Safety Recall S89 / NHTSA 16V-907 Crankshaft Camshaft .
February 2017Dealer Service Instructions for:Safety Recall S89 / NHTSA 16V-907Crankshaft Camshaft Sensor Wire HarnessModels20162016(JC) Dodge Journey(MK) Jeep Compass and Jeep PatriotNOTE: This recall applies only to the above vehicles equipped with a 2.0L(sales code ECN or ECT) or 2.4L (sales code ED3 or ED7) engine built fromMay 08, 2016 through July 12, 2016 (MDH 050800 through 071216).IMPORTANT: Some of the involved vehicles may be in dealer new vehicleinventory. Federal law requires you to complete this recall service on thesevehicles before retail delivery. Dealers should also consider this requirement toapply to used vehicle inventory and should perform this recall on vehicles in forservice. Involved vehicles can be determined by using the VIP inquiry process.SubjectThe crankshaft sensor and/or camshaft sensor electrical connector terminal(s) onabout 43,000 of the above vehicles may have been improperly manufactured.Improperly manufactured crankshaft or camshaft sensor electrical connectorterminal(s) could result in an intermittent electrical connection. An intermittentelectrical connection could cause a “no start” condition, the engine to stall whiledriving, and/or the illumination of the Malfunction Indicator Lamp (MIL). Anengine stall event while driving could cause a crash without warning. Copyright 2017, FCA US LLC, All Rights Reservedtdb
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 2Repair The crankshaft sensor electrical connector and terminals must be replaced onall involved (JC) Dodge Journey vehicles. The crankshaft sensor and camshaft sensor electrical connector andterminals must be replaced on all involved (MK) Jeep Compass and Jeep Patriot vehicles.NOTE: A small number of vehicles may have already had one or moreconnectors replaced during a repair process conducted at the assembly plant.If during the repair process it is determined that a particular connector hasalready been replaced it is not necessary to replace that connector a secondtime. On MK vehicles the crank and both cam sensors must ALL beinspected. One connector that was previously replaced does NOT indicatethat other connectors on that vehicle have also been replaced.Alternate TransportationDealers should attempt to minimize customer inconvenience by placing the ownerin a loaner vehicle if the vehicle must be held overnight.
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 3Parts InformationPart NumberDescriptionCSEGS892AA Wiring KitEach package contains the following components:Quantity1Part NumberDescriptionWiring Kit for (JC) Dodge JourneyDescriptionCSEGS891AA Wiring KitEach package contains the following components:Quantity3DescriptionWiring Kit for (MK) Jeep Compass and Jeep PatriotDealers should determine which wire harness kit is required for each vehicleat the time appointments are scheduled to assure that the correct part isavailable when the customer arrives.Parts ReturnNo parts return required for this campaign.Special ToolsThe following specials tools are required to perform this repair: NPNwiTECH micro pod II NPNLaptop Computer NPNwiTECH Software 10042Crimper, Wire/Terminal
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 4Service ProcedureNOTE: (JC) Dodge Journey vehicles: Only the crankshaft position sensorwire harness electrical connector requires replacement. The crankshaftposition sensor is located in the lower right rear of the engine block nearthe transmission bell housing.NOTE: (MK) Jeep Compass and Jeep Patriot vehicles: The crankshaftposition sensor, intake camshaft position sensor and exhaust camshaftposition sensor wire harness electrical connectors all require replacement.The crankshaft position sensor is located in the lower right rear of theengine block near the transmission bell housing. The intake camshaftposition sensor is located near the left rear corner of the engine head. Theexhaust camshaft position sensor is located near the right rear corner ofthe engine head.ENGINE COVER1. (MK) Jeep Compass and JeepPatriot vehicles: Remove and savethe engine cover (Figure 1).Figure 1 – (MK) Engine CoverAIR INLET DUCT2. (MK) Jeep Compass and JeepPatriot vehicles: Unlock the twoair inlet duct retainers.Thenremove and save the fresh air inletduct (Figure 2).RETAINERSFigure 2 – (MK) Air Inlet Duct
