Safety Recall Z11 – HV Battery – 2017-2018 Chrysler Pacifica Plug-In Hybrid Electric Vehicles (PHEV)

February 11, 2022 NHTSA CAMPAIGN NUMBER: 22V077000

Vehicle Fire When Parked

A vehicle fire increases the risk of injury.

 

NHTSA Campaign Number: 22V077

Manufacturer ChryslereBay logo (FCA US, LLC)

Components HYBRID PROPULSION SYSTEM

Potential Number of Units Affected 16,741

 

Summary

ChryslereBay logo (FCA US, LLC) is recalling certain 2017-2018 Pacifica Plug-In Hybrid Electric Vehicles (PHEV). A vehicle fire can occur when parked, even with the ignition in the “Off” position.

 

Remedy

Owners are advised not to recharge their vehicles, and to park outside and away from structures, until they are repaired. Dealers will update the high voltage battery pack control module (BPCM) software. In addition, dealers will inspect and if necessary, replace the battery pack assembly. Repairs will be performed free of charge. Interim letters, informing owners of the safety risk were mailed on February 25, 2022. Final owner notification letters were mailed October 6, 2022. Owners may contact FCA US LLC customer service at 1-800-853-1403. FCA US LLC’s number for this recall is Z11.

 

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.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


Revision 7 February 2023

Dealer Service Instructions for:

Safety Recall Z11 / NHTSA 22V-077 Plug-in Hybrid Electric Vehicle Fires

 

NOTE: Step numbers on pages 13, 14 and 30 have been revised.

 

Remedy Available

2017 – 2018(RU)ChryslereBay logo Pacifica (PHEV)

NOTE:  This recall applies only to the above vehicles equipped with a 3.6L PHEV Hybrid Engine (sales code EH3).

NOTE:  Some vehicles above may have been identified as not involved in this recall and therefore have been excluded from this recall.

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 toapply 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

Some of the above Plug-in Hybrid Electric Vehicles (PHEV) have experienced fires. A vehicle may experience a fire, even with the ignition in the “OFF” mode. A vehicle fire can result in increased risk of occupant injury and/or injury to persons outside the vehicle, as well as property damage.

 

Repair

Verify the state of the high voltage battery charge is below 50%. Inspect the Battery Pack Control Module (BPCM) for fault codes, follow service procedure to repair fault code(s). If no fault codes are present reprogram the BPCM with the most updated software and perform “Z11 BPCM Integrity Procedure”. and it will illuminate/continuously flash the Hybrid Electric Vehicle System  Begin at section A. Battery Pack Control Module Software Update and BPCM Integrity Procedure.

ALERT: Performing the BPCM flash will disable electric propulsion mode

Service lamp. Every step in the Z11 BPCM Integrity Verification Procedure MUST be completed in order to turn the flashing service lamp off.

 

Alternate Transportation

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

 

Parts Information

All parts required will be Ordered by STAR Center, once approved.

Very few vehicles are expected to require Hight Voltage Battery replacement.

NOTE: Please read and follow the I-Sheet instructions that are included with the replacement battery for unpacking upon receipt and packing for return of removed battery information. 

 

Parts Return

Parts return required for this campaign.

NOTE: Please read and follow the I-Sheet instructions that are included with the replacement battery for unpacking upon receipt and packing for return of removed battery information. 

 

Special Tools

The following special tools are required to perform this repair:

➢ NPNwiTECH MicroPod IIeBay logo
➢ NPNLaptop Computer
➢ NPNwiTECH Software
➢ 2035100082Covers, HEV Battery Terminal
➢ BX50-CHRTable, Bishamon Lift
➢ 2035200080Lift Straps, HEV Battery
➢ 10441Cone, Safety
➢  10442Cone, Safety
➢ 10452Sign, Danger High Voltage
➢ 10443Cards, Windshield and Dash Placement
➢ 126-1587Meter, Fluke
➢ ZEN4520Lift, Wheel Jack Dolly

 

Service Procedure

A. Battery Pack Control Module (BPCM) Software Update and BPCM Integrity Procedure

ALERT: This recall procedure REQUIRES you to reach the below screen message within the BPCM Integrity Procedure before returning the vehicle to a customer:

ALERT: Performing the BPCM flash will illuminate and continuously flash the Hybrid Electric Vehicle System Service lamp located in the instrument panel cluster. Every step in the Z11 BPCM Integrity Procedure MUST be completed in order to turn the flashing service lamp off.

Do not return the vehicle to the customer if the service lamp is flashing. (Figure 1).

 

NOTE: Before beginning the following Service Procedure: Open the hood and start the engine then allow the engine to reach normal operating temperature. This may be performed outside before technician receives the vehicle. Once normal operation temperature is reached technician may begin the procedure.

 

NOTE: Verify the vehicle high voltage battery is at or BELOW 50% State-of-Charge (SOC) on the instrument cluster, if not already below 50% SOC drive the vehicle to discharge the high voltage battery. DO NOT allow vehicle engine to run for a long period after the high voltage battery has been discharged, doing so will recharge the battery.

 

NOTE: The wiTECH scan tool must be used to perform this safety recall.  If the BPCM reprogramming is aborted or interrupted during reprogramming, it must be restarted. The BPCM software must be at the latest software calibration level after completing this safety recall.

