Dealer Service Instructions for: Customer Satisfaction Notification L10 Coolant Reservoir Outlet Hose

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1 Dealer Service Instructions for: Customer Satisfaction Notification L10 April 2011 Effective immediately all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) #11-015/ Service Bulletin (TSB) # is no longer applicable for the involved vehicles only. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2011 (LC) Dodge Challenger 2011 (LD) Dodge Charger 2011 (LX) Chrysler 300 NOTE: This notification applies only to the above vehicles equipped with a 3.6L engine (sales code ERB) built through February 3, 2011 (MDH ). IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The coolant reservoir outlet hose on about 2,620 of the above vehicles may leak coolant. Engine operation with a low coolant level could cause engine damage and/or low passenger compartment heater output. Copyright 2011, Chrysler Group LLC, All Rights Reserved

2 Customer Satisfaction Notification L10 Page 2 Repair The coolant reservoir outlet hose must be inspected at the coolant reservoir (bottle). Hoses found with a dimension that is greater than in. (7mm) and cannot be adjusted must be replaced. Parts Information Part Number AA Description Hose, Coolant Reservoir IMPORTANT: Due to the small number of involved vehicles, no parts will be distributed to involved dealers initially. Parts may be ordered as needed to support scheduled repairs. Part Number AB Description Coolant, Engine (MSQ: 6 one gallon bottles) NOTE: One gallon of coolant can top off 15 vehicle cooling systems. Special Tools No special tools are required.

3 Customer Satisfaction Notification L10 Page 3 Service Procedure A. Inspect Dimension 1. Open the hood. 2. Locate the coolant reservoir outlet hose (Figure 1). COOLANT RESERVOIR OUTLET HOSE RADIATOR CAP COOLANT RESERVOIR (BOTTLE) AIR CLEANER ASSEMBLY Figure 1 Coolant Reservoir and Outlet Hose Location

4 Customer Satisfaction Notification L10 Page 4 Service Procedure (Continued) 3. Measure the distance from the end of the coolant reservoir outlet hose to the coolant reservoir (bottle) (Figure 2): If the distance is in. (7mm) or less, no further action is required. Close the hood and return the vehicle to the customer. If the distance is greater than in. (7mm), continue with Section B. Adjust. COOLANT RESERVOIR OUTLET HOSE PROTECTIVE SLEEVE COOLANT RESERVOIR (BOTTLE) Figure 2 Dimension

5 Customer Satisfaction Notification L10 Page 5 Service Procedure (Continued) B. Adjust 1. Use the following procedure to remove the radiator cap: On a cold engine, slowly rotate the radiator cap counterclockwise until the radiator cap reaches the first stop (Figure 3). Then push down and rotate the radiator cap counterclockwise to remove the cap completely. WARNING: TO PREVENT SCALDING OR PERSONAL INJURY, THE RADIATOR CAP SHOULD NEVER BE REMOVED WHILE THE ENGINE COOLING SYSTEM IS HOT OR UNDER PRESSURE. On a hot engine, if the engine has been run recently, wait 15 minutes before removing the radiator cap. Then place a shop towel over the radiator cap and without pushing down slowly rotate the radiator cap counterclockwise to the first stop (Figure 3). Allow system pressure to escape through the overflow hose. After the system pressure has been released, push down and rotate the radiator cap counterclockwise to remove the cap completely. COOLANT RESERVOIR OUTLET HOSE RADIATOR CAP AIR CLEANER ASSEMBLY AIR CLEANER OUTLET HOSE CLAMP AIR CLEANER RETAINER SCREW AIR CLEANER OUTLET HOSE Figure 3 Underhood Component Identification

6 Customer Satisfaction Notification L10 Page 6 Service Procedure (Continued) 2. Remove the air cleaner retaining screw at the radiator core support (Figure 3). 3. Loosen the air cleaner outlet hose clamp at the air cleaner assembly and separate the air cleaner outlet hose from the air cleaner assembly (Figure 3). 4. Remove the air cleaner assembly to gain access to the coolant reservoir outlet hose clamp (Figure 3). 5. Release the coolant reservoir outlet hose clamp using hose clamp pliers and position the hose as far forward (in car position) as it will go on the coolant reservoir outlet nipple (Figure 4). COOLANT RESERVOIR OUTLET HOSE CLAMP HOSE CLAMP PLIERS COOLANT RESERVOIR (BOTTLE) SERPENTINE BELT Figure 4 Adjustment

7 Customer Satisfaction Notification L10 Page 7 Service Procedure (Continued) 6. Measure the distance from the end of the coolant reservoir outlet hose to the coolant reservoir (bottle) (Figure 2): If the distance is in. (7mm) or less, continue to Step 7. If the distance is greater than in. (7mm), continue with Section C. Replace. 7. Clean the filler neck sealing surface of the coolant reservoir (bottle). 8. Check the coolant level in the coolant reservoir (bottle) and add coolant if required. NOTE: Coolant being added must be premixed 50% water/50% coolant. 9. Install the radiator cap onto the coolant reservoir (bottle) filler neck (Figure 3). 10. Install the air cleaner assembly (Figure 3). 11. Install the air cleaner assembly retainer screw at the radiator core support (Figure 3). 12. Install the air cleaner outlet hose to the air cleaner assembly and tighten the air cleaner outlet hose clamp (Figure 3). 13. Close the hood and return the vehicle to the customer.

