STAR Center News

No. 88

Nov/Dec 2015

STAR Center News
All Hands on Deck…We Have a New Captain at the Helm!
We have a new leader here at Technical Service Operations…Tom McCarthy is our new Vice
President of Technical Service Operations.
Tom McCarthy hired into Chrysler in 1995 and has held many positions, each with increasing
responsibility. The majority of his career was spent on the product development side of the
company. In 2012, Tom was hired into Technical Service Operations as the Director of Technical
Service Development. He most recently became Vice President of Technical Service Operations in
December of 2014.
Tom holds a bachelor’s degree in mechanical engineering from Northeastern University and a
master’s degree in business administration from Walsh College. His Interests are car racing, car
restoration and animal (dog) rescue.
Tom brings with him a thorough knowledge of vehicle engineering and development processes and
believes in the need to align Engineering and Service to provide better tools, information, equipment
and support to the field/dealers to assist in fixing customer vehicles. Tom’s vision for TSO
is…focusing everything we do into fixing vehicles and improving the customer service experience.
-----------------------------------------------------------------------------------------------------------------------Where to Find the STAR News…
The STAR News link has always been located in TechConnect on the home page, in the left-side
window beneath the SEARCH Box. In addition STAR News will now be accessible through other
communication channels including:
1. Link on the LMS (Academy Site)
2. Monthly Master Tech
3. Instructor Lead Training will include a reminder of electronic file location and hard copies,
when possible
4. Via E-mail subscription – details to follow on how to submit your E-mail address to receive an
electronic copy of the STAR News.

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FCA US LLC

STAR Center
1-800-850-STAR

STAR Center Hours of Operation
M-F 8am-Midnight * Sat 9am-6pm * Open thru Lunch

Monday – Friday
8:00 AM – Midnight

Saturday
9:00 AM – 6:00 PM

Page 1

STAR Center News

No. 88

Top Tech Recognition
To kick off Mopar's new Technician Recognition
Program, FCA US LLC recently awarded the
Mopar "Top Techs" of 2014 with an all-inclusive
two-day event at FCA Headquarters in Auburn
Hills, Michigan. 27 Technicians (3 per business
center) were selected from over 20,000 eligible
technicians
that
showed
exemplary
performance in the areas of Fixed First Visit
(FFV) scores, dealership tenure and training
completion.

Nov/Dec 2015

Service Procedure for KL Negative
Battery Cable/IBS Module
Due to incidences of damage to the IBS module
occurring during the performance of service
procedures, please be sure to adhere to the
following recommendations when removing and
installing the negative battery cable/IBD
module.

2

1

REMOVAL
Top Techs group check out the wind tunnel at FCA
headquarters in Auburn Hills, Mi.

1. Loosen M6 captive hex nut (1) without
removing.
2. Insert medium-sized flat end of
screwdriver in pole clamp slot (2).
3. Lightly tap screwdriver to open pole
clamp slot to 3mm max.
4. Carefully lift IBS module upward to
remove it from the negative battery post.
INSTALLATION

As part of the two-day event, the technicians
were special guests as they toured FCA's scilab, wind tunnel and the 5-million square-foot,
world-class Sterling Heights Assembly Plant.

------------------------------------------------FCA US LLC

STAR Center
1-800-850-STAR

1. Place IBS module onto negative battery
post and push down to ensure it is
properly seated.
2. While applying downward force (20N
max) on IBS module to prevent rotation,
tighten M6 captive hex nut to 7Nm +/1Nm.
See service procedure in TechCONNECT for
any additional details.
----------------------------------------------------------

Monday – Friday
8:00 AM – Midnight

Saturday
9:00 AM – 6:00 PM

Page 2

STAR Center News

No. 88

3.0L Diesel PM and NOx Sensor
Removal Procedure Update

Nov/Dec 2015

PF Lighted Cluster Bezel Appearance

Some technicians are experiencing difficulty
removing the PM and NOx sensors from the
Selective Catalyst Reduction (SCR) during an
SCR replacement.

The lighted feature on the cluster bezel for the
PF is not lit in the area above the steering wheel
shroud by design (area in yellow below).
This area of the cluster is
not illuminated by design.

There are updates to the SCR removal
procedure and NOx Sensor removal procedure
to help the technician successfully remove the
sensors without damage.


Only use a six-sided crow’s foot tool to
remove the PM or NOx sensor from the
SCR.



If the PM or NOx sensor will not loosen,
use a torque wrench (Do not exceed
160 Nm (118 ft. lbs.)) and attempt to
loosen PM or NOx sensor.