 

  1. Install a battery charger. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to maintain 12-Volt continuous charge.

 

  1. Connect the wiTECH micro pod II to the vehicle data link connector.

 

  NOTE: Same wiTECH micro pod II MUST be used throughout the procedure.

 

  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. From the “Action Items” screen, select the “Topology” tab.

 

NOTE: Obtain a Vehicle Scan Report VSR and ECU details report. Both must be provided to the STAR Center for High Voltage Battery replacement authorization.

a. Create and save a Vehicle Scan Report VSR and ECU details report before proceeding. Both pre and post scan reports will be required for submission.

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

c. On the reports page, select “Vehicle Scan Report”.

d. Repeat to obtain ECU details report.

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

 

  1. From the “Topology” tab, select the “BPCM” module icon.

 

  1. Within BPCM, select “System Tests” then select “BPCM Warming Procedure” then select “Continue”.

 

NOTE: Ensure the vehicle hood is open and remains open or the BPCM warming procedure will abort.

 

  1. Follow the wiTECH screen instruction steps to perform the BPCM warming procedure if directed, otherwise proceed to the “NOTE” before Step 15.

 

  1. BPCM cell warming period duration will require separate technician time punch. BPCM cell warming duration will be recorded and traced by wiTECH 2. Individual punch time must reflect actual BPCM cell warming period or claim will be rejected or charged back to dealership.

 

  1. The following data will be displayed during the warming procedure.

 

NOTE: During the BPCM warming procedure, if the high voltage battery reaches near full state of charge, the vehicle engine may exhibit a bucking or jerking while running. This is normal as the charging system switches modes in order to prevent over charging the battery.

 

  1. The following will be displayed once warming procedure has completed. Perform the steps listed on the screen before continuing.

 

  1. The following will be displayed once the warming procedure has finished.

 

NOTE: Verify the vehicle high voltage battery is at or BELOW 50% State-of-Charge (SOC) on the instrument cluster, if not already below 50% SOC drive the vehicle to discharge the high voltage battery. DO NOT allow vehicle engine to run for a long period after the high voltage battery has been discharged, doing so will recharge the battery.

 

  1. From the “Topology” tab, select “ALL DTCs” then “Clear All”. If any fault code(s) are present, repair as directed in the service manual procedure. If there are no active fault code(s) proceed to Step 16.

 

  1. From the “Topology” tab, select the “BPCM” 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 24.
  • If the “Current ECU part Number” is NOT the same as the “New Part Number”, continue with Step 18.

 

  1. From the BPCM tab, select the latest BPCM 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. Cycle the ignition to the “Off” position, then to the “On” position.

 

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

 

  1. Place the ignition in the “OFF” position.

 

  1. Remove the 12-volt battery charger from the vehicle.

 

  1. Close the vehicle hood, doors and windows.

 

  1. Place the ignition in the “RUN” position.

 

  1. Confirm the vehicle high voltage battery is at 50% State-of-Charge (SOC) or less on the instrument cluster, if not already below 50% drive the vehicle to discharge the high voltage battery.

 

NOTE: Do not leave engine running once the battery has been discharged, this may recharge the battery

 

NOTE: It is important to disable Figure 1 – Apps Display Screen the Charging Schedule on the display. Failure to disable the charging schedule may require restarting the procedure.

 

  1. Select “Apps” then “Hybrid Electric” on the display (Figure 1).

 

  1. Select “Charging Schedule” (Figure 2).

 

  1. Verify the “Check Mark” is NOT selected in the “Enable Schedule” box (Figure 3).

 

  1. Park the vehicle next to an OUTDOOR Level 2 High Voltage Battery charger.

 

PREPARE THE WORK AREA

  • Assemble the six Cone, Safety 10441 and six Barriers, Safety 10442 around the vehicle/hoist area.
  • Position the two Sign, Danger High Voltage 10452 within the assembled safety cones and barriers.
  • Place the four Cards, Windshield and Dash Placement 10443 within the vehicle.
  • Create and tape a DO NOT DISTURB sign on driver’s door handle and near charge port.

 

  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. From the “Action Items” screen, select the “Topology” tab.

 

  1. Select “BPCM” Icon.

 

  1. Select “System Test” tab.

 

  1. Select Z11 BPCM Integrity Procedure.

 

  1. Select test “I am Starting from beginning” and begin procedure.

 

  1. Follow screen prompts displayed in the wiTECH routine. Charge the High Voltage Battery to a full charge and allow a rest period, as directed by the wiTECH routine (up to 7 hrs. total) based on  SOC and rate of charger input.

*Do Not Attempt to Return Earlier Than Directed*.

 

NOTE: Verify charger is charging by viewing the lights flashing on the dashboard, if only the 2 outer bars are illuminated, charger is not enabled restart the charging process. 

 

  1. Disconnect the wiTECH micro pod II from the vehicle data link connector.

 

  1. Place the ignition in the “OFF” position.

 

CAUTION: If charging indoors is unavoidable (not preferred). Do not leave the vehicle unattended while charging.  If any smoke is observed coming from the underbody, unplug the charge cable and, if safe to do so, slide the Lift, Wheel Jack Dolly under both front wheels (See Figure 4 and 5) elevate the vehicle and push it outside away from buildings and other vehicles.  Call your local fire department immediately.

