T21 Rev3

Revised May 2020
Dealer Service Instructions for:
Emissions Recall T21
Reprogram Engine Control Unit
NOTE: 2004 Model Year ONLY has been suspended until further notice.
Remedy Available
2005 - 2006 (VA) Dodge Sprinter
Remedy Unavailable
2004 (VA) Dodge Sprinter
IMPORTANT: Some of the involved vehicles may be in dealer used vehicle
inventory. Dealers should complete this campaign service on these vehicles
before retail delivery. Dealers should also perform this campaign on vehicles in
for service. Involved vehicles can be determined by using the VIP inquiry
process.
Subject
In the event of a Mass Air Flow (MAF) adaptation error, the Malfunction Indicator
Lamp (MIL) on about 52,900 of the above vehicles might not illuminate and the
corresponding fault code will not be stored in the Engine Control Unit (ECU) as
required by law. To remedy this issue, the ECU software must be updated.
 Copyright 2020, FCA US LLC, All Rights Reserved
(tdb)
Emissions Recall T21 – Reprogram Engine Control Unit
Page 2
Repair
The ECU on involved vehicles must be reprogrammed with new software. In
addition, the air intake system and Exhaust Gas Recirculation (EGR) system must be
inspected. Repairs to those systems may be necessary if new Diagnostic Trouble
Codes (DTCs) are activated which are directly related to the new ECU software.
Parts Information
NOTE: No additional repairs or parts are anticipated for this campaign. If any
additional repairs or parts related to this campaign are required, the dealer
must first check if a related LOP has been created for repairs prior to
performing the repair. If no related LOP is found, the LOP review process
must be followed to request a related Recall LOP be added as follows:
Submit a LOP Related Inquiry (located in DealerCONNECT > Service > Claim
Administration) for evaluation and update.
 IF the request is approved – the related Recall LOP will be added to the
Labor Operations and you are to proceed with normal Recall claim entry
process.
 IF the request is not approved – submit the repair under Warranty (W) if
the repair has been pre-authorized by your Area Manager or Business
Center representative.
Parts Return
No parts return required for this campaign.
Emissions Recall T21 – Reprogram Engine Control Unit
Page 3
Special Tools
NOTE: For DRB III Enhanced Emulator and TechTOOLS requirements and
troubleshooting, consult the wiTECH Knowledge Base from the wiTECH 2.0
menu.
The following special tools are required to perform this repair:
 NPN
wiTECH micro POD II
(Configured for wiTECH 1.0)
 NPN
Laptop Computer (Windows operating system)
 NPN
wiTECH 1.0 Software
 NPN
Enhanced DRB III Emulator Tool Software
(Launched through wiTECH 1.0)
 NPN
TechTOOLS Software (Desktop Application)
Emissions Recall T21 – Reprogram Engine Control Unit
Page 4
Service Procedure
A. Reprogram the ECU
NOTE: Technicians that are experiencing trouble completing the flash
portion of the T21 Recall process should contact the wiTECH Helpdesk to
receive technical support.
NOTE: The wiTECH scan tool must be used to perform this recall. The
wiTECH software is required to be at the latest release level before
performing this procedure. If the reprogramming flash for the ECU is
aborted or interrupted, repeat the procedure. The ECU must be at the latest
calibration level after completing this emissions recall.
1. Install a battery charger and verify that the charging rate provides 13.0 to 13.5
volts. Do not allow the charger to time out during the flash process. Set the
battery charger timer (if so equipped) to continuous charge.
NOTE: Use an accurate stand-alone voltmeter. The battery charger volt
meter may not be sufficiently accurate. Voltages outside of the specified
range will cause 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. Connect the wiTECH micro POD II to the vehicle data link connector.
3. Place the ignition in the “RUN” position.
4. Open the wiTECH Diagnostic application.
5. Starting at the “Select Tool” screen, highlight the row/tool for the micro POD II
device you are using. Then select “Launch DRBIII Enhanced” at bottom right
side of the screen.
6. Accept the software agreement. Click in the box next to “I Accept” then click
“Next”.
7. To begin the DRBIII Emulator tool, select “Yes”.
Emissions Recall T21 – Reprogram Engine Control Unit
Page 5
Service Procedure [Continued]
8. From “Main Menu” Select (1) “DRB III Standalone”.
9. Under heading “Stand-Alone Main Menu”, select (1) “1998-2010 Diagnostics”.
10. Under heading “1998-2010 Diagnostics”, select (6) “2002-2006 Sprinter”.
11. Under heading “Main Menu”, select (1) "System Select".
12. Under heading “System Select”, select (1) “Engine” then press “Enter”.
13. Module ID for ECM screen will appear. Inspect the ECM software file part
number:
 If ECM software file part number is 647 900 00 00, the ECM is already updated
with the current software file. Disconnect the wiTECH micro POD II and
battery charger from the vehicle. Claim the inspection LOP and return the
vehicle to the customer. Complete Proof of Correction Form for California
Residents.
 If ECM software file part number is NOT 647 900 00 00, press “Enter” on the
