THE StarSCAN FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET.
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1 NUMBER: GROUP: Vehicle Performance DATE: May 16, 2007 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation. THE StarSCAN FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. SUBJECT: Ram Truck 2500 & PCM May Not Reprogram And Engine System Enhancements 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. 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 April 14, 2007 (MDH 0414XX). 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 operator may experience a MIL illumination due to one of the following DTC's: a. P242B - Exhaust Gas Temperature Sensor Circuit Performance - Bank 1 Sensor 3. b. P245A - EGR Cooler By-Pass Control Circuit - Open. 3. An intermittent rough engine idle and/or white smoke following initial engine start. 4. A throttle tip-in stumble at engine speeds of 1,300 to 2,100 rpm. 5. An engine hesitation at altitude of 5,000 feet between engine speeds of 1,200 to 1,600 rpm. 6. A turbocharger chuff-like sound during rapid deceleration.
2 DIAGNOSIS: If one or more of the above condition(s) is/are present perform 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 7.04 SP1 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 AB Label, Authorized Modification SPECIAL TOOLS / EQUIPMENT REQUIRED: VEHICLES UPDATED USING StarSCAN NPN CH9401 CH9404 CH9409 CH9410 CH9412 Battery Charger StarSCAN Tool StarSCAN Vehicle Cable StarSCAN Documentation Kit StarSCAN Ethernet Cable, 12 ft. StarSCAN Software Update Device Kit TechCONNECT PC or equivalent
3 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 7.04 SP1 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 website under the "Download Center". 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 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.
4 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 7.04 SP1 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 AR or higher suffix in the last two digits of its part number). k. Select Download to Scantool. l. 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.
5 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 new 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 one (1) time at the Manage Files menu. 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 fail. 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 AR of 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.
6 NOTE: Due to the ECU (ECM) 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 Home 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 i. Disconnect the StarSCAN from the vehicle. NOTE: The following step is required by law when reprogramming a PCM or TCM. 5. Type the necessary information on the Authorized Modification Label p/n AB and attach near the VECI label (Fig. 1). Fig. 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
7 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: Description Amount Charge warranty to ECM FAILURE CODE: Module, Powertrain Control (PCM) - Reprogram w/bootloader and Application Software Files (B) 0.7 Hrs. ZZ Service Action
THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. StarSCAN SOFTWARE LEVEL MUST BE AT RELEASE 9.04 OR HIGHER.
NUMBER: 18-001-09 GROUP: Vehicle Performance DATE: January 21, 2009 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced,
THE StarSCAN FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET.
NUMBER: 18-031-07 GROUP: Vehicle Performance DATE: April 28, 2007 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced,
SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTC s) P0403, P0404, P0405, P0406
NUMBER: 18-010-04 GROUP: Vehicle Performance DATE: March 2, 2004 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced,
THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.
NUMBER: 18-034-05 GROUP: Vehicle Performance DATE: August 18, 2005 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced,
THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.
NUMBER: GROUP: 18-013-05 REV. A Vehicle Performance DATE: April 19, 2005 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may
THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.
NUMBER: 24-004-05 GROUP: Heating & Air Conditioning DATE: February 11, 2004 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may
THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.
NUMBER: GROUP: 18-031-04 REV. A Vehicle Performance DATE: November 12, 2004 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may
FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD AUGUST, 2004.
NUMBER: 21-009-04 GROUP: Transmission DATE: July 8, 2004 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored
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NUMBER: 08-033-04 GROUP: Electrical DATE: October 15, 2004 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced,
THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.
NUMBER: 08-008-07 GROUP: Electrical DATE: March 8, 2007 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored
THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.
NUMBER: 08-057-05 GROUP: Vehicle Performance DATE: October 27, 2005 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced,
THE SOFTWARE FOR StarSCAN VIA THE INTERNET AND DRBIII WILL BE AVAILABLE ON DealerCONNECT MAY 25, 2004.
NUMBER: GROUP: 18-014-04 REV. A Vehicle Performance DATE: May 25, 2004 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be
THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.
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THE DRBIII FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. THE DRBIII FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT.
NUMBER: 18-018-05 GROUP: Vehicle Performance DATE: May 06, 2005 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced,
THE DRBIII FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT.
NUMBER: 08-029-05 GROUP: Electrical DATE: June 10, 2005 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored
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NUMBER: 08-014-06 GROUP: Electrical DATE: March 16, 2006 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored
THE StarSCAN FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET.
NUMBER: 18-014-09 GROUP: Vehicle Performance DATE: May 9, 2009 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced,
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NUMBER: GROUP: 18-014-09 REV. A Vehicle Performance DATE: November 6, 2009 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may
Either witech OR StarMOBILE DESKTOP CLIENT can be used to perform this bulletin. FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.
NUMBER: 18-020-10 GROUP: Vehicle Performance DATE: June 10, 2010 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced,
THE StarSCAN FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET.
NUMBER: 18-015-09 GROUP: Vehicle Performance DATE: May 9, 2009 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced,
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