Revision (2) August 2022
Dealer Service Instructions for:

Emissions Recall U90
Catalyst Efficiency
NOTE: Some non-Partial Zero Emission Vehicle (PZEV) vehicles have been
added to this campaign.

Remedy Available
2016 (KL) Jeep® Cherokee (PZEV and non-PZEV)
2016 (PF) Dodge Dart (PZEV and non-PZEV)
2016 (UF) Chrysler 200 (PZEV and non-PZEV)
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.

Subject
About 232,707 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.
© Copyright 2022, FCA US LLC, All Rights Reserved

(tdb)

Emissions Recall U90 – Catalyst Efficiency

Page 2

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

Part Number

Description

CEZGU907AA

Upstream O2 Sensor (PF Only)

•

(PF) Dodge Dart

Part Number
Description
CEZGU905AA
Campaign Kit (Gasket and Heat Shield)
Each package contains the following components:
Quantity
Description
1
Upper Heat Shield
1
Gasket, Exhaust Manifold

Emissions Recall U90 – Catalyst Efficiency

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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
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

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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

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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. Remove push pin fasteners then remove closeout panel (Figure 5).

CLOSEOUT PANEL

PUSH PINS

Figure 5 – Closeout Panel

Emissions Recall U90 – Catalyst Efficiency

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Service Procedure [Continued]
12. 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

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. Disconnect the upstream oxygen
sensor and downstream oxygen
sensor wire harness connectors
(Figure 8 or 9).

WIRE HARNESS
RETAINER

WIRE HARNESS
CONNECTORS

Figure 8 – Oxygen Sensors Electrical
(UF) Chrysler 200
(KL) Jeep Cherokee

16. Disengage the upstream oxygen
sensor wire harness from the
retainer(s) (Figure 8 or 9).

WIRE HARNESS
RETAINERS

WIRE HARNESS
CONNECTORS

Figure 9 – Oxygen Sensors Electrical
(PF) Dodge Dart

Emissions Recall U90 – Catalyst Efficiency

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Service Procedure [Continued]
17. Remove and DISCARD the two
upper heat shield bolts and if
applicable, SAVE the oxygen
sensor wire harness retainer
bracket (Figure 10 or 11).

HEAT SHIELD

RETAINER BRACKET

BOLTS

Figure 10 – Maniverter Heat Shield
(UF) Chrysler 200
(KL) Jeep Cherokee

18. Remove and DISCARD the
maniverter upper heat shield nuts,
then remove and DISCARD the
maniverter upper heat shield
(Figure 10 or 11).

NUTS

HEAT SHIELD

Figure 11 – 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 12 – Maniverter to Engine

19. Remove the fasteners, six bolts and two nuts, securing the maniverter to the
engine cylinder head (Figure 12).
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 13).

20. Inspect the bolts and bolt holes for
any signs of thread loss then
DISCARD the bolts (Figure 11).

THREAD LOSS

• If bolt holes do not show signs of
thread loss, proceed to Step 23.
• If bolt holes show signs of thread
loss, continue with Step 21.
• If a bolt is broken off in the hole,
proceed to Step 22.
Figure 13 – Inspect for Thread Loss

Emissions Recall U90 – Catalyst Efficiency

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Service Procedure [Continued]
21. 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 23.
• If the bolt hole threads are stripped allowing the bolt to rotate, unable to achieve
proper torque, remove the bolt and continue with Step 22.

22. 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 23 - 25. 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 26.
GASKET

23. Remove the maniverter out the top
of the engine compartment and
retain the maniverter for core
return.

24. Remove and DISCARD the
exhaust
manifold
gasket
(Figure 14).

Figure 14 – Maniverter Gasket
CLEAN SEALING SURFACE

25. Clean the exhaust manifold gasket
sealing area of the engine cylinder
head (Figure 15).
Figure 15 – Clean Sealing Surface

Emissions Recall U90 – Catalyst Efficiency

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Service Procedure [Continued]
26. 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 16).

NEW GASKET

Figure 16 – Install New Gasket

MANIVERTER

27. Install the NEW maniverter
through the top of the engine
compartment. Set the maniverter
into position (Figure 17).

Figure 17 – Install New Gasket

28. Install the NEW maniverter bolts
and nuts. Following the torque
sequence, tighten the maniverter
fasteners to 34 N·m (25 ft. lbs.)
(Figure 18).

Figure 18 – Torque Sequence

Emissions Recall U90 – Catalyst Efficiency

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Service Procedure [Continued]
29. Install the NEW upper heat
shield
to
the
maniverter
(Figure 19).

NUTS

RETAINER BRACKET

30. If applicable, position the wire
harness retainer to the heat shield
(Figure 19).

31. Install the two NEW heat shield
bolts. Tighten the heat shield
bolts to 12 N·m (8 ft. lbs.)