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Generic Powertrain Control Module (Pcm) Procedure (18-042-14)

Publication date: 2014-07-30
Reference number: 18-042-14
Supersedes refnos: 18-006-04, 18-006-04 REV. A, 18-006-04 REV. B, 18-029-07

GENERIC POWERTRAIN CONTROL MODULE (PCM) PROCEDURE

GENERIC POWERTRAIN CONTROL MODULE (PCM) PROCEDURE

TECHNICAL SERVICE BULLETIN

Reference Number(s): 18-042-14, Date of Issue:  July 30, 2014
CHRYSLER: 2004 Dakota (AN); 2004 - 2005 Pacifica (CS), Ram Truck (DR), Sebring Convertible/Sebring Sedan/Stratus Sedan (JR), Liberty (KJ), Cherokee (International Markets) (KJ), Neon (PL), PT Cruiser (PT), Chrysler Voyager (International Markets) (RG), Town & Country/Caravan/Voyager (RS); 2005 Wrangler (TJ)
GROUP: Vehicle Performance
Superceded Bulletin(s): 18-029-07, Date of Issue:  April 26, 2007
NOTE: THE DRBIII® FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT.
NOTE: THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-029-07, DATED APRIL 26, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. IN ADDITION, ALL LH MODELS HAVE BEEN REMOVED FROM THE BULLETIN AS POWERTRAIN CONTROL MODULES FOR THESE VEHICLE ARE NOW SHIPPED IN A PRE-PROGRAMMED, NON-GENERIC STATE.

SUBJECT

Generic Powertrain Control Module (PCM) Procedure

OVERVIEW

This bulletin involves programming a generic PCM with software.

MODELS

MODEL INFORMATION

2004 (AN) Dakota
2004 - 2005 (CS) Pacifica
2004 - 2005 (DR) Ram Truck
2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan
2004 - 2005 (KJ) Liberty
2004 - 2005 (KJ) Cherokee (International Markets)
2004 - 2005 (PL) Neon
2004 - 2005 (PT) PT Cruiser
2004 - 2005 (RG) Chrysler Voyager (International Markets)
2004 - 2005 (RS) Town&Country/Caravan/Voyager
2005 (TJ) Wrangler
NOTE: Refer to the following table for specific applications.
MODEL INFORMATION

Model Engine Transmission
AN 3.7L or 4.7L Auto or Man
CS 3.5L Auto
DR 3.7L, 4.7L, or 5.7L Auto or Man
JR 2.0L, 2.4L, 2.4L Turbo or 2.7L Auto or Man
KJ 2.4L or 3.7L Auto or Man
PL 2.0L, 2.4L or 2.4L Turbo Auto or Man
PT 2.0L, 2.4L or 2.4L Turbo Auto or Man
RG 2.4L or 3.3L Auto or Man
RS 2.4L, 3.3L or 3.8L Auto
TJ 2.4L or 4.0L Auto or Man

DISCUSSION

Mopar® is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar®. Replacement of future PCMs will require programming utilizing the DRBIII® and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed".

CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration.

