NHTSA ID Number: 10225245
Manufacturer Communication Number: Z27
TSB/Document Date: 2022-10-31
Summary
Customer Satisfaction Notification Z27 PHEV Battery Replacement
August 2022
Dealer Service Instructions for:
Customer Satisfaction Notification Z27
PHEV Battery Replacement
Remedy Available
2021
NOTE: This campaign applies only to the above vehicles equipped with a 2.0L
engine (sales code ECX).
NOTE: Some vehicles above may have been identified as not involved in this
campaign and therefore have been excluded from this campaign.
IMPORTANT: Some of the involved vehicles may be in dealer new vehicle
inventory. Dealers should complete this campaign service on these vehicles
before retail delivery. Dealers should also perform this repair on vehicles in used
vehicle inventory and those vehicles in for service. Involved vehicles can be
determined by using the VIP inquiry process.
Subject
The Plug-in Hybrid
Electric Vehicle (PHEV) battery on about 20 of the above
vehicles may develop internal resistance which sets a Diagnostic Trouble Code
(DTC). When the DTC is set, the PHEV system is inoperative, and the vehicle
reverts to Internal Combustion Engine (ICE) propulsion only.
© Copyright 2022, FCA US LLC, All Rights Reserved (djt)
Customer Satisfaction Notification Z27 – PHEV
Battery Replacement
Page 2
Repair
Replace the PHEV battery.
Parts Information
Part Number
Qty.
Description
1
400V Battery
68163848AB
1
06512293AA
3
Use standard ordering through STAR for the battery.
Parts Return
Return instructions for the old battery are included in the container with the
new battery. There is a $2500.00 core charge for this battery.
NOTE: If the HV battery is missing its return instructions, contact the UPS
Call Center 800-567-9989.
Customer Satisfaction Notification Z27 – PHEV
Battery Replacement
Page 3
Special Tools
The following special tools are required to perform this repair:
➢ NPN
wiTECH MicroPod II
➢ NPN
➢ NPN
wiTECH Software
➢ 2035100082
Covers, HEV Battery Terminal
➢ 2035203080
Eyebolt, 10mm
➢ 2035200080
➢ 126-1587
Meter, Multi –
Originally Shipped In Kit Number(s) 10389.
➢ 10441
Cone, Safety
Originally Shipped In Kit Number(s) 10420.
➢ 10442
Barriers, Safety
Originally Shipped In Kit Number(s) 10420.
➢ 10152-1
Protective Glove Set – Small
Originally Shipped In Kit Number(s) 10075ACHR, 10075A-DOD, 10075-CHR, 10075CHRYSLER, 10075-DOD, 10075-DODGE,
10389.
➢ 10152-2
Protective Glove Set – Medium
Originally Shipped In Kit Number(s) 10075ACHR, 10075A-DOD, 10075-CHR, 10075CHRYSLER, 10075-DOD, 10075-DODGE,
10389.
➢ 10152-3
Protective Glove Set – Large
Originally Shipped In Kit Number(s) 10075ACHR, 10075A-DOD, 10075-CHR, 10075CHRYSLER, 10075-DOD, 10075-DODGE,
10389.
➢ 10440
Hard Hat and Face Shield
Originally Shipped In Kit Number(s) 10420.
Customer Satisfaction Notification Z27 – PHEV
Battery Replacement
Page 4
Special Tools [Continued]
➢ 10452
Sign, Danger High Voltage
Originally Shipped In Kit Number(s) 10420.
➢ 10443
Cards, Windshield and Dash Placement
Originally Shipped In Kit Number(s) 10420.
➢ 10451
Crate
Originally Shipped In Kit Number(s) 10420.
Customer Satisfaction Notification Z27 – PHEV
Battery Replacement
Page 5
Service Procedure
Only individuals with high voltage training and repair qualifications should
be allowed to handle, troubleshoot or repair High Voltage or Hybrid
components or systems.
Always wear safety glasses.
The following service information can be found in High Voltage Safety
Procedures in Service Library section 08, Standard Procedures.
NOTE: When performing any repairs that involve contact with high voltage
components or systems, the technician performing repairs on the vehicle must
verify that the system remains powered down during high voltage repairs.
This must be done by removing the test points access cover.
The high voltage power down procedure must also be performed to ensure
that the vehicle is properly powered down.
The technician must know the whereabouts of the test points access cover
throughout the repair.
The technician must ensure that no one reinstalls the test points access cover
while service is being performed.
The technician must recheck that the test points access cover has not been
reinstalled in cases where the vehicle was unattended.
Failure to comply with all of these warnings may result in personal injury
including: BURN, SHOCK OR FATAL INJURY.
WARNING: Before performing any diagnostic or service procedure, you
must thoroughly read and follow all applicable High Voltage Safety
Procedures. You must perform the High Voltage Battery Power Down
procedure before performing any repairs (Refer to 12 - Electrified Powertrain
System/High Voltage Battery/Standard Procedure).
Customer Satisfaction Notification Z27 – PHEV
Battery Replacement
Page 6
Service Procedure [Continued]
Personal Protection Equipment
WARNING: Be sure to utilize the proper Personal Protection Equipment
(PPE) when working on any high voltage system. Failure to do so may result
in serious or fatal injury.
• Safety Glasses
• Natural Fiber clothing
• Hand tools HV rated with a
dielectric barrier of not less
than 1000 volts
• Rated and non-expired rubber
insulating gloves with leather
protectors
Personal Protection Equipment (PPE)
Customer Satisfaction Notification Z27 – PHEV
Battery Replacement
Page 7
Service Procedure [Continued]
WARNING: Do not use leather protectors alone for protection against electric
shock. Serious injury or fatal injury will result. Always use rubber insulating
gloves in the proper voltage class.
• Proper use and care of rubber insulating gloves and sleeves are essential
to user safety. Do not wear rings, watches, jewelry and sharp objects on
your hands or arms, they will cause damage to the rubber gloves and
sleeves.
• Wear leather protectors over rubber insulating gloves to protect the
gloves from physical damage.
• To maintain an adequate flashover distance between the end of the
protector cuff and the end of the rubber glove cuff, the rubber glove
should be longer than the protector by at least one inch multiplied by
the rubber glove's Class number, but not less than one-half inch for
Class 00 and 0 gloves.
• Where the finger dexterity needed to manipulate small equipment and
parts requires use of rubber insulating gloves without leather
protectors, extra care must be taken by the user to prevent puncture,
abrasion and other damage to the gloves.
• Except for Class 00 and Class 0
gloves, rubber insulating gloves
used without leather protectors
must be one Class higher than
that required for the voltage
involved, and must not be used
at the higher voltage until given
an inspection and electrical
retest using the procedures in
the most recent edition of
ASTM Standard F496
(Specification for In-Service
Care of Insulating Gloves and
Sleeves), document can be
obtained at www.astm.org.
Customer Satisfaction Notification Z27 – PHEV
Battery Replacement
Page 8
Service Procedure [Continued]
WARNING [Continued]:
• To assure their continued
integrity, rubber insulating
gloves and sleeves must be
inspected on their inside and
outside surfaces at least once a
day, and more frequently when
used without leather protectors
or if the user suspects that the
rubber glove may have been
snagged or otherwise damaged
while in use.
Inspect Gloves
• Inspections should be
performed using the inspection
procedures describe in the latest edition of ASTM Standard F1236
(Guide for Visual Inspection of Electrical Protective Rubber Products)
looking for physical damage (punctures, cuts and abrasions), chemical
deterioration (swelling, softness, hardness, stickiness) ozone
deterioration and other irregularities. Document can be obtained at
www.astm.org.
• Do not use rubber gloves or sleeves showing any irregularities. Their
ability to protect against electric shock has been compromised, exposing
the user to the risk of serious or fatal injury.
• Leather protectors must also be inspected when inspecting the rubber
gloves. Metal particles, imbedded wire, abrasive material or any
substance that could physically damage the rubber glove must be
removed before using the protector.
Customer Satisfaction Notification Z27 – PHEV
Battery Replacement
Page 9
Service Procedure [Continued]
WARNING [Continued]:
Insulating Glove Usage Timeline
• Rubber insulating gloves must be retested electrically at least once every
six (6) months (and rubber insulating sleeves at least once every twelve
(12) months) using the test procedures described in the most recent
edition of ASTM Standard F496, document can be obtained at
www.astm.org.
• Rubber insulating gloves can be damaged by many chemicals, especially
petroleum-based products (oils, gasoline, hydraulic fluid) solvents, hand
creams, pastes and salves. If contact is made with these or other
chemical products, the contaminant should be wiped off immediately.
• To clean, rubber-insulating gloves should be washed with a mild soap,
rinsed thoroughly with clean water and air-dried.
• Rubber insulating gloves and sleeves should be stored in a protective
bag when not being used.
Customer Satisfaction Notification Z27 – PHEV
Battery Replacement
Page 10
Service Procedure [Continued]
Safety Equipment
WARNING: Be sure to utilize the proper safety equipment found in Kit,
Safety Service - HEV when working on any high voltage system. Failure to do
so may result in serious or fatal injury.
The Kit, Safety Service - HEV includes the following:
•
•
•
•
•
•
•
•
•
Cone, Safety 10441 (six required)
Barriers, Safety 10442 (six required)
Protective Glove Set - Small 10152-1
Protective Glove Set - Medium 10152-2
Protective Glove Set - Large 10152-3
Hard Hat and Face Shiel 10440
Sign, Danger High Voltage 10452 (two required)
Cards, Windshield and Dash Placement 10443 (set of four)
Crate 10451 (storage)
Cards, Windshield & Dash Placement consist of:
• Powered Up Signs
• Powered Down Signs
• 400 Volts HYBRID Electric Vehicle Signs
Customer Satisfaction Notification Z27 – PHEV
Battery Replacement
Page 11
Service Procedure [Continued]
Test Equipment
WARNING: Be sure to utilize the proper test equipment when working on
any high voltage system. Failure to do so may result in serious or fatal injury.
When taking electrical measurements, high voltage must never be allowed to
“escape” beyond the article under test. This assures:
•
•
•
•
That those taking measurements will not come into contact
That others in other areas will not come into contact
That equipment will not be damaged
That measurements will be accurate
For electrical measurements, there are three forms of separation:
•
•
•
Non-contact measurement or indirect sensing of high voltage current (in
amps) using a clamp-on type current probe
Isolating voltage probes or differential probes with galvanic separation
between the input probes and the measurement device
Isolation of the test equipment from the building using a Isolation
Transformer or a battery-powered device
The Fluke Meter, Multi 126-1587 is specifically rated for use measuring high
voltage sources and has been the default choice for testing the PHEV high
voltage electrical system.
Customer Satisfaction Notification Z27 – PHEV
Battery Replacement
Page 12
Service Procedure [Continued]
Prepare the Work Area
Assemble the six Cone, Safety 10441 and six Barriers, Safety 10442 around the
vehicle/hoist area.
Position the two Sign, Danger High Voltage 10452 within the assembled safety
cones and barriers.
Place the four Cards, Windshield and Dash Placement 10443 within the vehicle.
Battery Recycling
The Hybrid vehicles contain a High Voltage 400 Volt Lithium-Ion (Li-ion) battery.
It is important to understand that these batteries can be recycled. Prior to doing so,
refer to federal, state, local and provincial laws and regulations governing the
recycling, handling, and shipping of such batteries and materials.
Li-ion batteries contain several components, including iron, copper, nickel and
cobalt, each of which has value as recycled materials. Dealers should follow the
Service Information Procedures for proper disconnecting, removing and handling
of the Li-ion battery packs.
Since Li-ion batteries contain less toxic metals than other types of batteries which
may contain lead or cadmium they are generally categorized as non-hazardous
waste.
Customer Satisfaction Notification Z27 – PHEV
Battery Replacement
Page 13
Service Procedure [Continued]
WARNING: Before performing any diagnostic or service procedure, you
must thoroughly read and follow all applicable high voltage safety
procedures. You must perform the high voltage power down procedures.
Loss of Isolation (LOI) must be performed before high voltage power up in
cases where service has been performed on a high-voltage component or
when diagnosing a LOI condition.
Be sure to use the proper safety equipment when working on any high
voltage system or component. Failure to do so may result in serious or fatal
injury.
Wait a minimum of two minutes after performing the high voltage battery
disconnect procedure safety procedures before attempting to access the
high voltage system, failure to do so may result in serious or fatal injury.
CAUTION: Do not allow coolant to come in contact with any high voltage
component electrical connections. Engine coolant will create a conductive
path and cannot be effectively removed resulting in a loss of isolation and
replacement of the contaminated high voltage component.
NOTE: If the High Voltage (HV) battery is missing its return instructions,
contact the UPS Call Center 800-567-9989.
Customer Satisfaction Notification Z27 – PHEV
Battery Replacement
Page 14
Service Procedure [Continued]
NOTE: Observe the following precautions when handling the HV battery
pack:
• DO NOT touch the high voltage terminals.
• Always use the battery pack four lift points when moving the battery
pack.
• Keep the battery pack in the same orientation as when installed in the
vehicle.
• Store in a clean and dry environment.
• Store at a temperature of 10-30°C (50-86°F) with relative humidity
between 30-70%.
• Always store at a State Of Charge (SOC) of around 30%.
• Always store on an electrically nonconducting (insulated) material.
• Store with spatial gap of at least 50 cm (20 in.).
• DO NOT store the battery pack near any environmental condition
involving liquid, heat, strong magnetic field, electricity or that can
generate heat (for example: transformers).
NOTE: The HV battery pack weighs 167 kg (368 lb.).
Customer Satisfaction Notification Z27 – PHEV
Battery Replacement
Page 15
Service Procedure [Continued]
1. Using the wiTech tool, scan for set DTCs. If a code is present for stuck
contactors, special handling procedures are required.
• P0AA1-00 - HYBRID/EV BATTERY POSITIVE CONTACTOR “A”
STUCK CLOSED
• P0AA4-00-HYBRID BATTERY NEGATIVE CONTACTOR
CIRCUIT STUCK CLOSED
See “HV Battery Servicing with Welded Contactor(s)” at the beginning
of the PHEV Battery removal procedure in Service Library.
A. Power Down the High Voltage System
2. Power down the high voltage system. If the HV battery will not power down or
the vehicle has a welded contactor DTC active that will not clear, stop and
perform the “HV Battery Servicing with Welded Contactor(s)” at the
beginning of the PHEV Battery removal procedure in Service Library.
NOTE: When performing any repairs that involve contact with high
voltage components or systems, the technician performing repairs on the
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TSB/Document ID: Z27
Replacement Service Bulletin Number:
MFR Communication Date: 2022-08-25
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM:12V/24V/48V BATTERY
MFR Component System:
MFR Component Subsystem:
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