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Discussion Starter #1
I've been a member here for just over 6 years, and read lots and lots of your posts, learning about my 2007 SXT quite a bit along the way. I just came home a couple of weeks ago after being gone for quite a few months, and had a check engine light come on. This is pretty normal in the cooler months for my car, but it is often intermittent and usually has some code associated with it. I just failed my emissions test, but it gave no code to the mechanics, nor does the dash show any stored codes. I have just over 161k miles on what has otherwise been a trouble free vehicle. For the last few days it seems that I am not getting my usual high gas mileage, so I'm not sure if it is a lack of combustion problem leading to the emissions results or if that is a separate issue. I'd just like to have a few ideas to research before I turn it over to the mechanics to tear into tomorrow afternoon. Thanks.
 

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Discussion Starter #3
It was driven weekly while I was gone; some weeks more than others. It has had at least two tanks through it since I got back, the last one had a can of SeaFoam in it, and I am halfway through the next tank. Thanks.
 

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You said in the original post you had a check engine light come on - how did you clear the code? If by pulling fuses to reset the PCM, I believe that also resets the emissions ready flags as well as the codes and adaptives. If the flags are not set, it will fail emissions. I believe there are x number of start cycles and x number of drive miles before the flags are set "ready".
If I'm wrong here, someone please chime in.
 

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Discussion Starter #5
You said in the original post you had a check engine light come on - how did you clear the code? If by pulling fuses to reset the PCM, I believe that also resets the emissions ready flags as well as the codes and adaptives. If the flags are not set, it will fail emissions. I believe there are x number of start cycles and x number of drive miles before the flags are set "ready".
If I'm wrong here, someone please chime in.
I haven't cleared any code. The mechanics were very surprised that it didn't print a code on the emissions results. Afterwards, I tried the on-acc-on-acc-on and it doesn't indicate there is any code, either. I just have a check engine light.
 

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I haven't cleared any code. The mechanics were very surprised that it didn't print a code on the emissions results. Afterwards, I tried the on-acc-on-acc-on and it doesn't indicate there is any code, either. I just have a check engine light.
OK...I must have misunderstood the post....
Were any of the emissions results out of tolerances?
Usually(in TN anyway) the emission report shows the various gases and the actual versus allowed percentages.
 

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If the acc-on dance doesn't bring it up then it's a transmission code.
 

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Discussion Starter #9
If the acc-on dance doesn't bring it up then it's a transmission code.
I understand the basics, but am by no means a real car guy. What kind of problem would that be? I had transmission service done in the last 5k-10k miles, I believe.
 

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I understand the basics, but am by no means a real car guy. What kind of problem would that be? I had transmission service done in the last 5k-10k miles, I believe.
The acc-on thing has to be done 3 times in a row fast. Is that what you've been doing? If it says dONE and doesn't give you a code then the car needs to be scanned with a transmission code reader.
 

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I wish it said more. It doesn't tell me much

It actually tells you everything you need to know.




1. Your emissions test was an OBD test only (no tailpipe reading)

2. Your On Board Diagnostic system is storing a code that causes it to fail.

3. Your ability to read the code by the key trick is irrelevant, not all codes can be read that way.

4. You need to take it to a dealer to read the codes stored and correct the issue.
 

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Discussion Starter #12
I went out and tried it, again. I think I had ended with on rather than acc. This time I got a "1004" code. I'm going to start reading up on it and look forward to your input, as well.
 

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I went out and tried it, again. I think I had ended with on rather than acc. This time I got a "1004" code. I'm going to start reading up on it and look forward to your input, as well.
NUMBER: 18-003-07 REV. A
GROUP: Vehicle Performance
DATE: March 7, 2007


THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-003-07, DATED
JAN 17, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A
COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT
REVISIONS. ADDITIONAL MODELS AND REVISED DIAGNOSTICS HAVE BEEN
ADDED.

THE StarSCAN® FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM
THE INTERNET.

StarSCAN® SOFTWARE LEVEL MUST BE AT RELEASE 7.03 OR HIGHER FOR THIS
BULLETIN.

StarMOBILE® STANDALONE DOES NOT SUPPORT THIS SERVICE ACTION.

SUBJECT:

Flash: MIL Illumination DTC P1004 -Short Runner Valve Performance

OVERVIEW:

This bulletin involves reprogramming the Powertrain Control Module (PCM) with new
software and verifying the SRV function.

