Incorrect Adjustment of LED Headlights/FMVSS 108 – 2019 Maserati Levante

July 11, 2019 NHTSA CAMPAIGN NUMBER: 19V521000

Incorrect Adjustment of LED Headlights/FMVSS 108

Affecting the visibility of oncoming traffic can increase the risk of a crash.

NHTSA Campaign Number: 19V521

Manufacturer Maserati North America, Inc.

Components EXTERIOR LIGHTING

Potential Number of Units Affected 427

Summary

Maserati North America, Inc. (Maserati) is recalling certain 2019 Levante vehicles equipped with full LED headlights with Adaptive Front Lighting System (AFLS). The headlights may be misadjusted above the maximum height allowed, possibly impairing other driver’s visibility on the roadway. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 108, “Lamps, Reflective Devices, and Associated Equipment.”

Remedy

Maserati will notify owners, and dealers will adjust the headlights, free of charge. The recall began August 20, 2019. Owners may contact Maserati customer service at 1-877-696-2737. Maserati’s number for this recall is 387.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Check if your Maserati has a Recall

Date: July 29, 2019
Bulletin Number: MAS001935 – MTB -1914 /A
Recall 387 – LED Headlight Adjustment
Supersedes: N/A
Section: Compliance

Model Type: Levante (M161)
Model Year: 2019
Subject: Vehicle Safety Recall Campaign 387, LED Headlight Adjustment

NOTE:  Some vehicles above may have been identified as not involved in this  recall and therefore have been excluded from this recall. 

NOTE: Before starting this procedure, you MUST read these instructions carefully and completely.

MASERATI SAFETY RECALL NOTIFICATION

PERFORM THE PROCEDURE OUTLINED IN THIS TECHNICAL BULLETIN ON ALL AFFECTED VEHICLES BEFORE CUSTOMER DELIVERY OR THE NEXT TIME THE CAR IS IN THE SHOP FOR MAINTENANCE OR REPAIRS.

Maserati dealers must ensure recalls are completed after having been notified by Maserati North America, Inc. (MNA) that a safety-related defect or noncompliance exists in any motor vehicle or item of replacement equipment in the dealer’s possession at the time of notification.  In MNA’s case, this notification would typically be made by the issuance of a recall notification in the form of a Technical Bulletin. 

Some of the involved vehicles may be in dealer new vehicle inventory.  The National Traffic and Motor Vehicle Safety Act of 1966, as amended (or in the case of Canadian vehicles, Motor Vehicle Safety Act S.C. 1993, as amended), requires you to complete this recall service on these vehicles before retail delivery. This means that dealers cannot legally deliver new motor vehicles or new items of replacement equipment to consumers with an open recall.

Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service.  This also pertains to vehicles in the Certified Pre-Owned program, and to items of replacement equipment. 

Finally, MNA dealers should not sell or use parts that have been recalled by MNA.  Please follow the specific instructions provided by MNA on the return or disposition of the parts.   

Description of Vehicle Safety Recall 387

Maserati S.p.A., MNA and MC have determined that the above described vehicles equipped with the optional full LED headlights with Adaptive Front Lighting System (“AFLS”) did not have the AFLS properly adjusted during the vehicle assembly process.  Headlights adjusted above the maximum gradient allowed may impair the vision of drivers of other vehicles, and can cause a vehicle crash without prior warning.   Out of an abundance of caution, Maserati has decided to initiate this Voluntary Safety Recall #387 to adjust the AFLS properly (Fig.1).

Fig.1

This repair procedure will be performed free of charge to the customer.

Which Vehicles Are Affected

Please refer to the VIN List in ModisCS+ for the affected vehicles in the U.S. and Canada.

Vehicle Remedy Information

1. Check that the vehicle is included in this Recall Campaign, and that the repair has not been previously performed.
2. Perform the adjustment procedures to the “AFLS” LED Headlights as shown below and in Section 8.30.002.40 of the Workshop Manual.

3. The recall procedure is now complete.

Parts Needed For The Recall

No parts are required for this Recall Campaign.

IMPORTANT NOTES: Before beginning the headlight adjustment procedures, ensure the Headlight alignment tool p/n: 900000527 has been set up and registered on line as explained in Maserati Tech Tips 92.

Ensure the calibration date is set correctly on the tool by referring to MAS001600 (MCL 18-01) and MAS001638 (MCL 18-08).

When setting the tool up for use, refer to MAS001810 (MCL 19-07) for clarification on the inclination adjustment.

OPERATING PROCEDURES

Test area floor

1. The slope of the test area floor (longitudinally as well as laterally) may not exceed 1%.
2. The maximum accepted unevenness of the test area is 2mm/m.

Vehicle preparation

First check proper operation of the lamps and turn indicators.

Make sure that headlight mounts are not broken and that headlight surface is free of any cracks.

Position the vehicle on a level surface .

Using suitable products, clean headlight surface .

