C. Program the ECM

NOTE:
This repair procedure cannot be performed using the StarMOBILE in its standalone mode. Use the StarSCAN to perform this repair procedure.

NOTE:
Before performing this repair procedure, the operating software in the StarSCAN must be programmed with software release level 8.03 or higher. The software release level is visible in the blue header at the top of the StarSCAN screen.

CAUTION:
On 2007 model trucks, before the application software can be reprogrammed (flashed) into the Engine Control Module (ECM), the ECM must first be reprogrammed (flashed) with new "bootloader" software. Failure to reprogram the ECM with the new "bootloader" software first may cause the process of reprogramming the ECM with the application software to fail. The ECM "bootloader" software special flash procedure must be followed exactly to prevent damage to the ECM.

CAUTION:
When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort - recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement.

1. 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.

NOTE:
Do not allow the charging voltage to exceed 13.5 volts during the flash process.

2. Make sure the ignition is in the "RUN" position.

3. For 2007 model trucks, "bootloader" software replacement is required. Continue with Step 4 of this procedure.

For 2008 model trucks, "bootloader" software replacement is not required. Continue with Step 12 of this procedure.

4. Erase all flash files from the StarSCAN using the following procedure:

a. From the StarSCAN "Home" screen select "Show Short Cuts" button located in the upper right corner of the screen.

b. Select "Tool Menu" button in the upper left corner of the screen.

c. Select "Manage Files".

d. Select "More Options".

e. Select "Delete All".

f. Select "Yes" on the pop-up screen.

g. Select "OK" on the pop-up screen.

h. Select "Back" at the "User's Files" menu.

5. Obtain the ECM "Bootloader" software file and download it to the StarSCAN using the following procedure:

a. Select "ECU View".

b. Select "(PCM) Powertrain Control Module" from the list of modules.

c. Select "More Options".

d. Select "ECU Flash".

e. Record the part number of the new application software in the ECM ("Resident Flash File for Part # xxxxxxxxxx").

f. Select "Browse for New File".

g. Select "OK" at the flash down load screen.

h. Enter the required data and select "OK" at the password screen.

i. Select "Finish".

j. Highlight the ECM "Bootloader" software file.

CAUTION:
The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number. DO NOT select the application software file with the letters "AU" or higher suffix in the last two digits of its part number.

k. Select "Download to Scantool".

l. Select "Close" on the pop-up screen when the download is complete.

m. Select "Back" one (1) time.

CAUTION:
When performing the "bootloader" section of the repair procedure, DO NOT interrupt the ECM reprogramming session. This special ECM "bootloader" software reprogramming session does not support "abort recovery" mode. If "bootloader" software is interrupted, the ECM will be permanently disabled and will require replacement.

6. Close all doors and turn OFF all accessories (i.e. radio, hvac, lights, etc.).

7. Download the "Bootloader" software from the StarSCAN to the vehicle using the following procedure:

a. Highlight the "Bootloader" software selected previously.

NOTE:
The "Bootloader" file will have the letters "BT" in the last two digits (suffix) of its part number.

b. Select "Update Controller".

c. Select "OK" at ECU flash.

d. Select "OK" at the "Flash Update Successful" screen after the flash process is complete.

e. Select "Back" three (3) times to return to the "ECU View" screen.

8. Turn the ignition switch to the "OFF" position, remove the key from the ignition, and wait two minutes.

9. Insert the ignition key into the ignition switch and turn the ignition switch to the "RUN" position (do not start the engine).

10. Confirm that the ECM has the new "Bootloader" software using the following procedure:

a. From the "ECU View" screen, select "PCM" in the list of modules.

b. Select "More Options".

c. Select "ECU Flash".

d. Confirm that the available "Bootloader" software file part number matches the resident flash file part number in the ECM.

11. Erase the "Bootloader" software file from the StarSCAN using the following procedure:

a. Starting at the "Flash PCM" screen, select "Manage Files".

b. Highlight the "Bootloader" software file listed in the StarSCAN memory.

c. Select "Delete".

d. Select "YES" on the pop-up screen.

e. Select the "BACK" button five (5) times.

12. From the "Home" screen select "ECU View" (select the "BACK" button 4 times if bootloader was not reprogrammed).

13. Select "PCM Powertrain Control Module".

14. Select "More Options".

15. Select "ECU Flash".

16. Download the ECM application software file to the StarSCAN using the following procedure:

a. Select "Browse for New File".

b. Select "OK" at the Flash Download screen.

c. Enter the required data and select "OK" at the password screen.

d. Select "Finish" at the "Flash Update" screen to display download results.

e. Select the application software file.

NOTE:
The application software file will have suffix letters "AU" or higher for 2007 models or "AG" or higher for 2008 models (in the last two digits of the part number).

f. Highlight the application software file for download to the StarSCAN.

g. Select "Download to Scantool".

h. Select "Close" at the "Download File" screen when the download is complete.

i. After the file has been downloaded, select "Back" one (1) time.

17. Reprogram the ECM with new application software from the StarSCAN using the following procedure:

a. Highlight the application software file to be downloaded.

b. Select "Update Controller".

c. Select "OK" at the ECU Flash screen.

d. Wait for the software file to download to the ECM.

e. Select "OK" at the "Flash ECU Successful" screen after the download is complete.

18. Verify that the new software part number on the "Flash PCM" screen matches the downloaded file.

19. Select "Back" four (4) times to return to the "Home" screen.

20. Turn the ignition switch to the "OFF" position and wait 10 seconds.

21. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure:

a. Place the ignition switch to the "RUN" position (do not start the engine).

b. Select "System View".

c. Select "All DTC's".

d. Select "Clear All Stored DTC's".

e. Select "Yes" at the confirm screen.

f. Turn the ignition switch to the "OFF" position and wait 10 seconds.

g. Start the engine to verify that all DTC's have been erased.

h. Turn the ignition switch to the "OFF" position.

22. Turn off and disconnect the battery charger.

23. Disconnect the StarSCAN from the vehicle and continue with Section D - Install Authorized Modifications Label.