ZB7 Communication Loss May Cause Engine Shutdown – 2021-2023 Jeep Wrangler

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November 23, 2022 NHTSA CAMPAIGN NUMBER: 22V865000

Communication Loss May Cause Engine Shutdown

An engine shutdown can cause a loss of drive power, increasing the risk of a crash.

 

NHTSA Campaign Number: 22V865

Manufacturer Chrysler (FCA US, LLC)

Components ENGINE

Potential Number of Units Affected 62,909

 

Summary

Chrysler (FCA US, LLC) is recalling certain 2021-2023 Jeep Wrangler 4xe vehicles equipped with 2.0L Plug-In Hybrid Electric Vehicle engines. A loss of communication may cause an engine shutdown.

 

Remedy

There is more than one involved component and calibration software. Updating the calibration software in the Transmission Control Module, Hybrid Control Processor and Auxiliary Hybrid Control Processor that changes fail safe from shut down to limp home. Dealers will update the transmission control module software, Hybrid Control Processor and Auxiliary Hybrid Control Processor, free of charge. Owner notification letters were mailed December 22, 2022. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC’s number for this recall ZB7.

 

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

 


New Safety Recall Advanced Communication – ZB7

FCA US LLC (FCA US) has announced a safety recall on certain 2021 through 2023 Model Year (JL) Jeep® Wrangler 4xe PHEV vehicles equipped with a 2.0L engine (sales code ECX).

 

REASON FOR THIS SAFETY RECALL

Some of the above vehicles may experience an engine shut down condition caused by diagnostic reactions to faults caused by loss of communication. An engine shut down condition may result in an unexpected loss of motive power while driving, which can cause a vehicle crash without prior warning.

 

SERVICE ACTION

FCA US will conduct a voluntary safety recall on all affected vehicles to update vehicle control software. 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. This recall is estimated to launch in 1st Quarter of 2023.

 


(Revision 2) February 2023

Dealer Service Instructions for:

Safety Recall ZB7 / NHTSA 22V-865 Loss of Motive Power

 

NOTE: BPCM flash added to procedure and need to disable contactors removed.

 

Remedy Available

2021-2023 (JL) Jeep Wrangler 4xe

NOTE:  This recall applies only to the above vehicles equipped with a 2.0L Plug-in Hybrid Electric Vehicle (“PHEV”) engine.

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 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

About 62,900 of the above vehicles may experience an engine shut down condition caused by diagnostic reactions to faults caused by loss of communication. An engine shut down condition may result in an unexpected loss of motive power while driving, which can cause a vehicle crash without prior warning.

 

Repair

IMPORTANT: Make sure the Battery Pack Control Module (BPCM) calibration software is up to date BEFORE starting the repair process.

Repair process: Update the calibration software in the Power Inverter Module (PIM), comprised of the Hybrid Control Processor (HCP) and Auxiliary Hybrid Control Processor (AHCP), then update the calibration software in the Transmission Control Module (TCM).

IMPORTANT: Software update sequence outlined is CRITICAL! 

1. BPCM – MUST be up to date BEFORE starting the repair process.

2. PIM comprised of the HCP and AHCP.

3. TCM

Do NOT deviate from that order or vehicle software will not update properly.

 

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

No parts are required to perform this service procedure.

 

Parts Return

No parts return required for this campaign.

 

Special Tools

The following special tools are required to perform this repair:

➢ NPN wiTECH MicroPod II
➢ NPN Laptop Computer
➢ NPN wiTECH Software

 

Service Procedure 

NOTE: The wiTECH scan tool must be used to perform this Safety Recall.  The wiTECH software is required to be at the latest release level before performing this procedure.

 

NOTE: The Battery Pack Control Module (BPCM), Hybrid Control Processor (HCP), Auxiliary Hybrid Control Processor (AHCP) and Transmission Control Module (TCM) must be updated to the latest available software calibration level after completing this Safety Recall. This flash sequence is critical.

 

NOTE: If this software update flash process is interrupted/aborted, the flash should be restarted.

 

NOTE: It is normal for the high voltage charging lamp on the dash to flash like there is a charging system failure while performing software updates.

 

  1. Install a battery charger 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” your “Password” and your “Dealer Code”, then select “Finish” at the bottom of the screen.

 

  1. Starting at the “Vehicle Selection” screen, select the vehicle to be updated.

 

  1. From the “Action Items” screen, select the “All Flashes” tab. Inspect if new software flashes are available for the “BPCM” and/or “HCP” and/or “TCM”.

 

  • If no modules have new software available, then proceed to Step 26 and claim the inspection LOP to complete this recall.

 

  • If one or more modules have new software available, then continue with Step 8 and follow the flash sequence of BPCM, HCP, TCM.

 

  1. Create a Vehicle Scan Report (VSR) before proceeding with software updates.

 

  1. Ensure there are no current DTCs that could cause concern with modules being flashed. If any questions, please share the VSR with the STAR center.

 

  1. From the “Action Items” screen, select the “All Flashes” tab.

 

  • Select “BPCM” by clicking the arrow on the right side of the screen. Read the special flash instructions, then select “OK”. Continue with Step 11.

 

  • If “BPCM” is not displayed as one of the available flashes, the BPCM software is already at the current software level and does not require updating. Proceed to Step 15.

 

  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. Once the software is confirmed to be at the latest available calibration level, select “View DTCs”.

 

  1. Select the “Clear All DTCs” tab, then click “Clear All DTCs” and then select “Close”. It may be necessary to cycle the ignition OFF to RUN to clear the codes.

