| DodgeRam.info > TSB's > 18-033-07 REV. B |
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Date: June 28, 2007
StarSCAN FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET.
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-033-07 REV. A, DATED JUNE 12, 2007 (Rev A Spereseded TSB 18-033-07 dated May 16, 2007), WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION.
Models: 2007 (DH/D1) Ram Truck (2500 & 3500)
NOTE: This bulletin applies to Ram Truck 2500 & 3500 vehicles equipped with 6.7L Cummins turbo-diesel engine (sales code ETJ) built on or before June 11, 2007 (MDH 0611XX).
Overview:
This bulletin involves selectively erasing and reprogramming the Powertrain
Control Module (PCM) with "bootloader" software and application software.
CAUTION: A special "bootloader" software with special reprogramming (flash) procedures must be installed in the PCM before the application software. Once the "bootloader" software has been successfully installed (flashed) in the PCM, then the application software can be reprogrammed (flashed) into the PCM.
Symptom/Condition:
The vehicle operator and/or technician may experience one or more of the following
conditions and/or enhancements:
1. The technician may not be able to reprogram (flash) the PCM with new application software.
2. The vehicle may fail an Emission Inspection Maintenance (I/M) Test because
two or
more On-Board Diagnostic (OBD) monitors report that they are not ready for testing.
This condition may cause the customer vehicle to not pass an Emissions JIM test.
The
following is a list of OBD Monitors that may report as not ready for testing:
a. Non-Methane Hydrocarbon (NMHC) Catalyst Monitor.
b. Nitrogen Oxide (NOx) Absorber Monitor.
c. Exhaust Gas Temperature Sensor Monitor.
d. Electrical Charging System Monitor.
9. EGR System Monitor.
f. Oxygen Sensor Monitor.
3. After extensive idling of the vehicle engine or if an intake air leek is
present, the
vehicle operator may experience a MIL illumination and/or an Electronic Vehicle
Information Center (EVIC) message alert due to one or more of the following
DTC'S:
a. P1451 - Diesel Particulate Filter System Performance.
b. P2463 - Diesel Particulate Filter - Soot Accumulation.
c. P242F - Diesel Particulate Filter Restriction - Ash Accumulation.
4. The vehicle operator may experience a MIL illumination due to one of the
following DTC'S.
a. P0106 - Manifold Absolute Pressure Sensor Performance.
b. P242B - Exhaust Gas Temperature Sensor Circuit Performance
- Bank 1 Sensor 3.
c. P245A - EGR Cooler By-Pass Control Circuit - Open.
5. An intermittent rough engine idle and/or white smoke following initial engine start.
6. A throttle tip-in stumble at engine speeds of 1,300 to 2,100 rpm.
7. An engine hesitation at altitude of 5,000 feet between engine speeds of 1,200 to 1,600 rpm.
8. A turbocharger "chuff-like" sound during rapid deceleration.
Diagnosis:
1 .Connect the StarSCAN to the vehicle Diagnostic Link Connector
(DLC).
2. From the "Home" menu, select:
a. "ECU View".
b. "PCM Powertrain Control Module".
c. "View DTC's".
3. Record DTC's that are present in the PCM.
4. Is DTC P242F present?
a. If YES >>> then STOP. Contact STAR for additional
technical assistance.
b. If NO >>> then proceed to the next step.
5. Are either (or both) DTC P1451 or P2463 present?
a. If YES >>> then Section C - Exhaust System Aftertreatment
Regeneration must be
performed AFTER Sections A and B
(reprogramming the PCM for bootioader and
application software) of the Repair
Procedure have been completed. Read the
following Cautions and Notes, then
proceed to Section A of the Repair Procedure.
b. If NO >>> then Section C - Exhaust System Aftertreatrnent
Regeneration should
NOT be performed. Read the following
Cautions and Notes, then perform only
Sections A and B of the Repair Procedure.
CAUTION: Before the application software can be reprogrammed (flashed) into the Powertrain Control Module (PCM), the PCM must first be reprogrammed (flashed) with "bootloader" software. Failure to reprogram the PCM with the "bootloader" software first, may cause the process of reprogramming the PCM with the application software to fail. The PCM "bootloader" software special flash procedures must be followed closely to prevent damage to the PCM.
CAUTION: The Repair Procedure involves a special and different reprogramming
(flash) procedure for "bootloader" software. Follow the Repair Procedure
steps. When performing the "bootloader" section of the Repair
Procedure DO NOT interrupt the PCM reprogramming session. This special PCM "bootloader"
software reprogramming session does not support "abort - recovery"
mode. If "bootloader" software
reprogramming is interrupted the PCM will be permanently disabled, and will
require replacement.
