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April 27, 2023 NHTSA CAMPAIGN NUMBER: 23V303000
Unsecured Fuse inside High Voltage Battery
Excessive heat may cause the fuse to fail and result in a loss of drive power, increasing the risk of a crash.
NHTSA Campaign Number: 23V303
Manufacturer Chrysler (FCA US, LLC)
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 2,564
Summary
Chrysler (FCA US, LLC) is recalling certain 2022-2023 Jeep
Wrangler Plug-In Hybrid Electric vehicles (PHEV). The high voltage (HV) battery pack assembly was built with incorrect fasteners to secure the 200-amp fuse, which can generate excessive heat.
Remedy
Dealers will inspect and replace the HV battery fuse, as necessary. Dealers will also inspect the battery assembly for damage and replace it, if necessary. Repairs will be performed free of charge. Owner notification letters are expected to be mailed June 16, 2023. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler
’s number for this recall is 53A. This recall is an expansion of previous recall 22V-768.
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 – 53A
FCA US LLC (FCA US) has announced a safety recall on certain 2022 and 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 Plug-In Hybrid Electric Vehicles (PHEV) may have been built with incorrect fasteners securing the 200 amp fuse in the High Voltage (HV) battery. An incorrect fastener can cause high resistance in the 200 amp fuse interface, which will generate heat. Customer may notice a Malfunction Indicator Lamp (MIL), a change in drivability, and/or noise at the HV battery pack assembly. Excessive heat in the fuse interface may cause the fuse to fail resulting in a loss of motive power, which can cause a vehicle crash without prior warning.
SERVICE ACTION
FCA US will conduct a voluntary safety recall on all affected vehicles to inspect the HV battery fuse for the correct fasteners. If an incorrect fastener is found, FCA US will replace the fuse assembly. If charring or discoloration is present on the bus bars, FCA US will replace the HV battery pack assembly. 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 2nd Quarter of 2023.
SAFETY RECALL – NORTH AMERICA
Reference: 53A / NHTSA 23V-303
Revision | Edition | Detail |
0 | May 2023 | Initial Version. |
SYMPTOM DESCRIPTION
The high voltage battery on about 2,560 of the above vehicles may have been built with incorrect fasteners securing the 200 amp fuse in the High Voltage (HV) battery. An incorrect fastener can cause high resistance in the 200 amp fuse interface, which will generate heat. Customer may notice a Malfunction Indicator Lamp (MIL), a change in drivability, and/or noise at the HV battery pack assembly. Excessive heat in the fuse interface may cause the fuse to fail resulting in a loss of motive power, which can cause a vehicle crash without prior warning.
SCOPE
This recall applies only to the above Plug-In Hybrid Electric Vehicles (PHEV) equipped with a 2.0L engine (sales code ECX).
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.
REPAIR TO BE PERFORMED
Inspect fuse tray 200A fuse for proper fasteners and signs of carbon marks on bus bars. If incorrect fasteners are found with no carbon marks on bus bars, replace the 200A fuse and fasteners. If carbon marks are found, photograph the fasteners and bus bar contacts then replace HV battery as directed by the service procedure.
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: All vehicles will require the Authorized Modifications Label.
Part No. | Qty. | Part Name |
04275086AE | 1 | Label – Authorized Modifications |
NOTE: If Inspection Procedure confirms that a new fuse and fasteners are required, order Fuse Campaign Kit below:
Part No. | Qty. | Part Name |
CSANZ711AA | 1 | Fuse Campaign Kit |
Campaign kit contains the following components: | ||
1 | 200 Amp Fuse | |
2 | Fasteners |
NOTE: If Inspection Procedure confirms that a new battery is required, open a STAR case. Photographs of battery contacts damage must be attached to the STAR case.
Part No. | Qty. | Part Name |
68488244AA | 1 | 400V Battery |
68163849AB | 1 | Coolant |
06512293AA | 3 | Bolt, Rear Seat |
PARTS RETURN
Return instructions for the old battery are included in the container with the new battery. There is a core charge for this battery.
NOTE: If the battery return instructions are missing, a battery return I sheet can be downloaded from DealerCONNECT on the “Parts Tab” under the heading “Returns”.
SPECIAL TOOLS
The following special tools are required to perform this service procedure:
Number | Description |
126-1587 | Meter, Multi –
Originally Shipped In Kit Number(s) 10389. |
NPN | High Voltage Personal Protection Equipment: Hard Hat, Safety Glasses, Protective Gloves, Safety Barriers, etc. (Consult Service Library High Voltage Safety Procedures) |
If service procedure determines that the battery must be replaced. The following special tools are required to perform battery replacement:
Number | Description |
NPN | wiTECH MicroPod II![]() |
NPN | Laptop Computer |
NPN | wiTECH Software |
2035100082 | Covers, HEV Battery Terminal |
2035203080 | Eyebolt, 10mm |
2035200080 | Lift Straps, HV Battery |
SERVICE PROCEDURE
Only individuals with high voltage training and repair qualifications should be allowed to handle, troubleshoot or repair High Voltage or Hybrid components or systems.
Always wear safety glasses.
Review High Voltage Safety Procedures in Service Library section 08, Standard Procedures.
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.
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.
A. Power Down the High Voltage System
- Power down the high voltage system. If the HV battery will not power down or the vehicle has a welded contactor DTC active that will not clear, stop and perform the “HV Battery Servicing with Welded Contactor(s)” at the beginning of the PHEV Battery removal procedure in Service Library.
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 is done by removing the test points access cover.
- The high voltage power down procedure must be performed to ensure that the high voltage battery is properly powered down.
- The technician must know the whereabouts of the test points access cover throughout the repair.
- The technician must ensure that the test points access cover is not reinstalled while service is being performed.
- The technician must recheck that the test points access cover has not been reinstalled in cases where the vehicle was unattended.
- 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). See High Voltage Safety Procedures in Service Library section 08, Standard Procedures.
- 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 highvoltage. Do not insert probes, tools, objects or fluids into damaged high-voltage cables or components.
- Disconnect any charging equipment. Do not plug in the EVSE Recharge Coupler when working on the vehicle.
- Turn the ignition to Off by pressing the keyless go button (1) and move keys away from the car a minimum of 20 feet (Figure 1).
NOTE: If the READY indicator is NOT illuminated in instrument cluster, the vehicle is already shut off. DO NOT push the start/stop button as the vehicle may start.
- Wait five minutes to allow the high-voltage system to shut down without setting a fault code.
- Disconnect the IBS wire harness connector (2). Remove and isolate the battery negative cable (1) using Covers, HEV Battery Terminal 2035100082 (Figure 2).
- Remove the F09 (5 amp) fuse (3) from the Power Distribution Center (PDC) (Figure 2).
NOTE: This removes the fused B+ power supply to the Integrated Dual Charger Module (IDCM). Disabling the IDCM disables the DC/DC conversion between the HV battery and the charging output to the low voltage side of the system.
- 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.
- Using a multi-meter, check for voltage at the PDC fused B+ terminal to verify the low voltage system is powered down. The 12-volt electrical system is now powered down. There should be no voltage present with the IDCM disabled and the 12-volt battery disconnected.
- The high voltage service test points access cover (1) is located on the battery pack, under driver side rear seat cushion (Figure 3).
- Remove the M6 Torx screws (2) from the high voltage service test points access cover (1) (Figure 3).
- Carefully remove the test points access cover (1) and set in a protected location such that the cover plate alignment and HVIL pins are not damaged (Figure 3).
NOTE: Lift the cover straight up to avoid bending or Access Cover damaging the pin on the cover that is used to engage the HVIL switch (Figure 4).
NOTE: Removal of the test points access cover will affect the following:
- Disables the High Voltage Battery System by disengaging the internal High Voltage Interlock (HVIL) pin from the switch.
- Provides access to the high voltage positive and high voltage negative test points.
NOTE: These circuits are a sense circuit connected through large resistors inside the high voltage battery to the high voltage bus cables after the contactors. These circuits are safe even when high voltage is present on the circuits due to the large resistors reducing these circuits to milliamperes.
- Provides access to the fuse cover screw.
- Allows access to a service lockout loop.
NOTE: Always observe these precautions prior to taking a high-voltage measurement:
- Be sure to utilize the proper Personal Protection Equipment (PPE) when working on any high voltage system.
- Rated and non-expired rubber insulating gloves with leather protectors.
- Have known good test leads.
- Verify the multi-meter leads are rated “CAT III 1,000V”. This should be printed on the multi-meter leads.
- Install the multi-meter leads in the BLACK and RED sockets on the right side of the Fluke 1587 (VΩ (RED) and COM (BLACK)).
- Switch the FLUKE 1587 to the DC Volts selection and press the RANGE button until the 500V range is selected – just one digit (a zero) is displayed.
- Test the multi-meter operation by measuring the voltage across the 12-volt Battery.
- 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 manufacturer’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 (Figure 5).
