Fiat 500 Forum banner

AVOID BREAKDOWNS! 10/13/23 Update: 240V Plug-In Surge Protectors (item 6)

1 reading
23K views 31 replies 6 participants last post by  Electric Tire Shredder  
#1 · (Edited)
If you purchase any 500e these 6 simple actions will help keep it running (in no particular order, click pics to enlarge):

  • 2: Save the $10,000+ Battery Pack with free U69 software update: Check the VIN's recalls & "Notices" (click here for full list) fixed free at any FCA dealer such as Dodge, Jeep or Ram. Do not use the NHTSA site, since U69 doesn't show there. Click here or click "Recalls" under "Resources" at Mopar.com To avoid main drive battery damage, click "Customer Satisfaction Notices" & check for U69:
U69 work-around: Monitor the 12V (item 5 below) & watch for the car's gauge dropping more than a few % while parked.​

  • 3: Get a 65¢ wingnut (M8 x 1.25) or carry a wrench or at least pliers to disconnect the 12V starter battery if it ever needs a reboot in order to start/charge:
Left to right: OEM, 65¢ at local hardware, $6 on Amazon (search "m8-1.25 wingnut" or click here & scroll down til you see it).​

  • 4: Leave the humidity sensor unplugged. If the glass was replaced it's often tucked in the headliner. It creates many false alarms that can prevent starting/charging. At the very least, carry a round toothpick to unplug it when needed:

  • 5: OBD WITH ITS OWN SCREEN KILLS THE CAR! Keep the following in the car:
    • $45 OBDLink.com SX (click here) or $54 EX (incl. 10% off by signing up to free newsletter)**
    • $13 "Yellow ADAPTER", NOT just a yellow extension! (click here)
    • Charged-up OTG-ready Android** with $49 AlfaOBD.com app installed & $3 OTG adapter to fit (not just a charge-only adapter)
That's for 2 glitches that are unavoidable even with the humidity sensor unplugged:​
- Contactor Disable glitch prevents starting/charging. It needs the paid AlfaOBD app to fix:​
- Proxy Misalignment glitch makes the odometer flash & can make the % gauge oscillate so it dies while driving*. The fix needs the paid app & the Yellow Adapter which only works with an approved USB reader:​
* Work-around: Ignore the gauge, always charge til it stops at 100%, & zero out a trip gauge to keep track of your range.​

  • 6: Get a ~$26 Bluetooth battery alarm like a BM2 or BM6. The built-in alarm often activates AFTER the car dies :rolleyes:, & jumpstarting doesn't always work. Or at least use a $10 volt gauge periodically, after the 12V battery is 9 months old. Click here for the thread on this forum.

Optional preparation for key loss:

If you only have one key, & you lose it, it costs $1500 + towing (click here for explanation), so you might want to get a proper $400 transponder copy at a dealer, or else get some cheap non-transponder copies, then glue the good one inside the steering column cover & use the cheap ones to lock/unlock/start.

Optional(?) safety prep:
  • If possible, replace any 59¢ "residential grade" wall outlet you plan to use with a $4 "commercial grade" one to reduce risk of fire.
Optional 12V longevity prep:
Add a chunk of styrofoam insulation all the way down the side:


** You want one of those "pricey" OBD cables because a cheap Bluetooth won't fix the proxy glitch. Anyway, @Iceman advises against cheapies (post #6 here) AND @fast_dave advises against wireless (post #2 here). OBDs with their own screen can cause errors, but they're often fixed by the standard tricks (click here).

The AlfaOBD app is Android/Windows only, so if you have an iPhone, or you share the car, & none of your friends can donate an old OTG-compatible Android (check with the free "USB OTG Checker" app), you can put AlfaOBD on a ~$30 Amazon Android. No service needed, just download the app on Wi-Fi, & leave it charging off the glovebox USB. Before you buy one, check that it's OTG compatible.