Module ID for ECM screen to continue with the next step of this procedure.
14. Under heading “Select Function”, select (2) "DTC Functions".
15. Under heading “DTC Functions”, select (1) “Read Current DTCs”.
16. Record any Current DTCs before beginning the flash process. The codes if any
will be required later in this procedure.
17. Under heading “DTC Functions”, select (2) “Read Stored DTCs”.
18. Record any Stored DTCs before beginning the flash process. The codes if any
will be required later in this procedure.
19. Under heading “DTC Functions”, select (3) “Clear DTCs”.
20. Select “Yes” then follow screen prompts to clear DTCs.
Emissions Recall T21 – Reprogram Engine Control Unit
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Service Procedure [Continued]
NOTE: leave the DRB III Emulator tool open while performing the next
steps to launch TechTOOLS.
21. Open the “TechTOOLS Application” using the icon on the Windows desktop.
22. Enter your User ID, Password, and Dealer Code then press “OK”.
23. In the TechTOOLS window, enter the vehicle “VIN” or select the vehicle “Year,
Model, and Engine”. Place a check mark in the box next to “DRB III
Emulator” then click the “Show Updates” button.
24. Highlight the new part number for the 2004-2006 VA 2.7L PCM calibration
software file.
NOTE: The injector classification routine must be performed ONLY if
requested at the finalization of the ECM software update process, after
Step 32.
25. Click “Download/Update” at the bottom of the TechTOOLS window. A pop-up
window “Flash Download/Update Progress” will appear.
NOTE: Once the software file download has completed, do NOT close the
pop-up window. The “Flash Download/Update Progress” pop-up window
must remain open during the flash process.
26. Within the DRB III Emulator tool, exit the Sprinter diagnostic application and
select “OK”.
27. Page back to the “Main Menu” screen then select (7) “Vehicle Flash”.
Emissions Recall T21 – Reprogram Engine Control Unit
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Service Procedure [Continued]
28. From the “Vehicle Flash Menu” screen, select (1) “Flash Powertrain”.
29. Select “Start” on the Flash Application pop-up window and then follow the
screen instructions to complete the flash.
30. Once the flash has completed, a pop-up window will appear indicating that the
Reset Air System Adaptation routine must be run. Click “OK” to continue.
31. Page back to “DRB III Standalone” the select (1) “1998-2010 Diagnostics”.
32. Under heading “1998-2010 Diagnostics”, select (6) “2002-2006 Sprinter”.
33. Under heading “Main Menu”, select (1) "System Select".
34. Under heading “System Select”, select “Engine” then press “Enter”.
35. Module ID for ECM screen will appear. Confirm that the ECM software file part
number is now 647 900 00 00. Press “Enter” on the Module ID for ECM screen
to continue with the next step of this procedure.
36. Under heading “Select Function”, select (9) "Miscellaneous Functions".
37. Under heading “Miscellaneous Functions”, select (7) “Reset Air System
Adaption”.
38. Within the resetting air system values window, click “enter” to complete the air
system adaptation routine.
39. Verify that the ECM software file is now updated.
40. Under heading “Select Function”, select (2) “DTC Functions”.
41. Under heading “DTC Functions”, select (3) “Clear DTCs”.
42. Select “Yes” then follow screen prompts to clear DTCs.
43. Proceed to Section B. Visual Inspection of air intake path and EGR system.
Emissions Recall T21 – Reprogram Engine Control Unit
Page 8
Service Procedure [Continued]
B. Visual Inspection of air intake path and EGR system
NOTE: Vehicles involved in T21 emission recall campaign are not expected
to require any repairs to the air intake path and/or EGR systems. In the
unlikely event that any parts or repairs are required, do not proceed with
the repair until you have obtained a related recall labor operation (LOP),
otherwise your claim for additional components/repairs may be rejected.
1. Visually inspect the air intake path for missing, disconnected, and/or damaged
components. The air intake path consists of the air filter housing, MAF, turbo
charger, intercooler, and connecting hoses/components.
2. Visually inspect the EGR system for missing, disconnected, and/or damaged
components.
3. If any air intake path and/or EGR components are discovered to be missing,
disconnected, and/or damaged, those issues must be corrected. Obtain prior
approval in the form of a related recall LOP before making repairs, otherwise
your claim for additional components/repairs may be rejected.
4. Proceed to Section C. Perform Vehicle Repair Verification Test Drive.
Emissions Recall T21 – Reprogram Engine Control Unit
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Service Procedure [Continued]
C. Perform Vehicle Repair Verification Test Drive
1. Remove the battery charger from the vehicle.
NOTE: Vehicle must be driven long enough to allow system monitors to set
active DTCs for air intake and EGR systems faults if any faults exist.
2. Test drive the vehicle for a duration of at least 20 minutes.

