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Emissions Recall F47 Catalytic Converter And Reprogram Pcm (F47)

Publication date: 2007-03-01
Reference number: F47
Supersedes refnos: 11-002-06

EMISSIONS RECALL F47 CATALYTIC CONVERTER AND REPROGRAM PCM

EMISSIONS RECALL F47 CATALYTIC CONVERTER AND REPROGRAM PCM

SERVICE CAMPAIGN BULLETIN

Reference Number(s): F47, Date of Issue:  March 2007
CHRYSLER: 2006 (LX) Chrysler 300, Dodge Magnum and Charger
Superceded Bulletin(s): 11-002-06 Rev A, Date of Issue:  April, 2006
NOTE: Effective immediately all repairs on involved vehicles are to be performed according to this notification. Service Bulletin (TSB) #11-002-06 Rev A has been cancelled.

MODEL

2006 (LX) Chrysler 300, Dodge Magnum and Charger 

NOTE: This recall applies only to the above vehicles equipped with either a 2.7L or 3.5L engine  ("G, T, R or V" in the 8th VIN position), with California Emissions or 50-States Emissions (sales code NAE  or NAS  ), through November 10, 2005 (MDH: 111010).
IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery  . Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.

SUBJECT

The mini catalytic converter on about 350 of the above vehicles may fail and damage the downstream catalytic converter. This may cause the vehicle to release air pollutants which exceed Federal and California standards.

REPAIR

The right and left front exhaust catalyst assemblies must be replaced and the PCM must be reprogrammed (flashed).

PARTS INFORMATION

Each vehicle  requires application of the following label:

PARTS INFORMATION

Part Number Description
04275086AB Authorized Modifications Label

Due to the likelihood that the required Authorized Modifications Label is already in your parts inventory, no labels will be distributed to involved dealers initially. Labels may be ordered as needed to support scheduled repairs.

Front Exhaust Catalyst Assembly

NOTE: The DealerCONNECT VIP function lists the appropriate part numbers fore each involved vehicle.
FRONT EXHAUST CATALYST ASSEMBLY PART NUMBERS CHART

Engine (Sales Code) Trans Sales Code Emissions Sales Code Drive Train Right Front Exhaust Catalyst Assembly P/N Left Front Exhaust Catalyst Assembly P/N
2.7L (EER)
3.5L (EGG)		 DG6
DGJ		 NAE RWD 04578466AA or 04578466AB 04578467AA or 04578467AB
3.5L (EGG) DG6 NAS RWD 68002134AA(*) 68002135AA(*)
3.5L (EGG) DGJ NAE
NAS		 AWD 04581754AE(*) 04581755AE(*)

Each dealer  , to whom vehicles in the recall were assigned, will receive enough right and left front exhaust catatlyst assemblies to service 100% of those vehicles. Parts denoted with an asterisk (*) will NOT be distributed initially because very few vehicles were built. Please order these parts only as needed. 

SPECIAL TOOLS

The following special tools are required to perform this repair: 

