct to the radiator core support, install the bolt and
tighten to 8N·m (71In. lbs.).
90. VM Model: Fill the power steering reservoir with power steering fluid.
91. Fill the cooling system.
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 43
Service Procedure [Continued]
NOTE: The preferred method to remove air and fill the cooling system is
to perform the Coolant Air Evacuation procedure using the Mopar
Essential Tools and Service Equipment Tool, UView Airlift Cooling System
Refill 3999-550000 or equivalent.
92. Install the front tire and wheel assemblies and tighten the nuts to 120N·m
(89ft.lbs.) Aluminum Wheels , 86N·m (64ft. lbs.) Steel Wheels.
93. Install the clean air hose and engine over.
94. Connect the negative battery cable. If equipped with an Intelligent Battery
Sensor (IBS), connect the IBS connector.
95. Evacuate and charge the refrigerant system.
NOTE: The Cam/Crank Variation Relearn procedure must be performed
using the scan tool anytime there has been a repair/replacement made to a
powertrain system, for example: flywheel, valvetrain, camshaft and/or
crankshaft sensors or components.
a) Connect the wiTECH tool to the diagnostic connector.
b) Erase all DTC’s.
c) Navigate to “Miscellaneous Functions” and perform all Relearn
Procedures/Routines that are related to the component or system that was
repaired.
96. Start the engine and run it at idle.
97. Run the engine until it reaches normal operating temperature. Check the cooling
system and the transmission for correct fluid levels.
98. After it has cooled check that the fluid level is positioned at the MAX mark on
the tank. Add coolant if required. Install the cap.
99. Check for leaks and road test the vehicle.
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 44
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the
DealerCONNECT Claim Entry Screen located on the Service tab. Claims paid
will be used by FCA to record Customer Satisfaction Notification service
completions and provide dealer payments.
Use the following labor operation numbers and time allowances:
Labor Operation
Number
Time
Allowance
Initiate an Oil Consumption Test
09-W8-0L-81
0.3 hours
Complete Successful Oil Consumption Test
(Only after 1500-1700-mile road test
2400 - 2700 km)
09-W8-01-81
0.2 hours
Complete Failed Oil Consumption Test and
Replace long block (VM model)
09-W8-01-82
9.4 hours
Complete Failed Oil Consumption Test and
Replace long block (BU model)
09-W8-01-83
7.8 hours
Complete Failed Oil Consumption Test and
Replace long block (FB model)
09-W8-01-84
7.8 hours
09-W8-01-51
0.9 hours
09-W8-01-52
0.5 hours
Optional Equipment
AWD Equipped (FB Model Only)
09-W8-01-60
0.4 hours
Skid plate/Splash Shield equipped
09-W8-01-63
0.2 hours
Related Operation
R-1234yf Refrigerant A/C Evac and Recharge
2015-2018 BU, 2016-2018 FB
R-134a Refrigerant A/C Evac and Recharge
(VM Model Only) 2015-2018
Add the cost of the parts package plus applicable dealer allowance to your claim.
NOTE: See the Warranty Administration Manual, Recall Claim Processing
Section, for complete claim processing instructions.
Customer Satisfaction Notification W80 – Oil Consumption Inspection Page 45
Dealer Notification
To view this notification on DealerCONNECT, select “Global Recall System” on
the Service tab, then click on the description of this notification.
Owner Notification and Service Scheduling
All involved vehicle owners known to FCA are being notified of the service
requirement by mail. They are requested to schedule appointments for this service
with their dealers. A generic copy of the owner letter is attached.
Vehicle Lists, 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 campaign displayed can be sorted by:
those vehicles that were unsold at campaign launch, those with a phone number,
city, zip code, or VIN sequence.
Dealers should 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.
VIN lists may 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 notification only and is strictly prohibited from all other use.
Additional Information
If you have any questions or need assistance in completing this action, please
contact your Service and Parts District Manager.
Customer Service / Field Operations
FCA US LLC
This notice applies to your vehicle,
CUSTOMER SATISFACTION NOTIFICATION
Oil Consumption Inspection
[Model Year and Model]
VIN XXXXXXXXXXXXXXXXX
W80
Dear [Name],
LOGO
At FCA US LLC, we recognize that the success of our business depends on the satisfaction of
our customers. We are constantly monitoring the quality of our products and looking for
opportunities to improve our vehicles even after they are sold. Because your long-term
satisfaction is important to us, we are contacting you on important improvements we would
like to make to your vehicle [1]. This will be done at no charge to you.
VEHICLE PICTURE
We are recommending the following improvements be performed on certain [2015 -2018
Model Year (BU) Jeep Renegade, (VM) Ram Promaster City and 2016 -2018 Fiat 500X]
vehicles equipped with a 2.4L engine.
YOUR SCHEDULING OPTIONS
WHY DOES MY VEHICLE NEED REPAIRS?
FCA US has determined that some vehicles may have an engine that consumes more oil than
usual under certain operating conditions like continuous stop and go driving. The condition
results when a combination of components with certain manufacturing variances are present
and the current engine calibration strategy. While the condition is rare, your vehicle [1] falls
within the population where such variances could cause an oil consumption issue. If your
vehicle is subjected to a low oil condition, the oil indicator lamp on your instrument panel
cluster may illuminate or you will notice an oil level below the dipstick crosshatch range
markings when checking your vehicle’s oil level as recommended in your Owner’s Manual. If
left unaddressed, a low oil condition can eventually result in a vehicle stall.
1. RECOMMENDED OPTION
Call your authorized Chrysler /
Dodge / Jeep® / RAM Dealership
2. Call the FCA Recall Assistance
Center at 1-800-853-1403. An
agent
can
confirm
part
availability and help schedule an
appointment
3. Visit recalls.mopar.com, scan the
QR code below, or download the
Mopar Owner’s Companion App.
QR Code
HOW DO I RESOLVE THIS CUSTOMER SATISFACTION NOTIFICATION?
FCA US will repair your vehicle free of charge (parts and labor). In the rare event that a low
oil indicator lamp illuminates on your vehicle, or you notice an oil level below the dipstick
crosshatch range markings when checking your vehicle’s oil level, you should take your
vehicle to a dealership for an oil consumption test. FCA US will perform the oil consumption
test free of charge to determine if your vehicle has normal engine oil usage. If your vehicle is
found to have the manufacturing variances resulting in abnormal engine oil usage, your dealer
will replace the components necessary to correct the condition, free of charge.
An oil consumption test will require two dealership visits, one to initiate the testing and one to
confirm the results. Your time is important to us, so we recommend that you schedule a
service appointment to minimize your inconvenience. Please bring this letter with you to your
dealership.
TO SCHEDULE YOUR FREE REPAIR,
CALL YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY
Get access to recall notifications,
locate your nearest dealer, and more
through this website or Mopar
Owner’s Companion App. You will be
asked to provide your Vehicle
Identification Number (VIN) to
protect and verify your identity.
DEALERSHIP INSTRUCTIONS
Please reference CSN W80.
WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED?
If you have already experienced this specific condition and have paid to have it repaired, you
may visit www.fcarecallreimbursement.com to submit your reimbursement request online. [2]
Once we receive and verify the required documents, reimbursement will be sent to you within
60 days. If you have had previous repairs performed and/or already received reimbursement,
you may still need to have the repair performed.
We apologize for any inconvenience, but are sincerely concerned about your satisfaction.
Thank you for your attention to this important matter.
Customer Assistance/Field Operations
FCA US LLC
Mr. Mrs. Customer
1234 Main Street
Hometown, MI 48371
[1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information.
[2] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 218004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.