- Using the Fluke multi-meter, measure the voltage at the high voltage positive and high voltage negative test points (Figure 6):
- Measure for voltage between the positive and negative high voltage test points.
- Measure for voltage between positive test point and chassis ground.
- Measure for voltage between negative test point and chassis ground.
- The voltage reading should be 0 volts. (Some residual voltage may be present, up to 2.0 volts may be normal) (Figure 6).
- If the voltage measured is below 2 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 60 volts, an internal condition exists within the high voltage battery such as stuck contactors, that are preventing it from being powered down. This should be accompanied by contactor stuck DTCs. Do not attempt to carry out testing on any of the vehicle’s high-voltage components or wiring. The HV Battery Pack requires replacement. Reference the HV BATTERY SERVICING WITH WELDED CONTACTOR(S) procedure at the top of the HV PHEV BATTERY REMOVAL AND INSTALLATION procedure for safely removing a high voltage battery that will not power down (Refer to 08 – Electrical/Battery System/BATTERY/Removal and Installation).
- If the voltage is between 2.0 volts and 60 volts, the HV system is safe to work on, however there is a problem that should be diagnosed. Disconnect each of the following HV modules one at a time and check the voltage at the test points. If the voltage drops to 2.0 volts or less, the faulted module has been found. Reconnect each module before continuing to the next.
-
- Integrated Dual Charger Module (IDCM)
-
- Electronic A/C Compressor (EAC)
-
- HV Coolant Heater
B. High Voltage Fuse Inspection/Replacement
- Do the 200A fuse fasteners have a flange around the screw head or not as shown in (Figure 9)?
- Correct Screws – Flange Head: No further action required. Vehicle may be reassembled. Proceed to Step 10.
- Incorrect Screws – No Flange: Continue with Step 4.
- Inspect the 200A fuse and bus bar contacts for any signs of carbon marking as shown in (Figure 10).
- Photograph the bus bar and 200A fuse contact surfaces. Photographs showing the contact surfaces of the bus bar and 200A fuse will be required for the parts ordering process (Figure 10).
- Were the bus bar contacts clean or carbon marked as shown in (Figure 10)?
- Clean, no Carbon Marks: Replace the 200A fuse and fasteners. Continue with Step 8.
- Visible Carbon Marks: Battery will require replacement Proceed to Section C.
- Order and obtain the 200A fuse kit with proper screws. The photographs taken previously will be required to place the parts order.
- Replace the 200A fuse and fasteners from the kit then tighten the screws to 5.7 N·m (50 in. lbs.) (Figure 8)
- Install the fuse cover then tighten the cover screw to 6 N·m (53 in. lbs.) (Figure 7).
- Power up the HV battery system.
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 test points access cover.
- 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 test points access cover throughout the repair.
- The technician must ensure that no one reinstalls the test points access cover while service is being performed.
- The technician must recheck that the test points access cover has not been reinstalled in cases where the vehicle was unattended.
- Use of an insulation tester such as the Fluke Meter, Multi 126-1587 is recommended for Plug-In Hybrid Electric Vehicle (PHEV) circuit testing. Perform the multi-meter functionality tests per the manufacturer’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: Always observe these precautions prior to taking an isolation resistance measurement:
- Have known good test leads
- Set the test voltage to 500 Volts
- Always wear safety glasses
- Using the Meter, Multi 126-1587 measure and record the isolation resistance between the high voltage positive test point and chassis ground (Figure 11).
- Using the Meter, Multi 126-1587 measure and record the isolation resistance between the high voltage negative test point and chassis ground (Figure 12).
- Isolation resistance should be 2.3 Mohms (+/-.2). If the measured isolation resistance is outside of this range, a loss of isolation condition exists within the high voltage circuitry. Do not continue the High Voltage Power Up procedure until the condition causing the loss of isolation is corrected.1
- Install the test points access cover (1) to the battery pack and tighten the eight M6 Torx screws (2) to 8.8 N·m (78 in. lbs.) (Figure 13).
- Remove the cover, connect the negative battery cable to the IBS and tighten the fastener (1) to 10N·m (7 ft. lbs.) (Figure 14).
- Install the F09 (5 amp) IDCM fuse (3) in the Power Distribution Center (PDC) (Figure 14).
- Connect the IBS harness connector (2) (Figure 14).
- Perform Section D. Install the Authorized Modifications Label.
- If fuse did not require replacement, record on F09 and IBS Connector label “Fuse Inspected”.
- If fuse did require replacement, record on label “Fuse Replaced”.
- For California residents, complete Section E. Proof of Correction Form.
- Return the vehicle to customer or inventory.
C. HV Battery Replacement
NOTE: Observe the following precautions when handling the HV battery pack:
- DO NOT touch the high voltage terminals.
- Always use the battery pack 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 nonconducting (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: The HV battery pack weighs 167 kg (368 lb.).
NOTE: If the High Voltage (HV) battery is missing its return instructions, contact the UPS Call Center 800567-9989.
- Loosen the cap on the high voltage cooling reservoir.
- Raise and support the vehicle.
- Remove the eight push pin fasteners from the front air dam (1) (Figure 15).
- Remove the bolts (2) (Figure 15).
- Remove the air dam (1) (Figure 16).
- Remove the support and lower the vehicle.
- Disconnect the vacuum boost hose quick coupling (1) from the air cleaner body cover (Figure 17).
- Push in and hold both sides of the gray release (1) on the quick coupling (Figure 18).
- Pull the quick coupling away from air cleaner body cover.
- Disconnect the fuel vapor purge hose quick coupling (2) from the air cleaner body cover (Figure 17).
- Do not press on the green anti-tampering feature (1) (Figure 19).
- Push in and hold only the side of the release (2) with the green anti-tampering feature and pull the quick coupling away from air cleaner body cover.
- Loosen the clean air hose band clamp (2) (Figure 20).
- Remove the bolt (3) (Figure 20).
- Disengaging the air cleaner body (1) from the two lower rubber grommets and from the clean air hose (Figure 20).
- Raise and support the vehicle.
- Position a drain pan under the coolant hoses (Figure 21).
- Remove the coolant hoses from the coolant line and drain the power electronics cooling system (Figure 21).
- Once the system is completely drained, reinstall the coolant hose to the coolant line (Figure 21).
- Remove the fasteners (1) and the skid plate (2) from the vehicle (Figure 22).
- Disconnect the HV wire harness connectors (1) and (2) from the HV battery (Figure 23).
- Cap the HV cables using Covers, HEV Battery Terminal 2035100082.
NOTE: A Plug-in Hybrid Electric Vehicle (PHEV) HV Battery Cover/Plug Kit is also available from Mopar® Parts.
- Remove the support and lower the vehicle.
- Using a trim stick, release and remove the B-pillar trim cover (1) (Figure 24).
- Disconnect the wire harness connector (2) and release the door tether from the support bracket (1) (Figure 25).
- Remove the bolt (2) securing the door check (1) (Figure 26).
- Remove the nuts (3) and lift the door up off hinges (1) and remove (Figure 27).
- Raise the rear seat cushion.
- Remove the fasteners (1) from the side high voltage battery trim panels (2) (Figure 28).
- Using a trim stick or equivalent, remove the high voltage trim panel upward to release the retainers and remove the trim panel. Repeat for the passenger side.
- Lower the rear seat cushion.
- Using a trim stick or equivalent, release the retainers from the front high voltage battery closeout and remove from vehicle (Figure 29).
- Remove the rear seat to load floor gap hider (Figure 30).
- Disconnect the wire harness connectors, if equipped (4) (Figure 31).
- Remove the nut for the center seat belt anchor (6). Remove the seat belts from the floor stud (Figure 31).
- Disconnect the wire harness connectors (3), if equipped (Figure 32).
- Remove the bolts (1) at the front of the rear seat (Figure 32).
- Remove silencer pad (Figure 33).
- Remove the seat from the vehicle.
- Remove the fastener (1) and the chassis ground cable from the HV battery (2) (Figure 34).
- Disconnect the HV wire harness connectors (1) (Figure 35).
NOTE: Use an absorbent pad to collect any coolant
that may leak from the battery into the interior of the Connectors
NOTE: The HV battery pack weighs 167 kg (368 lb.).
- Remove the bolts (1) securing the HV battery to the vehicle (Figure 37).
- Install two Eyebolt, 10mm 2035203080 with the nuts to the front support mounting holes (1) (Figure 38).
- Thread the other two Eyebolt, 10mm 2035203080 (1) into the threaded holes next to the HV battery pack mounting bolt holes (2) on the rear side of the HV battery pack (Figure 39).
- Connect the Lift Straps, HV Battery 2035200080 to the eyebolts and the lifting device. Adjust the straps so that the battery will be level during lifting as shown in the picture (Figure 40).
- Remove the HV battery pack from the vehicle.
NOTE: When the HV battery pack is being replaced:
- Refer to the information supplied with the NEW 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.
- Place the HV battery pack in the shipping container or in a suitable storage location properly supported to prevent damage to the underside of the battery.
