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NUMBER: 18-032-07
GROUP: Vehicle Performance
DATE: May 16, 2007
SUBJECT:
Flash: MIL Illumination with DTC P2004
OVERVIEW:
This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module (PCM) with new software and replacing the intake manifold as required.
CAUTION: VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST BE INSTALLED.
MODELS:
| 2007- 2008 | (JS) | Avenger |
| 2007 | (JS) | Sebring |
| 2008 | (JS27) | Sebring Convertible |
| 2007 | (MK49) | Compass |
| 2007 | (MK74) | Patriot |
| 2007 | (PM) | Caliber |
NOTE: This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007 (MDH 0421XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold Replacement portion applies to models built through March 22, 2007 (MDH0322XX).
SYMPTOM/CONDITION:
Some customers may experience MIL Illumination with no other symptoms. The condition may occur intermittently. Further investigation by the technician may find DTC P2004 Intake Manifold Runner Control Stuck Open as the cause for MIL Illumination.
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 other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin.
Perform the standard diagnostic procedures for DTC P2004. If the diagnostics do not lead to the failure, perform the Repair Procedure.
PARTS REQUIRED:
| Qty. | Part No. | Description |
|---|---|---|
| 1 | 04275086AB | Label, Authorized Modification |
| 1 | 04884495AF | Manifold, Intake |
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 – USING THE INTERNET TO RETRIEVE THE FLASH FILE:
CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING PROCESS.
NOTE: When performing this Repair Procedure, the software release level in the StarSCAN; must be programmed with 7.04 SP1 software 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.
- Install a battery charger
and verify that the charging rate provides approximately 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. - Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer’s network drop.
- Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle.
- Power ON the StarSCAN.
- Using the StarSCAN at the “Home” screen:
- Select “ECU View”
- Touch the screen to highlight the PCM in the list of modules.
- Select “More Options”
- Select “ECU Flash”
- Record the part number at the top of the “Flash PCM” screen for later reference.
- Select “Browse for New File”. Follow the on screen instructions.
- Select “Download to Scantool”.
- Select “Close” after the download is complete, then select “Back”.
- Highlight the listed calibration.
- Select “Update Controller”. Follow on screen instructions.
- When the update is complete, select “OK”.
- Verify the part number at the top of the “Flash PCM” screen has updated to the new part number.
- Turn the ignition switch to the OFF position for no less than 15 seconds.
- Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds.
CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS.
NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle. 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.
PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows:
- Using the StarSCAN at the “Home” screen:
- Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the “Flash File List” screen?
- Yes >> No further action is necessary. Proceed to Step 9.
- No >> the TCM will require flash reprogramming, proceed to Step 8.
- Flash reprogram the TCM as follows:
- From the “Flash File List” screen, select “Download to Scantool”.
- Select “Close” after the download is complete, then select “Back”.
- Highlight the listed calibration.
- Select “Update Controller”. Follow on screen instructions.
- When the update is complete, select “OK”.
- Verify the part number at the top of the “Flash TCM” screen has updated to the new part number.
- Turn the ignition switch to the OFF position for no less than 15 seconds.
- Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20 seconds.
CAUTION: DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS.
NOTE: Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle. 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.
- Type the necessary information on the “Authorized Modification Label” p/n 04275086AB and attach near the VECI label (Fig. 1).
Fig. 1 AUTHORIZED MODIFICATION LABEL
1 – **POWERTRAIN CONTROL / TRANSMISSION CONTROL MODULE P/N’s (INSERT P/N’s) USED**
2 – CHANGE AUTHORITY: TSB XX-XXX-XX
3 – DEALER CODE: XXXXX
4 – DATE: XX-XX-XX
- Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF. Following the procedures listed in DealerCONNECT>TechCONNECT, replace the intake manifold.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
| Labor Operation No: | Description | Amount |
|---|---|---|
| 18-19-03-29 | Module, Powertrain Control (GPEC) – Reprogram (B) & (Check TCM if CVT Equipped – No Update) | 0.4 Hrs. |
| 18-19-03-30 | Module, Powertrain Control (GPEC) &
Transmission Control (TCM) – Reprogram (B) |
0.5 Hrs. |
| 09-50-01-90 | Manifold, Intake Replace (B) – All Models | 1.1 Hrs. |
FAILURE CODE:
| ZZ | Service Action |
THE StarSCAN FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET.
