Safety Recall UA4 / NHTSA 18V-636 Catalytic Converter – 2017-2018 Alfa Romeo Giulia and 2018 Alfa Romeo Stelvio

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NHTSA Campaign Number: 18V636
Manufacturer Chrysler (FCA US LLC)
Components ENGINE AND ENGINE COOLING, ELECTRICAL SYSTEM
Potential Number of Units Affected 37,228

 

Engine Misfire may cause Heat Damage

Heat damage to the engine compartment wiring or components can increase the risk of a fire or it can cause an engine stall, increasing the risk of a crash.

 

Summary

Chrysler (FCA US LLC) is recalling certain 2017-2018 Alfa Romeo Giulia and 2018 Alfa Romeo Stelvio vehicles, equipped with 2.0L engines. These engines may misfire causing the catalytic converter to overheat, possibly resulting in damage to the nearby wiring and engine components.

 

Remedy

Chrysler will notify owners, and dealers will inspect the vehicles for diagnostic codes, and update the engine control module software, free of charge. The recall is expected to begin November 3, 2018. Owners may contact Chrysler customer service at 1-844-253-2872. Chrysler’s number for this recall is UA4.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Vehicle has a Recall

 


September 2018

Dealer Service Instructions for:

Safety Recall UA4 / NHTSA 18V-636 Catalytic Converter

 

Remedy Available

2017 – 2018 (GA) Alfa Romeo Giulia
2018 (GU) Alfa Romeo Stelvio

 

NOTE:  This recall applies only to the above vehicles equipped with a 2.0L engine (Sales Code EC2).

 

IMPORTANT:  Some of the involved vehicles may be in dealer new vehicle inventory.  Federal law requires you to complete this recall service on these vehicles before retail delivery.  Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service.  Involved vehicles can be determined by using the VIP inquiry process.

 

Subject

The engine control software on about 34,300 of the above vehicles may contain inadequate catalytic converter overheat protection.  Engine misfire conditions can lead to elevated catalytic converter temperatures. This may result in localized damage to wiring and components in the engine compartment near the catalyst.  If certain engine compartment wiring or components are damaged, the customer may experience an engine stall resulting in a sudden loss of motive power, which can cause a vehicle crash without prior warning.  In some cases, an engine Malfunction Indicator Lamp (“MIL”) may illuminate, the engine may operate roughly, there may be temporary loss of engine power, or a burning odor may be noticeable prior to an engine stall or engine compartment fire.  An engine compartment fire may result in an increased risk of injury to motor vehicle occupants or persons outside the vehicle.

 

Repair

Inspect the vehicle for Diagnostic Trouble Codes (DTCs) related to potential catalyst function. A scan report must be performed on all vehicles:

  • If DTCs P0420, P0171, P2096, P2270 or P0299 are present, a STAR Case must be submitted including the scan report and then contact the STAR Center.
  • If DTCs P0420, P0171, P2096, P2270 or P0299 are not present, update the PCM with the latest available software. It is not necessary to submit a STAR Case or contact the STAR Center.

 

Alternate Transportation

Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that the vehicle must be held overnight.

 

Parts Information

NOTE: No additional parts are anticipated for this campaign. If any additional parts are determined to be required due to consequential repairs or collateral damage caused by a failed catalytic converter, the dealer must first check if a related LOP has been created for repairs prior to performing the repair.  If no related LOP is found, the LOP review process must be followed to request a related Recall LOP be added as follows: 

Submit a LOP Related Inquiry (located in DealerCONNECT > Service > Claim Administration) for evaluation and update. 

  • IF the request is approved – the related Recall LOP will be added to the Labor Operations and you are to proceed with normal Recall claim entry process. 
  • IF the request is not approved – submit the repair under Warranty (W) if the repair has been pre-authorized by your Area Manager or Business Center representative.

 

Parts Return

No parts return required for this campaign.

 

Special Tools

The following special tools are required to perform this repair:

  • NPN
wiTECH micro pod II
  • NPN
Laptop Computer
  • NPN
wiTECH Software

 

Service Procedure 

NOTE: The wiTECH scan tool must be used to perform this recall. 

NOTE: The Powertrain Control Module (PCM) must be updated to the latest available software calibration level after completing this Safety Recall.  If the reprogramming flash process for the PCM is aborted or interrupted, the flash should be restarted.

