California Emissions Recall # 893

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Date: September 2000

Models:

2001 (BE) Dodge Ram Truck

NOTE: This recall applies only to the above vehicles equipped with a 5.9L engine ("Z" in the 8th VIN position), an automatic transmission and a California emission control system (sales code NAE) built through February 17, 2000 (MDH 0217XX).

IMPORTANT: Some of the vehicles may be in dealer inventory. Federal law requires completion of this recall on these vehicles before delivery. This also applies to all applicable used vehicles in inventory, and vehicles brought in for service.

Subject:

About 1,250 of the above trucks were built with an incorrect Powertrain Control Module (PCM). This does not comply with Federal and California emission regulations.

Parts Information:

Each dealer to whom vehicles in the recall were invoiced (or the current dealer at the same street address) will receive enough Powertrain Control Modules to service about 25% of those vehicles.

Repair:

A.  Inspect the PCM:

1. Locate the PCM on the right (passenger) side of the dash panel (Figure 1).

2. Locate the part number on the original PCM (Figure 2).

 > 4WD vehicles involved in this recall require PCM part number 56029552AA. If the original PCM part number is 56028551AB, install a new PCM with part number 56029552AA. Continue with Section B - Replace the PCM. If the original PCM part number is 56029552AA, continue with Section E - Install the Authorized Modifications Label.

> 2WD vehicles involved in this recall require PCM part number 56028551AB. If the original PCM part number is 56029552AA, install a new PCM with part number 56028551AB. Continue with Section B - Replace the PCM. If the original PCM part number is 56028551AB, continue with Section E - Install the Authorized Modifications Label.

 

B.  Replace the PCM:

1. Disconnect the negative battery cable at the battery.

NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure

CAUTION: To avoid possible voltage spike damage to the PCM, the ignition key must be turned off, and the negative battery cable must be disconnected before unplugging the three PCM wiring connectors.

2. Carefully -unplug the three 32-way wiring connectors from the PCM (Figure 2).

3. Remove the three PCM mounting bolts and remove the PCM from the vehicle.

4. Install the new PCM, as determined in Section "A", onto the truck.

5. Install and tighten the PCM mounting bolts to 35 in. lbs. (4 N-m).

6. Connect the three 32-way wiring connectors to the PCM.

7. Connect the negative battery cable.

8. Using the DRB III scan tool, program the new PCM with the vehicle's Vehicle Identification Number (VIN) and current vehicle mileage.

NOTE: Failure to reprogram the new PCM with VIN information and mileage may cause a Diagnostic Trouble Code (DTC) to be set.

a. Connect the DRB III to the underdash diagnostic connector.

b. Select "DRBIII STANDALONE" (1) and then press "Enter".

c. Select "1998 - 2001 DIAGNOSTICS" (1) and then press "Enter".

d. Select "ENGINE" (1) and press "Enter" three times.

e. Select "FUNCTION SCREEN" and scroll to page two (press the right arrow key once).

f. Select "MISCELLANEOUS".

g. Select "CHECK VIN" (4) and then press "Enter".

h. Follow the instructions on the DRB III screen to enter the VIN.

CAUTION: Verify that the correct VIN is displayed on the DRB III before pressing the "Enter" key. The VIN cannot be changed once it is entered. If an incorrect VIN is entered, the module must be replaced to correct the VIN error.

i. Press the "PAGE BACK" button on the DRB III key pad.

j. Select "SRI MEMORY CHECK (3) and then press "Enter".

k. Follow the instructions on the DRB III to enter the current vehicle mileage

9. After entering the VIN and mileage, check for any additional software updates. Continue with Section C - Check for PCM Software Updates.

C.  Check for PCM Software Updates:

NOTE: The MDS2 (Mopar Diagnostic System) with the DRB III (Diagnostic Readout Box scan tool) operating at the latest release is required to perform this repair.

1. Log onto the MDS2 system.

2. Connect the MDS2 (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and switch the IGNITION KEY TO "ON".

3. Use the arrow keys and select #2 CONNECT TO MDS2 on the DRB III MAIN MENU SCREEN.

4. Use the arrow keys and select #2 RUN MDS2 APPLICATION on the DRB III MAIN MENU SCREEN.

NOTE: Once MDS2. DRB III and vehicle communication have been established, the CANNOT READ VIN FROM DRB III message will be replaced by the VEHICLE VIN. Press the "OK" button to request a MDS2 SESSION FOR THE VEHICLE VIN INDICATED. Press the "OK" button when asked to begin the session.

5. Push the FLASH TAB on the MDS2.

6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button.

NOTE: If the PCM on the vehicle has already been updated or reprogrammed, a Flash Update Information Box will appear that says ',',Part number (updated part number is displayed) is up to date and does not require any new updates." Verify that the part number of the PCM (or previously installed authorized software update label) matches the part number displayed on the MDS2. Press the "OK" button, then continue with Step E.

7. Select the NEW SOFTWARE PART NUMBER with the light pen and click UPDATE CONTROLLER SOFTWARE.

8. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process.

NOTE: Due to the PCM flash procedure, diagnostic trouble codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS) within the vehicle (if so equipped). Some DTC's may cause the Malfunction Indicator Light (MIL) to illuminate. All of the DTC's relate to a loss of communications with the module that is being flashed. Check all modules, record the trouble codes, and erase the trouble codes prior to returning the vehicle to the customer. Erase any trouble codes in the PCM only after all other modules have had their trouble codes erased.

9. Continue with Section D - Install Authorized Software Update Label.

D. Install Authorized Software Update Label:

Type or print (with a ballpoint pen) the part number, dealer code and date on the Authorized Software Update Label (Figure 3) and attach it to the PCM. Cover the label with the clear plastic portion of the label. Continue with Section E - Install the Authorized Modifications Label.

E.  Install Authorized Modifications Label:

Type or print (with a ballpoint pen) the recall number, dealer code and date on the Authorized Modifications Label (Figure 4). Then attach the label near the VECI label. Continue with Section F - Complete Proof of Correction Form for California Residents.

Figure 3	Figure 4

F. Complete Proof of Correction Form for California Residents:

This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration.

Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments.

Use one of the following labor operation numbers and time allowances:

Add the cost of the recall parts plus applicable dealer allowance to your claim.

NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

Parts Return

The original PCM must be returned to the Warranty Material Return Center. 

This page was edited on: May 3, 2004