 

CAUTION: Vehicles involved in this recall should NOT be left connected to a charger after business hours.

 

NOTE: Any of the below interruptions will require restarting the routine.

  • Lock doors and remove the key fob and set aside away from the vehicle ➢ DO NOT Disturb Vehicle while charging the High Voltage Battery
  • DO NOT disconnect charge cable from charge port while charging
  • DO NOT open any doors
  • Observe the LED Charge Indicator on dash to verify charge status

 

NOTE: It is critical that step 44 is completed in a timely manner; within 1 minute. Step 44 and step 45 must be completed in the exact order listed.  Failure to complete these steps in order may result in requiring the test to be re-performed.

 

  1. Only after the full time has passed, return to the vehicle. Using the key fob unlock then open the driver door and quickly place the ignition in the “RUN” position.

 

  1. Connect the wiTECH micro pod II to the vehicle data link connector.

 

  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. From the “Topology” tab, select the “BPCM” module icon.

 

  1. Select “System Test” tab.

 

  1. Select Z11 BPCM Integrity Procedure.

 

  1. Select test “I Am Returning After Vehicle Charge Or 3 Hour Soak” and begin procedure.

 

  1. Follow all screen prompts until completed. If the wiTECH Routine indicates the High Voltage Battery requires replacement, follow section: High Voltage Battery Pack Removal Procedure otherwise, proceed to Step 54.  

 

NOTE: High voltage battery pack must maintain not less than (50°F)(10°C) temperature environment during testing and wiTECH routine, failure to maintain the temperature may cause  repeat testing. 

 

  1. Allow the vehicle to rest an additional 3hrs (or longer) after completing Failure to complete these steps in order may result in requiring the test to Do not drive vehicle a long distance.

 

NOTE: It is critical that step 55 is completed in a timely manner; within 1 minute. Step 55 and step 56 must be completed in the exact order listed.  be re-performed.

 

  1. Open the driver door and quickly place the ignition in the “RUN” position.

 

  1. Connect the wiTECH micro pod II to the vehicle data link connector.

 

  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. From the “Topology” tab, select the “BPCM” module icon.

 

  1. Select “System Test” tab.

 

  1. Select Z11 BPCM Integrity Procedure.

 

  1. Select test “I Am Returning After Vehicle Charge Or 3 Hour Soak” and begin procedure. (NOTE: This is the final selection)

 

  1. Follow all screen prompts until test is completed.

 

  1. You MUST reach the wiTECH routine screen advising the vehicle can now be returned to the customer.

 

  1. If no DTCs are present, remove the wiTECH micro pod II device from the vehicle. If the wiTECH Routine indicates the High Voltage Battery requires replacement, follow section: High Voltage Battery Pack Removal Procedure.

 

B. High Voltage Battery Pack Removal Procedure 

NOTE: A Vehicle Scan Report VSR and ECU details report must be provided to the STAR Center for High Voltage Battery replacement authorization.

 

a. Create and save a Vehicle Scan Report VSR and ECU details report before proceeding. Both pre and post scan reports will be required for submission.

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

c. On the reports page, select “Vehicle Scan Report”.

d. Repeat to obtain ECU details report.

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

 

WARNING: Before performing any diagnostic or service procedure, you must thoroughly read and follow all applicable high voltage safety procedures. You must perform the high voltage power down procedures.

Loss of Isolation (LOI) must be performed before high voltage power up in cases where service has been performed on a high-voltage component or when diagnosing a LOI condition.

Be sure to use the proper safety equipment when working on any high voltage system or component. Failure to do so may result in serious or fatal injury.

Wait a minimum of two minutes after performing the high voltage battery disconnect procedure safety procedures before attempting to access the high voltage system, failure to do so may result in serious or fatal injury.

 

NOTE: Observe the following precautions when handling the high-voltage battery pack:

  • Do not touch the high voltage terminals.
  • Always use four lift points when moving the battery pack.
  • Keep the battery pack in an upright position.
  • Store in a clean and dry environment.
  • Store at a temperature of 10°-30°C (50°-86°F) with relative humidity between 30-70%.
  • Always store at a State-of-Charge (SOC) of around 30%.
  • Always store on an electrically non-conducting (insulated) material.
  • Store with spatial gap of at least 50 cm (20 in.).
  • Do not store the battery pack near any environmental condition involving liquid, heat, strong magnetic field, electricity or that can generate heat (for example: transformers).

NOTE: When performing any repairs that involve contact with high voltage components or systems, the technician performing repairs on the vehicle must verify that the system remains powered down during high voltage repairs.

  • This must be done by removing the service disconnect.
  • The high voltage power down procedure must also be performed to ensure that the vehicle is properly powered down.
  • The technician must know the whereabouts of the service disconnect throughout the repair.
  • The technician must ensure that no one reconnects the service disconnect while service is being performed.
  • The technician must recheck that the service disconnect has not been reinstalled in cases where the vehicle was unattended.

 

  1. Prepare the work area and familiarize yourself with all HIGH-VOLTAGE SAFETY PROCEDURES related to personal safety and vehicle safety associated with working on a Plug-In Hybrid Electric Vehicle (PHEV) (Refer to 08 – Electrical/Standard Procedure) .

