Stellantis Technical Service Bulletin VR3UHZKXZPT621030 PDF

# Technical Service Bulletin (TSB) ## STELLANTIS ### Parts & Services ## VR3UHZKXZPT621030 ### Reference **D1CW012AQO** ### Vehicles * 208 (P21E) & electric vehicle and electric motor 100kW 260 N/m and embedded single-power metasytem charger ### Date **27/03/2024** ### Version **4** ### Custo...

# Technical Service Bulletin (TSB) ## STELLANTIS ### Parts & Services ## VR3UHZKXZPT621030 ### Reference **D1CW012AQO** ### Vehicles * 208 (P21E) & electric vehicle and electric motor 100kW 260 N/m and embedded single-power metasytem charger ### Date **27/03/2024** ### Version **4** ### Customer Issue * Vehicle will not start, the warning light is on * Diagnostic presence of fault codes: P0C78 63, P0AE1 12, P2C89 ### Origin * Excessive resistance in the traction circuit during transition to "READY" mode ## Conditions of Appearance * No specific condition ## After-Sales Intervention ### Mandatory * Any personnel working on a vehicle equipped with traction batteries must have received specific training on electric vehicles and be qualified to work on these vehicles (comply with the regulations in force in the country concerned). ### Note * Interventions 1, 4, and 5 of this document must be the subject of a request for prior authorization from the warranty department. ### Constitution of the warranty file * Send a copy of the result tables. ### Attention * If several parts are diagnosed as faulty, create a dealer issue detection assistance (DIDA) before any intervention. ## Diagram Figure: D1CW03JD ``` 1 | 2 | /---\ 8 9 \---/ | 10 | /---\ 7 3 \---/ | 4 | /---\ 6 5 \---/ ``` ## Installation * (1) Traction battery * (2) Power wiring between the traction battery (1) and the additional electric water heater (3) * (3) Electric water heater * (4) Power wiring between the on-board charger/DC-DC converter and the electric water heater * (5) On-board charger/DC-DC converter * (6) Electric refrigeration compressor * (7) Power wiring between the set (5) on-board charger/DC-DC converter and the electric refrigeration compressor (6) * (8) Power wiring between the set (5) on-board charger/DC-DC converter and the traction electric machine (9) * (9) Traction electric machine * (10) Power wiring between the traction electric machine (9) and the traction battery (1) ## Reading Fault Codes * Turn off the vehicle. ### Resistance Check * Electric water heater (3) * Additional electric water heater (3) (Depending on version) * Electric refrigeration compressor (6) * Traction electric machine (9) between the traction electric machine and the set (5) on-board charger/DC-DC converter * Traction electric machine (9) between the traction electric machine and the traction battery (1) ### Replacement * Electric refrigeration compressor (6) (Depending on the results of the checks) * Traction battery (1) (Depending on the results of the checks) * Filter-dryer cartridge (Depending on the results of the checks) * Electric water heater (3) (Depending on the results of the checks) * On-board charger/DC-DC converter (5) (Depending on the results of the checks) * Traction electric machine (9) (Depending on the results of the checks) ## Required Parts * 1 Traction battery (part reference according to vehicle definition) (Depending on the results of the checks). * 1 Electric water heater (part reference according to vehicle definition) (Depending on the results of the checks). * 1 Additional electric water heater (part reference according to vehicle definition) (Depending on the results of the checks). * 1 Electric refrigeration compressor (part reference according to vehicle definition) (Depending on the results of the checks). * 1 Traction electric machine (part reference according to vehicle definition) (Depending on the results of the checks). * 1 On-board charger / DC-DC converter (part reference according to vehicle definition) (Depending on the results of the checks). ## Ingredients * Coolant (Depending on the interventions). ## Reading Fault Codes ### Mandatory * Follow the diagnostic tool usage procedures. The diagnostic only goes to the central servers if it is performed in internet-connected mode, if the technician is allowed to use the guided methods, and if the diagnostic is performed