Alternative: Keep a charged-up Windows laptop in the car, with the $49 AlfaOBD Windows app installed.

There's no contactor reset on the MultiEcuScan.net iPhone/Windows app, & you need the paid version just to clear codes.
 
#2 ·
UPDATE: Someone reported over a year ago that their 500e 12V died so bad it couldn't jumpstart, but I thought that was rare enough to not matter. Now someone else just reported that 2 different AAA trucks were unable to jump their 500e's dead 12V battery. So apparently the most reliable method to avoid inconvenience is replacement after 2 years (which seems pretty wasteful) or a voltage gauge, so I have edited the original post accordingly.
 
#5 ·
what does the styrofoam do? ...and thanks for tip on hood cover, i'll pull it.
It's the plastic motor cover that should be deleted, to allow heat to escape when charging with the hood open (doesn't seem to help with the hood closed).

The styrofoam insulation insulates the battery from the heat of the adjacent OBCM & the PIM right below that. The OBC gets so hot after a few minutes of L2 that I can barely put my hand on it.
 
#7 · (Edited)
If the car doesn't start, check the 1st post here:


How to use AlfaOBD is here:


What to check is item 1 of post 1 here:

 
#12 ·
47% on the display, & not charging normally means the main batt pack has dropped too low to charge, from extended parking unplugged. Possibly parked due to failure of the $2k OnBoard Charger or the $6k Power Inverter Module or the Battery Pack Control Module inside the main battery pack...
 
#13 ·
Those all have varying degrees of cost & difficulty.

Without doing a test, you can't tell if the other car has a weak cell, which also requires dropping the pack, but then requires either a new pack, all new cells, or good used cells to replace the bad ones, since apparently it's pretty bad to mix old & new cells in the same pack.
 
#14 ·
Since they turn on, you might be able to use AlfaOBD free demo app & a $10 Veepeak to check for imbalance indicating a weak cell, at least on the 67% one.

At the link below, the weak cell test is item 1, & diagnosis/repair is item 4:

MASTER LIST of 500e How-To Links: Fix, Drive, Charge...
 
#16 ·
It's possible.

Since it was likely driving when it crashed, maybe the other components are okay too.

However, it's also possible it was driving around with 1 or more very weak cells that can cut the range in half. That's why I'd never buy one without the cell test in post #7 above "What to check, pre-purchase".
 
#22 ·
...because here's what happened to the last guy who couldn't test before buying:

 
#25 ·
6 months and battery is still 67% or have some lock after crash to save battery?!
It's possible, but if the battery is locked out then the % gauge shouldn't be reading. It may be that 67% also indicates a dead battery. I think someone reported that 47% isn't the only false reading that can show when it's dead.

It will be better to buy this one with 47%
Maybe, maybe not. Either one of the two cars could have a crippling weak cell, or completely dead cells that won't recharge even with the pack removed, or a blown BPCM or PIM or OBC. There's no way to tell without OBD, which you want anyway if you're going to own a 500e (see post #1 of this thread).

Spend the $10 & try connect AlfaOBD. Wireless is okay for diagnosis, but check the OBD advice in post #1. On that note, we don't know if the cars have extra errors due to someone using an OBD with its own screen.
 
#28 ·
It's possible, but if the battery is locked out then the % gauge shouldn't be reading. It may be that 67% also indicates a dead battery. I think someone reported that 47% isn't the only false reading that can show when it's dead.



Maybe, maybe not. Either one of the two cars could have a crippling weak cell, or completely dead cells that won't recharge even with the pack removed, or a blown BPCM or PIM or OBC. There's no way to tell without OBD, which you want anyway if you're going to own a 500e (see post #1 of this thread).

Spend the $10 & try connect AlfaOBD. Wireless is okay for diagnosis, but check the OBD advice in post #1. On that note, we don't know if the cars have extra errors due to someone using an OBD with its own screen.
The battery on crashed is not stay all the time 67% after 6 days is 66% now. This is some kind good sign 👌