StarSCAN SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SP1 OR HIGHER FOR THIS BULLETIN.
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Chrysler J2534 Application Overview
The Chrysler J2534 System is a combination of the J2534 Application (2010 and newer Model Year Support) and the Chrysler J2534 Flash Application (2009-1996 Model Year Support). J2534 aftermarket users are required and responsible for installing the J2534 device driver provided by the device manufacturer. If you need support installing the device driver software contact the device manufacturer. See the related article “Chrysler J2534 Manual” for additional information. Chrysler J2534 application provides below capabilities:
| New J2534 Application: | |
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Application Usage and Support |
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| The Chrysler J2534 Flash Application: | |
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Application Usage and Support |
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Chrysler Recommended J2534 Devices
For Chrysler recommended J2534 device, see below table.
| J2534 Device |
Firmware Version |
| CTC Vehicle Box * | 1.9 |
| UCAN 2 | 1.0 |
| Blue Streak -2534 Global Programmer | 2.10 |
| Actia I+ME Passthru | 2.07 |
* Chrysler recommends the CTC Vehicle Box Device for Chrysler SCI ECU reprogramming. SCI reprogramming is used on most PCMs and TCMs prior to the introduction of CAN bus vehicles which began in 2004 (Durango).
Chrysler J2534 System Support:
Support for Chrysler J2534 System is available on-line. For more information, please refer to Chrysler J2534 Manual and knowledge base website.
Chrysler J2534 System
PC Requirements for Chrysler J2434 System:
The Chrysler J2534 Application has been verified to work with the following operating systems using open platform PCs or laptops:
• Windows 7 (32-Bit & 64-Bit)
• Windows XP (32-Bit only)
Chrysler J2434 System Release Notes:
Please click here to view the Application Release Notes.
Chrysler J2434 System Download:
For Chrysler J2534 System support, please refer to “Chrysler J2534 Manual“. Get the J2534 system.
Chrysler ECU Flash Availability matrix:
Click Flash Availability–J2534 Application and Flash Availability–Chrysler Diagnostic Application.
Adaptor Requirements:
A harness adaptor is required to update certain vehicles. The following tables list which vehicles / modules require which adaptor. Adaptors can be purchased through the SPX Miller Special Tools program. See SPX Miller Special Tools program for details.
MLR-J2534-MMC required on:
| SBEC III | 1996 – 1997 | SEBRING / AVENGER (FJ) |
| ETAX III | 1996 – 1997 | SEBRING / AVENGER (FJ) |
| SBEC IIIA | 1997 – 1998 | SEBRING / AVENGER (FJ) |
| ETAX IIIA | 1997 – 1998 | SEBRING / AVENGER (FJ) |
| Powertrain | 2001 – 2201 | SEBRING / STRATUS COUPE (ST) |
MLR-J2534-TCM required on:
| ETAX IIIB | 2003 – 2004 | SEBRING / STRATUS SEDAN (JR) |
| ETAX IVA | 2005 – 2006 | LIBERTY (DIESEL) JEEP (KJ) |
Additional Information and Known Issues / Concerns:
If you are reprogramming the 5.9L diesel engine controller on the 1996-2008 Dodge RAM vehicle, it is necessary to also reprogram the VIN after the ECU has been flashed. To write the VIN to the ECU, you may use aftermarket software support, or use an OEM FCA US LLC scan tool (DRBIII or StarSCAN). For more information, see the FCA US LLC Scan Tool Lease Options section.
- 1996-2009 ALL PCMs
If you are REPLACING a PCM or ECM and the vehicle is equipped with a theft deterrent system (Sentry Key), it must be initialized to properly function with the Anti Theft module. You also need to reprogram the VIN when replacing a PCM or ECM. To write the VIN to the ECU and initialize the PCM to work with the theft deterrent system, you may use aftermarket software support, or use an OEM FCA US LLC scan tool (DRBIII or StarSCAN). For more information, see the FCA US LLC Scan Tool Lease Options section.
FCA US LLC Scan Tool Lease Options:
- For 2009 model year vehicles and prior, it may be necessary to use either a DRBIII or a StarSCAN to perform function required after ECU replacement. To lease the DRBIII call 1-586-532-8400 or click here.
- Beginning with 2010 MY, function required to replace an ECU will be supported via the J2534 application.