Test drive must include 6 accelerations phases with full load over a time
period of 12 seconds.

Test drive must include 6 deceleration phases (coasting) over a time period
of 10 seconds.
3. Install a battery charger and verify that the charging rate provides 13.0 to 13.5
volts. Do not allow the charger to time out during the flash process. Set the
battery charger timer (if so equipped) to continuous charge.
NOTE: Use an accurate stand-alone voltmeter. The battery charger volt
meter may not be sufficiently accurate. Voltages outside of the specified
range will cause 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.
4. Using the DRB III Emulator, select (2) “DTC Functions”.
5. Under the heading “DTC Functions”, select (1) “Read Current DTCs” and
record any DTCs, then select (2) “Read Stored DTCs” and record any DTCs.
 No DTCs are present. Continue with the next step of this procedure.
 Yes DTCs are present. Proceed to Section D. Repair of DTCs related to
Campaign T21.
Emissions Recall T21 – Reprogram Engine Control Unit
Service Procedure [Continued]
6. Turn the ignition to the “OFF” position.
7. Disconnect the wiTECH micro POD II from the vehicle.
8. Remove the battery charger from the vehicle.
9. Return the vehicle to the customer.
10. Complete Proof of Correction Form for California Residents.
Page 10
Emissions Recall T21 – Reprogram Engine Control Unit
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Service Procedure [Continued]
D. Repair of DTCs related to Campaign T21.
1. Compare the list of current DTCs with the list of preexisting DTCs recorded
before the flash process. Are the current DTCs the same as the preexisting DTCs
recorded before the flash process?
 Yes, all current DTCs are the same as preexisting DTCs. Campaign T21 is
complete. Do not perform any additional repairs. Proceed to Step 4.
 No, one or more DTCs are new active DTCs which were not present prior to
the flash process. Continue with Step 2.
2. Compare only the new active DTCs with the list of DTCs related to campaign
T21. Any preexisting DTCs are not related to completion of campaign T21 and
are not to be considered.
List of DTCs related to Campaign T21
 P0105
 P1610
 P2030
 P0110
 P1611
 P2032
 P0115
 P1612
 P2034
 P0180
 P1615
 P2036
 P0190
 P1617
 P2038
 P0201
 P1630
 P2040
 P0202
 P2008
 P2041
 P0203
 P2009
 P2042
 P0204
 P2011
 P2043
 P0205
 P2013
 P2045
 P0300
 P2014
 P2047
 P0500
 P2016
 P2051
 P0600
 P2017
 P2057
 P1105
 P2018
 P2061
 P1222
 P2020
 P2062
 P1234
 P2021
 P2066
 P1353
 P2023
 P2067
 P1480
 P2025
 P2068
 P1482
 P2026
 P2088
 P1520
 P2028
 P2090




















