HEAT SHIELD

BOLTS

Figure 19 – Maniverter Heat Shield

32. Install the three NEW heat shield nuts. Tighten the heat shield nuts to 12 N·m
(8 ft. lbs.) (105 in. lbs.) (Figure 19).

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.

33. 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
29 N·m (36 ft. lbs.) (Figure 20).

UPSTREAM
OXYGEN SENSOR

DOWNSTREAM
OXYGEN SENSOR

Figure 20 – Oxygen Sensors

Emissions Recall U90 – Catalyst Efficiency

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Service Procedure [Continued]
34. Connect the upstream oxygen
sensor and downstream oxygen
sensor wire harness connectors
(Figure 21 or 22).

WIRE HARNESS
RETAINER

WIRE HARNESS
CONNECTORS

Figure 21 – Oxygen Sensors Electrical
(UF) Chrysler 200
(KL) Jeep Cherokee

35. Install the upstream oxygen
sensor wire harness to retainer(s)
(Figure 21 or 22).

WIRE HARNESS
RETAINERS

WIRE HARNESS
CONNECTORS

Figure 22 – Oxygen Sensors Electrical
(PF) Dodge Dart

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Service Procedure [Continued]
36. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor
(IBS), Connect the IBS connector after connecting the negative battery cable.

37. 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).

38. (KL) Jeep Cherokee Only: Install the air duct resonator assembly to the two
push pin grommets on the vehicle (Figure 6).

39. (KL) Jeep Cherokee Only: Install the closeout panel and push pin fasteners
(Figure 5).
SUPPORT
BRACKET

40. Close the hood.

41. Raise and support the vehicle.

42. 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 24).

BOLTS

Figure 24 – Maniverter Outlet Bracket

43. 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 24).

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Service Procedure [Continued]
44. Clean the exhaust crossunder
pipe flange sealing surface
(Figure 25).

CLEAN GASKET
SEALING SURFACE

Figure 25 – Crossunder Pipe Flange

45. Install the NEW exhaust flange
gasket
to
the
maniverter
(Figure 26).

NEW GASKET

Figure 26 – Exhaust Flange Gasket

Emissions Recall U90 – Catalyst Efficiency

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Service Procedure [Continued]
46. Position the exhaust crossunder
pipe to the catalyst flange
(Figure 27).

NUTS

EXHAUST
FLANGE

47. 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 27).

CROSSUNDER
PIPE

48. Install the bolt securing the
exhaust crossunder pipe support
bracket to the transmission.
Tighten the bolt to 20 N·m
(15 ft. lbs.) (Figure 27).

SUPPORT
BRACKET BOLT

Figure 27 – Crossunder Pipe

49. If equipped, position the engine belly pan to the underside of the vehicle
(Figure 1).

50. If equipped, install the fasteners securing the engine belly pan. Tighten the
fasteners securely (Figure 1).

51. Lower the vehicle.

52. 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.

53. Proceed to Section B. Prepare Maniverter for Core Return.

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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 28).
3. Separate the manifold portion from the catalyst. Discard/recycle the manifold
portion and return the catalyst portion for core return credit (Figure 28).
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 28 – Maniverter Cut/Remove Pipes

DISCARD / RECYCLE

Emissions Recall U90 – Catalyst Efficiency

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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.

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

Page 24

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. Place the ignition in the “OFF” position and then remove the wiTECH MicroPod
II device from the vehicle.

26. Remove the battery charger from the vehicle.

27. Proceed to Section D. Complete Proof of Correction Form for California
Residents.

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

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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) ONLY
(UF) ONLY
(PF) PCM ONLY (TCM not applicable)

09-U9-01-82
09-U9-01-82
09-U9-01-82

1.3 hours
1.4 hours
1.6 hours

Replace the Catalyst, Inspect the
PCM and TCM Software,
Reprogram PCM Only.
(KL), (UF) ONLY
(PF) PCM ONLY (TCM not applicable)

09-U9-01-83
09-U9-01-83

1.5 hours
1.7 hours

Replace the Catalyst, Inspect the
PCM and TCM Software,
Reprogram TCM Only.
(KL) ONLY
(UF) ONLY

09-U9-01-84
09-U9-01-84

1.4 hours
1.5 hours

Replace the Catalyst, Inspect and
Reprogram PCM and TCM with
Latest Released Level Software
(KL), (UF) ONLY

09-U9-01-85

1.6 hours

Emissions Recall U90 – Catalyst Efficiency

Page 27

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 28

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
VEHICLE PICTURE

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

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

FCA US LLC, has determined that certain [2016 Model Year (KL) Jeep® Cherokee, 2016 Model Year
(PF) Dodge Dart, 2016 Model Year (UF) Chrysler 200] vehicles equipped with a 2.4L engine may
release air pollutants which exceed tailpipe emission standards.
WHY DOES MY VEHICLE NEED REPAIRS?
Your vehicle [1] may exceed tailpipe emission standards due to a loss of catalyst CO/NOx
conversion efficiency resulting from the catalyst operating at high temperatures.
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.
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.