PARTS REQUIRED

PARTS REQUIRED

Qty. Part No. Description Model Remarks
1 56028805AD Generic Powertrain Control Module AN Vehicles with 3.7L and Manual Transmission
1 56028806AD Generic Powertrain Control Module AN Vehicles with 3.7L and Automatic Transmission
1 56028796AD Generic Powertrain Control Module AN Vehicles with 4.7L and Automatic Transmission
1 56028797AD Generic Powertrain Control Module AN Vehicles with 4.7L and Manual Transmission
1 05127196AA Kit, Generic Powertrain Control Module CS Built on or before July 11, 2003 with a VIN sequence of 4R499999 or lower.
1 05134856AA Generic Powertrain Control Module CS Built on or after July 12, 2003 through and including July 7, 2004
1 05161322AA Generic Powertrain Control Module CS Vehicles with 3.5L
Built on or after July 8, 2004
1 05161323AA Generic Powertrain Control Module CS Vehicles with 3.8L
Built on or after July 8, 2004
1 56028805AD Generic Powertrain Control Module DR 2004 Vehicles with 3.7L and Manual Transmission
1 56028879AB Generic Powertrain Control Module DR 2005 Vehicles with 3.7L and Manual Transmission
1 56028806AD Generic Powertrain Control Module DR 2004 Vehicles with 3.7L and Automatic Transmission
1 56028881AB Generic Powertrain Control Module DR 2005 Vehicles with 3.7L and Automatic Transmission
1 56028797AD Generic Powertrain Control Module DR 2004 Vehicles with 4.7L and Manual Transmission
1 56029079AD Generic Powertrain Control Module DR 2005 Vehicles with 4.7L and Manual Transmission
1 56028796AD Generic Powertrain Control Module DR 2004 Vehicles with 4.7L and Automatic Transmission
1 56028892AC Generic Powertrain Control Module DR 2005 Vehicles with 4.7L and Automatic Transmission
1 56028799AD Generic Powertrain Control Module DR 2004 Vehicles with 5.7L and Manual Transmission
1 56028878AB Generic Powertrain Control Module DR 2005 Vehicles with 5.7L and Manual Transmission
1 56028800AD Generic Powertrain Control Module DR 2004 Vehicles with 5.7L and Automatic Transmission
1 56028930AB Generic Powertrain Control Module DR 2005 Vehicles with 5.7L and Automatic Transmission
1 04896301AD Generic Powertrain Control Module JR Vehicles with 2.0L or 2.4L and Automatic Transmission
Built on or before July 7, 2004
1 04606912AC Generic Powertrain Control Module JR Vehicles with 2.0L, 2.4L or 2.4L Turbo and Automatic Transmission
Built on or after July 8, 2004
1 04896304AE Generic Powertrain Control Module JR Vehicles with a 2.0L or 2.4L and Manual Transmission
Built on or before July 7, 2004
1 04606913AC Generic Powertrain Control Module JR Vehicles with a 2.0L or 2.4L and Manual Transmission
Built on or after July 8, 2004
1 04606819AD Generic Powertrain Control Module JR Vehicles with 2.4L Turbo and Automatic Transmission
Built on or before July 7, 2004
1 04896302AD Generic Powertrain Control Module, JR Vehicles with a 2.7L and Automatic Transmission Built on or before June 30, 2004 **SEE NOTE BELOW (1)
1 04606916AC Generic Powertrain Control Module JR Vehicles with a 2.7L and Automatic Transmission
Built on or after July 1, 2004
1 56044397AD Generic Powertrain Control Module KJ Vehicles with 2.4L or 3.7L and Manual Transmission
Built on or before July 11, 2004
1 56044665AC Generic Powertrain Control Module KJ Vehicles with 2.4L or 3.7L and Manual Transmission
Built after July 12, 2004
1 56044396AD Generic Powertrain Control Module KJ Vehicles with 3.7L and Automatic Transmission
Built on or before July 11, 2004
1 56044666AB Generic Powertrain Control Module KJ Vehicles with 3.7L and Automatic Transmission
Built on or after July 12, 2004
1 05134852AB Generic Powertrain Control Module PL Vehicles with 2.0L, 2.4L, 2.4L Turbo and Manual Transmission
Built before July 8, 2004
1 05161105AA Generic Powertrain Control Module PL
PL SRT 4		 Vehicles with 2.0L, 2.4L, 2005 SRT-4 and Manual Transmission
Built on or after July 9, 2004
1 05134858AA Generic Powertrain Control Module PL Vehicles with 2.0L or 2.4L and Automatic Transmission
Built before July 8, 2004
1 05161104AA Generic Powertrain Control Module PL Vehicles with 2.0L or 2.4L and Automatic Transmission
Built on or after July 9, 2004
1 05134853AB Generic Powertrain Control Module PL SRT-4 All 2004 with 2.4L Turbo and Manual Transmission
Built on or before July 8, 2004
1 05033290AE Generic Powertrain Control Module PT Vehicles with a 2.0L, 2.4L or 2.4L Turbo and Manual Transmission
Built on or before July 22, 2004
1 05033326AE Generic Powertrain Control Module PT Vehicles with a 2.0L, 2.4L or 2.4L Turbo and Manual Transmission
Built on or after July 23, 2004
1 05033291AD Generic Powertrain Control Module PT Vehicles with a 2.0L or 2.4L and Automatic Transmission
1 05033327AC Generic Powertrain Control Module PT Vehicles with a 2.0L or 2.4L and Automatic Transmission
Built on or after July 23, 2004
1 05033292AD Generic Powertrain Control Module PT Vehicles with a 2.4L Turbo and Automatic Transmission
Built on or before July 22, 2004
1 05033328AC Generic Powertrain Control Module PT Vehicles with a 2.4L Turbo and Automatic Transmission
Built on or after July 23, 2004
1 05134854AA Generic Powertrain Control Module RG Vehicles with 2.4L and Manual Transmission
Built on or before October 17, 2004
1 05161103AA Generic Powertrain Control Module RG Vehicles with 2.4L and Manual Transmission
Built on or after October 18, 2004
1 05134855AA Generic Powertrain Control Module RS Vehicles with 2.4L and Automatic Transmission
Built on or before July 8, 2004
1 05161102AA Generic Powertrain Control Module RS Vehicles with 2.4L and Automatic Transmission
Built on or after July 9, 2004
1 05134857AA Generic Powertrain Control Module RG/RS Vehicles with 3.3L or 3.8L and Automatic Transmission
Built on or before July 7, 2004
1 05161324AA Generic Powertrain Control Module RG/RS Vehicles with 3.3L or 3.8L and Automatic Transmission
Built on or after July 8, 2004
1 56044499AD Generic Powertrain Control Module TJ Vehicles with 2.4L or 4.0L and Manual Transmission
1 56044529AC Generic Powertrain Control Module TJ Vehicles with 2.4L or 4.0L and Automatic Transmission
(1) Certain early built JR vehicles may not utilize a Generic Powertrain Control Module. These vehicle are identified by the number of connectors on the Powertrain Control Module. Modules using only 2 connectors are non-generic and are shipped to your dealership pre-programmed. No software programming is required in these situations.**

