RecallU90

(Revision 6) April 2023
Dealer Service Instructions for:
Emissions Recall U90
Catalyst Efficiency
NOTE: 2015 model year KL, PF, UF, BU, and VM have been added to campaign.
Remedy Available
2015-2016 (KL) Jeep® Cherokee
2015-2016 (PF) Dodge Dart
2015-2016 (UF) Chrysler 200
2015-2016 (BU) Jeep® Renegade
2016 (FB) Fiat 500X
2015-2016 (VM) Ram ProMaster City
NOTE: This recall applies only to the above vehicles equipped with a 2.4L Engine
(Sales Codes ED6, ED8 or EDD).
NOTE: Some vehicles above may have been identified as not involved in this
recall and therefore have been excluded from this recall.
IMPORTANT: Some of the involved vehicles may be in Dealer vehicle
inventory. Dealers should complete this recall service on these vehicles before
retail delivery. Involved vehicles can be determined by using the VIP inquiry
process.
© Copyright 2023, FCA US LLC, All Rights Reserved
(tdb)
Emissions Recall U90 – Catalyst Efficiency
Page 2
Subject
About 368,504 of the above vehicles may exceed tailpipe emission standards due to
a loss of catalyst CO/NOx conversion efficiency resulting from the catalyst
operating at high temperatures.
Repair
Install a new catalyst and reprogram the Powertrain Control Module (PCM) and
Transmission Control Module (TCM) with the latest software.
Parts Information
NOTE: ALL vehicles require campaign kit CEZGU901AA.
Part Number
Description
CEZGU901AA
Campaign Kit
Each package contains the following components:
Quantity
Description
6
Bolt, Manifold to Engine Cylinder Head M10x1.25x30.00
2
Nut, Manifold to Engine Cylinder Head M10x1.25
2
Nut, Maniverter to Exhaust Pipe Flange M8x1.25
1
O2 Sensor – Mid-bed / Downstream
1
Gasket, Maniverter Outlet
3
Nut, Maniverter Upper Heat Shield
2
Bolt, Maniverter Upper Heat Shield
1
Bolt, Maniverter Bracket to Engine M8x1.25x25.00
Emissions Recall U90 – Catalyst Efficiency
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Parts Information [Continued]
NOTE: ONLY ONE Upstream O2 Sensor below will be required depending on
vehicle application.
Part Number
Description
CEZGU906AA
Upstream O2 Sensor (Except PF)
•
•
•
•
•
(UF) Chrysler 200
(KL) Jeep Cherokee
(VM) Ram ProMaster City
(FB) Fiat 500X
(BU) Jeep Renegade
Part Number
Description
CEZGU907AA
Upstream O2 Sensor (PF Only)
•
(PF) Dodge Dart
Emissions Recall U90 – Catalyst Efficiency
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Parts Information [Continued]
NOTE: ONLY ONE Gasket and Heat Shield Campaign Kit below will be
required depending on vehicle model.
Part Number
Description
CEZGU905AA
Campaign Kit (Gasket and Heat Shield)
• (UF) Chrysler 200
• (KL) Jeep Cherokee
• (PF) Dodge Dart
Each package contains the following components:
Quantity
Description
1
Upper Heat Shield
1
Gasket, Exhaust Manifold
Part Number
CEZGU908AA
Description
Campaign Kit (Gasket and Heat Shield)
(VM) Ram ProMaster City
• (FB) Fiat 500X
• (BU) Jeep Renegade
Each package contains the following components:
Quantity
Description
1
Upper Heat Shield
1
Gasket, Exhaust Manifold
•
Emissions Recall U90 – Catalyst Efficiency
Page 5
Parts Information [Continued]
NOTE: ONLY ONE Maniverter Campaign Kit below will be required. Either
FED or PZEV depending on vehicle emissions.
