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TSB 18-25-97

EGR System Failure with Hex Code $2E on 5.9L Diesel

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Date: Aug.15,1997

Models: 1996-96 BR Cummins

NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 5.9L CUMMINS DIESEL ENGINE BUILT BETWEEN JAN. 1, 1996 (MDH 0101XX) AND DEC. 31,1996 (MDH 1231XX) AND CALIFORNIA EMISSIONS SALES CODE NAE

Symptoms:

While performing other diagnostics, the technician may notice Hex Code $2E - EGR SYSTEM FAILURE on the Diagnostic Scan Tool (DRB 111). The customer may or may not experience any engine driveability symptoms. The Malfunction Indicator lamp (MIL) will not be illuminated.

Diagnosis:

Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's or those listed above are present and any of the above symptoms have been experienced, perform the Repair Procedure. Diagnostic Chart

NOTE:  Whenever a PCM is replaced due to failure, the software of the replacement controller should be verified for the latest revision level.

Equipment/Parts Needed:

NOTE: THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1138 OR HIGHER MUST BE INSTALLED.

Repair Procedure:

This bulletin involves using revised test procedures to diagnose the EGR system and selectively erase and reprogram the Powertrain Control Module (PCM) with new software (calibration changes) for the condition listed.

NOTE: MAKE ANY NECESSARY REPAIRS BASED ON THE REVISED DIAGNOSTIC PROCEDURE BEFORE FLASH PROGRAMMING THE PCM.

1.    Perform revised diagnostic test TC-140A. The revised test is included with this Technical Service Bulletin and will be sent out under separate cover to revise the 1997 Powertrain Diagnostics Procedures Manual p/n 81-699-96041.

2.    If the EGR System is not operating properly, perform the necessary repairs per the new test procedure.

3.    Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up.

4.    Use the arrow keys and select #2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.

5.    Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.

6.    Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU.

7.    Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS & DRB III on the MDS, then press NEXT MENU.

8.    Follow the steps presented on the MDS and DRS III which will allow the DRB III to obtain the current part number of the PCM

9.    The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming.

If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair

10.   The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process.

NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW

11.    Type or print necessary info on the "Authorized Software Update" label (Fig 1) and attach it to the ECM. Cover the label with clear tape.

12.   Type or print the following information on the Authorized Modification Label and attach the label near the VECI label (Fig 2).

 

Notes:

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No: 08-19-47-99 ................. 0.5 Hrs.

FAILURE CODE: FM - Flash Module


Thanks to Bob Bergevin and Barry Drodge for supplying this TSB information

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This page was edited on: May 3, 2004