LEMON Manuals: Even more car manuals for everyone
Home >> Dodge and Ram >> 2009 >> Sprinter 2500, Van Cargo >> Repair and Diagnosis >> Quick Lookups >> Technical Bulletins >> Campaigns >> Engine Control Systems >> Emissions Recall H44 Reprogram ECM - EGR System (H44)

Emissions Recall H44 Reprogram ECM - EGR System (H44)

Publication date: 2009-02-01
Reference number: H44

EMISSIONS RECALL H44 REPROGRAM ECM - EGR SYSTEM

EMISSIONS RECALL H44 REPROGRAM ECM - EGR SYSTEM

SERVICE CAMPAIGN BULLETIN

Reference Number(s): H44, Date of Issue:  February, 2009
CHRYSLER: 2007-2009 (VB) Dodge Sprinter, Freightliner Sprinter

MODELS

2007-2009 (VB) Dodge Sprinter

2007-2009 (VB) Freightliner Sprinter

NOTE: This recall applies only to the above vehicles equipped with a 3.0L diesel engine ("5" in the 8th VIN position) and built from September 1, 2006 through October 22, 2008 (MDH 090100 through 102210). 
IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery.  Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process or GRS DealerCONNECT functions.

SUBJECT

Models The Engine Control Module (ECM) on about 39,100 of the above vehicles may not actuate the EGR valve sufficiently to prevent soot accumulation, resulting in improper valve operation or sticking. Improper valve operation may cause excessive exhaust emissions, illumination of the Malfunction Indicator Lamp and a vehicle limp-in condition.

REPAIR

The Engine Control Module (ECM) must be reprogrammed (flashed).

PARTS INFORMATION

Due to the likelihood that the required labels are already in your parts inventory, no labels will be distributed initially. The following label may be ordered as needed.

Each vehicle requires application of the following label:

PARTS INFORMATION

Part Number  Description 
04275086AC Authorized Modifications Label

SPECIAL TOOLS

The following existing special tools may be required to perform this repair: 

* Part of CH9400 kit.

SERVICE PROCEDURE

Program the ECM

NOTE: This procedure must be performed using StarSCAN with release 9.04 or higher before this procedure can be performed. The software release level is visible in the blue header at the top of the StarSCAN screen. If the flash is aborted or interrupted, repeat the procedure.
  1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process.
    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. Remove the OBD/fuse cover located at the lower left side of the steering column and open the black plastic cover of the data link connector. Connect the CH9404D vehicle cable to the StarSCAN and the vehicle data link connector.
  3. Turn the ignition key to the "RUN"  position.
  4. Power "ON"  the StarSCAN.
  5. Retrieve the old ECM part number. With the StarSCAN on the "Home"  screen, follow the procedure below:
    1. Select "ECU View"  .
    2. Touch the screen to highlight "ECM"  in the list of modules.
    3. Select "More Options"  .
    4. Select "ECU Flash"  .
    5. Record the "Part Number"  displayed at the end of the "Resident flash file for" statement near the top of "Flash ECM"  screen for later reference.
  6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the "Flash ECM"  screen, follow the procedure below:
    1. Select "Browse for New File".  Follow the on screen instructions.
    2. If the newly downloaded flash file "Part Number" description is the same as the number recorded in Step  e, then the ECM is up to date. Continue to Step  10.
    3. Highlight the listed calibration on the StarSCAN screen.
    4. Select "Download to Scantool"  .
    5. Select "Close"  after the download is complete, then select "Back"  .
    6. Highlight the listed calibration.
    7. Select "Update Controller"  and follow the on screen instructions.
    8. 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 ECM part number. With the StarSCAN on the "Home"  screen, follow the procedure below:
    1. Select "ECU View"  .
    2. Touch the screen to highlight "ECM"  in the list of modules.
    3. Select "More Options"  .
    4. Select "ECU Flash"  .
    5. 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.
    1. From the "Home"  screen select "System View"  .
    2. Select "All DTCs"  .
    3. Press "Clear All Stored DTCs"  if there are any DTCs shown on the list.
  11. Turn the ignition key to the "OFF"  position.
  12. Remove the StarSCAN unit, StarSCAN cable and battery charger from the vehicle.
  13. Close the black plastic cover of the data link connector and install the OBD/fuse cover.
  14. Return the vehicle to the customer.

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.
    G07709642
    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.

COMPLETION REPORTING AND REIMBURSEMENT

Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments.

Use one  of the following labor operation numbers and time allowances:

LABOR OPERATION NUMBER AND TIME ALLOWANCE

  Labor Operation Number  Time Allowance
ECM Update Previously Performed 08-H4-41-81 0.2 hours
Reprogram Engine Control Module 08-H4-41-82 0.4 hours

Add the cost of the label plus applicable dealer allowance to your claim.

NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

DEALER NOTIFICATION

To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification.

OWNER NOTIFICATION AND SERVICE SCHEDULING

All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is attached.

Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable.

VEHICLE LISTS, GLOBAL RECALL SYSTEM, VIP AND DEALER FOLLOW UP

All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.

GRS provides involved dealers with an updated  VIN list of their incomplete  vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission.

To use this system, click on the "Service"  tab and then click on "Global Recall System."  Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence.

Dealers must perform this repair on all unsold vehicles before retail delivery.  Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair.

Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. 

ADDITIONAL INFORMATION

If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager.

Customer Services Field Operations

Chrysler

EMISSIONS RECALL H44 - Reprogram Engine Control Module

Dear: (Name)

Chrysler has determined that some 2007-2009 Dodge and Freightliner Sprinter vehicles may release air pollutants which exceed Federal and California regulations.

The problem is...  The Engine Control Module on your vehicle (VIN: xxxxxxxxxxxxxxxxx) may not actuate the EGR valve sufficiently to prevent soot accumulation, resulting in improper valve operation or sticking. Improper valve operation may cause excessive exhaust emissions, illumination of the malfunction indicator lamp and a vehicle limp-in condition.

What your dealer will do... Chrysler will repair your vehicle free of charge (parts and labor).  To do this, your dealer will reprogram your vehicle's Engine Control Module. The work will take about 1/2 hour to complete. However, additional time may be necessary depending on service schedules.

What you must do...  Simply contact your dealer  right away to schedule a service appointment. Remember to bring this letter with you to the dealer. 

If you need help...  If you have questions or concerns which your dealer is unable to resolve, please contact Chrysler at 1-800-853-1403.

California residents... The State of California requires the completion of emission recall repairs prior to vehicle registration renewal.  Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the recall service is performed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof that the recall has been performed.

Please help us update our records by filling out the attached prepaid postcard, if any of the conditions listed on the card apply to you or your vehicle. You may also update this information on the web at CCCCCCCCCCCCCCCCCCCCCCCCCC

If you have already experienced this condition and have paid to have it repaired, you may send your original receipts and/or other adequate proof of payment to the following address for reimbursement: Chrysler Recall Customer Assistance, P.O. Box 21-8007, Auburn Hills, MI 48321-8007, Attention: Reimbursement.

In order to ensure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Further, without this repair, your vehicle may fail a state or local emission inspection test.

We are sorry for any inconvenience but trust that you understand our interest in clean air. Thank you for your attention to this important matter.

Customer Services Field Operations

Chrysler

Notification Code H44

scientia non olet · About LEMON Manuals