Part Number
Description
CEZGU902AB
Campaign Kit (Maniverter)
Equipped with: Federal (FED) emissions
• (UF) Chrysler 200
• (KL) Jeep Cherokee
• (PF) Dodge Dart
• (VM) Ram ProMaster City
• (FB) Fiat 500X
• (BU) Jeep Renegade
Each package contains the following components:
Quantity Description
1
Maniverter
2
Bolts, Maniverter to Outlet Bracket M8X1.25X25.00
1
Bracket, Maniverter to Outlet
Part Number
Description
CEZGU903AB
Campaign Kit (Maniverter)
Equipped with: Partial Zero-Emissions Vehicle (PZEV)
• (UF) Chrysler 200
• (KL) Jeep Cherokee
• (PF) Dodge Dart
Each package contains the following components:
Quantity Description
1
Maniverter
2
Bolts, Maniverter to Outlet Bracket M8X1.25X25.00
1
Bracket, Maniverter to Outlet
Emissions Recall U90 – Catalyst Efficiency
Page 6
Parts Information [Continued]
NOTE: No additional parts are anticipated for this campaign. If any additional
parts are determined to be required due to collateral damage or consequential
repairs caused by maniverter stripped holes or broken bolts in the cylinder
head, the dealer must first check if a related LOP has been created for repairs
prior to performing the repair. If no related LOP is found, the LOP review
process must be followed to request a related Recall LOP be added as follows:
Submit a LOP Related Inquiry (located in DealerCONNECT > Service > Claim
Administration) for evaluation and update.
➢ IF the request is approved – the related Recall LOP will be added to the
Labor Operations and you are to proceed with normal Recall claim entry
process.
➢ IF the request is not approved – submit the repair under Warranty (W) if
the repair has been pre-authorized by your Area Manager or Business
Center representative.
Parts Return
Return the maniverter catalyst to the Mopar Core Return Center for core credit.
Special Tools
The following special tools are required to perform this repair:
➢ NPN
wiTECH MicroPod II
➢ NPN
Laptop Computer
➢ NPN
wiTECH Software
Emissions Recall U90 – Catalyst Efficiency
Page 7
Service Procedure
A. Replace Maniverter (Manifold / Catalytic Converter)
1. Position the vehicle on a lift.
2. Raise and support the vehicle.
3. If equipped, remove and SAVE the fasteners securing the engine belly pan
(Figure 1).
4. If equipped, remove and SAVE the engine belly pan (Figure 1).
BELLY PAN
Figure 1 – Engine Belly Pan
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
WARNING: The maniverter
and exhaust pipes become very
hot during engine operation.
Allow engine to cool before
removing
exhaust
system
components. Failure to allow
engine to cool before removal
may result in personal injury
caused by burns.
5. Remove and SAVE the bolt
securing the exhaust crossunder
pipe support bracket to the
transmission (Figure 2).
NUTS
EXHAUST
FLANGE
CROSSUNDER
PIPE
SUPPORT
BRACKET BOLT
Figure 2 – Crossunder Pipe
6. Remove the and DISCARD the
two nuts securing the exhaust
flange crossunder pipe to the
maniverter (Figure 2).
7. Disconnect
the
exhaust
crossunder pipe from the
maniverter and support the
exhaust crossunder pipe to
prevent damage to the flex joint
(Figure 3).
CROSSUNDER
PIPE
SUPPORT
Figure 3 – Support Crossunder Pipe
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
8. Remove the and SAVE the bolt
securing the maniverter lower
support bracket to the engine oil
pan (Figure 4).
BOLTS
SUPPORT
BRACKET
9. Remove the and DISCARD the
two bolts securing the maniverter
lower support bracket to the
maniverter and DISCARD the
support bracket (Figure 4).
10. Lower the vehicle.
Figure 4 – Maniverter Support Bracket
11. (KL) Jeep Cherokee Only: Remove push pin fasteners then remove closeout
panel (Figure 5).
CLOSEOUT PANEL
PUSH PINS
Figure 5 – Closeout Panel
(KL) Jeep Cherokee
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
12. (KL) Jeep Cherokee Only:
Remove one bolt and release air
duct resonator assembly from the
two push pin grommets, then
remove the air duct resonator
assembly from the vehicle
(Figure 6).
