EMISSIONS RECALL #617 - OXYGEN SENSOR & CAT. CONV.

1988 Jeep Cherokee

EMISSION RECALL BULLETIN

EMISSIONS RECALL #617 - OXYGEN SENSOR AND CATALYTIC CONVERTER

Model(s): 1989 and 1990 Jeep Cherokee (XJ), Comanche (MJ) and

Wrangler (YJ) Vehicles Equipped With a 2.5L Engine and a Federal Emission Control System and Built After November 27, 1988

Bulletin No.: 617

Date: May, 1995

NOTE: This is an Emission Recall bulletin.

VEHICLES AFFECTED

1989 and 1990 Jeep Cherokee (XJ), Comanche (MJ) and Wrangler (YJ) Vehicles Equipped With a 2.5L Engine and a Federal Emission Control System and Built After November 27, 1988.

SERVICE INFORMATION

Failure of the oxygen sensor and catalytic converter on the listed models, may cause a vehicle to be in violation of U.S Environmental Protection Agency (EPA) Emissions Standards. To correct this condition, the oxygen sensor and catalytic converter must be replaced with improved design parts.

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 DEALERS

Each 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.

PARTS

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 Emission Service Packages, Recall PN C3906170, to service 25% of those vehicles.

Each parts package contains the following components: EMISSION SERVICE PACKAGE

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.

SERVICE PROCEDURE

A. Replace Oxygen Sensor

• Locate the oxygen sensor in the exhaust manifold as shown in
  Fig. 1.

• Disconnect the oxygen sensor electrical connector.

• Remove the oxygen sensor.

• Clean the exhaust manifold threads using a thread chaser.
  NOTE: Do not use solvents or lubricants on threads.

• Install provided oxygen sensor. Tighten to 22 ft-lbs (30 N-m)

• Connect oxygen sensor electrical connector.

Fig. 1: Oxygen Sensor Location B. Replace Catalytic Converter

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

1. Remove and discard the nuts, bolts and gasket at the front of the converter and the exhaust pipe clamp at the rear (see Fig. 2).

NOTE: Use penetrating oil if necessary.

• On Wrangler (YJ) vehicles: Support the transmission and remove the
  skid plate.

• 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.

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

Emissions Control Information Label on the underside of the hood.

D. 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 oxygen sensor and catalytic converter 25617182 0.8 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 429-10-04

P.O. Box 1919

Detroit, Michigan 48231-1919

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 OXYGEN SENSOR AND CATALYTIC CONVERTER

Dear Jeep Vehicle Owner:

Chrysler Corporation has determined that some 1989 and 1990 Jeep Cherokee, Comanche and Wrangler vehicles equipped with a 2 . 5L engine, may be in violation of Federal Emissions Standards.

The Problem is..

What you must do...

The oxygen sensor and catalytic convener on your vehicle (identified on the enclosed form), may be susceptible to failure. This 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.

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.