Revision (4) March 2021
Dealer Service Instructions for:

Emissions Recall T21
Reprogram Engine Control Unit
NOTE: Remedy for 2004 model year vehicles has been revised.

Remedy Available
2004 - 2006 (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 2021, FCA US LLC, All Rights Reserved

(tdb)

Emissions Recall T21 – Reprogram Engine Control Unit

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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.
2004 Model Year vehicles ONLY, may require an adapter wiring harness depending
on the instrument cluster installed in the vehicle.

Parts Information
2004 Model Year vehicles ONLY, may require an adapter wiring harness
depending on the instrument cluster installed in the vehicle. Perform the
instrument cluster part number inspection in Section A of the Service
Procedure first to determine if the wiring harness adapter is required or not.
Part Number

Qty.

CEA6T211AA

1

Description
Adapter, Wiring Harness

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.

Emissions Recall T21 – Reprogram Engine Control Unit

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Parts Return
No parts return required for this campaign.

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)

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Service Procedure
A. Vehicle Model Year Check
1. Is the vehicle 2004 Model Year?
 YES: Vehicle is 2004 Model Year; continue with the procedure in Section A,
Step 2 Instrument Cluster Part Number Check.
 NO: Vehicle is 2005 - 2006 Model Year; Skip Section A and proceed directly
to Section B on Page 11 Reprogram the ECU.

NOTE: Technicians experiencing difficulty using the DRBIII Emulator tool
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.

Instrument Cluster Part Number Check
2. Install a battery charger and verify that the charging rate provides 13.0 to 13.5
volts. 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. 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.

3. Connect the wiTECH micro POD II to the vehicle data link connector.

4. Place the ignition in the “RUN” position.

5. Open the wiTECH Diagnostic application.

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Service Procedure [Continued]
6. 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.

7. Accept the software agreement. Click in the box next to “I Accept” then click
“Next”.
8. To begin the DRBIII Emulator tool, select “Yes”.
9. From “Main Menu” Select (1) “DRB III Standalone”.
10. Under heading “Stand-Alone Main Menu”, select (1) “1998-2010 Diagnostics”.
11. Under heading “1998-2010 Diagnostics”, select (6) “2002-2006 Sprinter”.
12. Under heading “Main Menu”, select (1) "System Select".
13. Under heading “System Select”, select (1) “Instrument Cluster” then press
“Enter”.

14. Module ID for instrument cluster screen will appear. Inspect the instrument
cluster part number installed.
 If instrument cluster part number A0024466721 is installed in the vehicle,
then the Adapter Wiring Harness must be installed before reprogramming the
ECU. Continue with Step 15 on Page 6.
 If instrument cluster with a different part number other than A0024466721 is
installed in the vehicle, proceed to Section B. Reprogram the ECU, Page 11.

Emissions Recall T21 – Reprogram Engine Control Unit

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Service Procedure [Continued]
Immobilizer (with Transponder) Control Unit Installation
WARNING: To avoid personal injury or death, on vehicles equipped with
airbags, disable the supplemental restraint system before attempting any
steering wheel, steering column, airbag, seat belt tensioner, or instrument
panel component diagnosis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for the system capacitor to
discharge before performing further diagnosis or service. This is the only
sure way to disable the supplemental restraint system. Failure to take the
proper precautions could result in accidental airbag deployment.
15.

Disconnect and isolate the battery negative cable from the main battery:
a. Turn the ignition switch to the Off position. Be certain that all electrical
accessories are turned off.
b. Loosen the under hood battery negative cable terminal clamp pinch-bolt
hex nut.
c. Disconnect the battery negative cable terminal clamp from the battery
negative terminal post. If necessary, use a battery terminal puller to remove
the terminal clamp from the battery post.

16.

If equipped with an auxiliary battery, disconnect and isolate the battery
negative cable from the auxiliary battery:
a. Remove the passenger front seat assembly.
b. Remove the top cover from the seat base assembly.
c. Loosen the battery negative cable terminal clamp pinch-bolt hex nut.
d. Disconnect the battery negative cable terminal clamp from the battery
negative terminal post. If necessary, use a battery terminal puller to remove
the terminal clamp from the battery post.

