Figure 12 – Power Steering Pump

Emissions Recall U90 – Catalyst Efficiency

Page 14

Service Procedure [Continued]
21. Disconnect the upstream oxygen
sensor and downstream oxygen
sensor wire harness connectors
(Figure 13 or 14).

WIRE HARNESS
RETAINER

WIRE HARNESS
CONNECTORS

Figure 13 – Oxygen Sensors Electrical
(UF) Chrysler 200, (BU) Jeep Renegade,
(KL) Jeep Cherokee, (FB) Fiat 500X,
(VM) Ram Promaster City
22. Disengage the upstream oxygen
sensor wire harness from the
retainer(s) (Figure 13 or 14).

WIRE HARNESS
RETAINERS

WIRE HARNESS
CONNECTORS

Figure 14 – Oxygen Sensors Electrical
(PF) Dodge Dart

Emissions Recall U90 – Catalyst Efficiency

Page 15

Service Procedure [Continued]
23. Remove and DISCARD the two
upper heat shield bolts and if
applicable, SAVE the oxygen sensor
wire
harness
retainer
bracket
(Figure 15 or 16).

HEAT SHIELD

RETAINER BRACKET

BOLTS

Figure 15 – Maniverter Heat Shield
(UF) Chrysler 200, (BU) Jeep Renegade,
(KL) Jeep Cherokee, (FB) Fiat 500X,
(VM) Ram Promaster City

24. Remove and DISCARD the
maniverter upper heat shield nuts,
then remove and DISCARD the
maniverter upper heat shield
(Figure 15 or 16).

NUTS

HEAT SHIELD

Figure 16 – Maniverter Heat Shield
(PF) Dodge Dart

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Page 16

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 17 – Maniverter to Engine

25. Remove the fasteners, six bolts and two nuts, securing the maniverter to the
engine cylinder head (Figure 17).
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 18).

26. Inspect the bolts and bolt holes for
any signs of thread loss then
DISCARD the bolts (Figure 18).

THREAD LOSS

• If bolt holes do not show signs of
thread loss, proceed to Step 29.
• If bolt holes show signs of thread
loss, continue with Step 27.
• If a bolt is broken off in the hole,
proceed to Step 28.
Figure 18 – Inspect for Thread Loss

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Page 17

Service Procedure [Continued]
27. 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 29.
• If the bolt hole threads are stripped allowing the bolt to rotate, unable to achieve
proper torque, remove the bolt and continue with Step 28.

28. 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 29 - 31. 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 32.
GASKET

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

30. Remove and DISCARD the
exhaust
manifold
gasket
(Figure 19).

Figure 19 – Maniverter Gasket
CLEAN SEALING SURFACE

31. Clean the exhaust manifold gasket
sealing area of the engine cylinder
head (Figure 20).
Figure 20 – Clean Sealing Surface

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Page 18

Service Procedure [Continued]
32. 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 21).

NEW GASKET

Figure 21 – Install New Gasket
MANIVERTER

33. Install the NEW maniverter
through the top of the engine
compartment. Set the maniverter
into position (Figure 22).

Figure 22 – Install New Gasket

34. Install the NEW maniverter bolts
and nuts. Following the torque
sequence, tighten the maniverter
fasteners to 34 N·m (25 ft. lbs.)
(Figure 23).

Figure 23 – Torque Sequence

Emissions Recall U90 – Catalyst Efficiency

Page 19

Service Procedure [Continued]
35. Install the NEW upper heat
shield
to
the
maniverter
(Figure 24).

NUTS

RETAINER BRACKET

36. If applicable, position the wire
harness retainer to the heat shield
(Figure 24).

37. Install the two NEW heat shield
bolts. Tighten the heat shield
bolts to 12 N·m (8 ft. lbs.)
(105 in. lbs.) (Figure 24).

HEAT SHIELD

BOLTS

Figure 24 – Maniverter Heat Shield

38. Install the three NEW heat shield nuts. Tighten the heat shield nuts to 12 N·m
(8 ft. lbs.) (105 in. lbs.) (Figure 24).

