FCA CARIBBEAN WARRANTY OPERATIONS NEWSLETTER
VOLUME 9, ISSUE 5

Published June 28, 2023

2023 Jeep Grand Cherokee “L” Badge Is NOT Missing
As of January 9, 2023, the “L” badge previously
applied to the Liftgate has been intentionally
removed to reduce complexity (see photos
below). This is not a shortage or error; it is built

as designed. Warranty claims submitted for
“missing liftgate L badges” on vehicles built
after January 9, 2023, will be subject to
chargeback.

Removal of the Powertrain Service Center (PTSC) Phone Number
from DealerCONNECT
The PTSC phone number was removed from
DealerCONNECT on May 23rd. PTSC is no
longer receiving phone calls. Any PTSC
questions should be sent to the Warranty

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Information Center (WIC) Ask A Question
located on DealerCONNECT>Service>Warranty

Administration>Warranty Information Center
(WIC). See WIC article KB0039946 for details.

FCA CARIBBEAN WARRANTY OPERATIONS NEWSLETTER
VOLUME 9, ISSUE 5

A/C LOP Diagnostic Update
An evacuation and recharge of the refrigerant
with no leak found should not be used as a
stand-alone diagnostic tool. LOP 24-01-12-01 Evacuation and Recharge - No Leak Found has
been terminated and can no longer be used.
Anytime an evacuation and recharge is
performed, it must be associated with a repair.
A new LOP 85-41-24-01 - Air Conditioning &

Heater, Trouble Not Found - A/C Performance
Test, has been added to the Diagnostic LOPs.
This is to allow for the proper diagnostic steps
required to determine if a system is low on
refrigerant or operating as designed.
When an Air Conditioning functional issue is
being diagnosed, the first step is to perform the
A/C performance test outlined in Service
Library 24 - Heating and Air Conditioning /
Diagnosis and Testing A/C PERFORMANCE.
•

•

•

Recording pressures and temperatures
during this test is crucial; and should be
noted as part of the 3 Cs.
The A/C PERFORMANCE test will help
the technician determine if the vehicle is
operating to specifications or not and
avoid unnecessary repairs.
We understand that some vehicles,
when operating as deigned, may still
result in a customer dissatisfaction.

•
•

•

Knowing this allows for better
communication and understanding.
Our engineering and manufacturing
teams can utilize these test results to
address the designs that do not meet
expectations better if they can see the
issue more clearly.
Repairs attempted on an operating-asdesigned system can and do lead to lost
time on root cause activities from our
quality and engineering teams.

All Chrysler, Jeep, Dodge brand vehicles leave
the factory with dye added to the receiver
dryer. Because a new vehicle may not have
had enough time to circulate the factory dye, it
is best to add liquid dye when low refrigerant is
found with low time in service. The vehicle’s
A/C system will need to be operated to circulate
the dye (10 minutes of compressor on time is
sufficient); followed by time to find and repair
the leak prior to returning the vehicle to the
customer.
If the A/C performance test finds the system is
operating within the Service Library defined
parameters,
please
review
customer
expectations and compare this to other like
equipped vehicles.

Safety Recall Y78 – Fuel Tank Replacement REMOVED
A revision was made to the repair procedure
for Safety Recall Y78 in December 2022. The
replacement of the Fuel Tank is no longer
required for Safety Recall Y78. The current
repair procedure is to CLEAN the Fuel Tank
instead of replacing it, as the contaminants can
be removed by following the Tank Cleaning
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Procedure. The Warranty Contact Center is
receiving claims for Recall Y78 which includes a
Fuel Tank listed in the parts section. Any claims
submitted for review with a Fuel Tank listed in
the part section will be returned for the dealer
to remove the tank, as it is no longer included in
the Recall.

FCA CARIBBEAN WARRANTY OPERATIONS NEWSLETTER
VOLUME 9, ISSUE 5

Termination of Warranty Extension X89 (Warranty Bulletin ID-21-10)
On June 7, 2023 Warranty Extension X89 was
terminated and those vehicles were added to
Warranty Extension XJ1 (Warranty Bulletin ID23-11). The appropriate customers will receive a
letter advising that their vehicle is involved in

Warranty Extension XJ1. If a customer comes
in with a letter for X89, verify if the vehicle is
involved in XJ1 by running a VIP in
DealerCONNECT or wiADVISOR.

