Engine - Gasoline Engine Diagnostic Inspection Procedure
NUMBER: 09-001-13GROUP: Engine
DATE: February 06, 2013
SUBJECT:
Gasoline Engine Diagnostic Inspection Procedure
OVERVIEW:
This bulletin provides a procedure to determine repair versus replacement of a gasoline long block engine assembly. This procedure is to be used prior to conducting any engine related repairs or removal of engine components.
MODELS:
2007 - 2008 CS Pacifica
2007 - 2008 DR Ram 1500 Pickup
2009 - 2013 DS Ram 1500 Pickup
2007 - 2009 DH Ram 2500 Pickup
2010 - 2013 DJ Ram 2500 Pickup
2007 - 2009 D1 Ram 3500 Pickup
2013 D2 Ram 3500 Pickup
2009 DC Ram 3500 Cab Chassis
2012 - 2013 DD Ram 3500 Cab Chassis
2007 - 2009 HB Durango
2009 HG Aspen
2007 - 2013 JK Wrangler
2007 - 2013 JS Sebring/200/Avenger
2007 KJ Liberty
2008 - 2012 KK Liberty
2007 - 2011 KA Nitro
2007 - 2013 LX 300/Magnum/Charger
2011 - 2013 LD Charger
2008 - 2013 LC Challenger
2007 - 2013 MK Compass/Patriot
2007 - 2012 PM Caliber
2007 - 2010 PT PT Cruiser
2007 - 2011 ND Dakota
2007 RS Town & Country/Voyager/Grand Caravan
2008 - 2013 RT Town & Country/Grand Caravan
2007 - 2013 WK Grand Cherokee
2007 - 2010 XK Commander
2009 - 2013J C Journey
2012 - 2013 WD Durango
2013 PF Dart
2012 - 2013 FF Fiat 500
NOTE:
This bulletin applies to vehicles equipped with a gasoline engine repaired in the United States and Canada only.
DIAGNOSIS:
Engine Noise Diagnosis
1. Does engine exhibit an audible knock or tapping type noise at normal operating temperature?
a. Yes >>> Proceed to Step 2.
b. No >>> No further action necessary.
2. Perform Injector Kill Test (note: Injector Kill test may not be available on wiTECH for all vehicles. Manual injector deactivation may be necessary). Does the engine noise change in sound/intensity?
a. Yes >>> Remove engine oil pan and inspect connecting rod and main bearings for damage, then proceed to Step 3.
b. No >>> Continue normal diagnosis to pinpoint cause of noise, then proceed to Step 3.
3. Complete the Repair/Replace Powertrain Worksheet (70% rule analysis) available in TechCONNECT > Repair Information > Diagnostic Check Sheets > Repair Replace Worksheet.
Oil Consumption Diagnosis
1. Perform the Oil Consumption Test located in TechCONNECT > Service Info > 09 - Engine > Diagnosis and Testing>Oil Consumption Test and Diagnosis.(Note: This procedure can be found utilizing any 2011 Model Year and later Year/Model/Engine selection)Did the vehicle pass the Oil Consumption Test?
a. Yes >>> No further action necessary.
b. No >>> Proceed to Step 2.
2. Check the Positive Crankcase Ventilation(PCV) system. Make sure the system is not restricted and the PCV valve has the correct part number and correct vacuum source (18-20 in. Hg at idle below 3000 ft. above sea level is considered normal). Were any issues noted?
a. Yes >>> Repair as necessary.
b. No >>> Proceed to Step 3.
3. Perform a Cylinder Compression Test and record the results.(Note: Refer to the applicable service information for the vehicle in question to locate Cylinder Compression Test Specifications)
4. Perform a Cylinder Leak Down Test (Note: Cylinder leakage should not exceed 15%) Did the vehicle pass the Cylinder Compression Test and Cylinder Leak Down Test?
a. Yes >>> No further action necessary.
b. No >>> Continue normal diagnosis to pinpoint cause of failure then complete the Repair/Replace Powertrain Worksheet (70% rule analysis) available in TechCONNECT > Repair Information> Diagnostic Check Sheets > Repair Replace Worksheet.
POLICY:
Reimbursable within the provisions of the warranty.
NOTE:
These labor operation numbers are only to be used when repair exceeds 70% of the cost of engine long block assembly replacement. Also, these labor operation numbers are to be used in conjunction with a corresponding primary labor operation number.
NOTE:
Returned engine assemblies received with missing components are subject to warranty part return chargebacks. See Warranty Administration Manual, Parts Section, Warranty Parts Return (United States Only).
NOTE:
Warranty repairs claiming any engine long block replacement Labor Operation Numbers must include a completed Diagnostic Check Sheet. Refer to US Warranty Bulletin D-13-03 or Canadian Warranty Bulletins 2013-01/2012-11, available in DealerCONNECT under: efiles>Service>Warranty>CDJR Bulletins (Canada: efiles>Service>Warranty>Service Administration Bulletins), for additional information.
TIME ALLOWANCE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.