2023-2024 Alfa Romeo Tonale Reverse Polarity Issue

This Mopar Warranty Operations Newsletter, Volume 10, Issue 8, provides crucial service information for various models, including the 2023-2024 Alfa Romeo Tonale. It addresses several distinct technical issues and repair procedures. Key topics include a significant "Reverse Polarity Issue in IDCM" affecting multiple Stellantis vehicles, proper dual battery grounding for the 2025 RAM 1500, specific oil dye requirements for oil cooler repairs, and fastener replacement instructions for Pacifica Hybrid SI-EVT transmission service.

Reverse Polarity Issue in IDCM

Owners of 2023-2024 Alfa Romeo Tonale, Dodge Hornet, Jeep Wrangler, Jeep Grand Cherokee, Jeep Renegade, and Jeep Compass vehicles should be aware of a potential "Reverse Polarity Issue in IDCM" (Integrated Dual-Charging Module). This condition can arise from incorrect jump-starting procedures.

Symptoms and Fault Codes

If a reverse connection occurs during jump-starting, the vehicle may not start again, or the main battery could become sufficiently drained to trigger a P2AF5 DTC. This DTC indicates a low main battery condition.

Important Warnings for Owners

It is crucial to understand that this "Reverse Polarity Issue in IDCM" is not a warrantable issue. Furthermore, not following the updated service procedure will result in an IDCM failure, which will induce and IDCM replacement. The document also notes that no DTCs are triggered as the Reverse Polarity protection is not a requirement in this IDCM, meaning the vehicle's system may not explicitly warn of the reverse polarity event itself, only its consequences.

Owner Action

To prevent this issue, always adhere strictly to the standard jump-starting procedure. Ensure that the positive (B+) terminal of the battery is connected to the positive clamp and the ground (GND) is connected to the negative clamp. Incorrect connections can lead to significant damage and costly repairs that are not covered by warranty. If you experience a P2AF5 DTC or a no-start condition after a jump-start, consult a qualified technician.

Dual Battery System Grounding for 2025 RAM 1500

For the 2025 RAM 1500 (DT) equipped with a dual battery system, Mopar has identified a high number of open 150A Underhood PDC Fuse Arrays. This issue stems from a lack of understanding regarding the interconnected nature of the dual batteries.

Problem Description

The 150A fuse is designed to blow only when current exceeds approximately 200% of its rating (300 amps or more), typically due to a direct short to ground. The problem occurs when only one battery ground (either main or auxiliary) is disconnected during electrical repairs. If only one ground is removed, the other battery continues to supply 12V power, creating a risk of short-circuiting if contact is made with vehicle metal.

Repair Procedure Summary

To prevent the 150A Underhood PDC Fuse Array from blowing, service procedures require that both the main and auxiliary battery grounds be disconnected prior to performing any electrical repairs. Technicians must also ensure these disconnected grounds are protected from touching any vehicle metal to fully isolate all battery power from the vehicle.

Oil Cooler Adapter Housing Repair for 3.2L and 3.6L Engines

For oil cooler leaks on vehicles equipped with 3.2L (EHK) and 3.6L (ERC) engines, a specific diagnostic step is mandated to ensure proper repair.

Diagnosis and Important Warning

Technicians must use oil dye (P/N CH5010042AC) to accurately determine the location of the oil leak before replacing the oil cooler adapter housing. This step is critical because if oil dye has not been used, the repair will not be validated. This ensures that the correct source of the leak is identified and addressed.

SI-EVT Transmission Service for Pacifica Hybrid

The repair procedure for the SI-EVT transmission in Pacifica Hybrid vehicles involves the replacement of several one-time use fasteners during transmission removal and installation (R&I).

Repair Procedure Summary

During transmission R&I, technicians must install NEW flexplate to inertia ring bolts. When removing the front crossmember, technicians do not reuse fasteners; NEW fasteners must be installed and tightened to specifications. This includes new crossmember front and mid bolts, new shear bracket bolts, and a new pinch bolt for the steering shaft. For axle shaft R&I, a NEW lower ball joint pinch bolt and nut must be installed. Additionally, a NEW drive hub to halfshaft nut must always be installed, as the original hub nut is one-time use only and must be discarded when removed.

Required Parts

Specific part numbers for these one-time use fasteners include:

• 06503210 (Steering Gear Pinch Bolt)
• 06104414AA (Shear Bracket Bolt)
• 68470042AA (Lower Ball Joint Bolt Kit)
• 06509298AA (Hub Lock Nut)
• 68382486AA (Flexplate Bolts)
• 06511823AA (Cross member front Bolt)
• 06511822AA (Cross member mid Bolt)
• 06510676AA (Control Arm Nut)

Important Note

If the transmission and/or the Power Inverter Module (PIM) were replaced, the transmission to PIM gasket is not reusable and must be replaced with a NEW transmission to PIM gasket to maintain proper function and prevent future failures.

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Source: NHTSA ID 11007076, Mopar Warranty Operations Newsletter Volume 10, Issue 8