NOTE: Air duct resonator
assembly is slotted to slide onto
the push pin grommets. It is
not necessary to remove the
push pin grommets.
AIR DUCT RESONATOR
BOLT
PUSH PIN GROMMETS
Figure 6 – Air Duct Resonator
(KL) Jeep Cherokee
13. Release the engine cover from the ball studs if applicable or remove and SAVE
the four fasteners if applicable, then remove and SAVE the engine cover
(Figure 7).
ENGINE COVER
ENGINE COVER
FASTENERS
Figure 7 – Engine Cover
14. 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.
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
15. (VM) Ram ProMaster City
Only: Remove the bolt (1)
securing the top of the accessory
drive belt guard (2) (Figure 8).
Figure 8 – Belt Guard
16. (VM) Ram ProMaster City
Only: Remove three nuts (2) and
reposition the belt cover (1)
(Figure 9).
Figure 9 – Belt Guard
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
CAUTION: Do not let the tensioner arm snapback to the fully extended
position, severe damage may occur to the tensioner.
17. (VM) Ram ProMaster City Only: Decrease the belt tension by rotating the
center bolt of the tensioner pulley (1) counterclockwise, lift the belt (2) off one of
the pulleys and reposition the accessory drive belt then slowly release the
tensioner to the fully extended position (Figure 10).
Figure 10 – Accessory Belt
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
18. (VM) Ram ProMaster City
Only: Remove the three bolts (2)
and the power steering pump
pulley (1) (Figure 11).
Figure 11 – Pump Pully
19. (VM) Ram ProMaster City
Only: Remove the nut (3) from
the power steering pump support
bracket (4) (Figure 12).
20. (VM) Ram ProMaster City
Only: Remove the three bolts (6)
and reposition the power steering
pump (5) (Figure 12).
Figure 12 – Power Steering Pump
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
21. Disconnect the upstream oxygen
sensor and downstream oxygen
sensor wire harness connectors
(Figure 13 or 14).
WIRE HARNESS
RETAINER
WIRE HARNESS
CONNECTORS
Figure 13 – Oxygen Sensors Electrical
(UF) Chrysler 200, (BU) Jeep Renegade,
(KL) Jeep Cherokee, (FB) Fiat 500X,
(VM) Ram Promaster City
22. Disengage the upstream oxygen
sensor wire harness from the
retainer(s) (Figure 13 or 14).
WIRE HARNESS
RETAINERS
WIRE HARNESS
CONNECTORS
Figure 14 – Oxygen Sensors Electrical
(PF) Dodge Dart
Emissions Recall U90 – Catalyst Efficiency
Page 15
Service Procedure [Continued]
23. Remove and DISCARD the two
upper heat shield bolts and if
applicable, SAVE the oxygen sensor
wire
harness
retainer
bracket
(Figure 15 or 16).
HEAT SHIELD
RETAINER BRACKET
BOLTS
Figure 15 – Maniverter Heat Shield
(UF) Chrysler 200, (BU) Jeep Renegade,
(KL) Jeep Cherokee, (FB) Fiat 500X,
(VM) Ram Promaster City
24. Remove and DISCARD the
maniverter upper heat shield nuts,
then remove and DISCARD the
maniverter upper heat shield
(Figure 15 or 16).
NUTS
HEAT SHIELD
Figure 16 – Maniverter Heat Shield
(PF) Dodge Dart
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
CAUTION: Use care when
removing the bolts that secure
the maniverter to the engine
cylinder head.
Aluminum
cylinder head fastener threads
are susceptible to damage if the
bolts are not removed with care.
Use hand tools ONLY.
NOTE: Use compressed air or
other method to clean loose
debris away from exhaust
manifold before removal.
MANIVERTER
BOLTS
NUTS
Figure 17 – Maniverter to Engine
25. Remove the fasteners, six bolts and two nuts, securing the maniverter to the
engine cylinder head (Figure 17).
NOTE: Pay attention to the bolts
for signs of thread loss or bolt
breakage as they are removed
and note which hole they came
from (Figure 18).