NOTE: The Repair Procedure should not be performed using the StarMOBILE in
its STANDALONE mode. Use the StarSCAN to perform the entire Repair Procedure.
NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen.
Parts Required:
| Qty. | Part No. | Description |
| 1 | 04275086AB | Label, Authorized Modification |
| DSLFUELS | Fuel Allowance (4 gallon maximum) - Allowed only if an exhaust system rnanual aftertreatment regeneration is required. |
Special Tools/Equipment Required:
| NPN | Battery Charger |
| CH9401 | StarSCAN® Tool |
| CH9404 | StarSCAN® Vehicle Cable |
| CH9409 | StarSCAN® Documentation Kit |
| CH9410 | StarSCAN® Ethernet Cable, 12 ft. |
| CH9412 | StarSCAN® Software Update Device Kit |
| TechCONNECT PC or equivalent |
Repair Procedure:
A). REPROGRAMMING (FLASH) PCM WITH NEW "BOOTLOADER" SOFTWARE:
CAUTION: Before the application software can be reprogrammed (flashed) into the Powertrain Control Module (PCM), the PCM must first be reprogrammed (flashed) with "bootloader" software. Failure to reprogram the PCM with the "bootloader" software first, may cause the process of reprogramming the PCM with the application software to fail. The PCM "bootloader" software special flash procedures must be followed closely to prevent damage to the PCM.
CAUTION: The Repair Procedure involves a special and different reprogramming (flash) procedure for "bootloader" software. Follow the Repair Procedure steps. When performing the "bootloader" section of the Repair Procedure DO NOT interrupt the PCM reprogramming session. This special PCM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software reprogramming is interrupted the PCM will be permanently disabled, and will require replacement.
NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN must be programmed with software release level 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen.
NOTE: The Repair Procedure currently can not be performed using the StarMOBILE in its STANDALONE mode. Use the StarSCAN to perform the Repair Procedure.
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".
| 1. | Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 1 3.5 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. | Turn the ignition switch to the 'ON/RUN" position. |
| 5. | Power ON the StarSCAN. |
| 6. | Verify that the StarSCAN is at software release 8.01 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. |
| 7. | Erase all flash files from the StarSCAN. From the StarSCAN "Home"
screen: a. Select "Show Short Cuts". b. Select "Tool Menu"'. c. Select "Manage Files". d. Select "More Options. e. Select "Delete All". f. Select "Yes" at the "About to delete all user files. Are you sure you want to continue?" screen. g. Select "OK" at "All user files have been removed' screen. h. Select "Back" at "User's Files' menu. |
| 8. | Obtain PCM Bootloader software file and download to Scantool: a. Select "ECU View". b. Touch the StarSCAN screen to highlight the ECU (PCM) in the list of modules. c. Select "More Options". d. Select "ECU Flash". e. Record part number of new application software in PCM. f. Select "Browse for New File". g. Select "OK" at the Flash Download screen h. Select "OK" at password i. Select "Finish" j. Highlight the PCM Bootloader software file. The bootloader file will have the letters "BT",in the last two digits (suffix) of its part number. DO NOT select the Application software file (which will have the letters "AT"' or higher suffix in the last two digits of its part number). k. Select "Download to Scantool". 1. Select "'Back" one (1) time. |
| CAUTION: When performing the "bootloader" section of the Repair Procedure DO NOT interrupt the PCM reprogramming session. This special PCM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software reprogramming is interrupted the PCM will be permanently disabled, and will require replacement. | |
| NOTE: Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.). | |
| 9. | Reprogram PCM - Download Bootloader software from ScanTool to vehicle
PCM: a. Highlight Bootloader software selected previously. The bootloader file will have the letters "BT" in the last two digits (suffix) of its part number. b. Select "Update Controller". c. Select "OK" at ECU Flash. d. Wait until the PCM bootloader software flash is complete. Once complete: e. Select "OK" at the Flash Update Successful screen. f. Select "Back" three (3) times to return to the "ECU View" Screen. |
| CAUTION: The following steps must be performed as directed. | |
| 10. | At the "ECU View" screen, turn the ignition switch to the "OFF' position. |
| 11. | Remove the ignition key from the ignition switch. |
| 12. | WAIT TWO (2) MINUTES. |
| 13. | Install the ignition key in the ignition switch. |
| 14. | Turn the ignition switch to the "ON/RUN" position. |
| 15. | Confirm PCM has now Bootloader software. From "ECU View" screen: a. Touch the StarSCAN screen to highlight the ECU (PCM) in the list of modules. b. Select "More Options". c. Select "ECU Flash". d. Confirm that the available Bootloader software file matches the resident flash file in the PCM. |
| 16. | Erase Bootloader software file from the StarSCAN. From the "ECU Flash"
screen: a. Select "Manage Files". b. Highlight the Bootloader software file in the StarSCAN memory. c. Select "Delete". d. Select "Yes" at the "Are you sure you want to delete the ECU flash file (bootloader file) name?" screen. e. Select "Back" at the "Manage Files" menu. |
| 17. | Proceed to: Section B - Reprogramming (Flash) PCM With New Application Software. |
B). REPROGRAMMING (FLASH) PCM WITH NEW APPLICATION SOFTWARE:
CAUTION: Before the application software can be reprogrammed (flashed) Into the Powertrain Control Module (PCM), the PCM must first be reprogrammed (flashed) with "Bootloader" software. Failure to reprogram the PCM with the "bootloader" software first, may cause the process of reprogramming the PCM with the application software to fall.
