98A – PHEV Charging Cables – 2023-2024 Alfa Romeo Tonale & 2023-2024 Dodge Hornet PHEV

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September 7, 2023 NHTSA CAMPAIGN NUMBER: 23V623000

Loose Battery Cables May Cause Fire

A fire while parked or driving can increase the risk of injury.

 

NHTSA Campaign Number: 23V623

Manufacturer Chrysler (FCA US, LLC)

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 4,129

 

Summary

Chrysler (FCA US, LLC) is recalling certain 2023-2024 Alfa Romeo Tonale and 2023-2024 Dodge Hornet plug-in hybrid electric vehicles. The 12-volt battery positive cable and/or high voltage connector cable may not be tightened properly, which can overheat the electrical connections and result in a fire while parked or driving.

 

Remedy

Owners are advised to park outside and away from structures until the recall repair is complete. Dealers will inspect and tighten the cable connections as necessary, free of charge. Owner notification letters are expected to be mailed before October 27, 2023. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC’s number for this recall is 98A.

 

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

 


SAFETY RECALL

NORTH AMERICA

PHEV Charging Cables

 

Reference: 98A

 

Remedy available for

2023-2024 model year (GG) Dodge Hornet Plug-in Hybrid Electric Vehicles (PHEVs)

 

Remedy available for

2023-2024 model year (GC) Alfa Romeo Tonale Plug-in Hybrid Electric Vehicles (PHEVs)

Template Version 1.0
Revision Edition Detail
2 September 2023 Updated service procedure Steps 4 and 6 regarding cable connections.
Note added to Step 8 regarding 12V charging cable cap.

 

SYMPTOM DESCRIPTION

The 12 Volt (12V) battery positive cable on the Integrated Dual Charging Module (IDCM), as well as the two High Voltage (HV) connector nuts with grounds may have been built with missing or an incorrectly torqued nut on about 5,326 of the above vehicles. A loose positive 12V battery cable or high voltage connectors may result in a high resistance in the connection to the IDCM which may lead to a vehicle fire with the ignition on or off. A vehicle fire can result in increased risk of occupant injury and/or injury to persons outside the vehicle, as well as property damage.

Customers are advised to not park these vehicles inside of buildings or structures, or near other vehicles until the vehicle has the repair completed.

 

SCOPE

This recall applies only to the above Plug-in Hybrid Electric Vehicles (PHEVs).

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 and tighten the IDCM cables to the proper torque. Inspect or replace nut on positive cable from 12V Battery to the IDCM and tighten the nut to the proper torque.

 

ALTERNATE TRANSPORTATION

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

 

PARTS INFORMATION

Part No. Qty.  Part Name
06107272AA 1 Nut

 

PARTS RETURN

No parts return required for this campaign.

 

SPECIAL TOOLS

Number Description
NPN wiTECH MicroPod IIeBay / MDP
NPN Laptop Computer
NPN wiTECH Software
C-4829A Remover, Trim
2077100080 Kit, HV Circuit Tester Adapter

 

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.

 

SERVICE PROCEDURE

Inspect PHEV Cables For Proper Tightness

High Voltage System 

When performing repairs that directly involve or imply possible contact with live high voltage components/systems, the technician must ensure that the power supply of the high voltage system is disconnected throughout the operation.

  • Only specifically trained staff qualified to perform repairs on vehicles with high voltage systems under current national laws/regulations are authorized to work on the vehicle.

Before performing any repair/diagnostics on the vehicle, carefully read and comply with the general instructions for working safely on hybrid/electric vehicles and use suitable general equipment and personal protective equipment (PPE), referring to:

Refer to the detailed procedures available in DealerCONNECT > Service Library > under: 12 – Electrified Powertrain System > Warning.

 

  • Before proceeding with the repair, secure the vehicle by cutting off the high voltage power supply. Refer to the procedure:

Refer to the detailed procedures available in DealerCONNECT > Service Library > under: 12 – Electrified Powertrain System > High Voltage Battery > Standard Procedure > High Voltage Power Down.

 

  • The technician must ensure that no one can restore the high voltage supply by acting on the HVTSM (High Voltage Test Service Module) device while the operation is in progress.
  • The technician must check again that the connections in the HVTSM device were not re-established if the vehicle was left unattended during the service operation.
  • The loss of insulation test procedure must be performed before re-establishing the high voltage power supply whenever an operation is performed on the high voltage system components/wiring of the vehicle, as described in the procedure:

Refer to the detailed procedures available in DealerCONNECT > Service Library > under: 12 – Electrified Powertrain System > High Voltage Battery > Standard Procedure > Loss Of Isolation Test.

