WARRANTY OPERATIONS NEWSLETTER
VOLUME 11, ISSUE 4

Published April 9, 2025

Announcement Of Future Addition To Exchange Order Type
We are working on an improvement to the
Exchange Order Process to add the “Recall”
order type to the options. Today, dealer orders
for recall exchange parts are placed as
“Warranty” but the upcoming change will allow
the order type to match the claim type. The
exact date of the change is still in process and
will
be
communicated
in
a
future
announcement. There will be no change to the

claim requirements or chargeback process, but
only the addition of the recall order type.
Please always review the recall remedy
instructions to make sure that the latest
instructions are followed. The order type will be
communicated
in
the
specific
recall
instructions.

High Voltage Lithium - Ion Battery Exclusions
As per the Warranty booklets for vehicles with
High Voltage batteries: Your warranties do not
cover the costs of repairing damage or
conditions caused by any of the following:

•

Physically damaging the high voltage
lithium-ion battery or intentionally
attempting to reduce the life of the high
voltage lithium-ion battery
Leaving your vehicle for over 30 days
where the high voltage lithium-ion battery
reaches a zero or near zero state of
charge

•

•

•

•

•
•

Neglecting to follow correct charging
procedures as recommended in your
Owner’s Manual
Use of incompatible charging devices as
recommended in your Owner’s Manual
Opening the high voltage lithium-ion
battery enclosure or having it serviced by
someone other than an authorized repair
facility certified technician
Exposing the high voltage lithium-ion
battery to contact with a direct flame
Exposing your vehicle to ambient
temperatures above 140° F (60° C) for
over 24 hours

HV Pack Core Refund – Use I-Sheet Directions
There have been issues with dealers not
following the directions in the I-Sheets when
returning HV pack cores. There is a process in
place outlined in the I-Sheets for dealers to
manage HV pack core returns. Dealers in many
cases aren’t adhering to the I-Sheets (found in
the Dunnage or Service Library) and have been
using other processes to send the packs back to

the warehouses they were shipped from. If the
packs are not returned per proper processes,
dealers potentially WILL NOT be issued a core
refund. This is due to the pack being returned
incorrectly. This is causing logistical issues and
unnecessary expense to the company. (NOTE:
See DCMail ID: 104553 for an I-Sheet example)

WARRANTY OPERATIONS NEWSLETTER
VOLUME 11, ISSUE 4

Vehicle Maintenance – Engine Oil Filter
The engine oil filter should be replaced with a
new filter at every engine oil change.
SERVICING AND MAINTENANCE: A full-flow type
disposable oil filter should be used for
replacement. The quality of replacement filters
varies considerably. Only high quality Mopar®

filters should be used. If Mopar® Engine Oil
Filters are unavailable, it is preferred to use
bproauto filters as an alternative. If neither
Mopar® or bproauto are available, only use filters
that meet or exceed SAE/USCAR-36 Filter
Performance Requirements.

Side Marker Condensation - Model Year 2024 Fiat 500e (FG)
Under
certain
atmospheric
conditions,
condensation can appear inside the Side marker
in the 2024 Fiat 500e (PNs: 68656439A* and
68656440A*). This occurrence is normal, and
with time it goes away. The Side marker is a

decorative,
non-functional
part,
so
condensation does not pose any risk to the
performance or safety of the vehicle. The
part(s) is working as designed and will not be
covered under warranty.

Coolant Leak & Engine Overheating Issue MY 2021 – 2025 - Jeep Wrangler (JL), Jeep Grand Cherokee (WL),
Jeep Compass (MP), Dodge Hornet (GG)/ Alfa Romeo Tonale (GC)
To reduce the cost per repair, Engineering recommends using a long block instead of a complete engine
replacement for GME T4 DOHC.
*Long Blocks p/n list:

WARRANTY OPERATIONS NEWSLETTER
VOLUME 11, ISSUE 4
Before replacing a Long Block, Engineering is
asking to follow these pre-checks and checks
for an overheating suspect diagnosis:

combustion chamber. Hold
pressure for 1 hour and check
for leak down.

A. Pre-Check:
• Check and record level of coolant in
coolant bottle
• Check for thermostat and other
cooling system related issues (i.e.
Water pump, cooling fan, etc.).
• Drain a sample of oil and check for
coolant / moisture presence.

2. Cooling system leaks – available in
Service Library including:
• Internal
Engine
leakage
inspection

B. Checks
1. Perform Cylinder Leakage Test,
available in Service Library, on all
cylinders by pressurizing one
cylinder at a time with piston at TDC
with 5.5bar of air and check for
bubbles in the radiator coolant
• Perform coolant pressurization
test on cooling system,
(Pressurize to 2Bar / 30PSI),
Borescope cylinders to check
for presence of coolant in

If none of these checks (1-2-3) fails, it does not
need a long block (or a complete engine) but just
the component causing the coolant leak, more
likely ones listed below.

We are mainly focused on three of them:
A. Water pump inlet pipe (1) losing bolts/torque (2):

3. Perform CO2 leak test to check for
combustion gasses in cooling
system.

When diagnosing an engine overheated due to
coolant leak, be aware that it’s not necessary to
replace the full engine. There are several
components failing that may be the root cause
and, in most cases, just this component needs
to be replaced rather than the long block*.

WARRANTY OPERATIONS NEWSLETTER
VOLUME 11, ISSUE 4
B.

