THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. StarSCAN SOFTWARE LEVEL MUST BE AT RELEASE 9.04 OR HIGHER.

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1 NUMBER: 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, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of Chrysler LLC. THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. StarSCAN SOFTWARE LEVEL MUST BE AT RELEASE 9.04 OR HIGHER. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN REV. B, DATED July 13, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: FLASH: Engine Systems And Exhaust Aftertreatment Systems Enhancements OVERVIEW: This bulletin involves: MODELS: ==> Verifying that Bootloader software has been installed on 2007 MY vehicles. ==> Selectively erasing and reprogramming the Engine Control Module (PCM). ==> Selectively erasing and reprogramming the Cab Compartment Node (CCN). ==> Verifying the installation of a complete Documentation Kit containing: an Owners Manual Diesel Supplement, a driver side sun visor label, and an Informational DVD/CD kit. ==> One of several software changes allows for Net Zero and Net Reduction which will cause noticeable changes in idle speeds. Customers should be informed of these changes. They are explained in Symptom/Condition, Step #8. ==> Improvements that address erroneous MIL illumination for DTC P Fuel Rail Pressure Sensor Circuit Performance as well as other DTC's, (spelled out in SYMPTOM/CONDITION below). ==> Improvements to remote start capabilities to avoid erroneous P0513 during a quick restart, (If Equipped) (DC/DM) Ram Truck (3500/4500/5500 Cab Chassis) NOTE: This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ) built on or before January 13, 2009 (MDH 0113XX).

2 SYMPTOM/CONDITION: NOTE: The following conditions and improvements have been addressed with the latest Engine Control Module (PCM) software. This Service Bulletin (SB) only addresses the labor associated with the reprogramming of the PCM, the CCN, and the installation of a Documentation Kit. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately. 1. The latest PCM software will address the erroneous MIL illumination of the following faults. If the condition persists, (after this latest update), please perform the appropriate Diagnostic Procedure in DealerCONNECT/TechCONNECT for that fault code: a. P Fuel Rail Pressure Sensor Circuit Performance b. P Thermostat Rationality c. P Manifold Absolute Pressure Sensor Performance d. P Engine Oil Pressure Too Low e. P061A - ETC Level 2 Torque Performance f. P ECU Internal Performance 2. The latest PCM software will include the following operational and diagnostic improvements: a. Creation of a new Turbocharger DTCs to address VGT actuator calibration event failures separate from other VGT actuator communication faults for P0046 and inappropriate P2262 faults due to Foreign Object Debris. b. The new DTCs are: P003A - Turbocharger Boost Control Module Position Exceeded Learning Limit and P2563 Turbocharger Boost Control Position Sensor Performance. 3. Creation of three new DTC's to address the inlet air temperature sensor separate from the ambient air temperature sensor. The new DTC's are: a. P Inlet Air Temperature Sensor Rationality / Performance. This DTC enhances the current DTC P Inlet Air Temp Sensor Rationality / Ambient Air Temperature Sensor Performance. b. P Inlet Air Temperature Sensor Too Low. This DTC enhances the current DTC P Inlet Air Temp Sensor Voltage Too Low. c. P Inlet Air Temperature Sensor Too High. This DTC enhances the current DTC P Inlet Air Temp Sensor Voltage Too High. 4. Improvement to the single diagnostic DTC P Fuel Delivery Error. This DTC is now addressed by the following two DTC diagnostics: a. P Fuel Pump Delivery Pressure Too Low. b. P Fuel Pump Delivery Pressure Too High. 5. Improve engine cooling capability and prevention of over temp condition (P Coolant Temperature Too High) when operating with snow plow. 6. New feature that allows for customer selectable remote PTO speed (if equipped). a. Instructions for this new feature are available at 7. DTC P Invalid Skim Key may set during a quick restart using Remote Start feature (if equipped). 8. The latest PCM software includes a new extended idle feature to accommodate the extended idle times present in some duty cycles. This feature may help to reduce the accumulation of soot in the exhaust aftertreatment system when the engine is idling for an extended period of time. Briefly how this feature works:

3 a. As needed, the engine enters an idling mode which dramatically reduces the rate of soot accumulation in the diesel particulate filter (called Net Zero ). Further, under extended idle periods of 5 minutes or longer, the engine enters a mode which reduces the amount of soot accumulated in the diesel particulate filter (called Net Reduction ). While in these modes, the idle speed increases to 900 RPM for a period of time. The idle speed may return to normal idle speed and then return to 900 RPM to repeat this cycle during very long idle periods. b. These modes occur automatically depending on the need to regenerate the DPF as long as the vehicle is not driven over 20 MPH or operated at high load. If the vehicle is driven over 20 MPH normal mobile desoot will occur automatically. DIAGNOSIS: 1. On 2007 Model Year only, verify that Bootloader software is available as a downloadable file. Bootloader software is distinguished by the suffix BT at the end of the root number. If Bootloader software is available, follow REPAIR PROCEDURE A- (2007 MY ONLY) FLASH PCM WITH NEW BOOTLOADER SOFTWARE procedure. 2. Using the StarSCAN / StarMOBILE, determine current software level of the PCM and CCN. Record on the repair order, for later use, the current PCM and CCN software level part numbers. Proceed to the next step. 3. If the vehicle in question is a 2007 Model Year vehicle, then compare the current PCM software level part number. Determine if the current PCM software level part number, recorded in Step #4, is one of the following part numbers (or with a higher suffix): a AX (or higher) = DC L Manual Transmission 50 State. b AX (or higher) = DC L Automatic Transmission 50 State. 4. If the vehicle in question is a 2008 Model Year vehicle, then compare the current PCM software level part number. Determine if the current PCM software level part number, recorded in Step #4, is one of the following part numbers (or with a higher suffix): a AK (or higher) = DC L Manual Transmission 50 Stat b AK (or higher) = DC L Automatic Transmission 50 State. c AK (or higher) = DM 4500/ L Manual Transmission 50 State. d AK (or higher) = DM 4500/ L Automatic Transmission 50 State. 5. If the vehicle in question is a 2009 Model Year vehicle, then compare the current PCM software level part number. Determine if the current PCM software level part number, recorded in Step #4, is one of the following part numbers (or with a higher suffix): a AH (or higher) = DC L Manual Transmission 50 State. b AH (or higher) = DC L Automatic Transmission 50 State. c AH (or higher) = DM 3500/ L Manual Transmission 50 State. d AH (or higher) = DM 3500/ L Automatic Transmission 50 State. 6. Is the part number of the current PCM level software (recorded in Step #2) at (or higher) than one of the software part numbers listed in Step #3, Step #4 or Step #5 above? a. If YES ==> then the PCM DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO ==> then the PCM DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 7. Determine if the current CCN module level software part number, that was recorded earlier in Step #2, is one of the following (or with a higher suffix): a AH (or higher) = 2007 DC (3500) / DM (3500/4500). b AG (or higher) = 2008 DC (3500) / DM (3500/4500). c AG (or higher) = 2009 DC (3500) / DM (3500/ Is the part number of the current CCN level software at (or higher) than one of the software part numbers listed in Step #7?

4 a. If YES ==> then the CCN DOES NOT require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. b. If NO ==> then the CCN DOES require reprogramming as part of this repair. Record this on the repair order for later reference. Proceed to the next step. 9. Has the vehicle already had a COMPLETE Documentation Kit installed? Some vehicles may only have a part of the Documentation Kit (i.e. Diesel Owners Manual Supplement). Make sure the vehicle/customer has received a complete Documentation Kit. a. If YES ==> then the Documentation Kit DOES NOT need to be installed as part of this repair. Record this on the repair order for later reference. Proceed to the Repair Procedure. b. If NO ==> then the Documentation Kit DOES need to be installed as part of this repair. Record this on the repair order for later reference. Proceed to the Repair Procedure. PARTS REQUIRED: Qty. Part No. Description AB Label, Authorized Modification (AR) AA Documentation Kit (includes: Diesel Owners Manual Supplement, Sun Visor Label, and Informational DVD/CD Kit) - Kit is zero cost SPECIAL TOOLS / EQUIPMENT REQUIRED: NPN CH9401 CH9404D 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 REPAIR PROCEDURE A- (2007 MY ONLY) FLASH PCM WITH NEW BOOTLOADER SOFTWARE: NOTE: On 2008 models (or newer), Bootloader software updates are not required, perform REPAIR PROCEDURE B - FLASH PCM CAUTION: Before the application software can be reprogrammed (flashed) into the Powertrain Control Module (PCM) on some 2007 MY vehicles, 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.