from the "TROUBLESHOOTING" menu from the "Diagnostics" or "Expert" tab. At the end of the global test, wait for the "Diagnostic" tab to start (welcome screen with selection of methods by domain). Exit the "Diagnostics" session by returning to the "Welcome" tab. Confirm the message "Do you want to exit the current session?" ### Performing a Fault Code Reading: * If fault codes P0C78 63, P0AE1 12, P2C89 are present in the traction battery calculator: Perform the preliminary check 1 * If the fault codes P0C78 63, P0AE1 12, P2C89 are not present in the traction battery calculator: Do not apply this document ### Attention * The fault code(s) may be accompanied by other fault codes. ## Preliminary Operation * Print the tables from the “Summary of Measurement Results” chapter to record the results of the checks. * **Mandatory**: Disconnect the vehicle power supply ### Additional Parts to be Replaced Systematically: None. ## Diagram Figure: D1CW06ID ``` a | /---\ b e \---/ | 3 | c | 3 | d ``` ### Disconnecting: * Connector to the traction electric machine (9) ("a") * Connector to the electric water heater (3) ("b") * Connector from the traction electric machine (9) to the traction battery (1) ("c") * Connector to the additional electric water heater (3) (Depending on model) ("d") * Connector to the electric refrigeration compressor (6) ("e") ## Checks ### Check 1 (Resistance Check of the Electric Water Heater (3)) ## Diagram Figure: D1CW06LD ``` b | /---\ - - \---/ | - | /---\ - - \---/ | - ``` ### Note * Wait for the measurement to stabilize for at least 1 minute. This recommendation applies to all checks in this document. During the measurement, check the correct contact between the tip of the isolation controller and the connector pin. * Use a multimeter calibrated to 2 megaohms to measure the resistance of the 2 lines of connector "b". ### Note * If the measurement value is equal to 0, perform a measurement with the 200 kOhm scale. * Record the obtained value in the result tables. ### Following these measurements: * If the measurement value is greater than 1 kOhm: Perform Check 2 * If the measurement value is less than 1 kOhm: Perform Intervention 2 (Replacement of the electric water heater (3)) ### Note * For vehicles equipped with the additional electric water heater (3)(Depending on version). ## Diagram Figure: D1CW06OD ``` 3 | d | /---\ - - \---/ | - | /---\ - - \---/ | - ``` ### Check 2 (Resistance Check of the Additional Electric Water Heater (3)) * Disconnect the connector of the additional electric water heater (3) ("d"). * Use a multimeter calibrated to 2 megaohms to measure the resistance of the 2 lines of the additional electric water heater (3) connector ("d") ### Note * If the measurement value is equal to 0, perform a measurement with the 200 kOhm scale. * Record the obtained value in the result tables. ### Following these measurements: * If the measurement value is greater than 1 kOhm: Perform Check 2 * If the measurement value is less than 1 kOhm: Perform Intervention 2 (Replacement of the electric water heater (3)) ### Check 2 (Resistance Check of the Set (5) On-board Charger/DC-DC Converter) ## ## Diagram Figure: D1CW06RD ``` 5 | b | /---\ - - \---/ | - | /---\ - - \---/ | - ``` ### 208 (P21E) & ELECTRIC VEHICLE & EMBEDDED SINGLE-POWER METASYSTEM CHARGER * Use a multimeter calibrated to 200 kOhm to measure the resistance of the 2 lines on the connector base of set (5) the on-board charger/DC-DC converter ("b"). * Record the obtained value in the result tables. ## Diagram Figure: D1CW06TD ``` 5 | a | /---\ - - \---/ | - | /---\ - - \---/ | - ``` * Use a multimeter calibrated to 200 kOhm to measure the resistance of the 2 lines on the connector base of set (5) the on-board charger/DC-DC converter ("a"). * Record the obtained value in the result tables. ## Diagram Figure: D1CW06VD ``` 5 | e | /---\ - - \---/ | - | /---\ - - \---/ | - ``` * Use a multimeter calibrated to 200 kOhm to measure the resistance of the 2 lines on the connector base of set (5) the on-board charger/DC-DC converter ("e"). * Record the obtained value in the result tables. ### Following these measurements: * If one of the measurement values is greater than 10 kOhm: Perform Check 3 * If one of the measurement values is less than 