2021-2025 Alfa Romeo Tonale Coolant Leak & Overheating

This article summarizes key information from the FCA Caribbean Warranty Operations Newsletter, Volume 11, Issue 4 (NHTSA ID 11016951), providing essential details for owners of various 2021-2025 Alfa Romeo, Jeep, Dodge, and RAM models. The newsletter covers a range of topics from specific repair procedures to important warranty exclusions and general maintenance tips. This includes critical information regarding potential engine overheating and the Alfa Romeo Tonale coolant leak issue.

Coolant Leak and Engine Overheating Issue

This section addresses coolant leaks and engine overheating affecting 2021-2025 Jeep Wrangler (JL), Jeep Grand Cherokee (WL), Jeep Compass (MP), Dodge Hornet (GG), and Alfa Romeo Tonale (GC) models equipped with the GME T4 DOHC engine.

Symptoms

Owners may notice a low coolant level in the reservoir, the vehicle may not start, experience power or torque degradation, have a high level of misfire events, or see the check engine light illuminate. These symptoms indicate a potential coolant leak or engine overheating condition.

Diagnosis

Before replacing a long block, technicians are advised to perform several pre-checks and checks:

• Pre-Checks:
  • Check and record the coolant level in the coolant bottle.
  • Inspect for thermostat and other cooling system-related issues, such as problems with the water pump or cooling fan.
  • Drain an oil sample to check for coolant or moisture presence.
• Checks:
  • Perform a Cylinder Leakage Test on all cylinders by pressurizing each cylinder at Top Dead Center (TDC) with 5.5 bar of air and checking for bubbles in the radiator coolant.
  • Conduct a coolant pressurization test on the cooling system, pressurizing to 2 bar (30 PSI).
  • Borescope cylinders to check for coolant in the combustion chamber. Hold pressure for one hour and check for leak down.
  • Perform a CO2 leak test to check for combustion gasses in the cooling system.

Common failure points identified include water pump inlet pipe bolts losing torque, twisted water pump gaskets, and thermostat column manifold bolts losing torque. Other potential causes are cylinder block casting porosity or cracks, and internal cracks in the oil coolant exchanger, which can lead to coolant and oil mixing.

Repair Procedure Summary

Engineering recommends using a long block replacement to reduce repair costs, rather than replacing the entire engine. If the initial checks (1-3) do not fail, it suggests that a full engine or long block replacement is not necessary. Instead, technicians should focus on replacing the specific component causing the coolant leak. Long block part numbers include 68731685AA (18-24MY JL ESS & JL PHEV), 68731694AA (22-24MY WL PHEV), and 68731712AA (23-25MY MP, GG, GC).

Important Warnings for Coolant Leak and Overheating

When diagnosing an overheated engine with a coolant leak, it is crucial to understand that replacing the full engine is often unnecessary. Many cases only require replacing the specific failing component, not the entire long block.

High Voltage Lithium-Ion Battery Exclusions

For vehicles with High Voltage batteries, the warranty does not cover damage or conditions caused by specific actions. These exclusions include:

• Physically damaging the high voltage lithium-ion battery or intentionally attempting to reduce its life.
• Leaving the vehicle for over 30 days with the high voltage lithium-ion battery at a zero or near-zero state of charge.
• Neglecting to follow correct charging procedures as recommended in the Owner's Manual.
• Using incompatible charging devices.
• Opening the high voltage lithium-ion battery enclosure or having it serviced by unauthorized personnel.
• Exposing the high voltage lithium-ion battery to direct flame.
• Exposing the vehicle to ambient temperatures above 140°F (60°C) for over 24 hours.

Intelligent Battery Sensor (IBS) Diagnostics

This section provides diagnostic information for the Intelligent Battery Sensor (IBS) in 2024-2025 Domestic Models. The IBS communicates battery data to the Body Control Module (BCM) via the Local Interconnect Network (LIN) bus, which then transfers it to the Controller Area Network (CAN).

Symptoms and DTCs

Common symptoms and associated Diagnostic Trouble Codes (DTCs) related to the IBS include:

• LOC DTC U113E
• IBS Internal Error DTC B2193
• Loose Connection
• Vehicle No Start
• Bad Battery
• SOC Inaccurate
• Inadequate Battery Charging, Charging failure, Battery Telltale Light
• ESS Inop

Troubleshooting

For LOC DTC U113E and IBS Internal Error DTC B2193, troubleshooting steps involve checking battery connections, verifying voltage at the IBS connector, checking the IBS fuse, verifying LIN bus activity, performing continuity tests, and unplugging/plugging the IBS (reset). If these actions fail, the IBS should be replaced. For SOC Inaccurate issues, active IBS DTCs should be addressed, and visual/connection inspections performed. For ICE vehicles, a crank and quiescent state initiation are required for IBS SOC learning. If SOC accuracy is still low, driving the vehicle for 1-2 hours to monitor SOC change is recommended. For Inadequate Battery Charging, active IBS DTCs must be checked, and IBS/battery connections/voltage verified.