- Attach the Eyebolt, 10mm 2035203080 to the new HV battery pack in the same locations that were used for the removal. Connect the Lift Straps, HV Battery 2035200080 on the front and rear eyelets.
- Secure the HV battery pack to the lifting device.
- Install the HV battery pack in the vehicle making sure that the mounting holes align with the bolt holes in the body.
- Remove the lifting strap and eyebolts.
- Install the HV battery pack bolts (1) and tighten to (Figure 37):
- High Voltage Battery to Chassis M10 Bolts tighten to 45N·m (33 ft. lbs.).
- High Voltage Battery to Chassis M8 Bolts tighten to 21N·m (15 ft. lbs.).
- Install the chassis ground cable to the HV battery ground stud (1) and tighten to 9N·m (80 in. lbs.) (Figure 36).
- Connect the three HV wire harness connectors (1) (Figure 34).
- Install the silencer pad (Figure 33).
- Install the rear seat to the vehicle.
- Install the bolts at the front of the rear seat and tighten to 70N·m (52 ft. lbs.).
- Connect the wire harness connectors, if equipped (Figures 31 and 32).
- Install the seat belts from the floor stud.
- Install the nut for the center seat belt anchor and tighten to 70N·m (52 ft. lbs.).
- Raise the rear seat cushion.
- Install the rear seat to load floor gap hider.
- Align and install the retainers from the front high voltage battery closeout to the vehicle (Figure 29).
- Install the high voltage trim panel and press downward to seat the retainers (Figure 28).
- Install the fasteners to the side high voltage battery trim panels and tighten securely.
- Lower the rear seat cushion.
- Set the door into place on the hinges and install the door hinge pivot nuts. Tighten the nuts to 6N·m (53 in. lbs.) (Figure 27).
- Install the door check strap bolt securing the door check and tighten to 9N·m (80 in. lbs.) (Figure 26).
- Connect the wire harness connector and secure the door tether to the support bracket (Figure 25).
- Align and install the B-pillar trim cover (Figure 24).
- Raise and support the vehicle.
NOTE: When connecting the High Voltage connection verify that the connectors are clean and seated properly.
- Remove the battery port covers and transfer them to the old battery. Connect the HV wire harness connectors (1) and (2) to the HV battery and tighten to 9N·m (80 in. lbs.) (Figure 23).
- Install the battery skid plate (2) and tighten the fasteners (1) to 25N·m (18 ft. lbs.)
- Remove the support and lower vehicle.
WARNING: ANTIFREEZE COOLANT IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASED COOLANT PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE; PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN AND OTHER MOVING COMPONENTS WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED; PERSONAL INJURY CAN RESULT.
WARNING: WEAR APPROPRIATE EYE AND HAND PROTECTION WHEN PERFORMING THIS PROCEDURE.
- Fill the battery cooling system.
NOTE: Fill the High Voltage (HV) battery cooling system with the recommended MOPAR Antifreeze Coolant (Refer to 04 – Vehicle Quick Reference/Capacities and Recommended Fluids/Specifications in Service Library).
- Power up the HV battery system.
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 test points access cover.
- 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 test points access cover throughout the repair.
- The technician must ensure that no one reinstalls the test points access cover while service is being performed.
- The technician must recheck that the test points access cover has not been reinstalled in cases where the vehicle was unattended.
- Use of an insulation tester such as the Fluke Meter, Multi 126-1587 is recommended for Plug-In Hybrid Electric Vehicle (PHEV) circuit testing. Perform the multi-meter functionality tests per the manufacturer’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.
- Remove the M6 Torx screws from the high voltage service test points access cover (Figure 41).
- Carefully remove the test points access cover and set in a protected location such that the cover plate alignment and HVIL pins are not damaged (Figure 41).
NOTE: Lift the cover straight up to avoid bending or damaging the pin on the cover that is used to engage the HVIL switch.
NOTE: Always observe these precautions prior to taking an isolation resistance measurement:
- Have known good test leads
- Set the test voltage to 500 Volts
- Always wear safety glasses
- Using the Meter, Multi 126-1587 measure and record the isolation resistance between the high voltage positive test point and chassis ground (Figure 42).
- Using the Meter, Multi 126-1587 measure and record the isolation resistance between the high voltage negative test point and chassis ground (Figure 43).
- Isolation resistance should be 2.3 Mohms (+/-.2). If the measured isolation resistance is outside of this range, a loss of isolation condition exists within the high voltage circuitry. Do not continue the High Voltage Power Up procedure until the condition causing the loss of isolation is corrected.
- If required, remove the lockout-tagout padlock from the service lockout loop (1) (Figure 44).
- Install the test points access cover (1) to the battery pack and securely tighten the eight M6 Torx screws (2), identified with blue circles (Figure 44).
- Remove the cover, connect the negative battery cable to the IBS and tighten the fastener (1) to 10N·m (7 ft. lbs.) (Figure 45).
- Install the F09 (5 amp) IDCM fuse (3) in the Power Distribution Center (PDC) (Figure 45).
- Connect the IBS harness connector (2) (Figure 45).
- Using the scan tool, delete any DTCs that may have set due to the IDCM fuse being removed. Turn the key OFF and wait 2 minutes,
- Use the scan tool and flash program the BPCM with the latest software.
- Use the scan tool and perform the “Enable Contactor for Service” procedure in BPCM.
NOTE: If these procedures are not performed, the vehicle will not start. The high voltage battery pack is shipped with the contactors locked in the open position for safety concerns. Until these routines are performed, the battery pack contactors will not close resulting in a no start condition.
- Close the hood, press the START button and verify that the Hybrid Status Indicator is green and no warnings are displayed.
FILL AND BLEED USING THE SCAN TOOL (PREFERRED)
- Fill the HV battery pressurized coolant bottle to the max level.
- Cycle the ignition to the on position.
- With the scan tool, run the “Coolant Fill Procedure” routine in the Hybrid Control Processor (HCP). This should run all of the coolant pumps in all cooling systems.
- Continue adding coolant to the HV battery pressurized coolant bottle maintaining the coolant at the max level.
- When no more coolant is needed the system is filled and bled. The routine may time out before the system is full and take multiple cycles to bleed all of the air from the system.
- Stop the scan tool actuation. Fill the bottle slightly above the fill line in case of any air trapped in the system.
FILL AND BLEED WITHOUT THE SCAN TOOL
- Fill the HV battery pressurized coolant bottle to the max level.
- Cycle the key to the on position to power the battery coolant pump in order to fill and bleed the HV cooling system.
- Cycle the key to the off position after the pump times out and stops running.
- Fill the HV battery pressurized coolant bottle to the max level.
- Repeat the fill procedure until the proper coolant level is achieved. Fill the bottle slightly above the fill line in case of any air trapped in the system.
- Perform Section D. Install the Authorized Modifications Label.
- If battery require replacement, record on label “Battery Replaced”.
- For California residents, complete Section E. Proof of Correction Form.
- Return the vehicle to the customer or inventory.
D. Install the Authorized Modifications Label
Type or print (with a ballpoint pen) the necessary information shown in Figure 46 onto the Authorized Modifications Label.
Then attach the label near the VECI label.
E. 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.
Chronology :
- On February 2, 2023, the FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance (“TSRC”) organization received a report of a fuse melting in the HV battery of a 2022 MY Jeep
Wrangler PHEV.
- On February 20, 2023, the FCA US TSRC organization opened an investigation after receiving a second report of a fuse melting in the HV battery of a 2022 MY Jeep
Wrangler PHEV.
- On March 2, 2023, FCA US TSRC received fuse tray and battery pack trace data from the supplier.
- On March 28, 2023, FCA US TSRC identified additional vehicles affected by this issue.
- As of April 11, 2023, FCA US is aware of zero customer records, zero warranty claims, and two field reports potentially related to this issue for all markets with dates of receipt ranging from February 2, 2023 through February 20, 2023.
- As of April 11, 2023, FCA US is not aware of any accidents or injuries potentially related to this issue for all markets.
- On April 20, 2023, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles.
Z71 – Unsecured Fuse inside High Voltage Battery – 2022-2023 Jeep
Wrangler Plug-In Hybrid Electric (PHEV)
Z71 – Unsecured Fuse inside High Voltage Battery – 2022-2023 Jeep Wrangler Plug-In Hybrid Electric (PHEV)
2 Affected Products
Vehicle
MAKE | MODEL | YEAR |
JEEP![]() | WRANGLER | 2022-2023 |
4 Associated Documents
Defect Notice 573 Report
RCLRPT-23V303-2820.PDF 214.364KB
Recall Acknowledgement
RCAK-23V303-1311.pdf 645.418KB
Remedy Instructions and TSB
RCRIT-23V303-2466.pdf 1717.489KB
Manufacturer Notices(to Dealers,etc) – Dealer Notification re New Safety Recall Advanced Communication – 53A
Latest Recalls Documents
- ❤ [Question & Answer: Why can't find the device on app? or Can't find the device after changing phones]: Solutions: 1. Confirm your phone to connect with the 2.4Ghz wifi, not connect the wifi whose name has 5G suffix; 2. Turn on the wifi and bluetooth of the phone; 3. Factory Reset/Wifi reset: Pull out the charging gun, simultaneously long press the Ⓐ button and time button on the product screen until it shows "Factory Reset/Wifi reset". 4. Re-start and add your device.