10 kOhm: Perform Intervention 5 (Replacement of the set (5) on-board charger/DC-DC converter) ### Check 3 (Resistance Check of the Electric Refrigeration Compressor (6)) ## Diagram Figure: D1CW06XD ``` 7 | e | /---\ - - \---/ | - | /---\ - - \---/ | - ``` * Use a multimeter calibrated to 200 kOhm to measure the resistance of the 2 lines of the connector on the electric power wiring (7) of the electric refrigeration compressor (6) ("e"). * Record the obtained value in the result tables. ### Following these measurements: * If the measurement value is greater than 100 kOhm: Perform Check 4 * If the measurement value is less than 100 kOhm: Perform Intervention 3 (Replacement of the electric refrigeration compressor (6)) ### Check 4 (Resistance Check of the Traction Electric Machine (9)) ## Diagram Figure: D1CW06ZD ``` a | 8 | /---\ - - \---/ | - | /---\ - - \---/ | - ``` ### Attention * Wait for the measurement to stabilize for at least 1 minute. * Use a multimeter calibrated to 200 kOhm to measure the resistance of the 2 lines of the connector on the electric power wiring (8) of the traction electric machine (9) ("a"). * Record the obtained value in the result tables. * Reconnect the connector on the traction electric machine (9) ("c"). ## Diagram Figure: D1CW071D ``` 10 | f | /---\ - - \---/ | - | /---\ - - \---/ | - ``` * Use a multimeter calibrated to 200 kOhm to measure the resistance of the 2 lines of the connector of the electric power wiring (10) ("f"). * Record the obtained value in the result tables. ### Following these measurements: * If one of the measurement values is greater than 100 kOhm: Perform Check 5 * If one of the measurement values is less than 100 kOhm: Perform Intervention 4 (Replacement of the traction electric machine (9)) ### Check 5 (Resistance Check of the Traction Battery (1)) ### Note * Check 5 must determine if the traction battery (1) is faulty. Check 5 must be performed with the electric wiring equivalent to the power cable (10), present in the list of tools for the power-off method (part reference according to vehicle definition). * If fault code P0AE1 12 is present: Perform a reset of the traction battery pre-charge short-circuit counter. Use the diagnostic tool ("After-sales intervention" menu for the traction battery). * Connect the power cable (tool) to the traction battery (1). ### Mandatory * Place an insulating sheet at the other end of the power cable (tool), attach it to prevent the power cable from hanging under the vehicle and risking touching the ground or another part. * For vehicles equipped with an additional electric water heater (3): * Disconnect the connector of the high-power cable (2) from the traction battery. * Connect the part reference P.R 98 378 932 80 adapter on the traction battery. * Reconnect the fast charging connector of the traction battery (1) coming from the charging socket housing. * Reconnect the auxiliary battery. * Reconnect the circuit breaker. * Go to "READY" mode: * If transitioning is not possible: Perform Intervention 1 (Replacement of the traction battery (1)) * If transitioning is possible: Disconnect the auxiliary battery; Disable the circuit breaker; Disconnect the fast charging connector of the traction battery (1); Disconnect the power cable coming from the traction battery (1): The initial fault should have been identified during the previous steps. Repeat all the checks. ## Interventions ### Intervention 1 (Replacement of the Traction Battery (1)) * Take a picture of the label located on the rear left side of the traction battery (1) (on the side of the traction battery). * Read the value "Capacity of the traction battery to provide and store energy". Use the diagnostic tool (Parameters related to the power and energy of the traction battery). * Perform a dealer issue detection assistance (DID A) and send the following information: * Presence of the fault code(s) * Photo of the traction battery label * Measurement results table * Value "Capacity of the traction battery to provide and store energy". * Reinitialize the faults related to electrical insulation. Use the diagnostic tool ("After-sales intervention" menu for the traction battery). * Clear the faults present in all calculators. * If the fault code P0AE1 12 was present