1993 Jeep Cherokee

EMISSION RECALL BULLETIN

CALIFORNIA EMISSIONS RECALL #680 - CATALYTIC CONVERTER

Model(s): 1991-95 Jeep Cherokee (XJ)

1991-95 Jeep Wrangler (YJ)

1991-92 Jeep Comanche (MJ) Vehicles Bulletin No.: 680 Date: March, 1996

NOTE: This is an Emission Recall bulletin.

VEHICLES AFFECTED

Vehicles Listed Below Which Are Equipped With a 2.5L Engine and Are Currently Located in California:

65535. 1991 Through 1995 Model Year Jeep Cherokee (XJ) Vehicles Built
       Through February 14, 1995 (MOM 021411)

65536. 1991 Through 1995 Model Year Jeep Wrangler (YJ) Vehicles Built
       Through February 7, 1995 (MDH 020712)

65537. 1991 and 1992 Model Year Jeep Comanche (MJ) Vehicles

SERVICE INFORMATION

Failure of the catalytic converter on the above listed vehicles, may cause a vehicle to be in violation of California Air Resources Board (CARB) and/or U.S. Environmental Protection Agency (EPA) Emissions Standards. To correct this condition the catalytic converter must be replaced. Vehicles which are located outside of California will be serviced under Emissions Recall #681.

IMPORTANT: This recall is subject to the State of California

Registration Renewal/Emissions Recall Enforcement Program. Involved vehicles must have the recall service completed before registration renewal.

The servicing dealer must provide a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) to each owner upon completion of the recall service, for use as proof in renewal of the vehicle registration.

Details of this service action are explained in the following sections.

SERVICE PROCEDURE VIDEOTAPE

No videotape of the service procedure for this recall will be provided.

DEALER NOTIFICATION & VEHICLE LIST

INVOLVED DEALERS

Each dealer to whom involved vehicles were invoiced (or the current

dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by first class mail.

The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles as necessary.

ALL OTHER CALIFORNIA DEALERS

Each California Jeep & Eagle dealer who does not receive a Vehicle List will receive a copy of this dealer recall notification letter by first class mail.

DIAL SYSTEM FUNCTION 70

All involved vehicles will be entered to DIAL System Function 70 at the time of recall implementation for dealer inquiry by VIN as needed.

RECALL COMPLETION LABEL REQUIREMENT

There is a California Air Resources Board requirement to affix a label to the vehicle to certify that the emissions recall was

completed. A label is included in each emissions service parts package Refer to the Service Procedure of this letter for application

instructions.

PARTS INFORMATION

IMPORTANT: A quantity of parts will be distributed initially and

billed to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support customer demand.

Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Catalytic Converter Packages, Recall PN CHAR6801 (for 1991 and 1992 model year vehicles), and Recall PN CHBG68O2 for (1993, 1994 and 1995 model year vehicles) to service 25% of those vehicles.

Each parts package contains the following components: CATALYTIC CONVERTER PACKAGES

91/92	I MY Vehicles (CHARS801)	93/94/95 MY Vehicles (CHBG68O2)
Qty	Description	Qty	Description
1	Catalytic Converter	1	Catalytic Converter
1	Clamp	2	Clamp
4	Bolts	1	Recall Completion Label
4	Nuts	1	Instruction Sheet
1	Gasket
1	Recall Completion Label
1	Instruction Sheet

OWNER NOTIFICATION & SERVICE SCHEDULING

All involved vehicle owners known to Chrysler are being notified of

the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers at the earliest possible date. A copy of the CUSTOMER NOTIFICATION LETTER is in this bulletin.

Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.

A. REPLACE CATALYTIC CONVERTER

WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE FUEL LINES.

10. Raise vehicle on an appropriate hoist.

11. On Wrangler (YJ) vehicles:

Support the transmission and remove the skid plate.

3. Remove and discard the nuts, bolts and gasket at the front of the
converter and the exhaust pipe clamp at the rear (see Fig. 1).

NOTE: Use penetrating oil if necessary.

4. Place a block of wood against the rear of the converter and drive
the clamp converter forward to disengage the alignment tab on the
converter pipe from the alignment slot on the muffler.

Fig.

97F55546

1: Removing Converter and Exhaust Pipe Clamp

10. Twist the converter back and forth to separate it from the muffler.

11. Install the new converter into the muffler until the alignment tab
    is inserted into the alignment slot.

12. Using the provided gasket, nuts and bolts, attach the converter to
    the front exhaust pipe. Do not tighten the bolts.

13. Install and tighten the new exhaust pipe clamp, at the muffler to
    converter connection, to 40 ft-lbs (57 N-m).

14. Tighten the converter to front exhaust pipe bolts to 25 ft-lbs
    (34 N-m).

10. On Wrangler (YJ) vehicles:
    Install the skid plate.

11. Lower vehicle.

B. INSTALL RECALL COMPLETION LABEL

10. With a ball point pen, print your dealer code (5 digits) on the
    supplied Recall Completion Label.

11. Peel the label from its backing and apply it near the Vehicle
    Emissions Control Information Label on the underside of the hood.

