2024 Alfa Romeo Tonale PIM Software Update TSB

Owners of 2024 Alfa Romeo Tonale vehicles, specifically those built on or before May 24, 2024 (MDH 0524XX) and equipped with the 1.3L I4 DOHC Turbo PHEV Engine (Sales Code EYG), might encounter issues related to the Power Inverter Module (PIM).

This bulletin, TSB 08-045-24 REV. B, addresses the need for module software updates to resolve these concerns. It supersedes the previous TSB 08-045-24 REV. A, issued on April 24, 2024, and has also been released as Rapid Service Update (RSU) 24-153.

Symptoms

If your 2024 Alfa Romeo Tonale is affected by these issues, you may observe a Malfunction Indicator Lamp (MIL) illumination on your dashboard. This warning light indicates a fault within the vehicle's system.

In conjunction with the MIL, one or more specific Diagnostic Trouble Codes (DTCs) will be stored in the vehicle's computer system. These codes pinpoint the exact nature of the malfunction.

Fault Codes / DTCs

The following Diagnostic Trouble Codes (DTCs) are associated with the issues addressed by this TSB:

Code	Description	Module
P2601-00	Electric Coolant Pump Control Circuit Performance Stuck Off
U0623-00	Lost Communication With Coolant Pump "A"
P1DBA	Battery Cooling System Failure	Module, Hybrid Control Processor (HCP)

These codes indicate problems with the electric coolant pump control circuit or communication, and battery cooling system failure, all pointing towards the need for the Alfa Romeo Tonale PIM updates.

Diagnosis and Trigger Conditions

To confirm if your 2024 Alfa Romeo Tonale requires this update, a technician will use a Scan Tool (wiTECH) to perform diagnostic procedures. The presence of the aforementioned DTCs or the customer's reported symptoms will indicate the need for the repair.

It is crucial to verify if your vehicle's VIN is listed in the Rapid Service Update (RSU) VIN list or VIP (Vehicle Information Plus) system. If your VIN is on the list, the repair should be performed. Even if not on the RSU VIN list, if your Alfa Romeo Tonale exhibits any of the listed symptoms, the repair procedure should still be followed.

Important Warnings and Cautions

Several critical safety warnings and cautions are provided for technicians performing this repair:

• WARNING! Before performing software reprogramming, the vehicle must be made safe. When working on repairs involving or implying contact with live high-voltage components/systems, technicians must ensure the power supply of the high-voltage system is disconnected throughout the operation.
• WARNING! Only specifically trained technicians qualified to perform repairs on vehicles with high voltage systems under current national laws/regulations are authorized to work on the vehicle. Before any diagnostic repair work, carefully read and comply with general instructions for working safely on hybrid/electric vehicles and use suitable general equipment and Personal Protective Equipment (PPE).
• WARNING! The vehicle must not be connected to a high voltage charger when performing software updates.
• NOTE: Install a battery charger to ensure sufficient battery voltage is provided during the flash process. If the flash process is interrupted or aborted, it should be restarted.
• CAUTION! Removal of the Brake Booster Vacuum Pump is necessary for this Repair Procedure. Failure to remove the 30 Amp fuse may result in damage to the Brake Booster Vacuum Pump.

Repair Procedure Summary

The repair for the Alfa Romeo Tonale PIM updates involves reprogramming the Auxiliary Hybrid Control Processor (AHCP), also known as the Power Inverter Module (PIM), with the latest available software. The process includes several steps:

1. VIN Verification: Check if the vehicle's VIN is on the RSU VIN list. If not, further diagnostics are needed.
2. DTC Check: Confirm if DTC P1DBA is present. If not, the bulletin may not apply, and further diagnostics are required.
3. Disable HV Battery Contactors: Using the wiTECH tool, disable the high-voltage battery contactors via the Misc Functions tab and follow the prompts.
4. Confirm Contactor Status: Use wiTECH to confirm the contactors are open and wait five minutes. If they do not open, cycle the ignition.
5. Remove Fuse: Remove the 30 Amp fuse for the Brake Booster Vacuum Pump from the Power Distribution Center (PDC) in the engine compartment.
6. Reprogram PIM: Reprogram the PIM with the latest software using the wiTECH Diagnostic Application. Detailed instructions are available in the application's "HELP" tab.
7. Install Fuse: Install the 30 Amp Brake Booster Vacuum Pump fuse.
8. Enable HV Battery Contactors: Using wiTECH, enable the high-voltage battery contactors via the Misc Functions tab.
9. Clear DTCs: Clear any Diagnostic Trouble Codes that may have been set in any modules due to the reprogramming process.

Required Tools or Parts

Technicians will require a Scan Tool (wiTECH) with the appropriate Diagnostic Procedures available in DealerCONNECT/Service Library to perform the diagnosis and reprogramming. A battery charger is also necessary to maintain sufficient battery voltage during the software update.

Warranty Information

All repairs performed under Technical Service Bulletin 08-045-24 REV. B are reimbursable within the provisions of the vehicle's warranty. The appropriate failure code (RF for RSU, CC for TSB) must be selected by the dealer.

NHTSA ID: 11010632