26. Inspect the bolts and bolt holes for
any signs of thread loss then
DISCARD the bolts (Figure 18).
THREAD LOSS
• If bolt holes do not show signs of
thread loss, proceed to Step 29.
• If bolt holes show signs of thread
loss, continue with Step 27.
• If a bolt is broken off in the hole,
proceed to Step 28.
Figure 18 – Inspect for Thread Loss
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
27. If thread loss is suspected, use compressed air to remove any debris from the
suspect bolt hole. With the old maniverter and gasket still in place on the engine
head, install a NEW exhaust manifold bolt in the suspect hole and tighten the
bolt to 34 N·m (25 ft. lbs.) to determine if proper torque can be achieved.
• If the bolt is able to be tightened to 34 N·m (25 ft. lbs.), no further action is
required. Remove the bolt and proceed to Step 29.
• If the bolt hole threads are stripped allowing the bolt to rotate, unable to achieve
proper torque, remove the bolt and continue with Step 28.
28. For stripped hole(s) or broken bolt(s), submit a collateral damage claim to obtain
authorization for installing a helicoil in the damaged hole(s). Remove the
maniverter and gasket following Steps 29 - 31. Then use the special tool
2073500090 - Kit, Cylinder Head Thread Repair - 2.4L MAIR to perform the
helicoil thread repair operation by following the service instructions published in
DealerCONNECT / Service Library / Engine, 2.4L Multiair / Standard
Procedure / Exhaust Manifold Fastener Hole Repair. After the damaged bolt
hole(s) have been repaired with helicoil(s), proceed with Step 32.
GASKET
29. Remove the maniverter out the top
of the engine compartment and
retain the maniverter for core
return.
30. Remove and DISCARD the
exhaust
manifold
gasket
(Figure 19).
Figure 19 – Maniverter Gasket
CLEAN SEALING SURFACE
31. Clean the exhaust manifold gasket
sealing area of the engine cylinder
head (Figure 20).
Figure 20 – Clean Sealing Surface
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
32. DO NOT APPLY SEALER.
Install a NEW exhaust manifold
gasket onto the cylinder head,
taking care that the arrow shown in
the figure is pointing downwards
(Figure 21).
NEW GASKET
Figure 21 – Install New Gasket
MANIVERTER
33. Install the NEW maniverter
through the top of the engine
compartment. Set the maniverter
into position (Figure 22).
Figure 22 – Install New Gasket
34. Install the NEW maniverter bolts
and nuts. Following the torque
sequence, tighten the maniverter
fasteners to 34 N·m (25 ft. lbs.)
(Figure 23).
Figure 23 – Torque Sequence
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
35. Install the NEW upper heat
shield
to
the
maniverter
(Figure 24).
NUTS
RETAINER BRACKET
36. If applicable, position the wire
harness retainer to the heat shield
(Figure 24).
37. Install the two NEW heat shield
bolts. Tighten the heat shield
bolts to 12 N·m (8 ft. lbs.)
(105 in. lbs.) (Figure 24).
HEAT SHIELD
BOLTS
Figure 24 – Maniverter Heat Shield
38. Install the three NEW heat shield nuts. Tighten the heat shield nuts to 12 N·m
(8 ft. lbs.) (105 in. lbs.) (Figure 24).
NOTE: Threads of new oxygen
sensors are factory coated with
anti-seize compound to aid in
removal. DO NOT add any
additional anti-seize compound
to threads of a new oxygen
sensor.
39. Install the NEW upstream
oxygen sensors with black
connector and NEW downstream
oxygen sensors with white
connector to the mainverter.
Tighten the oxygen sensors to
49 N·m (36 ft. lbs.) (Figure 25).
UPSTREAM
OXYGEN SENSOR
DOWNSTREAM
OXYGEN SENSOR
Figure 25 – Oxygen Sensors
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
40. Connect the upstream oxygen
sensor and downstream oxygen
sensor wire harness connectors
(Figure 26 or 27).