MY 2019 – 2024 Ram 1500 Pickup (DT) - Exhaust Manifold
Replacement
We have seen an increased number of vehicles
being serviced for TSB 09-011-22, then
returning for additional repairs under the TSB
after an initial repair is performed. All defects
should be addressed/ serviced at the initial
visit. The Repair Procedure involves inspecting
both manifolds and replacing those which are
cracked. Most commonly, we have seen
vehicles which have a very noticeable crack
serviced; then after replacement of that one
side, the vehicle returns with continued
noise/leaks and an additional hairline crack is
found. Please ensure you are thoroughly
inspecting BOTH manifolds for cracks, leaks,
broken bolts, and abnormal noise. The cracked

manifold may be severe on one side and very
minor on the other side. Failure to inspect both
sides properly will lead to a return repair and
decreased customer satisfaction.
Please see (Figure 1) for an example of a minor
Right Side Manifold Leak. If this condition is
found, this also should be replaced as outlined
in the TSB. Failure to do so will cause the
manifold to crack more severely later, causing
additional concerns and additional repairs. As
always, your Tech notes should be very clear
on your findings to support the repair
performed and defects present.

Figure 1

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FCA CARIBBEAN WARRANTY OPERATIONS NEWSLETTER
VOLUME 9, ISSUE 5
We have also noticed an increased number of
claims submitted incorrectly. This TSB has
three repair options:
•
Replacement of Left Manifold
•
Replacement of Right Manifold
•
Replacement of Both Manifolds

There is a LOP available for all three options. If
you replace both, you MUST use the Both sides
LOP. We have seen claims using the Left and
Right side LOPs separately. This structure is
not correct and contains overlapping labor that
will result in payment delays, or it may result in
the claims being charged back for correction.
Please see (Figure 2) below.

LOP
09-45-01-A4 Exhaust Manifold – Replace (Both Sides)
09-45-01-A3 Exhaust Manifold – Replace (Right Side
Only)
09-45-01-A2 Exhaust Manifold – Replace (Left Side Only)

Parts
68591572AA & 68591573AA; RH & LH Exhaust Manifold
Kits
68591572AA; RH Exhaust Manifold Kit
68591573AA; LH Exhaust Manifold Kit

Figure 2

MY 2021 - 2023 – Jeep Grand Cherokee (WL) – Dual Battery
System Grounding Related to Blown 150A Rear PDC Fuse Array
Since the launch of the WL, there have been a
high number of blown 150A fuse arrays in
warranty, which has been proven to be from a
lack of knowledge of how the dual batteries are
interconnected and grounded. There are 2

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grounds (one from each battery) that are tied
together under the driver’s seat and to a single
ground point near the left side of the center
console. See Figure 1 below:

Figure 1

FCA CARIBBEAN WARRANTY OPERATIONS NEWSLETTER
VOLUME 9, ISSUE 5
From Figure 1, note that if the ground from only
Point #1 is removed, then the Main Battery will
still be feeding the system with 12V. The same
is true if only the ground from Point #2 is
removed; the Aux battery will then continue to
supply power. Therefore, it is very important
to properly disconnect the battery grounds
PRIOR to performing any Electrical repairs;
because any contact of the battery feed to
ground in the vehicle will most likely blow the
150A fuse in the rear PDC.
The 150A fuse is designed to only blow around
200% of its rating to protect the wiring;
therefore, this fuse will not blow unless there

If the 150A fuse is blown during service and the
batteries are fully charged, no issue will appear
immediately. However, if the vehicle is started
and ran for about 5 minutes with several loads
turned on and then the vehicle is shut off, upon

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are 300 amps or more which is typically from a
direct short to ground. Note that the maximum
amperage seen on the complete WL system is
only about 190 amps even with low state-ofcharge batteries.
Below is a picture of an actual WL from the 2nd
row seats showing where the batteries and
Rear PDC are located in the vehicle. The
service procedure requires that both grounds
be disconnected at the Main battery and
protect them from touching any vehicle metal in
order to fully disconnect any battery power
from the entire vehicle prior to performing
Electrical service. (See inside RED circle)

a restart of the vehicle the Aux battery may be
drained enough to set a P2AF5 DTC alerting the
technician that the Aux battery is low and most
likely the 150A fuse is blown.

FCA CARIBBEAN WARRANTY OPERATIONS NEWSLETTER
VOLUME 9, ISSUE 5

2018 – 2024 Jeep Wrangler (JL)/Jeep Gladiator (JT) Check Engine
Light with P0456 / P0455 – Evaporative Emissions System Leak
We understand that there is a vast assortment
of aftermarket accessories and modifications
available to our customers. Unfortunately, we
have seen some of them that the installation of
these non-MOPAR accessories have caused
damage to vehicle systems leading to check
engine lights and emissions leaks. Below are a
few examples that we have seen recently. As a

reminder, servicing of any damage to vehicle
system components caused by non-MOPAR
modifications is not a warrantable repair but
could be considered as Consumer Goodwill by
including the LOP 85-85-CG-09 as a related
LOP in the condition.