| 1. | Obtain PCM Application software file and download to Scantool: a. Select "Browse For New File". b. Select "OK" at the Flash Download screen. c. Select "Finish" at Flash Update screen display download results. d. Select the Application software file. The Application software file will have the letters "AT" or higher in the last two digits (suffix) of its part number. DO NOT select the Bootloader software file which has the letters "BT" in the last two digits (suffix) of its part number. e. Highlight the Application software file for download from the Web to StarSCAN. f. Select "Download to Scantool". g. Select "Close" at the Download file screen. When the Application file download from Web to StarSCAN is complete then: h. Select "Back"' one (1) time. |
||
| 2. | Reprogram PCM with new Application software from Scantool: a. Highlight the Application software file for download from StarSCAN to PCM. b. Select "Update Controller"'. c. Select 'OK" at ECU Flash screen. d. Wait for file download to PCM to complete. e. Select "OK" at the Flash ECU Successful screen. |
||
| 3. | Verify that the highlighted Application software file part number matches
the resident (application) flash file part number. a. Select "Back" four (4) times to return to the Home screen. b. Turn the ignition switch to the "OFF" position. WAIT 10 seconds. |
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| NOTE: Due to the ECU (PCM) programming procedure, a DTC may be set in other electronic modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. | |||
| 4. | Clear all DTC'S. At the Horne screen: a. Turn the ignition switch to the "ON/RUN" position. Do Not start vehicle engine. b. Select "System View". c. Select "All DTC's". d. Select "Clear All Stored DTC's". e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position. WAIT 10 seconds. g. Start the vehicle engine to verify that all DTC's have been erased. h. Stop the vehicle engine. Turn the ignition switch to the "OFF" position |
||
| NOTE: The following step is required by law when reprogramming a PCM and/or TCM. | |||
| 5. | Type the necessary information an the "Authorized Modification Label"
p/n 04275086AB and attach near the VECI label (Fig. 1). |
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C). EXHAUST SYSTEM AFTERTREATMENT REGENERATION - TO DESOOT:
NOTE: Perform an Exhaust System Aftertreatment Regeneration ONLY if DTC P1451 or P2463 are present. If DTC P242F is present then contact STAR for additional technical assistance.
Verify that the exhaust system aftertreatment is capable of regeneration:
| 1. | If not already connected, connect the StarSCAN to the vehicle Diagnostic
Link Connector (DLC). |
| 2. | Was DTC P242F present at the start of the Repair Procedure? a. If YES >>> then STOP. Contact STAR for additional technical assistance. b. If NO >>> then proceed to the next step. |
| 3. | Were either (or both) DTC P1451 or P2463 present at the start of the Repair
Procedure? a. If YES >>> then Section C - Exhaust System Aftertreatment Regeneration MUST BE performed. Proceed to the next step. b. If NO >>> then STOP. With no DTC present, then Section C - Exhaust System Aftertreatrnent Regeneration SHOULD NOT BE performed. |
| Vehicle engine set-up procedure to enable a manual (forced) aftertreatment regeneration: | |
| 1. | Turn the ignition switch to the "ON/RUN" position. DO NOT start the engine at this time. |
| 2. | From the "Home" screen on the StarSCAN: a. Select the "ECU View" button. b. Select the "PCM Powertrain Control Module" button. c. Select the "Misc. Functions" button. Wait while the StarSCAN enters the Miscellaneous Functions screen. d. Select/highlight "Reset Regenerative Filter Timers", and select the "START" button, e. Once in the "Reset Regenerative Filter Timers" screen select: the "NEXT" button, | then select the "FINISH" button. f. Turn the ignition switch to the "OFF" position and WAIT 10 seconds. |
| NOTE: It is IMPORTANT to turn the ignition switch to the "OFF"
position and WAIT 10 seconds. This will allow the PCM to reset. |
|
| 3. | Start the vehicle engine and allow to idle. The vehicle engine must be
running before proceeding further. |
| 4. | From the "Miscellaneous Functions" screen, scroll to and then