WIRE HARNESS
RETAINER
WIRE HARNESS
CONNECTORS
Figure 26 – Oxygen Sensors Electrical
(UF) Chrysler 200, (BU) Jeep Renegade,
(KL) Jeep Cherokee, (FB) Fiat 500X,
(VM) Ram Promaster City
41. Install the upstream oxygen
sensor wire harness to retainer(s)
(Figure 26 or 27).
WIRE HARNESS
RETAINERS
WIRE HARNESS
CONNECTORS
Figure 27 – Oxygen Sensors Electrical
(PF) Dodge Dart
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
42. (VM) Ram ProMaster City Only: Position the power steering pump (5) to the
support bracket then install the three bolts (6). Tighten the bolts to 44 N·m
(32 ft. lbs.) (Figure 12).
43. (VM) Ram ProMaster City Only: Install the nut (3) to the power steering pump
support bracket (4) and tighten the nut to 10 N·m (89 in. lbs.) (Figure 12).
44. (VM) Ram ProMaster City Only: Positon the power steering pump pulley (1)
then install the three bolts (2) and tighen to 25 N·m (18 ft. lbs.) (Figure 11).
45. (VM) Ram ProMaster City Only: Install the accessory drive belt (2) by
positioning the belt over all of the pulleys with the exception of the tensioner
pulley (1) (Figure 10).
CAUTION: Do not let the tensioner arm snapback to the fully extended
position, severe damage may occur to the tensioner.
46. (VM) Ram ProMaster City Only: Rotate the center bolt of the tensioner pulley
(1) counterclockwise, install the accessory drive belt (2) on the tensioner pulley
(1) and slowly release the tensioner (Figure 10). Visually inspect the belt to
pulley alignment.
47. (VM) Ram ProMaster City Only: Install the belt cover (1) with three nuts (2)
then tighten the nuts to 8 N·m (71 in. lbs.) (Figure 9).
48. (VM) Ram ProMaster City Only: Secure the top of the accessory drive belt
guard (2) with the bolt (1) tighened to 8 N·m (71 in. lbs.) (Figure 8).
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
49. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor
(IBS), Connect the IBS connector after connecting the negative battery cable.
50. Position the engine cover onto the ball studs. Using hands only, press down on
the top of the engine cover to engage the ball studs (Figure 7).
51. (KL) Jeep Cherokee Only: Install the air duct resonator assembly to the two
push pin grommets on the vehicle (Figure 6).
52. (KL) Jeep Cherokee Only: Install the closeout panel and push pin fasteners
(Figure 5).
SUPPORT
BRACKET
53. Close the hood.
51. Raise and support the vehicle.
55. Install the NEW catalytic
converter lower support bracket
to the engine oil plan using the
bolt saved from the removal step.
Do not tighten the bolt at this
time (Figure 28).
BOLTS
Figure 28 – Maniverter Outlet Bracket
56. Install two NEW bolts securing the lower support bracket to the catalytic
converter. Tighten all three catalytic converter lower support bracket bolts to
20 N·m (15 ft. lbs.) (Figure 28).
Emissions Recall U90 – Catalyst Efficiency
Page 23
Service Procedure [Continued]
57. Clean the exhaust crossunder
pipe flange sealing surface
(Figure 29).
CLEAN GASKET
SEALING SURFACE
Figure 29 – Crossunder Pipe Flange
58. Install the NEW exhaust flange
gasket
to
the
maniverter
(Figure 30).
NEW GASKET
Figure 30 – Exhaust Flange Gasket
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
59. Position the exhaust crossunder
pipe to the catalyst flange
(Figure 31).
NUTS
EXHAUST
FLANGE
60. Install the two NEW nuts
securing the exhaust flange
crossunder
pipe
to
the
maniverter. Tighten the nuts to
19 N·m (14 ft. lbs.) (Figure 31).
CROSSUNDER
PIPE
61. Install the bolt securing the
exhaust crossunder pipe support
bracket to the transmission.
Tighten the bolt to 20 N·m
(15 ft. lbs.) (Figure 31).
SUPPORT
BRACKET BOLT
Figure 31 – Crossunder Pipe
62. If equipped, position the engine belly pan to the underside of the vehicle
(Figure 1).