Standard “AERO 1”: it corresponds to vehicle in “Wheel alignment mode”. Launch the “Wheel alignment mode” from MD by selecting the SPECIFIC FUNCTION OF DASM, or enter it in the MTC+.

3. The car must be in this condition: Standard “AERO 1”

4. Perform a pressure check on the tires and, if necessary, inflate them to the correct pressure for Full load condition [Front – Rear 2.6 bar (38 psi) ].
5. Straighten wheels and set the steering wheel straight.

Tool positioning

The images shown here are for illustrative purposes only.

6. The headlight adjustment tool 900000527, must be positioned at a distance ranging between 30 – 50 cm from headlight as figured .

7. Select TEST SAE.

8. Select the option “Free Test”.

9. Set the parameters as shown in the picture below, then switch-on the laser as indicated

Use the buttons +/- to change the parameters value.

*Note SAE requires measurement in standard unit. Conversion from metric units may be required. 

10. Select the  option “NO” in the  screen concerning  the “Fog  lights”.

11. Find the center of the  headlamp by moving the
12. A laser cross is projected onto the headlamp for centering.

13. After adjusting the height of the tool so It’s centered in the headlight, make note of the measurement on the scale.

14. Using the level on the tool, perform the levelling.

15. If not correctly levelled, perform the tool adjustment by using the height-adjustable wheels.  Slightly loosen the 2 wheel knobs (1). Adjust the level of the tool by turning the 2 adjusting knobs (2). Check the spirit level and, when the bubble is levelled, tighten the wheel knobs (1).

16. Switch-on the alignment laser and search for two symmetrical parts at the front area of the vehicle.
17. Turn the plug with the light box, until the line projected by the alignment laser on the engine bay perfectly matches the two symmetrical reference points.

18. For example 2 symmetrical screws in the engine bay on the right and left sides as shown below.

19. Verify that the laser cross is still in the center of the headlamp, if not reposition the laser cross into the center of the headlamp.

The selection keys for the headlamps to be tested are always in the   driving direction of the vehicle. This means that the selection keys are laterally reversed in the settings mode. The labelling of the headlamps (left and right) do not change.

After entering the vehicle settings, the screen for the selection of the headlamp to be tested appears.

20. Click onto the symbol for the low beam headlamp to be tested (left or right).

21. Switch on the low beams of the vehicle, then press the start measurement symbol as shown below to start the test.

22. The screen shows the status of the headlamp: outside top tolerance, outside bottom tolerance. ►, outside right tolerance. ◄ outside left tolerance

23. A red dot indicates that the headlamp is not centered Your goal is to aim the beam into the dotted square displayed on the screen.

24. The screw positions to adjust the headlights are depicted below.

25. Using the vertical and horizontal adjustment screws. Adjust beam until dot enters the dotted square depicted on the screen. Correct adjustment is indicated by a green dot as seen below.

26. When adjustment is complete confirm by pressing the “SAVE” button.

27. Repeat procedure on the opposite headlight to be adjusted.
28. Ensure to printout results and attach results provided by beam setter to the repair order.

Entering A Warranty Claim

Warranty Information:

• Campaign Number………………………………………387
• Cost Code………………………………………………..24
• Defect Code………………………………………….….063
• Component code………………………………………..8.30.002
• Labor Operation Code……………..…………………..8.30.002.9 (0.55h)

IMPORTANT SAFETY RECALL INFORMATION

August 23, 2019

NHTSA Recall#: 19V521
Maserati Campaign#: 387

<<First>> <<Last>>
<<ADD1>>
<<ADD2>>
<<CITY>>, <<ST>> <<ZIP>>

This Notice Applies To Your Vehicle, Vehicle Identification Number:

Dear Maserati Customer:

This notification is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Maserati S.p.A. and Maserati North America, Inc. (MNA), have decided that certain 2019 Maserati Levante vehicles fail to conform to Federal Motor Vehicle Safety Standard (FMVSS) No. 108, “Lamps, Reflective Devices, and Associated Equipment”.

Maserati S.p.A. and MNA have determined that the above-described vehicles were manufactured with the optional full LED headlights with Adaptive Front Lighting System (AFLS) that may not have had the AFLS properly adjusted during the vehicle assembly process. Headlights adjusted above the maximum height allowed under FMVSS No. 108 may impair the vision of drivers of other vehicles, and may increase the risk of a vehicle crash without prior warning.

Your Maserati Dealer will adjust the light beam to the corrected parameters, free of charge. Since your vehicle is among those that may be affected by the above condition, we ask you to contact any Authorized Maserati Dealer in order to arrange for this recall action to be performed to your vehicle. The repair will take approximately 1.0 hour to complete. Please prepare to leave your vehicle with the dealership to allow the dealer to complete your repairs. Your Authorized Maserati Dealers have the necessary instructions and components to remedy your vehicle.

