RE: misfiring 3.3
This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retreival system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.
THE SOFTWARE IS AVAILABLE ON TechCONNECT.
FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE
AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD
Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303,
P0304, P0305, P0306
This bulletin involves replacing the spark plugs, ignition wires and if necessary,
reprogramming the Powertrain Control Module with new software.
2004 - 2005 (RG) Chrysler Voyager
2004 - 2005 (RS) Town & Country/Caravan
NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA
or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004
The vehicle operator may experience a MIL illumination. Further diagnosis may determine
that the MIL was caused by one or more of the following DTC's:
· P0300-MULTIPLE CYLINDER MISFIRE
· P0301-CYLINDER #1 MISFIRE
· P0302-CYLINDER #2 MISFIRE
· P0303-CYLINDER #3 MISFIRE
· P0304-CYLINDER #4 MISFIRE
· P0305-CYLINDER #5 MISFIRE
· P0306-CYLINDER #6 MISFIRE
Using a Scan Tool (DRBIII®) with TechCONNECT and the appropriate Diagnostic
Procedures, verify all engine systems are functioning as designed. If DTCs are present,
other than those listed above, 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 Repair
GROUP: Vehicle Performance
DATE: April 27, 2004
Procedure 1 and if necessary, Repair Procedure 2.
If an “Authorized Modification Label” is present and states that Service Bulletin 18-016-04
has been performed, it is not necessary to perform Repair Procedure 2.
Qty. Part No. Description
6 SPRE14PLP5 Spark Plug (04686742AD)
1 04686710AA Cable/Ignition (Cylinder #1)
1 04686734AA Cable/Ignition (Cylinder #2)
1 04686737AA Cable/Ignition (Cylinder #3)
1 04686738AA Cable/Ignition (Cylinder #4)
1 04686740AA Cable/Ignition (Cylinder #5)
1 04686741AA Cable/Ignition (Cylinder #6)
AR (1) 04275086AB Label, Authorized Modification (United States
and Canadian Markets)
AR (1) 05011058AA Label, Authorized Software Update (Markets
Outside the United States and Canada)
SPECIAL TOOLS/EQUIPMENT REQUIRED:
NPN Battery Charger
CH2002 General Purpose Interface Bus Cable Assembly
CH6000A Scan Tool (DRBIII®)
CH7000A/7001A J1962 Cable with Red DRBIII® Connector
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
REPAIR PROCEDURE 1:
Replace spark plugs and ignition cables
1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service
information available in TechCONNECT or the Town & Country and Caravan service
manual (publication no. 81-370-04062CD), page 8I-10.
2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2.
If Service Bulletin 18-016-04 has been performed, no further action is necessary.
REPAIR PROCEDURE 2:
Flash Reprogram PCM
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:
a. Simultaneously press the “MORE” and “YES” keys.
b. A screen will appear requesting a “COLD BOOT”.
c. Follow the on screen instructions by selecting the “F4” key.
d. 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:
a. "DRBIII® Standalone"
b. "1998 - 2004 Diagnostics"
c. "All (Except Below)"
e. “Module Display”
f. Record the “PCM part #” on the repair order for later reference.
3. Connect the DRBIII® to TechCONNECT. Open TechTOOLS and verify that the
"DRBIII® Status: Connected" message is in the upper right corner of the TechTOOLS
4. Enter the “PCM part #” recorded in Step #2 in the “Parts Criteria” area and select
“Show Updates”. TechTOOLS will populate the appropriate calibration.
5. Select the calibration.
6. Select the “DRBIII” radio button which is next to the “Download/Update” button.
7. Select the “Download/Update” button.
8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and
follow the instructions on TechCONNECT. When the flash process is complete,
proceed to Step #9.
9. Disconnect the DRBIII® from TechCONNECT.
10. Open the hood, install a battery charger and verify battery state is above 12.5 volts.
11. Connect the DRBIII® to the vehicle.
12. Download the flash from the DRBIII® to the vehicle. Using the DRBIII® select:
a. “Vehicle Flash”
b. Follow the directions on the DRBIII® screen. When the flash process is complete,
proceed to Step #13.
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.
NOTE: The following step is required by law.
13. Type the necessary information on the “Authorized Modification Label” p/n
04275086AB and attach near the VECI label (Fig. 1).
Fig. 1 AUTHORIZED MODIFICATION LABEL
1 - ENGINE CONTROL MODULE P/N (INSERT P/N) USED
2 - CHANGE AUTHORITY: TSB XX-XXX-XX
3 - DEALER CODE: XXXXX