SERVICE PROCEDURE

A. Replace Right and Left Front Exhaust Catalyst Assemblies

  1. Raise the vehicle on a suitable hoist.
  2. Disconnect the electrical harness connector from the left downstream oxygen sensor.
  3. Remove the right downstream oxygen sensor connector from the transmission support crossmember.
  4. Disconnect the electrical harness connector from the right downstream oxygen sensor.
  5. Remove both the left and right downstream oxygen sensors from the exhaust catalyst assemblies using special tool C-4907.
  6. Remove the brace (if so equipped) at the rear of front exhaust catalyst assemblies (Figure 1  ).
    G07706545
  7. Loosen the two clamps holding the right and left front exhaust catalyst assemblies to the "Y" collector pipe (Figure 2  ).
    G07706546
  8. Remove the front and rear resonator isolator hanger bolts.
  9. Separate the remaining rubber isolator hangers from the exhaust system (Figure 1  ).
  10. Support the muffler and tailpipe assembly with a suitable jack.
  11. Separate the exhaust system at the "Y" connector from the right and left exhaust catalyst assemblies (Figure 2  ).
  12. Remove the left exhaust catalyst assembly heat shield and nuts at the exhaust manifold ball flange
  13. Remove left exhaust catalyst assembly to exhaust manifold flange nuts.
  14. Remove the right exhaust catalyst assembly to exhaust manifold flange nuts.
  15. Remove both right and left exhaust catalyst assemblies from the vehicle.
  16. Position the new left front exhaust assembly to the exhaust manifold and tighten the flange nuts to 106 in. lbs. (12 N.m).
  17. Position the new right front exhaust assembly to the exhaust manifold and tighten the ball flange nuts to 106 in. lbs. (12 N.m).
  18. Connect the right and left exhaust catalyst assemblies to the "Y" collector pipe (Figure 1  ).
  19. Install the exhaust system rubber isolator onto the hangers.
  20. Install the front and rear resonator isolator hanger bolts. Tighten the bolts to 215 in. lbs. (25 N.m).
  21. Align the exhaust system so that the clearance between:
    1. Exhaust system and the fuel tank is a minimum of 5/8 in. (16 mm).
    2. Exhaust pipe and the tunnel reinforcement brace clearance is between 5/8" to 3/4" (16 mm to 20 mm).
  22. Tighten the two band clamps at the "Y" collector pipe to 36 ft. lbs. (50 N.m).
  23. Tighten the nuts to both the right and left front exhaust assembly ball flange joints to 25 ft. lbs. (34 N.m).
  24. Install the right front exhaust pipe heat shield nuts at the exhaust manifold ball flange. Tighten the bolts to 98 in. lbs. (10 N.m).
  25. Install the front exhaust pipe brace (if so equipped). Tighten the two bolts to 40 ft. lbs. (55 N.m).
  26. Install both left and right downstream oxygen sensors and tighten to 30 ft. lbs. (40 N.m).
  27. Connect the right electrical harness connector from the right downstream oxygen sensor.
  28. Attach the right downstream oxygen sensor connector to the transmission support crossmember.
  29. Connect the left electrical harness connector to the left downstream oxygen sensor.
  30. Lower the vehicle. Continue to Section B - Reprogram the PCM. 

B. Reprogram the Powertrain Control Module

NOTE: This procedure must be performed with release 7.03 or later. A CD containing software release 7.03 was sent to each dealer at the end of January, 2007. If the reprogramming flash for the PCM is aborted or interrupted, repeat the procedure.
  1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge.
    NOTE: Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the headlamps and/or HVAC blower motor to lower the voltage.
  2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop.
  3. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle.
  4. Place the Ignition in the "RUN"  position, then Power "ON"  the StarSCAN.
  5. Retrieve the old PCM part number. With the StarSCAN on the "Home"  screen, follow the procedure below:
    1. Select "ECU View" 
    2. Touch the screen to highlight "PCM"  in the list of modules.
    3. Select "More Options"  .
    4. Select "ECU Flash"  .
    5. Record the "Part Number"  displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM"  screen for later reference.
  6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM"  screen, follow the procedure below:
    1. Select "Browse for New File".  Follow the on screen instructions.
    2. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step  e, then the PCM is up to date. Continue to Step 10.
    3. Highlight the listed calibration on the StarSCAN screen.
    4. Select "Download to Scantool"  .
    5. Select "Close"  after the download is complete, then select "Back" 
    6. Highlight the listed calibration.
    7. Select "Update Controller"  and follow the on screen instructions.
    8. When the update is completed, select "OK"  .
  7. Disconnect the CH9404 StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected"  , then press "OK"  .
  8. Reconnect the CH9404 StarSCAN vehicle cable to the vehicle.
  9. Retrieve the PCM part number. With the StarSCAN on the "Home"  screen, follow the procedure below:
    1. Select "ECU View"  .
    2. Touch the screen to highlight "PCM"  in the list of modules.
    3. Select "More Options" 
    4. Select "ECU Flash"  .
    5. Verify the "Part Number"  (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully.
  10. Clear any Diagnostic Trouble Codes (DTCs) as follows:
    NOTE: Due to the PCM programming procedure, DTCs may be set in other modules (ABS, TCM, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate.
    1. From the "Home"  screen select "System View"  .
    2. Select "All DTCs"  .
    3. Press "Clear All Stored DTCs"  if there are any DTCs shown on the list.

