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TABLE OF CONTENTS - Jeep

1. DIESEL AUTO GLOW 86 86 PLUG SHUT cA cA DOWN RELA Y SELAN Jh 19 30 87 2 85 CABIN l HEATER 85 85 86 SPARE RELAY 4987 COMPRESSOR cay CLUTCH CLUTCH 080 85 INTERLOCK RELAY RELAY T PLUG 48 25 6 BLOWER MOTOR gt 530 7 RELAY o 4 5 85 85 STARTER WIPER MOTOR 87A 86 as aza HIGH LOW N RELAY 1 RELAY 4597 o gt 87 E FUEL je WIPER HEATER 6 5 RELAY i Ja RELA i w R U T 5 225 CONNECTOR PINOUTS FUSES DIESEL FUSE AMPS FUSED CIRCUIT FUNCTION NO 1 40A A122 120R FUSED B 2 30A 99 14RD VT FUSED B 50 13 10PK WT FUSED B 4 40A A10 12RD DG FUSED B 5 30 A32 14RD DB FUSED B
2. CAV CIRCUIT FUNCTION 1 142 14DG OR AUTO SHUT DOWN RELAY OUTPUT 2 46 18 FUEL PRESSURE SOLENOID CONTROL FUEL PUMP MODULE LT GRAY 4 WAY CAV CIRCUIT FUNCTION 1 2211 16BK GAS GROUND 2 K4 18BK LB SENSOR GROUND 3 K226 18DB WT FUEL LEVEL SENSOR SIGNAL 4 141 16DG WT GAS FUEL PUMP RELAY OUTPUT GENERATOR 3 WAY CAV CIRCUIT FUNCTION 1 FIELD WIRES 2 FIELD WIRE CONNECTOR 3 B OUTPUT TERMINALS GENERATOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 A71 18DG RD DIESEL FUSED AUTO SHUT DOWN RELAY OUTPUT 1 K20 18DG GAS GENERATOR FIELD CONTROL 2 K20 18DG DIESEL GENERATOR FIELD CONTROL 2 K125 18WT DB GAS GENERATOR SOURCE 223 N N E R E CONNECTOR PINOUTS BLACK 7 Are GLOW PLUG ASSEMBLY DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION GLOW 1 K154 10GY GLOW PLUG RELAY NO 1 OUTPUT PLUG 2 K104 10RD WT GLOW PLUG RELAY NO 2 OUTPUT ASSEMBLY DIESEL s BLACK LEFT SPEED CONTROL SWITCH EXCEPT BASE BLACK 4 WAY CAV CIRCUIT FUNCTION 2 20BK LB SENSOR GROUND LEFT V37 20RD LG SPEED CONTROL SWITCH SIGNAL SPEED CONTROL 4 SWITCH N N E R 4 7 224 CONNECTOR PINOUTS POWER DISTRIBUTION CENTER
3. 229 10 1 2002 KJ 2 5L TURBO 5 229 CHARTS AND GRAPHS 231 vi 1 0 INTRODUCTION The procedures contained in this manual include all the specifications instructions and graphics needed to diagnose engine control module ECM and sentry key immobilizer system SKIS prob lems they are no start diagnostic trouble code DTC and no trouble code problems for the ECM The diagnostics in this manual are based on the trouble condition or symptom being present at the time of diagnosis When repairs are required refer to the appropri ate service information for the proper removal and repair procedure Diagnostic procedures change every year New diagnostic systems may be added carryover sys tems may be enhanced IT 15 RECOMMENDED THAT YOU REVIEW THE ENTIRE MANUAL TO BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES This manual will cover all the necessary require ments to begin a logical diagnostic path for each problem If there 15 a diagnostic trouble code DTC detected go to the trouble code test If there are no DTCs present go to a no trouble code symptom based test This book reflects many suggested changes from readers of past issues After using this book if you have any comments or recommendations please fill out the form at the back of the book and mail it back to us 1 1 SYSTEM COVERAGE
4. LESS Ne 7 nO at ENGINE TEMPERATURE SENSOR 80d1b990 a L T N 5 80010959 7 a A 5 5 Mii 7 DUIS SS alk a TAS ES CRANKSHAFT OIL POSITION SENSOR SENSOR re 8 7 SWITCHES AIC LOW PRESSURE SWITCH AND 7 HARNESS CONNECTOR 4 Sa mie 47 AX a a 5 AP WA AT gt 80cceldce 212 COMPONENT LOCATIONS i GO AEAN CIS O VES Wa RR WA 112 7 INTERLOCK 14 SWITCH 1 80cdb402 2 L T N 5 213 NOTES 214 9 0 CONNECTOR PINOUTS BLACK 2 1 CEJ A C COMPRESSOR CLUTCH GRAY T A C HIGH PRESSURE SWITCH DIESEL GRAY A C LOW PRESSURE SWITCH ACCELERATOR PEDAL POSITION SENSOR DIESEL CONNECTOR PINOUTS A C COMPRESSOR CLUTCH BLACK 2 WAY CAV CIRCUIT FUNCTION C3 18DB BK A C COMPRESSOR CLUTCH RELAY OUTPUT Z246 18BK GY GROUND A C
5. 2 K4 18BK LB SENSOR GROUND 228 SCHEMATIC DIAGRAMS 10 0 SCHEMATIC DIAGRAMS 10 1 2002 KJ 2 5L TURBO DIESEL TRANSFER CASE POSITION SENSOR ACCEL PEDAL POSITION SENSOR LOW IDLE POSITION SWITCH gt RESUME ACCEL i CANCEL 9 DECEL PRESSURI FUEL RAIL E SENSOR ECT SENSOR BATTERY TEMP SENSOR FUEL LEVEL SENSOR WATER IN FUEL AC LOW PRESSURE SW SENSOR BOOST PRESSURE SENSOR INTAKE AIR TEMP SENSOR CRANKSHAFT POSITION SENSOR AIC HIGH PRESSURE SW 7 PDC FUSE 26 BRAKE SWITCH on fo 11850 DLC TO IGNITION SWITCH INJECTOR 1 4 INJECTOR 2 4 INJECTOR 3 4 INJECTOR 4 ASD RELAY FUSE 6 ENGINE CONTROL MODULE ECM GLOW PLUG RELAY 1 PLUGS 1 2 FUSE 10 Bt GLOW PLUG RELAY 2 PLUGS PDC FUSE 11 feu CAMSHAFT POSITION c SENSOR FUEL SOLENOID AiG RELAY PRESSURE t FUSE
6. Continued P0204 CYLINDER 4 1 ECTOR CIRCUIT CURRENT DECREASE When Monitored With the engine running Set Condition The ECM detects an incorrect rate of current decrease after injection occurs P0204 CYLINDER 4 INJ ECTOR CIRCUIT LOAD DROP When Monitored With the engine running Set Condition The ECM detects insufficient current through the injector driver P0204 CYLINDER 4 INJ ECTOR CIRCUIT OVERCURRENT HIGH SIDE When Monitored With the engine running Set Condition The ECM detects excessive current on the common driver circuit P0204 CYLINDER 4 INJ ECTOR CIRCUIT OVERCURRENT LOW SIDE When Monitored With the engine running Set Condition The ECM detects excessive current on the injector driver circuit POSSIBLE CAUSES ENGINE CONTROL MODULE INTERMITTENT CONDITION FUEL INJ ECTOR CONTROL CIRCUIT SHORTED TO VOLTAGE COMMON DRIVER CIRCUIT SHORTED TO VOLTAGE FUEL INJ ECTOR CONTROL CIRCUIT SHORTED TO GROUND COMMON DRIVER CIRCUIT SHORTED TO GROUND FUEL INJ ECTOR CIRCUITS SHORTED TOGETHER FUEL INJ ECTOR CONTROL CIRCUIT OPEN COMMON DRIVER CIRCUIT OPEN FUEL INJ ECTOR ACTION APPLICABILITY Turn the ignition on All With the DRBIII erase the ECM DTCs Test drive the vehide With the DRBIII read the ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 10 43 DRIVEABILITY DIESEL PO201 CYLINDER 1 INJECTOR CIRCUIT CURRENT DECREASE Continued ACTION APPLICABILITY Turn the ignition off Disco
7. STATUS FAILURE becuase ecg 197 SERIAL LINK EXTERNAL FAULT evar eres ev snares ee 197 ROLLING CODE FAILURE 199 VIN MISMATCH 246 cnc aan onde tude one deca es 199 TRANSPONDER COMMUNICATION 25 555524 56 594 8148 54 201 TRANSPONDER CYCLIC REDUNDANCY CHECK CRC FAILURE 201 TRANSPONDER ID MISMATCH 55555 00 dng 201 TRANSPONDER RESPONSE 15 es be eavaws wee 201 VERIFICATION TESTS VERIFICATION TESS 42 kareni pii Ri 204 COMPONENT LOCATIONS 209 CONTROL MODULES scrise rrepka ___ _ 209 82 CONTROLS AND SOLENOIDS 225565555 sa 209 8 3 DATA LINK CONNECTOR 2 hous 210 84 FUEL SYSIEM 2 ccovevercvS 210 211 8 6 5 5 Gerri __ _____ ____ 211 8 7 SWITCHES sande 5 212 CONNECTOR PINOUTS dae naa was 215 A C COMPRESSOR CLUTCH BLACK 2 215 A C HIGH PRESSURE SWITCH DIESEL GRAY 2 219 AIG LOW PRESSURE SWITCH GRAY 2 WAY 219
8. 151 P1652 J1850 COMMUNICATION BUS SHORT TO GROUND 153 P1652 J1850 COMMUNICATION BUS SHORT TO VOLTAGE 153 P1685 SKIM SYSTEM INVALID KEY CODE 155 P1685 SKIM SYSTEM INVALID SECRET KEY IN 155 P1685 SKIM SYSTEM KEY COMMUNICATION TIMED 155 P1685 SKIM SYSTEM WRITE ACCESS TO EEPROM FAILURE 155 P1830 CLUTCH RELAY CIRCUIT 157 P1830 CLUTCH OVER RIDE RELAY CIRCUIT SHORTED 157 2120 PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY 160 2120 PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH BRAKE SWITCH ieaie aone caw teases 160 2120 PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH LOW IDLE SWITCH 160 2120 PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH POTENTIOMETER we oe ax 160 2120 PEDAL POSITION SENSOR 1 SIGNAL VOLTAGE TOO HIGH 160 P2120 ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE TOO LOW 160 P2120 ACC PEDAL POSITION SENSOR 1 CKT SUPPLY VOLTAGE TOO HIGH OR LOWS a ia a a en E 160 Ps INDIE UR TIVE serei Sree mas a GR alate a S E 169 A C OPERATES IN ALL MODE SWITCH 5 173 CH
9. APPLICABILITY Turn the ignition on All Fully depress the accelerator pedal With the DRBIII read the PEDAL OUTPUT VOLTS Does the 111 display between 4 1 and 4 6 volts Yes GoTo 9 No Replace the Accelerator Pedal Position Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on With the DRB III read the PEDAL OUTPUT VOLTS With the accelerator pedal in the idle position slowly depress the accelerator pedal until the pedal is fully depressed NOTE The PEDAL OUTPUT VOLTS should increase smoothly as the pedal is depressed Does the voltage increase smoothly with the accelerator pedal travel Yes GoTo 10 No Replace the Accelerator Pedal Position Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on With the DRB III select Engine and with the custom display feature select Low Idle Switch input and the Accel Pedal Slowly depress and release the accelerator pedal several times while monitoring the DRB III display NOTE The Low Idle Switch state should change between 5 and 10 of Accelerator Pedal position Did the Low Idle Switch state change between 5 and 10 of Accelerator Pedal position Yes GoTo 11 No Replace the Accelerator Pedal Position Sensor Perform ROAD TEST VERIFICATION VER 2 164 DRIVEABILITY DIESEL P2120 ACC PEDAL POSITION SENSOR 1CKT
10. 6 A9 14RD YL FUSED B 6 30A A9 14RD YL FUSED B 7 50A A7 10RD BK FUSED B 40 A2 12PK BK FUSED B 9 50A A18 10PK FUSED B 10 50 54 1080 FUSED B 11 504 58 10RD GY FUSED B 12 20A A34 16LB RD FUSED B 13 40A A25 12DB FUSED B 14 1 12RD FUSED B 15 50A 12 10RD TN FUSED B 16 15 71 18DG RD FUSED AUTO SHUT DOWN RELAY OUTPUT 17 18 19 4 12BK PK FUSED B N 20 N 21 20 17 18RD BK FUSED B 21 17 18RD BK FUSED B 22 23 24 R 25 20 A20 12RD DB FUSED B 26 10 F92 18YL BR FUSED B 27 28 245 18YL BR FUSED IGNITION SWITCH OUTPUT START N 28 15 F45 18YL BR FUSED IGNITION SWITCH OUTPUT START U A C COMPRESSOR CLUTCH RELAY T CAV CIRCUIT FUNCTION S A17 18RD BK FUSED B 85 13 1800 EXCEPT RHD A C COMPRESSOR CLUTCH RELAY CONTROL 85 13 18DB OR RHD A T A C COMPRESSOR CLUTCH RELAY CONTROL 86 71 18DG RD DIESEL FUSED AUTO SHUT DOWN RELAY OUTPUT 86 18DB GAS FUSED IGNITION SWITCH OUTPUT RUN START 86 F1 1808 GAS FUSED IGNITION SWITCH OUTPUT RUN START 87 C3 18DB BK A C COMPRESSOR CLUTCH RELAY OUTPUT 87A 226 AUTO SHUT DOWN RELAY CONNECTOR PINOUTS CAV CIRCUIT FUNCTION 30 9 14RD YL FUSED B 30 9 14RD YL DIESE
