Date: 120608
Engine Controls - MIL ON/DTC's P0420 Or P0430
NUMBER: 11-003-12
GROUP: Exhaust System
DATE: June 08, 2012
THIS SERVICE BULLETIN IS ALSO BEING RELEASED AS RAPID RESPONSE
TRANSMITTAL (RRT) 12-038. ALL APPLICABLE SOLD AND UN-SOLD RRT VIN's
HAVE BEEN LOADED. TO VERIFY THAT THIS RRT SERVICE ACTION IS
APPLICABLE TO THE VEHICLE, USE VIP OR PERFORM A VIN SEARCH IN
TECHCONNECT. ALL REPAIRS ARE REIMBURSABLE WITHIN THE PROVISIONS OF
WARRANTY.
SUBJECT:
Long Term Exhaust System Durability And/Or MIL Illumination
OVERVIEW:
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This bulletin involves inspecting the Julian Date on JK vehicles and only if necessary replacing the Y-Pipe. For RT vehicles it will be necessary to
replace the front catalytic converter and gasket on all vehicles.
MODELS:
2012 (JK) Wrangler
2012 (RT) Caravan/ Town and Country
NOTE:
This bulletin applies to RT vehicles equipped with an 3.6L engine (Sales code ERB) built between December 12, 2011 (MDH 1212XX) and
December 13 (MDH 1213XX) and JK vehicles equipped with an 3.6L engine (Sales code
EAB) built between December 12, 2011 (MDH 1212XX) and December 16 (MDH 1216XX).
SYMPTOM/CONDITION:
The MIL light could be illuminated and further investigation by the Technician could find that Diagnostic Trouble Code(s) P0420 - Catalyst
Efficiency (Bank 1) or P0430 - Catalyst Efficiency (Bank2) has been set active or stored.
If a customers VIN is listed in VIP or your RRT VIN list, or the condition is present perform the Diagnosis.
DIAGNOSIS:
1. Is the vehicle a RT?
a. Yes -> proceed to RT Repair Procedure.
b. No -> proceed to Step # 2.
2. Raise vehicle on hoist.
3. Remove skid plate (Fig. 1).
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4. Locate y-pipe, using a grey scuff pad, lightly sand the surface to a matte like appearance (Fig. 2).
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5. Using a mirror, inspect the Julian Date ((Fig. 3) and (Fig. 4)).
6. Is the Julian Date "34611"?
a. Yes >>> proceed to Step # 7
b. No >>> This bulletin does not apply return vehicle to inventory/customer. If DTC's are set it will be necessary to perform the appropriate
diagnostic procedures available in DealerCONNECT/TechCONNECT.
7. Is the sequence Date "5198 through 5520"?
a. Yes >>> proceed to JK Repair Procedure.
b. No -> This bulletin does not apply return vehicle to inventory/customer. If DTC's are set it will be necessary to perform the appropriate
diagnostic procedures available in DealerCONNECT/TechCONNECT.
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PARTS REQUIRED:
RT REPAIR PROCEDURE:
1. Disconnect negative battery cable.
2. Disconnect upstream 02 sensor connector.
3. Hoist vehicle.
4. Disconnect downstream 02 sensor connector.
5. Saturate the exhaust fasteners with Mopar rust penetrant. Allow 5 minutes for penetration.
6. Remove the two front Catalytic to cross under pipe bolts.
7. Remove the bolt from the front motor mount.
8. Remove rear motor mount heat shield.
9. Remove the bolt from the rear motor mount.
10. Using a long pry bar rock motor forward and block to support motor in the forward position (Fig. 5).
11. Remove the 2 nuts at rear catalytic converter cross under pipe.
NOTE:
It may be necessary to heat the studs for ease of removal.
12. Remove the two studs on the cross under pipe.
13. Remove the bolts on the cross under pipe support bracket.
14. Remove the two front catalytic converter bolts.
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15. Remove the front catalytic converter support bracket bolts.
16. Clean cross under pipe flange.
17. Replace the front catalytic converter and gasket. Refer to the detailed service procedures available in DealerCONNECT > TechCONNECT
under: Service Info > 11-Exhaust System> Converter, Catalytic removal and installation.
JK REPAIR PROCEDURE:
1. Saturate the studs and nuts (13) & (3 ) with Mopar rust penetrant. Allow 5 minutes for penetration (Fig. 6).
2. Remove the isolator (1) from rod hanger on the extension pipe (4).
3. Loosen the nut on the clamp (3) to the extension pipe and pull the extension pipe (4) rearward until it fully disengages from the exhaust pipe
assembly (12).
4. Remove the bolts (13) on exhaust pipe assembly 2 per side.
5. Pull the y-pipe (12) until it comes off the pipe and converter assembly.
6. Discard y pipe.
7. Install new y-pipe (p/n68085142ab). Position the y-pipe (12) into the exhaust pipe with converters (5).
8. Loosely position the fasteners (13) to the y-pipe with converters (5).
9. Install exhaust y-pipe (12) to the exhaust front pipe (5).
10. Install the isolator (1) to the exhaust extension pipe (4).
NOTE:
Make sure the exhaust pipe/exhaust system is aligned and has the proper clearance. The minimum clearance is 21 mm . Make the necessary
adjustments, if needed before tightening.
11. Tighten the y-pipe (12) to front exhaust pipe with catalytic converter flange (5) to 25 N-m (18.5 ft. lbs.).
12. Tighten the y-pipe extension (12) to front exhaust pipe with converters (5) to 55 N-m (40 ft. lbs). Follow the torque Sequence : Run Left hand
screws in 1-2-1 sequence Run Right hand screw in 1-2-1 sequence.
NOTE:
Make sure there is uniformity of the flanges, they are parallel.
13. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
POLICY:
Reimbursable within the provisions of the warranty.
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