before the intervention: Perform a reset of the traction battery pre-charge short-circuit counter. Use the diagnostic tool ("After-sales intervention" menu for the traction battery). ### Intervention 2 (Replacement of the Electric Water Heater (3)) #### 208 (P21E) * Replace the electric water heater (3). ### Additional Parts to be Replaced Systematically: None ### Additional actions required for this intervention: * Follow the safety and cleanliness instructions. * Disconnect the vehicle power supply. * Drain the hybrid traction chain cooling circuit. * Follow the tightening torques. * Reconnect the vehicle power supply. * Fill and bleed the electric traction chain cooling circuit. ### Intervention 3 (Replacement of the Electric Refrigeration Compressor (6)) #### 208 (P21E) * Replace the electric refrigeration compressor (6). ### Additional Parts to be Replaced Systematically: 4 O-rings ### Additional actions required for this intervention: * Follow the safety and cleanliness instructions. * Disconnect the vehicle power supply. * Perform the disconnection procedure for the power wiring connectors. * Follow the tightening torques of the refrigeration circuit components. * Follow the wheel tightening torques. * Reconnect the vehicle power supply. * Drain the new electric refrigeration compressor. * Replace the filter-dryer cartridge. ### Additional Parts to be Replaced Systematically: 4 O-rings ### Additional actions required for this intervention: * Follow the safety and cleanliness instructions. * Perform the actions to be performed before disconnecting the auxiliary battery. * Follow the tightening torques. * Perform the actions to be performed after reconnecting the auxiliary battery. * When filling the circuit with refrigerant, add the amount of oil corresponding to that which was in the replaced component (filter-dryer cartridge). * Charge the refrigeration circuit. * Reinitialize the faults related to electrical insulation. Use the diagnostic tool ("After-sales intervention" menu for the traction battery). * Clear the faults present in all calculators. * If the fault code P0AE1 12 was present before the intervention: Perform a reset of the traction battery pre-charge short-circuit counter. Use the diagnostic tool ("After-sales intervention" menu for the traction battery). ### Intervention 4 (Replacement of the Traction Electric Machine (9)) #### 208 (P21E) * Replace the traction electric machine (9). ### Additional Parts to be Replaced Systematically: None ### Additional actions required for this intervention: * Follow the safety and cleanliness instructions. * Disconnect the vehicle power supply. * Drain the electric traction chain cooling circuit. * Drain the reducer. * Remove the auxiliary battery and its support. * Remove the front driveshafts. * Remove the front cradle. * Follow the wheel tightening torques. * Follow the front axle tightening torques. * Follow the tightening torques of the electric equipment. * Follow the tightening torques of the electric traction machine and reducer suspension assembly. * Reinstall the front cradle. * Reinstall the front driveshafts. * Reinstall the auxiliary battery and its support. * **Mandatory**: Reconnect the vehicle power supply. ### Fill: * The reducer * The electric traction chain cooling circuit ### Attention * The diagnostic tool must be updated to the latest version available on the after-sales telematics server. * Download the latest traction electric machine calculator software available on the after-sales server. * Clear the fault codes. * Reinitialize the faults related to electrical insulation. Use the diagnostic tool ("After-sales intervention" menu for the traction battery). * Clear the faults present in all calculators. * If the fault code P0AE1 12 was present before the intervention: Perform a reset of the traction battery pre-charge short-circuit counter. Use the diagnostic tool ("After-sales intervention" menu for the traction battery). ### Intervention 5 (Replacement of the Set (5) On-board Charger/DC-DC Converter) ### 208 (P21E) * Replace the set (5) on-board charger/DC-DC converter. ### Additional Parts to be Replaced Systematically: None ### Additional actions required for this intervention: * Follow the safety and cleanliness instructions. * Disconnect