select: a. "Mobile DeSoot - NO Minimum Required Soot Load". Look closely and make sure you have selected the correct function. b. Select the "START" button. c. Once in the "Mobile DeSoot - NO Minimum Required Soot Load" screen, select the "NEXT" button, then select the "FINISH" button. |
| 5. | The vehicle engine set-up for manual aftertreatment regeneration mode
is now set and ready for the vehicle regen road drive. |
| NOTE: If the above screen displays "Mobile DeSoot - NO
Minimum Required Soot Load enabling failed. Please retry or exit", verify that the engine was started prior to entering the Mobile DeSoot screen |
|
| Aftertreatment Regeneration Road Drive: | |
| 1. | Page back one time to the "PCM Powertrain Control Module" screen. Select the "Data Display" button. |
| 2. | Once in the 'Data Display" screen: a. Select/highlight "PT/Combustion Manager interface Mode", and then select "Add To Graph". b. Select/highlight "Exhaust Gas Temp Sensor 3" in degrees F, and then select "Add To Graph". c. Select the "Show Graph" button. |
| 3. | The manual aftertreatment regeneration process for DeSoot will stop if
one of the following occurs: a. Ignition switch is turned to the "OFF" position. b. Transmission is in PARK. c. A door is opened when at a stop. d. The parking brake is set when the transmission is in neutral. e. Exhaust temperature is below 525F. f. Certain diagnostic trouble codes (DTC's) are present. |
| 4. | Drive the vehicle at highway speed, between 50 to 60 mph (preferred),
and monitor the "PT/Combustion Manager Interface Mode" and the "Exhaust Gas Temp Sensor 3" values. Note the gradual increase in exhaust temperature. DO NOT stop the engine during the manual regen road drive. The vehicle may come to a stop and engine may idle during the manual regen road drive without significant impact to the aftertrestrnent regeneration process, other then extending the time it will take to complete a full regeneration of the aftertreatment system. Too much extended idling or stopping will cause exhaust temperature to drop 525F, which may cause the manual regen process to stop. |
| NOTE: The data value will not change from "Normal" to "DeSoot" until the appropriate exhaust temperatures and/or vehicle speed are achieved. | |
| NOTE: Driving the vehicle at highway speeds between 50 to 50 mph is the ideal environment to allow maximum DeSoot to occur in the quickest amount of time. The manual regan road drive time will vary due to several parameters and your driving environment. DeSoot will occur at other vehicle speeds, but may take longer to complete. The vehicle may come to a stop, with the engine at idle, and the aftertreatment regeneration process for DeSoot may continue to occur (at a slower rate), as long as the exhaust temperature remains above 525F. | |
| 5. | Use the StarSCAN graph to monitor the progress of the manual aftertreatment regeneration process for DeSoot. |
| 6. | When the "PT/Combustion Manager Interface Mode" no longer enters DeSoct Mode, and instead remains in the "Normal" or "DeNOx" modes, then the manual aftertreatment regeneration process for DeSoot is complete. You will also notice a decrease in exhaust temperature. |
| 7. | When the road drive is complete and the vehicle has returned to the dealership, stop the vehicle engine. |
| 8. | Clear all DTC'S. At the "HOME" screen of the StarSCAN: a. Turn the ignition switch to the "ON/RUN" position. Do not start vehicle engine. b. Select "System View". c. Select "All DTC's'. d. Select "'Clear All Stored DTC's"'. e. Select "Yes" at the confirm screen. f. Turn the ignition switch to the "OFF" position. WAIT 10 seconds. g. Start the vehicle engine to verify that all DTC's have been erased. h. Stop the vehicle engine. Turn the ignition switch to the "OFF" position. |
Policy: Reimbursable within the provisions of the warranty.
Time Allowance:
| Labor Operation No: | Description | Amount |
| 18-19-04-35 | Module, Powertrain Control (PCM) Cummins - Reprogram w/Bootloader and Application Software Files (B) |
0.7 Hrs. |
| 11-50-02-90 | Additional Operation (as required): Exhaust System After Treatment Regeneration for 6.7L Cummins (B) |
1.2 Hrs. |
Failure Code:
| ZZ | Service Action |
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. |
This page was edited on: July 31, 2007
