0900322

NUMBER:
GROUP:
DATE:
09-003-22
09 - Engine
March 1, 2022
This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of FCA US LLC.
SUBJECT:
Yellow Warning Labels on the 3.0L Diesel Engines Cylinder Head Covers
OVERVIEW:
This bulletin outlines the correct procedure for all the repairs that involve:.
• Fuel Injector(s).
• Cylinder head(s).
• Cylinder head cover(s).
The engine may have a yellow warning label applied to the plastic cylinder head cover to alert the
technician special procedures required for Injector Removal/Install. Failure to follow the procedure
can result in excessive engine soot.
MODELS:
2022
2022
2022
(JT)
(DT)
(JL)
Jeep Gladiator
RAM 1500 Pickup
Jeep Wrangler
NOTE: This bulletin applies to vehicles within the following markets/countries: North
America and EMEA.
NOTE: This bulletin applies to the listed vehicles:
• DT vehicles equipped with a 3.0L V6 Turbo Diesel Engine GEN 3 (Sales Code EXH).
• JL/JT vehicles equipped with a 3.0L V6 Turbo Diesel Engine W/ESS G3 (Sales Code
EXJ).
SYMPTOM/CONDITION:
If specific yellow warning labels (Fig. 1) are applied on engine cylinder head cover(s), follow the
procedures reported in this bulletin.
During the following repairs:
• Fuel injector(s) replacement, removal and installation.
• Cylinder head replacement
• Cylinder head cover replacement.
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DISCUSSION:
Fig. 1
Yellow Labels
NOTE: The yellow labels on the cylinder head covers (Fig. 1) , alerts that the fuel injector(s)
are installed with two washers, standard copper and a thinner stainless steel between
the injector and copper shim.
NOTE: The label may be present on the left, right, or both cylinder heads. Only follow the
repairs outlined in this bulletin on cylinder banks that have this label.
If the stainless stainless steel washer isn’t present at injector removal, Do not install this additional
washer (Fig. 2) .
Fig. 2
Fuel Injector
1 - Fuel Injector
2 - Stainless Steel Washer
3 - Copper Shim
NOTE: The fuel sealing is assured by the copper shim and the injector seat in the cylinder
head. The upper stainless steel shim washer does not have sealing function (Fig. 2) .
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09-003-22
FUEL INJECTOR(S), REMOVAL AND INSTALLATION (LEFT AND RIGHT BANK)
NOTE: The fuel injector are installed with two washers, standard copper and another thinner
stainless steel between injector and copper shim. If the stainless steel washer isn’t
present, Do Not install an additional washer (Fig. 2) .
REMOVAL
1. Follow the Fuel Injector service procedure. Refer to the detailed service procedures available in
DealerConnect> Service Library under: Service Info>09 - Engine, 3.0L Turbo Diesel / Fuel
Injection / Injector(s), Fuel / Removal and Installation> Right or Left Bank.
2. When the fuel injector is removed, discard the lower sealing copper shim (Fig. 2) .
3. Remove the stainless steel washer, clean it with a lint-free cloth (this washer is reusable),
reinstall it onto the fuel injector and place a protective cap over the nozzle and injector bore
(Fig. 2) .
NOTE: The stainless steel washer is reusable, but if it is not possible to clean it properly, or
it is lost it must be replaced.
INSTALLATION
1. Follow the Fuel Injector service procedure. Refer to the detailed service procedures available in
DealerConnect> Service Library under: Service Info>09 - Engine, 3.0L Turbo Diesel / Fuel
Injection / Injector(s), Fuel / Removal and Installation> Right or Left Bank.
2. Verify that the stainless steel washer is reinstalled onto the fuel injector (Fig. 2) .
3. Install a NEW copper sealing shim onto the fuel injector (Fig. 2) .
FUEL INJECTOR(S), REPLACEMENT
NOTE: New fuel injector(s) are equipped only with standard copper shim (Fig. 2) .
NOTE: Before installing the fuel injector(s) in the cylinder head, the correct sequence of the
washers must match with (Fig. 2) .
If fuel injector(s) need to be replaced with a new one, follow this procedure:
1. Ensure that the new fuel injector(s) came with a new copper sealing shim.
2. Remove the new copper shim from the new fuel injector(s).
3. Install the stainless steel washer onto the new fuel injector, and reinstall the new copper shim.
4. Install the fuel injector in the cylinder head.
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CYLINDER HEAD(S), REPLACEMENT
NOTE: When replacing a cylinder head on the bank that contains the yellow label, it will be
necessary to discard the stamped steel washer from the fuel injector, and remove the
label from the cylinder head cover.
Fig. 3
Cylinder Head
1 - Fuel Injector
2 - Copper Shim
NOTE: New fuel injector(s) are equipped only with standard copper shim, and if new fuel
injector(s) is installed in a new cylinder head, the stainless steel shim washer does
not have to be used (Fig. 3) .
If cylinder head(s) are being replaced on a bank that has the yellow label, follow the following
procedure:
1. If the fuel injectors will be reinstalled, during the injector removal discard both copper and
stainless steel washers (Fig. 3) .
2. When the fuel injector(s) are re-installed in the new cylinder head follow exactly the Service
procedure, Install a NEW copper sealing shim onto the fuel injector. and Do Not add the
stainless steel washer between injector and copper shim (Fig. 3) .
3. Remove the yellow label from the cylinder head cover only on the bank with new head being
replaced.
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09-003-22
CYLINDER HEAD COVER REPLACEMENT ONLY
NOTE: The new cylinder head cover does not have the yellow label.
If the cylinder head cover has to be replaced, follow the procedure:
Fig. 4
Yellow Label on Cylinder Head Cover
1. Order a yellow label (Fig. 4) .
2. Clean the area of the cylinder head cover to allow a proper bonding of the label (Fig. 4) .
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Fig. 5
Yellow Label Placement
3. Attach the label on the cylinder head cover according with the dimension reported in (Fig. 5) .
POLICY:
Information Only