- ❤ [NO Need to Install the Additional GFCI Breaker & Why No Power When Using the Nema 5-15p to 14-50R Adapter]: Built-in CCID20 leakage detection and protection device, it is no need to install additional GFCI breaker for NEMA 14-50 receptacles. [Kindly Note When Using the 5-15P Adapter]: 1. Please confirm whether the Adapter cable is used for EVs before choosing the adapter cable. 2. The EV Chargers have a different wiring sequence than RVs even though they are the same adapter, so that causes the adapter you bought to not work.
- ❤ [6X Faster with ETL, FCC and CE Listed, Meets the Safety Criteria Defined by: SAE J1772, UL2231-1/-2, UL 991, UL 2231, UL 2251, UL1998 and UL 2594 & Compatible with all EVs and PHEVs Sold in North America]: Say goodbye to slow level 1 ev charger and enjoy 6X faster charging. Designed with J1772 TYPE 1 standard connector, compatible with Tesla (Adaptor Needed), Ford, GM, Nissan, Audi, Kia, Honda, BMW, Kia, Hyundai, Gmc, Chevy, etc.
- ❤ [Smart WIFI APP, You can Set the Charging Period]: Check the charging cost, history, fully-charged notification, track the charging status, during off-peak period. ❤ [Wi-Fi Reset/Factory Reset Function, Add New Device Quickly]: If you can't find your device or you have replaced a new phone, just pull out the charging gun, simultaneously long press the Ⓐ button and time adjustment button on the product screen until it shows "Factory Reset", then re-start your device.
- ❤ [Up to 7.68kWh High Speed Charging & Adjustable Amperage from 16A to 32A by Screen Button or APP]: Maximum current output of 32 Amps for 40A circuit breaker, 24 Amps for 30A circuit breaker, or 16 Amps for 20A circuit breaker (Please pull out the charging gun, long press "A" button to change the current). You can also adjust the current/amperage by APP before the charging.
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- COMPATIBILITY: Wall Connector is compatible with all Tesla models: Model S, Model 3, Model X and Model Y.
- CHARGING SPEED: Up to 44 miles of range per hour of charge, with up to 11.5 kW / 48 amp output, depending on Tesla model and breaker size.
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- CONNECTIVITY: Connecting the Wall Connector to a local Wi-Fi network enables over-the-air firmware updates for continual product improvements and remote access control.
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- CHARGING SPEED: Up to 44 miles of range per hour of charge, with up to 11.5 kW / 48 amp output, depending on Tesla model and breaker size.
- CONVENIENCE: Indoor or outdoor installation (by your own electrician or one of the 1,400+ Tesla Certified Electricians) with variable amperage that allows max output to be customized to an existing power supply and supports any output up to 48A. Possible max output configurations include: 48A, 40A, 32A, 24A, 16A, 12A.
- CONNECTIVITY: Connecting the Wall Connector to a local Wi-Fi network enables over-the-air firmware updates for continual product improvements and remote access control via the app.
- POWER-SHARE: Power-share is ideal for locations that need to charge more than one Tesla at the same time. This functionality allows up to six Wall Connectors to be linked for efficient power management.
- Flex Level 1 EV Charger - The EVDANCE Level 1 electric car charger is compatible with J1772 electric vehicles and plug-in hybrid vehicles (North American Standard). *Tesla requires a SAE J1772 adapter.
- Convenient to Use - This charger has both NEMA 6-20 plug for 16A 240V charging (3.68kW, 10-12 mi/h) and a NEMA 6-20 to 5-15 plug adapter for 12A 120V charging (1.44kW, 2-5 mi/h). The included bag makes it easier to carry on the go. It also has a 25ft cable length, you can use it flexibly from anywhere in the garage or driveway.
- Indication Displays - LED display that can tell you the status as well as indicate errors while charging your electric vehicle.
- Durable and Safe - This electric car charger is made of high-grade rugged materials, FCC and CE certified. The intelligent chip design of its control box can keep monitoring the charging status at any time, and the protection level of the housing is IP66 and the fire rating is UL 94 V-0.
- Contact Us Anytime - This electric vehicle charger has a 1-year warranty, if you feel that the product doesn't meet your expectations, please feel free to contact us and we will solve the problem.
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- UNIVERSAL COMPATIBILITY: Our Type 1 charger is designed to both 240V and 120V household plugs with the included adapter cable. Works with popular EVs, including popular models from Toyota, BMW, Hyundai, Ford, VW, Nissan, Kia, Audi, and many more.
- EXTENDED REACH: With a 16.5-foot cable, the Asani EV charger provides flexibility. Its plug-&-play design ensures ease of use, while LED indicator lights keep you updated on charging status. Included adapters and a storage bag enhance portability.
- ON-THE-GO CONVENIENCE: Our portable electric vehicle charger comes with a storage bag and is crafted from anti-rolling, anti-scratch material, making it perfect for outdoor adventures. With an IP66 waterproof rating, it's built to withstand the elements.
- SAFE CHARGING GUARANTEED: This electric car charger boasts CE certification and comes equipped with built-in protection against lightning, over-voltage, under-voltage, over-charge, and over-current, ensuring the utmost safety for your vehicle.
- 9X FASTER than your portable basic charger: EVIQO electric vehicle charging stations are set as a plug-in level 2 EV charger 40 Amp (9.6 kWh) by default. Plug & Charge, no electrician needed. NEMA 14-50 outlet (up to 50A circuit) required. To make EVIQO a 48Amp EV charger level 2 (11.5 kWh), hardwire electrical installation required (remove input cable and prepare a custom whip, 60A or more circuit required). Adjustable current intensity: 1A increment in EVIQO app + hardware dip switch. US-based customer support Mon-Sat, 8 AM - 4 PM PT.
- SAFE, USA CERTIFIED: EVIQO electric vehicle charging equipment is UL compliant, Energy Star, ETL and FCC certified EV car charger level 2 with 3-year Warranty. EVIQO EV charging station is weatherproof: outdoor EV charger / indoor electric vehicle charger. EVIQO home EV wall charger level 2 meets NEMA 4 and IP66 protection standards.
- SMART APP: EVIQO surveyed 1,800 EV owners to create EV home charger level 2 app. Set up to 3 schedules and save costs during off-peak rates. Get smart tips and reminders, track power/costs live and monitor the charging history. Enjoy sleek intuitive interface of your home EV charger level 2. EVIQO solar EV charger box consistently enhances its firmware with remote OTA updates.
- COMPATIBLE WITH ALL EVs: EVIPOWER NEMA 14-50 EV charger is equipped with heavy duty rubberized SAE J1772 connector compatible with all EVs / PHEVs in NA: all Tesla models, Chevy Bolt, Chevy Volt, VW ID 4, Nissan Leaf Charger, Polestar 2, Ford Mach E Charger, IONIQ 5 / 6, Kia Nino, EV6, EV9, Mercedes EQS, Audi, Rav4, Jeep 4xe Charger (This is J1772 level 2 charger, adapter required for Tesla).
- FIRST-IN-CLASS: EVIQO level 2 EV chargers offer EXTRA LONG EV charging cable 25' and EXTRA LONG 37" input cable.
- Universal Charger J1772 to Tesla Charger Adapter: Compatible with all EVs in the US including NACS charging port. 2.4" LED display for live vehicle charging updates.
- Plug & Play Installation: Simple equipment setup w/ Level 2 NEMA 14-50 outlet for EV charging and NEMA 5-15 outlet adaptor for Level 1 ev charger. No professional installation or extra tools required.
- Fast & Portable ev charger: Enjoy up to 40Amp EV charger level 2 power w/ this versatile mobile ev charger w/ a long cord. Cool stuff for home or on the go use. This supercharger let's u stay powered. A great Tesla emergency charger when you need it most. The maximum 40A of current is the equivalent to 9.6 kW of power.
- Cost-Efficient & Forward compatible: level 2 ev charger w/ smart power management. An electric car charger built to react to new electric vehicle model technology & future charging advancements. Control your charging directly through the display or via app (Bluetooth and Wi-Fi enabled)
- Trusted Support & Warranty: Our portable electric car charger is backed by excellent customer service and a 5-year warranty. We're here to ensure a worry-free experience every step of the way. You’ll probably upgrade your vehicle twice before changing the charger
- Grizzl-E Avalanche Edition NEMA 14-50 Plug with 24 Feet Premium Cable is a simple, powerful, heavy-duty and portable Electric Vehicle Charging Station which is suitable for any weather. Compatible with all EVs and PHEVs sold in North America.
