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TSB 18-033-04

Generic Cummins Engine Control Module (ECM) Procedure

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Date: August 20, 2004

THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-030-03 REV. A DATED OCTOBER 17, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES.

THE DRBIII FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT.

FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD OCTOBER, 2004.

Models: 1998.5-2005 (BR/BE, DH/DR) Ram Truck

1998 1/2 - 2002 (BE/BR) Ram Truck
2003 - 2005       (DH/DR) Ram Truck

NOTE: This bulletin applies to all ram trucks equipped with the 5.9L Cummins 24-valve diesel engine (sales codes ETC or ETH).

Overview:
This bulletin involves programming a generic Cummins ECM with software

Discussion:
Mopar is phasing out pre-programmed Cummins Diesel Engine Control Modules (ECM). New modules will no longer be preprogrammed when received from Mopar. Replacement of future ECM's will require programming utilizing the DRBIII and TechCONNECT. 1998 1/2 - 2002 modules will cause the "Wait to Start" light to flash, indicating the module has not been programmed.

CAUTION: Extreme care must be taken when changing the calibration of an unprogrammed ECM. Do not randomly select a calibration. If in doubt, contact the STAR Center for assistance. Installing an incorrect calibration into an ECM can cause severe engine damage. 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	Application
1	R5083996AA	Re-Man Module, Engine Controller	1998 1/2 - 1999
1	R5083997AA	Re-Man Module, Engine Controller	2000 - 2002
1	05083997AA	New Module, Engine Controller	2000 - 2002
1	R5086154AB	Re-Man Module, Engine Controller	2003
1	05086154AB	New Module, Engine Controller	2003
1	05086155AB	New Module, Engine Controller	2004 - Automatic Trans. Built on or before Dec. 10, 2003
1	R5086155AB	Re-Man Module, Engine Controller	2004 - Automatic Trans. Built on or before Dec. 10, 2003
1	05086172AB	New Module, Engine Controller	2004 - Manual Trans. Built on or before Dec. 10, 2003
1	R5086172AB	Re-Man Module, Engine Controller	2004 - Manual Trans. Built on or before Dec. 10, 2003
1	05137543AB	New Module, Engine Controller	2004 - Automatic Trans Built on or after Dec. 11, 2003
1	R5137543AB	Re-Man Module, Engine Controller	2004 - Automatic Trans Built on or after Dec. 11, 2003
1	05086173AC	New Module, Engine Controller	2004 - Manual Trans Built on or after Dec. 11, 2003
1	R5086173AC	Re-Man Module, Engine Controller	2004 - Manual Trans Built on or after Dec. 11, 2003
1	05135591AA	New Module, Engine Controller	2005 - Automatic Trans
1	R5135591AA	Re-Man Module, Engine Controller	2005 - Automatic Trans
1	05135590AA	New Module, Engine Controller	2005 - Manual Trans
1	5135590AA	Re-Man Module, Engine Controller	2005 - Manual Trans

Special Tools/Equipment Required:

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.	Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII memory. To clear the memory from the MAIN MENU power up the DRBIII and then: a.    Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. the DRBIII reboots to the MAIN MENU, proceed to Step #2
2.	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 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. On 1998 1/2 - 2003 vehicles, select "Cummins". 2004 and later vehicles, proceed to next step. f. "Module Display" g. Record the "ECM part number, on the repair order for later reference.
NOTE: If the ECM is not operational, the "ECM part number" can be obtained from the label on the controller. For 1998 1/2 - 2002 vehicles, if the label on the controller is not legible, proceed to next step. For 2003 and later vehicles, if the label on the controller is not legible, record the "Reference No." for use later. The "Reference No." is located In the Reference No. box at the top, center of the Engine Data Plate (Fig. 1). Do not use the reference number shown in the figure below. The Engine Data Plate is located on the intake side of the breather cover or affixed to the APPS bracket.
Fig- 1 ENGINE DATA PLATE (2003 AND LATER SHOWN)                    1 - Reference No.
3.	Page back to the "Main Menu'
4.	Determine it the vehicle is equipped with SKIM. Using the DRBIII select: a.    "DRBIII Standalone" b. "1998 - 2005 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for 'SKIM" in the list of modules.
5.	If the vehicle is not equipped with SKIM then proceed to STEP 6. 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 District Manager.
CAUTION: Failure to install the SKIM pin number into the module after flashing the Cummins ECM will cause a start and stall condition.
6.	Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts.
7.	If the old "ECM part number" is known, or for 2003 and later vehicles, proceed to STEP #14. On 1998 1/2 - 2002 vehicles, it the old "ECM part number" is not known, proceed to next step.
8.	On DealerCONNECT select the "Service" tab.
9.	Select "Vehicle Information Plus".
10.	Select "Single VIN inquiry.
11.	Manually enter the VIN and mileage and select "Enter".
12.	Select the "Vehicle Option" tab.
13.	Under the "Vehicle Option' window, identify and record: a.    Engine (sales code and description). b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.).
NOTE: When reprogramming a Cummins ECM be sure to do the following: Download the flash from TechCONNECT to the DRBIII with the DRBIII disconnected from the vehicle. Download the flash from the DRBIII to the vehicle with the DRBIIII disconnected from TechCONNECT.
14.	Connect the DRBIII to TechCONNECT, Open TechTOOLS and verify that the "DRBIII Status: Connected" message is in the upper right corner of the TechTOOLS screen.
15.	Enter the old Cummins "ECM part number" obtained from the DRBIII in STEP #2 into the "Parts Criteria" window.
16.	Select "Show Updates".
17.	Highlight the proper calibration from the list: a.    If the old "ECM part number" is known, highlight the calibration in the list, based on the old "ECM part number" recorded earlier STEP #2. b. For 1998 1/2 - 2002, if the old "ECM part number" is not known, highlight the correct calibration based on the information that was recorded from "Vehicle Options STEP #13. c. For 2003 and later, if the old part number is not known, highlight the proper calibration based on the Reference No. located in the "Ref. No." box, at the top, center of the Engine Data Plate (Fig. 1).
18.	Select the "DRBIII" radio button which is next to the "Download/Update" button.
19.	Select the "Download/Update" button.
20.	Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to the next step.
21.	Disconnect the DRBIII from TechCONNECT
22.	Connect the DRBIII to the vehicle.
23.	Download the flash from the DRBIII to the vehicle. Using the DRBIII select: a.    "Vehicle Flash" b. Follow the directions on the DRBIII screen. When the flash process is complete, proceed to the next step.
24.	It the vehicle is equipped with SKIM, proceed to STEP #25. If the vehicle is not equipped with SKIM, proceed to STEP #26.
25.	On vehicles equipped with SKIM, transfer the VIN and Security Key information from the SKIM to the ECM. Using the DRBIII select: a.    "DRBIII Standalone" b. "1998 - 2005 Diagnostics" c. "All" d. "Theft Alarm" e. "SKIM" f. "Miscellaneous" g. "Cummins ECM Replaced" h. Follow the directions on the DRBIII screen. When the process is complete, proceed to STEP #27.
26	On vehicles not equipped with SKIM, manually enter the VIN in the ECM. Using the DRBIII select: a.    "DRBIII Standalone" b. "1998 - 2005 Diagnostics" c. "All" d. "Engine" e. "Cummins Controller (ECM/ENGINE)" f. "Miscellaneous" g. "CM84X Check VIN" h. Follow the directions on the DRBIII screen. When the process is complete, proceed to next step.
NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (PCM, 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.
26.	Type the necessary information on the 'Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). 1 - CUMMINS ENGINE CONTROL MODULE P/N (INSERT P/N) USED 2 - CHANGE AUTHORITY: TSB XX-XX-XX 3 - DEALER CODE: XXXXX 4 - DATE: XX-XX-XX

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:
Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual.

This page was edited on: May 3, 2004