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TSB 18-004-02

1999 Model Year Engine Spark Knock

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Date: Jan. 28, 2002

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-06-00 REV C, DATED DEC 01, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES.

Models: 1999 BR/BE Ram Truck with gas engine

1999      (AB) Ram Van/Wagon
1999 (AN) Dakota
1999 (BR/BE)      Ram Truck
1999 (DN) Durango

NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.9L (ECH), 5.2L (ELF), or 5.9L LIGHT DUTY (EML) GASOLINE ENGINE. SEE THE FOLLOWING TABLE FOR SPECIFIC EXCLUSIONS.

NOTE: THIS BULLETIN DOES NOT APPLY TO THE FOLLOWING SPECIFIC VEHICLES WHEN EQUIPPED AS LISTED IN THE FOLLOWING TABLE. THE PCM CALIBRATION SOFTWARE OF ANY EXCLUDED VEHICLE IS NOT TO BE REPROGRAMMED FOR A SPARK KNOCK COMPLAINT. BEFORE ATTEMPTING A REPROGRAMMING SESSION, INSPECT THE VEHICLE, TYPE, ENGINE, TRANSMISSION, AND EMISSIONS CATEGORY FOR POSSIBLE EXCLUSION.

VEHICLE ENGINE TRANSMISSION EMISSIONS CD RELEASE
AN ALL A4 / M5 Fed and Calif 2072
AN 5.9L A4 Calif Only 2076
AN 5.9L A4 Fed Only 2072
BR/BE 3.9L A4 / M5 Fed and Calif 2072
BR/BE 5.2L A4 / M5 Fed and Calif 2072
BR/BE 5.9L A4 / M5 Fed and Calif 2072
DN 5.2L A4 Fed and Calif 2072
DN 5.9L A4 Fed Only 2072
DN 5.9L A4 Calif Only 2076
      
Legend: A3 = 3 spd auto A4 = 4 spd auto M5 = 5 spd manual  

NOTE: The following emission packages are not approved and are excluded from this bulletin. The PCM calibration of any excluded vehicle is not to be reprogrammed for a spark knock complaint. Before attempting a reprogramming session inspect the type of vehicle and engine for possible exclusion.

VEHICLE TYPE ENG / TRANS / EMISS
AN ALL 2.5L / M5 / Fed and Calif
AN ALL 5.9L/ A4 / Fed and Calif
BR/BE ALL 5.9L Heavy Duty (EMM - SALES CODE)
BR/BE ALL 8.0L (EWA - SALES CODE)
BR/BE 2500 Cab-Chassis 5.9L Lt Duty / A4 or M5 / Fed
BR/BE 2500 Cab-Chassis 5.9L Lt Duty / A4 / Calif
BR/BE 3500 Series 5.9L Lt Duty / A4 or M5 / Calif
BR/BE 3500 Cab-Chassis 5.9L Lt Duty / A4 or M5 / Calif
Legend: A3 = 3 spd auto A4 = 4 spd auto M5 = 5 spd manual

Discussion:
This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software (calibration level 99Cal16B, 99Cal17, AND 99Cal17A)

Symptoms:
Some vehicle engines may exhibit a light-to-moderate spark knock condition during acceleration (under load).

Diagnosis: 

1. Verify that the following NOTE(S) have been reviewed and completed as necessary.

2. Verify that the engine coolant contains the correct mixture of a quality antifreeze to water. The coolant mixture should consist of 44% to 68% antifreeze.

3. If the only condition seen is the light-to-moderate engine spark knock, perform the Repair Procedure.

NOTE: VERIFY THAT TSB 18-48-98, FOR IGNITION WIRE ROUTING, HAS BEEN COMPLETED.

NOTE: THIS REPAIR PROCEDURE WILL NOT COMPENSATE FOR HEAVY SPARK KNOCK CONDITIONS. IF A HEAVY KNOCK IS EXPERIENCED, FURTHER DIAGNOSIS WILL BE REQUIRED. REFER TO TSB 09-05-00 FRO ADDITIONAL ASSISTANCE.

NOTE: WHEN PULLING A HEAVY LOAD OR DRIVING A FULLY LOADED VEHICLE USE A PREMIUM UNLEADED FUEL TO HELP MINIMIZE SPARK KNOCK.

Parts Required:

1    04669020 Label,   Authorized Software Update
1    04275086 Label,   Authorized Modification

Equipment Required:

CH6000             Scan Tool   (DRB III)
CH7035             General Purpose Interface Bus Cable (GPIB)
CH7000/7001    J1962 Cable
                          MDS2

Repair: 

1.    Flash the controller using the MDS2 (Mopar Diagnostic System) and DRBIII.

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: THE FOLLOWING STEPS ARE REQUIRED BY LAW.
2.    Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.

 3.  Type or print the following information on the "Authorized Modification Label" P/N 04275086 and attach the label near the VECI label (Fig 2).

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:
Labor Operation No:  08-19-44-92 (Reprogram PCM) ...................................0.5 Hrs.

Failure Code:  FM - Flash Module


Thanks to David Lovell for supplying this TSB information

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This page was edited on: May 3, 2004