Engine Controls - Poor/Erratic A/C Performance
NUMBER: 24-006-05 REV. CGROUP: Heating and A/C
DATE: October 7, 2005
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 24-006-05 REV. B, DATED SEPTEMBER 21, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A THIRD LABOR OPERATION NUMBER AND REVISED FAILURE CODE.
THE StarSCAN FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET. THE FLASH FILE WILL BE AVAILABLE ON THE NEXT StarSCAN(R) UPDATE CD RECEIVED AFTER CD 6.03
SUBJECT:
5.7L Flash: Improved A/C Performance
OVERVIEW:
This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software and installing revised condenser fan shroud assembly and expansion valve.
MODELS:
2004 - 2005 (HB) Durango
NOTE:
This bulletin applies to vehicles equipped with a 5.7L engine (sales code EZA), built on or before May 1, 2005 (MDH 0501XX). Vehicles built on or after December 7, 2004 (MDH 1207XX) are equipped with the revised expansion valve. Vehicles built on or after October 22, 2004 (MDH 1022XX) are equipped with the revised condenser fan shroud assembly and do not require replacement of these parts.
SYMPTOM/CONDITION:
The following enhancements are included with this software:
^ Improved A/C performance - Reduced incidence of A/C compressor cut out at idle or in city traffic. The vehicle operator may describe A/C inoperative at idle, in city traffic or after a warm engine start up.
^ Reduced incidence of A/C compressor turning on and then not turning off causing the evaporator to freeze up which results in a significant loss of outlet air flow and A/C performance. The A/C performance returns after the A/C has been shut off for several minutes.
DIAGNOSIS:
Using a Scan Tool (StarSCAN) with TeChCONNECT or the appropriate Diagnostic Procedures Manual, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin.
If the vehicle operator describes or experiences the Symptom/Condition, perform the appropriate Repair Procedure.
PARTS REQUIRED
NOTE:
The Parts Required (expansion valve, 0-rings, cooling fan and shroud are not required on vehicles built on or after December 7, 2004 (MDH 1207XX).
NOTE:
Steps 1 through 14 apply to vehicles built on or before December 6, 2004 (MDH1206XX). If the vehicle you are repairing was built on or after December 7, 2004, the Flash Procedure is all that is required.
REPAIR PROCEDURE:
1. Disconnect and isolate the negative battery terminal.
2. Using the procedures outlined in the appropriate service manual with approved recovery equipment, recover the A/C refrigerant.
3. Remove the expansion valve.
4. Install a new expansion valve, p/n 05061342AD with new 0-rings, p/n 4882136/7.
5. Disconnect the refrigerant hoses from the condenser.
6. Disconnect the wire harness.
7. Remove the condenser from the radiator support.
8. Remove the fan and shroud assembly from the condenser.
9. Install the new fan and shroud, p/n 52029175AD, on to the condenser,
10. Install the condenser.
11. Connect the wire harness.
12. Connect the refrigerant hoses.
13. Charge the system with the appropriate refrigerant charge as stated on the A/C system label.
14. Connect the negative battery cable.
EQUIPMENT REQUIRED
NOTE:
There are two methods to download flash files to StarSCAN. The first method (NEW) is to download the flash files to the StarSCAN from the internet. The second method is to download the flash files from the StarSCAN Software Update CD.
FLASH PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE:
NOTE:
The StarSCAN(R) must be at version 5.02 or higher before the "Using The Internet To Retrieve The Flash File" repair procedure can be performed.
NOTE:
The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. For instruction on setting up your StarSCAN(R) for the dealer's network; refer to the StarSCAN(R) Quick Start Networking Guide available on the www.dcctools.com website under the "download center".
NOTE:
If this flash process is interrupted/aborted, the flash should be restarted.
1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts.
2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop.
3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle.
4. Power ON the StarSCAN(R).
5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home" screen:
a. Select "ECU View"
b. Touch the screen to highlight the appropriate ECU in the list of modules.
c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference.
6. Download the flash file from the internet to the StarSCAN(R). Using the StarSCAN(R) at the "ECU Overview" screen:
a. Select "More Options"
b. Select "ECU Flash".
c. Select "Browse for New File". Follow the on screen instructions.
d. Select "Download to Scantool".
e. Select "Close" after the download is complete, then select "Back".
f. Highlight the listed calibration.
g. Select "Update Controller".
h. When the update is complete, select "OK".
NOTE:
Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored DTC's" if there are any DTC's shown on the list.
NOTE:
The following step is required by law when reprogramming a PCM and/or TCM.
7. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1).
REPAIR PROCEDURE - USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE:
NOTE:
Before flashing this module, make sure the StarSCAN(R) is operating at 5.02 or later.
NOTE:
If this flash process is interrupted/aborted, the flash should be restarted.
NOTE:
For detailed information on the operation of the StarSCAN(R), refer to the Quick Reference documentation provided in the StarSCAN(R) documentation kit. In addition, more recent information may also be available at the www.dcctools.com website. Look under "Training Aids" and also under "Download Center > Frequently Asked Questions" for more help.
1. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts.
2. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle.
3. Power ON the StarSCAN(R).
4. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home" screen:
a. Select "ECU View"
b. Touch the screen to highlight the appropriate ECU in the list of modules.
c. Record the "Part Number", displayed on the "ECU Overview" screen, for later reference.
5. Insert the StarSCAN(R) Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) Software Update CD will start automatically. Select "Download Flash Updates".
6. At the "Select a method for looking up controller flash updates." screen:
a. Select "Enter part number". Enter the "Part Number" recorded in Step # 4 when prompted to do so.
b. Follow the on screen instructions.
c. When completed, proceed to Step # 7.
7. With the StarSCAN(R) powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) USB port (Fig. 2).
8. Connect the StarSCAN(R) to the vehicle (if not already connected).
9. Power ON the StarSCAN(R).
10. Download the flash file from the USB key to the StarSCAN(R). Using the StarSCAN(R) at the "Home" screen:
a. Select "Retrieve files from the USB storage device"
b. Highlight the appropriate calibration. Select "Download to Scan Tool"
c. When the download is complete, select "Close" and "Back".
11. Reprogram the ECU by downloading the file from the USB key to the StarSCAN(R). Using the StarSCAN(R) at the "Home" screen:
a. Select "ECU View".
b. Select "More Options".
c. Select "ECU Flash".
d. Highlight the appropriate calibration.
e. Select "Update Controller". Follow the on screen instructions.
f. When the update is complete, select "OK".
NOTE:
Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. 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.
12. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1).
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE
FAILURE CODE
DISCLAIMER
This bulletin is supplied for technical information only and is not an authorization for repair.