 

REMOVAL 

  1. Remove the support platform. Refer to the detailed procedures available in DealerCONNECT > Service Library > under: 23 – Body > Decklid/Hatch/Liftgate/Tailgate/Swing Gate > PANEL, Close Out > Removal and Installation > Support Platform.

 

  1. Remove the luggage compartment/load platform oddment compartment. Refer to the detailed procedures available in DealerCONNECT > Service Library > under: 23 – Body > Interior > HOUSING, Luggage Compartmet ? Removal and Installation > Oddment Compartment – PHEV.

 

  1. Remove the IDCM guard, undo the fixing screws (1a) along the perimeter and remove the shield (1b).

 

  1. Check that the 5 connections are tightened securely.

 

  1. Check that the ground cable (1) is tightened to the prescribed torque of 15 Nm (11 Ft. Lbs.).

 

  1. Check that the upper and lower HV connectors (2) and (3) are tightened to the prescribed torque of 9 Nm (80 In. Lbs.).

 

  1. Check that the ground cable (4) is tightened to the prescribed torque of 15 Nm (11 Ft. Lbs.).

 

  1. Check the presence of the nut on the charging cable (5).

 

NOTE: Not all vehicles will have a cap covering the nut on the charging cable (5). It is NOT necessary to install a cap if it is not present.

 

  1. If the nut for positive cable from 12V battery to the IDCM is not present, the vehicle is NOT compliant (NOK), proceed with inserting the NEW nut and correctly tighten to the prescribed torque of 11 Nm (97 In. Lbs.).

 

  1. If the nut for positive cable from 12V battery to the IDCM is present and correctly tightened at the prescribed torque of 11 Nm (97 In. Lbs.), the vehicle is compliant (OK).

 

Installation

  1. Install the the IDCM guard, securing the fixing screws (1a) along the perimeter and remove the shield (1b).

 

  1. Install the luggage compartment/load platform oddment compartment. Refer to the detailed procedures available in DealerCONNECT > Service Library > under: 23 – Body > Interior > HOUSING, Luggage Compartmet ? Removal and Installation > Oddment Compartment –

 

  1. Install the support platform. Refer to the detailed procedures available in DealerCONNECT > Service Library > under: 23 – Body > Decklid/Hatch/Liftgate/Tailgate/Swing Gate > PANEL, Close Out > Removal and Installation > Support Platform.

 

  1. The loss of insulation test procedure must be performed before re-establishing the high voltage power supply whenever an operation is performed on the high voltage system components/wiring of the vehicle, as described in the procedure: Refer to the detailed procedures      available          in DealerCONNECT > Service Library > under: 12 – Electrified Powertrain System > High Voltage Battery > Standard Procedure > Loss Of Isolation Test.

 

  1. Power up the high voltage system Refer to the detailed procedures available in DealerCONNECT > Service Library > under: 12 – Electrified Powertrain System > High Voltage Battery > Standard Procedure > High Voltage Power Up.

 

  1. Return the vehicle back to the customer or inventory.

 


Chronology :

  • On August 23, 2023, the Stellantis Europe S.p.A. Customer Experience (“CX”) organization opened an investigation as a result of an assembly plant report checking presence and torque of the IDCM positive battery cable nut.
  • From August 23, 2023, through August 29, 2023, Stellantis Europe S.p.A. CX reviewed production data, met with engineering to understand the design and history, and reviewed torque traceability data.
  • On August 24, 2023, the Pomigliano plant issued a corrective action by updating the wireless screwdriver and adding results tracking to their manufacturing execution system.
  • As of August 30, 2023, Stellantis Europe S.p.A. is aware of zero customer assistance records, zero warranty claims, and two field reports potentially relating to this issue for all markets with dates of receipt ranging from July 18, 2023, through August 14, 2023.
  • As of August 30, 2023, Stellantis Europe S.p.A. is not aware of any accidents or injuries potentially relating to this issue for all markets.
  • On August 30, 2023, Stellantis Europe S.p.A. determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles.

 


4 Affected Products

Vehicles

MAKE MODEL YEAR
ALFA ROMEO TONALE 2023-2024
DODGE HORNET 2023-2024

 


6 Associated Documents

Defect Notice 573 Report

RCLRPT-23V623-5962.PDF 216.269KB

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Remedy Instructions and TSB

RCRIT-23V623-1787.pdf 511.472KB

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Recall Acknowledgement

RCAK-23V623-5348.pdf 645.427KB

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Remedy Instructions and TSB

RCRIT-23V623-9331.pdf 554.458KB

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Remedy Instructions and TSB

RCRIT-23V623-6488.pdf 730.393KB

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Recall 573 Report – 9/19/23

RCLRPT-23V623-4938.PDF 216.268KB

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Latest Recalls Documents

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

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V623&docType=RCL

 


 

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