Technical Service Bulletin: 2003-2005 5.9 L Cummins PCM Reflash

SUBJECT

Flash: 5.9L Turbo-Diesel Engine System Enhancements

OVERVIEW

This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software.

SYMPTOM/CONDITION

The following enhancements are included with this software:

1. Improved engine cooling (radiator fan activation) and prevention of possible engine overheat. When coolant temperature faults are present the radiator fan is enabled (turned on) during vehicle operation.
2. Correction to oil pressure reading when engine is operating at higher engine temperatures above 91°C (195°F).
3. Improvement to the Temperature Sensor Rationality Test to prevent possible false test failures and the following related Diagnostic Trouble Codes (DTC’s):
   1. DTC P0071 – Inlet Air Temperature Sensor Rationality.
   2. DTC P0111 – Intake Air Temperature (IAT) Sensor Rationality.
   3. DTC P0514 – Battery Temperature Sensor Rationality.
4. Additional Water-In-Fuel (WIF) warning added to indicate that the operator has had a WIF DTC P2269 and has continued to operate (drive) the vehicle in excess of 500 miles without draining the water from the fuel filter. The following is the new WIF DTC that has been added:
   1. DTC P0169 – WIF Too Long Error
5. ** Improvement to the Fuel Pressure Rationality Test to prevent possible false test failures and the following related Diagnostic Trouble Code:
   1. DTC P0191 – Fuel Rail Pressure Sensor Circuit Performance (2004.5 to 2005 M.Y. vehicles). **

DIAGNOSIS

Using a Scan Tool (DRBIII®) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs 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 Repair Procedure.

SPECIAL TOOLS / EQUIPMENT REQUIRED

REPAIR PROCEDURE

1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII® memory. To clear the memory from the MAIN MENU power up the DRBIII® and then:
   1. Simultaneously press the “MORE” and “YES” keys.
   2. A screen will appear requesting a “COLD BOOT”.
   3. Follow the on screen instructions by selecting the “F4” key.
   4. When the DRBIII® reboots to the MAIN MENU, proceed to Step #2
2. With the ignition switch in the “RUN” position, determine and record the “ECM part number” of the ECM currently in the vehicle. Using the DRBIII® select:
   1. “DRBIII® Standalone”
   2. “1998 – 2007 Diagnostics”
   3. “All (Except Below)”
   4. “Engine”
   5. “Module Display”
   6. Record the “ECM part number” on the repair order for later reference.
   NOTE: If the ECM is not operational, the “ECM part number” can be obtained from the label on the controller. For 2003 and later vehicles, if the label on the controller is not legible, record the “Reference No.” for use later. The “Reference No.” is located in the Reference No. box at the top, center of the Engine Data Plate (Fig 1). Do not use the reference number shown in the figure. The Engine Data Plate is located on the intake side of the breather cover or affixed to the APPS bracket.
   Fig 1: Identifying Engine Data Plate (2003 And Later Shown)Courtesy of CHRYSLER CORP.
3. Page back to the “Main Menu”
4. Determine if the vehicle is equipped with SKIM. Using the DRBIII® select:
   1. “DRBIII Standalone”
   2. “1998 – 2007 Diagnostics”
   3. “All”
   4. “System Monitor”
   5. “J1850 Module Scan”
   6. Look for “SKIM” in the list of modules.
5. If the vehicle is not equipped with SKIM then proceed to Step #6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with Step #6. This information is available from:
   1. The original selling invoice.
   2. The DealerCONNECT system under the “Parts” tabs – select “Key Codes”.
   3. By contacting the District Manager.
   CAUTION: Failure to install the SKIM pin number into the module after flashing the Cummins ECM will cause a start and stall condition.
6. Install a battery charger and verify that the charging rate provides approximately 13.2 – 13.8 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: When reprogramming a Cummins ECM be sure to do the following;

   • Download the flash file from TechCONNECT to the DRBIII® with the DRBIII® disconnected from the vehicle.
   • Download the flash file from the DRBIII® to the vehicle with the DRBIII® disconnected from TechCONNECT.
7. Connect the DRBIII® to TechCONNECT. Open TechTOOLS and verify that the “DRBIII® Status: Connected” message is in the upper right corner of the TechTOOLS screen.
8. Enter the old Cummins “ECM part number” obtained from the DRBIII® in Step # 2 into the “Parts Criteria” window.
9. Select “Show Updates”.
10. Highlight the proper flash file from the list:
    1. If the old “ECM part number” is known, highlight the flash file listed, based on the old “ECM part number” recorded earlier Step # 2.
    2. If the old part number is not known, highlight the proper flash file based on the Reference No. located in the “Ref. No.” box, at the top, center of the Engine Data Plate (Fig 1).
11. Select the “DRBIII” radio button which is next to the “Download/Update” button.
12. Select the “Download/Update” button.
13. Monitor the “Flash Download/Update Progress” window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to the next step.
14. Disconnect the DRBIII® from TechCONNECT.
15. Connect the DRBIII® to the vehicle.
16. Download the flash file from the DRBIII® to the vehicle. Using the DRBIII® select:
    1. “Vehicle Flash”
    2. Follow the directions on the DRBIII® screen. When the flash process is complete, proceed to the next step.
17. If the vehicle is equipped with SKIM, proceed to Step #18. If the vehicle is not equipped with SKIM, proceed to Step # 19.
18. On vehicles equipped with SKIM, transfer the VIN and Security Key information from the SKIM to the ECM. Using the DRBIII® select:
    1. “DRBIII Standalone”
    2. “1998 – 2007 Diagnostics”
    3. “All”
    4. “Theft Alarm”
    5. “SKIM”
    6. “Miscellaneous”
    7. “Cummins ECM Replaced”
    8. Follow the directions on the DRBIII® screen. When the process is complete, proceed to Step # 20.
19. On vehicles not equipped with SKIM, manually enter the VIN in the ECM. Using the DRBIII® select:
    1. “DRBIII Standalone”
    2. “1998 – 2007 Diagnostics”
    3. “All”
    4. “Engine”
    5. “Cummins Controller (ECM/ENGINE)”
    6. “Miscellaneous”
    7. “CM84X Check VIN”
    8. Follow the directions on the DRBIII® screen. When the process is complete, proceed to next step.
    NOTE: Due to the Cummins controller programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC’s may cause the MIL to illuminate. Check all modules using “Module Scan”, record the DTC’s, and erase these DTC’s prior to returning the vehicle to the customer. Erase any DTC’s in the PCM only after all other modules have had their DTC’s erased.
    NOTE: The following step is required by law.
20. Type the necessary information on the “Authorized Modification Label” p/n 04275086AB and attach near the VECI label (Fig 2).
    Fig 2: Identifying Authorized Modification LabelCourtesy of CHRYSLER CORP.