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Service Procedure [Continued]
17.

Remove the screws (2) from the instrument cluster bezel (Figure 1).

18.

Using a trim stick C-4755 or equivalent, separate cover (1) (Figure 1).

19.

Disconnect electrical connectors (3) and (4) then remove the bezel (Figure 1).

Figure 1 – Instrument Cluster Bezel

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Service Procedure [Continued]
20.

Remove the two screws (1) then using a trim stick C-4755 or equivalent,
remove the instrument cluster top cover (2) (Figure 2).

21.

Remove the two screws (3) that secure the instrument cluster (4) mounting
ears to the instrument panel base structure (Figure 2).

22.

Lift the instrument cluster upward far enough to disengage the two molded
plastic pivot loops (5) integral to the base of the cluster hood from the two
pairs of molded plastic pivot hooks that are integral to the top of the
instrument panel base structure (Figure 2).
NOTE: Do not disconnect the instrument panel electrical connectors.

Figure 2 – Instrument Cluster

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Service Procedure [Continued]
23.

Disconnect the electrical connector from the Remote Keyless Entry (RKE)
immobilizer module on the back of the instrument cluster rear cover
(Figure 3).
NOTE: The RKE immobilizer module does not need to be removed from
the instrument cluster.

24.

Install adapter wiring harness (3) and connect to RKE immobilizer module (1)
(Figure 3).

25.

Connect electrical connector (2) to adapter wiring harness (3) (Figure 3).

26.

Wrap electrical connector (2) together with adapter wiring harness (3) in foam
material (5) already present in the instrument panel (Figure 3).
NOTE: The foam material (5) will serve as chafe protection and
soundproofing (Figure 3).

Figure 3 – Install Adapter Wiring Harness
1.
2.
3.
4.
5.

RKE Immobilizer Module
Electrical Connector
Adapter
Instrument Cluster
Foam Material

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Service Procedure [Continued]
27. Align the two molded plastic pivot loops (5) integral to the base of the cluster
hood between the two pairs of molded plastic pivot hooks that are integral to the
top of instrument panel base structure, then push downward on the top of the
cluster until the loops snap into engagement with the hooks (Figure 2).
28. Roll the top of the instrument cluster (4) forward to position the instrument
cluster into the instrument panel (Figure 2).
29. Install and tighten the two screws (3) that secure the instrument cluster mounting
ears to the instrument panel base structure (Figure 2). Tighten the screws to
2 N·m (20 in. lbs.).
30. Install the instrument cluster cover (2) then install the two screws (1) and tighten
securely (Figure 2).
31. If equipped with an auxiliary battery:
a.

Reconnect the battery negative cable terminal clamp to the battery negative
terminal post. Tighten the terminal clamp pinch-bolt hex nut to 7.9 N·m (70
in. lbs.).

b.

Apply a thin coating of petroleum jelly or chassis grease to the exposed
surfaces of the battery cable terminal clamps and the battery terminal posts.

c.

Install the top cover on the seat base assembly.

d.

Install the passenger front seat assembly.

32. Main battery reconnect procedure:
a.

Reconnect the battery negative cable terminal clamp to the battery negative
terminal post. Tighten the terminal clamp pinch-bolt hex nut to 7.9 N·m (70
in. lbs.).

b.

Apply a thin coating of petroleum jelly or chassis grease to the exposed
surfaces of the battery cable terminal clamps and the battery terminal posts.

33. Proceed to Section B. Reprogram the ECU, Page 11.

Emissions Recall T21 – Reprogram Engine Control Unit

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Service Procedure [Continued]
B. 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”.

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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.

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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”.

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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 C. Visual Inspection of air intake path and EGR system.

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Service Procedure [Continued]
C. 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 D. Perform Vehicle Repair Verification Test Drive.

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Service Procedure [Continued]
D. 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 E. 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.

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