SPECIAL TOOLS/EQUIPMENT REQUIRED

SPECIAL TOOLS/EQUIPMENT

NPN Battery Charger
CH2002 General Purpose Interface Bus Cable Assembly
CH6000A Scan Tool (DRBIII®)
CH7000A/7001A J1962 Cable with red DRBIII® connector
  TechCONNECT Workstation
NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII® connection. Use this cable whenever a flash is being performed.
NOTE: The DRBIII® Emulator available in the wiTECH Diagnostic Application may also be used in the event a DRBIII® is unavailable.

REPAIR PROCEDURE

NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin #9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connnector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE.
NOTE: Whenever a controller is programmed, the software in the DRBIII®; must be programmed with the latest revision level available.
NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII®.
  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 DRB III® reboots to the MAIN MENU, proceed to Step 2.
  2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII® select:
    1. "DRBIII® Standalone"
    2. "1998 - 2004 Diagnostics"
    3. "All (Except Below)"
    4. "Engine"
    5. "Module Display"
    6. Record the first ten (10) characters of the "PCM part #" on the repair order for later reference.
    NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step.
  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 - 2004 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 one of the following:
    1. The original selling invoice.
    2. **The DealerCONNECT system under the "Service" or "Parts" tabs - select "Key Codes".**
    3. **By contacting the Customer Assistance Center (CAC) at 1-800-992-1997.**
      CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition.
  6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation.
  7. Open the hood, install a battery charger and verify battery state is above 11.5 volts.
  8. Connect the DRBIII® to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII® Status: Connected" message is in the upper right corner of the TechTOOLS screen.
  9. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria" area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates.
  10. Select the correct calibration.
  11. Select the "Download/Update" button.
  12. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII®. When the flash process is completed, proceed to next step.
  13. Enter the VIN in the PCM. Using the DRBIII® select:
    1. "DRBIII Standalone"
    2. "1998 - 2004 Diagnostics"
    3. "All"
    4. "Engine"
    5. "Miscellaneous"
    6. "Check VIN"
    7. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII®. When the VIN and SKIM key has been programmed, proceed to step 20.
    8. Enter the VIN as requested by the DRBIII®.
  14. Update the PCM mileage. Using the DRBIII® select:
    1. "DRBIII® Standalone"
    2. "1998 - 2004 Diagnostics"
    3. "All (Except Below)"
    4. "Engine"
    5. "Miscellaneous"
    6. "Check PCM Odometer"
    7. "NO"
    8. Enter the current odometer mileage and then press "Enter".
    9. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter".
  15. Proceed as follows:
    1. If the vehicle is equipped with an automatic transmission, proceed to step 24.
    2. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24.
    3. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23.
  16. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII® select:
    1. "DRBIII® Standalone"
    2. "1998 - 2004 Diagnostics"
    3. "All (Except Below)"
    4. "Engine"
    5. "Miscellaneous"
    6. "Pinion Factor"
    7. Select the correct tire size and then select "Page Back" to exit.
    8. Proceed to step 24.
  17. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII® select:
    1. "DRBIII® Standalone"
    2. "1998 - 2004 Diagnostics"
    3. "All (Except Below)"
    4. "Transmission"
    5. "Transmission Module"
    6. "Miscellaneous"
    7. "Pinion Factor"
    8. Select the correct tire size and then select "Page Back" to exit.
    9. Enter "Quick Learn" and then follow the instructions on the DRBIII®.
      NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (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.

POLICY

Reimbursable within the provisions of the warranty.

TIME ALLOWANCE

Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual.

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