63. If equipped, install the fasteners securing the engine belly pan. Tighten the
fasteners securely (Figure 1).
64. Lower the vehicle.
65. Initialize the steering. Start the engine, then turn the steering wheel from one lock
to the other and then turn it back into the center position. Turn the engine off.
Emissions Recall U90 – Catalyst Efficiency
Page 25
Service Procedure [Continued]
66. Ram ProMaster City: Set the clock within the Uconnect radio/information
center:
a. Press the “Settings” button on the faceplate to display the menu.
b. Select “Clock & Date” from the settings menu.
c. Set the “date” and “time” or select “Sync Time” if available.
d. Exit the “Settings” menu.
67. Proceed to Section B. Prepare Maniverter for Core Return.
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
B. Prepare Maniverter For Core Return
1. Removal of upper rear heat shield may improve access for cutting of runner
pipes. Removal of heat shields and oxygen sensors are not required for catalyst
recycling core return credit.
2. Cut the four runner pipes from the maniverter as close to the weld seam as
possible (Figure 32).
3. Separate the manifold portion from the catalyst. Discard/recycle the manifold
portion and return the catalyst portion for core return credit (Figure 32).
4. Proceed to Section C. Reprogram the ECM and TCM with the Latest
Software
RETURN FOR CORE DEPOSIT
CUT AT WELD
CUT AT WELD
Figure 32 – Maniverter Cut/Remove Pipes
DISCARD / RECYCLE
Emissions Recall U90 – Catalyst Efficiency
Page 27
Service Procedure
C. Reprogram the ECM and TCM with the Latest Software
NOTE: The wiTECH scan tool must be used to perform this recall. If the
reprogramming flash for the PCM or TCM is aborted or interrupted, repeat
the procedure.
CAUTION: Both the PCM and TCM software must be at the latest software
calibration level after completing this recall. Failure to do so may result in
undesirable transmission shift quality.
First the PCM must be
reprogrammed; second the TCM must be programmed.
NOTE: (PF) only, TCM software is not coordinated to PCM software, so
TCM software flash is not applicable to (PF) vehicles for this campaign.
1. Open the hood and install a battery charger. Verify that the charging rate
provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash
process. Set the battery charger timer (if so equipped) to continuous charge.
NOTE: Use an accurate stand-alone voltmeter. The battery charger volt
meter may not be sufficiently accurate. Voltages outside of the specified
range will cause an unsuccessful flash. If voltage reading is too high, apply
an electrical load by activating the park or headlamps and/or HVAC blower
motor to lower the voltage.
2. Connect the wiTECH MicroPod II to the vehicle data link connector.
3. Place the ignition in the “RUN” position.
4. Open the wiTECH 2.0 website.
5. Enter your “User id” and “Password” and your “Dealer Code”, then select
“Sign In” at the bottom of the screen. Click “Accept”.
6. From the “Vehicle Selection” screen, select the vehicle to be updated.
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
7. From the “Action Items” screen, select the “Topology” tab.
8. From the “Topology” tab, select the “PCM” module icon.
9. From the “Flash” tab, compare the “Current Electronic Control Unit (ECU)
Part Number” with the “New ECU Part Number” listed.
➢ If the “Current ECU part Number” is the same as the “New Part
Number”, proceed to Step 15.
➢ If the “Current ECU part Number” is NOT the same as the “New Part
Number”, continue with Step 10.
10. From the PCM tab, select the PCM flash part number. Read the flash special
instructions page. Select “OK” to continue.
11. From the flash ECU agreement page, agree to terms by checking the box.
12. Select “Flash ECU” and then follow the wiTECH screen instructions to
complete the flash.
13. Confirm the software is at the latest available calibration level.
14. Click “View DTCs”, select “Clear All DTCs”, click “Continue” and then click
“Close”.
NOTE: (PF) only, TCM software is not coordinated to PCM software, so
TCM software flash is not applicable to (PF) vehicles for this campaign. For
(PF) vehicles skip to Step 25.