Water Pump Gasket is twisted inside its groove:

Other items may also indicate the issue, like the
coolant reservoir shows a low coolant level,
vehicle may not start, power/torque degradation,
high level of misfire events, the check engine light
on.
For any of the above listed functions, technicians
often replace the full engine needlessly. On many
of the parts that have been returned, after

C. Thermostat column manifold
losing torque/bolts:

testing they are determined to be no trouble
found. Above are the possible parts which may
be causing the coolant leak: water pump inlet
pipe bolts losing torque (refer to CSN ZD8),
thermostat’s bolts losing torque, cylinder block
casting porosity /cracks versus combustion
chamber, oil coolant exchanger internal crack
(evidence of coolant and oil mixing).

2021 – 2025 MY Jeep Grand Cherokee (WL), Wagoneer/ Grand
Wagoneer (WS) – Park Assist Sensors Damage
We have found during supplier analysis, that the
park assist sensors are found to have physical
damage, potentially caused by an external force
such as road debris. Symptoms for this issue are
found in Service Library. If the park assist

sensor has physical damage, it is not considered
a defect in material or workmanship yet could be
considered for Consumer Goodwill with the
support of the business center.

WARRANTY OPERATIONS NEWSLETTER
VOLUME 11, ISSUE 4
If that is not obtained, then this is considered an
Insurance claim with the vehicle car insurance. In
any event, it is not supported for a warranty
reimbursement as damage is not a defect in
material or workmanship.

Examples of Physical Damage:

Example of Sensor Connector Corrosion:

Please remove sensors
performing repairs.

carefully

when

If corrosion is visible in sensor connector area,
LOP should be assigned to a wiring repair. Only
use the Park Assist sensor LOP if the sensor is
replaced.

WARRANTY OPERATIONS NEWSLETTER
VOLUME 11, ISSUE 4

2024 – 2025 Domestic Models Intelligent Battery Sensor (IBS)
Diagnostics
GENERAL INFORMATION
This information is communicated by Intelligent
Battery Sensor (IBS) to Body Control Module
(BCM) over Local Interconnect Network (LIN) bus
which then gets transferred to Controller Area
Network (CAN) network for other end consumers
of the data.

voltage sensing, a micro containing analog
acquisition, logic processer, and memory.

Internally, the IBS includes a current shunt for the
battery measurement, temp sensing element,

It is suggested that the claims indicate the checklist
was followed and the step it failed, along with any
applicable Diagnostic Trouble Codes (DTCs).

IBS claims shall indicate the symptom the repair
pertains to. This list should cover nearly all cases,
however; if symptom is not listed above, note
“other” and describe symptom in detail.

WARRANTY OPERATIONS NEWSLETTER
VOLUME 11, ISSUE 4
Symptom

IBS Troubleshoot Actions

LOC DTC U113E

 Check battery connections
 Verify voltage at IBS 2-way
connector (Battery supply and
LIN).
 Check IBS fuse
 Verify LIN bus activity with Mopar
scope

Additional comments

Please ensure claim
narratives list and
reference any DTCs
mentioned in this
document and state the
DTCs set at time of IBS
Replacement.

 Perform Continuity Test
 Unplug and plug back IBS
(Reset)

Replace IBS if all actions above fail to
work.
IBS Internal Error DTC B2193

 Check battery connections
 Unplug and plug back IBS (Hard
Power Reset).
 Replace IBS if all actions above
fail to remove the DTC.
 Turn off vehicle and allow IBS to
undergo SOC Learning. Follow
SoC learning steps.

Please ensure claim
narratives list and
reference any DTCs
mentioned in this
document and state the
DTCs set at time of IBS
replacement.

 Replace IBS if all actions above
fail to work.

Loose Connection

 Verify clamp retention.
 Verify IBS fasteners joints are
tightened adequately.
 Repair if damaged (e.g. threads,
clamp, or battery post).
 If loose only, mount to battery
negative post with clamp seated
as far down as possible. Then
tighten IBS clamp fastener to
secure IBS on battery.

Vehicle No Start

 Ensure IBS is not loose.
 Check battery connections
 Recharge and test 12V batteries.
 Follow standard repair procedure
for vehicle no start (i.e. issue is
not related to IBS).

IBS should not impact starting
unless it is loose, significantly
corroded or disconnected.

WARRANTY OPERATIONS NEWSLETTER
VOLUME 11, ISSUE 4
Bad Battery

 Follow std repair procedures for
battery diagnostics to determine
if new battery is required or
requires charging only.
 Avoid blind charging the IBS

SOC Inaccurate

 Check for active IBS DTCs
(U113E, B2193). Repair
accordingly if present.
 Visual and connection inspection
 for ICE vehicles, perform crank,
turn off vehicle to initiate
quiescent state and IBS SOC
learning. After 4 hours crank the
vehicle and check SOC.
 In case vehicle is equipped with
DC/DC converter, use of external
charger or fails previous step,
leave vehicle off for two days,
and check SOC Accuracy status
again.

An aged battery should
not require a new IBS.
Turn off vehicle and allow IBS to
undergo SOC Learning in case
IBS gets disconnected during
repair. Follow SoC learning
steps.

During quiescent state IBS shall
battery quiescent/Sleep time is
defined as Quiescent phase: [500mA, 50mA] battery current.
All vehicle by design meets this
requirement.
Disconnect external charger
during IBS learning.

SOC cannot be instantaneously
estimated.

 If SOC Accuracy is reported
accurate and SOC level seems
low (e.g. SOC