 

  1. Inspect all orange high-voltage cables, and high-voltage components labeled with the high-voltage symbol for physical damage. If damage is present, extra caution must be taken to avoid contact with unprotected high -voltage. Do not insert probes, tools, objects or fluids into damaged high-voltage cables or components.
  2. Disconnect any charging equipment, turn off the ignition, remove the keys, open the hood and leave the vehicle doors open.

 

  1. Remove the air cleaner body.

 

  1. Use of an insulation tester such as the Fluke Meter, Multi 126-1587 is recommended for PHEV circuit testing. Perform the multi-meter functionality tests per the manufacture’s directions. Verify the multi-meter is operating correctly by measuring voltage from a known good power source, such as the vehicle’s 12-volt battery. If at any point during the procedure, the multi-meter settings are changed, or the probes are repositioned in the meter, verification with a known good power source must be repeated.

 

NOTE: Before performing step 6, verify the CAN C bus is asleep before removing the positive battery cable from the Power Distribution Center (PDC). Failure to do so may result in fault codes.

 

  1. Disconnect the B+ battery cable (1) from the 12-volt Power Distribution Center (PDC) (Figure 6).

 

  1. Isolate the battery cable terminal with Cover, Protective 10084

 

NOTE: Wait a minimum of 2 minutes before removing the manual service disconnect.

 

  1. Lift the carpet away from the high-voltage MSD floor access cover.

 

  1. Remove the four screws (2) and remove the high-voltage MSD access cover (1) (Figure 7).

 

  1. Depress the lever release latch (2) firmly. With the latch fully depressed, rotate the lever (1) upward. The lever will stop at the 45° position (Figure 7).

 

NOTE: At this stage, the High Voltage Inter-Lock (HVIL) connection has been broken and the circuit is de-energized.

 

  1. Again, depress the locking tab (2) and continue to rotate the lever to the end of travel (90° position) (Figure 8).

 

  1. Pull straight back on the plug lever (1) to disengage and remove the high-voltage manual service disconnect from the receptacle (Figure 9).

 

  1. Cap the receptacle on the high-voltage battery with the Covers, HEV Battery Terminal 2035100082 (1) to prevent foreign objects from entering (Figure 10).

 

NOTE: Make sure the location of the high-voltage MSD is always known; after removal, it is best practice to place the high-voltage MSD in a highly visible location.

 

NOTE: Always wear HV gloves and safety glasses for the next two steps

 

  1. Loosen two captive screws (1) and remove the single High Voltage Inter-Lock (HVIL) connector from the Power Inverter Module (PIM) cover (Figure 11).

 

  1. Loosen five captive screws (1) and remove the PIM cover (Figure 12).

 

NOTE: Always observe these precautions prior to taking a high-voltage measurement:

  • Have known good test leads.
  • Set the range to no decimal points.
  • Read a known good low-voltage source first.
  • High voltage Personnel Protection Equipment (PPE) must be worn.

 

  1. Measure the voltage at the PIM high voltage terminals:
  • Measure between the positive and negative high voltage terminals.
  • Measure between each high voltage terminal and chassis ground.

 

  1. The measured voltage should be near 0 volts (Figure 13).
  • If the voltage measured is near 0 volts, it is safe to work on the high-voltage components with the exception of the high-voltage battery internal components.
  • If the voltage is greater than 0 volts, an internal condition exists within the high-voltage battery that is preventing it from being powered down. Do not attempt to carry out repairs on any of the vehicle’s high-voltage components or wiring. Perform the HIGH VOLTAGE LOSS OF ISOLATION TEST PROCEDURE (Refer to 08 – Electrical/Standard Procedure)

 

  1. After confirming that the high voltage battery is powered down and locked out it is safe to power up the 12-volt system if needed to perform diagnostics or repairs.

 

  1. Raise and support the vehicle.

 

  1. Remove the engine belly pan, charger belly pan, battery belly pan and rear suspension belly pan.

 

  1. Using suitable hose-pinching pliers, clamp-closed the coolant inlet (1) and outlet (2) hoses near the high-voltage battery (Figure 14).

 

CAUTION: Do not allow coolant to come in contact with any high voltage component electrical connections. Engine coolant will create a conductive path and cannot be effectively removed resulting in a loss of isolation and replacement of the contaminated high voltage component.

 

  1. Place a suitable coolant recovery container under the coolant inlet and outlet hoses.

 

  1. Disengage the quick-connect couplings and carefully remove the coolant inlet (1) and outlet (2) hoses from the high voltage battery (Figure 15).

 

NOTE: Not all coolant will drain from the high voltage battery.

 

  1. If all coolant must be removed, as in the case of a high voltage battery replacement, use a shop air supply hose connected to the battery coolant inlet port (1). Adjust the air pressure regulator to not exceed 100 kPa (15 psi) and force the coolant from the battery coolant outlet port (2).
  2. Cap the nipples on the high-voltage battery with the Covers, HEV Battery Terminal 2035100082 and plug the coolant hose ends.