8 Customer Satisfaction Notification L10 Page 8 Service Procedure (Continued) C. Replace 1. Drain and save one gallon of coolant from the radiator into a clean container. 2. Remove the coolant reservoir outlet hose (Figure 1). 3. Transfer the protective sleeve and rear hose clamp (in car position) from the old coolant reservoir outlet hose to the new coolant reservoir outlet hose (Figure 2). 4. Install the new coolant reservoir outlet hose by positioning the end of the hose with the glued on clamp as far forward (in car position) as it will go on the coolant reservoir outlet nipple. Then install the rear section of the coolant reservoir outlet hose until it makes contact with the aluminum heater tube stop bead. 5. Open the bleeder screw on the thermostat housing (Figure 5). ENGINE OIL FILL CAP THERMOSTAT HOUSING BLEEDER SCREW THERMOSTAT HOUSING COOLANT RESERVOIR (BOTTLE) Figure 5 Thermostat Housing Bleeder Screw Location

9 Customer Satisfaction Notification L10 Page 9 Service Procedure (Continued) 6. Clean the filler neck sealing surface of the coolant reservoir (bottle) (Figure 3). 7. Fill the cooling system with the coolant that was removed in Step Once coolant begins to drip from the thermostat housing bleeder screw, close the bleeder screw (Figure 5). 9. Check the coolant level in the coolant reservoir (bottle) and add additional coolant if required. NOTE: Coolant being added must be premixed 50% water/50% coolant. 10. Install the radiator cap onto the coolant reservoir (bottle) filler neck (Figure 3). 11. Install the air cleaner assembly (Figure 3). 12. Install the air cleaner assembly retainer screw at the radiator core support (Figure 3). 13. Install the air cleaner hose to the air cleaner assembly and tighten the air cleaner hose clamp (Figure 3). 14. Rinse any residual coolant from the engine and belly pan as necessary. 15. Close the hood and return the vehicle to the customer.

10 Customer Satisfaction Notification L10 Page 10 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 Chrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use one of the following labor operation numbers and time allowances: Labor Operation Number Time Allowance Inspect Coolant Reservoir Outlet 07-L hours Hose Dimension Inspect and Adjust Coolant Reservoir 07-L hours Outlet Hose Inspect and Replace Coolant Reservoir 07-L hours Outlet Hose Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification 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 Chrysler are being notified of the service requirement by 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.

11 Customer Satisfaction Notification L10 Page 11 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 should 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. 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 notification 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 Service / Field Operations Chrysler Group LLC

12 CUSTOMER SATISFACTION NOTIFICATION L10 COOLANT RESERVOIR OUTLET HOSE Dear: (Name) At Chrysler Group LLC, you can be assured that we are changing the way we look at quality. To prove our commitment to quality, the company is investing in and prioritizing improvements for every vehicle that we build. As part of that commitment, we are also targeting existing vehicles on the road today and contacting our customers to provide these quality improvements, at no charge, that will help to improve your ownership satisfaction. We are recommending the following improvements be performed on some 2011 model year Chrysler 300, Dodge Charger and Dodge Challenger vehicles equipped with a 3.6 liter engine. Recommended Service: What your dealer will do: What you should do: The coolant reservoir outlet hose on your vehicle (VIN: xxxxxxxxxxxxxxxxx) may leak coolant. Engine operation with a low coolant level could cause engine damage and/or low passenger compartment heater output. Chrysler will service your vehicle free of charge (parts and labor). To do this, your dealer will inspect the coolant reservoir outlet hose and replace it if required. The work will take about ½ hour to complete. We recommend that you make an appointment with your dealer to minimize your inconvenience. Simply contact your Chrysler, Jeep, or Dodge dealer, at your convenience, to schedule a service appointment. Your dealer will collect the necessary information to ensure that the appropriate parts are available so your service can be completed in a timely manner. Although not required, we recommend bringing this letter with you to your dealer, when you bring your vehicle in for this service. If you need help: Please contact the Chrysler Customer Assistance Center at If you have already experienced this condition and have paid to have it repaired, please send your original receipts and/or other adequate proof of payment to the following address for reimbursement: Chrysler Customer Assistance, P.O. Box , Auburn Hills, MI , Attention: Reimbursement. Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. Please help us update our records by filling out the attached prepaid postcard, if any of the conditions listed on the card apply to your vehicle. You may also update this information on the web at CCCCCCCCCCCCCCCCCCCCCCCCC We apologize for any inconvenience this service may cause to your schedule. Moving forward we are committed to providing our customers with world class quality products, ensuring that you have a positive dealership experience and following up on any issues and concerns that you may have in a timely manner through our Customer Assistance Center. Sincerely, Customer Service / Field Operations Chrysler Group LLC Notification Code L10

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