- UL Full Tested and Certified. Eligible for the Federal Rebate Program. IP67 (Water resistant), Fire resistant. Over Current, Over Voltage , Under Voltage, Missing Diode, Ground Fault, and Over Temperature Protections. Self-Monitoring and Recovery, Power Outage Recovery. Built in GFCI.
- Fast charging and adjustable amperage: 40A, 32A, 24A, 16A. Maximum current output of 40 Amps for 50A circuit breaker, 32 Amps for 40A circuit breaker, 24 Amps for 30A circuit breaker, or 16 Amps for 20A circuit breaker. Charge Rate: 28-30 miles per hour at 40A, 22-25 miles per hour at 32A, 15-18 miles per hour at 24A and 10-12 miles per hour at 16A.
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- WORKS WITH ALL J1772 EVs AND HYBRIDS: Whether you're on a family road trip or charging at home after a busy day, our 32A Level 2 SAE J1772 charger is designed to work seamlessly with all electric vehicles and plug-in hybrids(North American Standard). You can be confident that your vehicle will always be ready for your next adventure, no matter where the road takes you. Designed with J1772 TYPE 1 standard connector, Ford, GM, Nissan, Audi, Kia, Honda, BMW, Kia, Hyundai, Gmc, Chevy, etc.
- SAFETY & RELIABILITY: Safety is our top priority. Our charger is equipped with advanced safety features like overvoltage, overcurrent, overheating protection, and IP66 waterproof rating. Certified by FCC and CE, its intelligent chip continuously monitors the charging status, while the housing has an IP66 protection level and a UL94V-0 fire rating. This means you can charge your EV with peace of mind, knowing that you and your loved ones are safe during every charge.
- STAY INFORMED, STAY IN CONTROL: After researching the preferences of 10,000 US EV users, the Ecogenix R&D team found that 98.6% wanted a clearer display on their vehicle chargers. In response, our 32A Ecogenix charger features an enhanced TFT screen, which, while compact, provides real-time updates on voltage, current, and power load—ensuring all essential information is easily visible during every charge.
SEOCONTENT-START
OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-303 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Chrysler (FCA US, LLC) Submission Date : APR 27, 2023 NHTSA Recall No. : 23V-303 Manufacturer Recall No. : 53A Manufacturer Information : Manufacturer Name : Chrysler (FCA US, LLC) Address : 800 Chrysler Drive CIMS 482-00-91 Auburn Hills MI 48326-2757 Company phone : 1-800-853-1403 Population : Number of potentially involved : 2,564 Estimated percentage with defect : 1 % Vehicle Information : Vehicle 1 : 2022-2023 Jeep Wrangler Vehicle Type : Body Style : SUV Power Train : NR Descriptive Information : Some 2022 – 2023 MY Jeep Wrangler Plug-In Hybrid Electric Vehicles (“PHEV”) may have been built with incorrect fasteners securing the 200 amp fuse in the high voltage (“HV”) battery. The suspect period began on January 10, 2022, when incorrect fasteners securing the 200-amp fuse were introduced into vehicle production, and ended on September 20, 2022, when the incorrect fasteners were no longer used. The suspect population was determined using vehicle and supplier manufacturing records. Similar vehicles not included in this recall were built before or after the suspect period, were included in 22V-768 (Z71), were built with correct fasteners securing the 200 amp fuse, or were not PHEVs. Production Dates : JAN 10, 2022 – SEP 20, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : An incorrect fastener can cause high resistance in the 200 amp fuse interface, which will generate heat. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Excessive heat in the fuse interface may cause the fuse to fail resulting in a Part 573 Safety Recall Report 23V-303 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Description of the Safety Risk : loss of motive power, which can cause a vehicle crash without prior warning. Description of the Cause : NR Identification of Any Warning that can Occur : Customer may notice a Malfunction Indicator Lamp (MIL), a change in drivability, and/or noise at the HV battery pack assembly. Involved Components : Component Name 1 : Hybrid Battery Pack Assembly Component Description : Battery Pack Assembly – Hybrid Component Part Number : 05193168AH Supplier Identification : Component Manufacturer Name : SAMSUNG SDI AMERICA INC Address : 4121 N Atlantic Blvd Auburn Hills Michigan 48326 Country : United States Chronology : • On February 2, 2023, the FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance (“TSRC”) organization received a report of a fuse melting in the HV battery of a 2022 MY Jeep Wrangler PHEV. • On February 20, 2023, the FCA US TSRC organization opened an investigation after receiving a second report of a fuse melting in the HV battery of a 2022 MY Jeep Wrangler PHEV. • On March 2, 2023, FCA US TSRC received fuse tray and battery pack trace data from the supplier. • On March 28, 2023, FCA US TSRC identified additional vehicles affected by this issue. • As of April 11, 2023, FCA US is aware of zero customer records, zero warranty claims, and two field reports potentially related to this issue for all markets with dates of receipt ranging from February 2, 2023 through February 20, 2023. • As of April 11, 2023, FCA US is not aware of any accidents or injuries potentially related to this issue for all markets. Part 573 Safety Recall Report 23V-303 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 • On April 20, 2023, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles. Description of Remedy : Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles to inspect the HV battery fuse for the correct fasteners. If an incorrect fastener is found, FCA US will replace the fuse assembly. If charring or discoloration is present on the bus bars, FCA US will replace the HV battery pack assembly. FCA US has a longstanding policy and practice of reimbursing owners who have incurred the cost of repairing a problem that subsequently becomes the subject of a field action. To ensure consistency, FCA US, as part of the owner letter, will request that customers send the original receipt and/or other adequate proof of payment to the company for confirmation of the expense. How Remedy Component Differs from Recalled Component : The remedy component will be an HV battery fuse assembly with correct fasteners. Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : **04/27/2023: FCA US will notify dealers and begin notifying owners on or about 06/16/2023. Planned Dealer Notification Date : JUN 16, 2023 – JUN 16, 2023 Planned Owner Notification Date : JUN 16, 2023 – JUN 16, 2023 * NR – Not Reported
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04/28/2023 _____________________________________________________________________ New Safety Recall Advanced Communication – 53A FCA US LLC (FCA US) has announced a safety recall on certain 2022 and 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 Plug-In Hybrid Electric Vehicles (PHEV) may have been built with incorrect fasteners securing the 200 amp fuse in the High Voltage (HV) battery. An incorrect fastener can cause high resistance in the 200 amp fuse interface, which will generate heat. Customer may notice a Malfunction Indicator Lamp (MIL), a change in drivability, and/or noise at the HV battery pack assembly. Excessive heat in the fuse interface may cause the fuse to fail resulting in a loss of motive power, which can cause a vehicle crash without prior warning. SERVICE ACTION FCA US will conduct a voluntary safety recall on all affected vehicles to inspect the HV battery fuse for the correct fasteners. If an incorrect fastener is found, FCA US will replace the fuse assembly. If charring or discoloration is present on the bus bars, FCA US will replace the HV battery pack assembly. 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 2nd Quarter of 2023. 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. Customer Services Field Operations FCA US LLC
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SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 1/39 Remedy available for: 2022-2023 (JL) Jeep® Wrangler 4XE PHEV Template Version 1.0 Revision Edition Detail 0 May 2023 Initial Version. SYMPTOM DESCRIPTION The high voltage battery on about 2,560 of the above vehicles may have been built with incorrect fasteners securing the 200 amp fuse in the High Voltage (HV) battery. An incorrect fastener can cause high resistance in the 200 amp fuse interface, which will generate heat. Customer may notice a Malfunction Indicator Lamp (MIL), a change in drivability, and/or noise at the HV battery pack assembly. Excessive heat in the fuse interface may cause the fuse to fail resulting in a loss of motive power, which can cause a vehicle crash without prior warning. SCOPE This recall applies only to the above Plug-In Hybrid Electric Vehicles (PHEV) equipped with a 2.0L engine (sales code ECX). 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. REPAIR TO BE PERFORMED Inspect fuse tray 200A fuse for proper fasteners and signs of carbon marks on bus bars. If incorrect fasteners are found with no carbon marks on bus bars, replace the 200A fuse and fasteners. If carbon marks are found, photograph the fasteners and bus bar contacts then replace HV battery as directed by the service procedure. 