NUMBER:
GROUP:
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25-004-13
Emissions Control
September 12, 2013

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 otha1Wisa, without written permission of DaimlerChryster Corporation.

THIS BULLETIN SUPERSEDES SERVICE BULLETIN 25-001-07, DATED FEBRUARY
9, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS**. THIS BULLETIN ALSO INCLUDES THE
ADDITION OF LIFETIME WARRANTY EXTENSION X51.
SUBJECT:
l/M Readiness Check Continues To Indicate OBD System Is Not Ready For l/M Testing
(X51 Liftetime Warranty Extension)
OVERVIEW:
This bulletin involves modifying wiring in the Power Distribution Center (PDC).
MODELS:

2005 - 2006

(T J)

Wrangler

NOTE: This Extended Warranty Bulletin applies to vehicles equipped with a 2.4L or
4.0L engine (sales code ED1 or ERH respectively).
SYMPTOM/CONDITION:
**The Catalyst Monitor, Oxygen Sensor Monitor, and Oxygen Sensor Heater Monitors may
indicate "Not Ready" even if the monitor is operating correctly and determining pass/fail
results. Two or more monitors indicating "Not Ready" will result in vehicle rejection during
an l/M test. In addition, the vehicle On Board Diagnostics (OBD) system may not indicate
readiness for l/M emissions testing during the key-on test. (See 'Emissions Inspection and
Maintenance Programs' in section 7 of the Wrangler owner's manual to determine if
vehicle is ready for l/M testing).**
DIAGNOSIS:
After tu rning ignition key to the ON position without cranking the engine, the Malfunction
Indicator Lamp (M IL) should remai n illuminated solid. If the MIL flashes for 10 seconds
approximately 15 seconds after tu rning the key to the ON position (without cranking the
engine) and then returns to solid illumination, the vehicle is not ready for l/M testing.
Perform the Repair Proced ure.
PARTS REQUIRED:

Qty.

Part No.

Description

AR

NPN

Solder, Rosin Core

2

05018395AA

Kit, Splice

,

'

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25-004-13

SPECIAL TOOLS/EQUIPMENT REQUIRED:

05019912AA

MOPAR Crimping Tool

NPN

Soldering Iron

NPN

Heat Gun

REPAIR PROCEDURE:
1. Remove and isolate the positive and negative battery cables from the battery.
2. Remove the Power Distribution Center (PDC) cover from the PDC.
3. Locate the ASD (Auto Shut Down) and the Fuel Pump relays in the PDC.
4. Remove the two nuts used to secure the positive battery cable to the PDC. Remove
the positive battery cable from the PDC.
5. Remove the PDC from its bracket and remove the cover from the bottom of the PDC
to expose the underside wiring.
6. Locate the terminal end in PDC cavity A 13 that connects to the ASD relay pin 85. Two
20 gauge wires, each of PK/WT color, are crimped to this terminal end (Fig. 1).

811>41b98

Fig. 1 TWO 20 GA. PK WT WIRES IN CAVITY A 13
1-TWO20 GA. PK/WT WIRES-AT PDC CAVITY A13 (FOR ASD RELAY PIN 85)

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25-004-13

I

7.
8.

At PDC cavity A13 (ASD), locate the one PK/WT wire that connects to the fuel pump
relay terminal.
Cut the PK/WT wire, that connects to the fuel pump relay, as close to the PDC cavity
A13 terminal as possible (Fig. 2).

81b4fb96

Fig. 2 CUT ASD 20 GA. PK WT TO FUEL PUMP
1 ·CUT PDC CAVITY A13 PKIWTWIRE THAT GOES TO THE FUEL PUMP RELAY CLOSE TO TERMINAL

9.

At the same PDC cavity A 13, cut the other PK/WT wire approximately 2 inches from
the terminal.
10. There are now three (3) PK/WT wires. Strip approximately 0.25 inches of the insulation
from the ends of all three PK/WT wires.
11. Spice the one PK/WT wire leading from fuel pump relay to the one PK/WT wire leading
from wire harness bundle with convolute (Fig. 4). Be sure to slide shrink tube over
wire before crimping. Splice the wires with kit p/n 05018395AA.

NOTE: The remaining ASD relay wire in PDC cavity A 13 (2 inch lead) should not be
connected to anything at this point.

25-004-13

-4-

12. Locate the RD/YL 18 gauge wire connected to the terminal end in PDC cavity A15.
This wire connects the ASD relay pin 30 to fuse #9 (ASD power) in the PDC.
13. Cut this wire approximately 2 inches from the PDC cavity A 15 terminal (ASD relay pin
30) (Fig. 3).

Fig. 3 CUT ASD 18 GA. RD YL WIRE IN CAVITYA15
1-CUT PDC CAVITY A1518 GA. RDNL WIRE THAT GOES TOASD RELAY PIN 30 TWO INCHES FROM TERMINAL

14. Strip approximately 0.25 inches of insulation from both ends of the RD/YL wire cut in
Step #13.
15. Splice the two RD/YL wires to the one remaining PK/WT wire (2 inch lead at A13)
together (Fig. 4). Be sure to slide shrink tube over wire before crimping. Splice the
wires with kit p/n 05018395M.
16. After both splices are complete, solder crimp splices with non-acid core solder.
17. Slide shrink tube over soldered splices and shrink with a heat gun until sealant is
visible on both ends of the splice (Fig. 4 ).

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•

81c35303

Fig. 4 COMPLETED WIRE SPLICES
1 - 20 gauge PK/WT wire from wire harness bundle with convolute
2 - Splice repair (2 wires)

3 - 20 gauge PK/WT wire from fuel pump relay
4 - 20 gauge PK/WT wire from PDC cavity A13 for ASD relay pin 85
5- 18 gauge RDIYL wire from PDC cavity A15 for ASD relay pin 30

6 - Splice Repair (3 wires)
7 - 18 gauge RDIYL wire from PDC fuse #9 for ASD power

18. Install the cover on the bottom of the POC.
19. Install the POC to its bracket.
20. Install the positive battery cable to the POC. Tighten both attaching nuts to 11.3 Nm
(100 in. lbs.).
21. Install the positive and negative battery cables from the battery.
22. Set the clock to the correct time.
23. After the Repair Procedure is completed, the vehicle will need to be driven to update
the 080 system. It may require several days of normal drive cycles to update all of the
required 080 monitors.
a. The vehicle is ready for 1/M emissions testing when the Malfunction Indicator Lamp
(MIL) remains illuminated continuously after turning the ignition key to the ON
position without cranking the engine.
b. The vehicle is NOT ready for 1/M emissions testing, when the MIL flashes for 10
seconds approximately 15 seconds after turning the key to the ON position (without
cranking the engine) and then returns to continuous illumination. The vehicle will
require further drive cycles. If this condition persists after several days of further
drive cycles, then additional diagnosis may be required.

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2,5!.QQ4-13

POLICY:
Reimbursable within the provisions of the warranty.
NOTE: Vehicles included in this Service Bulletin have a lifetime coverage warranty
for this repair. See Warranty Bulletins; U.S. D-13-38, Canada SAB-2013-29 or
International ID-13-12 for details associated with the extended warranty.

TIME ALLOWANCE:
Labor Operation No:
08-90-65-90

MIL continues to indicate OBD
system is not ready for testing Repair (B)

FAILURE CODE:

lzz

Description

IService Action

Amount
0.8 Hrs.