Engine Stall With Intermittent Restart
The Office of Defects Investigation (ODI) has received 80 consumer complaints alleging an engine stall and loss of motive power on model year (MY) 2022 RAM 1500 pickup trucks and 2022 Jeep Wagoneer SUV vehicles. The particular engines in the subject vehicles are equipped with the Fiat Chrysler Automotive Group LLC (FCA) 5.7L Hemi eTorque system. The eTorque system is a mild hybrid system that lets the vehicle partially power itself. It accomplishes this by converting the captured energy from the braking system into electricity for the battery pack, which is then used to power a variety of electrical components. ETorque engines replace the alternator with a 48-volt battery-powered belt drive and a motor generator. The motor generator provides extra torque to the crankshaft during gear changes. Simultaneously, the motor generator uses the 48-volt battery pack to increase torque. Many of the complaints state that the vehicle's engine would shut off, often while travelling at slow speed, the vehicle would shift into park and apply the emergency brake. The vehicles were sometimes able to be restarted. In addition, complaints state that the malfunction warning light with the battery fault symbol appeared on the dash. Many complaints state that a low voltage condition fault is present, sometimes not being able to restart the vehicle. On April 13, 2023, FCA announced recall 23V-265 describing a defect in certain 2021 Ram 1500 vehicles equipped with 5.7L eTorque engines. The recall described a defect in the powertrain control module software can cause an incorrect fuel mixture condition in the engine, and result in an engine stall. In February of 2024, ODI provided the complaints on the 2022 Ram 1500 and Wagoneer vehicles to FCA. After reviewing the complaints, FCA stated that “the loss of motive power was likely not caused by an over rich fuel condition (as outlined in recall 23V-265), but rather some other cause (e.g., an electrical concern that causes the engine to shut down).” A Preliminary Evaluation has been opened to assess the scope, frequency, root cause(s) and consequences of these loss/stall of motive power incidents. Additionally, ODI may expand the scope of the subject population during the investigation, if needed. To review the ODI reports cited in the Opening Resume ODI Report Identification Number document, go to NHTSA.gov.
ELECTRICAL SYSTEM:12V/24V/48V BATTERY
High pressure fuel pump failure
The Office of Defects Investigation (ODI) opened PE21-021 on October 14, 2021, to investigate incidents alleging a stall/loss of motive power as a result of high-pressure fuel pump failures in certain model year (MY) 2019-2020 Ram 2500, 3500, 4500, and 5500 heavy duty trucks equipped with 6.7L Cummins turbodiesel engines. During the investigation, ODI sought to determine if the related defect allegation was limited in scope to the recalled population. After review of information request response materials from both FCA and BMW, NHTSA determined that sufficient information to identify a comprehensive recall population could not be produced by FCA and BMW.During the investigation FCA filed recalls 22V406, 22E048, 22V767, and 22E087 which include vehicles not identified in the initial subject population by ODI. ODI also received recall 21V586, involving loss of motive power due to failed CP4 fuel pumps on certain BMW manufactured vehicles. An information request letter response received from BMW indicated that failed pumps on their vehicles were caused by an interaction between pump internal components and US market diesel fuel, leading to increased slip and eventual particle-generating wear surface. Additional work will be done to identify whether a similar root cause is associated with the FCA recalled population and if similar wear dynamics occur on pumps supplied to vehicle manufacturers other than those included in the recalled population.ODI has upgraded this investigation to an EA in order to 1) determine engineering specifications of internal pump components that are correlated with pump failure leading to loss of motive power or other safety related hazards, 2) identify vehicle populations equipped with alleged defective pump variants, 3) assess if vehicles equipped with alleged defective pump variants result in an unreasonable risk to motor vehicle safety and 4) gather and review any other relevant information related to high pressure fuel pump failure associated with the subject populations of recalls 21V586, 21V880, 21E094, 22V406, 22E048, 22V767, and 22E087.Review of the above information will allow NHTSA to confirm root cause and recall remedy viability, and identify and evaluate vehicle populations equipped with pump components that may pose an unreasonable risk to motor vehicle safety.The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID using the following complaint identification numbers: 11257550, 11351441, 11361603, 11361616, 11365300, 11365426, 11365858, 11366401, 11372337, 11373793, 11374797, 11376793, 11377871, 11378173, 11384377, 11386063, 11387018, 11399710, 11402550, 11415339, 11418868, 11418870, 11427075, 11434276, 11436807, 11437226, 11437249, 11437273, 11437292, 11437294, 11437394, 11437399, 11437403, 11437405, 11437423, 11437528, 11437565, 11437579, 11437580, 11437590, 11437679, 11437744, 11437781, 11437842, 11437993, 11438006, 11438008, 11438121, 11438138, 11438155, 11438392, 11438629, 11439359, 11439879, 11440397, 11443030, 11446542, 11448163, 11453556, 11458918, 11460558, 11469337
FUEL SYSTEM, DIESEL:DELIVERY:FUEL PUMPLed to recall 24V957