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 COMPLETION REPORTING / 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 the following labor operation numbers and time allowances: Labor Description Number Hrs Inspect 200A Fuse, Passed Inspection 08-53-A1-81 0.8 Inspect/Replace 200A Fuse 08-53-A1-82 1.0 Inspect 200A Fuse / Replace PHEV Battery 08-53-A1-83 3.2 Add the cost of the recall parts plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. PARTS INFORMATION NOTE: All vehicles will require the Authorized Modifications Label. Part No. Qty. Part Name 04275086AE 1 Label – Authorized Modifications NOTE: If Inspection Procedure confirms that a new fuse and fasteners are required, order Fuse Campaign Kit below: Part No. Qty. Part Name CSANZ711AA 1 Fuse Campaign Kit Campaign kit contains the following components: 1 200 Amp Fuse 2 Fasteners SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 2/39 NOTE: If Inspection Procedure confirms that a new battery is required, open a STAR case. Photographs of battery contacts damage must be attached to the STAR case. Part No. Qty. Part Name 68488244AA 1 400V Battery 68163849AB 1 Coolant 06512293AA 3 Bolt, Rear Seat PARTS RETURN Return instructions for the old battery are included in the container with the new battery. There is a core charge for this battery. NOTE: If the battery return instructions are missing, a battery return I sheet can be downloaded from DealerCONNECT on the “Parts Tab” under the heading “Returns”. SPECIAL TOOLS The following special tools are required to perform this service procedure: Number Description 126-1587 Meter, Multi – Originally Shipped In Kit Number(s) 10389. NPN High Voltage Personal Protection Equipment: Hard Hat, Safety Glasses, Protective Gloves, Safety Barriers, etc. (Consult Service Library High Voltage Safety Procedures) If service procedure determines that the battery must be replaced. The following special tools are required to perform battery replacement: Number Description NPN wiTECH MicroPod II / MDP NPN Laptop Computer NPN wiTECH Software 2035100082 Covers, HEV Battery Terminal 2035203080 Eyebolt, 10mm 2035200080 Lift Straps, HV Battery 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 / 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. SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 3/39 SERVICE PROCEDURE Only individuals with high voltage training and repair qualifications should be allowed to handle, troubleshoot or repair High Voltage or Hybrid components or systems. Always wear safety glasses. Review High Voltage Safety Procedures in Service Library section 08, Standard Procedures. 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. 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. SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 4/39 A. Power Down the High Voltage System 1. Power down the high voltage system. If the HV battery will not power down or the vehicle has a welded contactor DTC active that will not clear, stop and perform the “HV Battery Servicing with Welded Contactor(s)” at the beginning of the PHEV Battery removal procedure in Service Library. 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 is done by removing the test points access cover. • The high voltage power down procedure must be performed to ensure that the high voltage battery is properly powered down. • The technician must know the whereabouts of the test points access cover throughout the repair. • The technician must ensure that the test points access cover is not reinstalled while service is being performed. • The technician must recheck that the test points access cover has not been reinstalled in cases where the vehicle was unattended. 2. 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). See High Voltage Safety Procedures in Service Library section 08, Standard Procedures. SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 5/39 3. 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. 4. Disconnect any charging equipment. Do not plug in the EVSE Recharge Coupler when working on the vehicle. 5. Turn the ignition to Off by pressing the keyless go button (1) and move keys away from the car a minimum of 20 feet (Figure 1). NOTE: If the READY indicator is NOT illuminated in instrument cluster, the vehicle is already shut off. DO NOT push the start/stop button as the vehicle may start. 6. Wait five minutes to allow the high-voltage system to shut down without setting a fault code. Figure 1 – Keyless Go Button SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 6/39 7. Disconnect the IBS wire harness connector (2). Remove and isolate the battery negative cable (1) using Covers, HEV Battery Terminal 2035100082 (Figure 2). 8. Remove the F09 (5 amp) fuse (3) from the Power Distribution Center (PDC) (Figure 2). NOTE: This removes the fused B+ power supply to the Integrated Dual Charger Module (IDCM). Disabling the IDCM disables the DC/DC conversion between the HV battery and the charging output to the low voltage side of the system. 9. 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. 10. Using a multi-meter, check for voltage at the PDC fused B+ terminal to verify the low voltage system is powered down. The 12-volt electrical system is now powered down. There should be no voltage present with the IDCM disabled and the 12-volt battery disconnected. Figure 2 – 12-Volt Battery 1 – Battery Negative Cable Nut 2 – IBS Wire Harness Connector 3 – F09 (5 amp) fuse SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 7/39 11. The high voltage service test points access cover (1) is located on the battery pack, under driver side rear seat cushion (Figure 3). 12. Remove the M6 Torx screws (2) from the high voltage service test points access cover (1) (Figure 3). 13. Carefully remove the test points access cover (1) and set in a protected location such that the cover plate alignment and HVIL pins are not damaged (Figure 3). NOTE: Lift the cover straight up to avoid bending or damaging the pin on the cover that is used to engage the HVIL switch (Figure 4). Figure 3 – High Voltage Test Point Access Cover 1 – High Voltage Test Point Access Cover 2 – M6 Torx Screws Figure 4 – Access Cover Pins PINS SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 8/39 NOTE: Removal of the test points access cover will affect the following: • Disables the High Voltage Battery System by disengaging the internal High Voltage Interlock (HVIL) pin from the switch. • Provides access to the high voltage positive and high voltage negative test points. NOTE: These circuits are a sense circuit connected through large resistors inside the high voltage battery to the high voltage bus cables after the contactors. These circuits are safe even when high voltage is present on the circuits due to the large resistors reducing these circuits to milliamperes. • Provides access to the fuse cover screw. • Allows access to a service lockout loop. NOTE: Always observe these precautions prior to taking a high-voltage measurement: • Be sure to utilize the proper Personal Protection Equipment (PPE) when working on any high voltage system. • Rated and non-expired rubber insulating gloves with leather protectors. • Have known good test leads. • Verify the multi-meter leads are rated “CAT III 1,000V”. This should be printed on the multi-meter leads. • Install the multi-meter leads in the BLACK and RED sockets on the right side of the Fluke 1587 (VΩ (RED) and COM (BLACK)). • Switch the FLUKE 1587 to the DC Volts selection and press the RANGE button until the 500V range is selected – just one digit (a zero) is displayed. • Test the multi-meter operation by measuring the voltage across the 12-volt Battery. SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 9/39 14. 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 manufacturer’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 (Figure 5). 15. Using the Fluke multi-meter, measure the voltage at the high voltage positive and high voltage negative test points (Figure 6): • Measure for voltage between the positive and negative high voltage test points. • Measure for voltage between positive test point and chassis ground. • Measure for voltage between negative test point and chassis ground. Figure 5 – Fluke Meter, Multi 126-1587 Figure 6 – Measuring at High Voltage Test Points SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 10/39 16. The voltage reading should be 0 volts. (Some residual voltage may be present, up to 2.0 volts may be normal) (Figure 6). • If the voltage measured is below 2 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 60 volts, an internal condition exists within the high voltage battery such as stuck contactors, that are preventing it from being powered down. This should be accompanied by contactor stuck DTCs. Do not attempt to carry out testing on any of the vehicle’s high-voltage components or wiring. The HV Battery Pack requires replacement. Reference the HV BATTERY SERVICING WITH WELDED CONTACTOR(S) procedure at the top of the HV PHEV BATTERY REMOVAL AND INSTALLATION procedure for safely removing a high voltage battery that will not power down (Refer to 08 – Electrical/Battery System/BATTERY/Removal and Installation). • If the voltage is between 2.0 volts and 60 volts, the HV system is safe to work on, however there is a problem that should be diagnosed. Disconnect each of the following HV modules one at a time and check the voltage at the test points. If the voltage drops to 2.0 volts or less, the faulted module has been found. Reconnect each module before continuing to the next. o Integrated Dual Charger Module (IDCM) o Electronic A/C Compressor (EAC) o Battery Coolant Heater o HV Coolant Heater o Power Inverter Module (PIM) SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 11/39 B. High Voltage Fuse Inspection/Replacement 1. Remove the fuse cover screw then remove the fuse cover (Figure 7). 2. Inspect the 200A fuse fasteners in the fuse tray under the fuse cover (Figure 8). Figure 7 – Fuse Cover FUSE COVER FUSE COVER SCREW Figure 8 – 200A Fuse Fasteners 200A FUSE FASTENERS SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 12/39 3. Do the 200A fuse fasteners have a flange around the screw head or not as shown in (Figure 9)? ➢ Correct Screws – Flange Head: No further action required. Vehicle may be reassembled. Proceed to Step 10. ➢ Incorrect Screws – No Flange: Continue with Step 4. 4. Remove the incorrect fasteners securing the 200A fuse then also remove the fuse (Figure 9). Correct Screws – Flange Head Incorrect Screws – No Flange Figure 9 – 200A Fuse Fastener Inspection FLANGE NO FLANGE SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 13/39 5. Inspect the 200A fuse and bus bar contacts for any signs of carbon marking as shown in (Figure 10). 