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 5Service Procedure [Continued]3. (JC) Dodge Journey vehicles:Remove the battery negative cableremote terminal nut from the batterynegative remote post. Remove andisolate the battery negative cableterminal from the battery negativeremote post (Figure 3).BATTERY NEGATIVE CABLE REMOTE TERMINALFigure 3 – (JC) Battery Negative Cable4. (MK) Jeep Compass and JeepPatriot vehicles: Disconnect andisolate the battery negative cableterminal (Figure 4).5. (MK) Jeep Compass and JeepPatriot vehicles: Remove and savethe three PCM mounting bolts. Notethe location of the PCM groundwire for later reassembly (Figure 5).BATTERY NEGATIVE CABLE TERMINALFigure 4 – (MK) Battery Negative CableGROUND WIREPCM6. (MK) Jeep Compass and JeepPatriot vehicles: Position the PCMaside (Figure 5).PCM MOUNTING BOLTSFigure 5 – (MK) PCM
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 6Service Procedure [Continued]7. (MK) Jeep Compass andJeepPatriotvehicles:Loosen the air inlet tubeclamp at the air cleaner bodyand disconnect the air inlettube from the air cleanerbody (Figure 6).8. (MK) Jeep Compass andJeepPatriotvehicles:Disconnect the make-up airhose from the air cleanerbody (Figure 6).AIR CLEANERBODYMAKE-UPAIR HOSEAIR INLETTUBECLAMPFigure 6 – (MK) Air Cleaner Body9. (MK) Jeep Compass and Jeep Patriot vehicles: Remove and save the boltattaching the air cleaner body support bracket to the strut tower (Figure 7).10. (MK) Jeep Compass andJeep Patriot vehicles: Pullthe air cleaner body upwardto disengage the air cleanerbody locating pins from therubber mounting grommets.11. (MK) Jeep Compass andJeepPatriotvehicles:Remove and save the aircleaner body.AIR CLEANERBODYSUPPORTBRACKETBOLTFigure 7 – (MK) Air Cleaner BodySTRUTTOWER
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 7Service Procedure RNESSRETAINERCLIPSCRANKSHAFTPOSITION SENSORWIREHARNESSFigure 8 – Electrical Wire Harness To Heat Shield Edge Biting Retainer Clips12. Release the two edgebiting retainer clipssecuring the wire harnessto the heat shield(Figure 8).13. Front Wheel Drivevehicles: Disconnect theO2 sensor wire harnesselectricalconnectors(Figure 9).O2 SENSOR ELECTRICALCONNECTORSO2 SENSORWIRE RETAINERHEATSHIELDRETAINERCLIPFigure 9 – Front Wheel Drive Vehicles: O2 SensorWire Harness Electrical Connectors
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 8Service Procedure [Continued]NOTE: On front wheel drive vehicles only, steps 14 through 16 may beperformed from above or below the vehicle per technician preference.14. Remove and save the one nut and two bolts retaining the heat shield(Figure 10).15. Remove and save the heat shield (Figure 10).16. Unlock the connector position assurance (CPA) retainer then disconnect theelectrical connector from the crankshaft position sensor (Figure 10).17. Route the crankshaft position sensor wire harness takeout branch up to the topof the engine compartment for accessibility while splicing the electricalconnector wires.18. Front Wheel Drive vehicles: For improved access to the crankshaft positionsensor electrical connector for wire splicing, the O2 sensor wire retainer may bereleased to provide additional wire harness length (Figures 9 and 10).HEAT SHIELDHEAT SHIELDNUTHEAT SHIELDBOLT M6ELECTRICAL CONNECTORO2 SENSORWIRE RETAINERCPA RETAINERHEAT SHIELDBOLT M6HEAT SHIELDBOLT M8HEAT SHIELDBOLT M8CRANKSHAFT POSITION SENSORFigure 10 – Heat Shield And Crankshaft Position Sensor Electrical Connector
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 9Service Procedure [Continued]19. (MK) Jeep Compass andJeep Patriot vehicles: nector from the exhaustcamshaftpositionsensor(Figure 11).NOTE:Theexhaustcamshaft position sensor islocated near the right rearcorner of the engine head.ELECTRICAL CONNECTORCPA RETAINEREXHAUST CAMSHAFTPOSITION SENSORMIRROR SHOWINGBACK SIDE OFENGINE HEADFigure 11 – (MK) Exhaust Camshaft PositionSensor Electrical ConnectorRETAINER CLIPEXHAUST CAMSHAFTPOSITION SENSOR20. (MK) Jeep Compass andJeepPatriotvehicles:Release the retainer clipattaching the wire harness tothe valve cover fastener stud(Figure 12).WIRE HARNESSFigure 12 – (MK) Wire Harness Retainer Clip21. (MK) Jeep Compass andJeepPatriotvehicles:Unlock the CPA retainer thendisconnecttheelectricalconnector from the intakecamshaftpositionsensor(Figure 13).NOTE: The intake camshaftposition sensor is locatednear the left rear corner ofthe engine head.ELECTRICALCONNECTORINTAKE CAMSHAFTPOSITION SENSORWIRE HARNESSCPA RETAINERFigure 13 – (MK) Intake Camshaft PositionSensor Electrical Connector