 

  1. Open the hood. Install a battery charger Safety Recall UA4 / NHTSA 18V-636 Catalytic Converter - 2017-2018 Alfa Romeo Giulia and 2018 Alfa Romeo Stelvio | small light and verify that the charging rate provides 13.0 to 13.5 volts.  Do not allow the charger to time out during the flash process.  Set the battery charger timer (if so equipped) to continuous charge.
  1. Connect the wiTECH micro pod II to the vehicle data link connector.
  1. Place the ignition in the “RUN” position.
  1. Open the wiTECH 2.0 website.
  1. Enter your “User id” and “Password” and your “Dealer Code”, then select “Sign In” at the bottom of the screen. Click “Accept”.
  1. From the “Vehicle Selection” screen, select the vehicle to be updated.
  1. Create and save a Vehicle Scan Report (VSR) before proceeding. A scan report will be required before contacting the STAR Center.

a. From the left column in the analysis section, select “Reports”.

b. On the reports page, select “Scan Report”.

c. Select “ECU Summary” from the dropdown menu on the right.

d. Select “Printer Friendly” then save file type as “PDF”. Name the file with the last eight digits of the vehicle VIN.

 

  1. From the “Action Items” screen, select the “Topology” tab.
  1. From the “Topology” screen, select the “All DTCs” tab to view the DTCs.
  1. Are DTCs P0420, P0171, P2096, P2270 or P0299 present?
  • YES: A STAR Case must be submitted including the scan report and then contact the STAR Center for further direction.
  • NO: Continue with the next step; to reprogram the PCM with new software.

 

  1. From the “Topology” tab, select the “PCM” module icon.
  1. From the “Flash” tab, compare the “Current Electronic Control Unit (ECU) Part Number” with the “New ECU Part Number” listed.
    • If the “Current ECU part Number” is the same as the “New Part Number”, proceed to Step 17.
    • If the “Current ECU part Number” is NOT the same as the “New Part Number”, continue with Step 13.
  1. Select the flash part number. Read the flash special instructions page.  Select “OK” to continue.
  1. From the flash ECU agreement page, agree to terms by checking the box.
  1. Select “Flash ECU” and then follow the wiTECH screen instructions to complete the flash.
  1. Confirm the software is at the latest available calibration level.
  1. Click “View DTCs”, select “Clear All DTCs”, click “Continue” and then click “Close”.

 

NOTE: Target Linear Compensation (TLC) relearn process must be completed.  Before beginning the TLC relearn, start the engine with no DTCs and let it run until coolant temperature reaches 80°C (175°F).

 

  1. In the PCMMisc Functions” menu, perform the “Phonic Wheel Replacement” procedure. Follow the prompts shown on the diagnostic scan tool in order to complete the TLC.

 

NOTE: The TLC relearn will not begin until the proper coolant temperature has been reached.  When the desired engine temperature has been reached, click continue then stab and release the throttle pedal to obtain an RPM of 6000 RPMs three times.

 

  1. Click “View DTCs”, select “Clear All DTCs”, click “Continue” and then click “Close”.

 

NOTE: An additional key cycle may be necessary to move active DTCs to stored DTCs then it will be necessary to clear all DTCs again.

 

  1. Place the ignition in the “OFF” position and then remove the wiTECH micro pod II device from the vehicle.
  1. Remove the battery charger from the vehicle.
  1. Close the vehicle hood.
  1. Complete Proof of Correction Form for California Residents.

 

Complete Proof of Correction Form for California Residents:

This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program.  Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration.

Process Steps to obtain the California Proof of Correction form:

  1. Access the “DealerCONNECT” website.
  2. Select the “Service” tab.
  3. Under the “Publications” heading, select the “ePublishing” link.
  4. Sign in using your Dealer Code and Password.
  5. Select the “Proof of Correction form”.

 

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 paid will be used by FCA to record recall service completions and provide dealer payments.

Use only one of the following labor operation numbers and time allowances:

Labor Operation
Number
Time
Allowance
Create Scan Report, Inspect for Identified DTCs, Inspect that the PCM Software is at Latest Released Level 18-UA-41-81 0.2 hours
Create Scan Report, Inspect for Identified DTCs, Reprogram PCM with the Latest Released Level Software 18-UA-41-82 0.4 hours

 

NOTE:  See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall 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 FCA are being notified of the service requirement by first class mail.  They are requested to schedule appointments for this service with their dealers.  A generic copy of the owner letter is attached.

 

 

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 must 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.

