TSB 18-019-01 - Cold Idle Engine Warming for 2nd Gen VP44 Cummins

Date: September 3, 2001

Models: 1998 1/2-2002 BR/BE Ram Trucks

NOTE: THIS BULLETIN APPLIES TO ALL RAM TRUCKS BUILT AFTER DECEMBER 17,1997 AND EQUIPPED WITH THE 24-VALVE 5.9L CUMMINS DIESEL ENGINE.

Discussion:

This bulletin involves selectively erasing and reprogramming the Engine Control Module (ECM) with new software (Cal 55Tl8, 57Tl1, 56Tl3, 59T7b, and 59T8b.)

Symptom/Condition:

Extended idle operation, especially in cold weather, can lead to stuck valves and bent push-tubes due to insufficient cylinder heat. This allows varnishes/oils to condense on the exhaust valve stems, leading to stuck valves, and damaged valve train components. A new software feature, enabled or disabled through the DRB III (See instructions under Repair Procedure), reduces the chance of valve sticking and improves cab heat warm-up time.

Once enabled, idle speed will slowly ramp up from 800 rpm to 1200 rpm when all of the following conditions are met:

1. Intake Manifold Temperature less than 0°C (32°F) and,
2. Coolant Temp is less than 60°C (140°F) and,
3. The Transmission is in Neutral or Park and,
4. The Service Brake pedal is not depressed and,
5. Throttle = 0% and,
6. Vehicle Speed = 0 mph

Additionally, if Intake Manifold Temperature (IMT) is less than -9°C (15°F), and all of the parameters above are met, three of the cylinders will be shut off upon reaching 1200 rpm, creating a slight change in engine sound which is normal. This allows the engine to create increased heat in the cooling system, allowing more rapid engine warm up and cab heating.

Both features will automatically disable when one of the following occurs:

1. The Automatic Transmission is placed in gear (forward or reverse) or,
2. The Service Brake pedal is depressed or,
3. Throttle position is greater than 0% or,
4. Vehicle Speed is greater than 0 mph or,
5. Coolant Temperature is greater than 79°C (175°F).

Engine speed will return to normal operation at 800 rpm. If the engine continues to idle and coolant temperature is at or below 60°C (140°'F), the feature will re enable. In order to operate properly, the Accelerator Pedal Position Sensor (APPS) must stay at idle.

NOTE: ANY TYPE OF AFTERMARKET IDLE SPEED KICKER THAT ACTIVATES THE APPS WILL DISABLE THIS FEATURE.

Use of the 110V block heater will not allow the feature to function after an overnight soak. If the vehicle is left idling, without use of the block heater, 1200 rpm operation will begin when the intake temperature drops below O°C (32°F) and coolant is less than 60°C (140°F).

Diagnosis:

1. Using the Diagnostic Scan Tool (DRBIII) with the appropriate Diagnostic Procedures, verify all engine/transmission systems are functioning as designed. If other Diagnostic Trouble Codes (DTC) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin.

Parts Required:

Equipment Required:

NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III, THE SYSTEM MUST BE OPERATING AT CIS CD 2090 OR HIGHER (2090 ARRIVES IN DEALERSHIPS ON SEPTEMBER 3, 2001).

Repair Procedure:

1. Log onto the MDS2 (Mopar Diagnostic System).

2. Connect the MDS2 and DRBIII to the vehicle and switch the ignition key to"ON".

NOTE: AUTO CONNECTION WILL OCCUR ONCE THE DRB III, MDS2, AND VEHICLE ESTABLISH COMMUNICATION. THE "CANNOT READ VIN FROM DRB III" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A L4DS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK"BUTTON WHEN ASKED TO BEGIN SESSION.

3. Push the FLASH tab on the MDS2.

4. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2.

NOTE: A MESSAGE MAY APPEAR (AFTER STEP 3 OR 4) THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION.

5. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE.

6. The MDS2 and DRB III will prompt for any operator action needed during the remainder of the reprogramming process.

NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM, ETC.) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED.

NOTE: ONCE THE VEHICLE HAS BEEN REPROGRAMMED TO THE PROPER SOFTWARE LEVEL, YOU MUST USE THE DRB III TO ENABLE THE 3 CYLINDER IDLE FEATURE. TO DO SO FOLLOW THE INSTRUCTIONS BELOW.

7. Connect the DRB III to the vehicle without connecting to MDS2 and follow the menu structures it appears below.

8. MAIN MENU - 1998 - 2002 DIAGNOSTICS

9. 1998 - 2002 DIAGNOSTICS - ALL (EXCEPT BELOW)

10. SELECT SYSTEM - 1 ENGINE

11. CONTROLLER TYPE - 1 CUMMINS (ECM/ENGINE)

12. SELECT FUNCTION - 1 MISCELLANEOUS (Misc. is on second page)

13. 3.3 CYLINDER IDLE - Follow the instructions

The DRB III will indicate whether the feature is enabled or disabled.
14. Push 1 to Enable, 2 to Disable.

15. You are instructed to cycle the ignition to complete the repair.

16. Press Page Back to Exit.

NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW.

17. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Fig. 1). Attach the label to the PCM and cover the label with the clear plastic overlay.