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 10Service Procedure [Continued]NOTE: (JC) Dodge Journeyvehicles: Only the crankshaftposition sensor wire harnesselectrical connector requiresreplacement.NOTE: (MK) Jeep Compassand Jeep Patriot vehicles: Thecrankshaft position sensor,intakecamshaftpositionsensor and exhaust camshaftposition sensor wire harnesselectricalconnectorsallrequire replacement.NOTE:Follow the wiresplicing Steps 22-34 for each ofthe affected crankshaft sensorand camshaft sensor electricalconnectorsthatrequirereplacement per vehicle model.ABRASION RESISTANTSLEEVE AND TAPEELECTRICALCONNECTORFigure 14 – Wire Harness Takeout BranchELECTRICALCONNECTORWIRES EXPOSEDFOR SPLICINGNOTE: Wire colors within thewire harness takeout may varydepending on sensor locationand vehicle configuration.Figures 15-25 are for referenceONLY; specific wire colors onthe vehicle may be different.22. Remove the tape and abrasionresistant sleeve from the wireharness takeout branch in orderto expose the wire splice area(Figures 14 and 15).Figure 15 – Splice Area Exposed
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 11Service Procedure [Continued]NOTE: A small number ofvehicles may have already hadone or more connectorsreplaced during a repairprocess conducted at theassembly plant. If the wiretakeout branch looks likeFigure 25 with spliced purplecolor wires and a NEWconnector, it has already beenrepaired. If the connector waspreviously replaced, proceedto Step 35 to retape the wiretakeout branch. On MKvehicles a replaced connectordoes not indicate otherconnectors on that vehiclehave been replaced. All crankand cam sensors must beinspected and repaired if notpreviously repaired.WIRE CUTTERSTAGGER CUT WIRESFOR SPLICINGFigure 16 – Stagger Cut Wire Splice AreasWIRES STAGGER CUT23. Stagger the wire splice areas topreventincreasedharnessdiameter and to retain flexibilityof the wire harness takeoutbranch (Figures 16 and 17).NOTE: Temporally save theremoved connector with wiresattached for reference of wirelengths and wire colors duringthe splicing process.24. Cut the wires to prepare forsplicing (Figures 16 and 17).Figure 17 – Wires Cut In Stagger Pattern
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 12Service Procedure [Continued]NOTE:Thenewwireterminal kit should includethefollowing:connectorhousing, three wires, threesplice bands and three piecesofheatshrinktubing(Figure 18).25. Insert the new wires withterminal ends into the new wireharness connector housing(Figure 19).WIRES WITHTERMINAL ENDSCONNECTOR HOUSINGFigure 18 – Wire Splice Kit ContentWIRESNOTE: The new connectorhousing does not include aconnector position assurance(CPA) retainer lock. This isby design and it is notnecessary to transfer orreplace the CPA.26. Depress the wire terminal lockon the end of the connectorhousing (Figure 19).27. Stagger cut the wire splicelocations on the new connectorto match the wire length of theold connector plus 13 mm(0.50 in.) to compensate for thesplice overlap (Figure 20).HEAT SHRINKTUBINGSPLICE BANDSCONNECTOR HOUSINGDEPRESS WIRETERMINAL LOCKFigure 19 – Assemble Electrical ConnectorSTAGGER CUT WIRES TOMATCH LENGTH OF WIRESON OLD CONNECTOR PLUS13 MM (0.50 IN) FOR SPLICEINSULATION REMOVEDFOR SPLICINGNEW CONNECTOROLD CONNECTORMATCH WIRE LENGTHS28. Remove 13 mm (0.50 in.) ofinsulation from each wire thatneeds to be spliced (Figure 20).Figure 20 – Stagger Cut Wires To MatchWith Vehicle Wire Harness Splice Area
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 13Service Procedure [Continued]HEAT SHRINKTUBINGSPLICE BANDWIRES OVERLAPPEDFigure 21 – Stagger Cut Wire Splice Areas29. Place a piece of adhesivesealant-lined heat shrink tubingsupplied in the kit over the wireon one side of the splice. Becertain the length of tubing willbe sufficient to cover and sealtheentirerepairarea(Figure 21).CRIMPING TOOLWIRESPLICE BAND30. Place the strands of the wiresbeing spliced so that they areoverlapping each other withinthe splice band (Figure 21).31. Using crimping tool 10042 orequivalent, crimp the spliceband and wires togethersecurely (Figure 22).Figure 22 – Use Crimping Tool To CrimpThe Splice Band And Wires Together.