P2091
P2100
P2104
P2113
P2114
P2115
P2116
P2117
P2123
P2124
P2132
P2133
P2134
P2135
P2136
P2137
P2139
P2140
P2141
P2142




















P2143
P2144
P2145
P2149
P2152
P2153
P2195
P2197
P2198
P2199
P2203
P2204
P2208
P2209
P2210
P2211
P2214
P2217
P2218
P2219
Emissions Recall T21 – Reprogram Engine Control Unit
 P2220
 P2243
 P2338

 P2221
 P2244
 P2339

 P2222
 P2306
 P2342

 P2223
 P2319
 P2343

 P2224
 P2321
 P2347

 P2225
 P2322
 P2350

 P2226
 P2323
 P2353

 P2227
 P2324
 P2355

 P2228
 P2325
 P2356

 P2229
 P2329
 P2358

 P2230
 P2332
 P2359

 P2232
 P2333
 P2500

P2501
P2502
P2511
P2514
P2521
P2526
P2527
P2574
P2575
P2576
P2577
P2578
Page 12
 P2663
 P2670
 P2671
 P2672
 P2673
 P2679
 P2817
 P2822
 P2823
3. Are any of the new active DTCs shown in the list of DTCs related to campaign
T21?
 Yes, If any new active DTCs are listed as DTCs related to campaign T21
those DTCs must be corrected. Obtain prior approval in the form of a related
recall LOP before making repairs, otherwise your claim for additional
components/repairs may be rejected. Once DTC related repairs are completed
and DTCs have been cleared, continue with step 4.
 No, the new active DTCs are not listed as DTCs related to campaign T21. No
further action is required. Continue with step 4.
4. Turn the ignition to the “OFF” position.
5. Disconnect the wiTECH micro POD II from the vehicle.
6. Remove the battery charger from the vehicle.
7. Return the vehicle to the customer. If preexisting DTCs are still present, explain
to the customer that repair of preexisting DTCs is not covered under this
campaign.
8. Complete Proof of Correction Form for California Residents.
Emissions Recall T21 – Reprogram Engine Control Unit
Page 13
Service Procedure [Continued]
Complete Proof of Correction Form for California Residents:
This recall is subject to the State of California Registration
Renewal/Emissions Recall Enforcement Program. Complete a Vehicle
Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply
it to vehicle owners residing in the state of California for proof that this recall
has been performed when they renew the vehicle registration.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the
DealerCONNECT Claim Entry Screen located on the Service tab. Claims paid will
be used by FCA to record recall service completions and provide dealer payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation
Number
Time
Allowance
Inspect ECM Software Level Only
18-T2-11-81
0.2 hours
Inspect/Reprogram ECM, Inspect
Air Intake Path/EGR Systems and
Road Test Vehicle.
18-T2-11-82
1.4 hours
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
NOTE: See the Warranty Administration Manual, Recall Claim Processing Section,
for complete recall claim processing instructions.
Dealer Notification
To view this notification on DealerCONNECT, select “Global Recall System” on the
Service tab, then click on the description of this notification.
Emissions Recall T21 – Reprogram Engine Control Unit
Page 14
Owner Notification and Service Scheduling
All involved vehicle owners known to FCA are being notified of the service
requirement by first class mail. They are requested to schedule appointments for this
service with their dealers. A generic copy of the owner letter is attached.
Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
All involved vehicles have been entered into the DealerCONNECT Global Recall
System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles.
The owner’s name, address and phone number are listed if known. Completed
vehicles are removed from GRS within several days of repair claim submission.
To use this system, click on the “Service” tab and then click on “Global Recall
System.” Your dealer’s VIN list for each recall displayed can be sorted by: those
vehicles that were unsold at recall launch, those with a phone number, city, zip code,
or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule
appointments for this repair.
Recall VIN lists may contain confidential, restricted owner name and address information that was
obtained from the Department of Motor Vehicles of various states. Use of this information is
permitted for this recall only and is strictly prohibited from all other use.
Additional Information
If you have any questions or need assistance in completing this action, please contact
your Service and Parts District Manager.
Customer Services / Field Operations
FCA US LLC
REPROGRAM ENGINE CONTROL UNIT
__________________________________________________________________________________
Emissions Recall Information
T21
This notice applies to your vehicle (VIN: xxxxxxxxxxxxxxxxx).
Dear: (Name)
FCA US LLC recently contacted you regarding improvements we would like to make to your [2004