MODELS:
2007 (CS) Pacifica
2007 (JS) Sebring
2007 (LE) 300/Touring (International Markets)
2007 (LX) 300/Magnum/Charger

NOTE: This bulletin applies to CS models built prior to December 15, 2006 (MDH
1215XX) with a 4.0L engine (Sales Code EGQ), JS models built prior to
December 13, 2006 (MDH1213XX) with a 3.5L engine (Sales Code EGF), LX
models built prior to February 5, 2007 (MDH0205XX) with a 3.5L engine (Sales
Code EGG), and LE models built prior to February 10, 2007 (MDH0210XX)
with a 3.5L engine (Sales Code EGG)



18-003-07 REV. A -2


SYMPTOM/CONDITION:

Some customers may experience MIL illumination with no other symptoms noted. Upon
investigation the technician may find DTC P1004 -Short Runner Valve Performance as an
active (MIL on) or stored (MIL off) fault. The fault may be intermittent, difficult to duplicate
and may be more prevalent on low mileage vehicles.

DIAGNOSIS:

Using a Scan Tool (StarSCAN®) with the appropriate Diagnostic Procedures available in
TechCONNECT, verify all engine/transmission systems are functioning as designed. If
DTC's other than those listed above are present record them on the repair order and repair
as necessary before proceeding further with this bulletin.

If the above DTC is found perform the Repair Procedure. After the repair, perform the
verification procedures listed at the end of this bulletin.

PARTS REQUIRED:

Qty. Part No. Description
1 04275086AB Label, Authorized Modification
AR (1) 04593578AC Plenum, Upper CS 4.0L
AR (1) 04593676AB Actuator, SRV CS 4.0L
AR (1) 04593649AB Plenum, Upper JS 3.5L
AR (1) 05149095AA Actuator, SRV JS 3.5L
AR (1) 04591863AJ Plenum, Upper LE/LX 3.5L
AR (1) 04593839AA Actuator, SRV LE/LX 3.5L

SPECIAL TOOLS / EQUIPMENT REQUIRED:


NPN Battery Charger
CH9401 StarSCAN® Tool
CH9404 StarSCAN® Vehicle Cable
CH9409 StarSCAN® Documentation Kit
CH9410 StarSCAN® Ethernet Cable, 12 ft.
CH9412 StarSCAN® Software Update Device Kit
TechCONNECT PC or equivalent

REPAIR PROCEDURE -USING THE INTERNET TO RETRIEVE THE FLASH FILE:

NOTE: When performing this Repair Procedure, the software release level in the
StarSCAN®; must be programmed with 7.03 level software or higher. The
software release level is visible in the blue header at the top of the
StarSCAN® screen.


-3- 18-003-07 REV. A


NOTE: The StarSCAN® diagnostic scan tool fully supports Internet connectivity.
However, to take advantage of this feature you must first configure the
StarSCAN® for your dealership's network. Make sure the StarSCAN® is
configured to the dealership's network before proceeding. For instruction on
setting up your StarSCAN® for the dealer's network refer to either:
“DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online
Documentation”, or refer to the StarSCAN® Quick Start Networking Guide.
The StarSCAN® Quick Start Networking Guide is also available on the
www.dcctools.com website under the "Download Center".

NOTE: If this flash process is interrupted/aborted, the flash should be restarted.

1. Install a battery charger and verify that the charging rate provides approximately 13.5
volts. Set the battery charger to continuous charge. Do not allow the charger to time
out during the flash process. Remove the charger from the battery when the flash
process is complete.
2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN® and the dealer's
network drop.
3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN® and the vehicle.
4. Power ON the StarSCAN®.
5. Retrieve the old PCM part number. Using the StarSCAN® at the “Home” screen:
a. Select “ECU View”
b. Touch the screen to highlight the PCM in the list of modules.
c. Select “More Options”
d. Select “ECU Flash”
e. Record the part number at the top of the “Flash PCM” screen for later reference.
f. Select “Browse for New File”. Follow the on screen instructions.
g. Select “Download to Scantool”.
h. Select “Close” after the download is complete, then select “Back”.
i. Highlight the listed calibration.
j. Select “Update Controller”. Follow on screen instructions.
k. When the update is complete, select “OK”.
l. Verify the part number at the top of the “Flash PCM” screen has updated to the new
part number.
NOTE: Due to the PCM programming procedure, a DTC may be set in other modules
(TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some
DTC's may cause the MIL to illuminate. From the “Home” screen select
“System View”. Then select “All DTCs”. Press “Clear All Stored DTCs” if
there are any DTCs shown on the list.

NOTE: The following step is required by law when reprogramming a PCM and/or
TCM.

6. Type the necessary information on the “Authorized Modification Label” p/n
04275086AB and attach near the VECI label (Fig. 1).

18-003-07 REV. A -4-



Fig. 1 AUTHORIZED MODIFICATION LABEL

1 -POWERTRAIN CONTROL MODULE P/N (INSERT P/N) USED
2 -CHANGE AUTHORITY: TSB XX-XXX-XX
3 -DEALER CODE: XXXXX
4 -DATE: XX-XX-XX

DTC P1004 VERIFICATION PROCEDURE:

1. Install a battery charger and verify that the charging rate provides approximately 13.5
volts during the following steps.
NOTE: The following SRV actuator tests MAY not function if DTC's are present.
Check and Clear ALL faults before proceeding and throughout the process
as necessary.