15. From the “Action Items” screen, select the “Topology” tab.
16. From the “Topology” tab, select the “TCM” module icon.
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
17. From the “Flash” tab, compare the “Current Electronic Control Unit (ECU)
Part Number” with the “New ECU Part Number” listed.
➢ If the “Current ECU part Number” is the same as the “New Part
Number”, proceed to Step 22.
➢ If the “Current ECU part Number” is NOT the same as the “New Part
Number”, continue with Step 18.
18. From the TCM tab, select the TCM flash part number. Read the flash special
instructions page. Select “OK” to continue.
19. From the flash ECU agreement page, agree to terms by checking the box.
20. Select “Flash ECU” and then follow the wiTECH screen instructions to
complete the flash.
21. Confirm the software is at the latest available calibration level.
22. Click “View DTCs”, select “Clear All DTCs”, click “Continue” and then click
“Close”.
23. Using wiTECH, navigate to the TCM data and locate the transmission fill and
fast fill counters.
➢ If all counters have a value greater than zero, proceed to Step 25.
➢ If all counters have a value equal to zero, continue with “Quick Learn”
Step a.
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
a. Select the “Quick Learn” procedure then follow the on-screen instructions to
reset and learn the clutch adaptive values.
NOTE: If the “Quick Learn” option does not appear on wiTECH and both
the TCM and PCM were just updated, restart the wiTECH application
which should now be populated with the “Quick Learn” option.
NOTE: If the vehicle is equipped with the start/stop feature (sales code
XBU) it must be disabled prior to performing the quick learn procedure. To
disable, press the on/off switch located on the center switch bank near the
HVAC controls.
b. Click “View DTCs”, select “Clear All DTCs”, click “Continue” and then click
“Close”.
25. All vehicles equipped with Electronic Power Steering (ESP) perform the ESP
verification test.
a. Start the engine and allow it to run for two minutes.
b. Turn the steering wheel from stop to stop, holding at each stop position for one
second.
26. Turn the ignition off and wait five minutes.
27. Turn the ignition on then read any DTCs.
➢ If DTCs are present, determine if they are related to the repair and correct if
caused by repair before proceeding.
➢ No DTCs present, proceed to next step.
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure [Continued]
28. Place the ignition in the “OFF” position and then remove the wiTECH MicroPod
II device from the vehicle.
29. Remove the battery charger from the vehicle.
30. Road test the vehicle for at least five minutes to confirm repair was performed
properly.
31. Proceed to Section D. Complete Proof of Correction Form for California
Residents.
32. Return the vehicle to the customer or inventory.
Emissions Recall U90 – Catalyst Efficiency
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Service Procedure (Continued)
D. Complete Proof of Correction Form for California Residents:
This recall is subject to the State of California Registration
Renewal/Emissions Recall Enforcement Program. Complete a Vehicle
Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply
it to vehicle owners residing in the state of California for proof that this recall
has been performed when they renew the vehicle registration.
Process Steps to obtain the California Proof of Correction form:
a. Access the “DealerCONNECT” website.
b. Select the “Service” tab.
c. Under the “Publications” heading, select the “ePublishing” link.
d. Sign in using your Dealer Code and Password.
e. Select the “Proof of Correction form”.
Emissions Recall U90 – Catalyst Efficiency
Page 33
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 recall service completions and provide dealer payments.
Use the following labor operation numbers and time allowances:
Labor Operation
Time
Number
Allowance
Replace the Catalyst, Inspect that the
PCM and TCM Software is currently
at the Latest Released Level.
(KL), (BU), (FB) ONLY
(UF) ONLY
(VM) ONLY
(PF) PCM ONLY (TCM not applicable)
09-U9-01-82
09-U9-01-82
09-U9-01-82
09-U9-01-82
1.3 hours
1.4 hours
1.6 hours
1.6 hours
Replace the Catalyst, Inspect the
PCM and TCM Software,
Reprogram PCM Only.
