2023-2024 Alfa Romeo Tonale / Dodge Hornet Headlamp Condensation TSB

Symptoms

Owners of 2023-2024 Alfa Romeo Tonale and Dodge Hornet vehicles may notice headlamp and tail lamp assembly condensation. This typically appears as a light layer of fogging on the inside of the exterior lamp lenses. The TSB notes that "Some customers may report that on occasion, vehicle exterior lamp assemblies are fogged with a light layer of condensation on the inside of the lenses."

Diagnosis / Trigger Conditions

Condensation in headlamp and tail lamp assemblies can occur under various atmospheric conditions. This includes rapid cooling after the lamps have been on, exposure to cold water from rain or car washes, or after being parked outside overnight during warm, humid days followed by cool nights. Normally, this condensation clears as atmospheric conditions change, converting the moisture back into a vapor. Turning the headlamps ON can accelerate this process.

To evaluate the condition, technicians are advised to dry the outside surface of the lamp lens, start the vehicle's engine, and turn on the headlamps and hazard warning flashers. This procedure helps determine if the condensation is normal or indicative of a sealing issue.

Important Warnings

Stellantis provides specific guidance to prevent unnecessary replacements and ensure proper diagnosis:

• If the condensation or fogging begins to clear from the headlamp or tail lamp lens while the lamps are operating, this indicates the lamp's sealing is intact, and "the lamp assembly does NOT need to be replaced."
• Conversely, if the condensation does not clear with the lamps operating, or if large amounts of water droplets are visible inside the assembly, it suggests a sealing problem. In such cases, "Any assembly that exhibits internal moisture permanently, should be replaced."
• If physical damage such as breakage, cracks, or holes is found on the assembly housing, which allows moisture to enter, the failure code "BROKEN OR CRACKED" must be recorded.

Repair Procedure Summary

The Technical Service Bulletin 08-157-24 outlines a standard procedure for lamp lens defogging and evaluation. The primary goal is to differentiate between normal, temporary condensation and persistent moisture caused by a compromised lamp seal or physical damage.

Technicians will first attempt to clear the condensation by drying the exterior of the lamp, starting the vehicle, and activating the headlamps and hazard flashers. If the condensation dissipates during this process, the lamp assembly is considered functional and does not require replacement. However, if the fogging persists or if there are significant water droplets inside, it indicates a defect in the lamp's sealing, necessitating replacement of the headlamp or tail lamp assembly. Any visible damage to the lamp housing will also lead to replacement.

Owner Action

If you observe 2024 Alfa Romeo Tonale headlamp condensation or tail lamp condensation, first note the conditions under which it appears and whether it clears on its own. Turning on your vehicle's headlamps can often help dissipate the moisture more quickly. If the condensation is persistent, does not clear, or if you notice large water droplets or any physical damage to the lamp assembly, it is recommended to contact your authorized Alfa Romeo or Dodge dealer. They can perform the evaluation procedure outlined in TSB 08-157-24 to determine if a repair or replacement is necessary.