PCM - Ticking Noise/EGR DTC/Hard Throttle
NO: 18-02-96GROUP: Vehicle Performance
DATE: Jan 19, 1996
SUBJECT: Ticking Noise in Engine Compartment/EGR Monitor Fault/Increased Throttle Effort
MODELS: 1995 (FJ) Avenger/Sebring/Talon
NOTE:
This bulletin applies to vehicles equipped with a 2.0l DOHC (Non Turbo) engine built after June 19, 1994 MDH (06-19-XX).
SYMPTOM/CONDITION:
1. Ticking noise (at idle) from engine compartment. Condition is most noticeable in cold ambient temperatures (below 40°F).
2. The Check Engine Light may be illuminated and Diagnostic Trouble Code (DTC) "EGR SYSTEM FAILURE" may be present in ambient temperatures below 32°F.
3. Increased effort required to move accelerator pedal from the idle position.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Scan Tool (DRB III) with the appropriate Diagnostic Procedure Manual, verify all engine/transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) other than the those listed are present, record them on the repair order and repair as necessary before proceeding further with this bulletin.
Symptom 1
1. Start vehicle and warm engine. Verify ticking noise in right front corner of engine compartment with engine at idle. Use the DRB III to selectively turn the duty cycle purge solenoid off. Select engine diagnostics/system test/purge vapor test/block. If the noise disappears, proceed with the flash programming and solenoid replacement repair.
Symptom 2
2. If no codes or only DTC "EGR SYSTEM FAILURE" is present and all systems are functioning correctly, proceed with the flash programming repair.
Symptom 3
3. If no codes are present and all systems are functioning correctly, proceed with the flash programming repair.
EQUIPMENT1PARTS REQUIRED:
All Symptoms (Flash Programming)
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7010 J1962/MMC Cable
1 4669020 Label - Authorized Software Update
1 4275086 Label - Authorized Modification
Symptom 1
1 4874833 Duty Cycle Purge Solenoid
NOTE:
The Mopar Diagnostic System may be required to perform part of the repair and the system must be operating with release 17 or higher and TIL CD release 1093 or higher must be installed.
REPAIR PROCEDURE:
This repair involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration changes) for all symptoms listed. In addition to flash programming, replacement of the duty cycle purge solenoid with a quieter assembly for Symptom 1 is required.
Flash Programming (All Symptoms)
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select CONTROLLER PROGRAMMING on the MDS, then press NEXT MENU.
5. Use the arrow keys and select PROGRAM CONTROLLER PART on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE message will be displayed. Check the part number of the PCM on the vehicle and compare it to the part number displayed. If the PCM has already been updated, then another condition exists that will require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the programming process.
NOTE:
The following steps are required by law.
9. Type the necessary information on the "Authorized Software Update Label" P/N 4669020. Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the Authorized Modification Label and attach the label near the VECI Label.
Duty Cycle Purge Solenoid Replacement (Symptom 1)
1. Raise the vehicle on a hoist and remove the right front wheel and splash shield to gain access to the duty cycle purge solenoid.
2. Remove the purge solenoid from its bracket and install new solenoid P/N 4874833.
NOTE:
Be sure to connect the purge hoses properly to the new solenoid.
3. Install the splash shield and wheel.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-43-95 Reprogram Powertrain Control Module 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Labor Operation No: 25-01-40-90 Solenoid, Duty Cycle Replace 0.5 Hrs.
FAILURE CODE: P8 - New Part