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TSB 18-007-03 Rev D

Generic Powertrain Control Module (PCM) Procedure

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Date: September 5, 2003

This bulletin supersedes TSB 18-007-03 Rev C

Models: 2004 (DR) Ram Truck

2004             (AN) Dakota
2004             (CS) Pacifica
2004             (DR) Ram Truck
2004             (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan
2004             (KJ) Liberty
2004             (KJ) Cherokee (International Markets)
2002 - 2004  (LH) 300M/Concorde/Intrepid
2004             (PL) Neon/SX 2.0
2004             (PT) PT Cruiser
2004             (RG) Chrysler Voyager (international Markets)
2004             (RS) Town & Country/ Caravan/Voyager

NOTE. Refer to the following table for specific applications.

Model Engine Transmission
AN 3.7L or 4.7L Auto or Man
CS 3.5L Auto
DR 3.7L, 4.7L, or 5.7L Auto or Man
JR 2.0L, 2.4L, 2.4L Turbo, or 2.7L Auto or Man
KJ 2.4L or 3.7L Auto or Man
LH All Auto
PL 2.0L, 2.4L, or 2.4L Turbo Auto or Man
PT 2.0L, 2.4L, or 2.4L Turbo Auto or Man
RG 2.4L or 3.3L Auto or Man
RS 2.4L, 3.3L or 3.8L Auto

Overview:
This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software.

Discussion:
Mopar is currently phasing out pre-programmed PCMs for the vehicles listed. Now modules will no longer be pre-programmed when received from Mopar. Replacement of future PCMs will require programming utilizing the DRBIII and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed".

CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration version is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of the same released calibration.

Parts Required:
Qty. Part No. Description
1 05127196AA Kit, Generic Powertrain Control Module, All LH vehicles and CS built on or before July 11, 2003 with a VIN sequence of 4R499999 or lower.
1 05134856AA Generic Powertrain Control Module, CS built on or after July 12, 2003 with a VIN sequence of 4R500000 or higher
1 05033290AD Generic Powertrain Control Module, PT Vehicles
with a 2.4L or 2.4L Turbo with Manual Transmission
1 05033291AD Generic Powertrain Control Module, PT Vehicles
with a 2.4L with Automatic Transmission
1 05033292AD Generic Powertrain Control Module, PT Vehicles
with a 2.4L Turbo with Automatic Transmission
1 04896304AD Generic Powertrain Control Module, JR Vehicles
with a 2.0L or 2.4L with Manual Transmission
1 04896302AD

Generic Powertrain Control Module, JR Vehicles
with a 2.7L with Automatic Transmission
1 05134852AA Generic Powertrain Control Module, PL Vehicles
with 2.0L, 2.4L with Manual Transmission
1 05134853AA Generic Powertrain Control Module, PL, SRT-4 Vehicles
with 2.4L Turbo with Manual Transmission
1 05134854AA Generic Powertrain Control Module, RG Vehicles
with 2.4L with Manual Transmission
1 05134855AA Generic Powertrain Control Module, RG/RS Vehicles
with 2.4L with Automatic Transmission
1 56028796AD Generic Powertrain Control Module, AN/DR Vehicles
with 4.7L with Automatic Transmission
1 05134857AA Generic Powertrain Control Module, RG/RS Vehicles
with 3.3L or 3.8L with Automatic Transmission
1 04896301AD Generic Powertrain Control Module, JR Vehicles
with 2.0L or 2.4L with Automatic Transmission
1 05134858AA Generic Powertrain Control Module, PL Vehicles
with 2.0L or 2.4L with Automatic Transmission
1 04606819AD Generic Powertrain Control Module, JR Vehicles
with 2.4L Turbo with Automatic Transmission
1 56044396AD Generic Powertrain Control Module, KJ Vehicles
with 3.7L with Automatic Transmission
1 56044397AD Generic Powertrain Control Module, KJ Vehicles
with 2.4L or 3.7L with Manual Transmission
1 56028806AD Generic Powertrain Control Module, AN/DR Vehicles
with 3.7L with Automatic Transmission
1 56028796AD Generic Powertrain Control Module, AN/DR Vehicles
with 4.7L with Automatic Transmission
1 56028800AD Generic Powertrain Control Module, AN/DR Vehicles
with 5.7L with Automatic Transmission
1 56028805AD Generic Powertrain Control Module, AN/DR Vehicles
with 3.7L with Manual Transmission
1 56028797AD Generic Powertrain Control Module, AN/DR Vehicles
with 4.7L with Manual Transmission
1 56028799AD Generic Powertrain Control Module, AN/DR Vehicles
with 5.7L with Manual Transmission
1 04669020 Label, Authorized Software Update

Special Tools/Equipment Required:
NPN     Battery Charger
CH2002 General Purpose Interface Bus Cable Assembly
CH6000A Scan--Tool (DRBIII)
CH7000A/7001A J1962 Cable with red DRBIII connector
  TechCONNECT Workstation

NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII connection. Use this cable whenever a flash is being performed.