11. Does the code appear Yes Replace and program the Engine Control Module in accordance with the Service Information Perform SKIS VERIFICATION Test Complete Turn the ignition off Note Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any Technical Service Bulletins TSB that may apply Were any problems found Yes Repair wiring harness connectors as necessary Perform SKIS VERIFICATION No Test Complete 198 VEHICLE THEFT SECURITY Symptom List ROLLING CODE FAILURE VIN MISMATCH Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be ROLLING CODE FAILURE When Monitored and Set Condition ROLLING CODE FAILURE When Monitored At ignition on after ignition on during any rolling code handshake that occurs with the ECM due toa SKIM or ECM reset Set Condition When a PCM STATUS message with a Valid K ey status is not received by the SKIM within 3 5 seconds of transmitting the last Valid Key Code message tothe ECM VIN MISMATCH When Monitored With the ignition on Set Condition When the VIN received from the ECM does not match the VIN stored the SKIM s EEPROM POSSIBLE CAUSES VERIFYING ECM VIN INTERMITTENT WIRING HARNESS PROBL
12. STACK OVERFLOW FAILURE When Monitored With the ignition on Set Condition The microcontroller has exceeded its stack space limit 195 VEHICLE THEFT SECURITY ANTENNA FAILURE Continued POSSIBLE CAUSES SKIM INTERNAL DTC FAILURE ACTION APPLICABILITY Note This trouble code indicates an internal SKIM fault All With the read and record the SKIM DTCs and then erase the SKIM DTCs Perform 10 ignition key cycles leaving the ignition key on for a minimum of 90 seconds per cycle With the DRBIII read the SKIM DTCs Did the same SKIM DTC return Yes Replace and program the Sentry Key Immobilizer Module accordance with the Service Information Perform SKIS VERIFICATION Test Complete 196 VEHICLE THEFT SECURITY Symptom List PCM STATUS FAILURE SERIAL LINK EXTERNAL FAULT Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be PCM STATUS FAILURE eT When Monitored and Set Condition PCM STATUS FAILURE When Monitored With the ignition on Set Condition ThisDTC exists when STATUS message was not received from the ECM for at least 20 0 consecutive seconds SERIAL LINK EXTERNAL FAULT When Monitored At ignition on after ignition on during any rolling code handshake that occurs with the ECM duetoa SKIM reset or during SECRET KEY transfers tothe ECM Set Condition When the SKIM does not receive an expected
13. 1 NOTE IMPORTANT If the Engine Control Module or Sentry Key Immobilizer All Module has been replaced ensure the programming procedures for the module has been performed in accordance with the Service Information 2 Inspect the vehicle to ensure that all engine components are properly installed and connected Reassemble and reconnect components as necessary 3 Inspect the engine oil for contamination If it is contaminated change the oil and filter 4 With the DRB erase all diagnostic trouble codes DTCs 5 Turn the ignition off for at least 10 seconds 6 Attempt to start the engine 7 If the engine is unable to start look for any Technical Service Bulletins TSBs that may relate to this condition Return to the Symptom List if necessary 8 If the engine starts and continues to run the repair is now complete Are any DTCs or symptoms remaining Yes Repair is not complete refer to appropriate symptom No Repair is complete 206 VERIFICATION TESTS VERIFICATION TESTS Continued ROAD TEST VERIFICATION VER 2 APPLICABILITY 1 Inspect the vehicle to ensure that all engine components are properly installed and All connected Reassemble and reconnect components as necessary 2 If this verification procedure 15 being performed after non DTC test perform steps and 4 3 Check to see if the initial symptom still exists If there trouble codes and the symptom no longer exists the repa
14. 47 150 20WT TN PRIMARY BRAKE SWITCH SIGNAL CONTROL L K29 20WT PK SECONDARY BRAKE SWITCH SIGNAL 0 MODULE 50 T 51 DIESEL 5 53 54 55 B22 20DG YL VEHICLE SPEED SIGNAL 56 57 58 5 59 60 _ 7 2008 FUEL PRESSURE SENSOR 5 VOLT SUPPLY 61 K51 20DB YL AUTO SHUT DOWN RELAY CONTROL 62 63 64 K151 20WT LOW IDLE POSITION SWITCH SENSE 65 66 67 68 69 C13 2006 COMPRESSOR CLUTCH RELAY CONTROL 70 71 72 K236 20GY PK GLOW PLUG RELAY RELAY NO 2 CONTROL 73 _ K90 2071 CLUTCH SWITCH OVERRIDE RELAY CONTROL 75 K132 20DG LB CABIN HEATER RELAY CONTROL 76 z 77 K152 20WT GLOW PLUG RELAY NO 1 CONTROL 78 79 80 _ 200R BK FUEL PRESSURE SOLENOID CONTROL 81 K46 200R BK FUEL PRESSURE SOLENOID CONTROL 219 CONNECTOR PINOUTS ENGINE CONTROL MODULE C2 DIESEL BLACK 40 WAY CAV CIRCUIT FUNCTION 82 D21 20PK SCI TRANSMIT 83 84 85 86 87 88 89 K35 20GY YL EGR SOLENOID CONTROL 90 91 92 BLACK 93 94 95 96 97 116 121 98 114 89 119 99 113 100 101 C18 2008 A C PRESSURE SIGNAL 102 82 90 98 106 103 104 ENGINE CONTROL ne MODULE 2 DIESEL 107 108 109 110 N N E R 111 112 113 114 115 K14 2 5mmLB BR F
15. ECTOR CIRCUIT OVERCUR RENT LOW SIDE ECM ERROR GATE ARRAY COMMUNICA TION ECM ERROR GATE ARRAY QUANTITY STOP ECM ERROR RECOVERY HAS OCCURRED ECM ERROR REDUNDANT OVERRUN MONI TORING EEPROM PLAUSIBILITY CHECKSUM ER ROR EEPROM PLAUSIBILITY CODE WORD IN CORRECT OR MISSING EEPROM PLAUSIBILITY COMMUNICATION ERROR CIRCUIT LOAD CIRCUIT LOAD CIRCUIT LOAD CIRCUIT LOAD EEPROM PLAUSIBILITY VARIATION NUM BER ERROR EEPROM PLAUSIBILITY WRITE ERROR EGR SOLENOID CIRCUIT OPEN CIRCUIT EGR SOLENOID CIRCUIT SHORT CIRCUIT ENGINE COOLANT TEMP SENSOR CIRCUIT ENGINE 15 COLD TOO LONG ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW FUEL PRESS SENSOR CIRCUIT MALF SIG NAL VOLTAGE TOO HIGH FUEL PRESS SENSOR CIRCUIT MALF SIG NAL VOLTAGE TOO LOW FUEL PRESS SENSOR CIRCUIT MALF SUP PLY VOLTAGE TOO HIGH OR LOW FUEL PRESSURE SOLENOID OPEN CIRCUIT FUEL PRESSURE SOLENOID SHORT CIR CUIT FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO HIGH SHUT OFF FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO LOW FUEL RAIL PRESSURE MALFUNCTION SO LENOID OPEN GENERATOR FIELD CONTROL MALF BAT TERY VOLTAGE DEVIATION TOO HIGH GENERATOR FIELD CONTROL MALF BAT TERY VOLTAGE DEVIATION TOO LOW GENERATOR FIELD CONTROL
16. Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 124 DRIVEABILITY DIESEL Symptom P0685 ASD RELAY CONTROL CIRCUIT SHUTS OFF TOO EARLY When Monitored and Set Condition P0685 ASD RELAY CONTROL CIRCUIT SHUTS OFF TOO EARLY When Monitored During after run Set Condition The internal ECM timer determines that the ASD Relay has shut off before the AFTER RUN mode of operation has been completed POSSIBLE CAUSES CHECK FOR OTHER DTCS INTERMITTENT CONDITION SUBSTITUTE ASD RELAY ASD RELAY CONTROL CIRCUIT OPEN INTERMITTENTLY ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB check for additional DTCs Are other DTCs present Yes Refer tothe Symptom List for diagnosis of the other DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 GoTo 2 Turn the ignition on With the DRB erase ECM DTCs Perform several ignition key cycles pausing for at least 10 seconds between ea
17. 71 P0382 GLOW PLUG 2 CONTROL CIRCUIT SHORT CIRCUIT 71 P0403 EGR SOLENOID CIRCUIT OPEN CIRCUIT iiecc scr eeeeeesedaeens 74 P0403 EGR SOLENOID CIRCUIT SHORT 76 P0460 FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH 78 P0460 FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW 81 PO500 VEHICLE SPEED SENSOR FREQUENCY TOO 83 0500 SPEED SENSOR HIGH LEVEL 83 POS0U VEHICLE SPEED SENSOR PLAUSIBILITY 246 sees vou ee 83 0500 SPEED SENSOR SIGNAL VOLTAGE TOO HIGH 83 P0514 BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH 87 P0514 BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW 90 P0520 OIL PRESS SENSOR CIRCUIT MALF PLAUSIBILITY 92 P0520 OIL PRESS SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW 95 PUS6U SY SIEM VOLTAGE TOO HIGH 97 P0560 SYSTEM VOLTAGE TOO LOW stat dag 99 THE CHARGING SYSTEM OPERATION 99 0579 5 SWITCH SIGNAL CIRCUIT PLAUSIBILITY 102 P0579 S C SWITCH SIGNAL CIRCUIT SIGNAL VOLTAGE TOO HIGH 104 P0579 S C SWITCH SIGNAL CIRCUIT SIGNAL VOLTAGE LOW 106 P0620 GENERATOR FIELD CONTROL MALF BA
18. BODY VERIFICATION TEST VER 1 1 Disconnect all jumper wires and reconnect all previously disconnected components and connectors 2 If the Sentry Key Immobilizer Module SKIM the Engine Control Module ECM was replaced proceed to number 5 If the SKIM or ECM was not replaced continue to the next number 3 If the Body Control Module was replaced turn the ignition for 15 seconds to learn VIN If the vehicle is equipped with VTSS use the and enable VTSS 4 Program tire size country code and all RKE transmitters if RKE Module was replaced other options as necessary Proceed to number 12 5 Obtain the Vehicle s unique PIN assigned to it s original SKIM from the vehicle s invoice 6 NOTE Once Secured Access Mode is active the SKIM will remain in that mode for 60 seconds 7 With the DRBIII select THEFT ALARM SKIM MISCELLANEOUS select SKIM REPLACED Enter the 4 digit PIN to put the SKIM in Secured Access Mode 8 The DRBII1I will prompt for the following steps 9 Using the DRBII1 program all customer keys intothe SKIM memory This requires that the SKIM bein Secured Access Mode using the 4 digit PIN 10 Note If the ECM replaced the VIN and the unique Secret Key data must be transferred from the SKIM tothe ECM This procedure requires the SKIM to be placed in Secured Access Mode using the 4 digit PIN 11 Note If 3 attempts made to enter Secured Access ode using an
19. HOT ACTION APPLICABILITY NOTE The thermostat must be operating correctly for this test to be valid All With the DRBIII in Sensors read and note the engine coolant temperature Using a temperature probe measure the engine block temperature near the ECT Sensor NOTE The engine temperature should be below 50 C 120 F Are readings within 7 C 13 F of each other Yes GoTo 2 No Replace the Engine Coolant Temperature Sensor Perform ROAD TEST VERIFICATION VER 2 NOTE The thermostat must be operating correctly for this test to be valid Start the engine and bring the engine to operating temperature thermostat open Turn the engine off and wait 10 minutes to allow the engine temperature to stabilize Using a temperature probe measure the engine block temperature near the ECT Sensor With the DRBIII select Engine then Sensors and read the engine coolant temperature the readings within 7 C 13 F of each other Yes Test Complete No Replace the Engine Coolant Temperature Sensor Perform ROAD TEST VERIFICATION VER 2 179 DRIVEABILITY DIESEL Symptom CHECKING THE ENGINE MECHANICAL SYSTEMS POSSIBLE CAUSES CHECKING ENGINE MECHANICAL SYSTEMS ACTION APPLICABILITY NOTE The following items should be checked as a possible cause of a All Driveability or No Start problem WARNING Do not attempt to remove or separate high pressure fuel line Attempting to do so coul
