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Home >> Dodge or Ram Truck >> 2003 >> RAM 3500 Truck 2WD L6-5.9L DSL Turbo VIN 6 >> Repair and Diagnosis >> Powertrain Management >> Emission Control Systems >> Technical Service Bulletins >> By Symptom >> Recall - ECM Update For OBD Readiness >> Service Procedure

Service Procedure

NOTE:
The DRBIII(R) must be used to perform this recall on 2003 Model Year (MY) vehicles. The 2003 MY procedure is found in Section D of the Service Procedure. Either wiTECH, StarMOBILE or StarSCAN can be used to perform this recall on 2006-2007 MY vehicles. This procedure must be performed with software release level 10.03 or higher for wiTECH and Star Mobile applications, or software release level 9.05 for StarSCAN applications. If the reprogramming flash for the ECM is aborted or interrupted, repeat the procedure.

A. Reprogram the ECM Using wiTECH:

1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process.

Set the battery charger timer (if so equipped) to continuous charge.

NOTE:
Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage.

2. Connect the wiTECH VCI pod to the vehicle data link connector located under the steering column.

3. Place the ignition in the "RUN" position.

4. Open the wiTECH Diagnostic application.

5. Starting at the "Select Tool" screen, select the row/tool for the wiPOD device you are using.

6. Enter your "User id" and "Password", then select "OK".

7. Select the "Next" tab at the bottom of the screen.

8. From the "Vehicle View" screen, click on the PCM icon.

9. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" continue to Step 15. If the part numbers are not the same, continue to Step 10.

10. With the cursor over the desired flash file, click the small green arrow button on the right side of the screen.

11. From the "ECU Flash" screen follow the wiTECH screen instructions to complete the flash.

12. Once the flash is complete click the "OK" button on the "ECU Flash" screen.

13. From the "Clear Stored DTC" screen clear all Diagnostic Trouble Codes (DTC's) by clicking the "Clear DTC's" button.

14. From the "PCM View" screen, compare the "Current ECU Flash Number" with the "New Part Number" listed on the "sort table". If the "Current ECU Flash Number" is the same as the "New Part Number" the flash is complete. If the part numbers are not the same, repeat Steps 8 through 14.

15. Turn the ignition to the "OFF" position, remove the wiPOD and battery charger from the vehicle.

16. Continue with Section E. Install Authorized Modifications Label.

B. Reprogram the ECM Using StarSCAN:

1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge.

NOTE:
Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage.

2. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop.

3. Connect the CH9404D StarSCAN vehicle cable to the StarSCAN and the vehicle.

4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN.

5. Retrieve the old PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below:

a. Select "ECU View".

b. Select "PCM" in the list of modules.

c. Select "More Options".

d. Select "ECU Flash".

e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference.

6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash PCM" screen, follow the procedure below:

a. Select "Browse for New File". Follow the on screen instructions.

b. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 5e, then the PCM is up to date. Continue to Step 11. If the part numbers are not the same, continue to Step 6c.

c. Highlight the listed calibration on the StarSCAN screen.

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" and follow the on screen instructions.

h. When the update is completed, select "OK".

7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads "Vehicle Disconnected", then press "OK".

8. Reconnect the CH9404D StarSCAN vehicle cable to the vehicle.

9. Retrieve the PCM part number. With the StarSCAN on the "Home" screen, follow the procedure below:

a. Select "ECU View".

b. Select "PCM" in the list of modules.

c. Select "More Options".

d. Select "ECU Flash".

e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully.

10. Clear any Diagnostic Trouble Codes (DTCs) as follows:

NOTE:
Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate.

a. From the "Home" screen select "System View".

b. Select "All DTCs".

c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list.

11. Turn the ignition key to the "OFF" position and remove the StarSCAN unit, StarSCAN cable, StarSCAN ethernet cable and battery charger from the vehicle.

12. Continue with Section E. Install Authorized Modification Label.

C. Reprogram the ECM Using StarMOBILE:

1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge.

NOTE:
Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage.

2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position.

3. Power ON the StarMOBILE scan tool.

4. From the desktop, launch the "StarMOBILE Desktop Client" software.

5. Establish a connection with the StarMOBILE scan tool.

6. Retrieve the old PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below:

a. Select "ECU View".

b. Select "PCM" in the list of modules.

c. Select "More Options".

d. Select "ECU Flash".

e. Record the "Part Number" displayed at the end of the "Resident flash file for" statement near the top of "Flash PCM" screen for later reference.

7. Download the flash file from the internet to the StarMOBILE. With the StarMOBILE on the "Flash PCM" screen, follow the procedure below:

a. Select "Browse for New File". Follow the on screen instructions.

b. Enter your "User id" and "Password", then select "OK".

c. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step 6e, then the PCM is up to date. Continue to Step 10. If the part numbers are not the same, continue to Step 7d.

d. Highlight the listed calibration on the StarMOBILE screen.

e. Select "Download to Client".

f. Select "Close" after the download is complete, then select the "Back" arrow.

g. Highlight the listed calibration.

h. Select "Update Controller" and follow the on screen instructions.

i. When the update is completed, select "OK".