DODGE / FREIGHTLINER SPRINTER] vehicle.
Due to a part shortage concern, your vehicle will be temporarily suspended for this Emissions
Recall. During this time, your vehicle will NOT be subject to registration restrictions, if
applicable in your state, due to this recall being open on your vehicle.
You will be re-notified once parts become available for this Emissions Recall, T21.
There is currently no action required on your part.
If you have additional questions or concerns about this issue, please contact the FCA US Recall
Assistance Center at 1-800-853-1403. An FCA representative will be glad to answer any further
questions you may have regarding this issue.
We apologize for any inconvenience this issue may have caused. Thank you for your attention to this
important matter.
Customer Services / Field Operations
FCA US LLC
This notice applies to your vehicle,
[Model Year and Model]
IMPORTANT EMISSIONS RECALL
VIN XXXXXXXXXXXXXXXXX
Reprogram Engine Control Unit
T21
Dear [Name],
LOGO
VEHICLE PICTURE
YOUR SCHEDULING OPTIONS
1. RECOMMENDED OPTION
Call your authorized Chrysler /
Dodge / Jeep® / RAM Dealership
2. Call the FCA Recall Assistance
Center at 1-800-853-1403. An
agent can confirm part availability
and help schedule an appointment
3. Visit recalls.mopar.com, scan the
QR code below, or download the
Mopar Owner’s Companion App.
QR Code
Get access to recall notifications, locate
your nearest dealer, and more through
this website or Mopar Owner’s
Companion App. You will be asked to
provide your Vehicle Identification
Number (VIN) to protect and verify
your identity. The last eight characters
of your VIN are provided above.
DEALERSHIP INSTRUCTIONS
Please reference Emissions Recall
T21.
FCA US LLC, has determined that certain [2005 - 2006 Model Year Dodge Sprinter] vehicles may
not comply with Federal and California emission regulations/standards.
WHY DOES MY VEHICLE NEED REPAIRS?
In the event of a Mass Air Flow (MAF) adaptation error, the Malfunction Indicator Lamp (MIL)
on your vehicle [1] might not illuminate and the corresponding fault code will not be stored in
the Engine Control Unit (ECU) as required by law. To remedy this issue, the ECU software
must be updated.
HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE?
FCA will repair your vehicle [2] free of charge (parts and labor). To do this, your dealer will
reprogram the ECU with new software. As part of this recall, your dealer will inspect and may
perform repairs to the air intake system and Exhaust Gas Recirculation (EGR) system if new
Diagnostic Trouble Codes (DTCs) are activated which are directly related to the new ECU
software. In addition, your dealer will require your vehicle for proper check-in, preparation, and
check-out during your visit. The estimated repair time is two hours. Your time is important to
us; please be aware that these steps may require more time. We recommend that you schedule
a service appointment to minimize your inconvenience. Please bring this letter with you to your
dealership.
TO SCHEDULE YOUR FREE REPAIR CALL 1-800-853-1403
OR YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY
CALIFORNIA RESIDENTS
The State of California requires the completion of emission recall repairs prior to vehicle
registration renewal. Your dealer will provide you with a Vehicle Emission Recall Proof of
Correction Form after the Emission Recall service is performed. Be sure to save this form since
the California Department of Motor Vehicles may require that you supply it as proof that the
Emission Recall has been performed.
WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED?
If you have already experienced this specific condition and have paid to have it repaired, you
may visit www.fcarecallreimbursement.com to submit your reimbursement request online. [3]
Once we receive and verify the required documents, reimbursement will be sent to you within
60 days. If you have had previous repairs performed and/or already received reimbursement,
you may still need to have the recall repair performed.
We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you
for your attention to this important matter.
Customer Assistance/Field Operations
Fiat Chrysler Automobiles US LLC
Mr. Mrs. Customer
1234 Main Street
Hometown, MI 48371
[1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information.
[2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway
Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-4249153), or go to safercar.gov.
[3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-8004,
Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.
Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days.