20. PO606 ECM ERROR GATE ARRAY QUANTITY STOP When Monitored With the ignition on Set Condition The ECM detects an internal failure PO606 ECM ERROR RECOVERY HAS OCCURRED When Monitored With the ignition on Set Condition The ECM detects an internal failure ERROR REDUNDANT OVERRUN MONITORING When Monitored With the ignition on Set Condition The ECM detects an internal failure 1601 VOLTAGE 1 VOLTAGE TOO HIGH When Monitored With the engine running During every 180 of engine rotation Set Condition The ECM determines that the capacitor voltage is out of range P1601 CAPACITOR VOLTAGE 1 VOLTAGE TOO LOW When Monitored With the engine running During every 180 of engine rotation Set Condition The ECM determines that the capacitor voltage is out of range P1606 AFTER RUN SHUT OFF ERROR INJ ECTION POWERSTAGE When Monitored At ignition off Set Condition detects the engine speed has not fallen below 650 RPM within 0 5 seconds after ignition off P1606 AFTER RUN SHUT OFF ERROR ZERO QUANTITY When Monitored At ignition off Set Condition detects the engine speed has not fallen below 650 RPM within 0 5 seconds after ignition off 1652 1850 COMMUNICATION BUS LOST ARBITRATION When Monitored With the ignition on Set Condition The ECM fails to broadcast any messages the J 1850 Bus circuit 20 DRIVEABILITY DIESEL P0O105 BAROMETRIC PRESSUR
21. This diagnostic procedures manual covers all 2002 KJ body vehicles equipped with the 2 5L VM diesel engine 1 2 SIX STEP TROUBLESHOOTING PROCEDURE Diagnosis of the engine control module ECM and sentry key immobilizer system SKIS is done in six basic steps verification of complaint verification of any related symptom e symptom analysis e problem isolation repair of isolated problem verification of proper operation NOTE All tests in this manual should be per formed with the engine at operating temperature unless specified within a particular test GENERAL INFORMATION IDENTIFICATION OF SYSTEM The ECM is located in the left side of the engine compartment between the left front headlamp and theintelligent power module The sentry key immo bilizer module SKIM is located below the steering column behind the steering wheel 2 0 3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 3 1 GENERAL DESCRIPTION The 2 5L VM diesel engine system is equipped with the latest in technical advances The on board diagnostics incorporated in the engine control mod ule and SKIM are intended to assist the field technician in repairing vehicle problems by the quickest means The engine system incorporates a common rail fuel delivery design This design utilizes electroni cally controlled solenoid valve type fuel injectors Each injector is controlled individually by the ECM Injector timing and fuel quant
22. BUS message trans mission acknowledgement from the ECM after 3 transmit attempts POSSIBLE CAUSES INTERMITTENT WIRING HARNESS PROBLEM WIRING HARNESS INSPECTION SKIM ECM APPLICABILITY NOTE Ensure the ECM has proper power and ground connections before All continuing With the DRBIII read and record the SKIM then erase the SKIM Turn the ignition off Wait 2 minutes Turn the ignition on With the DRBIII read the SKIM Does the DRBIII display the DTC that was previously erased Yes GoTo 2 GoTo 4 197 VEHICLE THEFT SECURITY PCM STATUS FAILURE Continued ACTION APPLICABILITY Turn the ignition off All NOTE Visually inspect the related wiring harness and CCD PCI Bus whichever applicable circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any Technical Service Bulletins TSB that may apply Were any problems found Yes Repair as necessary Perform SKIS VERIFICATION GoTo 3 NOTE Before proceeding it will be necessary to obtain the SKIM PIN number Turn the ignition on With the DRBIII display and erase all ECM and SKIM DTC s Perform 5 ignition key cycles leaving theignition key on for a minimum of 90 seconds per cycle With the DRBIII read the SKIM
23. CAV CIRCUIT FUNCTION 58 10RD GY FUSED B 85 K236 18GY PK GLOW PLUG RELAY NO 2 CONTROL 86 71 1800 80 FUSED AUTO SHUT DOWN RELAY OUTPUT 87 K104 10RD WT GLOW PLUG RELAY NO 2 OUTPUT 87A 227 N N E R 4 2 N N E R 4 7 CONNECTOR PINOUTS K BLACK RIGHT SPEED CONTROL SWITCH SENTRY KEY IMMOBILIZER MODULE EXCEPT BASE s BLACK TRANSFER CASE POSITION SENSOR GRAY WATER IN FUEL SENSOR DIESEL RIGHT SPEED CONTROL SWITCH EXCEPT BASE BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 K4 20BK LB SENSOR GROUND 3 V37 20RD LG SPEED CONTROL SWITCH SIGNAL 4 SENTRY KEY IMMOBILIZER MODULE EXCEPT BASE BLACK 6 WAY CAV CIRCUIT FUNCTION 1 F33 20PK RD FUSED B 2 211 20BK WT GROUND 3 F1 2008 FUSED IGNITION SWITCH OUTPUT RUN START 4 Z110 20BK TN GROUND 5 D25 20YL VT BK PCI BUS 6 TRANSFER CASE POSITION SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K77 20BR WT DIESEL TRANSFER CASE POSITION SENSOR INPUT K77 18BR WT GAS TRANSFER CASE POSITION SENSOR INPUT 2 K4 18BK LB SENSOR GROUND WATER IN FUEL SENSOR DIESEL GRAY 2 WAY CAV CIRCUIT FUNCTION 1 G123 20DG WT WATER IN FUEL SENSOR SIGNAL
24. DIESEL CHECKING THE SPEED CONTROL OPERATION Continued APPLICABILITY Turn the ignition on All With the DRBIII in Sensors read the Vehicle Speed Sensor signal Have an assistant drive the vehicle while you are observing the Vehicle Speed Signal the DRBIII While observing vehicle speed signal note any rapid changes signal drop outs in the reading that do not correspond with actual vehicle speed 15 the DRBIII displaying an accurate Vehicle Speed Signal Yes GoTo 5 No Refer to symptom list for problems related to the Vehicle Speed Sensor Perform SPEED CONTROL VERIFICATION VER 4 Turn the ignition on With the DRBIII Inputs Outputs read the Primary and Secondary switch states while pressing and releasing the Brake Pedal several times Did the DRBIII indicate the correct brake pedal state when pressing and releasing the Brake Pedal Yes GoTo 6 No Refer tosymptom list for problems related to Brake Switch input Perform SPEED CONTROL VERIFICATION VER 4 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent
25. GoTo 2 No Repair leaking or restricted Vacuum Supply Hose or faulty Vacuum Supply Pump Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the EGR Solenoid harness connector Turn the ignition on Using 12 volt test light connected to ground check the ASD Relay Output circuit at the EGR Solenoid harness connector Is the test light on Yes GoTo 3 No Repair the ASD Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Measure the resistance of the EGR Solenoid Control circuit 15 the resistance below 10 0 ohms Yes GoTo 4 No Repair the EGR Solenoid Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 NOTE The Vacuum Output Hose must not be leaking or restricted for the result of this test to be valid Turn the ignition off Disconnect the Vacuum Supply and Vacuum Output Hoses in the EGR Solenoid vacuum connector Connect the Vacuum Supply Hose to the Vacuum Output Hose Test drive the vehicle and observe vehicle performance 15 there a power reduction on vehicle acceleration Yes Test Complete No Replace the EGR Valve Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the EGR Solenoid harness connector Disconnect the ECM harness connectors 178 DRIVEABILITY DIESEL Symptom CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR CALIBRATION POSSIBLE CAUSES ECT SENSOR COLD ECT SENSOR
26. No Replace the EGR Solenoid Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair All Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 75 DRIVEABILITY DIESEL Symptom P0403 EGR SOLENOID CIRCUIT SHORT CIRCUIT When Monitored and Set Condition P0403 EGR SOLEN
27. P0115 E NGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the ECT Sensor harness connector Measure the resistance between the ECT Sensor Signal circuit and Sensor Ground circuit Is the resistance above 1000 ohms Yes GoTo 5 Repair the ECT Sensor Signal and Ground circuits for a short together Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wir
28. P0641 SENSOR REFERENCE VOLTAGE VOLTAGE TOO HIGH Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 113 DRIVEABILITY DIESEL Symptom P0641 SENSOR REFERENCE VOLTAGE CKT VOLTAGE TOO LOW E When Monitored and Set Condition P0641 SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO LOW When Monitored With the ignition on Set Condition The ECM detects a short to ground on the Sensor Reference Voltage
29. that cause the SKIM DTC Perform SKIS VERIFICATION With the DRBIII attempt to reprogram the ignition keys to the SKIM With the DRBIII erase the SKIM DTC s Wait 10 seconds Turn the ignition on With the DRBIII read the SKIM DTC s Does the DTC reset Yes GoTo 5 No Test Complete Replace the ignition key with a new key With the DRBIII program the new ignition key to the SKIM With the DRBIII erase the SKIM DTC s Turn the ignition off Wait 10 seconds Turn the ignition on With the DRBIII read the SKIM Does the DTC reset Yes GoTo 6 No Test Complete 202 VEHICLE THEFT SECURITY TRANSPONDER COMMUNICATION FAILURE Continued APPLICABILITY If there are no possible causes remaining view repair All Repair Replace and program the Sentry Key Immobilizer Module in accordance with the Service Information Perform SKIS VERIFICATION Turn the ignition off Note Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any Technical Service Bulletins TSB that may apply Were any problems found Yes Repair wiring harness connectors as necessary Perform SKIS VERIFICATION Test Complete 203 VERIFICATION TESTS VERIFICATION TESTS
30. 1 CONTROL CIRCUIT SHORTED TO GROUND GLOW PLUG RELAY 1 CONTROL CIRCUIT OPEN ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB actuate Glow Plug Relay 1 Is Glow Plug Relay 1 clicking Yes GoTo 2 GoTo 3 68 DRIVEABILITY DIESEL P0380 GLOW PLUG 1 CONTROL CIRCUIT OPEN CIRCUIT Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete Turn the ignition off All Remove
31. 2 No Test Complete Turn the ignition off All Remove Glow Plug Relay 2 from the PDC Turn the ignition on Using a 12 volt test light connected to ground check the ASD Relay Output circuit Does the test light illuminate brightly Yes GoTo 4 No Repair the ASD Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Install a substitute relay in place of Glow Plug Relay 2 Perform several ignition key cycles pausing for at least 10 seconds between each cycle Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes GoTo 5 No Replace Glow Plug Relay 2 Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Remove Glow Plug Relay 2 from the PDC Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage on the Glow Plug Relay 2 Control circuit 15 the voltage above 1 0 volt Yes Repair the Glow Plug Relay 2 Control circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No GoTo 6 72 DRIVEABILITY DIESEL P0382 GLOW PLUG 2 CONTROL CIRCUIT OPEN CIRCUIT Continued APPLICABILITY Turn the ignition off All Remove Glow Plug Relay 2 from the PDC Disconnect the ECM harness connectors Measure the resistance between ground and the Glow Plu
