Technical Service Bulletins

Funky Sprinter EGR

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Funky Sprinter EGR

This TSB applies to 2007-2009 Dodge and Freightliner Sprinter vehicles equipped with the 3.0L diesel engine (“5” in the 8th VIN position) and built from Sept. 1, 2006, through Oct. 22, 2008, (MDH 090100 through 102210).

The ECM on about 39,100 of these vehicles may not actuate the EGR valve sufficiently to prevent soot accumulation, resulting in improper valve operation or sticking. This may cause excessive exhaust emissions, illumination of the MIL and a vehicle limp-in condition.

The ECM must be reprogrammed (flashed).


-          CH9401………StarSCAN tool

-          CH9404D…….StarSCAN vehicle cable

-          CH9409………StarSCAN documentation kit

-          CH9410………StarSCAN Ethernet 12 ft cable

-          CH9412………StarSCAN software update device kit

The ECM reprogram procedure must be performed using StarSCAN with release 9.04 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen. If the flash is aborted or interrupted, repeat the procedure.

1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts. If the battery charger is timer controlled, set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Use an accurate stand-alone voltmeter, as the battery charger voltmeter may not be sufficiently accurate. Voltages outside the specified range will result in an unsuccessful flash. If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage.

2. Remove the OBD/fuse cover located at the lower left side of the steering column and open the black plastic cover of the data link connector. Connect the CH9404D vehicle cable to the StarSCAN and the vehicle’s data link connector.

3. Turn the ignition key to the “RUN” position.

4. Power “ON” the StarSCAN.

5. Retrieve the old ECM part number. With the StarSCAN on the “HOME” screen, follow this procedure:

-  Select “ECU View.”

-  Tough the screen to highlight “ECM” in the list of modules.

-  Select “More Options.”

-  Select “ECU Flash.”

-  Record the “Part Number” displayed at the end of the “Resident flash file for” statement near the top of “Flash ECM” screen for later reference.

6. Download the flash file from the internet to the StarSCAN. With the StarSCAN on the “Flash ECM” screen, follow the procedure listed here:

-  Select “Browse for New File.” Follow the on-screen instructions.

-  If the newly downloaded flash file “Part Number” description is the same as the number recorded in Step 5, then the ECM is up to date. Continue to Step 10.

-  Highlight the listed calibration on the StarSCAN screen.

-  Select “Download to Scantool.”

-  Select “Close” after the download is complete, then select “Back.”

-  Highlight the listed calibration.

-  Select “Update Controller” and follow the on-screen instructions.

-  When the update is complete, select “OK.”

7. Disconnect the CH9404D StarSCAN vehicle cable from the vehicle. Wait until the StarSCAN screen reads “Vehicle Disconnected,” then press “OK"

8. Reconnect the CH9404D vehicle cable to the vehicle.

9. Retrieve the ECM part number. With the StarSCAN on the “HOME” screen, follow this procedure:

-  Select “ECU View.”

-  Touch the screen to highlight “ECM” in the list of modules.

-  Select “More Options.”

-  Select “ECU Flash.”

-  Verify the “Part Number” (displayed at the end of the “Resident flash file for” statement) has been updated to the new part number. If it has updated, then the flash has been completed successfully.

 10. Clear any DTCs. NOTE: Due to the ECM programming procedure, DTC(s) may be set in other modules (TCM, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some DTCs may cause the MIL to illuminate.

- From the “Home” screen, select “System View.”

- Select “All DTCs.”

- Press “Clear All Stored DTCs” if there are any DTCs shown on the list.

 11. Turn the ignition to the “OFF” position.

12. Remove the StarSCAN unit, StarSCAN cable and battery charger from the vehicle.

13.  Close the black plastic cover of the data link connector and install the OBD/fuse cover.

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