Recall - Emissions System Modification
No.542February, 1994
To: All Dodge and Chrysler-Plymouth Dealers
Subject:
Emissions Recall # 542 -- CO and NOx Emissions
Models:
1986 Model Year Dodge 600, Lancer, Omni GLH, Shelby Charger and Daytona; Plymouth Caravelle; and Chrysler New Yorker, Laser, LeBaron, Town & Country, LeBaron GTS and Limousine Vehicles Equipped With a 2.2L Turbocharged Engine and Federal Emissions Control System.
Carbon monoxide (CO) and oxides of nitrogen (NOx) levels for the listed model vehicles may exceed the limits allowed by Federal Emissions Standards. To correct the condition, the oxygen sensor and EGR backpressure transducer must be replaced and the exhaust pipe must be insulated.
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.
All other dealers: Each Dodge and Chrysler-Plymouth 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.
Three unique parts packages are required for this recall depending upon the vehicle being serviced. See illustration for the proper part application.
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 to service 25% of the affected vehicles.
Each parts package contains the following components:
Quantity Description Quantity Description
1 Oxygen Sensor 1 Insulation Wrap -- Rear
1 EGR Backpressure Transducer 6 Clamp
1 Insulation Wrap - Front 1 Instruction Sheet
Owner Notification and 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 owner notification letter is attached.
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 EGR Backpressure Transducer:
1. Disconnect vacuum source hose, backpressure signal tube and vacuum hose to EGR valve from the EGR backpressure transducer (Figure 1).
2. Install the supplied backpressure transducer in the orientation shown in Figure 1.
3. Connect both vacuum hoses and the backpressure signal tube to the backpressure transducer.
B. Replace Oxygen Sensor:
CAUTION:
Use care in working around sensor as the exhaust manifold may be extremely hot.
1. Disconnect the oxygen sensor electrical connector.
2. Remove the oxygen sensor using Special Tool C-4589.
3. Clean the exhaust manifold threads with a thread chaser.
NOTE:
Do not use solvents or lubricants on threads.
4. Install provided oxygen sensor. Tighten to 20 ft-lbs (27 Nom).
5. Connect oxygen sensor electrical connector.
C. Install Exhaust Pipe Insulation Wrap:
1. Raise vehicle on hoist to access front exhaust pipe in front of catalytic converter.
2. Install the upper and lower halves of the front insulation wrap on the exhaust pipe in front of the exhaust clamp (Figure 2).
3. Loosely install three (3) clamps over the insulation wrap. Locate clamps in the center and approximately 2 inches from each end.
NOTE:
On Dodge Omni GLH and Shelby Charger (L-Body) vehicles evenly space two (2) clamps on the front insulation wrap and four (4) clamps on the rear insulation wrap.
4. Align the insulation wrap to provide a good fit and adequate clearance to floor pan and exhaust heat shields.
5. Carefully tighten clamps to secure insulation wrap in position.
NOTE:
Only tighten clamps enough to hold insulation in place. Do not crush or collapse insulation.
6. Repeat Steps 2 through 5 to install the rear insulation wrap between the exhaust clamp and the catalytic converter (Figure 3).
7. Lower vehicle.
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 EGR backpressure 25542182 0.4 Hours
transducer; and install exhaust insulation wrap
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
Parts Return
Initially, a small number of oxygen sensors and backpressure transducers are required to be returned to the Warranty Material Return Center. When an adequate number of returned parts have been accumulated, Parts Return Documents will no longer be generated and parts are to be discarded.
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.
Dear Chrysler Vehicle Owner:
Chrysler Corporation and the Environmental Protection Agency have determined that your 1986 Chrysler vehicle, with a 2.2 liter turbocharged engine, may be in violation of Federal Emissions Standards. Carbon monoxide and oxides of nitrogen levels could be above the allowable limits which were established to protect the public health from the dangers of air pollution. For this reason, we are asking you to return your vehicle -- identified by the Vehicle Identification Number on the enclosed form -- to your dealer for a special service repair. This service will be provided free of charge.
The needed instructions and parts have been sent to all Dodge and Chrysler-Plymouth dealers. The service will not hurt your engine performance or fuel economy. To obtain this free service:
^ Contact your dealer as soon as possible to make a service appointment.
^ Take the enclosed Owner Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and recall for which service is required.
^ The dealer will replace the oxygen sensor and exhaust gas recirculation (EGR) backpressure transducer. The exhaust pipe will also be insulated. The service will take about one half hour, but additional time may be required depending on how service appointments are scheduled and processed.
In order to ensure your full protection under the emission warranty made applicable to your vehicle under Federal law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair your vehicle may fail a state or local emission inspection test.
If you have any problem obtaining the service, please call the Chrysler Customer Center, toll free, at (800) 992-1997. A representative will assist you in getting your vehicle repaired. If you are still unable to obtain the repair as described in this letter within a reasonable time, you may also contact the Manufacturers Operations Division of the Environmental Protection Agency (6405J), 401 M Street S.W., Washington, D.C. 20460.
We regret any inconvenience this action may cause, but trust you understand our interest in clean air and in your continuing satisfaction with our product. Thank you for your prompt attention to this important matter.