32. 21 AIC CLUTCH EGR SOLENOID VISCOUS CABIN HEATER RELAY FAs PDC FUSE 21 VISCOUS CABIN HEATER GENERATOR FIELD 28 229 CLUTCH INTERLOCK RELAY IGNITION SWITCH TO STARTER RELAY 80d31840 5 H E M T G R M 5 NOTES 11 0 CHARTS AND GRAPHS Range Offset Probe Coupling 20 0 4 00v x10 DC READ HELP VOLTAGE RECORD CURSOR Camshaft Position Sensor Signal During Engine Cranking 80c7708b Range Offset Probe Coupling 20 0 8 00v 10 READ 1 HELP VOLTAGE RECORD CURSOR CKP Sensor 1 Signal 80bc7b84 231 CHARTS AND GRAPHS Range Offset Probe Coupling 20 0 4 00 x10 DC READ 20 5 gt 4 H R T 5 N G R H 5 8 1 at 1 0 I 1 1 1 t 1 1 Chani So a a ee 2 eee HELP VOLTAGE RECORD CURSOR Vehicle Speed Signal Driving in 3rd gear at 1100 1200 RPM 80bc7ab4 Range Offset Probe Coupling 20 0 8 00v x10 DC READ Chanti HELP VOLTAGE RECORD CURSOR CKP Sensor 2 Signal podosadt NOTES 232
33. ACCELERATOR PEDAL POSITION SENSOR DIESEL BLACK 10 215 BATTERY TEMPERATURE SENSOR BLACK 2 216 BOOST PRESSURE SENSOR DIESEL 4 216 BRAKE LAMP SWITCH BLACK 6 WAY 216 CABIN HEATER DIESEL BLACK 2 216 CAMSHAFT POSITION SENSOR DIESEL WAY 217 CLUTCH INTERLOCK SWITCH M T BLACK 2 217 CRANKSHAFT POSITION SENSOR DIESEL BLACK 3 WAY 217 DATA LINK CONNECTOR BLACK 16 WAY 217 EGR SOLENOID DIESEL 2 WAY ec bee ee es 218 ENGINE CONTROL MODULE C1 DIESEL BLACK 81 219 ENGINE CONTROL MODULE C2 DIESEL BLACK 40 WAY 220 ENGINE COOLANT LEVEL SENSOR DIESEL LT GRAY 2 WAY 220 ENGINE COOLANT TEMP SENSOR DIESEL BLACK 2 WAY 221 ENGINE OIL PRESSURE SENSOR BLACK WAY 221 FUEL HEATER DIESEL BLACK 2 221 FUEL INJECTOR NO 1 DIESEL BLACK 2 221 FUEL INJECTOR NO 2 DIESEL BLACK 2 222 10 0 11 0 TABLE OF CONTENTS Continued FUEL INJECTOR NO 3 DIESEL BLACK 2
34. AIR TEMPERATURE SENSOR SIGNAL 3 18VT WT SENSOR REFERENCE VOLTAGE B 4 K37 20DB YL BOOST PRESSURE SENSOR SIGNAL BRAKE LAMP SWITCH BLACK 6 WAY CAV CIRCUIT FUNCTION 1 F32 18PK DB FUSED B 2 L50 18WT TN GAS BRAKE LAMP SWITCH OUTPUT 2 L50 18WT TN DIESEL PRIMARY BRAKE SWITCH SIGNAL 3 V30 18DB RD SPEED CONTROL BRAKE SWITCH OUTPUT 4 V32 18YL RD SPEED CONTROL SUPPLY 5 23 18BK OR GROUND 6 K29 18WT PK GAS BRAKE SWITCH SENSE 6 K29 18WT PK DIESEL SECONDARY BRAKE SWITCH SIGNAL CABIN HEATER DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 C151 18DB WT CABIN HEATER RELAY OUTPUT Z186 12BK OR GROUND 216 1100 000 CAMSHAFT POSITION SENSOR DIESEL BLACK CLUTCH INTERLOCK SWITCH CRANKSHAFT POSITION SENSOR DIESEL CONNECTOR CONNECTOR PINOUTS CAMSHAFT POSITION SENSOR DIESEL 3 WAY 217 CAV CIRCUIT FUNCTION 1 944 20BK LB CAMSHAFT POSITION SENSOR GROUND 2 K44 20TN YL CAMSHAFT POSITION SENSOR SIGNAL 3 A142 14DG OR AUTO SHUT DOWN RELAY OUTPUT CLUTCH INTERLOCK SWITCH M T BLACK 2 WAY CAV CIRCUIT FUNCTION 1 1141 18YL RD CLUTCH SWITCH OVERRIDE RELAY OUTPUT 2 F45 18YL BR FUSED IGNITION SWITCH OUTPUT START CRANKSHAFT POSITION SENSOR DIESEL BLACK 3 WAY
35. C HEATER CONTROL MODULE BODY CONTROL MODULE ACTION APPLICABILITY With the DRBIII check for ECM DTCs All Are any DTCs present Yes Return tothe symptom list and choose the symptom s Perform ROAD TEST VERIFICATION 2 GoTo 2 Position the Mode switch on the A C Heater Control Module to the Panel position A C off Turn the ignition on With the DRBIII in BCM select Inputs Outputs Monitor the A C Select Switch state while turning the Mode switch from Panel A C off to Bi Level A C on then back to Panel A C off Does the switch state change from Off to On then back to Off Yes GoTo 3 No GoTo 6 Turn the ignition off Disconnect the A C Clutch harness connector WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Start the engine and observe the A C Clutch and Compressor Does the A C Compressor run with the harness connector disconnected Yes Replace the A C Clutch in accordance with the Service I nforma tion Perform ROAD TEST VERIFICATION VER 2 GoTo 4 173 DRIVEABILITY DIESEL A C OPERATES IN ALL MODE SWITCH POSITIONS Continued ACTION APPLICABILITY Turn the ignition off Remove the A C Clutch Relay from the PDC Disconnect the A C Clutch harness connector Measure the voltage of the A C Clutch Relay Output circuit Is the voltage
36. CAV CIRCUIT FUNCTION 1 K24 20GY BK CRANKSHAFT POSITION SENSOR SIGNAL 1 2 K3 20LB BK CRANKSHAFT POSITION SENSOR SIGNAL 2 3 Y101 20BK OR CRANKSHAFT POSITION SENSOR SHIELD DATA LINK CONNECTOR BLACK 16 WAY CAV CIRCUIT FUNCTION 1 2 D25 18YL VT PCI BUS 3 4 2252 18BK GY GROUND 5 2252 18BK GY GROUND 6 D32 20LG DG GAS SCI RECEIVE 6 D32 20LG DG DIESEL NOT USED 7 021 20PK RD SCI TRANSMIT 8 D24 18WT DG FLASH ABS 9 D19 20VT OR BODY CONTROL MODULE FLASH ENABLE 11 12 13 14 020 20LG DIESEL NOT USED 14 020 20LG GAS SCI RECEIVE 15 16 F33 20PK RD FUSED B N N E R 4 2 95 CONNECTOR PINOUTS 2 o0 1 EGR SOLENOID DIESEL 2 WAY CAV CIRCUIT FUNCTION 1 71 18DG RD FUSED AUTO SHUT DOWN RELAY OUTPUT EGR 2 K35 18GY YL EGR SOLENOID CONTROL SOLENOID DIESEL N N E R 4 218 CONNECTOR PINOUTS ENGINE CONTROL MODULE 1 DIESEL BLACK 81 WAY CAV CIRCUIT FUNCTION 1 2108 14BK DG GROUND 2 7108 14BK DG GROUND 3 1806 GENERATOR FIELD CONTROL A142 14DG 0R AUTO SHUT DOWN RELAY OUTPUT 5 _ A142 14DG 0R AUTO SHUT DOW
37. CHARGING VERIFICATION VER 3 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform CHARGING VERIFICATION VER 3 110 DRIVEABILITY DIESEL P0620 GE FIELD CONTROL BATTERY VOLTAGE DEVI ATION TOO HIGH Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform CHARGING VERIFICATION VER 3 No Test Complete 111 DRIVEABI
38. Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 37 DRIVEABILITY DIESEL Symptom P0O190 FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW When Monitored and Set Condition P0190 F UEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW When Monitored With the ignition on Set Condition The Fuel Rail Pressure Sensor Signal voltage is below 0 2 volt POSSIBLE CAUSES FUEL PRESSURE SENSOR INTERMITTENT CONDITION FUEL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND FUEL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND ECM FUEL PRESSURE SENSOR SIGNAL SHORTED TO GROUND ACTION APPLICABILITY WARNING THE FUEL INJ ECTION PUMP SUPPLIES HIGH PRESSURE All FUEL TO EACH INDIVIDUAL INJ ECTOR THROUGH HIGH PRESSURE FUEL LINES FUEL UNDER HIGH PRESSURE CAN PENETRATE SKIN AND CAUSE PERSONAL INJ URY WEAR SAFETY GOGGLES AND ADE QUATE PROTECTIVE CLOTHING NOTE If DTC P0641 or P0651 is present with this DTC diagnose DTCs P0641 and P0651 before diagnosing this DTC
39. DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 156 DRIVEABILITY DIESEL Symptom List P1830 CLUTCH OVER RIDE RELAY CIRCUIT OPEN P1830 CLUTCH OVER RIDE RELAY CIRCUIT SHORTED Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P1830 CLUTCH OVER RIDE RELAY CIRCUIT OPEN eee When Monitored and Set Condition P1830 CLUTCH OVER RIDE RELAY CIRCUIT OPEN When Monitored With the ignition on Set Condition TheECM does not detect volta
40. GROUND SENSOR REFERENCE VOLTAGE B CIRCUIT SHORTED TO GROUND SENSOR REFERENCE VOLTAGE B CIRCUIT SHORTED TO SENSOR GROUND ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY CIRCUIT SHORTED TO SENSOR GROUND ENGINE CONTROL MODULE ACTION APPLICABILITY All Turn the ignition on With the DRB erase ECM DTCs Monitor the DRB for ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 8 122 DRIVEABILITY DIESEL P0651 SENSOR REFERENCE VOLTAGE VOLTAGE TOO LOW Continued APPLICABILITY Turn the ignition on All With the DRBIII in Sensors monitor the Accelerator Pedal Position and Boost Pressure Sensors only One at time while monitoring the sensor readings disconnect then reconnect the Boost Pressure Accelerator Pedal Position and Engine Oil Pressure Sensor harness connectors WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Start the engine NOTE If one of the sensors is shorted to ground internally disconnecting it will cause the voltage reading on the DRB to rise for the monitored sensor that has not been disconnected NOTE Disconnecting components will generate new DTCs which should be ignored Did either of the monitored sensor voltage readings rise when one sensor was disconnected Y
41. Glow Plug Relay 1 from the PDC Turn the ignition on Using a 12 volt test light connected to ground check the ASD Relay Output circuit Does the test light illuminate brightly Yes GoTo 4 No Repair the ASD Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Install a substitute relay in place of Glow Plug Relay 1 Perform several ignition key cycles pausing for at least 10 seconds between each cycle Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes GoTo 5 No Replace Glow Plug Relay 1 Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Remove Glow Plug Relay 1 from the PDC Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage on the Glow Plug Relay 1 Control circuit 15 the voltage above 1 0 volt Yes Repair the Glow Plug Relay 1 Control circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No GoTo 6 69 DRIVEABILITY DIESEL P0380 GLOW PLUG 1 CONTROL CIRCUIT OPEN CIRCUIT Continued APPLICABILITY Turn the ignition off All Remove Glow Plug Relay 1 from the PDC Disconnect the ECM harness connectors Measure the resistance between ground and the Glow Plug Relay 1 Control circuit Is the resistance above 1000 ohms
42. Glow Plug Relay of the affected cylinder s Perform ROAD TEST VERIFICATION VER 2 182 DRIVEABILITY DIESEL Symptom CHECKING THE SPEED CONTROL OPERATION POSSIBLE CAUSES CHECKING CRUISE SWITCHES CHECKING THE BRAKE SWITCH INPUT CHECKING THE ECM FOR DTC S CHECKING THE VSS SIGNAL ECM INTERMITTENT CONDITION APPLICABILITY Turn the ignition on All With the DRBIII read the ECM DTCs Are there any ECM DTC s present Yes Refer tosymptom list for problems related to the ECM DTC Perform SPEED CONTROL VERIFICATION 4 No GoTo 2 NOTE Prior to testing the speed control operation ensure the Learn Speed Control feature has been performed on the ECM Test drive the vehicle above 60 Km h 35 mph Attempt to Set the Speed Control Is the Speed Control function operating properly Yes Test Complete No GoTo 3 Start the engine With the DRBIII read the CRUISE SW VOLTS Observe the cruise switch volts on the DRBIII while pressing and holding each cruise button separately NOTE Pressing each cruise button should result in the following voltages ON OFF 0 7v 1 0 SET 3 0 3 5v RESUME ACCEL 3 9 4 2v CANCEL 1 5 1 9v COAST 2 5 2 9v No Button Pressed 4 4 4 8v Does each switch provide the correct voltage Yes GoTo 4 No Refer to symptom list for problems related to S C Switches Perform SPEED CONTROL VERIFICATION 4 183 DRIVEABILITY