(BU), (FB) ONLY
(KL), (UF) ONLY
(VM) ONLY
(PF) PCM ONLY (TCM not applicable)
09-U9-01-83
09-U9-01-83
09-U9-01-83
09-U9-01-83
1.4 hours
1.5 hours
1.7 hours
1.7 hours
Replace the Catalyst, Inspect the
PCM and TCM Software,
Reprogram TCM Only.
(BU), (FB), (KL) ONLY
(UF) ONLY
(VM) ONLY
09-U9-01-84
09-U9-01-84
09-U9-01-84
1.4 hours
1.5 hours
1.7 hours
Replace the Catalyst, Inspect and
Reprogram PCM and TCM with
Latest Released Level Software
(BU), (FB) ONLY
(KL), (UF) ONLY
(VM) ONLY
09-U9-01-85
09-U9-01-85
09-U9-01-85
1.5 hours
1.6 hours
1.8 hours
Emissions Recall U90 – Catalyst Efficiency
Page 34
Completion Reporting and Reimbursement [Continued]
Labor Operation
Time
Number
Allowance
Related Operations
Perform Transaxle Quick Learn
09-U9-01-50
0.4 hours
Remove pipe from catalyst for core return
up to $3 reimbursement per vehicle for
cutting supplies, bill as NPN
09-U9-01-52
0.2 hours
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
NOTE: See the Warranty Administration Manual, Recall Claim Processing Section,
for complete recall claim processing instructions.
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 first class mail. They are requested to schedule appointments for this
service with their dealers. A generic copy of the owner letter is attached.
Emissions Recall U90 – Catalyst Efficiency
Page 35
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 recall displayed can be sorted by: those
vehicles that were unsold at recall launch, those with a phone number, city, zip code,
or VIN sequence.
Dealers must 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.
Recall 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 recall 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 Services / Field Operations
FCA US LLC
This notice applies to your vehicle,
[Model Year and Model]
IMPORTANT EMISSIONS RECALL
VIN XXXXXXXXXXXXXXXXX
Catalyst Efficiency
U90
Dear [Name],
LOGO
FCA US LLC, has determined that certain [2015 - 2016 Model Year (KL) Jeep® Cherokee, 2015 2016 Model Year (PF) Dodge Dart, 2015-2016 Model Year (VM) RAM ProMaster City, 2015 - 2016
Model Year (UF) Chrysler 200, 2015-2016 Model Year (BU) Jeep® Renegade, and 2016 Model Year (FB)
FIAT 500X] vehicles equipped with a 2.4L engine may release air pollutants which exceed
VEHICLE PICTURE
tailpipe emission standards.
WHY DOES MY VEHICLE NEED REPAIRS?
Your vehicle
may exceed tailpipe emission standards due to a loss of catalyst CO/NOx
conversion efficiency resulting from the catalyst operating at high temperatures.
[1]
YOUR SCHEDULING OPTIONS
1. RECOMMENDED OPTION
Call your authorized Chrysler /
Dodge / Jeep® / RAM /
BusinessLink / 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 IMPORTANT EMISSIONS ISSUE?
FCA will repair your vehicle [2] free of charge (parts and labor). To do this, your dealer will
reprogram the Powertrain Control Module (PCM) and Transmission Control Module (TCM)
with the latest software. In addition, your dealer will install a new catalyst. The estimated repair
time is 2 hours. In addition, your dealer will require your vehicle for proper check-in,
preparation, and check-out during your visit, which may require more time. 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
CALIFORNIA RESIDENTS
The State of California requires the completion of emission recall repairs prior to vehicle
registration renewal. Your dealer will provide you with a Vehicle Emission Recall Proof of
Correction Form after the Emission Recall service is performed. Be sure to save this form since
the California Department of Motor Vehicles may require that you supply it as proof that the
Emission Recall has been performed.
In order to ensure your full protection under the emissions warranty provisions, it is
recommended that you have your vehicle serviced as soon as possible. Failure to do so could
be determined as lack of proper maintenance of your vehicle.
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. The last eight characters
of your VIN are provided above.
DEALERSHIP INSTRUCTIONS
Please reference Emissions Recall
U90
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 recall 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 21-8004,
Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.