If the PM or NOx sensor fastener is still
not loose after using the torque wrench
method, use a heat gun to heat the
sensor boss for 1 minute at 450° C (842°
F). NOTE: DO NOT use a torch as a
heat source.

See service procedure in TechCONNECT for
any additional details.
----------------------------------------------------------

New Field Technical Support Members
The Field Technical Support (FTS) Team would
like to welcome three new Service Engineers to
the group.
Patrick Waligore – Body/Chassis
Mike Russell – Diesel/Transmission
Bryan Green – Driveability/Engine/HVAC
Our new knowledge experts are looking forward
to assisting the STAR Center, Tech Advisors and
you with those difficult-to-diagnose vehicles.
---------------------------------------------------------FCA US LLC

STAR Center
1-800-850-STAR

If a customer notes this, explain that it is by
design intent and that all Darts equipped with
the lighted bezel feature have this appearance.
Comparison to another PF that is similarly
equipped may be helpful.
----------------------------------------------------------

Higher Shipping Pressure for Tires
Prevents Flat Spots
FCA is making process changes to reduce
customer complaints of vibration at highway
speeds due to tire flat-spotting. Tire flatspotting is the temporary flatness of the tire
overlay construction that can occur during
vehicle transportation and storage.
Flat
spotting can be driven out in 20 miles of
highway driving. To minimize flat spotting,
vehicles will be shipped at maximum sidewall
pressures. FCA currently ships vehicles at
maximum tire sidewall pressures with the
exception of Heavy Duty Trucks.
Tire pressure should be left at maximum
sidewall pressure during PDI in order to prevent
flat-spotting during storage. When a vehicle is
evaluated by or delivered to the customer, the
tire pressure must be reduced to the proper
cold tire inflation pressure that’s listed on the
vehicle certification label. It’s located on the
driver’s-side b-pillar or the rear edge of the
driver’s-side door. Tire pressures not adjusted
to placard pressure may cause a harsh ride
condition.
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Monday – Friday
8:00 AM – Midnight

Saturday
9:00 AM – 6:00 PM

Page 3

STAR Center News

No. 88

Air Filter Fault or Filter Minder
Warnings on 13 -14 M.Y. DJ, DD, DP,
D2 with 6.7L Cummins

Nov/Dec 2015

Inspect for signs of flashing material in the air
intake shield plastic tube (3) (see photo below).

Some customers may experience a premature
“Service Air Filter” message displayed on the
EVIC. The mil may also be illuminated when this
occurs. If the MIL is on, fault code P2280 - AIR
FLOW RESTRICTION / LEAK BETWEEN AIR
CLEANER AND MAF is likely to be set in the
PCM. This condition may occur on vehicles
with relatively low mileage.
The message in the EVIC as well as the DTC is
intended to inform that the air filter has become
restricted, requiring replacement. However,
other inlet restrictions may also trigger the
message and fault. Other possible causes are:

Also inspect for a collapsed air intake shield
porous tube (4) (if equipped) (see photo below).

1. Debris blocking the Air Inlet Adapter or
Ambient Air Duct (1) and (2).
2. Blocked air intake shield plastic tube (3).
3. Collapsed air intake shield porous tube
(4).

If both pieces have no problem found, replace
the air filter.
----------------------------------------------------------

LC/LA Challenger TR6060 6-Speed
Manual Transmission 1 – 4 Skip Shift
Feature

Before replacing the air filter, make sure to
remove the inlet shield ducting (3 and 4) to the
lower portion of the air box.

The TR6060 6-speed manual transmission in the
2009 – 2016 Challenger is equipped with a 1–4
Skip Shift feature. This is a solenoid-actuated
transmission feature that guides the shift lever
from 1st-to-4th gear under certain conditions to
maximize fuel economy. This is a normal
function of the TR6060 6-speed manual
transmission.
“SHIFT” continued on next page

FCA US LLC

STAR Center
1-800-850-STAR

Monday – Friday
8:00 AM – Midnight

Saturday
9:00 AM – 6:00 PM

Page 4

STAR Center News

No. 88

“SHIFT” continued from last page

When the following conditions are met, the shift
mechanism will only allow shifts from 1st to 4th
gear:
 Engine coolant temperature is higher
than 106 F (41 C).
 Vehicle speed is greater than 19 mph (30
km/h) but less than 21 mph (34 km/h).
 The transmission is in first gear.
 The accelerator is at ¼ throttle or less.
After completing the shift from 1st to 4th gear,
the clutch pedal can be depressed and the
transmission can be shifted into another
forward gear.
For customers who want to avoid the 1–4 Skip
Shift, the most effective method is shifting at a
higher or lower speed or applying additional
throttle.
Disconnecting the transmission
solenoid wiring will cause a check engine lighton condition and set a fault code for P0803-Skip
Shift Control Circuit to be set in the PCM.
Therefore, this is not an acceptable way to
disable the 1–4 Skip Shift feature.
Customers may be aware of a “Skip Shift
eliminator kit” that is available from various
sources in the aftermarket. Installation of this
type of device on the TR6060 manual
transmission is not authorized or recommended
by Fiat Chrysler Automobiles.
----------------------------------------------------------