C. Install the Authorized Modifications Label

  1. Type or print (with a ballpoint pen) the necessary information shown in Figure 3  onto the Authorized Modifications Label.
  2. Attach the label near the VECI label and close the hood.
    G07706547

D. Complete Proof of Correction Form for California Residents

This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program  . Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053)  and supply it to vehicle owners residing in the state of California  for proof that this recall has been performed when they renew the vehicle registration.

COMPLETION REPORTING AND REIMBURSEMENT

Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments.

Use the following labor operation number and time allowance:

LABOR OPERATION NUMBER AND TIME ALLOWANCE

  Labor Operation Number  Time Allowance
Replace the right and left exhaust catalyst assemblies only. PCM already updated. 11-F4-71-82 1.1 hours
Replace the right and left exhaust catalyst assemblies and reprogram the PCM. 11-F4-71-83 1.3 hours

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

NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

PARTS RETURN

The old right and left front exhaust catalyst assemblies must be returned to the Warranty Material Return Center.

DEALER NOTIFICATION

All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification.

OWNER NOTIFICATION AND SERVICE SCHEDULING

All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is attached.

Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable.

VEHICLE LISTS, GLOBAL RECALL SYSTEM, VIP AND DEALER FOLLOW UP

All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.

GRS provides involved dealers with an updated  VIN list of their incomplete  vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission.

To use this system, click on the "Service"  tab and then click on "Global Recall System."  Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence.

Dealers must perform this repair on all unsold vehicles before retail delivery  . Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair.

Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. 

ADDITIONAL INFORMATION

If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager.

Customer Services Field Operations

DaimlerChrysler Corporation

EMISSIONS RECALL F47 - MINI CATALYTIC CONVERTER

Dear: (Name)

DaimlerChrysler has determined that some 2006 Chrysler 300, Dodge Magnum and Charger vehicles may be releasing air pollutants which exceed Federal and California standards.

The problem is...  The mini catalytic converters on your vehicle (VIN: xxxxxxxxxxxxxxxxx) may fail and damage the downstream catalytic converter.

What your dealer will do... DaimlerChrysler will repair your vehicle free of charge (parts and labor)  . To do this, your dealer will replace the right and left exhaust catalytic converter assemblies and reprogram the powertrain control module on your vehicle. The work will take about 1 1/2 hours to complete. However, additional time may be necessary depending on service schedules.

What you must do...  Simply contact your dealer  right away to schedule a service appointment. Ask the dealer to hold the part for your vehicle or to order it before your appointment.

If you need help...  If you have questions or concerns which your dealer is unable to resolve, please contact DaimlerChrysler at 1-800-853-1403.

California residents... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal.  Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is performed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof that the recall has been performed.

Please help us update our records, by filling out the attached prepaid postcard, if any of the conditions listed on the card apply to you or your vehicle.

If you have already experienced this condition and have paid to have it repaired, you may send your original receipts and/or other adequate proof of payment to the following address for reimbursement: DaimlerChrysler P.O. Box 4639 Oak Ridge, TN 37831, Attention: Reimbursement.

In order to ensure your full protection under the emission warranty made applicable to your vehicle by 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 are sorry for any inconvenience but trust that you understand our interest in clean air. Thank you for your attention to this important matter.

Customer Services Field Operations

DaimlerChrysler Corporation

Notification Code F47

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