2021-2025 Alfa Romeo Tonale Coolant Leak & Brake Switch Issues

The FCA Caribbean Warranty Operations Newsletter Volume 10, Issue 11 addresses common concerns among owners of 2021-2025 Alfa Romeo Tonale (GC), Jeep Wrangler (JL), Jeep Grand Cherokee (WL), Jeep Compass (MP), and Dodge Hornet (GG) vehicles. This important communication provides guidance for technicians on proper diagnosis and repair of engine coolant leaks, overheating, and brake pedal switch malfunctions, aiming to prevent unnecessary full engine replacements.

Owners searching for information regarding an Alfa Romeo Tonale coolant leak or overheating in their related FCA vehicle will find critical insights into the diagnostic and repair process.

Symptoms of Coolant Leak and Overheating

Owners may notice several indicators of a coolant leak or engine overheating. These can include a low coolant level in the reservoir, difficulty starting the vehicle, a reduction in power or torque, and an increase in engine misfire events. A critical symptom to watch for is when the "check engine light is on" on the dashboard.

Diagnosis for Coolant Leaks

Before considering a long block (full engine) replacement, technicians are advised to perform a series of pre-checks and detailed diagnostic tests:

Pre-Checks

• Coolant Level: Verify and record the coolant level in the coolant bottle.
• Cooling System Components: Inspect the thermostat, water pump, and cooling fan for any issues.
• Oil Sample: Drain a sample of engine oil to check for the presence of coolant or moisture, indicating an internal leak.

Detailed Checks

1. Cylinder Leakage Test: Perform this test on all cylinders. Pressurize each cylinder to 5.5 bar (83 PSI) with the piston at Top Dead Center (TDC) and observe the radiator coolant for bubbles. This indicates a head gasket leak or crack.
2. Coolant Pressurization Test: Pressurize the entire cooling system to 2 bar (30 PSI) and hold the pressure for one hour, checking for any leak down. Additionally, use a borescope to inspect the combustion chambers for coolant presence.
3. CO2 Leak Test: Conduct a CO2 leak test to detect combustion gasses in the cooling system, which can indicate a head gasket failure.

Common Root Causes and Repair Recommendations for Coolant Leaks

If the initial checks and tests do not indicate a need for a long block replacement, the issue likely stems from a specific component. The FCA Caribbean Warranty Operations Newsletter Volume 10, Issue 11 highlights several common culprits for an Alfa Romeo Tonale coolant leak and overheating:

• Water Pump Inlet Pipe Bolts: Loose bolts on the water pump inlet pipe, potentially requiring a torque check (refer to CSN ZD8).
• Thermostat Column Manifold Bolts: Loose bolts on the thermostat column manifold.
• Cylinder Block Casting: Porosity or cracks in the cylinder block casting, particularly around the combustion chamber.
• Oil Coolant Exchanger: An internal crack in the oil coolant exchanger, evidenced by coolant and oil mixing.

The communication strongly advises replacing only the faulty component rather than the entire engine, as many returned engines are found to have no trouble found after testing.

Brake Pedal Switch Stuck Condition

For 2023-2025 MY (VF) vehicles, claims have been received regarding brake pedal switch performance issues.

Symptoms

Owners may report that the "brake lights remaining ON" or that the "vehicle being able to start without pressing the brake pedal." Additionally, the switch plunger may be stuck and non-functional. Other scenarios include "Brake lights are triggered without pressing the brake pedal," "Flickering of brake lights," "Continuous operation of brake lights," and "Switch gears without pressing the brake pedal."

Associated Fault Codes (DTCs)

When diagnosing a brake pedal switch stuck condition, technicians may find the following Diagnostic Trouble Codes (DTCs) present as active or stored:

Code
P057B
P0572
P0703

Diagnosis for Brake Pedal Switch

Before proceeding with repair, technicians should confirm the following scenarios are present:

1. Pre-Check: Verify if any of the symptoms listed above are present.
2. Plunger Contact Check: Ensure the switch plunger is in contact with the brake pedal. This is a critical step before attempting uninstallation.

Repair Procedure for Brake Pedal Switch

1. Vehicle Preparation: Install a battery charger to maintain a 12-volt system voltage throughout the process.
2. Software Reprogramming: Reprogram the ACC module with the latest software using the wiTECH Diagnostic Application. If the flash process is interrupted, it should be restarted.
3. Clear DTCs: Clear any DTCs that may have been set in any modules due to reprogramming. The wiTECH application will automatically present all DTCs after the flash and allow them to be cleared.
4. Switch Uninstallation: To remove the brake pedal switch, apply a 45-degree clockwise twisting motion, then remove it from the mounting bracket.
5. Switch Inspection:
   • Manufacturing Inspection: Visually verify if the brake pedal switch housing is damaged, and check if the small plastic tabs positioned beside the plunger are damaged or broken.
   • Plunger Verification: Measure the exposed plunger's initial position length, which should be 16.90mm. Manually press and release the plunger, then measure its length again. If the plunger lacks range of motion or fails to emerge, it may be damaged.

Important Warranty Information and Warnings

• Fuse Replacements: "Blown fuses, when not included in an electrical wiring repair, are NOT covered under the warranty." Claims solely for fuses, without other justifiable electrical repair, are considered a maintenance cost and are not warrantable. They will be charged back with a statement of “Fuses alone are considered a maintenance cost and are not a warrantable component.”
• ACC Module Reprogramming: If the flash process for the ACC module is interrupted or aborted, the flash should be restarted.
• Brake Pedal Switch Removal: Failing to follow proper uninstallation procedures for the brake pedal switch may result in additional issues, specifically the switch plunger becoming stuck. If the plunger switch is not in contact with the brake pedal during uninstallation, potential additional damages or a stuck condition may occur.
• Balljoint Removal: When removing the front lower control arm balljoint from the front steering knuckle, "do not hammer any of the components." This includes the knuckle, balljoint stud, or lower control arm, as hammering can damage the stud and crack the knuckle.
• TSB 08-136-24: This Technical Service Bulletin should only be applied if a "Malfunction Indicator Lamp is present, either actively or reported by the customer." Vehicles should not be updated with new software unless these criteria are met.

Required Parts and Tools

For coolant leak issues, specific long block part numbers are referenced:

• 18-24MY JL ESS: PN 68731685AA
• 21-24MY JL PHEV: PN 68731693AA
• 22-24MY WL PHEV: PN 68731694AA
• 23-25MY MP / 23-25MY GG/GC: PN 68731712AA

For the brake pedal switch issue, the replacement part number is:

• 23-27MY VF BPS: PN 68517960AA

For Ram 1500 (DT) front lower control arm to knuckle balljoint removal, a specialized tool is required:

• Remover, Ball Joint: Item Number 8677A

NHTSA ID: 11011964