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.

39. 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
49 N·m (36 ft. lbs.) (Figure 25).

UPSTREAM
OXYGEN SENSOR

DOWNSTREAM
OXYGEN SENSOR

Figure 25 – Oxygen Sensors

Emissions Recall U90 – Catalyst Efficiency

Page 20

Service Procedure [Continued]
40. Connect the upstream oxygen
sensor and downstream oxygen
sensor wire harness connectors
(Figure 26 or 27).

WIRE HARNESS
RETAINER

WIRE HARNESS
CONNECTORS

Figure 26 – Oxygen Sensors Electrical
(UF) Chrysler 200, (BU) Jeep Renegade,
(KL) Jeep Cherokee, (FB) Fiat 500X,
(VM) Ram Promaster City

41. Install the upstream oxygen
sensor wire harness to retainer(s)
(Figure 26 or 27).

WIRE HARNESS
RETAINERS

WIRE HARNESS
CONNECTORS

Figure 27 – Oxygen Sensors Electrical
(PF) Dodge Dart

Emissions Recall U90 – Catalyst Efficiency

Page 21

Service Procedure [Continued]
42. (VM) Ram ProMaster City Only: Position the power steering pump (5) to the
support bracket then install the three bolts (6). Tighten the bolts to 44 N·m
(32 ft. lbs.) (Figure 12).

43. (VM) Ram ProMaster City Only: Install the nut (3) to the power steering pump
support bracket (4) and tighten the nut to 10 N·m (89 in. lbs.) (Figure 12).

44. (VM) Ram ProMaster City Only: Positon the power steering pump pulley (1)
then install the three bolts (2) and tighen to 25 N·m (18 ft. lbs.) (Figure 11).

45. (VM) Ram ProMaster City Only: Install the accessory drive belt (2) by
positioning the belt over all of the pulleys with the exception of the tensioner
pulley (1) (Figure 10).

CAUTION: Do not let the tensioner arm snapback to the fully extended
position, severe damage may occur to the tensioner.

46. (VM) Ram ProMaster City Only: Rotate the center bolt of the tensioner pulley
(1) counterclockwise, install the accessory drive belt (2) on the tensioner pulley
(1) and slowly release the tensioner (Figure 10). Visually inspect the belt to
pulley alignment.

47. (VM) Ram ProMaster City Only: Install the belt cover (1) with three nuts (2)
then tighten the nuts to 8 N·m (71 in. lbs.) (Figure 9).

48. (VM) Ram ProMaster City Only: Secure the top of the accessory drive belt
guard (2) with the bolt (1) tighened to 8 N·m (71 in. lbs.) (Figure 8).

Emissions Recall U90 – Catalyst Efficiency

Page 22

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

50. 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).

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

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

53. Close the hood.

51. Raise and support the vehicle.

55. 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 28).

BOLTS

Figure 28 – Maniverter Outlet Bracket

56. 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 28).

Emissions Recall U90 – Catalyst Efficiency

Page 23

Service Procedure [Continued]
57. Clean the exhaust crossunder
pipe flange sealing surface
(Figure 29).

CLEAN GASKET
SEALING SURFACE

Figure 29 – Crossunder Pipe Flange

58. Install the NEW exhaust flange
gasket
to
the
maniverter
(Figure 30).

NEW GASKET

Figure 30 – Exhaust Flange Gasket

Emissions Recall U90 – Catalyst Efficiency

Page 24

Service Procedure [Continued]
59. Position the exhaust crossunder
pipe to the catalyst flange
(Figure 31).

NUTS

EXHAUST
FLANGE

60. 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 31).

CROSSUNDER
PIPE

61. Install the bolt securing the
exhaust crossunder pipe support
bracket to the transmission.
Tighten the bolt to 20 N·m
(15 ft. lbs.) (Figure 31).

SUPPORT
BRACKET BOLT

Figure 31 – Crossunder Pipe

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

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

64. Lower the vehicle.

65. 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.