Safety Recall P23 Power Inverter Module (RC-P23-14)

SAFETY RECALL P23 POWER INVERTER MODULE

SERVICE CAMPAIGN BULLETIN

SERVICE INFORMATION

MODELS

2013 - 2014 (FF) Fiat 500e Battery Electric Vehicle (BEV) 

SUBJECT

The Power Inverter Module (PIM) on about 19 of the above vehicles may contain cooling plates that leak coolant into areas of high-voltage circuitry. This can result in an overcurrent electrical condition, which will cause the high-voltage battery manual service disconnect fuse to open. An open high-voltage battery manual service disconnect fuse will cause a loss of vehicle propulsion and could cause a crash without warning.

REPAIR

The Power Inverter Module must be replaced.

PARTS INFORMATION

Part Number	Description
CBA0P231AA	Module, Power Inverter
CBA0P232AA	Power Inverter Module Installation Package

Each package contains the following components:

Quantity	Description
1	Cover, Power Inverter
7	Screw, Power Inverter Module Cover
5	Bolt, HV Cable&Motor Cable (internal)
5	Bolt, HV Cable&Motor Cable (external)
2	Nut, 12 Volt Battery Cable
1	Bolt, Ground Strap

SPECIAL TOOLS

The following special tools are required to perform this repair: 

• NPN wiTECH VCI Pod Kit
• NPN Laptop Computer
• NPN wiTECH Software
• 10288 Pliers, Hose Clamp
• 126-1587 Fluke Multi-Meter (or equivalent)
• 10420 BEV Safety Kit

SERVICE PROCEDURE

• This must be done by removing the service disconnect. 
• The high-voltage check out procedure must also be performed to ensure that the vehicle is properly powered down. 
• The technician must know the whereabouts of the service disconnect throughout the repair. 
• The technician must ensure that no one reconnects the service disconnect while service procedure is being performed. 
• The technician must recheck that the service disconnect has not been reinstalled in cases where the vehicle was unattended. 