Recall 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 recall 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 Services / Field Operations

FCA US LLC


This notice applies to your vehicle,

 [Model Year and Model]  VIN XXXXXXXXXXXXXXXXX UA4/NHTSA 18V-636

 

LOGO

VEHICLE PICTURE

YOUR SCHEDULING OPTIONS

 

  1. RECOMMENDED OPTION Call your authorized Chrysler / Dodge / Jeep® / RAM / Alfa Romeo Dealership 
  1. Call the FCA Recall Assistance Center at 1-800-853-1403 or Alfa Romeo Premium Care at 1-844253-2872. An agent can help schedule an appointment 
  1. Visit mopar.com, scan the QR code below, or download the Mopar Owner’s Companion App.

 

QR Code

 

Get access to recall notifications, locate your nearest dealer, and more through this website or Mopar Owner’s Companion App. You will be asked to provide your Vehicle Identification Number (VIN) to protect and verify your identity. The last eight characters of your VIN are provided above.

 

DEALERSHIP INSTRUCTIONS

Please reference Safety Recall UA4.


IMPORTANT SAFETY RECALL

Catalytic Converter

 

Dear [Name],

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. 

FCA has decided that a defect, which relates to motor vehicle safety, exists in certain [2017 – 2018 Model Year (GA) Alfa Romeo Giulia, 2018 Model Year (GU) Alfa Romeo Stelvio] vehicles equipped with a 2.0L engine.

It is extremely important to take steps now to repair your vehicle to ensure the safety of you and your passengers.

 

WHY DOES MY VEHICLE NEED REPAIRS?

The engine control software on your vehicle [1] may contain inadequate catalytic converter overheat protection.  Engine misfire conditions can lead to elevated catalytic converter temperatures.  This may result in localized damage to wiring and components in the engine compartment near the catalyst.  If certain engine compartment wiring or components are damaged, the customer may experience an engine stall resulting in a sudden loss of motive power, which can cause a vehicle crash without prior warning.  In some cases, an engine Malfunction Indicator Lamp (“MIL”) may illuminate, the engine may operate roughly, there may be temporary loss of engine power, or a burning odor may be noticeable prior to an engine stall or engine compartment fire.  An engine compartment fire may result in an increased risk of injury to motor vehicle occupants or persons outside the vehicle.

 

HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE?

FCA will repair your vehicle [2] free of charge (parts and labor).  To do this, your dealer will inspect the vehicle for diagnostic codes related to potential catalyst function, part inspections and replacement if required and update the powertrain control module software to control fuel delivery during certain engine misfire conditions to prevent catalytic converter overheat.  In addition, your dealer will require your vehicle for proper check-in, preparation, and check-out during your visit.  Your time is important to us; please be aware that these steps may require more time.  The estimated repair time is one hour.  We recommend that you schedule a service appointment to minimize your inconvenience.  Please bring this letter with you to your dealership.

 

TO SCHEDULE YOUR FREE REPAIR, CALL YOUR CHRYSLER, DODGE, JEEP, RAM OR ALFA ROMEO DEALER TODAY

 

CALIFORNIA RESIDENTS

The State of California requires the completion of emission recall repairs prior to vehicle registration renewal.  Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the Emission Recall service is performed.  Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof that the Emission Recall has been performed.

In order to ensure your full protection under the emissions warranty provisions, it is recommended that you have your (vehicle or engine) serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your (vehicle or engine).

 

WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED?

If you have already experienced this specific condition and have paid to have it repaired, you may visit www.fcarecallreimbursement.com to submit your reimbursement request online. [3] Once we receive and verify the required documents, reimbursement will be sent to you within 60 days.  If you have had previous repairs performed and/or already received reimbursement, you may still need to have the recall repair performed.

We apologize for any inconvenience, but are sincerely concerned about your safety.  Thank you for your attention to this important matter.

 

Customer Assistance/Field Operations

FCA US LLC


Mr. Mrs. Customer
1234 Main Street
Hometown, MI 48371

[1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information.

[2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC  20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-4249153), or go to safercar.gov.

[3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-8004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.

 

Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days.


