18-013-08
GROUP: Vehicle Performance
DATE: March 13, 2008
SUBJECT:
FLASH: Engine System And Exhaust Aftertreatment System Enhancements
OVERVIEW:
This bulletin involves:
==> If eligible, verifying that Emission Recall G30 - Replace Oxygen Sensor
Module and Reprogram ECM has been performed. If not, perform Recall G30 first.
==> Verifying software level, and if necessary, selectively erasing and
reprogramming the Engine Control Module (ECM) with new software.
==> Verifying software level, and if necessary, selectively erasing and
reprogramming the Cab Compartment Node (CCN) module with new software.
SYMPTOM/CONDITION:
NOTE: The following conditions and improvements have been addressed with the latest Engine Control Module (ECM) software. This Service Bulletin (SB) only
addresses the labor associated with the reprogramming of the ECM, the CCN, and the installation of a Documentation Kit. Any other labor associated with the performance of additional diagnostics is not addressed by this SB and must be claimed separately.
A. ISSUES ADDRESSED BY VARIOUS ECM SOFTWARE RELEASES TO DATE:
NOTE: With this latest ECM software release listed in this Service Bulletin, the
following symptoms have been completely addressed.
1. The technician may not be able to reprogram (flash) the PCM with new application software.
2. One of the following driveability conditions:
a. An intermittent rough engine idle and/or white smoke following initial engine start.
b. A throttle tip-in stumble at engine speeds of 1,300 to 2,100 rpm.
c. An engine hesitation at altitude of 5,000 feet between engine speeds of 1,200 to 1,600 rpm.
d. A turbocharger “chuff-like” sound during rapid deceleration.
3. The vehicle may fail an Emission Inspection Maintenance (I/M) Test because two or more On-Board Diagnostic (OBD) monitors report that they are not ready for testing.
This condition may cause the customer vehicle to not pass an Emissions I/M test. The following is a list of OBD Monitors that may report as not ready for testing:
a. Non-Methane Hydrocarbon (NMHC) Catalyst Monitor.
b. Nitrogen Oxide (NOx) Absorber Monitor.
c. Exhaust Gas Temperature Sensor Monitor.
d. Electrical Charging System Monitor.
e. EGR System Monitor.
f. Oxygen Sensor Monitor.
4. Malfunction Indicator Lamp (MIL) due to one or more of the following Diagnostic
Trouble Codes (DTC):
a. P0101 - Mass Air Flow (MAF) Sensor Rationality
b. P0128 - Thermostat Rationality
c. P061A - ETC Level 2 Torque Performance.
d. U1421 - Implausible Ignition Key Off Time Received
B. ISSUES IMPROVED SIGNIFICANTLY BY VARIOUS ECM SOFTWARE RELEASES
TO DATE:
NOTE: The following symptoms and conditions have been significantly enhanced by
the latest ECM software listed in this Service Bulletin. Always check
TechCONNECT to see if there are new or additional Service Bulletins that
may apply to a condition. If condition persists contact STAR for further
assistance.
1. The latest ECM software includes a new extended idle feature to accommodate the
extended idle times present in some duty cycles. This feature may help to reduce the
accumulation of soot in the exhaust aftertreatment system when the engine is idling for
an extended period of time. Briefly how this feature works:
a. As needed, the engine enters an idling mode which dramatically reduces the rate of
soot accumulation in the diesel particulate filter (called “Net Zero”). Further, under
extended idle periods of longer than 2 hours, the engine enters a mode which
reduces the amount of soot accumulated in the diesel particulate filter (called “Net
Reduction”). While in these modes, the idle speed increases to 900 rpm for a period
of time. The idle speed may return to normal idle speed and then return to 900 rpm
to repeat this cycle during very long idle periods.
b. These modes occur automatically provided two conditions are met. The vehicle
must be in Park (automatic transmission) or have the Parking Brake engaged
(manual transmission) for these modes to be enabled. There must also be no
accelerator pedal input.
c. After extended idling, if operation of the engine consists of light loads for short
periods of time the engine will return more quickly to the Net Zero or the Net
Reduction mode of the extended idle operation feature.
d. After extended idling, if operating the engine consists of higher loads for longer
periods of time the engine must again idle for an extended period before the engine
will return to the Net Zero or the Net Reduction mode of the extended idle operation
feature.
2. A MIL illumination due to one of the following DTC's:
a. P2000 - NOx Absorber Efficiency Below Threshold - Bank 1
b. P2A00 - Oxygen Sensor 1/1 Circuit Performance
c. P2A01 - Oxygen Sensor 1/2 Circuit Performance
Perform this Service Bulletin and the appropriate Diagnostic Procedures for the respective
DTC. If condition persists contact STAR for further assistance.
