NUMBER:
GROUP:
DATE:

08-061-16
Electrical
May 13, 2016

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.

THIS SERVICE BULLETIN IS ALSO BEING RELEASED AS RAPID RESPONSE
TRANSMITTAL (RRT) 16-040. ALL APPLICABLE SOLD AND UN-SOLD RRT VIN's
HAVE BEEN LOADED. TO VERIFY THAT THIS RRT SERVICE ACTION IS
APPLICABLE TO THE VEHICLE, USE VIP OR PERFORM A VIN SEARCH IN
TECHCONNECT. ALL REPAIRS ARE REIMBURSABLE WITHIN THE PROVISIONS OF
WARRANTY.
SUBJECT:
Wire Termination Seal On 2.4L Engine Wiring Harness
OVERVIEW:
This bulletin involves wire repairs to the engine harness.
MODELS:
2015

(BU)

Jeep Renegade

2016

(FB)

Fiat 500X

NOTE: This bulletin applies to vehicles within the following markets/countries:
NAFTA.
NOTE: This bulletin applies to vehicles built on or after March 07, 2015 (MDH
0307XX) and on or before May 09, 2015 (MDH 0509XX) equipped with a 2.4L
engine (Sales Code ED6).
SYMPTOM/CONDITION:
Customers may experience a Malfunction Indicator Lamp (MIL) illumination. Upon further
investigation the technician may find the following Diagnostic Trouble Codes (DTCs) listed
below:
•
•
•

P0652 - Sensor Reference Voltage 2 Circuit Low.
P0340 - Camshaft Position Sensor Circuit - Bank 1 Sensor 1.
P1185 - General Pressure Sensor Correlation.

In addition, customers may experience one or more of the following conditions:
•
•
•

Excessive engine crank times.
Engine stall at startup.
Vehicle in limp in mode (engine won’t go over 2,000 RPM).

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DIAGNOSIS:
All vehicles on the RRT VIN list are to be inspected and repaired as necessary. If the
customer describes the symptom/condition listed, perform the Repair Procedure.
PARTS REQUIRED:
Qty.

Part No.

Description

1

04778570

Heat Shrink Tube

1

68328970AA

Reflective Tape

1

68065586AA

Tesa Tape

REPAIR PROCEDURE:
1. Open and support the hood.
2. Remove the engine cover. Refer to the detailed service procedures available in
DealerCONNECT> TechCONNECT under: Service Info> Engine/Cover,
Engine/Removal and Installation.
3. Inspect for a white witness mark on the plastic wire harness retainer (Fig. 1).
4. Is there a white witness mark on the harness retainer (Fig. 1)?
a. YES >>> This bulletin has been completed, use LOP (08-94-TF-90) to close the
active RRT. Reinstall the engine cover.
b. NO >>> Proceed to Step #5.

Fig. 1 White Witness Mark Placement
5. Disconnect and isolate the negative battery cable.

-36. Locate the engine wiring harness (Fig. 2).

Fig. 2 Engine Harness

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-4-

7. Using a suitable tool, remove plastic wire harness retainer from threaded stud (Fig. 3).
CAUTION: Failure to carefully cut reflective tape may lead to damage to the engine
harness.
8. Using a suitable cutting tool, carefully cut reflective tape open and remove from engine
harness in the area shown to expose three terminated wire ends (Fig. 3).

Fig. 3 Reflective Tape And Retainer
1 - Retainer
2 - Threaded Stud
3 - Reflective Tape Area To Cut

-5NOTE: Stagger cut all wire ends before proceeding to Step #10.
9. Remove and discard electrical tape from three wire ends (Fig. 4).

Fig. 4 Electrical Tape And Wire Ends
1 - Electrical Tape
2 - Wire Ends

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10. Cut three equal lengths of heat shrink tubing and place tubing over three wire ends
(Fig. 5).
11. Using a suitable heat gun, heat all tubing until it is tightly sealed and sealant begins to
seep out of both ends of the tubing (Fig. 5).

Fig. 5 Heat Shrink Tubing
1 - Heat Shrink Tubing
2 - Wire Ends
3 - Sealant

-712. Using Tesa tape, wrap three wires to engine harness (Fig. 6).

Fig. 6 Tesa Tape And Engine Harness
1 - Tesa Tape
2 - Engine Harness

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13. Using reflective tape, completely cover Tesa tape (Fig. 7).
14. Install plastic harness retainer to threaded stud (Fig. 7).
15. Using a white paint pen, place witness mark on wire harness retainer (Fig. 7).

Fig. 7 Reflective Tape And Retainer
1 - Harness Retainer
2 - Threaded Stud
3 - Reflective Tape

16. Install the engine cover. Refer to the detailed service procedures available in
DealerCONNECT> TechCONNECT under: Service Info> Engine/Cover,
Engine/Removal and Installation.
17. Connect the negative battery cable.
18. Close hood.
19. Clear any DTCs that may have been set.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation
No:

Description

Skill Category

Amount

08-94-TF-90

Wiring Harness, Engine - Inspect
(2 - Skilled)

6 - Electrical And
Body Systems

0.2 Hrs.

08-94-TF-91

Wiring Harness, Engine - Repair
(2 - Skilled)

6 - Electrical And
Body Systems

0.3 Hrs.

FAILURE CODE:
ZZ

Service Action