 

  1. Disengage the two wire harness retainers (2) from the high-voltage battery (Figure 16).

 

  1. Unlock and disconnect the Power Inverter Module (PIM) high-voltage wire harness connector (1) from the highvoltage battery. Cap the connector on the high-voltage battery with the Covers, HEV Battery Terminal 2035100082

 

  1. Unlock and disconnect the low-voltage wire harness connectors (1) from the high-voltage battery (Figure 17).

 

  1. Unlock and disconnect the Onboard Charging Module (OBCM) and Electric Coolant Heater (ECH) high-voltage wire harness connectors (2) from the high-voltage battery.

 

  1. Cap the connectors on the high-voltage battery with the Covers, HEV Battery Terminal 2035100082.   

 

  1. Remove the nut (1) and the chassis ground cable from the high-voltage battery ground stud (2) (Figure 18).

 

  1. Position a suitable lifting device, such as Table, Bishamon Lift BX50-CHR, under the high-voltage battery pack. Secure the high-voltage battery pack to the lifting device.

 

NOTE: The high-voltage battery pack weighs 167 kg (368 lb.).

 

  1. Remove the eight bolts and Figure 18 – Ground Stud and Nut remove the high-voltage battery from the vehicle.

 

  1. Remove the nuts (1) and the heat shield from the high-voltage battery (Figure 19).

 

  1. Install the Lift Straps, HV Battery 2035200080 (1) and remove the high-voltage battery pack from the lifting device. Place the high-voltage battery pack in the shipping container or in a suitable storage location (Figure 20).

 

NOTE: If the high-voltage battery pack is being replaced; 

  • The Manual Service Disconnect (MSD) from this battery must be retained and returned with the battery.
  • All coolant must be removed from the battery. Use a shop air supply hose connected to the battery coolant inlet port. Adjust the air pressure regulator to not exceed 100 kPa (15 psi) and force the coolant from the battery coolant outlet port.
  • All coolant ports and electrical connections must be capped.

 

CAUTION: Do not allow coolant to come in contact with any high voltage component electrical connections. Engine coolant will create a conductive path and cannot be effectively removed resulting in a loss of isolation and replacement of the contaminated high voltage component.

 

NOTE: If the High Voltage battery is missing its return instructions, contact the UPS Call Center 800-567-9989.

 

B. High Voltage Battery Pack Installation Procedure. 

  1. Install the Lift Straps, HV Battery 2035200080 and place the high-voltage battery pack on a suitable lifting device, such as Table, Bishamon Lift BX50-CHR. Secure the high-voltage battery pack to the lifting device.

 

  1. Install the heat shield to the high-voltage battery and securely tighten the nuts. Secure the high-voltage battery pack to the lifting device.

 

NOTE: The high-voltage battery pack weighs 167 kg (368 lb.).

 

  1. Install the high-voltage battery pack in the vehicle and tighten the eight bolts to 48 N·m (35ft. lbs.)

 

  1. Install the chassis ground cable to the high-voltage battery ground stud (2) and tighten the nut to 9 Nm (80In. lbs.).

 

  1. Remove the low-voltage battery port covers, connect and lock the low-voltage wire harness connectors to the high-voltage battery.

 

  1. Remove the high-voltage battery port covers, connect and lock the On-board Charging Module (OBCM) and Electric Coolant Heater (ECH) high-voltage wire harness connectors to the high-voltage battery.

 

  1. Remove the battery port cover, connect and lock the Power Inverter Module (PIM) high-voltage wire harness connector to the high-voltage battery.

 

  1. Engage the two wire harness retainers to the high-voltage battery.

 

  1. Install the coolant inlet (1) and outlet (2) hoses to the high-voltage battery and engage the quick-disconnects.

 

  1. If required: Remove the hose-pinching pliers from the coolant inlet and outlet hoses.

 

  1. Install the rear suspension belly pan, battery belly pan, charger belly pan and engine belly pan.

 

  1. Remove the support and lower the vehicle.

 

CAUTION: Only deionized or distilled water can be used in the PHEV cooling systems. The use of tap water is prohibited as this can damage the required, such as MOPAR 68163849AB 50/50 Prediluted Antifreeze/Coolant.  components.

 

NOTE: A 50/50 mixture of an ethylene glycol based antifreeze formulated with Organic Additive Technology (OAT) and deionized or distilled water is

 

  1. The preferred method to remove air and fill the cooling system is to perform the Coolant Air Evacuation procedure using the Mopar Essential Tools and Service Equipment Tool, UView Airlift™ Cooling System Refill 399-550000 or equivalent.

 

  1. Remove the filler cap from the coolant reservoir.

 

  1. If cooling system evacuation and purging equipment is not available:
  • Slowly add the engine coolant through the filler neck until the coolant level reaches the MAX level of the coolant reservoir.
  • Attach the SVT275 Cooling Pressure Tester (2), available from Mopar® Service Equipment, or an equivalent to the pressurized coolant bottle (1).
  • Operate tester pump to apply 100 kPa (15 psig) pressure to system. This should force coolant into any voids created by trapped air.
  • Release pump pressure and remove tester.
  • Add engine coolant until the coolant level again reaches the MAX level of the coolant reservoir.
  • Repeat this process until the coolant level stabilizes at the MAX level of the coolant reservoir.