43. HIGH PRESSURE SWITCH DIESEL GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C18 20DB A C PRESSURE SIGNAL 2 C21 18DB OR A C SWITCH SENSE A C LOW PRESSURE SWITCH GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C21 18DB OR A C SWITCH SENSE 2 Z142 18BK WT RHD GROUND 2 2212 18BK OR LHD GROUND ACCELERATOR PEDAL POSITION SENSOR DIESEL BLACK 10 WAY CAV CIRCUIT FUNCTION 1 2 3 4 K4 18BK LB SENSOR GROUND 5 K151 20WT LOW IDLE POSITION SWITCH SENSE 6 7 K81 20VT TN ACCELERATOR PEDAL POSITION SENSOR SIGNAL 8 K255 20WT DG ACCELERATOR PEDAL POSITION SENSOR GROUND 9 10 852 20VT WT ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY 215 N N E R 4 2 15 N N E R 4 7 CONNECTOR PINOUTS BLACK TEMPERATURE SENSOR BOOST PRESSURE SENSOR DIESEL BLACK SWITCH CABIN HEATER DIESEL BLACK BATTERY TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K118 18PK YL BATTERY TEMPERATURE SENSOR SIGNAL 2 K4 18BK LB SENSOR GROUND BOOST PRESSURE SENSOR DIESEL 4 WAY CAV CIRCUIT FUNCTION 1 K4 18BK LB SENSOR GROUND 2 K21 18BK RD INTAKE
44. Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the 5 volt Supply circuit 15 the resistance below 10 0 ohms Yes GoTo 17 No Repair 5 volt Supply circuit an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between the 5 volt Supply circuit and the Sensor Ground circuit at the APP Sensor harness connector 15 the resistance above 1000 ohms for both of the measurements Yes GoTo 18 No Repair the 5 volt Supply circuit for short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the 5 volt Supply circuit 15 the resistance below 1000 ohms Yes Repair 5 volt Supply circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 No GoTo 19 166 DRIVEABILITY DIESEL P2120 ACC PEDAL POSITION SENSOR 1CKT PLAUSIBILITY Continued ACTION APPLICABILITY Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 an
45. LOW present Yes Replace the Fuel Pressure Sensor Perform ROAD TEST VERIFICATION VER 2 GoTo 8 If there no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Fuel Pressure Sensor Signal circuit 15 the resistance below 5 0 ohms Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the Fuel Pressure Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 36 DRIVEABILITY DIESEL 190 PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set
46. MULTIMETER IS DANGEROUS CAN EXPOSE YOU TO SERIOUS OR POSSIBLY FATAL INJURY CAREFULLY READ AND UNDERSTAND THE CAUTIONS AND SPECIFICATION LIMITS Follow the vehicle manufacturer s service specifi cations at all times Do not use the DRBIII if it has been damaged Do not use the test leads if the insulation is damaged or if metal is exposed To avoid electrical shock do not touch the test leads tip or the circuit being tested Choose the proper range and function for the measurement Do not try voltage or current mea surements that may exceed the rated capacity e Donot exceed the limits shown in the table below FUNCTION INPUT LIMIT Volts 0 500 peak volts AC 0 500 volts DC Ohms Resistance 0 1 12 megohms Frequency Measure 0 10 kHz Frequency Generated Temperature 58 1100 F 50 600 C Ohms cannot be measured if voltage is present Ohms can be measured only in a non powered circuit Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC e Use caution when measuring voltage above 25v DC or 25v AC The circuit being tested must be protected by a 10 amp fuse or circuit breaker GENERAL INFORMATION Use the low current shunt to measure circuits up to 10 amps Use the high current shunt to mea sure circuits exceeding 10 amps e When testing for the presence of voltage or cur rent make sure the meter is functioning cor rectly Take a reading
47. NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 154 DRIVEABILITY DIESEL Symptom List P1685 SKIM SYSTEM INVALID KEY CODE RECEIVED P1685 SKIM SYSTEM INVALID SECRET KEY IN EEPROM P1685 SKIM SYSTEM KEY COMMUNICATION TIMED OUT P1685 SKIM SYSTEM WRITE ACCESS TO EEPROM FAILURE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be 1685 5 SYSTEM INVALID KEY CODE RECEIVED When Monitored and Set Condition P1685 SKIM SYSTEM WRIT
48. No Repair 5 volt Supply circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Oil Pressure Sensor harness connector Measure the resistance between Sensor Ground and the 5 volt Supply circuit at the Oil Pressure Sensor harness connector 15 the resistance above 1000 ohms Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the 5 volt Supply circuit for a short to Sensor Ground Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring h
49. Note All symptoms listed above are diagnosed using the same tests The title for the tests will be 1652 1850 COMMUNICATION BUS SHORT TO GROUND When Monitored and Set Condition 1652 1850 COMMUNICATION BUS SHORT TO GROUND When Monitored With the ignition on Set Condition ECM detects continuous low voltage the J 1850 Bus circuit 1652 1850 COMMUNICATION BUS SHORT TO VOLTAGE When Monitored With the ignition on Set Condition ECM detects continuous high voltage on the J 1850 Bus circuit POSSIBLE CAUSES VERIFY ACTIVE DTC VERIFY INSTRUMENT CLUSTER COMMUNICATION INTERMITTENT CONDITION ACTION APPLICABILITY Turn the ignition on All With the DRBIII attempt to communicate with the Instrument Cluster Is the Instrument Cluster communicating with the DRB Yes GoTo 2 No Refer to the appropriate symptom in the Body Diagnostic Infor mation Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on With the DRBIII erase the ECM DTCs Turn the ignition off then turn the ignition on and wait 60 seconds With the DRBIII read the ECM DTCs Does the DRB display this DTC Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 3 153 DRIVEABILITY DIESEL 1652 1850 COMMUNICATION BUS SHORT TO GROUND Continued APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO
50. OFF ERROR ZERO QUANTITY P1610 VOLTAGE REGULATOR SIGNAL VOLTAGE TOO HIGH P1610 VOLTAGE REGULATOR SIGNAL VOLTAGE TOO LOW 1652 1850 COMMUNICATION BUS LOST ARBITRATION 1652 1850 COMMUNICATION BUS UNAUTHORIZED RESET P1680 EEPROM PLAUSIBILITY CHECKSUM ERROR P1680 EEPROM PLAUSIBILITY CODE WORD INCORRECT OR MISSING P1680 EEPROM PLAUSIBILITY COMMUNICATION ERROR P1680 EEPROM PLAUSIBILITY VARIATION NUMBER ERROR P1680 EEPROM PLAUSIBILITY VIN CHECKSUM ERROR P1680 EEPROM PLAUSIBILITY WRITE ERROR Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be 0105 PRES SURE CIRCUIT SIGNAL VOLTAGE TOO HIGH When Monitored and Set Condition P0105 BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition The Barometric Pressure Sensor Signal is above 4 75 volts 0105 PRESSURE CIRCUIT SIGNAL VOLTAGE TOO LOW When Monitored With the ignition on Set Condition The Barometric Pressure Sensor Signal is below 2 2 volts 19 DRIVEABILITY DIESEL PO105 BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH Continued ERROR GATE ARRAY COMMUNICATION When Monitored With the ignition on Set Condition The ECM detects an internal failure PO606 ECM ERROR GATE ARRAY COMMUNICATION NOT VERIFIED When Monitored With the ignition on Set Condition The ECM detects an internal failure
51. Output circuit in ECM harness connector C1 cavity 22 Is the test light on Yes GoTo 3 Repair the Fused Ignition Switch Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Using a 12 volt test light connected to ground check the Fused ASD Relay Battery Supply circuit in ASD Relay connector cavity 30 Is the test light on Yes GoTo 4 No Repair the Fused ASD Relay Battery Supply circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect jumper wire between cavity 30 and cavity 87 in the ASD Relay connector Using 12 volt test light connected to ground check theASD Relay Output circuit in ECM harness connector C1 cavities 4 and 5 Did the test light illuminate for both circuits Yes Test Complete Repair the ASD Relay Output circuit s for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Remove the ASD Relay from the PDC 177 DRIVEABILITY DIESEL Symptom CHECKING THE EGR SYSTEM POSSIBLE CAUSES ASD RELAY OUTPUT CIRCUIT OPEN EGR SOLENOID CONTROL CIRCUIT OPEN EGR VALVE VACUUM SUPPLY HOSE ACTION APPLICABILITY Disconnect the Vacuum Supply Hose at the EGR solenoid Connect a vacuum gauge to the Vacuum Supply Hose Start the engine and allow the engine to idle Is the vacuum above 10 inches of mercury at idle Yes
52. P0514 BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 89 DRIVEABILITY DIESEL Symptom P0514 BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE LOW POSSIBLE CAUSES INTERMITTENT CONDITION BATTERY TEMPERATURE SENSOR BATTERY TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND BATTERY TEMPERATURE SENSOR SIGNAL AND GROUND CIRCUITS SHORTED TOGETHER ENGINE
53. PLAUSIBILITY Continued APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set by slowly pressing and releasing the accelerator pedal several times Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the APP Sensor Signal circuit 15 the resistance below 1000 ohms Yes Repair the APP Sensor Signal circuit for a short to gro
54. PLAUSIBILITY P0O836 TRANSFER CASE POSITION SENSOR PLAUSIBILITY 2 PO836 TRANSFER CASE POSITION SENSOR SIGNAL VOLTAGE TOO HIGH PO836 TRANSFER CASE POSITION SENSOR SIGNAL VOLTAGE TOO LOW Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will PO836 TRANSFER CASE POSI TION SENSOR PLAUSIBILITY je When Monitored and Set Condition P0O836 TRANSFER CASE POSITION SENSOR PLAUSIBILITY When Monitored When the ECM detects the transfer case in 4WD low Set Condition ECM detects a vehicle speed that is higher than is possible 4WD low PO836 TRANSFER CASE POSITION SENSOR PLAUSIBILITY 2 When Monitored With the ignition on Set Condition TheECM detects a voltage signal from the transfer case switch that does not fall into a valid switch position voltage range 836 5 CASE POSITION SENSOR SIGNAL VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition TheECM detects an open or short to voltage on the Transfer Case Position Sensor Signal circuit P0O836 TRANSFER CASE POSITION SENSOR SIGNAL VOLTAGE TOO LOW When Monitored With the ignition on Set Condition TheECM detects a short to ground on the Transfer Case Position Sensor Signal circuit POSSIBLE CAUSES CHECKING THE TRANSFER CASE POSITION SENSOR INTERMITTENT WIRING AND CONNECTORS TRANSFER CASE POSITION SENSOR SIGNAL CIRCUIT OPEN TRANSFER CASE POSITION SENSOR SIGNAL CIRCUIT SHORT TO GROUND T
