NHTSA ID Number: 10225240
Manufacturer Communication Number: Z63
TSB/Document Date: 2022-10-31
Summary
Customer Satisfaction Notification Z63 Oil Starvation
Figure 22 – Closed Crankcase
Ventilation Connector
7. Loosen clamp (1) and remove the
clean air hose (2) (Figure 23).
Figure 23 – Clean Air Hose
Customer Satisfaction Notification Z63 – Oil Starvation
Page 21
Service Procedure [Continued]
8. Remove the
(Figure 24).
vent
hose
(1)
Figure 24 – Vent Hose
9. Remove the bolts (2) and the left
fuel rail cover (1) (Figure 25).
Figure 25 – Left Fuel Rail Cover
Customer Satisfaction Notification Z63 – Oil Starvation
Page 22
Service Procedure [Continued]
10. Disconnect the fuel injector wire
harness connectors (1) (Figure 26).
Figure 26 – Fuel Injector Connectors
11. Lift up the locking tab (1) to
unlock it (Figure 27).
12. Disconnect the fuel return line (2)
by wiggling the hose free from the
fuel injector (Figure 27).
Figure 27 – Locking Tabs
Customer Satisfaction Notification Z63 – Oil Starvation
Page 23
Service Procedure [Continued]
NOTE: Use a backing wrench on the fuel injector when unscrewing the
union nut.
13. Unscrew the union nuts (1 and 3)
and remove cylinder No. 4 fuel
tubes (2) (Figure 28).
14. Install protective caps onto the fuel
injectors and fuel rail.
15. Unscrew the union nuts (4, 6) and
remove cylinder No. 5 fuel tube (5)
(Figure 28).
16. Install protective caps onto the fuel
injectors and fuel rail.
Figure 28 – Fuel Lines
17. Unscrew the union nuts (7, 9) and
remove cylinder No. 6 fuel tube (8) (Figure 28).
18. Install protective caps onto the fuel injectors and fuel rail.
19. Remove the bolt (1) securing the Charge Air Cooling (CAC) hose (Figure 29).
20. Release the retaining clip and
disconnect the CAC hose (2) from
the turbocharger elbow and remove
the hose (Figure 29).
Customer Satisfaction Notification Z63 – Oil Starvation
Page 24
Service Procedure [Continued]
21. Remove the nut (1) and the right
fuel rail cover (2) (Figure 30).
Figure 30 – Right Fuel Rail Cover
22. Remove the left side bolts (1) from
the upper High Pressure (HP)
Exhaust Gas Recirculation (EGR)
tube (2) (Figure 31).
23. Remove the right side bolts (3) and
the upper HP EGR tube (2).
(Figure 31).
Figure 31 – HP EGR Tube
Customer Satisfaction Notification Z63 – Oil Starvation
Page 25
Service Procedure [Continued]
24. Lift up the locking tab (1) to
unlock it (Figure 32).
25. Disconnect the fuel return line (2)
by wiggling the hose free from the
fuel injector (Figure 32).
NOTE: Use a backing wrench on
the
fuel
injector
when
unscrewing the union nut.
Figure 32 – Injector Locking Tabs
Customer Satisfaction Notification Z63 – Oil Starvation
Page 26
Service Procedure [Continued]
26. Unscrew the union nuts (7 and 9)
and remove cylinder No. 1 fuel
tube (8) (Figure 33).
27. Install protective caps onto the fuel
injectors and fuel rail.
28. Unscrew the union nuts (4, 6) and
remove cylinder No. 2 fuel tube (5)
(Figure 33).
29. Install protective caps onto the fuel
injectors and fuel rail.
Figure 33 – Injector Tubes
30. Unscrew the union nuts (1, 3) and remove cylinder No. 3 fuel tube (2)
(Figure 33).
31. Install protective caps onto the fuel injectors and fuel rail.
32. Clean the area around the fuel injector to be removed, so no debris falls into the
injector bore.
33. Remove the bolt (1) and the fuel
injector clamp (2) (Figure 34).
Figure 34 – Fuel Injector Clamp
Customer Satisfaction Notification Z63 – Oil Starvation
Page 27
Service Procedure [Continued]
34. Using your hand, pull fuel injector
(1) straight up from cylinder head
for removal. Discard the lower
sealing washer and place a
protective cap over the nozzle and
injector bore (Figure 35).
Figure 35 – Fuel Injector
35. If injector can't be removed by
hand, install the Remover, Fuel
Injector VM.10358A (1) to remove
the fuel injector (2). Discard the
lower sealing washer and place a
protective cap over the nozzle and
injector bore (Figure 36).
Figure 36 – VM.10358A
Customer Satisfaction Notification Z63 – Oil Starvation
Page 28
Service Procedure [Continued]
36. To remove the rear injector on the
right side of the engine, remove the
EGR Cooler Vacuum Bypass.
Remove the E-clip from shaft on
the cooler, and two T25 Torx
screws. Set the bypass aside with
heat shield and bracket (Figure 37).
SCREWS
Figure 37 – EGR Cooler Bypass
NOTE: Check and MAKE SURE that the copper sealing washer did not
remain in the cylinder head.
