2021-2022 Jeep Wrangler Coolant Leak Notification ZD8

Fiat Chrysler Automobiles (FCA) has released Customer Satisfaction Notification ZD8 to address a potential coolant leak issue in certain 2021-2022 Jeep Wrangler vehicles. This notification, last revised on May 3, 2024, aims to prevent engine damage caused by loose coolant inlet tube fasteners. The repair is covered by FCA and involves a specific procedure to secure these fasteners properly.

Symptoms of the 2022 Jeep Wrangler Coolant Leak

Owners of affected 2021-2022 Jeep Wrangler vehicles, specifically those equipped with the 2.0L engine (sales codes EC1, EC3, and ECX), may notice a coolant weep or drip. This condition arises when the coolant inlet tube fasteners become loose. If left unaddressed, this coolant loss can cause the engine to overheat, potentially leading to severe engine failure. The Customer Satisfaction Notification ZD8 is designed to proactively fix this issue.

Important Warnings for Owners and Technicians

FCA emphasizes several critical safety warnings related to this repair, especially concerning the high-voltage system in PHEV-equipped vehicles and handling the cooling system:

• Cooling System Pressure: Do not remove or loosen the coolant pressure cap, cylinder block drain plugs, or the draincock when the system is hot and under pressure because serious burns from the coolant can occur.
• PHEV High Voltage Safety: For PHEV-equipped vehicles, technicians must ensure the high voltage system is powered down correctly. Do not plug in the EVSE Recharge Coupler when working on the vehicle. After turning off the ignition and moving keys at least 20 feet away, wait five minutes to allow the high voltage system to shut down without setting a fault code.
• Voltage Checks: When working on PHEV models, verify that the vehicle's electrical system is powered down by measuring voltage at specific test points. While some residual voltage (up to 2.0 volts) may be normal due to capacitors, anything less than 1.0 volts is generally considered safe for work.

Diagnosis and Trigger Conditions

The primary cause of the 2022 Jeep Wrangler coolant leak is identified as loose coolant inlet tube fasteners. These fasteners, located on the water pump inlet tube, can loosen over time, allowing coolant to seep out. This weep can then progress into a noticeable drip. The issue affects approximately 90,811 vehicles in the U.S.

Repair Procedure Summary

The repair procedure for Customer Satisfaction Notification ZD8 involves securing the coolant inlet tube fasteners to prevent leaks. For PHEV-equipped vehicles, specific high-voltage system lockout steps must be followed before proceeding with the mechanical repair.

PHEV High Voltage System Power Down (if applicable):

1. Use a scan tool to check for active or stored "stuck contactors" DTCs. Address any DTCs before proceeding, as they can prevent proper high voltage system shutdown.
2. Disconnect any charging equipment and ensure the EVSE Recharge Coupler is not plugged in.
3. Turn the ignition to "Off" and move keys at least 20 feet away. Wait five minutes for the high voltage system to power down.
4. Disconnect and isolate the negative battery cable from the 12-volt battery.
5. Access the high voltage test points cover (located on the battery pack, behind the driver's side seat) and remove the M6 Torx screws.
6. Remove the cover to open the internal High Voltage Interlock (HVIL) loop.
7. Use an insulation tester, such as the Fluke Meter, Multi 126-1587, to perform multimeter functionality tests and verify the high voltage system is powered down. Measure voltage at high voltage positive and negative test points, and between the Power Distribution Center (PDC) positive battery cable connection and chassis ground. Readings should ideally be 0 volts, with anything less than 1.0 volts considered safe.

Coolant Inlet Tube Fastener Repair:

1. Raise and support the vehicle.
2. Remove one of the coolant inlet tube fasteners (as shown in Figure 3 of the service document, which depicts the water pump inlet tube screws).
3. Clean the threads of the fastener.
4. Apply Thread Loc (thread sealant) to the threads.
5. Reinstall the fastener and tighten it to 11 N·m (8 ft. lbs.).
6. Repeat this process for the other fastener.

System Reassembly and Checks:

1. For PHEV-equipped vehicles, install the high voltage test points access cover to close the internal HVIL loop and install the M6 Torx screws.
2. Reconnect the 12-volt negative battery cable.
3. For PHEV-equipped vehicles, clear any DTCs that may have set due to the power down procedure.
4. Check the coolant level and add fluid as necessary.
5. Perform a final check for any coolant leaks.
6. Return the vehicle to the customer.

Required Parts

The repair requires specific materials to ensure the coolant inlet tube fasteners remain secure.

• Part Number 04318031: Lock & Seal Adhesive (MS-90061) MSQ of 12. One tube of this adhesive is sufficient for multiple vehicles. Dealers are instructed not to charge for the entire tube on each claim.

No special tools are required for this service procedure. The labor operation number for adding Thread Loc to inlet tube fasteners is 07-ZD-81-82, with an allowance of 0.5 hours. For PHEV vehicles, a related labor operation number 08-00-01-51 has an allowance of 0.4 hours.

What Owners Should Do

FCA is notifying all involved vehicle owners by mail regarding Customer Satisfaction Notification ZD8. If you own a 2021-2022 Jeep Wrangler with a 2.0L engine, you are encouraged to schedule an appointment with an authorized Chrysler, Dodge, Jeep, or RAM dealership to have this service performed. The repair will be completed free of charge (parts and labor).

Dealers are also instructed to perform this repair on all unsold vehicles in their inventory before retail delivery, as well as on used vehicles and those brought in for service. You can determine if your vehicle is involved by using the VIP inquiry process or by contacting the FCA Recall Assistance Center at 1-800-853-1403.

Source: NHTSA ID: 11001089