 

NOTE: The PIM contains two processors, Hybrid Control Processor (HCP) and Auxiliary Hybrid Control Processor (AHCP).  The HCP and AHCP are combined into one PIM software update.  The software update must begin with updating the HCP.  The AHCP will update immediately following the HCP.

 

  1. From the “Action Items” screen, select the “All Flashes” tab.

 

  • Select “HCP” by clicking the arrow on the right side of the screen. Read the special flash instructions, then select “OK”. Continue with Step 16.

 

  • If “HCP” is not displayed as one of the available flashes, the PIM software is already at the current software level and does not require updating. Proceed to Step 20.

 

  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. Once the software is confirmed to be at the latest available calibration level, select “View DTCs”.

 

  1. Select the “Clear All DTCs” tab, then click “Clear All DTCs” and then select “Close”. It may be necessary to cycle the ignition OFF to RUN to clear the codes.

 

  1. From the “Action Items” screen, select the “All Flashes” tab.

 

  • Select “TCM” by clicking the arrow on the right side of the screen. Read the special flash instructions, then select “OK”. Continue with Step 21.

 

  • If “TCM” is not displayed as one of the available flashes, the TCM software is already at the current software level and does not require updating. Proceed to Step 25.

 

  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. Once the software is confirmed to be at the latest available calibration level, select “View DTCs”.

 

  1. Select the “Clear All DTCs” tab, then click “Clear All DTCs” and then select “Close”. It may be necessary to cycle the ignition OFF to RUN to clear the codes.

 

  1. Create a VSR to ensure P0AA4/P0AA1 or any DTC is not active or pending.

 

  1. Turn the ignition to the “OFF” position and then remove the wiTECH micro pod II device from the vehicle.

 

  1. Remove the battery charger from the vehicle.

 

  1. Return the vehicle to the customer or inventory.

 

RCMN-22V865-7501

 

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.

 


Chronology :

  • On September 8, 2021, FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance (“TSRC”) opened an investigation into 2021-2023 MY Wrangler 4xe PHEVs for a loss of motive power.
  • From September 2021, through October 2022, FCA US TSRC conducted an analysis of stall reports and vehicle history and determined that the affected vehicles reported multiple cause and correction details with varied commonality.
  • As of November 3, 2022, FCA US is aware of 112 customer assistance records, 196 warranty claims, and 65 field reports potentially related to this issue for all markets with dates of receipt ranging from December 17, 2020, to October 26, 2022.
  • As of November 3, 2022, FCA US is aware of two accidents and one injury potentially related to this issue for all markets.
  • On November 17, 2022, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles.

 


3 Affected Products

Vehicle

MAKE MODEL YEAR
JEEP WRANGLER 2021-2023

 


15 Associated Documents

Manufacturer Notices(to Dealers,etc) – New Safety Recall Advanced Communication – ZB7

RCMN-22V865-8931.pdf 48.192KB

RCMN-22V865-8931

 


Defect Notice 573 Report

RCLRPT-22V865-9895.PDF 213.973KB

RCLRPT-22V865-9895

 


Manufacturer Notices(to Dealers,etc) – New Safety Recall Advanced Communication – ZB7

RCMN-22V865-2690.pdf 50.581KB

RCMN-22V865-2690

 


Recall Acknowledgement

RCAK-22V865-1952.pdf 692.321KB

RCAK-22V865-1952

 


Remedy Instructions and TSB

RCRIT-22V865-0023.pdf 337.965KB

RCRIT-22V865-0023

 


Remedy Instructions and TSB

RCRIT-22V865-4394.pdf 338.914KB

RCRIT-22V865-4394

 


Recall 573 Report – 12/22/22

RCLRPT-22V865-2005.PDF 214.014KB

RCLRPT-22V865-2005

 


ISSUED Owner Notification Letter(Part 577)

RCONL-22V865-8324.pdf 175.258KB

RCONL-22V865-8324

 


Recall Quarterly Report #1, 2022-4

RCLQRT-22V865-1606.PDF 211.151KB

RCLQRT-22V865-1606

 


Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re RETRACTED Dealer Service Instructions for: Safety Recall ZB7 / NHTSA 22V-865 Loss of Motive Power

RCMN-22V865-7501.pdf 400.413KB

RCMN-22V865-7501

 


ISSUED Renotification Notice

RCRN-22V865-8853.pdf 138.051KB

RCRN-22V865-8853

 


Recall Quarterly Report #2, 2023-1

RCLQRT-22V865-1220.PDF 211.258KB

RCLQRT-22V865-1220

 


Miscellaneous Document – FCA USA LLC ZB7 Involved Component Part Numbers Jeep Wrangler PHEV Vehicle Control Calibrations

RMISC-22V865-9808.pdf 101.353KB

RMISC-22V865-9808

 


Recall 573 Report – 7/13/23

RCLRPT-22V865-1647.PDF 214.298KB

RCLRPT-22V865-1647

 


Recall Quarterly Report #3, 2023-2

RCLQRT-22V865-7965.PDF 211.353KB

RCLQRT-22V865-7965

 


Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V865&docType=RCL

 


 

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

ZB7 Communication Loss May Cause Engine Shutdown - 2021-2023 Jeep Wrangler | small light CarDAQ-Plus 3 All Makes J2534 Reprogramming Tool
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BOSCH Automotive Tools MTECH2 Mastertech II J2534 VCI

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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

ZB7 Communication Loss May Cause Engine Shutdown - 2021-2023 Jeep Wrangler | 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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Last update on 2024-02-17 / Affiliate links / Images from Amazon Product Advertising API

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