6. Photograph the bus bar and 200A fuse contact surfaces. Photographs showing the contact surfaces of the bus bar and 200A fuse will be required for the parts ordering process (Figure 10). Good Contacts No Carbon Marking Signs of Carbon Marking Figure 10 – Inspect for Signs of Carbon Marking SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 14/39 7. Were the bus bar contacts clean or carbon marked as shown in (Figure 10)? ➢ Clean, no Carbon Marks: Replace the 200A fuse and fasteners. Continue with Step 8. ➢ Visible Carbon Marks: Battery will require replacement Proceed to Section C. 8. Order and obtain the 200A fuse kit with proper screws. The photographs taken previously will be required to place the parts order. 9. Replace the 200A fuse and fasteners from the kit then tighten the screws to 5.7 N·m (50 in. lbs.) (Figure 8) 10. Install the fuse cover then tighten the cover screw to 6 N·m (53 in. lbs.) (Figure 7). 11. Power up the HV battery system. 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 test points access cover. • 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 test points access cover throughout the repair. • The technician must ensure that no one reinstalls the test points access cover while service is being performed. • The technician must recheck that the test points access cover has not been reinstalled in cases where the vehicle was unattended. SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 15/39 12. Use of an insulation tester such as the Fluke Meter, Multi 126-1587 is recommended for Plug-In Hybrid Electric Vehicle (PHEV) circuit testing. Perform the multi-meter functionality tests per the manufacturer’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: Always observe these precautions prior to taking an isolation resistance measurement: • Have known good test leads • Set the test voltage to 500 Volts • Always wear safety glasses 13. Using the Meter, Multi 126-1587 measure and record the isolation resistance between the high voltage positive test point and chassis ground (Figure 11). Figure 11 – Measure and Record Isolation Resistance Between HV Positive Test Point and Chassis Ground SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 16/39 14. Using the Meter, Multi 126-1587 measure and record the isolation resistance between the high voltage negative test point and chassis ground (Figure 12). 15. Isolation resistance should be 2.3 Mohms (+/-.2). If the measured isolation resistance is outside of this range, a loss of isolation condition exists within the high voltage circuitry. Do not continue the High Voltage Power Up procedure until the condition causing the loss of isolation is corrected.1 16. Install the test points access cover (1) to the battery pack and tighten the eight M6 Torx screws (2) to 8.8 N·m (78 in. lbs.) (Figure 13). Figure 12 – Measure and Record Isolation Resistance Between HV Negative Test Point and Chassis Ground Figure 13 – Test Point Access Cover SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 17/39 17. Remove the cover, connect the negative battery cable to the IBS and tighten the fastener (1) to 10N·m (7 ft. lbs.) (Figure 14). 18. Install the F09 (5 amp) IDCM fuse (3) in the Power Distribution Center (PDC) (Figure 14). 19. Connect the IBS harness connector (2) (Figure 14). 20. Using the scan tool, delete any DTCs that may have set due to the IDCM fuse being removed. 21. Perform Section D. Install the Authorized Modifications Label. • If fuse did not require replacement, record on label “Fuse Inspected”. • If fuse did require replacement, record on label “Fuse Replaced”. 22. For California residents, complete Section E. Proof of Correction Form. 23. Return the vehicle to customer or inventory. Figure 14 – Negative Battery Cable, Fuse F09 and IBS Connector SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 18/39 C. HV Battery Replacement NOTE: Observe the following precautions when handling the HV battery pack: • DO NOT touch the high voltage terminals. • Always use the battery pack 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 nonconducting (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: The HV battery pack weighs 167 kg (368 lb.). NOTE: If the High Voltage (HV) battery is missing its return instructions, contact the UPS Call Center 800-567-9989. 1. Loosen the cap on the high voltage cooling reservoir. 2. Raise and support the vehicle. 3. Remove the eight push pin fasteners from the front air dam (1) (Figure 15). 4. Remove the bolts (2) (Figure 15). Figure 15 – Air Dam Fasteners SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 19/39 5. Remove the air dam (1) (Figure 16). 6. Remove the support and lower the vehicle. 7. Disconnect the vacuum boost hose quick coupling (1) from the air cleaner body cover (Figure 17). • Push in and hold both sides of the gray release (1) on the quick coupling (Figure 18). • Pull the quick coupling away from air cleaner body cover. Figure 16 – Air Dam Figure 17 – Air Cleaner Cover Figure 18 – Hose Connections SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 20/39 8. Disconnect the fuel vapor purge hose quick coupling (2) from the air cleaner body cover (Figure 17). • Do not press on the green anti-tampering feature (1) (Figure 19). • Push in and hold only the side of the release (2) with the green anti-tampering feature and pull the quick coupling away from air cleaner body cover. 9. Loosen the clean air hose band clamp (2) (Figure 20). 10. Remove the bolt (3) (Figure 20). 11. Disengaging the air cleaner body (1) from the two lower rubber grommets and from the clean air hose (Figure 20). Figure 19 – Hose Connections Figure 20 – Air Cleaner SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 21/39 12. Raise and support the vehicle. 13. Position a drain pan under the coolant hoses (Figure 21). 14. Remove the coolant hoses from the coolant line and drain the power electronics cooling system (Figure 21). 15. Once the system is completely drained, reinstall the coolant hose to the coolant line (Figure 21). 16. Remove the fasteners (1) and the skid plate (2) from the vehicle (Figure 22). Figure 21 – Coolant Hoses Figure 22 – Skid Plate COOLANT HOSES SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 22/39 17. Disconnect the HV wire harness connectors (1) and (2) from the HV battery (Figure 23). 18. Cap the HV cables using Covers, HEV Battery Terminal 2035100082. NOTE: A Plug-in Hybrid Electric Vehicle (PHEV) HV Battery Cover/Plug Kit is also available from Mopar® Parts. 19. Remove the support and lower the vehicle. 20. Using a trim stick, release and remove the B-pillar trim cover (1) (Figure 24). Figure 23 – HV Battery Wiring Connectors Figure 24 – B-pillar Trim Cover SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 23/39 21. Disconnect the wire harness connector (2) and release the door tether from the support bracket (1) (Figure 25). 22. Remove the bolt (2) securing the door check (1) (Figure 26). Figure 25 – Harness to Support Bracket Figure 26 – Door Check Bolt SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 24/39 23. Remove the nuts (3) and lift the door up off hinges (1) and remove (Figure 27). 24. Raise the rear seat cushion. 25. Remove the fasteners (1) from the side high voltage battery trim panels (2) (Figure 28). 26. Using a trim stick or equivalent, remove the high voltage trim panel upward to release the retainers and remove the trim panel. Repeat for the passenger side. 27. Lower the rear seat cushion. Figure 27 – Hinge Pin Nuts Figure 28 – HV Battery Side Trim SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 25/39 28. Using a trim stick or equivalent, release the retainers from the front high voltage battery closeout and remove from vehicle (Figure 29). 29. Remove the rear seat to load floor gap hider (Figure 30). Figure 29 – HV Battery Front Trim Figure 30 – Gap Hider SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 26/39 30. Disconnect the wire harness connectors, if equipped (4) (Figure 31). 31. Remove the nut for the center seat belt anchor (6). Remove the seat belts from the floor stud (Figure 31). 32. Remove the rear seat fasteners (2) at the rear of the seat (Figure 31). 33. Disconnect the wire harness connectors (3), if equipped (Figure 32). 34. Remove the bolts (1) at the front of the rear seat (Figure 32). Figure 31 – Rear Seat Components 1 – Rear Seat 4 – Wire Harness Connector 2 – Rear Seat Nuts 5 – Seat Belts 3 – Wire Harness Connector 6 – Center Seat Belt Anchor nut Figure 32 – Rear Seat Components 1 – Rear Seat Bolts 2 – Wire Harness Connectors 3 – Rear Seat SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 27/39 35. Remove silencer pad (Figure 33). 36. Remove the seat from the vehicle. 37. Remove the fastener (1) and the chassis ground cable from the HV battery (2) (Figure 34). Figure 33 – Silencer Pad SILENCER PAD Figure 34 – HV Battery Fastener and Ground Cable SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 28/39 38. Disconnect the HV wire harness connectors (1) (Figure 35). NOTE: Use an absorbent pad to collect any coolant that may leak from the battery into the interior of the vehicle. 39. Disconnect and plug the HV battery coolant line connectors (1) (Figure 36). Figure 35 – HV Wire Harness Connectors Figure 36 – HV Battery Coolant Connectors SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 29/39 NOTE: The HV battery pack weighs 167 kg (368 lb.). 40. Remove the bolts (1) securing the HV battery to the vehicle (Figure 37). 41. Install two Eyebolt, 10mm 2035203080 with the nuts to the front support mounting holes (1) (Figure 38). 42. Thread the other two Eyebolt, 10mm 2035203080 (1) into the threaded holes next to the HV battery pack mounting bolt holes (2) on the rear side of the HV battery pack (Figure 39). Figure 37 – HV Battery Bolts Figure 38 – Support Mounting Holes Figure 39 – Eyebolt Installation SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 30/39 43. Connect the Lift Straps, HV Battery 2035200080 to the eyebolts and the lifting device. Adjust the straps so that the battery will be level during lifting as shown in the picture (Figure 40). 