 

  1. Position the white sleeve in the full upright position for installation of the MSD to verify proper engagement as shown (Figure 21).

 

NOTE: If necessary, use a small screwdriver to loosen and guide the white sleeve to the full upward position as shown (Figure 22).

 

  1. Ensure that the mounting interface surface of the high-voltage Manual Service Disconnect (MSD) and the receptacle wall is clean, and that there are no surface contaminants or foreign objects within the receptacle.

 

  1. Align the polarization feature (1) of the high-voltage MSD with the receptacle on the high-voltage battery  (Figure 23).

 

  1. Push the high-voltage MSD evenly into the receptacle with the lever (1) in the 90° position.

 

NOTE: With the high-voltage MSD properly aligned with the receptacle, the lever (1) will be released and allowed to rotate to the lock position (Figure 24).

 

  1. Rotate the lever (1) while maintaining a slight force on the high-voltage MSD. The lever will engage the receptacle and draw the high-voltage MSD down onto the receptacle as the lever is rotated.

 

  1. Rotate the lever (1) downward until it is fully engaged and locked by the lever release latch (2). An audible “click” will be heard as the lever latches into position. Gently pull the high-voltage MSD upward to ensure that it is fully seated in the receptacle and locked. If the MSD is able to be removed, repeat steps 16 – 21 (Figure 25).

 

  1. Install the high-voltage MSD floor access cover and tighten the four screws to 2.5 N·m (22In. lbs.).

 

NOTE: The clearance between the top of the high-voltage MSD and the bottom of the access cover is such that the access cover cannot be installed if the high-voltage MSD is not fully seated.

 

  1. Install the rear carpet.

 

  1. Connect the B+ battery cable to the 12-volt Power Distribution Center (PDC) and tighten the terminal nut to 9 N·m (80In. lbs.).

 

  1. Install the air cleaner body.

 

  1. Close the hood, insert the key in the ignition, press the START button and verify that the Hybrid Status Indicator is green and no warnings are displayed.

 

  1. Connect the WiTECH tool to the vehicle diagnostic connector and perform the “Replace BPCM” procedure in the BPCM section of the scan tool.

 

NOTE: If this procedure is not run the vehicle will not start. The high voltage battery pack is shipped with the contactors locked in the open position for safety concerns. Until this routine is run the battery p ack contactors will not close resulting in a no start condition.

  1. The new high-voltage battery pack must be flash programmed to operate.

 

  1. With the scan tool, flash program the Battery Pack Control Module (BPCM) with the latest software.

 

  1. Return the vehicle to the customer.

 


New Safety Recall Advanced Communication – Z11

FCA US LLC (FCA US) has announced a safety recall on certain 2017 and 2018 Model Year (RU) ChryslereBay logo Pacifica vehicles equipped with a 3.6L PHEV Hybrid Engine.

 

REASON FOR THIS SAFETY RECALL

Some of the above Plug-in Hybrid Electric Vehicles (PHEV) have experienced fires. The defect has not yet been identified and the root cause of these fires is still being investigated. A vehicle may experience a fire, even with the ignition in the “OFF” mode. A vehicle fire can result in increased risk of occupant injury and/or injury to persons outside the vehicle, as well as property damage.

Until further notice, FCA is advising owners of these hybrid vehicles to refrain from recharging the high voltage battery, and to park them away from structures and other vehicles.

 

SERVICE ACTION

FCA US will conduct a voluntary safety recall on all affected vehicles. The remedy for this condition is not currently available.  Dealers will be notified of the launch of this safety recall by way of established communication methods.

We ask that you please take the time to ensure that your personnel are aware of this communication and are prepared to execute a customer friendly process for inquiries regarding involved vehicles.

 


FEB 2022

SAFETY RECALL Z11: MY 2017-18 CHRYSLER PACIFICA

(RU) PHEV — CUSTOMER COMMUNICATIONS

 

The Z11 recall involves model year 2017 and 2018 ChryslereBay logo Pacifica Hybrid vehicles for a possible fire event; no other Pacifica models are affected.

Until further notice, the company is advising owners of these hybrid vehicles to refrain from recharging them and to park them away from structures and other vehicles.

JeepeBay logo® Brand plug-in hybrid vehicles with 4xe technology are unaffected.

Stellantis will contact customers if their vehicles are affected; notification by mail is expected to begin this month. U.S. based customers with additional questions or concerns may call 800-853-1403.

To ensure a consistent message to our customers and avoid misinformation, please ensure your customer-facing dealer personnel have reviewed the following talking points.

 

POTENTIAL CUSTOMER COMMUNICATION TOPICS

  • If a customer requires immediate assistance, please contact Customer Care on the customer’s behalf at 800-853-1403.
  • If a customer asks if there a connection between the fires and recharging: “We have not made that determination. Out of an abundance of caution, we are advising owners of MY17-18 ChryslereBay logo Pacifica Hybrid vehicles to refrain from recharging until their vehicles are remedied.”
  • If a customer asks if he or she can drive their vehicle: “We are unaware of any incidents that involve customers driving their vehicle.”
  • If a customer asks why the company is not recalling MY19-22 vehicles: “There is no data to suggest a problem with these vehicles. As with all our vehicles, if we identify a defect, we conduct a safety recall. There is no such finding for any other model years.”
  • If a customer asks what is causing the fires: “We are working to confirm the cause.”
  • If a customer asks when the company will complete its investigation: “We’re working as expeditiously as possible, within the confines of scientific and engineering disciplines. Our investigation will conclude when we’re satisfied that our findings will protect our customers.”
  • If a customer asks if there is a link to a previous recall involving ChryslereBay logo Pacifica Hybrid fires: “No. This campaign is unrelated to any other. The previous ChryslereBay logo Pacifica Hybrid campaign involved only the 12-volt battery system and a smaller number of fires.”
  • If a customer asks when a remedy will become available: “The remedy is under development. We are expediting, but with due care. Remedy development is a process that includes numerous steps from validation to writing and distributing repair instructions for service technicians.”

