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Intermittent MIL W/Hex Code $1B (P0123) TPS Voltage High

NUMBER: 18-22-99

GROUP: Vehicle Performance

DATE: Sep. 17, 1999

SUBJECT:
Intermittent MIL Illumination With Hex Code $1B (P0123) Throttle Position Sensor (TPS) Voltage High

OVERVIEW:
This bulletin involves replacing the TPS harness insulator with a new part and flash updating the Powertrain Control Module (PCM).

MODELS:
1998 - 1999 (NS) Town & Country/Caravan/Voyager

NOTE:
THIS INFORMATION APPLIES TO ALL 1998 MODELS EQUIPPED WITH A 3.0L ENGINE AND 1999 MODELS EQUIPPED WITH A 3.0L ENGINE BUILT PRIOR TO FEB. 5, 1999 (MDHO1O5XX). SOME VEHICLES BUILT BETWEEN JAN 1, 1999 AND FEB. 5, 1999 MAY HAVE UPDATED PCM SOFTWARE.

SYMPTOM/CONDITION:
Some vehicles may exhibit intermittent MIL illumination with hex code $1 B (P0123) Throttle Position Sensor (TPS) Voltage High. This may be caused by an intermittent connection at the TPS connector or too short of a mature time for DTC detection.

DIAGNOSIS:
Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning as designed. If other Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If DTC $1B (P0123) Throttle Position Sensor (TPS) Voltage High was/is present, perform the diagnostics associated with the TPS DTC. If the DTC cannot be duplicated or if the root cause cannot be found for the DTC, perform the Repair Procedure.

NOTE:
WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.

PARTS REQUIRED:

1 04669020 Label, Authorized Software Update
1 04275086 Label, Authorized Modification
1 56045375AA Insulator, TPS Wiring Harness

EQUIPMENT REQUIRED:

1 CH6OOO Scan Tool (DRB III(R))
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7OOO/7001 J1962 Cable
1 MDS2

NOTE:
THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE MDS2 SYSTEM MUST BE OPERATING AT CIS CD2042 OR HIGHER.

REPAIR PROCEDURE:

1. Log onto the MDS2 system.

2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and switch the ignition key to "ON".

3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN MENU SCREEN.

4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN.

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

5. Push the FLASH tab on the MDS2.

NOTE:
A MESSAGE MAY APPEAR 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.

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

NOTE:
A MESSAGE MAY APPEAR 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.

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

8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process.

NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.





9. 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.





10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2).

11. Disconnect the positive battery lead and remove the wiring connector from the TPS.

12. Remove the wedge lock and use a terminal removal tool to remove the wiring terminals from the original connector and insert them into the new connector insulator p/n 56045375AA. Discard the old insulator.

NOTE:
SWAP THE TERMINALS ONE AT A TIME TO PREVENT CROSS WIRING THE NEW INSULATOR.

13. Reconnect the positive battery lead.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: 08-19-44-91 Module Reprogram 0.5 Hrs.
08-90-65-95 Insulator, Replace 0.1 Hrs.

FAILURE CODE: FM - Flash Module P8 - New Part