55. POSITION SENSOR 1 CKT PLAUSIBILITY WITH POTENTIOMETER P2120 ACC PEDAL POSITION SENSOR 1 SIGNAL VOLTAGE TOO HIGH P2120 ACC PEDAL POSITION SENSOR 1 SIGNAL VOLTAGE TOO LOW P2120 ACC PEDAL POSITION SENSOR 1 SUPPLY VOLTAGE TOO HIGH OR LOW Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P2120 ACC PEDAL POSITION SENSOR 1CKT PLAUSIBILITY a ey When Monitored and Set Condition P2120 ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY When Monitored With the ignition on Set Condition TheAccelerator Pedal Position Sensor Signal is below 1 6 or above 17 6 and the idle switch is not in the correct state NOTE The idle switch is designed to transition when the accel position is approximately 16 1 00 volt This code sets the ECM to Limp in Mode which includes a fixed engine speed of 1100 RPM P2120 ACC PEDAL POSITION SENSOR 1 PLAUSIBILITY WITH BRAKE SWITCH When Monitored With the ignition on Set Condition detects the Accelerator Pedal and the Brake Pedal have been depressed at the same time for longer than the allowable time P2120 ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH LOW IDLE SWITCH When Monitored With the ignition on Set Condition TheAccelerator Pedal Position Sensor Signal is below 0 20 volts the idle switch transitions at too high a percentage intermittently or the idle switch is not in the correct state intermittently
56. PRESSURE SENSOR PLAUSIBILITY BOOST PRESSURE SENSOR SIGNAL VOLT AGE TOO HIGH BOOST PRESSURE SENSOR SIGNAL VOLT AGE TOO LOW BOOST PRESSURE SENSOR SUPPLY VOLT AGE TOO HIGH OR LOW BRAKE SWITCH SIGNAL CIRCUITS PLAUSI BILITY AFTER INIT BRAKE SWITCH SIGNAL CIRCUITS PLAUSI BILITY WITH REDUNDANT CONTACT CAPACITOR VOLTAGE 1 VOLTAGE TOO HIGH CAPACITOR VOLTAGE 1 VOLTAGE TOO LOW CKP POSITION SENSOR CIRCUIT OVER SPEED RECOGNITION CLUTCH PEDAL SW OVERRIDE RELAY SHORT CIRCUIT CMP POSITION SENSOR CIRCUIT CMP CKP SYNC FAILURE CMP POSITION SENSOR CIRCUIT CORREC TION FOR MAIN INJECTION DELAYED CMP POSITION SENSOR CIRCUIT DYNAMIC PLAUSIBILITY CMP POSITION SENSOR CIRCUIT SIGNAL FREQUENCY TOO HIGH CMP POSITION SENSOR CIRCUIT STATIC PLAUSIBILITY CYLINDER 1 INJ ECTOR CIRCUIT CURRENT DECREASE CYLINDER 1 INJ ECTOR DROP CYLINDER 1 INJ ECTOR CIRCUIT OVERCUR RENT HIGH SIDE CYLINDER 1 INJ ECTOR CIRCUIT OVERCUR RENT LOW SIDE CYLINDER 2 INJ ECTOR CIRCUIT CURRENT DECREASE CYLINDER 2 INJ ECTOR DROP CYLINDER 2 INJ ECTOR CIRCUIT OVERCUR RENT HIGH SIDE CYLINDER 2 INJ ECTOR CIRCUIT OVERCUR RENT LOW SIDE CYLINDER 3 INJ ECTOR CIRCUIT CURRENT DECREASE CYLINDER 3 INJ ECTOR DROP CYLINDER 3 INJ ECTOR CIRCUIT OVERCUR RENT HIGH SIDE CYLINDER 3 INJ ECTOR CIRCUIT OVERCUR RENT LOW SIDE CYLINDER 4 1 ECTOR CIRCUIT CURRENT DECREASE CYLINDER 4 1 ECTOR DROP CYLINDER 44 ECTOR CIRCUIT OVERCUR RENT HIGH SIDE CYLINDER 44
57. Part Time 1 78 2 12 2WD 2 43 2 77 Does each position provide the correct voltage Yes Replace and program the ECM in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace the Transfer Case Position Sensor Perform ROAD TEST VERIFICATION VER 2 The conditions necessary to set this DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring while checking for shorts and open circuits Were there any problems found Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 135 DRIVEABILITY DIESEL Symptom List P1130 FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DE TECTED P1130 FUEL RAIL PRESSURE MALFUNCTION PRESSURE HIGH SHUT OFF P1130 FUEL RAIL PRESSURE MALFUNCTION PRESSURE LOW P1130 FUEL RAIL PRESSURE MALFUNCTION SOLENOID OPEN Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P1130 FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED E When Monitored and Set Condition P1130 FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED When Monitored With the engine running Set Condition The ECM detects the desired flow of fuel at idle is greater than 5000 mm sec P1130 FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO HIGH SHUT OFF When Monitored With the ignition on Set Condition The fuel r
58. RELAY OPEN CIRCUIT en When Monitored and Set Condition P1643 VISCOUS HEATER RELAY OPEN CIRCUIT When Monitored With the ignition on Set Condition The ECM does not detect voltage on the Viscous Heater Relay Control circuit P1643 VISCOUS HEATER RELAY SHORT CIRCUIT When Monitored With the ignition on Set Condition ECM detects excessive current the Viscous Heater Relay Control circuit POSSIBLE CAUSES INTERMITTENT CONDITION ASD RELAY OUTPUT CIRCUIT OPEN SUBSTITUTE VISCOU HEATER RELAY VISCOUS HEATER RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE VISCOUS HEATER RELAY CONTROL CIRCUIT SHORTED TO GROUND VAISCOUS HEATER RELAY CONTROL CIRCUIT OPEN ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRBIII actuate the Viscous Heater Relay 15 the Viscous Heater Relay clicking Yes GoTo 2 GoTo 3 148 DRIVEABILITY DIESEL P1643 VISCOUS HEATER RELAY OPEN CIRCUIT Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to
59. Refer tothe Symptom List for diagnosis of the other DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 GoTo 2 Turn the ignition on With the DRB erase ECM DTCs Perform several ignition key cycles pausing for at least 10 seconds between each cycle Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes GoTo 3 No GoTo 6 127 DRIVEABILITY DIESEL 685 5 RELAY CONTROL CIRCUIT SHUTS OFF TOO LATE Continued APPLICABILITY Turn the ignition off Install a substitute relay in place of the ASD Relay Perform several ignition key cycles pausing for at least 10 seconds between each cycle Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes GoTo 4 No Replace theASD Relay Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove the ASD Relay from the PDC Disconnect the ECM harness connectors Measure the resistance between ground and the ASD Relay Control circuit while wiggling the wiring harness and connectors Was the resistance below 5 0 ohms at any time while wiggling the wiring harness and connectors Yes Repair the ASD Relay Control circuit an intermittent short to ground Perform ROAD TEST VERIFICATION VER 2 GoTo 5 Turn the ignition off All Remove the ASD Relay from the PDC Turn the ignition on Measure the voltage of the ASD Relay Output circuit 15 the volt
60. Test drive the vehicle With the DRBIII read the ECM DTCs Does the III display this DTC Yes GoTo 3 GoTo 8 Turn the ignition off Remove the CMP Sensor Inspect the camshaft Position Sensor for conditions such as loose mounting screws damage or debris also check the camshaft for cracked teeth 15 there any evidence of these conditions Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No GoTo 4 65 DRIVEABILITY DIESEL 40 POSITION SENSOR CIRCUIT CMP CKP SYNC FAILURE Continued ACTION APPLICABILITY Turn the ignition off Remove the CKP Sensor Inspect the Crankshaft Position Sensor for conditions such as loose mounting screws damage or debris Is there any evidence of these conditions Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 GoTo 5 Turn the ignition off Using the DRB lab scope backprobe the CMP Sensor Signal circuit at the CMP Sensor harness connector Start the engine if the engine will not start crank the engine for several seconds while monitoring the DRB NOTE Refer to Charts and Graphs to view a correct CMP Sensor signal Does the DRB display a steady clean CMP Signal pattern Yes GoTo 6 No Perform Test for DTC P0340 Camshaft Position Sensor Circuit Static Plausibility Perform ROAD TEST VERIFICATION VER 2 Using the DRB lab scope backprobe both of the CKP Sensor Signal cir
61. above 1 0 volt Yes Repair theA C Clutch Relay Output circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 5 Turn the ignition off Install a substitute relay in place of the A C Clutch Relay Turn the ignition on With the DRBIII actuate the A C Clutch Relay Does the A C Clutch Relay cycle on and off Yes Replace the A C Clutch Relay Perform ROAD TEST VERIFICATION VER 2 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Perform BODY VERIFICATION TEST VER 1 Turn the ignition off NOTE Make sure that the BCM harness connectors are connected to the BCM Disconnect the A C Heater Control C1 harness connector Turn the ignition on With the DRBIII in BCM select Inputs Outputs Monitor the A C Select Switch state while connecting a jumper wire between ground and theA C On Off Control circuit in the A C Heater Control C1 harness connector Does the A C Select Switch state change from Off to On when the jumper wire is connected Yes Replace the A C Heater Control Module accordance with the Service nformation Perform BODY VERIFICATION TEST VER 1 Replace and program the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 Turn the ignition off All Disconnect the BCM C1 harness connector Disconnect the A C Hea
62. cable With the DRBIII select Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Set Probe to x10 Press F2 again when complete Connect the Black lead to ground Connect the Red lead to the PCI Bus circuit in the ECM connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the PCI Bus circuit for an open Perform ROAD TEST VERIFICATION VER 2 COMMUNICATION Symptom NO RESPONSE FROM ECM SCI ONLY DIESEL ONLY POSSIBLE CAUSES CHECK ECM POWERS AND GROUNDS SCI TRANSMIT CIRCUIT SHORTED TO GROUND SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE SCI TRANSMIT CIRCUIT OPEN ENGINE CONTROL MODULE TEST ACTION APPLICABILITY Perform the symptom Checking ECM Power and Ground Circuits in the Driveability category Did the vehicle pass this test Yes GoTo 2 No Repair as necessary Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the DRB from the DLC Measure the resistance between ground and the SCI Transmit circuit 15 the resistance below 5 0 ohms Yes Repair the SCI Transmit circuit for a short to gr
63. conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete Turn the ignition off All Disconnect the Clutch Interlock Relay from the PDC Using 12 volt test light connected to ground check the Ignition Switch Output circuit at the Clutch Interlock Relay connector in the PDC Turn the ignition to the on start position Does the test light illuminate brightly Yes GoTo 4 No Repair the Ignition Switch Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Install a substitute relay in place of the Clutch Interlock Relay Turn the ignition on With the DRBIII actuate the Clutch Interlock Relay With the DRB read ECM DTCs Did this DTC reset Yes GoTo 5 No Replace Clutch Interlock Relay Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Remove the Clutch Interlock Relay Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector in the PDC Turn the ig
64. connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC 140 DRIVEABILITY DIESEL P1131 F PRESSURE SOLENOID OPEN CIRCUIT Continued APPLICABILITY Turn the ignition off All Disconnect the Fuel Pressure Solenoid harness connector Disconnect the ECM harness connectors Measure the resistance of the Fuel Pressure Solenoid Control circuit NOTE The Fuel Pressure Solenoid Control circuit is duplicated at ECM cavities C1 80 and C1 81 15 the resistance below 5 0 ohms Yes GoTo 6 No Repair the Fuel Pressure Solenoid Control circuit an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Fuel Pressure Solenoid harness connector Turn the ignition on With the DRB erase ECM DTCs Monitor the DRB for ECM DTCs NOTE The DRB should display P1131 FUEL PRESSURE SOLENOID OPEN CIRCUIT Turn the ignition off Connect a jumper wire between cavity 1 and cavity 2 of the Fuel Pressure Solenoid harness connector Turn the ignition on With the DRB erase ECM DTCs Monitor the DRB for ECM DTCs NOTE The DRB should display P1131 FUEL PRESSURE SOLENOID SHORT CIRCUIT Does the DRB display the appropriate DTC for each condition Yes Replace the Fuel Pressure Solenoid Fuel Pump Assembly in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 7 If there are no possible causes remain
65. incorrect PIN Secured Access M ode will be locked out for 1 hour which causes the to display Signals Open To exit this mode turn ignition to Run for 1 hour 12 Ensure all accessories are turned off and the battery is fully charged 13 Turn the Ignition on and with the DRBIII erase all Diagnostic Trouble Codes from ALL modules Start the engine and allow it to run for 2 minutes and fully operate the system that was malfunctioning 14 Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRBIII read DTC s from ALL modules any DTC s present or is the original complaint still present Yes Repair is not complete refer to the appropriate symptom No Repair is complete 204 APPLICABILITY All VERIFICATION TESTS VERIFICATION TESTS Continued BODY VERIFICATION TEST VER 1 APPLICABILITY 1 Disconnect all jumper wires and reconnect all previously disconnected components and All connectors 2 If the Sentry Key Immobilizer Module SKIM the Powertrain Control Module PCM was replaced proceed to number 8 If the SKIM or PCM was not replaced continue to the next number 3 If the Body Control Module was replaced turn the ignition for 15 seconds to learn VIN If the vehicle is equipped with VTSS use the and enable VTSS 4 Program tire size country code radio EQ setting and all RKE transmitters if RKE Module was replaced and othe
66. level is correct Start the engine With the DRBIII set the engine RPM to 1500 and allow the engine to warm up for 10 15 minutes With the DRBIII monitor the Engine Coolant Temperature value during the warm up Make sure the transition of temperature change is smooth Did the engine temperature reach a minimum of 80 C 176 F Yes Test Complete No Refer to the Service Information for cooling system performance diagnosis The most probable cause is a Thermostat problem Also refer to any related TSBs Perform ROAD TEST VERIFICATION VER 2 28 DRIVEABILITY DIESEL Symptom P0115 E NGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLT AGE TOO HIGH When Monitored and Set Condition PO11L5 ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition TheEngine Coolant Temperature Sensor Signal voltageis above 4 95 volts for more than 1 second POSSIBLE CAUSES INTERMITTENT CONDITION ECM ECT SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE ECT SENSOR GROUND CIRCUIT OPEN ECT SENSOR ECT SENSOR SIGNAL CIRCUIT OPEN ENGINE CONTROL MODULE APPLICABILITY NOTE If multiple DTCs are present the most likely cause is 5 Volt Supply All or Sensor Ground circuit shorted to voltage or ground Refer to the Service Information Wiring section for circuits that would affect multiple DTCs Turn the ignition on With the DRB monitor the Engine Coolant Tem
67. lntake Air Temperature Sensor Perform ROAD TEST VERIFICATION VER 2 GoTo 8 Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Ensure good terminal contact between the Turbocharger Boost Pressure IAT Sensor harness connector the sensor repair is complete Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair a
68. read the ECM DTCs Does the DRBIII display this DTC Yes GoTo 3 No GoTo 7 Turn the ignition off Disconnect the ECM harness connectors Disconnect all of the Fuel Injector harness connectors Measure the resistance between ground and each of the Fuel Injector Control circuits Is the resistance below 1000 ohms for any of the measurements Yes Repair the appropriate Fuel Injector Control circuit for a short to ground No GoTo 5 Turn the ignition off Disconnect the ECM harness connectors Disconnect all of the Fuel Injector harness connectors Measure the resistance of the Common Injector Driver circuit between the ECM harness connector and each Fuel Injector harness connector 15 the resistance below 10 0 ohms for each measurement Yes GoTo 6 Turn the ignition off All Inspect the entire fuel system for leakage 15 there any evidence of leakage Yes Repair as necessary in accordance with the Service Information No GoTo 4 Repair Injector Common Driver circuit for an open 137 DRIVEABILITY DIESEL P1130 FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED Continued APPLICABILITY Refer to the appropriate Service Information and perform the Fuel Pressure Test All NOTE The following is a list of problems that can cause the fuel pressure to become out of specification restricted fuel filter or fuel lines failed fuel pressure solenoid air in fuel
69. the PDC and the Clutch Interlock Switch harness connector 15 the resistance below 10 0 ohms Yes Repair the Ignition Switch Start Output circuit to the Clutch Interlock Switch Perform NO START VERIFICATION VER 1 Repair the Clutch Interlock Switch Output circuit for an open Perform NO START VERIFICATION 1 Remove the Starter Relay from the PDC Using a 12 volt test light connected to ground check the Fused B circuit in the Starter Relay connector in the PDC Is the test light on Yes GoTo 9 No Repair the Fused circuit for an open Perform NO START VERIFICATION 1 Does the test light illuminate brightly Yes GoTo 10 No Repair the Starter Relay Output circuit for an open Perform NO START VERIFICATION 1 Using the Service Information check the battery cables for high resistance Did either battery cable have a voltage drop greater than 0 2 volts Yes Replace the battery cable s Perform NO START VERIFICATION 1 No GoTo 11 Turn the ignition off Attempt to manually rotate the crankshaft 360 15 the crankshaft able to rotate 360 Yes Replace the Starter Motor Perform NO START VERIFICATION VER 1 No Repair the engine mechanical problem Perform NO START VERIFICATION VER 1 Turn the ignition off All Remove the Starter Relay from the PDC Disconnect the Starter Relay Output wire from the Starter Solenoid Conne
70. the 5 volt supply circuit at the APP Sensor harness connector With the DRBIII read the PEDAL OUTPUT VOLTS Does the display between 4 0 and 5 5 volts Yes GoTo 5 No GoTo 12 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the APP Sensor Ground circuit 15 the voltage above 1 0 volt Yes Repair the App Sensor Ground circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No GoTo 6 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Sensor Ground circuit between theAPP Sensor and the ECM 15 the resistance below 10 0 ohms Yes GoTo 7 No Repair the APP Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on With the 111 read the PEDAL OUTPUT VOLTS with the accelerator pedal in the at rest position Does the 111 display between 0 50 and 1 00 volt Yes GoTo 8 No Replace the Accelerator Pedal Position Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 163 DRIVEABILITY DIESEL P2120 ACC PEDAL POSITION SENSOR 1CKT PLAUSIBILITY Continued
71. the complete ignition cycle If a fault is stored SKIM memory which prevents the system from operating properly the ECM will allow the engine to start and idle for 2 seconds then stall This may occur up to six times After the sixth attempt the ECM disables fuel delivery until the fault is corrected 3 3 DIAGNOSTIC TROUBLE CODES Each diagnostic trouble code DTC is diagnosed by following a specific procedure The diagnostic test procedure contains step by step instruction for determining the cause of the DTC as well as no trouble code problems It is not necessary to per form all of the tests in this book to diagnose an individual code Always begin diagnosis by reading the DTCs using the DRBIII GENERAL INFORMATION 3 3 1 HARD CODE A DTC that comes back within one cycle of the ignition key is a hard code This means that the problem is current every time the ECM SKIM checks that circuit or function Procedures in this manual verify if the DTC is a hard code at the beginning of each test When the fault is not a hard code an intermittent test must be performed NOTE If the DRBIII displays faults for multiple components i e ECT VSS sensors identify and check the shared circuits for possible problems before continuing i e sensor grounds or 5 volt supply circuits Refer to the appropriate schematic to identify shared circuits 3 3 2 INTERMITTENT CODE A DTC that is not current every time the ECM SK
72. values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 67 DRIVEABILITY DIESEL Symptom List P0380 GLOW PLUG 1 CONTROL CIRCUIT OPEN CIRCUIT P0380 GLOW PLUG 1 CONTROL CIRCUIT SHORT CIRCUIT Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be PO380 GLOW PLUG 1 CONTROL CIRCUIT OPEN CIRCUIT en When Monitored and Set Condition P0380 GLOW PLUG 1 CONTROL CIRCUIT OPEN CIRCUIT When Monitored With the ignition on Set Condition TheECM does not detect voltage on the Glow Plug Relay 1 Control circuit P0380 GLOW PLUG 1 CONTROL CIRCUIT SHORT CIRCUIT When Monitored With the ignition off Set Condition The ECM detects excessive current on the Glow Plug Relay 1 Control circuit POSSIBLE CAUSES INTERMITTENT CONDITION ASD RELAY OUTPUT CIRCUIT OPEN SUBSTITUTE GLOW PLUG RELAY 1 GLOW PLUG RELAY 1 CONTROL CIRCUIT SHORTED TO VOLTAGE GLOW PLUG RELAY
73. voltage reading Voltage is above 5 5 volts GoTo 4 Voltage is between 4 7 and 5 4 volts GoTo 5 Voltage is below 4 7 volts GoTo 7 Turn the ignition off All Disconnect the Oil Pressure Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the Oil Pressure Sensor Signal circuit 15 the voltage below 1 0 volt Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the Oil Pressure Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Oil Pressure Sensor harness connector Measure the resistance of the 5 Volt Supply circuit between the ECM harness connector and the Oil Pressure Sensor harness connector 15 the resistance below 10 0 ohms Yes GoTo 6 No Repair the 5 Volt Supply circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Oil Pressure Sensor harness connector Measure the resistance of the Sensor Ground circuit 15 the resistance below 10 0 ohms Yes Replace the Oil Pressure Sensor Perform ROAD TEST VERIFICATION VER 2 No Repair the Sensor G