1. Set up safety cone barrier around the vehicle.
2. Set the vehicle up to be raised on an appropriate hoist.
3. Remove and save the electric motor plastic cover.
4. Use the following procedure to power-down the vehicle's high-voltage electrical system:
   1. Inspect all orange high-voltage cables, and high-voltage components labeled with the high-voltage symbol for physical damage. If damage is present, extra caution must be taken to avoid contact with unprotected high-voltage. Do not insert probes, tools, objects or fluids into damaged high-voltage cables or components.
   2. Verify that 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.
   3. Verify the vehicle's ignition switch is in the OFF position.
   4. Remove the three high-voltage power distribution center (PDC) box cover screws and box cover (Figure 1).
   5. Using a Fluke 126-1587 multi-meter (or equivalent), insert the test leads into the positive (red) test point and the negative (black) test point in the high-voltage PDC box (Figure 2).
   6. Turn the ignition switch to the ON position, and measure the voltage available at the high-voltage PDC test points.
      • If the reading is between 200-volts to 400-volts, proceed to Step 3G.
      • If the reading is less than 200-volts, check for DTCs in the Battery Pack Control Module (BPCM), Power Inverter Module (PIM), On-Board Charging Module (OBCM) and Electric Vehicle Control Unit (EVCU). Perform the diagnostic test procedure related to the DTC.
   7. Turn the ignition switch to the OFF position.
      CAUTION: Wait a minimum of three minutes from the time the ignition key was turned OFF before removing the manual service disconnect.
      Before turning ignition off, open all doors and leave them open. After the ignition is off for three minutes, the high-voltage battery enters "sleep mode" and opening or closing the doors or plugging in or unplugging the Electric Vehicle Service Equipment (EVSE) will wake the high-voltage battery.
   8. Pull the rear seat cushion release strap and position the rear seat cushion away from the high-voltage manual service disconnect cover (Figure 3).
   9. Release the tab and position the high-voltage manual service disconnect cover aside (Figure 4).
   10. Release the locking tab and position the high-voltage manual service disconnect release lever partially upward until it stops. Release the locking tab and position the release lever fully upward until the high-voltage manual service disconnect latch is fully disengaged (Figure 5).
   11. Lift upward, and remove the high-voltage manual service disconnect.
       CAUTION: To make sure the location of the high-voltage manual service disconnect is always known when it is removed, it is recommended that the high-voltage manual service disconnect be placed in a highly visible location, such as on the vehicle antenna, when removed.
   12. Verify that the multi-meter is operating correctly by measuring voltage from a known-good power source, such as the vehicle's 12-volt battery.
   13. Insert the appropriate multi-meter test leads into the positive (red) test point and the negative (black) test point in the high-voltage PDC.
   14. Measure the voltage available at the high-voltage PDC test leads.
       • If the voltage measured is below 60-volts, it is safe to work on the high-voltage components with the exception of the high-voltage battery internal components. Continue to Step 5 of this procedure.
       • If the voltage is greater than 60-volts, an internal condition exists within the high-voltage battery that is preventing it from being powered down. Do not attempt to carry out repairs on any of the vehicle's high-voltage components or wiring. Contact the STAR Center for service support. 
5. Use the following procedure to power-down the vehicle's 12-volt electrical system:
   1. Turn the ignition switch to the OFF position, and wait five minutes to allow the high-voltage system to shut down without setting a Diagnostic Trouble Code.
   2. Disconnect the negative 12-volt battery cable from the 12-volt battery (Figure 6).
   3. The 12-volt electrical system is now powered down. Continue with Step 6 of this procedure.
6. Remove and save the two On-Board Charging Module (OBCM) connector shield nuts and the OBCM high-voltage electrical connector shield (Figure 6).
7. Disconnect the On-Board Charging Module (OBCM) black 12-volt electrical connector (Figure 7).
8. Use the following procedure to disconnect the three orange high-voltage electrical connectors located on the OBCM:
   1. Release the orange connector white locking clip by sliding it rearward (Figure 8).
   2. Depress the connector release tab, and pull back on the orange electrical connector until it stops (Figure 9).
   3. Insert a suitable hook tool to disengage the connector secondary lock, and disconnect the orange electrical connector (Figure 10).
      NOTE: Lift the orange plastic connector body slightly with a hook tool while pulling on the connector to release.
      CAUTION: Use extreme care not to damage the orange electrical connectors.
9. Remove and save the six OBCM mounting bolts (Figure 11).
10. Lift the OBCM and using suitable hose-pinching pliers, clamp-closed the three coolant hoses at the OBCM (Figure 12).
11. Using hose clamp pliers (special tool 10288), release the three OBCM coolant hose clamps and disconnect the hoses (Figure 13).
12. Remove and save the OBCM assembly from the vehicle.
13. Remove and save the 12-volt battery (Figure 14).
14. Remove and save the 12-volt battery tray (Figure 14).
15. Raise the vehicle on an appropriate hoist.
16. Remove and save the underbody high-voltage connector splash shield (Figure 15).
17. Disconnect the two high-voltage battery cable electrical connectors (Figure 16).
    CAUTION: Use extreme care not to damage the orange electrical connectors.
18. Remove and discard the two nuts from the wire trough guide (Figure 17). The wire trough guide is located in the underbody tunnel just to the rear of the motor cradle. Do not reuse the nuts. 
    NOTE: Prior to cutting the four tie-straps attaching the high-voltage battery cable harness, note the locations to allow new tie-straps to be installed during installation.
19. Cut and discard the four tie-straps attaching the PIM high-voltage wiring harness to the vehicle.