If the dealer fails or is unable to make the necessary repairs free of charge within a reasonable time, or if you have any problem obtaining the needed repair, you should inform the national headquarters of Maserati North America, Inc., at:

Maserati North America, Inc.
1 Chrysler Drive
Auburn Hills, MI 48326
(877) 696-2737 (Customer Care)

If you believe that Maserati has failed to remedy the defect described in this letter free of charge to you and within a reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration U.S. Department of Transportation, 1200 New Jersey Avenue, S.E., Washington DC 20590; or call the toll- free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153), or go to  https://www.safercar.gov.

Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten working days. If you no longer own this vehicle or your address has changed, please complete the enclosed prepaid yellow card and return it to Maserati North America, Inc.

We apologize for any inconvenience this may cause you.

Sincerely,

Maserati North America, Inc. Vehicle Safety and Regulatory Compliance

Q&A

Management Summary of Maserati Safety Recall Campaign #387

Headlight Adjustment

Q&A

IMPORTANT SAFETY RECALL INFORMATION   

July 29, 2019

NHTSA Recall#: 19V521
Maserati Campaign#: 387

Dear Maserati Dealer:

This notification is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Maserati S.p.A. and Maserati North America, Inc. (MNA), have decided that a noncompliance to Federal Motor Vehicle Safety Standard (FMVSS) No. 108, Lamps, Reflective Devices, and Associated Equipment,  exists in 2019 Model Year Maserati Levante vehicles.

Maserati S.p.A. and MNA have determined that the above-described vehicles were manufactured with the optional full LED headlights with Adaptive Front Lighting System (AFLS) that may not have had the AFLS properly adjusted during the vehicle assembly process. Headlights adjusted above the maximum gradient allowed under FMVSS No. 108 may impair the vision of drivers of other vehicles, and may increase the risk of a vehicle crash without prior warning.

The remedy is to adjust the light beam on the affected vehicles.  The remedy will be performed free of charge to the vehicle owner.  We will, of course, reimburse you for the labor necessary to carry out this recall campaign.  The necessary components for this recall are currently available to dealers, and owners will be directed to call their dealers for repairs.

Maserati dealers must ensure safety recalls are completed after having been notified by MNA that a safety-related defect or noncompliance exists in any motor vehicle or item of replacement equipment in the dealer’s possession at the time of notification. In MNA’s case, this notification would typically be made by the issuance of a safety recall notification in the form of a Technical Bulletin.  

Under the National Traffic and Motor Vehicle Safety Act of 1966, as amended, if a safety recall campaign is announced by MNA, dealers must ensure that all recalls on new vehicles and new items of replacement equipment are completed BEFORE delivery to the consumer. This means that dealers may not legally deliver new motor vehicles or new items of replacement equipment to consumers with an open safety recall.

The Safety Act also prohibits dealers from selling or leasing the motor vehicle or item of replacement equipment, unless and until the open safety recall has been completed BEFORE delivery.

Under the terms of the Certified Pre-Owned (“CPO”) program, CPO vehicles with an open safety recall may not be sold or delivered to the consumer.

Finally, MNA dealers should not sell or use parts that have been recalled by MNA. Please follow the specific instructions provided by MNA on the return or disposition of the parts.

Obviously, if you have any of the affected vehicles in your stock, you must not sell them until you have performed the necessary repairs on the vehicle. If you have already sold any of the vehicles with the indicated VIN in the enclosed instructions and have not yet sent in the new owner information to MNA, please do so at once so we may notify these owners.

Thank you for your cooperation.

Sincerely,
Maserati Vehicle Safety and Regulatory Compliance

1 Affected Product

Vehicle

9 Associated Documents

Recall Acknowledgement

RCAK-19V521-9970.pdf 244.865KB

Manufacturer Notices(to Dealers,etc) Q&A for Maserati Safety Recall Campaign #387 – Headlight Adjustment for Levante Model Year 2019.

RCMN-19V521-1104.pdf 62.477KB

Non-Compliance Notice 573 Report

RCLRPT-19V521-1859.PDF 213.898KB

Recall Quarterly Report #1, 2019-3

RCLQRT-19V521-6855.PDF 211.147KB

Recall Quarterly Report #3, 2020-1

RCLQRT-19V521-2780.PDF 211.329KB

Remedy Instructions and TSB

RCRIT-19V521-3610.pdf 3824.13KB

ISSUED Owner Notification Letter(Part 577)

RCONL-19V521-4942.pdf 159.273KB

Recall Quarterly Report #2, 2019-4

RCLQRT-19V521-4047.PDF 211.249KB

Manufacturer Notices(to Dealers, etc.) A noncompliance to Federal Motor Vehicle Safety Standard (FMVSS) No. 108, Lamps, Reflective Devices, and Associated Equipment, exists in 2019 Model Year Maserati Levante vehicles.

RCMN-19V521-0687.pdf 52.876KB

Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=19V521&docType=RCL

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