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 14Service Procedure [Continued]CONNECTORSPLICE BANDHEAT SHRINKTUBINGWIRESFigure 23 – Solder The Wire And Splice Band Connection TogetherCAUTION: Never use acid core solder for electrical wiring repairs.32. Using rosin core type solder only and a suitable soldering iron, solder the wireand splice band connection together (Figure 23).33. Center the heat shrink tubing over the splice joint and heat using a suitable heatgun. Heat the joint until the tubing is tightly sealed and sealant begins to oozeout of both ends of the tubing (Figure 24).CONNECTORHEAT SHRINKTUBINGWIRESFigure 24 – Seal The Splice Joint With Heat Shrink Tubing
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 15Service Procedure [Continued]WIRES SPLICEDAND SEALEDCONNECTORFigure 25 – All Three Wires Spliced And Sealed34. Repeat Steps 29-33 for the remaining wires (Figure 25).35. Tape the wire harness takeout branch 13 mm (0.5 in) behind the connector tosecure the branch abrasion resistant sleeve. Then install the abrasion resistantsleeve and tape in place taking care that no wires remain exposed (Figure 26).TAPEaABRASION RESISTANTSLEEVE AND BRASION RESISTANTSLEEVE AND TAPEcFigure 26 – Install Protective Tape And Sleeve To Wire Harness Takeout Branch
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 16Service Procedure [Continued]NOTE: (MK) Jeep Compass and Jeep Patriot vehicles will require thecrankshaft position sensor, intake camshaft position sensor and exhaustcamshaft position sensor wire harness electrical connectors replaced.Complete steps 22-35 for all involved sensor electrical connectors.36. (MK) Jeep Compass and Jeep Patriot vehicles: Connect the electricalconnector to the intake camshaft position sensor (Figure 13). Be sure to tugfirmly on the electrical connector to ensure that the electrical connector issecurely fastened to the sensor.37. (MK) Jeep Compass and Jeep Patriot vehicles: Install the retainer clipattaching the wire harness to the valve cover fastener stud (Figure 12).38. (MK) Jeep Compass and Jeep Patriot vehicles: Connect the electricalconnector to the exhaust camshaft position sensor (Figure 11). Be sure to tugfirmly on the electrical connector to ensure that the electrical connector issecurely fastened to the sensor.39. Route the crankshaft position sensor wire harness takeout branch from the topof the engine compartment down to the crankshaft position sensor.40. Connect the electrical connector to the crankshaft position sensor (Figure 10).Be sure to tug firmly on the electrical connector to ensure that theelectrical connector is securely fastened to the sensor.41. Install the heat shield (Figure 10).42. Install the heat shield fasteners; one nut and two bolts, then tighten the fastenerssecurely (Figure 10).43. Front Wheel Drive vehicles: Connect the O2 sensor wire harness electricalconnectors (Figure 9).44. Front Wheel Drive vehicles: If previously released, secure the O2 sensor wireretainer (Figures 9 and 10).45. Install the two edge biting retainer clips securing the wire harness to the heatshield (Figure 8).