20. Remove the PIM high-voltage battery cable harness bracket bolt, and detach the bracket from the harness (Figure 18).
21. Disconnect the electric drive motor high-voltage electrical connector, and position the connector upward to allow the PIM to be repositioned (Figure 19).
22. Remove the PIM ground strap bolt (Figure 20).
23. Lower the vehicle from the hoist.
24. Use the following procedure to disconnect the high voltage Power Distribution Center (PDC) harness high-voltage electrical connector at the PIM  (Figure 21).
    CAUTION: The high voltage Power Distribution Center (PDC) harness high-voltage electrical connector is very difficult to access. It is located between the two high-voltage battery cables and the three high-voltage electric drive motor cables on the bottom side of the PIM housing. Extreme patience and perseverance is required.
    1. Release the connector red locking clip.
    2. Depress the connector release tab, and pull back on the electrical connector until it stops.
    3. Insert a suitable tool to disengage the connector secondary lock, and disconnect the electrical connector
25. Detach the positive and negative PIM-to-battery 12-volt battery cable push-pin retainers (Figure 22).
26. Loosen, but do not completely remove the PIM bracket bolt forward of the cradle front support (Figure 23).
27. Remove and save the four PIM retaining bolts (Figure 24).
28. Remove and save the left side PIM bracket (Figure 25).
29. Disconnect the PIM coolant hoses from the PIM (Figure 26).
    CAUTION: Avoid spilling coolant on any open electrical connector(s). Should coolant be accidentally spilled onto an open electrical connector(s), use compressed air to clean coolant from the electrical connector(s).
30. Disconnect the PIM black 12-volt electrical connector (Figure 27).
    CAUTION: The 12-volt electrical connector must be removed prior to rotating the PIM in order to gain access to the PIM cover and high-voltage cables. Slightly rotate the PIM in order to gain access to the 12-volt electrical connector. Do not rotate the PIM 180 degrees with the 12-volt electrical connector attached to the PIM. Doing so will pull the wires out of the connector.
31. Rotate the PIM to gain access to the PIM cover and 12-volt battery cable nuts (Figure 28).
32. Remove and discard the two PIM 12-volt battery cable nuts and detach the cables from the PIM (Figure 29). Do not reuse the nuts. 
33. Remove and discard the seven PIM cover screws and the PIM cover (Figure 30). The PIM cover and screws must be replaced. 
34. Using a permanent marker, draw a minus symbol on the two wire cable connector surfaces to match with the minus (negative) symbol on the PIM case (Figure 31).
35. Using a permanent marker, draw a plus symbol on the two wire cable connector surfaces to match with the plus (positive) symbol on the PIM case (Figure 31).
    CAUTION: Failure to identify and label the high-voltage cables correctly can result in improper reassembly which could result in high-voltage battery failure.
36. Remove and discard the two high-voltage cable eyelet bolts (Figure 32). Do not reuse the bolts.
37. Remove the two high-voltage battery connector guide bracket retaining screws at the PIM, and detach the cables from the PIM.
38. Remove the original PIM from the vehicle with the three wire electric motor high-voltage harness still attached (Figure 32).
    CAUTION: Avoid spilling coolant on any open electrical connector(s). Should coolant be accidentally spilled onto an open electrical connector(s), use compressed air to clean coolant from the electrical connector(s).
39. Remove and discard the three wire electric motor high-voltage harness eyelet connector bolts (Figure 33). Do not reuse the bolts. 
40. Remove and save the three electric motor high-voltage harness cable connector screws (Figure 34).
41. Detach and save the electric motor high-voltage harness from the PIM (Figure 33).
42. Transfer the PIM braided ground strap onto the new PIM (Figure 33).
43. Install the three wire electric motor high-voltage harness into the new PIM.
    CAUTION: When properly installed, the eyelets will have a downward travel to ensure a positive contact with the PIM high-voltage contacts. When properly installed, the connector face locator will be in the upper position.
44. Install the three wire electric motor high-voltage harness guide bracket screws (Figure 34).
45. Install three NEW  high-voltage harness eyelet connector bolts (Figure 33).
    CAUTION: Make sure the three high-voltage harness cables are not twisted by ensuring the eyelets have a downward travel to properly align with the PIM contacts.
46. Tighten the three eyelet electric motor high-voltage harness connector bolts to 18 ft. lbs. (24 N.m).
47. Using a permanent marker, transfer the "+" and "-" marks made on the original PIM housing to the same location on the new PIM housing (Figure 31).
48. Place the new PIM into position in the vehicle with the PIM cover opening facing upward.
49. With the PIM opening upright, position the 2-wire high-voltage battery connector into the PIM with the locator pin at the top of the guide bracket connector.
    CAUTION: Make sure the locator pin is aligned with the locator bore. While mating the surfaces, make sure the pin easily seats into the bore. Also verify the "+" and the "-" symbols align (Figure 31).
50. Fully seat the connector guide bracket into the slot of the PIM case.
51. Install the two high voltage battery connector guide bracket retaining screws. Tighten the screws to 15 ft. lbs. (20 N.m).
52. Install two NEW  high-voltage cable eyelet bolts.
    CAUTION: Make sure the high-voltage harness cables are not twisted by ensuring the eyelets have a downward travel to properly align with the PIM contacts.
53. Tighten the two high-voltage cable eyelet bolts to 18 ft. lbs. (24 N.m).
54. Install a NEW  PIM cover. Install seven NEW  PIM cover screws (Figure 30). Tighten the screws to 71 in. lbs. (8 N.m).
55. Attach the 12-volt battery cables to the studs (Figure 29). Make sure the positive cable (RED) is attached to the stud with the "+" symbol. Make sure the negative cable (BLACK) is attached to the stud with the "-" symbol on the (PIM) case.  Install two NEW  nuts to the studs and tighten the nuts to 15 ft. lbs. (20 N.m).