UA4

September 2018

https://static.nhtsa.gov/odi/rcl/2018/RCRIT-18V636-7118.pdf

RC-UA4-18

 


Safety Recall Advanced Communication – UA4

09/21/2018

https://static.nhtsa.gov/odi/rcl/2018/RCMN-18V636-8708.pdf

RCMN-18V636-8708

 


FCA US LLC Chronology
2017-2018 MY Alfa Romeo Giulia and 2018 MY Alfa Romeo Stelvio
Submitted on September 14, 2018

https://static.nhtsa.gov/odi/rcl/2018/RMISC-18V636-8890.pdf

RMISC-18V636-8890

 


Recall Acknowledgement

October 5, 2018

https://static.nhtsa.gov/odi/rcl/2018/RCAK-18V636-5663.pdf

RCAK-18V636-5663

 


 

Reprogramming

Chrysler J2534 Application Overview

 

DRB III Emulator

Flash Availability - J2534/Pass Thru Device

Vehicle to Diagnostic Tool Reference Chart

 

Chrysler Recommended J2534 Devices

For Chrysler recommended J2534 device, see below table.

J2534 Device Firmware Version
CTC Vehicle Box * 1.9
UCAN 2 1.0
Blue Streak -2534 Global Programmer 2.10
Actia I+ME Passthru 2.07

* Chrysler recommends the CTC Vehicle Box Device for Chrysler SCI ECU reprogramming. SCI reprogramming is used on most PCMs and TCMs prior to the introduction of CAN bus vehicles which began in 2004 (Durango).

 

Compatible J2534 Devices

Safety Recall UA4 / NHTSA 18V-636 Catalytic Converter - 2017-2018 Alfa Romeo Giulia and 2018 Alfa Romeo Stelvio | small light CarDAQ-Plus 3 All Makes J2534 Reprogramming Tool
Safety Recall UA4 / NHTSA 18V-636 Catalytic Converter - 2017-2018 Alfa Romeo Giulia and 2018 Alfa Romeo Stelvio | small light CarDAQ-Plus 2 Diagnostic Code Reader and J2534 Programming Tool
Safety Recall UA4 / NHTSA 18V-636 Catalytic Converter - 2017-2018 Alfa Romeo Giulia and 2018 Alfa Romeo Stelvio | small light CarDAQ-Plus
Safety Recall UA4 / NHTSA 18V-636 Catalytic Converter - 2017-2018 Alfa Romeo Giulia and 2018 Alfa Romeo Stelvio | small light CarDAQ-M
Safety Recall UA4 / NHTSA 18V-636 Catalytic Converter - 2017-2018 Alfa Romeo Giulia and 2018 Alfa Romeo Stelvio | small light VSI J2534 ECU Reprogrammer
Safety Recall UA4 / NHTSA 18V-636 Catalytic Converter - 2017-2018 Alfa Romeo Giulia and 2018 Alfa Romeo Stelvio | small light

Bosch Automotive Tools MTECH2 Mastertech II J2534 VCI with Wired/Wireless Capability for OEM Reprogramming and Diagnostics on GM, Ford, FCA, Nissan/Infiniti, Honda/Acura, and Toyota/Lexus Vehicles

Safety Recall UA4 / NHTSA 18V-636 Catalytic Converter - 2017-2018 Alfa Romeo Giulia and 2018 Alfa Romeo Stelvio | small light

RAP2 OEM J2534 Remote Reprogramming Tool

Safety Recall UA4 / NHTSA 18V-636 Catalytic Converter - 2017-2018 Alfa Romeo Giulia and 2018 Alfa Romeo Stelvio | small light

BOSCH Automotive Tools MTECH2 Mastertech II J2534 VCI

Safety Recall UA4 / NHTSA 18V-636 Catalytic Converter - 2017-2018 Alfa Romeo Giulia and 2018 Alfa Romeo Stelvio | small light

Autel MaxiFlash VCI Vehicle Communication Interface J2534 PassThru ECU Programming Device Bluetooth Connection Internet Update Support CAN FD, 4 CAN Channels, DoIP, D-PDU Works with PC or Autel MS909

Safety Recall UA4 / NHTSA 18V-636 Catalytic Converter - 2017-2018 Alfa Romeo Giulia and 2018 Alfa Romeo Stelvio | small light

GODIAG J2534

 


Click on the link below to:

Download J2534 Application

(Install the wiTECH 2.0 J2534 Application on your computer)

Download the Setup Utility

(Configure your microPod/MDP device)

Launch wiTECH 2.0

(Once subscription and users are assigned to a tool please follow this link to access wiTECH)

https://www.mopartsp.com/support

 


Chrysler J2534 Manual

wiTECH Software

www.techauthority.com

 


 

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