37. Remove and discard lower sealing
washer (2) and place a protective
cap over the nozzle and injector
bore (Figure 38).
Figure 38 – Injector
Customer Satisfaction Notification Z63 – Oil Starvation
Page 29
Service Procedure [Continued]
38. With the injectors removed, inspect each cylinder with a borescope. Rotate the
engine so that the whole bore top to bottom can be viewed. Are there any signs
of scoring (Figure 39)?
➢ YES. Engine replacement is required. See Engine Removal and Installation in
Service Library at 09 - Engine, 3.0L Turbo Diesel / Removal and Installation.
➢ NO. Perform C. Engine Oil Filter Adapter Replacement.
Figure 39 – Cylinder Bore Inspection
39. If the bores show no sign of scoring, clean the injector bores and injector as
described in the following steps.
NOTE: Before cleaning the injector bore, seal the injector holes in the
injector bore with the appropriate cap to prevent debris from falling into
the cylinder.
40. Remove and discard the fuel injector O-ring seal.
41. Using a lint-free rag, wipe the cylinder head around the fuel injector.
42. Wipe out the injector bore with a lint-free cloth.
Customer Satisfaction Notification Z63 – Oil Starvation
Page 30
Service Procedure [Continued]
CAUTION: Make sure the injector bore bottom is clean of debris
otherwise a leak could occur.
43. Clean the bottom of the fuel injector bore with Brush, Injector Bore 9717 and
make sure the old copper sealing washer (2) is not stuck in the bore
(Figure 38).
44. Blow out the recess with shop air and clean again with a lint-free cloth and
cover.
45. Perform these steps for each injector recess.
NOTE: DO NOT clean the tip of the fuel injector with a wire brush.
46. Clean the fuel injector body (1) with a wire brush (Figure 38).
47. Remove the copper sealing washer (2) and clean the sealing surface (Figure 38).
48. Check the tip of the fuel injector. If the tip is found to be loose, replace the fuel
injector.
49. Clean the fuel injector tips with a lint-free cloth.
NOTE: DO NOT apply anti-seize lubricant to the fuel injector nozzle, only
apply anti-seize lubricant to the fuel injector body.
50. Lubricate the fuel injector body
with Nickel Anti-Seize Lubricant
(Figure 41).
NOTE: Always replace the seals
in the cylinder head cover and
replace the copper sealing
washer on the bottom of injector.
Figure 41 – Lubricate the Fuel Injector
Customer Satisfaction Notification Z63 – Oil Starvation
Page 31
Service Procedure [Continued]
WARNING: No sparks, open flames or smoking. Risk of poisoning from
inhaling and swallowing fuel. Risk of injury to eyes and skin from contact
with fuel. Pour fuels only into suitable and appropriately marked
containers. Wear protective clothing.
NOTE: When a NEW fuel injector is being installed, or if an existing
injector is installed in any location other than its original location, the
injector quantity adjustment procedure must be performed (Refer to 14 Fuel System/Fuel Injection - Standard Procedure).
51. Remove the protective cap from the appropriate injector bore.
NOTE: Make sure the old copper sealing washer is not stuck in bore.
52. Install a NEW fuel injector seal (1)
in the cylinder head cover
(Figure 42).
53. Install a NEW sealing washer (2)
onto the fuel injector (1)
(Figure 38).
Figure 42 – Fuel Injector Seal
NOTE: Do Not apply any lubricant to the fuel injector nozzle. Care must
be taken not to restrict the discharge orifices in the nozzle.
Customer Satisfaction Notification Z63 – Oil Starvation
Page 32
Service Procedure [Continued]
54. Install the fuel injector (1) in the
cylinder head (Figure 43).
Figure 43 – Fuel Injector Install
55. Install the fuel injector clamp (2) and tighten the bolt (1) to 33 N·m (24 ft. lbs.)
(Figure 34).
56. Install the fuel supply tubes and tighten the fuel tube union nuts to:
• At fuel injector, tighten to 11 N·m + 75° (8 ft. lbs. + 75°).
• At fuel rail, tighten to 5 N·m + 75° (44 in. lbs. + 75°).
NOTE: Do not use any type of lubrication when installing the fuel injector
return line.
57. Install the fuel injector return line and be sure it is fully seated.
58. Push down on the lock tab (1) to lock in place (Figure 32).
59. Connect the fuel injector wire harness connector(s) (1) (Figure 25).
60. Install the EGR Cooler Vacuum Bypass and heat shield. Install and securely
tighten the two T25 Torx screws. Install the E-clip to the shaft on the cooler
(Figure 37).
Customer Satisfaction Notification Z63 – Oil Starvation
Page 33
Service Procedure [Continued]
61. Install the upper HP EGR tube (2), a new gasket, and reuse the O-ring. (Figure
31). Tighten fasteners to:
• M6 fasteners to 11 N·m (8 ft. lbs.).
• M8 fasteners to 25 N·m (18 ft. lbs.).
NOTE: Before injector silencer pad install, briefly run the engine and
check carefully for fuel leaks.