56. Using compressed air, blow out any coolant that may have spilled into the 12-volt connector. Be sure to blow out the connector receptacle on the PIM and the wire harness connector.
57. Connect the PIM black 12-volt electrical connector (Figure 27).
58. Place the PIM in the installed position.
59. Place the right side PIM bracket into position (Figure 23).
60. Install and tighten the four PIM retaining bolts to (18 ft. lbs. 24 N.m) (Figure 24).
61. Tighten the PIM bracket bolt forward of the cradle front support to 18 ft. lbs. (24 N.m) (Figure 23).
62. Install the left side PIM bracket.
63. Attach the negative and positive PIM-to-battery 12-volt battery cable push-pins retainers (Figure 22).
64. Connect the Power Distribution Center (PDC) harness high-voltage electrical connector at the PIM (Figure 21).
65. Raise the vehicle on an appropriate hoist.
66. Install and tighten the PIM ground strap bolt to 9 ft. lbs. (12 N.m) (Figure 20).
67. Connect the electric motor high-voltage electrical connector (Figure 19).
68. Install the PIM high-voltage battery cable harness bracket, and the high-voltage battery cable harness bracket bolt (Figure 18).
69. Install new tie-straps on the high-voltage battery cable harness in the locations noted during removal.
70. Position the wire trough guide into position over the two underbody studs (Figure 17). Install the NEW  nuts to secure the trough guide. Tighten the two nuts to 87 in. lbs. (10 N.m).
    CAUTION: Be sure to engage the wire trough locking clips.
71. Using compressed air, blow off the high-voltage battery cable electrical connectors.
    CAUTION: Failure to ensure that no dirt is in the high-voltage battery cable electrical connectors could result in a connector breaking during installation.
72. Connect the two high-voltage battery cable electrical connectors at the high-voltage battery (Figure 16).
73. Install the underbody high voltage connector splash shield (Figure 15).
74. Lower the vehicle on the hoist.
75. Attach the two PIM coolant hoses to the PIM, and install the clamps (Figure 26).
76. Use the following procedure to install the On-board Charging Module (OBCM):
    1. Install the OBCM and the six OBCM mounting bolts (Figure 11).
    2. Install the hose clamps on the three OBCM coolant hoses, connect the three hoses to the OBCM and tighten the clamps.
    3. Remove the pinch-off pliers from all three coolant hoses (Figure 12).
    4. Connect the three OBCM high-voltage orange electrical connectors and the OBCM black 12-volt electrical connector (Figure 7).
    5. Install the OBCM connector shield, and the two OBCM connector shield nuts (Figure 6).
77. Install the 12-volt battery tray (Figure 14).
78. Install the 12-volt battery (Figure 14). Do not connect the battery terminal cables to the battery at this time.
79. Use the following procedure to power-up the high-voltage system:
    1. Connect a voltmeter (special tool Fluke 126-1587) to the high-voltage Power Distribution Center (PDC) (Figure 2).
    2. Align the manual service disconnect with the manual service disconnect socket on the high-voltage battery, and install the manual service disconnect with the handle in the upright position (Figure 5).
    3. Rotate the manual service disconnect handle downward until it is fully engaged and locked by the locking tab.
    4. Gently pull the manual service disconnect upward to ensure that it is fully seated in the socket and locked.
    5. Install the high-voltage manual service disconnect cover (Figure 4).
    6. Install the rear seat cushion (Figure 3).
80. Top-off the power electronics reservoir (Figure 35).
81. Connect the 12-volt positive battery cable to the 12-volt positive battery post and install the terminal protective cover (Figure 35).
82. Connect the 12-volt negative battery cable to the 12-volt negative battery post.
83. Using the procedure below, perform the Resolver Relearn procedure:
    1. Raise the vehicle until the front tires are approximately 12 inches (30 cm.) off the ground.
    2. Connect the wiTECH scan tool to the diagnostics connector.
    3. Place the ignition key in the "ON" position.
    4. Clear all Diagnostic Trouble Codes (DTC's).
       NOTE: Two active DTC's will be present (code B23AE-00 PIM Fault and P0C17-00 Drive Motor A Position Sensor 1 not learned).
    5. Enter the vehicle and make sure the vehicle doors are closed  to prevent the automatic "Shift-to-Park" function from engaging during the test.
    6. Turn off the Electronic Stability Control (ESC) button on the instrument panel.
       NOTE: If the ESC button will not disable the ESC system, turn the ignition key to the "OFF" position and remove the key. Wait three minutes and then insert the key and turn the ignition to the "RUN" position.
    7. Switch the vehicle to READY mode.
    8. Select "EVCU"  from the vehicle view screen.
    9. Select "Misc. Functions"  tab.
    10. Select "Motor Resolver Offset Learn"  from the list.
    11. Follow the step-by-step instructions on the wiTECH scan tool screen.
84. Bleed the power electronics cooling system using wiTECH and the following procedure:
    1. Fill the power electronics coolant reservoir to the MAX FILL level.
    2. Select "EVCU"  from the vehicle view screen.
    3. Select "Misc. Functions"  tab.
    4. Select "High Voltage Battery Coolant Fill"  from the list.
    5. Follow the step-by-step instructions on the wiTECH scan tool screen.
       CAUTION: As the coolant filling routine is running, monitor the power electronics coolant reservoir and fill the coolant level as necessary.
    6. Place the key in the OFF position and remove the wiTECH pod from the vehicle.
85. With the key off, wait three minutes for the high-voltage battery to power down.
86. With the voltmeter reading below 5 volts, remove the voltmeter from the high-voltage PDC.
87. Install the high-voltage PDC box cover and three fasteners. Tighten the fasteners to 18 in. lbs. (2 N.m).
88. Install the electric motor plastic cover using the following procedure:
    1. Position the plastic cover over the four mounting posts.
    2. Using palm pressure, push down onto the cover at the four points above the posts until fully seated.
    3. Pinch the power electronics coolant reservoir return hose and insert into the notch.
89. Remove the vehicle from the hoist and return the vehicle to the customer.