Thank you,

Mopar

 


Chronology :

  • On August 31, 2021, the FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance organization opened an investigation as a result of detecting a potential trend in fires in certain ChryslereBay logo Pacifica PHEVs.
  • From September 2021, to January 2022, FCA US repurchased two vehicles for origin and cause investigation.

    The cause of these fires is under investigation.
  • As of February 4, 2022, FCA US is aware of ten additional fires. The cause of these fires is under investigation.
  • As of February 4, 2022, FCA US has identified five customer records, zero warranty claims, and 12 field reports potentially relating to this issue for all markets with dates of receipt ranging from April 23, 2019, to December 14, 2021.
  • As of February 4, 2022, FCA US is not aware of any accidents or injuries potentially relating to this issue for all markets.
  • On February 6, 2022, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles.
  • As of February 21, 2022, FCA US has not made a determination of whether the HV battery pack assembly is defective and/or the root cause of these fires.

 


2 Affected Products

Vehicle

MAKEMODELYEAR
CHRYSLEReBay logoPACIFICA HYBRID2017-2018

 


28 Associated Documents

Recall Acknowledgement

RCAK-22V077-8147.pdf 776.278KB

 


Defect Notice 573 Report

RCLRPT-22V077-3486.PDF 213.975KB

 


Manufacturer Notices(to Dealers,etc) – NSRAC re FCA US LLC (FCA US) has announced a safety recall on certain 2017 and 2018 Model Year (RU) ChryslereBay logo Pacifica vehicles equipped with a 3.6L PHEV Hybrid Engine.

RCMN-22V077-3070.pdf 51.377KB

 


Manufacturer Notices(to Dealers,etc) – SAFETY RECALL Z11: MY 2017-18 CHRYSLEReBay logo PACIFICA (RU) PHEV — CUSTOMER COMMUNICATIONS

RCMN-22V077-8275.pdf 134.9KB

 


Manufacturer Notices(to Dealers,etc) – NSRAC Final re FCA US LLC (FCA US) has announced a safety recall on certain 2017 and 2018 Model Year (RU) ChryslereBay logo Pacifica vehicles equipped with a 3.6L PHEV Hybrid Engine.

RCMN-22V077-8435.pdf 52.212KB

 


Miscellaneous Document – FCA US LLC Z11 Involved Component Part Numbers ChryslereBay logo Pacifica PHEV Battery Pack Assembly

RMISC-22V077-7295.pdf 334.061KB

 


Manufacturer Notices(to Dealers,etc) – NSRAC Combo re FCA US LLC (FCA US) has announced a safety recall on certain 2017 and 2018 Model Year (RU) ChryslereBay logo Pacifica vehicles equipped with a 3.6L PHEV Hybrid Engine.

RCMN-22V077-2384.pdf 165.073KB

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-22V077-8347.pdf 127.551KB

 


Miscellaneous Document – Campaign update

RMISC-22V077-7440.pdf 164.134KB

 


Remedy Instructions and TSB

RCRIT-22V077-7110.pdf 1009.655KB

 


Recall 573 Report – 8/30/22

RCLRPT-22V077-7527.PDF 214.584KB

 


Recall 573 Report – 9/22/2022

RCLRPT-22V077-6946.PDF 214.613KB

 


Recall 573 Report – 2/21/2022

RCLRPT-22V077-7442.PDF 214.407KB

 


Remedy Instructions and TSB

RCRIT-22V077-1792.pdf 1191.213KB

 


Manufacturer Notices(to Dealers,etc) – Dealer Resource Guide – ChryslereBay logo Pacifica Plug-In Hybrid Electric Vehicles (“PHEVs”) Resource Guide September 2022

RCMN-22V077-7190.pdf 623.581KB

 


Remedy Instructions and TSB

RCRIT-22V077-7245.pdf 1191.56KB

 


Remedy Instructions and TSB

RCRIT-22V077-1585.pdf 1191.447KB

 


ISSUED Owner Notification Letter(Part 577)

RCONL-22V077-4454.pdf 176.343KB

 


Manufacturer Notices(to Dealers,etc) – Z11 RENTAL ALLOWANCE CLARIFICATION

RCMN-22V077-6209.pdf 227.933KB

 


Miscellaneous Document – Unapproved Email Distribution of 10/27/22

RMISC-22V077-5317.pdf 135.199KB

 


Remedy Instructions and TSB

RCRIT-22V077-5391.pdf 1214.721KB

 