5 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 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. 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 9.04 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 ECU Flash. e. Select More Options.

6 f. Select Delete All. g. Select Yes at the About to delete all user files. Are you sure you want to continue? screen. h. Select OK at All user files have been removed screen. i. Select Back at User's Files menu. NOTE: If Bootloader software (BT suffix) is NOT available in the following steps, then Bootloader is already up to date. There is no need to flash bootloader software into the ECU. Continue to REPAIR PROCEDURE B - FLASH PCM at this time. 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. 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. 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.

7 15. Confirm that the PCM has the 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. 17. Proceed to: Section B - Reprogramming (Flash) PCM With New Application Software. REPAIR PROCEDURE B - FLASH PCM: CAUTION: Before the application software can be reprogrammed (flashed) into the Powertrain Control Module (PCM) on 2007 MY vehicles, 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. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > 8E - Electronic Control Modules > Module - Engine Control, Diesel > Standard Procedure > PCM Reprogramming - Diesel. 2. Type the necessary information on the Authorized Modification Label and attach it near the VECI label. REPAIR PROCEDURE C: CCN MODULE REPROGRAM - USING THE INTERNET TO RETRIEVE THE FLASH FILE: StarSCAN SOFTWARE LEVEL MUST BE AT RELEASE 9.04 OR HIGHER. NOTE: CCN software controls the Electronic Vehicle Information Center (EVIC) messages. The CCN software must be up to date (correct software level) in order for the new engine system and exhaust aftertreatment system messages to be displayed on the EVIC. These new messages are addressed on the new sun visor label and in the new Diesel Owners Manual Supplement. 1. Verify that Cabin Control Node (CCN) software is up to date. If new CCN software is available, perform the following steps: 2. 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.

8 If not already performed, connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop. 4. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle. 5. Turn the ignition switch to the RUN/ON position. 6. Power ON the StarSCAN. 7. Retrieve the old ECU (CCN) module part number and reprogram the CCN module. Using the StarSCAN at the Home screen: a. Select ECU View b. Touch the screen to highlight the CCN in the list of modules. c. Select More Options d. Select ECU Flash. e. Record the part number at the top of the Flash CCN 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 CCN module update is complete, select OK. StarSCAN SOFTWARE LEVEL MUST BE AT RELEASE 9.04 OR HIGHER. REPAIR PROCEDURE D- INSTALLATION OF THE DOCUMENTATION KIT: NOTE: Some vehicles had previously received only a partial Documentation Kit. Please ensure a complete Documentation Kit is installed and it's contents explained to the customer. 1. Verify the vehicle has had a COMPLETE Documentation Kit installed. If Complete Documentation Kit has not been installed, perform the following steps: a. Place the new Diesel Owners Manual Supplement in the vehicle Glove Box. b. Place the Informational DVD/CD in the vehicle Glove Box. c. Install the new Sun Visor Label to the left (driver) side sun visor. The label should be centered on the sun visor and to the left of the seat belt warnings. Verify that the label is firmly attached to the sun visor material. NOTE: IMPORTANT: At time of customer vehicle pickup, the dealer should take the time to review the Documentation Kit material with the customer. POLICY: Reimbursable within the provisions of the warranty.

9 TIME ALLOWANCE: Labor Operation No: Description Amount Module, Powertrain Control (PCM/ECU) - Reprogram w/ Bootloader Software Files (B) 2007 Models only Module, Powertrain Control (PCM) - Reprogram w/application Software Files (B) Module, Cab Compartment Node (CCN) - Reprogram (B) 0.7 Hrs. 0.4 Hrs. 0.3 Hrs Kit, Documentation - Install 0.2 Hrs. FAILURE CODE: ZZ Service Action