When performing the appropriate Diagnostic Procedures for this condition. Make certain
to remove and thoroughly CLEAN BOTH OXYGEN SENSORS using a clean cloth
and compressed air. Do not use any type of liquid cleaner to clean the oxygen
sensor tips. Use compressed air to remove all soot from the oxygen sensor tip that is
inside (under) the metal shield/cover. Blow compressed air into the center hole of the
sensor shield to remove soot from the sensor tip. Ensure all soot has been removed from
the sensor tip (inside the shield) and on the outside of the sensor tip shield.
-3- 18-013-08
3. After extended idling or if an intake leak is present, the vehicle operator may
experience a MIL illumination and/or an Electronic Vehicle Information Center (EVIC)
message alert due to one or more of the following DTC's:
a. P1451 - Diesel Particulate Filter System Performance.
b. P2463 - Diesel Particulate Filter - Soot Accumulation.
c. P242F - Diesel Particulate Filter Restriction - Ash Accumulation.
Perform this Service Bulletin and Service Bulletin (SB) 11-002-07. It is VERY
IMPORTANT that SB 11-002-07 be performed COMPLETELY to return the engine and
exhaust aftertreatment systems to a “like new” condition. If condition persists contact
STAR for further assistance.
4. A MIL illumination due to the following DTC:
a. P2262 - Turbocharger Boost Pressure Not Detected - Mechanical
Perform this Service Bulletin and Service Bulletin (SB) 11-003-07. It is VERY
IMPORTANT that SB 11-003-07 be performed COMPLETELY to return the engine and
exhaust aftertreatment systems to a “like new” condition. If condition persists contact
STAR for further assistance.
5. A MIL illumination due to one of the following DTC's:
a. P0106 - Manifold Absolute Pressure Sensor Performance.
Perform this Service Bulletin and the appropriate Diagnostic Procedures for the respective
DTC. If condition persists contact STAR for further assistance.
6. A MIL illumination due to one of the following DTC's:
a. P200C - Diesel Particulate Filter Over Temperature - Bank 1
b. P242B - Exhaust Gas Temperature Sensor Circuit Performance - Bank 1 Sensor 3.
Perform this Service Bulletin and the appropriate Diagnostic Procedures for the respective
DTC. If condition persists contact STAR for further assistance. Ensure that the exhaust
temperature sensors have been thoroughly cleaned for any temperature sensor related DTC's.
7. A MIL illumination due to one of the following DTC's:
a. P0401 - EGR System Performance
b. P0402 - EGR Flow Excessive Detected
c. P0403 - EGR Control Circuit - Open
d. P0405 - EGR Position Sensor Circuit Low
e. P042E - EGR Control Stuck Open
f. P0489 - EGR Control Circuit - Low
8. A MIL illumination due to the following DTC:
a. P245A - EGR Cooler Bypass Control Circuit - Open.
Perform this Service Bulletin and the appropriate Diagnostic Procedures for the respective
DTC. If condition persists contact STAR for further assistance. IMPORTANT: Ensure that
the EGR Temperature Sensor is thoroughly cleaned for if this DTC occurs .
C. IMPROVED DIAGNOSTIC CAPABILITIES:
NOTE: A number of improvements have been made to the engine diagnostics.
Performing this Service Bulletin completely will enable these diagnostic
improvements.
1. Improved Fuel Level Sensor diagnostics in the ECM.
2. Improvement to the single diagnostic DTC P0148 - Fuel Delivery Error. This DTC is
now addressed by the following two DTC diagnostics:
a. P1011 - Fuel Pump Delivery Pressure Too Low
b. P1012 - Fuel Pump Delivery Pressure Too High
Perform this Service Bulletin. If a DTC is present, perform the appropriate Diagnostic
Procedure. If condition persists contact STAR for further assistance.
3. Creation of three new DTC's to address the inlet air temperature sensor separate from
the ambient air temperature sensor. The new DTC's are:
a. P1191 - Inlet Air Temperature Sensor Rationality / Performance. This DTC
enhances the current DTC P0071 - Inlet Air Temp Sensor Rationality / Ambient Air
Temperature Sensor Performance - TIPM.
b. P1192 - Inlet Air Temperature Sensor Too Low. This DTC enhances the current
DTC P0072 - Inlet Air Temp Sensor Voltage Too Low - TIPM.
c. P1193 - Inlet Air Temperature Sensor Too High. This DTC enhances the current
DTC P0073 - Inlet Air Temp Sensor Voltage Too High - TIPM.
Perform this Service Bulletin. If a DTC is present, perform the appropriate Diagnostic
Procedure. If condition persists contact STAR for further assistance.
4. New ECM and CCN software that together will improve the customer understanding of
the exhaust aftertreatment system messages that can be displayed on the overhead
Electronic Vehicle Information Center
Attention: TDR Forum Junkies 