Important Warnings for IBS Diagnostics

Claim narratives must list and reference any DTCs mentioned in this document and state the DTCs set at the time of IBS replacement. The IBS should not impact starting unless it is loose, significantly corroded, or disconnected. An aged battery should not require a new IBS. External chargers should be disconnected during IBS learning.

12V Battery Charging and PHEV Jump Start

This section addresses issues related to 12V battery charging and jump-starting procedures for 2023-2025 Dodge Hornet (GG) and Alfa Romeo Tonale (GC) PHEV vehicles. Incorrect procedures can lead to damage to the Integrated Dual Charging Module (IDCM), indicated by DTC U12AF.

Charging Procedure for Discharged 12V Batteries on PHEV/BEV

To avoid damaging the IDCM, follow these steps when charging a completely discharged 12V battery:

1. Measure the battery voltage at the battery posts with a voltmeter. A battery below 10 volts is considered extremely discharged.
2. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector FIRST before disconnecting the negative battery cable.

Jump Start Procedure for PHEV Vehicles

To properly jump-start PHEV vehicles:

1. Remove the IDCM KL30 line fuse from the LV PDC box under the hood.
2. Connect the jump-box or booster to the 12V battery. Ensure the positive terminal is connected to the 12V battery positive terminal, and the negative terminal to the 12V battery negative terminal or vehicle chassis ground. Avoid reverse polarity.
3. Wait a few minutes to charge the 12V battery until it reaches at least 10.5V.
4. Key on the vehicle. As soon as it cranks, remove the jump-box/booster connections and re-install the KL30 line fuse. Do not re-install the fuse before disconnecting the jump-box/booster.
5. Check the 12V battery voltage level.

Important Warnings for 12V Battery Charging and Jump Start

It is highly recommended to charge the 12V battery rather than jump-start the vehicle. If the negative ground cable is not disconnected during charging of completely discharged 12V batteries on PHEV/BEV vehicles, it can cause damage to the Integrated Dual Charging Module (IDCM), resulting in its premature replacement. Additionally, when jump-starting, do not re-install the fuse before disconnecting the jump-box/booster.

Park Assist Sensors Damage

For 2021-2025 Jeep Grand Cherokee (WL) and Wagoneer/Grand Wagoneer (WS) models, physical damage to park assist sensors has been observed, often caused by external forces like road debris.

Symptoms

Symptoms for this issue are found in the Service Library. Examples of physical damage are shown in the document.

Important Warnings for Park Assist Sensors

Physical damage to park assist sensors is not considered a defect in material or workmanship and is not supported for warranty reimbursement. It may be considered for Consumer Goodwill with business center support or an insurance claim. If corrosion is visible in the sensor connector area, a wiring repair should be assigned. The Park Assist sensor LOP should only be used if the sensor is replaced.

RAM Truck Power Seat Adjuster Motor Connection Inspection

RAM 2500, 3500, and 5500 trucks may experience an inoperative fore/aft front seat adjuster function due to a loose connection to the motor. This issue was noted on 3/12/2025.

Repair Procedure Summary

1. Position the seat for inspection.
2. Disconnect the seat wire harness motor connector from the fore/aft motor on the seat adjuster. Wait 10 seconds, then reconnect.
3. Verify the function of the fore/aft adjuster.

If the motor does not function after reconnection, refer to the Replacement Procedure. The procedure also involves adjusting the driver front seat fully up, removing and discarding the four seat-to-floor bolts (part number 06508069AA), laying the seat on its back for access, and then disconnecting/reconnecting the motor connector. After cycling the seat to check function, reassemble the seat using new bolts and torque to 47 Nm. The passenger seat follows the same procedure.

Required Parts

• Four (4) Replacement floor attachment bolts: 06508069AA
• When applicable: Replacement power seat adjusters (part numbers: 68455847AA, 68455848AA, 68455849AA)

Key Fob Signal Interference

Jeep Wrangler (JL) and Jeep Gladiator (JT) owners may experience issues with their key fobs due to wireless signal interference.

Symptoms

The key fob's wireless signal may be blocked if it is located near a mobile phone, laptop, or other electronic device. This can result in poor performance, the key fob not being detected by the vehicle Passive Entry system, or the