44. Remove the HV battery pack from the vehicle. NOTE: When the HV battery pack is being replaced: • Refer to the information supplied with the NEW 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. • Place the HV battery pack in the shipping container or in a suitable storage location properly supported to prevent damage to the underside of the battery. Figure 40 – Lift Straps SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 31/39 24. Attach the Eyebolt, 10mm 2035203080 to the new HV battery pack in the same locations that were used for the removal. Connect the Lift Straps, HV Battery 2035200080 on the front and rear eyelets. 25. Secure the HV battery pack to the lifting device. 26. Install the HV battery pack in the vehicle making sure that the mounting holes align with the bolt holes in the body. 27. Remove the lifting strap and eyebolts. 28. Install the HV battery pack bolts (1) and tighten to (Figure 37): • High Voltage Battery to Chassis M10 Bolts tighten to 45N·m (33 ft. lbs.). • High Voltage Battery to Chassis M8 Bolts tighten to 21N·m (15 ft. lbs.). 29. Install the chassis ground cable to the HV battery ground stud (1) and tighten to 9N·m (80 in. lbs.) (Figure 36). 30. Connect the HV battery coolant line connectors (1) (Figure 35). 31. Connect the three HV wire harness connectors (1) (Figure 34). 32. Install the silencer pad (Figure 33). 33. Install the rear seat to the vehicle. 34. Install the bolts at the front of the rear seat and tighten to 70N·m (52 ft. lbs.). 35. Connect the wire harness connectors, if equipped (Figures 31 and 32). 36. Install the rear seat fasteners at the rear of the seat and tighten to 70N·m (52 ft. lbs.). 37. Install the seat belts from the floor stud. SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 32/39 38. Install the nut for the center seat belt anchor and tighten to 70N·m (52 ft. lbs.). 39. Raise the rear seat cushion. 40. Install the rear seat to load floor gap hider. 41. Align and install the retainers from the front high voltage battery closeout to the vehicle (Figure 29). 42. Install the high voltage trim panel and press downward to seat the retainers (Figure 28). 43. Install the fasteners to the side high voltage battery trim panels and tighten securely. 44. Lower the rear seat cushion. 45. Set the door into place on the hinges and install the door hinge pivot nuts. Tighten the nuts to 6N·m (53 in. lbs.) (Figure 27). 46. Install the door check strap bolt securing the door check and tighten to 9N·m (80 in. lbs.) (Figure 26). 47. Connect the wire harness connector and secure the door tether to the support bracket (Figure 25). 48. Align and install the B-pillar trim cover (Figure 24). 49. Raise and support the vehicle. NOTE: When connecting the High Voltage connection verify that the connectors are clean and seated properly. 50. Remove the battery port covers and transfer them to the old battery. Connect the HV wire harness connectors (1) and (2) to the HV battery and tighten to 9N·m (80 in. lbs.) (Figure 23). SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 33/39 51. Install the battery skid plate (2) and tighten the fasteners (1) to 25N·m (18 ft. lbs.) 52. Remove the support and lower vehicle. WARNING: ANTIFREEZE COOLANT IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASED COOLANT PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE; PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN AND OTHER MOVING COMPONENTS WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED; PERSONAL INJURY CAN RESULT. WARNING: WEAR APPROPRIATE EYE AND HAND PROTECTION WHEN PERFORMING THIS PROCEDURE. 53. Fill the battery cooling system. NOTE: Fill the High Voltage (HV) battery cooling system with the recommended MOPAR Antifreeze Coolant (Refer to 04 – Vehicle Quick Reference/Capacities and Recommended Fluids/Specifications in Service Library). SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 34/39 54. Power up the HV battery system. 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 test points access cover. • 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 test points access cover throughout the repair. • The technician must ensure that no one reinstalls the test points access cover while service is being performed. • The technician must recheck that the test points access cover has not been reinstalled in cases where the vehicle was unattended. 55. Use of an insulation tester such as the Fluke Meter, Multi 126-1587 is recommended for Plug-In Hybrid Electric Vehicle (PHEV) circuit testing. Perform the multi-meter functionality tests per the manufacturer’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. SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 35/39 56. Remove the M6 Torx screws from the high voltage service test points access cover (Figure 41). 57. Carefully remove the test points access cover and set in a protected location such that the cover plate alignment and HVIL pins are not damaged (Figure 41). NOTE: Lift the cover straight up to avoid bending or damaging the pin on the cover that is used to engage the HVIL switch. NOTE: Always observe these precautions prior to taking an isolation resistance measurement: • Have known good test leads • Set the test voltage to 500 Volts • Always wear safety glasses 58. Using the Meter, Multi 126-1587 measure and record the isolation resistance between the high voltage positive test point and chassis ground (Figure 42). Figure 42 – Measure and Record Isolation Resistance Between HV Positive Test Point and Chassis Ground Figure 41 – Test Point Access Cover SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 36/39 59. Using the Meter, Multi 126-1587 measure and record the isolation resistance between the high voltage negative test point and chassis ground (Figure 43). 60. Isolation resistance should be 2.3 Mohms (+/-.2). If the measured isolation resistance is outside of this range, a loss of isolation condition exists within the high voltage circuitry. Do not continue the High Voltage Power Up procedure until the condition causing the loss of isolation is corrected. 61. If required, remove the lockout-tagout padlock from the service lockout loop (1) (Figure 44). Figure 43 – Measure and Record Isolation Resistance Between HV Negative Test Point and Chassis Ground Figure 44 – Service Lockout Loop SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 37/39 62. Install the test points access cover (1) to the battery pack and securely tighten the eight M6 Torx screws (2), identified with blue circles (Figure 44). 63. Remove the cover, connect the negative battery cable to the IBS and tighten the fastener (1) to 10N·m (7 ft. lbs.) (Figure 45). 64. Install the F09 (5 amp) IDCM fuse (3) in the Power Distribution Center (PDC) (Figure 45). 65. Connect the IBS harness connector (2) (Figure 45). 66. Using the scan tool, delete any DTCs that may have set due to the IDCM fuse being removed. Turn the key OFF and wait 2 minutes, 67. Use the scan tool and flash program the BPCM with the latest software. 68. Use the scan tool and perform the “Enable Contactor for Service” procedure in BPCM. NOTE: If these procedures are not performed, the vehicle will not start. The high voltage battery pack is shipped with the contactors locked in the open position for safety concerns. Until these routines are performed, the battery pack contactors will not close resulting in a no start condition. 69. Close the hood, press the START button and verify that the Hybrid Status Indicator is green and no warnings are displayed. Figure 45 – Negative Battery Cable, Fuse F09 and IBS Connector SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 38/39 FILL AND BLEED USING THE SCAN TOOL (PREFERRED) a) Fill the HV battery pressurized coolant bottle to the max level. b) Cycle the ignition to the on position. c) With the scan tool, run the “Coolant Fill Procedure” routine in the Hybrid Control Processor (HCP). This should run all of the coolant pumps in all cooling systems. d) Continue adding coolant to the HV battery pressurized coolant bottle maintaining the coolant at the max level. e) When no more coolant is needed the system is filled and bled. The routine may time out before the system is full and take multiple cycles to bleed all of the air from the system. f) Stop the scan tool actuation. Fill the bottle slightly above the fill line in case of any air trapped in the system. FILL AND BLEED WITHOUT THE SCAN TOOL a) Fill the HV battery pressurized coolant bottle to the max level. b) Cycle the key to the on position to power the battery coolant pump in order to fill and bleed the HV cooling system. c) Cycle the key to the off position after the pump times out and stops running. d) Fill the HV battery pressurized coolant bottle to the max level. e) Repeat the fill procedure until the proper coolant level is achieved. Fill the bottle slightly above the fill line in case of any air trapped in the system. 70. Perform Section D. Install the Authorized Modifications Label. • If battery require replacement, record on label “Battery Replaced”. 71. For California residents, complete Section E. Proof of Correction Form. 72. Return the vehicle to the customer or inventory. SAFETY RECALL – NORTH AMERICA High Voltage Battery Fuse Reference: 53A / NHTSA 23V-303 FCA US LLC _________________________________________________________ Strictly respect STELLANTIS Group safety, cleanliness, and environmental instructions for any vehicle service. Document exclusively reserved for dealer information. Internal distribution to be ensured by dealer. Reproduction forbidden without the written agreement of STELLANTIS Group. (tdb) 39/39 D. Install the Authorized Modifications Label Type or print (with a ballpoint pen) the necessary information shown in Figure 46 onto the Authorized Modifications Label. Then attach the label near the VECI label. E. 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: a. Access the “DealerCONNECT” website. b. Select the “Service” tab. c. Under the “Publications” heading, select the “ePublishing” link. d. Sign in using your Dealer Code and Password. e. Select the “Proof of Correction form”. Figure 46 – Authorized Modifications Label RECORD IN THIS AREA THE RECALL NUMBER AND IF THE FUSE WAS INSPECTED OR IF THE FUSE OR THE BATTERY WERE REPLACED
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Last update on 2025-04-17 / Affiliate links / Images from Amazon Product Advertising API
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