2023-2024 Alfa Romeo Tonale Dome Lamps Not Illuminating TSB

Owners of 2023-2024 Alfa Romeo Tonale vehicles may experience issues with their dome lamps failing to illuminate. This problem, detailed in Technical Service Bulletin (TSB) 08-048-24 REV. A, is attributed to a wiring issue within the vehicle's electrical system.

This bulletin, issued on October 1, 2024, supersedes a previous version, TSB 08-048-24, dated February 17, 2024. It also correlates with Rapid Service Update (RSU) 24-020, released on the same date.

Symptoms

Customers with an Alfa Romeo Tonale dome lamps not illuminating may observe one or more of the following conditions:

• "Dome lamps do not illuminate when the door is opened."
• "Dome lamps do not illuminate when switched to ON."

Cause

The root cause of the Alfa Romeo Tonale dome lamps not illuminating is identified as a wiring issue within the vehicle's electrical system. Specifically, the repair involves modifying the dome lamp wiring harness by adding a resistor in line with circuit M24.

Important Warnings and What Owners Should Know

Owners and technicians should be aware of several critical instructions outlined in TSB 08-048-24 REV. A:

• Battery Voltage: When performing the repair, a battery charger must be installed to maintain battery voltage above 13.2 volts. The charging voltage must not exceed 13.5 volts during the flash process to prevent damage.
• Flash Interruption: If the BCM flash process is interrupted or aborted, it must be restarted immediately.
• Soldering Caution: When soldering, it is crucial to cover and protect the instrument panel and center console. Failure to do so may result in damage to these components.
• Heat Shrink Tubing: During the repair, technicians are explicitly instructed not to heat the heat shrink tubing until specified steps are completed.
• RSU 24-020: This Technical Service Bulletin has also been released as Rapid Service Update (RSU) 24-020. All applicable RSU VINs have been loaded. To verify if this service action applies to a specific vehicle, technicians must use VIP or perform a VIN search in DealerCONNECT/Service Library. All repairs are reimbursable under warranty provisions.

Diagnosis

Diagnosis for the Alfa Romeo Tonale dome lamps not illuminating involves checking if the customer's VIN is listed in VIP or the RSU VIN list. If the VIN is listed, the repair procedure should be performed.

Required Tools or Parts

To perform the repair described in TSB 08-048-24 REV. A, the following special tools and parts are required:

• Special Tools:
  • wiTECH or Equivalent diagnostic tool
  • Soldering Tool
• Spare Parts:
  • Part Number 68676594AA (NA), 5050173 (EMEA), 68065586AA (NA): Wiring, Overhead Console (Kit contains three heat shrink tubes).
  • Tesa Tape

Repair Procedure Summary

The repair for the Alfa Romeo Tonale dome lamps not illuminating involves several steps, focusing on modifying the dome lamp wiring harness. The general procedure includes:

1. BCM Reprogramming: Reprogram the Body Control Module (BCM) with the latest available software using the wiTECH diagnostic application. If any issues arise during flashing, a ticket should be submitted to the Helpdesk.
2. DTC Clearance: Clear any Diagnostic Trouble Codes (DTCs) that may have been set in any module due to the reprogramming process.
3. Battery Disconnection: Disconnect and isolate the negative battery cable. If the vehicle is equipped with an Intelligent Battery Sensor (IBS), its connector must be disconnected first.
4. Dome Lamp Removal: Remove the front dome lamp assembly from the vehicle.
5. Wiring Harness Modification: Carefully remove a small section of tape (0.7 - 1.18 cm) from the dome lamp wiring harness. This exposes the yellow/white wire (pin 6).
6. Wire Cutting and Splicing: Cut the yellow/white wire. Position heat shrink tubing onto one of the cut wires, then connect the yellow/white wires from the dome lamp harness to the jumper harness. Solder these connections. After soldering, heat the heat shrink tubing until it is tightly formed and sealant seeps out.
7. Additional Splicing: Repeat the process for the red jumper harness wire, connecting it to the cut dome lamp yellow/white wire connector side (pin 6) and soldering it. Heat the heat shrink tubing.
8. Black Wire Modification: Cut the dome lamp wire connector harness black wire (pin 2). Position heat shrink, connect all three black wires from the jumper harness and the dome lamp harness, then solder them. Heat the heat shrink tubing.
9. Taping and Reinstallation: Use Tesa tape to secure the soldered wire connections to the dome lamp wiring harness. Insert the modified dome lamp wire harness into the mounting cavity and reinstall the dome lamp assembly.
10. Battery Reconnection: Reconnect the negative battery cable, ensuring the IBS connector (if equipped) is connected first.

Warranty Information

Repairs performed under TSB 08-048-24 REV. A are reimbursable within the provisions of the warranty.

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Source: NHTSA ID: 11008742