NUMBER: GROUP: DATE: 18-037-05 Vehicle Performance October 20, 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 in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.
18-037-05 -2- 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006
-3- 18-037-05 Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs.
18-037-05 -4- If the TechCONNECT Client is current and the DRBIII® is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII® updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII® must have the LATEST software revisions installed.
-5- 18-037-05 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions.
18-037-05 -6- Fig. 2 CH2002 ASSEMBLY 1 - CH7035B 2 - CHGPIB-B 3 - CH7036 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII®. Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear.
-7- 18-037-05 teamPSE Part No. Description OT-CH7000A-1 J1962 Banjo Clip Repair Kit. OT-CH7035B-1 GPIB Cable Cup Kit. The kit contains - 4 retaining clips, 2 pivot pins, and instructions. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool.
18-037-05 -8- unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII® remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII® is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles).
-9- 18-037-05 To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII®. Step by step instruction will follow on the DRBIII® display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII®, or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box".
18-037-05 -10- instructions were followed, perform the following: • • • • Cold boot the DRBIII®. This resets memory and removes all update files from the DRBIII®. (Push MORE and YES buttons at the same time, then press F4). Reload the flash update file from the TechCONNECT Client. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII®. Proceed to reflash the module.
-11- 18-037-05 There are two methods for abort-recovery. The newer method is called “Enhanced Abort Recovery”. This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM’s or TCM’s. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules.
18-037-05 -12- the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII® Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position.
-13- 18-037-05 Enhanced Abort Recovery Screens A prior attempt to flash the NGC ETC engine control module on a 2003 DR 5.7L V8 vehicle, was interrupted. Press YES if you want to attempt abort recovery or NO to decline.
18-037-05 -14- 1992 - 1999 PCM CONFIGURATION YEAR/ MODEL PCM TYPE 96-97 SR, Truck and Jeep except ZG, XJ 2.5 Diesel JTEC 97 FJ, JA, JX SBEC 3+ 98-99 All except GS 2.5 Diesel, NS 3.0 (early 99), PL 2.0, SR, All Truck and Jeep SBEC 3A 98-99 (early) NS 3.0, PL 2.0 SBEC 3 98 SR, All Truck and Jeep except AN, XJ, ZG 2.5 Diesel, BR/BE 5.9 Diesel JTEC 99 SR, All Truck and Jeep except AN, XJ 2.5 Diesel, BR/BE 5.9 Diesel, WG Diesel JTEC+ 98 AN, XJ, ZG 2.5 Diesel SBEC 2B/ MSA-15 98 GS 2.
-15- 18-037-05 2000 - 2002 PCM CONFIGURATION MODEL/YEAR PCM TYPE 02 All Truck and Jeep except BR/BE 5.9 Diesel, DN 4.7 (Early 02), JTEC + KJ 2.5 Diesel, WG 2.7 Diesel 02 LH NGC 02 PG/PL 1.6 SIM70 02 PG 2.2 Diesel, RG 2.5 Diesel, KJ 2.5 Diesel, WG 2.7 Diesel EDC15-C5 02 PL 2.0, RG 3.3, RS 3.3, 3.8 SBEC 3B 02 DN 4.7 (Late 02) NGC 2003 PCM CONFIGURATION YEAR/MODEL PCM TYPE 03 All except JR 2.7, PT 1.6, 2.2 Diesel, PL 1.6, RG 2.5 Diesel, RS NGC 3.3, 3.8, ZB, All Truck and Jeep except AN/DN/DR 4.
18-037-05 -162005 PCM CONFIGURATION YEAR/MODEL PCM TYPE CS, DR, JR, KJ, PL, PT, RG, RS, TJ NGC3 PT (BUX) 1.6 SIM70 PT 2.2 Diesel, RG 2.5/2.8 Diesel EDC15-C5 KJ 2.8 Diesel EDC16 ZB and SRT - 10 JTEC + DH 5.9 Diesel Cummins CM848 ZH ME 2.8 Bosch ST-22 MMC - Melco 2006 PCM CONFIGURATION YEAR/MODEL PCM TYPE DR, JR, KJ, PL, PT, RG, RS, TJ NGC3 CS NGC3A PT (BUX) 1.6L SIM70 KJ 2.8 Diesel, PT 2.2 Diesel, RG 2.5/2.8 Diesel EDC15-C5 ZB and SRT - 10 JTEC + DH 5.
-17- 18-037-05 *** The EATX 4 uses an EATX 4A for service replacements. 2001 - 2003 TCM CONFIGURATION YEAR/MODEL TCM TYPE 01 All FWD EATX 3B 02 All FWD except LH EATX 3B 03 All except RS 3.3/3.8, JR 2.7, DR 5.7 (NGC w/ETC), TJ, KJ, WJ/WG 4.7/WG 2.7 Diesel NGC 01 PT (early) EATX 3A 01 XJ AW4 01-02 AN/DN, WJ/WG 4.7, DN (early) EATX 4 02 LH, DN (late) NGC 02-03 WG 2.7 Diesel EGS52 03 RS 3.3/3.8, RG 3.3, JR 2.7, TJ, KJ (late), RG 3.3 EATX 3B 03 DR 5.7 (NGC wETC), KJ (early), KJ 2.
-037-05 -18- types and variations, followed by items to note, and finally, abort recovery specifics if applicable. POWERTRAIN MODULES - ENGINE AND TRANSMISSION ENGINE - POWERTRAIN CONTROL MODULE (PCM) There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBIII®. PCM information is used by many modules.
-19- 18-037-05 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGC1 and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM.
18-037-05 -20- BOSCH Types: • EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. TRANSMISSION CONTROL MODULES (TCM) Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a “QuickLearn” to the TCM.
-21- 18-037-05 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: • Follow DRBIII® prompts carefully. JTEC Types: • JTEC, JTEC + NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles.
18-037-05 -22- NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: • • • Follow DRBIII® prompts carefully. BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: • CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: • Follow DRBIII® prompts carefully.
-23- 18-037-05 Abort Recovery Specifics: • Follow DRBIII® prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: • PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: • Follow DRBIII® prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: • DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: • Follow DRBIII® prompts carefully.
18-037-05 -24- Abort Recovery Specifics: • • Follow DRBIII® prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. The DRBIII® may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: • ARKEM NOTE: Arkem modules are found on PL and PT vehicles.
-25- 18-037-05 NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: • Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: • SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: • Follow DRBIII® prompts carefully.
