Challenger TSB 09 001 16 Air Intake Bypass

NUMBER: 09-001-16
GROUP: Engine
DATE: January 15, 2016
This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of FCA US LLC.
THIS SERVICE BULLETIN IS ALSO BEING RELEASED AS RAPID RESPONSE

TRANSMITTAL (RRT) 16-006. ALL APPLICABLE SOLD AND UN-SOLD RRT VIN's
HAVE BEEN LOADED. TO VERIFY THAT THIS RRT SERVICE ACTION IS
APPLICABLE TO THE VEHICLE, USE VIP OR PERFORM A VIN SEARCH IN
TECHCONNECT. ALL REPAIRS ARE REIMBURSABLE WITHIN THE PROVISIONS OF
WARRANTY.
SUBJECT:
Headlamp Air Intake Bypass Port Is Capped Off
OVERVIEW:
This bulletin involves the removal of the close out cover inside the driver’s headlamp
assembly.
MODELS:
2016 (LA) Dodge Challenger
NOTE: This bulletin applies to vehicles within the following markets/countries:

NAFTA, EMEA, and LATAM.
NOTE: This bulletin applies to vehicles built on or after October 19, 2015 (MDH
1019XX) and on or before October 30, 2015 (MDH 1030XX) equipped with the
6.2L V8 Supercharged Engine (Sales Codes ESD).
SYMPTOM/CONDITION:
The customer may describe less than expected engine performance.
DIAGNOSIS:
Using a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in
TechCONNECT, verify all engine systems are functioning as designed. If DTCs or
symptom conditions, other than the ones listed above are present, record the issues on the
repair order and repair as necessary before proceeding further with this bulletin.
If a customer’s VIN is listed in VIP or your RRT VIN list, perform the repair. For all other
customers that describe the symptom/condition listed above, perform the Repair
Procedure.
09-001-16 -2-
REPAIR PROCEDURE:
1. Visually inspect the driver’s headlamp assembly for the close out cover as shown in
(Fig. 1).
Fig. 1 Air Intake And Headlight Assembly
2. Is the close out cover present?

a. YES>>> Continue with the Repair Procedure.
b. NO>>> This Bulletin does not apply. Use Inspection Only LOP (14-10-01-94) to
close the active RRT.
3. Disconnect and isolate the negative battery cable.
-3- 09-001-16
4. Disconnect the Mass Air Flow (MAF) sensor wire harness connector (Fig. 2).
Fig. 2 Removal Of Air Filter Housing Cover
1 - Mass Air Flow Sensor Connector

2 - Air Cleaner Cover
3 - Air Cleaner Tube Clamp
4 - Air Cleaner Cover Retaining Screws
5. Remove the three air cleaner cover retaining screws as noted in (Fig. 2).
6. Loosen the air cleaner tube clamp to remove air cleaner cover if necessary as noted in
(Fig. 2).
7. Lift the air cleaner cover while separating the locating tabs from the air cleaner body.
09-001-16 -4-
8. Remove the air cleaner element from the air cleaner body (Fig. 3).
Fig. 3 Removing Air Filter
9. Locate the air intake bypass port in the air cleaner body as shown in (Fig. 4).
Fig. 4 Insertion Point Of Handle
10. Insert the handle of a hammer/rubber mallet through the duct, towards the inside of the
headlamp assembly.
-5- 09-001-16
11. Push the hammer/rubber mallet so that the handle end removes the close out cover in
the driver’s headlamp assembly as shown in (Fig. 5).
Fig. 5 Removing Air Intake Cover
1 - Mallet Handle
2 - Air Intake Close Out Cover
12. Install the air cleaner element into the air cleaner body.
13. Align the air cleaner cover locating tabs into the air cleaner body while lowering the
cover into position.
14. If removed, insert air cleaner cover into the air cleaner tube and tighten the clamp to 4
N·m (35 in. lbs).
15. Install the three air cleaner cover retaining screws and tighten to 3 N·m (26 in. lbs.).
16. Connect the MAF sensor wire harness connector.
17. Connect the negative battery cable.
POLICY:
Reimbursable within the provisions of the warranty.
09-001-16 -6-
TIME ALLOWANCE:
Labor Description Skill Category Amount

Operation No:
14-10-01-94 Inspection Only 8 - Engine Performance 0.2 Hrs.
(0 - Introduction)
14-10-01-95 Inspect And Remove 8 - Engine Performance 0.2 Hrs.
(0 - Introduction)
FAILURE CODE:
ZZ Service Action

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NUMBER: 09-001-16

DATE: January 15, 2016

THIS SERVICE BULLETIN IS ALSO BEING RELEASED AS RAPID RESPONSE

2016 (LA) Dodge Challenger

NOTE: This bulletin applies to vehicles within the following markets/countries:

Fig. 1 Air Intake And Headlight Assembly

2. Is the close out cover present?

Fig. 2 Removal Of Air Filter Housing Cover

1 - Mass Air Flow Sensor Connector

Fig. 3 Removing Air Filter

Fig. 4 Insertion Point Of Handle

Fig. 5 Removing Air Intake Cover

Labor Description Skill Category Amount

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