Manufacturer Notices(to Dealers,etc) – Z11 RECALL STEPS

RCMN-22V077-2129.pdf 156.844KB

 


Remedy Instructions and TSB

RCRIT-22V077-2535.pdf 922.664KB

 


Miscellaneous Document – Email Blast

RMISC-22V077-1277.pdf 170.119KB

 


Remedy Instructions and TSB

RCRIT-22V077-7319.pdf 1072KB

 


Recall Quarterly Report #1, 2022-4

RCLQRT-22V077-6799.PDF 211.145KB

 


Remedy Instructions and TSB

RCRIT-22V077-7220.pdf 1070.937KB

 


ISSUED Renotification Notice

RCRN-22V077-4271.pdf 102.511KB

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V077&docType=RCL

 


 

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AIMILER Level 2 Electric Vehicle (EV) Charger(WIFI APP/Plug-play), 32A, 25ft Cable ETL Certified, 220V-240V NEMA 14-50P Plug EVSE w/ J1772 Connector, Portable EV Car Charging Stations for Home Level 2
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ChargePoint HomeFlex Level 2 EV Charger J1772 - Fast Smart Battery Power Charging at Home for Electric Automobile Vehicles
  • Charge With Confidence: ChargePoint builds reliable, flexible EV charging stations for home, business, and fleets. Get 24/7 support and access to hundreds of thousands of North American charging locations.
  • Charge Smart: With the user-friendly ChargePoint Mobile App, you can control your electric car charger, manage reminders, connect to smart home devices, find stations, get data and charging info, and access the latest features. Note: WIFI is needed for certain functionalities and troubleshooting steps if connectivity issues arise.
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  • Safe & Durable: Rely on this UL-certified EV Charger for safe home charging. It can be installed indoors or outdoors by an electrician and includes a cold-resistant cable.
  • Fast & Powerful: This EV Charger charges 9× faster than a 120V outlet, delivering up to 45 mi/hr., dependent upon your vehicle. It features a J1772 connector for all non-Tesla EVs and requires a 20A or 80A circuit. For Tesla EVs, this will require an adapter.
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Lectron Level 1 EV Charger - ETL Certified, 120V, 15 Amp, 16 ft Extension Cord & J1772 Cable - Portable Electric Car Charger for J1772 EVs and Plug-in Hybrid Vehicles
  • Lectron Level 1 EV Charger - ETL Certified, 120V, 15 Amp, 16 ft Extension Cord & J1772 Cable - Portable Electric Car Charger for J1772 EVs with NEMA 5-15 Plug
  • CONVENIENT OVERNIGHT CHARGING - The Lectron 15 Amp EV Charger is a more affordable and faster charging option compared to other Level 2 EV chargers, delivering an extra 40-50 miles of overnight charge at home — without breaking the bank
  • J1772 COMPATIBILITY – Designed for EVs and plug-in hybrids with a standard J1772 charging inlet. Not a Tesla-native charger; Tesla vehicles require a compatible J1772-to-Tesla adapter. Please confirm vehicle inlet and adapter compatibility before purchase.
  • SAFE AND RELIABLE - FCC and ETL certified (UL2594 standard) for safety with overvoltage, overcurrent, and short circuit protection; Energy Star certified for efficiency; IP65 rated for dust and water resistance
  • PORTABLE CONVENIENCE - Whether you're on a road trip or visiting a friend, you can easily plug in your EV and charge with our portable EV charger. Please refer to the included User Manual for complete operating instructions and compatibility requirements
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AIXINE Level 1&2 EV Charger,J1772 16A EV Charger with 25FT Extension Cord Cable,Portable Electric Car Charger 240V NEMA 6-20 Plug&120V NEMA 5-15 Adapter for All SAE J1772
  • 【AIXINE INNOVATION】Rooted in the USA,refined through 8 years of continuous innovation.AIXINE dedicated to creating a safe,smart,and sustainable living experience for eco-conscious households.
  • 【J1772 COMPATIBILITY】Compatible with all J1772 standard electric vehicles,the AIXINE Level 2 EV charger compatible with numerous automotive brands on the market.
  • 【QUALIFICATION CERTIFICATION】Core components are meticulously crafted from the top worldwide factories,Compliance with UL,ETL,FCC standards.
  • 【FLEXIBILITY AND EFFICIENCY】The electric vehicle charger comes equipped with a NEMA 6-20 plug and a NEMA 6-20 to 5-15 adapter.It delivers fast charging at 240V 16A (3.68kW) and includes a 25-ft (7.62-meter) cable,making it easy to charge your vehicle anywhere.
  • 【PORTABLE AND DURABLE】Featuring industrial-grade construction with high-strength TPU-coated cables and 99.95% oxygen-free copper cores.AIXINE EV charger boasts an IP67 rating for reliable operation in extreme temperatures.Its ultra-portable design comes with a waterproof storage case,fitting easily into your trunk for dependable road trip charging.
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MECMO EV Charger Holder SAE J1772 Wall Mount Charging Cable Hanger Organizer, Nozzle Holster Dock Electric Vehicle EVSE PHEV Car Plug Space Saving Garage Wall Connector Cord Hook for Outdoor Indoor
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Last update on 2026-06-19 / Affiliate links / Images from Amazon Product Advertising API

 


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