2. Using a Scan Tool (StarSCAN®) view the data display for the SRV in its de-energized
state. Read the percent feed back from the StarSCAN® screen. Normal percent
feedback will equal 50% + or -5%.
3. Using a Scan Tool (StarSCAN®) select the actuator tests menu and actuate the SRV.
With the SRV actuated, go to the data display for the SRV in its energized state. Read
the percent feed back from the StarSCAN® screen. Normal percent feedback will
equal 80% + or -5%.
4. De-energize the SRV, feedback should return to 50% + or -5%.
5. Does the percent feedback meet the specifications listed in steps 2, 3, and 4?
a. Yes -No Further Action is Required.
b. No -Proceed to Step 6.
6. Check and Clear ALL faults. Start the engine and raise the RPM to 4000 in park. In the
de-energized state, does the SRV return to 50% + or -5%? when de-energized?
a. Yes -Check and Clear ALL faults -No Further Action is Required.
b. No -Proceed to Step 7.
7. Use the following diagnostic flow to determine SRV malfunction:
a. Verify wiring integrity using the information found in
DealerCONNECT>TechCONNECT. If wiring problems are found make repairs and
confirm correct operation starting with step 3 above. If wiring problems are not
found, proceed to b.

-5-18-003-07 REV. A


b. Remove the SRV actuator following the procedures listed in
DealerCONNECT>TechCONNECT. By hand, rotate the SRV shaft (in manifold).
The shaft should rotate freely within 60 degrees as follows: (CS 11 O'clock to 9
O'clock — JS 1 O'clock to 3 O'clock — LX/LE 8 O'clock to 10 O'clock). If the shaft
binds within these ranges, replace the intake manifold. If the shaft rotates freely,
replace the SRV actuator.
c. After making appropriate repairs -Check and Clear ALL faults -Verify correct
operation starting with step 3 above.
POLICY:

Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No: Description Amount
18-19-06-41 Module, Powertrain Control -Reprogram
& Perform Verification (B)
0.5 Hrs.
14-40-14-90 Actuator, Short Runner Valve -Replace (CS) 0.7 Hrs.
(JS) 0.3 Hrs.
(LX/LE) 0.3 Hrs.
09-50-05-90 Manifold, Two Piece Intake -Upper Intake
-Replace
(CS) 0.8 Hrs.
(JS) 1.3 Hrs.
(LX/LE) 1.0 Hrs.
 

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Discussion Starter #14
Thanks, that's what I found and am printing. Not looking good that the $385 part is now grouped with a $2050 setup.
 

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Thanks, that's what I found and am printing. Not looking good that the $385 part is now grouped with a $2050 setup.
Ebay and don't take it to the dealership. Find a good local mechanic.
 

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Discussion Starter #16
I've got a local mechanic, but can't find anything listed on ebay with the part number. I may have to let the mechanic order the part, as I only have 14 days to bring it into compliance.
 

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Thanks, that's what I found and am printing. Not looking good that the $385 part is now grouped with a $2050 setup.
Take it to the dealer and have it diagnosed. Some 3.5L engines with this issue simply need the short runner valve assembly cleaned, dirt build-up causes it to stick.
 

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Discussion Starter #18 (Edited)
Update

Took it to the dealer. They said I needed the upper intake replaced as per the TSB I took in with me. The good news is they said the part was now $800 and the labor just over $300. I don't know if this was normal price or they knew by my request to only flash the PCM that I was looking at having the work done elsewhere, so they quoted me a reasonable amount. In the end, they said my PCM had the update from the TSB already and the only other PCM flash available, that I didn't already have, addressed the transmission. I'm going to drop it at my local mechanic and get a quote from them.

Take it to the dealer and have it diagnosed. Some 3.5L engines with this issue simply need the short runner valve assembly cleaned, dirt build-up causes it to stick.
I'm going to do some searching tomorrow and try and find instructions for cleaning it over the weekend. Thanks for the suggestion.
 

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Discussion Starter #19 (Edited)
Update 2

Took the four bolts off, sprayed all the oil off the SRV actuator and inside with carb cleaner, manually moved both the actuator and whatever the part it moves is after cleaning. Re-installed and connected the battery. Drove great, power was back, no light on, then when I stopped and started it after about 15 miles driving, the light came back on and it feels sluggish. Should I just order and replace the actuator next?
 

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Took the four bolts off, sprayed all the oil off the SRV actuator and inside with carb cleaner, manually moved both the actuator and whatever the part it moves is after cleaning. Re-installed and connected the battery. Drove great, power was back, no light on, then when I stopped and started it after about 15 miles driving, the light came back on and it feels sluggish. Should I just order and replace the actuator next?
Probably. It likely has wear on the moving parts that is causing it to bind and hang up.
 
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