6F24 Oil Pan Serviceability
If servicing a Dodge Dart, Jeep Compass or
Jeep Patriot with the Powertech 6F24 6spd
automatic transmission, please note that it is no
longer necessary to buy the oil pan service kit
(68192621AA) to get the oil pan gasket.
The oil pan gasket has been made available
individually via part number 68192622AA
(please, always check STAR Parts for part
number supersedence).
FCA US LLC

STAR Center
1-800-850-STAR

Nov/Dec 2015

Please remember that this gasket is to be
installed WITHOUT any type of sealer.
If you are replacing the gasket for a leak
condition, please verify that the threaded case
plugs above the oil pan rail are not the source of
the leak, as there have been some unnecessary
oil pan/gasket replacements due to this
condition.
----------------------------------------------------------

2015/2016 RT vehicles equipped with
Keyless Go with Push Button Start
The RT is the last FCA vehicle with the “Push to
Start Button” as an option. The “Push to Start”
button is an independent component which is
removable, and can be serviced independently
for vehicles equipped with Keyless Go starting
using the button.
The button is to be installed during dealer prep
prior to customer delivery. It is supplied within
its own packaging inside the Floor Mat Kit of the
vehicle.
There have been warranty claims against this
part for binding, sticking or popping off the
Wireless Ignition Node (WIN), in which it is
installed.
Parts returned for analysis have not shown or
tested to be defective and have been validated
to work correctly within other vehicles over
extended-time-period testing.
Please ensure that the “Push to Start” button is
installed correctly and functions without
sticking, binding, or popping off prior to
releasing the vehicle to the customer after
purchase.
Your support in protecting the customer is
greatly appreciated!
----------------------------------------------------------

Monday – Friday
8:00 AM – Midnight

Saturday
9:00 AM – 6:00 PM

Page 5

STAR Center News

No. 88

Pentastar Upgrade (PSU) engine
The 3.6L Pentastar Upgrade (PSU) engine was
designed with a vision of providing our
customers with fuel economy improvements of
up to 6%, while improving low-end performance
and maintaining refinement.
To accomplish this, 80% of the 3.6L PSU’s
components are all new, in comparison with the
Pentastar “Classic” engine. In addition, the
engine includes notable technology additions of
2-step variable intake valve lift (VVL) and cooled
exhaust gas recirculation (EGR).

Nov/Dec 2015

New TPM Sensors for 2016
Challengers, Chargers, and Chrysler
300’s
Starting in December 2015, Dodge Challenger,
Charger and Chrysler 300 tire pressure monitor
(TPM) sensors will have a different look.
The old sensor, a Schrader WAL I model, is
black. The new sensor, a Schrader WAL II,
appears identical in shape to the WAL I but is
colored gray to distinguish it from the old
sensor.

The 2-step VVL system allows the intake valves
to open fully for optimized performance, or
roughly half-way for optimized efficiency
through reduced pumping losses. This creates
unique OBD II diagnostics for the system
performance.
The cooled EGR system passes a portion of the
hot exhaust gas through a cross-flow cooler to
reduce the temperature of the gas down to
approximately 110 deg. C prior to flowing into
the intake manifold. This allows for increased
use of EGR in engine operation during times
when high efficiency is required without
adversely affecting engine knock. As with the
2-step VVL system, this new system for the PSU
requires new diagnostics.
The PSU engine launched at Trenton North
Engine Plant on 6/29/15 and will be first used in
the 2016 WK and WD vehicles prior to replacing
the Pentastar Classic in other applications.
The important thing to remember is that,
although the PSU will immediately be
recognizable as a member of the Pentastar
family of engines, almost all key components
and systems have been redesigned. Familiarity
with Pentastar engines aside, it will be essential
to verify part numbers and service procedures
specific to the PSU as many of them are new or
have been modified.

New MY2016 production will use the new gray
sensor and, as Mopar inventories are depleted,
the gray sensor (68241067AB) should be ordered
and used in place of the black sensor
(56029398AB). Please, always refer to STAR
PARTS to check for part supersedence. There
is no change in installation procedures and the
new sensor is interchangeable with the old
sensor. Gray and black sensors can be mixed
on the same vehicle. All four wheels do not