62. Install the right fuel rail cover (2) and securely tighten the nut (1) (Figure 30).
63. Connect the CAC hose (2) to the turbocharger elbow and install the hose
(Figure 29).
64. Install the bolt (1) securing the Charge Air Cooling (CAC) hose. Tighten to
7 N·m (63 in. lbs.) (Figure 29).
65. Install the left fuel rail cover (1) and securely tighten the bolts (2) (Figure 24).
66. Install the vent hose (1) (Figure 23).
67. Install the clean air hose (2) and tighten the clamp (1) (Figure 22).
68. Connect the crankcase breather hose.
69. Attach the CCV heater wire harness retainer (2) (Figure 21).
70. Connect the Closed Crankcase Heater Ventilation (CCV) heater wire harness
connector (1) (Figure 21).
71. Install the bolt (3) securing the clean air hose (Figure 20).
72. Attach the coolant hose retainer (2) to the clean air hose (Figure 20).
Customer Satisfaction Notification Z63 – Oil Starvation
Service Procedure [Continued]
73. Connect the clean air hose and tighten the clamp (1) Figure 20).
74. Check and clear codes.
75. Check and add oil as needed.
Page 34
Customer Satisfaction Notification Z63 – Oil Starvation
Page 35
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 Customer Satisfaction Notification service
completions and provide dealer payments.
Use the following labor operation numbers and time allowances:
Labor Operation
Number
Time
Allowance
Perform Vehicle Scan Report,
Inspect Oil Filter and
Replace Oil Filter Adapter/Cooler Assembly
09-Z6-31-82
2.1 Hrs.
Perform Vehicle Scan Report,
Inspect Oil Filter and Cylinder Bores
and Replace Oil Filter Adapter/Cooler Assembly
09-Z6-31-83
4.6 Hrs.
Perform Vehicle Scan Report,
Inspect Oil Filter and Cylinder Bores
and Replace Engine
09-Z6-31-84
10.2 Hrs.
Optional Equipment: (Engine Replacement Only)
4X4 Equipped
09-Z6-31-60
0.2 Hrs.
Running Boards/Side Steps
09-Z6-31-61
0.4 Hrs.
In addition, enter “MATL” in the Part Number section of your claim with the
applicable Material Allowance where appropriate.
NOTE: See the Warranty Administration Manual, Recall Claim Processing
Section, for complete claim processing instructions.
Customer Satisfaction Notification Z63 – Oil Starvation
Page 36
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 mail. They are requested to schedule appointments for this service
with their dealers. A generic copy of the owner letter is attached.
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 campaign displayed can be sorted by:
those vehicles that were unsold at campaign launch, those with a phone number,
city, zip code, or VIN sequence.
Dealers should 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.
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 notification only and is strictly prohibited from all other use.
Customer Satisfaction Notification Z63 – Oil Starvation
Page 37
Additional Information
If you have any questions or need assistance in completing this action, please
contact your Service and Parts District Manager.
Customer Service / Field Operations
FCA US LLC
This notice applies to your vehicle,
CUSTOMER SATISFACTION NOTIFICATION
Oil Starvation
[Model Year and Model]
VIN XXXXXXXXXXXXXXXXX
Z63
LOGO
VEHICLE PICTURE
YOUR SCHEDULING OPTIONS
1. RECOMMENDED OPTION
Call your authorized Chrysler
/
Dodge / Jeep® / RAM 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.
DEALERSHIP INSTRUCTIONS
Please reference CSN Z63.
Dear [Name],
At FCA US LLC, we recognize that the success of our business depends on the satisfaction of
our customers. We are constantly monitoring the quality of our products and looking for
opportunities to improve our vehicles even after they are sold. Because your long-term
satisfaction is important to us, we are contacting you on important improvements we would
like to make to your vehicle [1]. This will be done at no charge to you.
We are recommending the following improvements be performed on certain [2022 (DT) Ram
1500 Pickup] vehicles equipped with the 3.0L diesel engine.
WHY DOES MY VEHICLE NEED REPAIRS?
The engine oil anti-drain valve O-ring in the engine oil filter adapter on your vehicle [1] may be
the incorrect size, potentially limiting or preventing internal engine oil flow. Restricted internal
engine oil flow can cause a knocking noise or a Malfunction Indicator Lamp (MIL) and fault
code. If this condition is not addressed, it can eventually lead to premature engine failure.
HOW DO I RESOLVE THIS CUSTOMER SATISFACTION NOTIFICATION?
FCA US will repair your vehicle free of charge (parts and labor). To do this, your dealer
will inspect the engine for signs of damage. If no signs of damage are found the engine oil
filter adapter will be replaced. If the engine is damaged, it will be replaced. The estimated
repair time for the engine oil filter adapter is 2.5 hours. If engine replacement is needed more
extensive time will be required. 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
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 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 218004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.
- 6X better wear protection on critical engine parts than...
- 1.3X better sludge protection than industry standards*
- 3X Stronger against viscosity breakdown than leading full...
- Protection for 10,000 miles between oil changes
- Meets or exceeds the following specifications: API SP/SN...
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TSB/Document ID: Z63
Replacement Service Bulletin Number:
MFR Communication Date: 2022-08-03
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
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