Stellantis recalls its plug-in hybrid models... then also recalls the replaced engines, themselves contaminated by sand

Just a few months after a massive first recall, Stellantis is once again faced with a problem that is as unexpected as it is embarrassing for its plug-in hybrid engines. This time, it's not the vehicles that are directly affected, but the replacement motors themselves... contaminated with sand.

A second recall reopens an already sensitive issue

The case dates back to November 2025, when Stellantis recalled over 112,000 plug-in hybrid vehicles in the USA, including the Jeep Wrangler 4xe and Grand Cherokee 4xe. The cause: a risk of engine failure linked to residues from the manufacturing process.

But the problem didn't stop there. In April 2026, Stellantis North America launched a new recall campaign, this time on 2,689 2.0L turbo GME engines intended to replace those already defective. These engines, supplied by Mopar as spare parts, could also contain internal debris... including sand from the casting process. A particularly problematic scenario: engines that are supposed to correct a defect could in fact reproduce the same risk of failure.

Contamination linked to the industrial process

The origin of the problem has now been clearly identified. It stems from the foundry process used to manufacture engine blocks, carried out by supplier Nemak in Mexico. During this stage, sand is used to mold the aluminum parts.

But in some cases, this sand may not have been properly removed after manufacture. As a result, particles can remain inside the engine, causing internal damage and even complete breakdown.

According to Stellantis estimates, around 4.3 % of the engines affected by this new recall could be contaminated. While no accidents or fires have been reported to date for this new campaign, the previous recall already gave an idea of the potential seriousness of the problem: loss of propulsion, engine fires, and even several reported injuries.

Investigation re-launched after suspicious fire

This second recall didn't happen by chance. It was triggered after an incident in 2024, when a Jeep Grand Cherokee 4xe caught fire in the engine compartment.

This vehicle was not part of the first recall, but its engine had been produced during the same risk period. This event prompted Stellantis to reopen the investigation, which eventually led to the identification of new potentially defective engines, including those sold as spare parts.

To rectify the problem, Stellantis is applying a now well-established procedure: complete inspection of the engines and replacement if necessary. Engines not yet installed will be inspected or repurchased, while those already installed in vehicles will be replaced at no cost to the customer. In some cases, an engine management software update will accompany the intervention. Affected owners will be informed from May 7, 2026.

A new blow for Stellantis PHEVs

This recall comes at a time when the Group's plug-in hybrids are already under pressure in North America. As we recently reported, Stellantis has decided to end sales of several PHEV models as early as 2026, including the Jeep Wrangler 4xe and Grand Cherokee 4xe.

Officially, this decision is linked to changing demand and a strategic refocusing on conventional hybrids and range-extending electrics. But it's hard not to make the connection with the accumulation of technical problems and recalls that have severely damaged the image of these models.

In any case, this latest episode reinforces a clear trend: the 2.0L GME PHEV engine, once the mainstay of the Group's plug-in hybrid offering, seems to be living out its final hours in North America. Between repeated recalls, the gradual abandonment of 4xe models and a strategic reorientation, Stellantis is gradually turning the page on the PHEV. It remains to be seen whether this technology will one day return in a more reliable form... or whether it is already a thing of the past for the group in the USA. Engines produced in Europe are not concerned.