С COMPLETE PROOF OF CORRECTION FORM

1. Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner.

SERVICE PROCEDURE FOR 1993,1994 AND 1995 MY VEHICLES

A. REPLACE CATALYTIC CONVERTER

WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE FUEL LINES.

10. Raise vehicle on an appropriate hoist.

11. On Wrangler (YJ) vehicles:

Support the transmission and remove the skid plate.

10. Remove the U-bolt clamps from the exhaust pipe and muffler
    connections at the front (see Fig. 2 and 3) and rear (see Fig. 4)
    of the catalytic converter.

11. Heat the catalytic converter to muffler connection with an
    oxyacetylene torch until the metal becomes cherry red.

97C56921

Fig. 2: Front U-Bolt Clamps and Muffler Connections (XJ Vehicles)

97H55548

Fig. 3: Front U-Bolt Clamps and Muffler Connections (YJ Vehicles)

5. While the metal is still cherry red, twist the muffler assembly back and forth to separate it from the converter.

10. Disconnect the front exhaust pipe from the catalytic converter.
    If necessary, heat the pipe connection as described above.

11. Connect the supplied catalytic converter to the front exhaust
    pipe. Use one of the supplied clamps and tighten the nuts to
    45 ft-lbs (61 N.m).

12. Install the muffler on to the catalytic converter until the
    alignment tab is inserted into the alignment slot.

13. Install and tighten the new exhaust pipe clamp, at the muffler
    to converter connection, to 45 ft-lbs (61 Nm).

supplied Recall Completion Label.

2. Peel the label from its backing and apply it near the Vehicle

Emissions Control Information Label on the underside of the hood.

С COMPLETE PROOF OF CORRECTION FORM

1. Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner.

COMPLETION REPORTING AND REIMBURSEMENT

Claims for vehicles which have been serviced must be submitted on the DIAL System Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments.

Use the following labor operation number and time allowance:

Labor

Operation Time Number Allowance

Replace Catalytic Converter 11680182 0.7 Hours

Add the cost of the recall parts package plus applicable dealer allowance to your claim.

PARTS RETURN

Removed catalytic converters must be returned to the Warranty Material Return Center.

NOTE: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing and material return instructions.

VEHICLE NOT AVAILABLE

If a vehicle is not available for service for a known reason, let us know by filling out the pre-addressed Vehicle Disposition Form portion of the Owner Notification Form, or describe the reason on a postcard and mail to:

Chrysler Corporation

CIMS 482-00-85

800 Chrysler Drive East

Auburn Hills, Michigan 48326-2757

Following the above procedures will expedite the processing of your claim.

If you have any questions or need assistance in completing this action, please contact your Zone Service Office.

Customer Services Field Operations Chrysler Corporation

CUSTOMER NOTIFICATION LETTER

EMISSIONS RECALL TO REPLACE YOUR VEHICLE�S CATALYTIC CONVERTER

Dear Jeep Vehicle Owner:

It has been determined that some 1991 through 1995 Jeep, Cherokee, Comanche and Wrangler vehicles equipped with a 2.5L engine, may be in violation of California Emissions Standards.

The Problem is...

What Chrysler and your dealer will do. . .

What you must do.

If you don�t get this done.._o

The catalytic converter on your Jeep vehicle (identified by the Vehicle Identification Number on the enclosed form), may be susceptible to failure. Failure of the catalytic converter could result in hydrocarbon (HC), carbon monoxide (CO) and oxides of nitrogen (NOx) emission levels above the allowable limits, which were established to protect the public health from the dangers of air pollution.

HC emissions consist of unburned fuel that is released into the atmosphere. HC in combination with NOx in the presence of sunlight, can cause the formation of ozone. CO emissions are formed by the incomplete combustion of fuel. These pollutants are the primary components of smog.

Chrysler will repair your vehicle free of charge (parts and labor). To do this, your dealer will replace the catalytic converter. The service will take about one hour but additional time may be required depending on how service work is scheduled and processed.

. * Simply contact your Jeep dealer to schedule a service appointment. Ask the dealer to hold parts for your vehicle or order them prior to your appointment.

* Bring the enclosed Owner Notification Form with you to your dealer. It tells the dealer what service is required for your vehicle.

The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. In addition, the State requires that every vehicle must pass an emission test (SMOG Check) every two years and before it is sold. Without the free service we are providing, your vehicle may be more likely to fail this test and require that you make costly repairs.

Further, in order to ensure your full protection under the emission 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.

How the state knows that the recall has been performed.._a

State of California regulations require Chrysler to provide the Department of Motor Vehicles with a record of all vehicles which have not had the recall service performed. If your vehicle is not on this list, the state will know that the recall has been completed.

Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is completed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof of recall completion.

If you need help... If you have trouble getting your vehicle

repaired, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired.

We are sorry for any inconvenience, but trust you understand our interest in clean air and in your continued satisfaction with our products. Thanks for your attention to this important matter.

Customer Services Field Operations Chrysler Corporation