Mounting bolt for aftermarket “Rock-Lights” (wheel well lights) rubbed a hole
into the EVAP canister

Hole drilled through floor to run wires for aftermarket device (drill bit went too
far and dilled a hole in evap. line)

Hole drilled into canister when installing aftermarket accessory

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FCA CARIBBEAN WARRANTY OPERATIONS NEWSLETTER
VOLUME 9, ISSUE 5

Popular JL aftermarket modification where the rear parking brake
cables are rerouted under the frame cross member to attain greater
rear suspension articulation. This can cause excessive side-loading
of the evaporative lines and cracks/damages to the purge line
expansion tank mounted on the cross-member. The location of all
components is engineered to work together with all other items.
Modifications are not necessary.

2023 DT - Removal of Mylar Films from Truck Rear Flares
In the interest of the customer and to
aesthetically improve the appearance quality of
the RAM Truck flares, Stellantis decided to
remove the mylar covering on the rear flares of
all RAM trucks from production. This change

was initiated on November 22, 2022. This
feature will now be offered through MOPAR if
customers wish to have it applied to their
vehicle.

Image 1 – Individual Mylar Pieces Shown

Reasons for deletion
A warranty study of the rear flares of the RAM
trucks showed that there was excessive
peeling of the mylar at the ends which was also
leading to dirt and debris build up underneath

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the mylar. This condition was prevalent on all
painted flares and was most evident on the
brighter paints such as white and red.

FCA CARIBBEAN WARRANTY OPERATIONS NEWSLETTER
VOLUME 9, ISSUE 5

Heat Tabs on Engines and Intake Manifold Replacement Guidelines
Heat Tabs
All remanufactured engines are equipped with
Heat tabs. Heat tabs can be found on the back
of heads and in a core cup plug. If heat tabs
are white, then the engine has not been over
heated. If the heat tabs are pink, the engine
coolant temp has reached 255°F. If the heat
tabs are red, the engine coolant temp has
exceeded 255°F. This will cause the heads to
warp and leak coolant. Examples of heat tabs
are below. The root cause of the overheat
condition must be addressed. Engines only

Normal White Sensor

overheat from a lack of coolant which causes
the heads to warp.
The cause of the overheat condition must be
identified. If the component is not covered by a
warranty, then the overheated engine cannot
be claimed as a warrantable repair; as a noncovered component that causes a covered
component to fail, will cause the covered
component to no longer be covered. Engines
returned with indications of an overheat may
be charged back in full.

Overheated Pink Sensor
255°F Coolant Temp

Overheated Red Sensor
+255°F Coolant Temp

Intake Manifold Replacement
If an engine suffered a catastrophic failure and
is equipped with a plastic intake manifold, the
intake manifold must be replaced during engine

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replacement. Remanufactured engines come
with protective intake port warning tape (see
below) that advises of this requirement.

FCA CARIBBEAN WARRANTY OPERATIONS NEWSLETTER
VOLUME 9, ISSUE 5
Engines returned with debris in the combustion
chambers from a previous engine replacement
may be charged back in full for failing to install a

new intake
replacement.

manifold

during

the

first

5.7L/ 6.4L Multi-Displacement System (MDS) Lifters
The MDS deactivating lifters (1) can be
distinguished from the non-MDS lifters (2) by
the disconnecting pin (3) on the side of the MDS
lifter. We have seen technicians replace the

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lifters needlessly because the pin has moved
and is partially blocking the hole. This is a
normal condition and does not constitute a
reason for MDS lifter replacement.

FCA CARIBBEAN WARRANTY OPERATIONS NEWSLETTER
VOLUME 9, ISSUE 5

Charger (LD)/ Challenger (LA) Open End Lug Nuts
There are wheel packages on the LD/LA vehicles
that come with open end lug nuts. Please review
sales code and options, before replacing these as
a warranty shortage and error.
The following vehicles and sales code
combinations are correctly equipped with open
ended lug nuts:
Charger Superbee – WPJ/TTH
Challenger 1320 – WPJ/TTH
Challenger D170 – WCT/TCR

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Shortage and error claims for this
are subject to chargeback.