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 17Service Procedure [Continued]46. (MK) Jeep Compass and Jeep Patriot vehicles: Install the air cleaner bodyby pushing the air cleaner body downward to engage the air cleaner bodylocating pins to the rubber mounting grommets.47. (MK) Jeep Compass and Jeep Patriot vehicles: Install the bolt attaching theair cleaner body support bracket to the strut tower (Figure 7). Tighten the boltto 10 N·m (89 in. lbs.).48. (MK) Jeep Compass and Jeep Patriot vehicles: Connect the make-up airhose to the air cleaner body (Figure 6).49. (MK) Jeep Compass and Jeep Patriot vehicles: Connect the air inlet tube tothe air cleaner body then tighten the air inlet tube clamp at the air cleaner body(Figure 6).50. (MK) Jeep Compass and Jeep Patriot vehicles: Position the PCM on top ofthe air cleaner body (Figure 5).51. (MK) Jeep Compass and Jeep Patriot vehicles: Position the PCM groundwire then install the three PCM mounting bolts. Tighten the bolts to 10 N·m(89 in. lbs.) (Figure 5).52. (MK) Jeep Compass and Jeep Patriot vehicles: Connect the battery negativecable terminal to the battery. Tighten the cable clamp nut to 5 N·m (45 in. lbs.)(Figure 4).53. (JC) Dodge Journey vehicles: Position the battery negative cable terminalonto the battery negative remote post. Install the nut to the battery negativeremote post and tighten the nut to 28 N·m (18 ft. lbs.) (Figure 3).54. (MK) Jeep Compass and Jeep Patriot vehicles: Install the fresh air inlet ductthen secure the air inlet duct retainers (Figure 2).55. (MK) Jeep Compass and Jeep Patriot vehicles: Install the engine cover(Figure 1).
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 18Service Procedure [Continued]56. Install a battery charger and verify that the charging rate provides 13.0 to 13.5volts. Do not allow the charger to time out during the flash process. Set thebattery charger timer (if so equipped) to continuous charge.NOTE: Use an accurate stand-alone voltmeter. The battery charger voltmeter may not be sufficiently accurate. Voltages outside of the specifiedrange will cause an unsuccessful flash. If voltage reading is too high, applyan electrical load by activating the park or headlamps and/or HVACblower motor to lower the voltage.57. Connect the wiTECH micro pod II to the vehicle data link connector.58. Place the ignition in the “RUN” position.59. Open the wiTECH 2.0 website.60. Enter your “User id”, “Password” and “Dealer Code” then select “Finish” at thebottom of the screen.61. Starting at the “Vehicle Selection” screen, select the vehicle.62. Verify that all Diagnostic Trouble Codes (DTCs) have been cleared.63. Turn the ignition to the “OFF” position.64. Remove the wiTECH micro pod II from the vehicle.65. Remove the battery charger from the vehicle.66. Return the vehicle to the customer.67. Complete Proof of Correction Form for California Residents.
Safety Recall S89 -- Crankshaft Camshaft Sensor Wire HarnessPage 19Complete Proof of Correction Form for California ResidentsThis recall is subject to the State of California Registration Renewal/EmissionsRecall Enforcement Program. Complete a Vehicle Emission Recall Proof ofCorrection Form (Form No. 81-016-1053) and supply it to vehicle ownersresiding in the state of California for proof that this recall has been performedwhen they renew the vehicle registration.Completion Reporting and ReimbursementClai
remote post (Figure 3). 4. (MK) Jeep Compass and Jeep Patriot vehicles: Disconnect and isolate the battery negative cable terminal (Figure 4). 5. (MK) Jeep Compass and Jeep Patriot vehicles: Remove and
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Dealer Ser vice Instructions for: Safety Recall S89 Crankshaft Camshaft Sensor Wire Harness Models 2016 (JC) Dodge Journe y 2016 (MK) Jeep Compass and Jeep Patriot NOTE: This recall applies only to the above vehicles equipped with a 2.0L (sales code ECN or ) or 2.4L (sales code ED3 or ED7) engine built from May 08, 2016 through July 12 .
2015 May 8 DODGE Recall Manufacturer Recall Issued Recall # R16 2015 May 29 DODGE Recall Manufacturer Recall Issued Recall # R25 2016 Mar 7 Motor Vehicle Dept. Ontario, Canada Canadian Renewal Registration Issued or Renewed New Owner reported Previous Use: Commercial 2016 Jul 1 DODGE Recall Manufacturer Recall Issued Recall # S43
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