8. Retrieve the PCM part number. With the StarMOBILE on the "Home" screen, follow the procedure below:

a. Select "ECU View".

b. Select "PCM" in the list of modules.

c. Select "More Options".

d. Select "ECU Flash".

e. Verify the "Part Number" (displayed at the end of the "Resident flash file for" statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully.

9. Clear any Diagnostic Trouble Codes (DTCs) as follows:

NOTE:
Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate.

a. From the "Home" screen select "System View".

b. Select "All DTCs".

c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list.

10. Turn the ignition key to the "OFF" position and remove the StarMOBILE unit, StarMOBILE vehicle cable, and battery charger from the vehicle.

11. Continue with Section E. Install Authorized Modification Label.

D. Reprogram the ECM Using DRBIII(R):

The DealerCONNECT System, DRBIII(R) (Diagnostic Readout Box scan tool),
CH7000A flash cable and CH7035B data cable are required to perform this
repair. Do not attempt to perform the flash procedure using an outdated
CH7000/CH7001 flash cable.

NOTE:
Whenever a controller is reprogrammed, the software in the DRBIII scan tool must be programmed with the latest revision level available.

NOTE:
If the flash process is interrupted or aborted, the flash should be restarted and then follow the directions on the DRBIII scan tool.

1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. Do not allow the charger to time out during the flash process. Set the battery charger timer (if so equipped) to continuous charge.

NOTE:
Use an accurate stand alone voltmeter. The battery charger volt meter may not be sufficiently accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage.

2. Connect the DRBIII CH7000A flash cable from the DRBIII scan tool to the data link connector located inside the vehicle under the steering column.

3. Connect the CH7035B data cable from the DealerCONNECT machine to the MDS port on the DRBIII scan tool.

4. Place the vehicle's ignition key in the "RUN" position.

5. From the DealerCONNECT "WELCOME" screen, enter your "User I.D.," "Password" and "Dealer Code".

6. From the DealerCONNECT "HOME PAGE" select the "SERVICE" tab.

7. From the "SERVICE" tab screen select "TechTOOLS".

8. If the DRBIII scan tool does not "Auto Connect" select # 2 on the DRBIII key pad "Connect to TechCONNECT".

9. After the "Auto Connect" process is complete, select "READ PART NUMBER(S) FROM VEHICLE" on the TechCONNECT screen.

10. Continue following the TechCONNECT on-screen instructions.

11. Select the applicable update calibration.

12. Select the "DRBIII" button located at the bottom of the TechCONNECT monitor screen.

13. Select the "DOWNLOAD / UPDATE" button located next to the "DRBIII" button.

NOTE:
The system software will automatically download to the DRBIII scan tool.

14. After the software download to the DRBIII scan tool is complete, close the "DOWNLOAD / UPDATE PROGRESS" window.

15. Disconnect the DRBIII scan tool from the TechCONNECT CH7035B data cable.

16. Select # 1 "RETURN TO NORMAL MODE" on the DRBIII scan tool.

17. Use the following procedure to download the flash from the DRBIII scan tool to the vehicle.

a. Select # 7 "VEHICLE FLASH" on the DRBIII scan tool.

b. Follow the directions displayed on the DRBIII scan tool screen.

c. After the reprogramming is complete, record the new module part number displayed on the DRBIII scan tool screen.

d. Press the "PAGE BACK" button on the DRBIII scan tool.

18. Due to the ECM flash procedure, Diagnostic Trouble Codes (DTC's) may be set in other modules (ETAX, BCM, MIC, SKIM, ABS, ORC) 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 using the following procedure:

a. Turn the vehicle's ignition key to the "RUN" position.

b. From the DRBIII scan tool Main Menu select # 1 "DRBIII Stand-Alone".

c. From the DRBIII scan tool Stand-Alone menu select # 3 "Vehicle Module Scan".

d. From the DRBIII scan tool Vehicle Module Scan menu select # 1 "1998 - 2005 Module Scan".

e. Select "YES" on the DRBIII scan tool key pad to scan for DTC's.

f. Follow the instructions on the DRBIII scan tool screen.

g. Once the scanning process is complete, the DRBIII scan tool will display a list of all the modules. Modules on the list that have an asterisk next to them have DTC's that need to be cleared.

h. Select the module that needs to have the DTC's cleared and follow the instructions on the DRBIII scan tool screen to clear the DTC's.

i. Turn the vehicle's ignition key to the "OFF" position.

NOTE:
Erase any DTC's in the ECM only after all other modules have had their DTC's erased.

19. Disconnect the DRBIII scan tool from the vehicle.

20. Turn off the battery charger and disconnect it from the vehicle.

21. Continue with Section E. Install Authorized Modification Label.

E. Install the Authorized Modifications Label:





1. Type or print (with a ballpoint pen) the recall number, repair modification, dealer code and date on the Authorized Modifications Label (Figure 1).

2. Attach the label near the VECI label and then close the hood.

3. Complete Proof of Correction Form for California Residents.

NOTE:
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.

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