Repair Procedure:

NOTE: Whenever a controller Is programmed, the software in the DRBIII must be programmed with the latest revision level available.

NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII.
1.     

With the ignition switch in the "RUN" position, determine and record the "ECM part number of the ECM currently in the vehicle. Using the DRBIII select:

a.    "DRBIII Standalone"
b. "1998 - 2004 Diagnostics"
c. "All (Except Below)"
d. "Engine"
e. "Module Display"
f. Record the first (10) characters of the "PCM part number, on the repair order for later reference.
NOTE: If the PCM is not operational, the "PCM part number" can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step.
2. Page back to the "Main Menu'
3.

Determine it the vehicle is equipped with SKIM. Using the DRBIII select:

a.    "DRBIII Standalone"
b. "1998 - 2004 Diagnostics"
c. "All"
d. "System Monitor"
e. "J1850 Module Scan"
f. Look for 'SKIM" in the list of modules.
4.

If the vehicle is not equipped with SKIM then proceed to step 5. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 5. This information is available from:

a.    The original selling invoice.
b. The DealerCONNECT system under the 'Sales" or "Parts" tabs - select "Key Codes".
c. By contacting the DaimlerChrysler customer Assistance Center (DCCAC) at 1-800-992-1997.
CAUTION: Failure to install the SKIM pin number into the module after flashing the module will cause a start and stall condition.
5. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation.
6. Open the hood, install a battery charger and verify battery state is above 11.5 volts.
7. If the old PCM part number is known, proceed to step13. If the old PCM part number is not known, proceed to the next step.
8. On DealerCONNECT select the "Service" tab.
9. Select "Vehicle Information Plus".
10. Manually enter the VIN and mileage and select "Enter".
11. Select the "Vehicle Option" tab.
12.

Under the "Vehicle Option' window, identify and record:

a.    Engine.
b. Emissions (Federal or California).
c. Transmission (Automatic, 5-speed manual, etc.).
13. Connect the DRBIII to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII Status: Connected" message is in the upper right corner of the TechTOOLS screen.
14. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria" area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates.
15.

Determine the proper calibration:

a.    If the old "PCM part number" is known, enter the part number of the old controller in the "Parts Criteria" p/n window. Proceed to step 16.
b. If the old "PCM part number" is not known, select the correct calibration based on the information that was recorded from "Vehicle Options in step 12.
16. Select the correct calibration.
17. Select the "Download/Update" button.
18. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII. When the flash process is complete, proceed to the next step.
19.

Enter the VIN in the PCM. Using the DRBIII select:

a.    "DRBIII Standalone"
b. "1998 - 2004 Diagnostics"
c. "All (Except Below)"
d. "Engine"
e. "Miscellaneous"
f. "Check VIN"
g. If the vehicle is not equipped with SKIM proceed to step 18h. If the vehicle is equipped with SKIM follow the directions on the DRBIII. When the VIN and SKIM key has been programmed, proceed to step 20.
h. Enter the VIN as requested by the DRBIII
20.

Update the PCM mileage. Using the DRBIII select:

a.    "DRBIII Standalone"
b. "1998 - 2004 Diagnostics"
c. "All (Except Below)"
d. "Engine"
e. "Miscellaneous"
f. "Check PCM Odometer"
g. "NO"
h. Enter the current odometer mileage and press "Enter"
i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter".
21.

Proceed as follows:

a.    If the vehicle is equipped with an automatic transmission, proceed to step 23.
b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24.
c. If the vehicle is equipped with a turbo engine and manual transmission, proceed to step 22.
22.

On vehicles equipped with a turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII select:

a.    "DRBIII Standalone"
b. "1998 - 2004 Diagnostics"
c. "All (Except Below)"
d. "Engine"
e. "Miscellaneous"
f. "Pinion Factor"
g. Select the correct tire size and then "Page Back" to exit.
h. Proceed to step 24.
23.

On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII select:

a.    "DRBIII Standalone"
b. "1998 - 2004 Diagnostics"
c. "All (Except Below)"
d. "Transmission"
e. "Transmission Module"
f. "Miscellaneous"
g. "Pinion Factor"
h. Select the correct tire size and then "Page Back" to exit.
i. Enter "Quick Learn" and then follow the instructions on the DRBIII.
NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC'S, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased.
NOTE: The following step is required by law.
24.

Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:

Labor Operation No:   Description Amount
08-19-06-94 Replace Powertrain Control Module with Generic and Reprogram With New Software 0.9 Hrs.

Failure Code:

DR        Controller Internal Fault

I would like to thank Bob Bergevin, Arthur Cantrall, Barry Drodge, David Lovell, Bill Maurits, and Steve for supplying the information for these bulletins. And a big thank you goes to Geno's Garage for making DodgeRam.info possible.
 

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This page was edited on: May 3, 2004