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TSB 18-027-07

Flash: MIL Illumination Due To EGR Position Sensor DTC - P0404, P0405, or P0406

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Date: April 17, 2007  

Models: 2006 - 2007 (DR) Ram Truck (1500)

2006 - 2007 (DR) Ram Truck (1500)
2006 - 2007 (HB / HG) Durango / Aspen
2006 - 2007 (LX/LE) 300 / Magnum I Charger
2006 - 2007 (WK WH) Grand Cherokee
2006 - 2007 (XK XH) Commander

NOTE: This bulletin applies to vehicles equipped with a 5.7L engine with MDS
(sales code EZB) built on or before February 15, 2007 (MDH 0215XX).

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

Symptom/Condition:
The vehicle operator may experience a Malfunction Indicator Lamp (MIL) illumination
due to one or more of the following Diagnostic Trouble Codes (DTC):

P0404 - EGR Position Sensor Performance
P0405 - EGR Position Sensor Circuit Low
P0406 - EGR Position Sensor Circuit High

Diagnosis:
Using a Scan Tool (StarSCAN) with the appropriate Diagnostic Procedures
available in TechCONNECT, verify all engine systems are functioning as designed.
If DTC's are present record them on the repair order and repair as necessary before
proceeding further with this bulletin.

If the vehicle operator describes or experiences the Symptom/Condition,
perform the Repair Procedure.

Parts Required:

Qty.	Part No.	Description
1	04275086AB	Label, Authorized Modification

Special Tools/Equipment Required:

Repair Procedure: 

REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE:

NOTE: Before performing this Repair Procedure, the operating software in the
StarSCAN must be programmed with software release level 7.03 SPI or higher.
The software release level is visible in the blue header at the top of the StarSCAN screen.

NOTE: The StarSCAN diagnostic scan tool fully supports Internet connectivity. However,
to take advantage of this feature you must first configure the StarSCAN for your dealership's
network. Make sure the StarSCAN is configured to the dealership's network before
proceeding. For instruction on setting up your StarSCAN for the dealer's network refer
to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online
Documentation", or refer to the StarSCAN Quick Start Networking Guide. The StarSCAN
Quick Start Networking Guide is also available on the www.dcctools.com website under
the "Download Center".

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

1.	Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete.
NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process.
2.	Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop.
3.	Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle.
4.	Power ON the StarSCAN.
5.	Retrieve the old ECU part number. Using the StarSCAN at the "Home" screen:     a. Select "ECU View"     b. Touch the screen to highlight the PCM in the list of modules.     c. Select "More Options".     d. Select "ECU Flash".     e. Record the part number at the top of the "Flash PCM" screen for later reference.     f. Select "Browse for New File". Follow the on screen instructions.     g. Select "Download to Scantool".     h. Select "Close" after the download is complete, then select "Back".     i. Highlight the listed calibration.     j. Select "Update Controller".     k. When the update is complete ,select "OK".
NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View,". Then select "All DTCS". Press "Clear All Stored DTCS" if there are any DTCs shown on the list.
NOTE- The following step is required by law when reprogramming a PCM and/or TCM.
6.	Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1).
	FIGURE 1 - AUTHORIZED MODIFICATION LABEL 1 - POWERTRAIN CONTROL MODULE P/N (INSERT P/N) USED 2 - CHANGE AUTHORITY: TSB XX-XXX-XX 3 - DEALER CODE: XXXXX 4 - DATE: XX-XX-XX

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:

Failure Code:

This page was edited on: February 28, 2008