the vehicle power supply. * Drain the traction chain cooling circuit. * Follow the tightening torques. * Reconnect the vehicle power supply. * Fill and bleed the traction chain cooling circuit. ## Attention * The diagnostic tool must be updated to the latest version available on the after-sales telematics server. * Download the latest software for the embedded charger/DC-DC converter circuit available on the after-sales server. * Clear the fault codes. * Reinitialize the faults related to electrical insulation. Use the diagnostic tool ("After-sales intervention" menu for the traction battery). * Clear the faults present in all calculators. * If the fault code P0AE1 12 was present before the intervention: Perform a reset of the traction battery pre-charge short-circuit counter. Use the diagnostic tool ("After-sales intervention" menu for the traction battery). ## Summary of Measurement Results * Print the tables for recording the results of the checks ### Note * Specify the corresponding unit for each measurement. #### Parameters recorded during Check 1 (Resistance Check of the Electric Water Heater (3) CTP) | Parameters | Expected Values | Measured Values | |---|---|---| | Resistance between the 2 lines of connector "b" | Greater than 1 kOhm | | #### Parameters recorded during Check 1 (Insulation Check of the Additional Electric Water Heater (3) CTP ADD) (For vehicles equipped with the additional electric water heater (3)) | Parameters | Expected Values | Measured Values | |---|---|---| | Resistance between the 2 lines of the connector base "d" | Greater than 1 kOhm | | #### 208 (P21E) & ELECTRIC VEHICLE & EMBEDDED SINGLE-POWER METASYSTEM CHARGER #### Parameters recorded during Check 2 (Resistance Check of the Set (5) On-board Charger/DC-DC Converter) | Parameters | Expected Values | Measured Values | |---|---|---| | Resistance between the 2 lines of the connector base "a" | Greater than 10 kOhm | | | Resistance between the 2 lines of the connector base "b" | Greater than 10 kOhm | | | Resistance between the 2 lines of the connector base "e" | Greater than 10 kOhm | | #### Parameters recorded during Check 3 (Resistance Check of the Electric Refrigeration Compressor (6) REFRI) | Parameters | Expected Values | Measured Values | |---|---|---| | Resistance between the 2 lines of the connector "e" | Greater than 100 kOhm | | #### Parameters recorded during Check 4 (Resistance Check of the Traction Electric Machine (9) MEL) | Parameters | Expected Values | Measured Values | |---|---|---| | Resistance between the 2 lines of the connector "a" | Greater than 100 kOhm | | | Resistance between the 2 lines of the connector "f" | Greater than 100 kOhm | | #### Parameters recorded during Check 5 (Resistance Check of the Traction Battery (1) BATT HT) | Parameters | Expected Values | Measured Values | |---|---|---| | Transition to "READY" mode with the power cable (tool) | Yes/No | | ## Intervention Times #### 208 (P21E) * Fault code reading + Vehicle power off + Check 1 + Intervention 2 * Billable time: 2.70 H * Operation code: 99F25A * Fault code reading + Vehicle power off + Check 1 + Check 2 + Intervention 5 * Billable time: 3.10 H * Operation code: 99F29A * Fault code reading + Vehicle power off + Check 1 + Check 2 + Check 3 + Intervention 3 * Billable time: 2.70 H * Operation code: 99F25A * Fault code reading + Vehicle power off + Check 1 + Check 2 + Check 3 + Check 4 + Intervention 4 * Billable time: 8.40 H * Operation code: 99F82A * Fault code reading + Vehicle power off + Check 1 + Check 2 + Check 3 + Check 4 + Check 5 + Intervention 1 * Billable time: 5.20 H * Operation code: 99F50A ### Note * **In the event of a SAFETY INCIDENT, and ONLY in this case, send a Dealer Issue Detection Security (DIDS) to obtain the instructions to be followed, even if this document would apply. If a safety incident occurs, in the event of a RECURRENT fault after applying this document, a Dealer Issue Detection (DID) report is required (see below).** * (*Dealer Issue Detection Incident (DIDI) if the authorized repairer (AR) was able to solve the problem without the assistance of technical help. * (*Dealer Issue Detection Assistance (DIDA) if the authorized repairer (AR) requires technical assistance to deal with the problem.