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 submitted will be used by Chrysler to record recall service completions and provide dealer payments.

Use the following labor operation number and time allowance:

	Labor Operation Number	Time Allowance
Replace the Power Inverter Module (PIM)	08-P2-31-82	3.5 hours

Add the cost of the recall parts package plus applicable dealer allowance to your claim.

OWNER NOTIFICATION AND SERVICE SCHEDULING

All involved vehicle owners should be notified of the service requirement by their Dealer. Owners are requested to schedule appointments for this service. A sample copy of the owner notification letter is attached.

VEHICLE LISTS, GLOBAL RECALL SYSTEM, VIP AND DEALER FOLLOW UP

All involved vehicles have been entered into the 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. Completed vehicles are removed from GRS within several days of repair claim submission.

Dealers must 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.

ADDITIONAL INFORMATION

If you have any questions or need assistance in completing this action, please contact your International Service and Parts Manager.

Global Service and Parts - International

Chrysler Group LLC

IMPORTANT SAFETY RECALL

P23 

This notice applies to your vehicle (VIN: xxxxxxxxxxxxxxxxx).

Dear Fiat Vehicle Owner:

Chrysler has decided that a defect, which relates to motor vehicle safety, exists in certain 2013 and 2014 model year Fiat 500e Battery Electric Vehicles (BEV). 

The problem is... The Power Inverter Module (PIM) on your vehicle may contain cooling plates that leak coolant into areas of high-voltage circuitry. This can result in an overcurrent electrical condition, which will cause the high-voltage battery manual service disconnect fuse to open. An open high-voltage battery manual service disconnect fuse will cause a loss of vehicle propulsion and could cause a crash without warning. 

What your studio will do... Fiat will repair your vehicle free of charge (parts and labor).  To do this, your studio will replace the Power Inverter Module. The work will take about 3 1/2 hours to complete. However, additional time may be necessary depending on service schedules.

What you must do to ensure your safety...  Simply contact your dealer  right away to schedule a service appointment. Ask the dealer to hold the parts for your vehicle or to order them before your appointment. Please bring this letter with you to your dealer. 

If you need help...  If you have trouble getting your vehicle serviced, please contact the Dealer nearest your location. A representative will assist you in getting your vehicle serviced. This information can be found in the Customer Assistance section of your Owner's Manual.

We apologize for any inconvenience, but we are sincerely concerned about your safety. Thank you for your attention to this important matter.

Global Service & Parts - International

Chrysler Group LLC

Notification Code P23