1988 JEEP CHEROKEE catalytic converter

\003
EM IS SIO NS R EC ALL # 617 - O XYG EN S EN SO R & C AT. C O NV.

1 988 J e ep C hero ke e
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







\









\









\








\








\









\









\

 
Qty  Description  Qty  Description 






\b



\









\









\



\b




\
\b








\









\









1  Oxygen Sensor  1  Clamp 

1  Catalytic Converter  4  Bolts 

1  Gasket  4  Nuts 

1  Recall Completion Label  1  Instruction Sheet 










\









\









\








\








\









\









\
\f
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
1. Locate the oxygen sensor in the exhaust manifold as shown in
Fig. 1 .
2. Disconnect the oxygen sensor electrical connector.
3. Remove the oxygen sensor.
4. Clean the exhaust manifold threads using a thread chaser.
NOTE: Do not use solvents or lubricants on threads.
5. Install provided oxygen sensor. Tighten to 22 ft-lbs (30 N-m)
6. 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.

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... 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.
What you must do... * 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.
What Chrysler and Chrysler will repair your vehicle free of charge
your dealer will do... (parts and labor). To do this, your dealer will
replace the oxygen sensor and catalytic
converter. The service will take about one hour
but additional time may be required depending on
how service work is scheduled and processed.
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. 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.
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.
We're sorry for any inconvenience, but trust that you understand our
interest in clean air and your continuing satisfaction with our
product. Thanks for your attention to this important matter.
Customer Services Field Operations
Chrysler Corporation

EM IS SIO NS S TA N DAR DS

1988 J e ep C hero ke e
1988 EMISSION & TUNE-UP STANDARDS
MANUFACTURING STANDARDS
Federal and state governments have established air quality
standard during the past 20 years. Automobile manufacturers design
their vehicles to conform to standards where the vehicle will be sold
and operated. These standards cover carbon monoxide (CO), hydrocarbons\
(HC) and oxides of nitrogen (NOx).
Federal and California Standards which must be met by
manufacturers are specified in units easily measured in a testing
laboratory. Since 1970, these standards have been in "grams per mile".
This means no vehicle, whether 2-cylinder or V8, may emit more than a
set weight (in grams) of pollutants for each mile travelled. Since
large engines burn more fuel per mile than do small engines, they must
be "cleaner" per gallon burned if they are to meet these standards.
When manufacturers certify vehicle models prior to sale,
the vehicles are placed on a dynamometer and the exhaust gases are
collected in a bag. After the vehicle runs for a specified time, the
gases are analyzed and weighed. Engines and emission systems are
designed so the weight of emissions will be less than the specified
grams per mile standard.
Infra-red exhaust analyzers are commonly used in vehicle test
stations. The analyzer uses a test probe placed in the exhaust stream
to sample the exhaust gases, and measure the percentage of CO and the
parts per million of HC. These are not the same units used by the
manufacturer when the vehicle is certified. The NOx emissions cannot
be measured by an infra-red exhaust analyzer. Laboratory equipment
must be used to determine NOx emissions.
TUNE-UP STANDARDS
The technician must use the proper specifications when
adjusting the vehicle during a tune-up. The first few years of
emission-regulated vehicles were adjusted using an exhaust gas
analyzer which measured CO and HC.
In the past few years, manufacturers have produced much
cleaner running vehicles. The CO (percentage) and HC (ppm) have beco\
me
very low, especially when measured downstream of catalytic converter.
It has become difficult to measure the effect of fuel and ignition
adjustments.
One solution to this problem for vehicles using carburetors
requires the use of artificially-enriched propane adjustments. The
added propane increases or decreases engine RPM for evaluation of
carburetor rich/lean setting. This allows the technician to check
carburetor setting quickly and accurately.
As computer-controlled systems were developed, it became
possible for the vehicles to adjust the air/fuel ratio, ignition
timing and emission control device operation throughout the entire
driving range. These computer control systems use a variety of sensors
that provide the electronic control unit with information on vehicle
speed, altitude of vehicle operation and transmission gear position,
along with engine operating conditions.
Fuel delivery to achieve a lean air/fuel ratio is controlled
by the computer. The computer controls the on/off (duty cycle) time of\
the fuel injector(s) or carburetor mixture control solenoid to achieve\
leanest possible air/fuel ratio while maintaining good driveability.
Although most repair shops have exhaust gas analyzers,
computer-controlled vehicles normally do not have a CO and HC

\003
* E XH AU ST S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 988 J e ep C hero ke e
GENERAL INFORMATION
Exhaust Systems Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
Exhaust
CATALYTIC CONVERTERS
EXHAUST AND TAIL PIPES
EXHAUST CONNECTIONS
HANGERS
HEAT RISERS (MECHANICAL EFE DEVICES)
HEAT SHIELDS
MANIFOLDS (CAST AND TUBE TYPE)
MECHANICAL EFE DEVICES
MUFFLERS AND RESONATORS
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication

1 - Part is close to the end of its useful life (just above
discard specifications, or weak; failure likely to occur
soon, etc.)
2 - To address a customer need, convenience, or request (to
stiffen ride, enhance performance, eliminate noise,
etc.)
3 - To comply with maintenance recommended by the vehicle's
Original Equipment Manufacturer (OEM)
4 - Technician's recommendation based on substantial and
informed experience
NOTE: Suggested services are always optional. When presenting
suggested repairs to the customer, you must present
the facts, allowing the customer to draw their own
conclusions and make an informed decision about how to
proceed.
EXHAUST
SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER
VEHICLE OPERATION
WARNING: Federal EPA rules prohibit altering an exhaust system in
any way that defeats the emission reduction components of a
vehicle. Be sure to review and adhere to EPA policy on
removing and replacing catalytic converters. Where state or
local laws are stricter, they take precedence over these
guidelines.
NOTE: Some exhaust systems are of a welded design. It is not
required that the entire system be replaced. Determine the
need to replace individual components based on conditions of
component.
CATALYTIC CONVERTERS
CAUTION: Before working on an exhaust system, review EPA
regulations on removing and replacing catalytic converters.
NOTE: Any time a converter has failed, further diagnosis is
required to determine the reason(s) for converter failure.
CATALYTIC CONVERTER INSPECTION









\









\









\









\









\









\









\


Condition Code Procedure
Air injection tube
broken ................. A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
burnt .................. A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
leaking ................ A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube