- Storage temperature minimum -40 °C
- Storage temperature maximum 70 °C
- Racks & dunnage: store in shipping dunnage with covers
- Stacking (racks): 3 high (maximum)
- State of Charge (SOC): 30% or less
- Warehouse temperature: 10 C - 25 C
- Warehouse humidity: 35% - 65% non-condensing
- Storage time: 6 months (maximum) First in First out to be
followed.
- All the batteries should be segregated with a fire suppression
system to allow for individual battery type response to a
thermal event.
55. Place the suspect HV battery
pack onto the foam on the inside
of the top cover (Figure 26).

Figure 26 – HV Battery on Top Cover

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 32

Service Procedure [Continued]
WARNING: Do not place the
suspect HV BATTERY PACK on
any surface other than the foam
on the top cover. Damage will
occur to the coolant duct and
relief valve assemblies
(underneath HV Battery Pack)
leading to coolant leakage if this
is not followed. This damage may
void warranty and core return
(Figure 27).

Figure 27 – HV Battery Bottom View

Note: If coolant hoses w/quick connect have been damaged, contact Star
Center by creating a Star Case.

NOTE: Leave replacement HV BATTERY PACK in the crate until ready to
install in vehicle. Damage will occur to the coolant duct and relief valve
assemblies (underneath HV Battery Pack) leading to coolant leakage if the HV
BATTERY PACK is placed on any surface other than the foam in the
dunnage.

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 33

Service Procedure [Continued]
B. HV Battery Installation
1. Attach the Eyebolt, 10mm 2035203080 to the new HV battery pack in the same
locations that were used for the removal. Connect the Lift Straps, HV Battery
2035200080 on the front and rear eyelets.
2. Secure the HV battery pack to the lifting device.
3. Install the HV battery pack in the vehicle making sure that the mounting holes
align with the bolt holes in the body.
4. Remove the lifting strap and eyebolts.
5. Install the HV battery pack bolts (1) and tighten to (Figure 28):
• High Voltage Battery to Chassis M10 Bolts tighten to 45N·m
(33 ft. lbs.).
• High Voltage Battery to Chassis M8 Bolts tighten to 21N·m
(15 ft. lbs.).
6. Install the chassis ground cable to the HV battery ground stud (1) and tighten to
9N·m (80 in. lbs.) (Figure 25).
7. Connect the HV battery coolant line connectors (1) (Figure 21).
8. Connect the three HV wire harness connectors (1) (Figure 20).
9. Install the silencer pad (Figure 18).
10. Install the rear seat to the vehicle.
11. Install NEW bolts at the front of the rear seat and tighten to 70N·m (52 ft. lbs.).
12. Connect the wire harness connectors, if equipped (Figures 16 and 17).
13. Install the rear seat fasteners at the rear of the seat and tighten to 70N·m
(52 ft. lbs.).
14. Install the seat belts from the floor stud.

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 34

Service Procedure [Continued]
15. Install the nut for the center seat belt anchor and tighten to 70N·m (52 ft. lbs.).
16. Raise the rear seat cushion.
17. Install the rear seat to load floor gap hider.
18. Align and install the retainers from the front high voltage battery closeout to the
vehicle (Figure 14).
19. Install the high voltage trim panel and press downward to seat the retainers
(Figure 13).
20. Install the fasteners to the side high voltage battery trim panels and tighten
securely.
21. Lower the rear seat cushion.
22. Set the door into place on the hinges and install the door hinge pivot nuts.
Tighten the nuts to 6N·m (53 in. lbs.) (Figure 12).
23. Install the door check strap bolt securing the door check and tighten to 9N·m
(80 in. lbs.) (Figure 11).
24. Connect the wire harness connector and secure the door tether to the support
bracket (Figure 10).
25. Align and install the B-pillar trim cover (Figure 9).
26. Raise and support the vehicle.
NOTE: When connecting the High Voltage connection verify that the
connectors are clean and seated properly.
27. Remove the battery port covers and transfer them to the old battery. Connect
the HV wire harness connectors (1) and (2) to the HV battery and tighten to
9N·m (80 in. lbs.) (Figure 8).

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 35

Service Procedure [Continued]
28. Install the battery skid plate (2) and tighten the fasteners (1) to 25N·m
(18 ft. lbs.) (Figure 7).
29. Remove the support and lower vehicle.

WARNING: ANTIFREEZE COOLANT IS HARMFUL IF
SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO
GLASSES OF WATER AND INDUCE VOMITING. IF INHALED,
MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION
IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED
CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY
AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP
OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASED
COOLANT PROPERLY. CONTACT YOUR DEALER OR
GOVERNMENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM
WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT
UNDER PRESSURE; PERSONAL INJURY CAN RESULT. AVOID
RADIATOR COOLING FAN AND OTHER MOVING COMPONENTS
WHEN ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED; PERSONAL INJURY CAN RESULT.

WARNING: WEAR APPROPRIATE EYE AND HAND PROTECTION
WHEN PERFORMING THIS PROCEDURE.

30. Fill the battery cooling system.

NOTE: Fill the High Voltage (HV) battery cooling system with the
recommended MOPAR Antifreeze Coolant (Refer to 04 - Vehicle Quick
Reference/Capacities and Recommended Fluids/Specifications in Service
Library).

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 36

Service Procedure [Continued]
31. Power up the HV battery system.

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.

32. Use of an insulation tester such as the Fluke Meter, Multi 126-1587 is
recommended for Plug-In Hybrid Electric Vehicle (PHEV) circuit testing.
Perform the multi-meter functionality tests per the manufacturer’s directions.
Verify the multi-meter is operating correctly by measuring voltage from a
known good power source, such as the vehicle’s 12-volt battery. If at any point
during the procedure, the multi-meter settings are changed, or the probes are
repositioned in the meter, verification with a known good power source must be
repeated.

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 37

Service Procedure [Continued]
33. Remove the Test Point Access Cover (Figure 31).
NOTE: Always observe these precautions prior to taking an isolation
resistance measurement:
• Have known good test leads
• Set the test voltage to 500 Volts
• Always wear safety glasses
34. Using the Meter, Multi 1261587 measure and record the
isolation resistance between the
high voltage positive test point
and chassis ground (Figure 28).

Figure 28 – Measure and Record Isolation
Resistance Between HV Positive Test
Point and Chassis Ground

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 38

Service Procedure [Continued]
35. Using the Meter, Multi 1261587 measure and record the
isolation resistance between the
high voltage negative test point
and chassis ground (Figure 29).
36. Isolation resistance should be
2.3 Mohms (+/-.2). If the
measured isolation resistance is
outside of this range, a loss of
isolation condition exists within
the high voltage circuitry. Do
not continue the High Voltage
Power Up procedure until the
condition causing the loss of
isolation is corrected.

Figure 29 – Measure and Record Isolation
Resistance Between HV Negative Test
Point and Chassis Ground

37. If required, remove the lockouttagout padlock from the service
lockout loop (1) (Figure 30).

Figure 30 – Service Lockout Loop

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 39

Service Procedure [Continued]
38. Install the test points access
cover (1) to the battery pack and
securely tighten the eight M6
Torx screws (2), identified with
blue circles (Figure 31).

Figure 31 – Test Point Access Cover

39. Remove the cover, connect the
negative battery cable to the IBS
and tighten the fastener (1) to
10N·m (7 ft. lbs.) (Figure 32).
40. Install the F09 (5 amp) IDCM
fuse (3) in the Power
Distribution Center (PDC)
(Figure 32).
41. Connect the IBS harness
connector (2) (Figure 32).
42. Using the scan tool, delete any
DTCs that may have set due to
the IDCM fuse being removed.
Turn the key OFF and wait 2
minutes,

Figure 32 – Negative Battery Cable, Fuse
F09 and IBS Connector

43. Use the scan tool and flash program the BPCM with the latest software.

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 40

Service Procedure [Continued]
44. Use the scan tool and perform the “Enable Contactor for Service” procedure in
BPCM.
NOTE: If these procedures are not performed, the vehicle will not start.
The high voltage battery pack is shipped with the contactors locked in the
open position for safety concerns. Until these routines are performed, the
battery pack contactors will not close resulting in a no start condition.
45. Close the hood, press the START button and verify that the Hybrid Status
Indicator is green and no warnings are displayed.

FILL AND BLEED USING THE SCAN TOOL (PREFERRED)
a) Fill the HV battery pressurized coolant bottle to the max level.
b) Cycle the ignition to the on position.
c) With the scan tool, run the “Coolant Fill Procedure” routine in the
Hybrid Control Processor (HCP). This should run all of the coolant
pumps in all cooling systems.
d) Continue adding coolant to the HV battery pressurized coolant bottle
maintaining the coolant at the max level.
e) When no more coolant is needed the system is filled and bled. The
routine may time out before the system is full and take multiple cycles
to bleed all of the air from the system.
f) Stop the scan tool actuation. Fill the bottle slightly above the fill line
in case of any air trapped in the system.
FILL AND BLEED WITHOUT THE SCAN TOOL
a) Fill the HV battery pressurized coolant bottle to the max level.
b) Cycle the key to the on position to power the battery coolant pump in
order to fill and bleed the HV cooling system.
c) Cycle the key to the off position after the pump times out and stops
running.
d) Fill the HV battery pressurized coolant bottle to the max level.
e) Repeat the fill procedure until the proper coolant level is achieved.
Fill the bottle slightly above the fill line in case of any air trapped in
the system.
46. Return the vehicle to the customer.

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 41

Complete Proof of Correction Form for California Residents
This campaign is subject to the State of California Registration
Renewal/Emissions Recall Enforcement Program.
Complete a Vehicle
Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it
to vehicle owners residing in the state of California for proof that this campaign
has been performed when they renew the vehicle registration.
Process Steps to obtain the California Proof of Correction form:
a. Access the “DealerCONNECT” website.
b. Select the “Service” tab.
c. Under the “Publications” heading, select the “ePublishing” link.
d. Sign in using your Dealer Code and Password.
e. Select the “Proof of Correction form”.

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 42

Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the
DealerCONNECT Claim Entry Screen located on the Service tab. Claims paid
will be used by FCA to record Customer Satisfaction Notification service
completions and provide dealer payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation
Number

Time
Allowance

Inspect PHEV Battery For Fault Codes

08-Z2-71-81

0.2 hours

Inspect and Replace High Voltage
PHEV Battery

08-Z2-71-82

3.1 hours

Add the cost of the campaign parts package plus applicable dealer allowance to
your claim.
NOTE: See the Warranty Administration Manual, Recall Claim Processing
Section, for complete claim processing instructions.

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 43

Dealer Notification
To view this notification on DealerCONNECT, select “Global Recall System” on
the Service tab, then click on the description of this notification.

Owner Notification and Service Scheduling
All involved vehicle owners known to FCA are being notified of the service
requirement by mail. They are requested to schedule appointments for this service
with their dealers. A generic copy of the owner letter is attached.

Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
All involved vehicles have been entered into the DealerCONNECT Global Recall
System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.
GRS provides involved dealers with an updated VIN list of their incomplete
vehicles. The owner’s name, address and phone number are listed if known.
Completed vehicles are removed from GRS within several days of repair claim
submission.
To use this system, click on the “Service” tab and then click on “Global Recall
System.” Your dealer’s VIN list for each campaign displayed can be sorted by:
those vehicles that were unsold at campaign launch, those with a phone number,
city, zip code, or VIN sequence.
Dealers should perform this repair on all unsold vehicles before retail
delivery. Dealers should also use the VIN list to follow up with all owners to
schedule appointments for this repair.
VIN lists may contain confidential, restricted owner name and address information that was
obtained from the Department of Motor Vehicles of various states. Use of this information is
permitted for this notification only and is strictly prohibited from all other use.

Customer Satisfaction Notification Z27 – PHEV
Battery Replacement

Page 44

Additional Information
If you have any questions or need assistance in completing this action, please
contact your Service and Parts District Manager.
Customer Service / Field Operations
FCA US LLC

This notice applies to your vehicle,

CUSTOMER SATISFACTION NOTIFICATION
PHEV Battery Replacement

[Model Year and Model]
VIN XXXXXXXXXXXXXXXXX

Z27

LOGO

VEHICLE PICTURE

Dear [Name],
At FCA US LLC, we recognize that the success of our business depends on the satisfaction of
our customers. We are constantly monitoring the quality of our products and looking for
opportunities to improve our vehicles even after they are sold. Because your long-term
satisfaction is important to us, we are contacting you on important improvements we would
like to make to your vehicle [1]. This will be done at no charge to you.
We are recommending the following improvements be performed on certain [2021 (JL) Jeep
Wrangler PHEV] vehicles.
WHY DOES MY VEHICLE NEED REPAIRS?
The Plug-in Hybrid Electric Vehicle (PHEV) battery on your vehicle 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.

YOUR SCHEDULING OPTIONS
1. RECOMMENDED OPTION
Call your authorized Chrysler /
Dodge / Jeep® / RAM Dealership.
2. Call the FCA Recall Assistance
Center at 1-800-853-1403. An
agent
can
confirm
part
availability and help schedule an
appointment
3. Visit recalls.mopar.com, scan the
QR code below, or download the
Mopar Owner’s Companion App.

QR Code

HOW DO I RESOLVE THIS CUSTOMER SATISFACTION NOTIFICATION?
FCA US will repair your vehicle free of charge (parts and labor). To do this, your dealer
will replace the PHEV battery. The estimated repair time is 3.5 hours. In addition, your dealer
will require your vehicle for proper check-in, preparation, and check-out during your visit,
which may require more time. Your time is important to us, so we recommend that you
schedule a service appointment to minimize your inconvenience. Please bring this letter with
you to your dealership.
TO SCHEDULE YOUR FREE REPAIR,
CALL YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY
CALIFORNIA RESIDENTS
The State of California requires the completion of this emission recall repair prior to vehicle
registration renewal. Your dealer will provide you with a Vehicle Emission Recall Proof of
Correction Form after the Customer Satisfaction Notification service is performed. Be sure to
save this form since the California Department of Motor Vehicles may require that you supply
it as proof that the Customer Satisfaction Notification has been performed.
In order to ensure your full protection under the emissions warranty provisions, it is
recommended that you have your vehicle serviced as soon as possible. Failure to do so could
be determined as lack of proper maintenance of your (vehicle or engine).

Get access to recall notifications,
locate your nearest dealer, and more
through this website or Mopar
Owner’s Companion App. You will be
asked to provide your Vehicle
Identification Number (VIN) to
protect and verify your identity.
DEALERSHIP INSTRUCTIONS
Please reference CSN Z27.

WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED?
If you have already experienced this specific condition and have paid to have it repaired, you
may visit www.fcarecallreimbursement.com to submit your reimbursement request online. [2]
Once we receive and verify the required documents, reimbursement will be sent to you within
60 days. If you have had previous repairs performed and/or already received reimbursement,
you may still need to have the repair performed.
We apologize for any inconvenience, but are sincerely concerned about your satisfaction.
Thank you for your attention to this important matter.
Customer Assistance/Field Operations
FCA US LLC

Mr. Mrs. Customer
1234 Main Street
Hometown, MI 48371

[1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information.
[2] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 218004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.