74. 1 0 2 0 3 0 4 0 5 0 6 0 7 0 TABLE OF CONTENTS INTRODUCTION 11 SYSTEM COVERAGE ace 12 SIX STEP TROUBLESHOOTING PROCEDURE IDENTIFICATION OF 5 2 2 2 SYSTEM DESCRIPTION AND FUNCTIONAL 3 1 GENERAL DESCRIPTION 22 FUNCTIONAL OPERATION 321 ECM ON BOARD 5 5 3 2 2 ECM OPERATING 3232 MONITORED CIRCUIT ene es 324 SKIS OVERIVEW 3 25 SKIS ON BOARD DIAGNOSTICS 326 SKIS OPERATION 3 3 DIAGNOSTIC TROUBLE CODES eee de ae Oy 33 1 HARD ve ure Sie oe ne vee aes 3 3 2 INTERMITTENT 2446 oad Geer ere weeds ox 333 ECM DIAGNOSTIC TROUBLE 334 SKIM DIAGNOSTIC TROUBLE CODES 3 3 5 HANDLING NO TROUBLE CODE PROBLEMS 34 USING THE DRBING hat dus aceite abe es 3 4 1 DRBIII DOES NOT POWER 3 4 2 DISPLAY IS NOT DISCLAIMERS S
75. 19 P1680 EEPROM PLAUSIBILITY WRITE 19 0110 AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH 23 0110 AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW 26 0115 COOLANT TEMP SENSOR CIRCUIT ENGINE IS COLD TOO 28 0115 COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE HIGH cue sete heehee ga sen ________ 248 29 0115 COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE LOW 32 P0190 FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH 34 P0190 FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW 38 P0190 FUEL PRESS SENSOR CIRCUIT MALF SUPPLY VOLTAGE TOO HIGH OR LOW Satan dette seein gt ______________ 40 P0201 CYLINDER 1 INJECTOR CIRCUIT CURRENT DECREASE 41 P0201 CYLINDER 1 INJECTOR CIRCUIT LOAD 41 P0201 CYLINDER 1 INJECTOR CIRCUIT OVERCURRENT HIGH SIDE 41 P0201 CYLINDER 1 INJECTOR CIRCUIT OVERCURRENT LOW SIDE 41 P0202 CYLINDER 2 INJECTOR CIRCUIT CURRENT DECREASE 41 P0202 CYLINDER 2 INJECTOR CIRCUIT LOAD 41 P0202 CYLINDER 2 INJECTOR CIRCUIT OVERCURRENT HIGH SIDE 41 P0202 CYLINDER 2 INJECTOR CIRCUIT OVERCURRENT LOW SIDE 41 P0203 CYLINDER 3 INJECTOR CIRCUIT CURREN
76. 222 FUEL INJECTOR 4 DIESEL BLACK 2 222 FUEL PRESSURE SENSOR DIESEL BLACK 3 222 FUEL PRESSURE SOLENOID DIESEL BLACK 2 WAY 223 FUEL PUMP MODULE LT GRAY 4 223 GENERATOR 3 223 GENERATOR BLACK 2 WAY 223 GLOW PLUG ASSEMBLY DIESEL BLACK 2 224 LEFT SPEED CONTROL SWITCH EXCEPT BASE BLACK 4 WAY 224 FUSES DIESEL 226 COMPRESSOR CLUTCH 226 AUTO SHUT DOWN RELAY 2 2 2 2 227 CABIN HEATER RELAY 1 227 CLUTCH SWITCH OVERRIDE RELAY 227 FUEL HEATER RELAY DIESEL n unanou naonna aonan rran rrn nrn 227 GLOW PLUG RELAY 1 227 GLOW PLUG RELAY NO 2 0 0 cece 227 RIGHT SPEED CONTROL SWITCH EXCEPT BASE BLACK 4 WAY 228 SENTRY KEY IMMOBILIZER MODULE EXCEPT BASE BLACK 6 WAY 228 TRANSFER CASE POSITION SENSOR BLACK 2 228 WATER FUEL SENSOR DIESEL GRAY 2 228 SCHEMATIC 6
77. 5 Remove the Glow Plug Relay of the affected cylinder s Turn the ignition on Measure the voltage on the Glow Plug Relay Output circuit of the affected cylinder s 15 the voltage above 1 0 volt Yes Repair the Glow Plug Relay Output circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 5 Turn the ignition off All Disconnect the Glow Plug harness connectors of the affected cylinder s Remove the Glow Plug Relay of the affected cylinder s Measure the resistance between ground and the Glow Plug Relay Output circuit of the affected cylinder s 15 the resistance above 100 kohms Yes GoTo 6 Repair the Glow Plug Relay Output circuit a short to ground Inspect the fuse or fuselink and replace as necessary Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Glow Plug harness connectors of the affected cylinder s Remove the Glow Plug Relay of the affected cylinder s Connect a jumper wire across Glow Plug Relay connector cavities 30 and 87 Using a 12 volt test light connected to ground check the Glow Plug Relay Output circuit at the Glow Plug harness connectors of the affected cylinder s Is the test light on at each Glow Plug harness connector Yes GoTo 7 No Repair the Glow Plug Relay Output circuit an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace the
78. A circuit or a short to ground on the Fuel Pressure Sensor 5 Volt Supply circuit POSSIBLE CAUSES INTERMITTENT CONDITION FUEL PRESSURE SENSOR SHORT TO GROUND FUEL PRESSURE SENSOR 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND FUEL PRESSURE SENSOR 5 VOLT SUPPLY CIRCUIT SHORTED TO SENSOR GROUND ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Monitor the DRB for ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 6 Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Turn the ignition on Measure the voltage of the Fuel Pressure Sensor 5 Volt Supply circuit Is the voltage above 4 8 volts Yes Replace the Fuel Pressure Sensor Perform ROAD TEST VERIFICATION VER 2 GoTo 3 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Fuel Pressure Sensor harness connector Measure the resistance between ground and the Fuel Pressure Sensor 5 Volt Supply circuit 15 the resistance above 100 kohms Yes GoTo 4 No Repair the Fuel Pressure Sensor 5 Volt Supply circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 114 DRIVEABILITY DIESEL P0641 SENSOR REFERENCE VOLTAGE VOLTAGE TOO LOW Continued APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Fuel Pressure Sensor harness connector Measure the resistanc
79. A 5 9 ERR S ETERNA D WKS FS j 4 lt be WRK CM ROD 9 3 FUEL HEATER WATER FUEL LS AND HARNESS SENSOR ANY gt CONNECTOR CONNECTOR gt I BY Leap LE BOOST PRESSURE 99 P HARNESS AAN CONNECTOR 80cd3faf 210 COMPONENT LOCATIONS 8 5 RELAYS M H IR HAA o 3 AIC COMPRESSOR N VLAE CLUTCH RELAY TY WA 502 H VISCOUS HEATER FUEL HEATER lt RELAY RELAY 0 a ASD dy STARTER A c ip ion AL GLOW PLUG ee 384 RELAY 2 Ta ED RELAY CLUTCH SWITCH N OVERRIDE RELAY 5 8 6 SENSORS ACCELERATOR PEDAL POSITION SENSOR i eal ee cis Be REIL ey EVAL ASO 2 ice SN 9 A KSA ACCELERATOR PEDAL POSITION SENSOR HARNESS CONNECTOR soea3701 TEMPERATURE 4 SENSOR BATTERY BATTERY TEMPERATURE SENSOR HARNESS CONNECTOR 80cdb996 211 6 apt AN 4 7 1 80cd3913 TRANSFER CASE POSITION SENSOR AND HARNESS CONNECTOR 80d07a7a COMPONENT LOCATIONS 8 6 SENSORS Continued GLOW PLUGS 3 amp 4 12 7
80. AFETY 4 1 DISCLAIMERS et 42 SAFETY 421 TECHNICIAN SAFETY 4 2 2 VEHICLE PREPARATION FOR 5 423 SERVICING SUB ASSEMBLIES 424 DABIII SAFETY 1 43 WARNINGS AND CAUTIONS 431 ROAD TEST WARNINGS 4 3 2 VEHICLE DAMAGE CAUTIONS REQUIRED TOOLS AND EQUIPMENT GLOSSARY OF TERMS vas isiscne ee eee ee DIAGNOSTIC INFORMATION AND 8 COMMUNICATION NO RESPONSE FROM ECM PCI BUS DIESEL RESPONSE FROM ECM SCI ONLY DIESEL ONLY PGI BUS COMMUNICATION FAILURE i226 222202406 0008429 DRIVEABILITY DIESEL P0070 AMBIENT AIR TEMPERATURE CIRCUIT RECEIVE TIMEOUT P0070 AMBIENT AIR TEMPERATURE CIRCUIT SIGNAL VOLTAGE TOO HIGH P0070 AMBIENT AIR TEMPERATURE CIRCUIT SIGNAL VOLTAGE TOO LOW TABLE OF CONTENTS Continued P0105 BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH 19 P0105 BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TO
81. ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage on the Sensor Reference Voltage B circuit Is the voltage above 1 0 volt Yes Repair the Sensor Reference Voltage circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 3 NOTE Remove the jumper wire and reinstall the ASD Relay 120 DRIVEABILITY DIESEL P0651 SENSOR REFERENCE VOLTAGE VOLTAGE TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Accelerator Pedal Position Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage on the Accelerator Pedal Position Sensor 5 Volt Supply circuit 15 the voltage below 1 0 volt Yes GoTo 4 Repair theAccelerator Pedal Position Sensor 5 Volt Supply circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 NOTE Remove the jumper wire and reinstall the ASD Relay If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR T
82. BIII read the SKIM DTCs Are there any SKIM DTCs Yes Repair is not complete refer to appropriate symptom No Repair is complete 207 VERIFICATION TESTS VERIFICATION TESTS Continued SPEED CONTROL VERIFICATION VER 4 1 Inspect the vehicle to ensure that all engine components are properly installed and connected Reassemble and reconnect components as necessary 2 With the DRB erase all diagnostic trouble codes DTCs 3 Road test the vehicle at a speed above 58 km h 35 MPH 4 Turn the speed control ON OFF switch on 5 Depress and release the SET switch If the speed control does not engage the repair is not complete continue with step 12 6 Quickly depress and release the RESUME ACCEL switch If the vehicle speed does not increase by 3 km h 2 MPH the repair is not complete continue with step 12 7 Using caution depress and release the brake pedal If the speed control does not disengage the repair is not complete continue with step 12 8 With the vehicle speed at least 56 km h 35 MPH depress the RESUME ACCEL switch If the speed control does not resume at the previously set speed the repair is not complete continue with step 12 9 Hold down the COAST switch If the vehicle does not decelerate the repair is not complete continue with step 12 10 Whilestill holding down the COAST switch ensure the vehicle speed is at least 56 km h 35 MPH and release the COAST switch If the vehic
83. CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB monitor the Battery Temperature Sensor voltage 15 the Battery Temperature Sensor voltage below 0 3 volt Yes GoTo 2 GoTo 5 Turn the ignition off Disconnect the Battery Temperature Sensor harness connector Turn the ignition on With the DRB read the Battery Temperature Sensor voltage Is the voltage above 4 0 volts Yes Replace the Battery Temperature Sensor in accordance with the Service nformation Perform ROAD TEST VERIFICATION VER 2 GoTo 3 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Battery Temperature Sensor harness connector Measure the resistance between ground and the Battery Temperature Sensor Signal circuit 15 the resistance above 1000 ohms Yes GoTo 4 No Repair the Battery Temperature Sensor Signal circuit for short to ground Perform ROAD TEST VERIFICATION VER 2 90 DRIVEABILITY DIESEL P0514 BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Battery Temperature Sensor harness connector Measure the resistance between the Battery Temperature Sensor Signal circuit and Sensor Ground circuit 15 the resistance above 1000 ohms Yes Replace and program the Engine Control Module in accordance with the Service Information Perf
84. CUIT CURRENT DECREASE P0203 CYLINDER 3 ECTOR CIRCUIT LOAD DROP P0O203 CYLINDER 3 INJ ECTOR CIRCUIT OVERCURRENT HIGH SIDE PO203 CYLINDER 3 INJ ECTOR CIRCUIT OVERCURRENT LOW SIDE P0O204 CYLINDER 4 ECTOR CIRCUIT CURRENT DECREASE P0204 CYLINDER 4 CIRCUIT LOAD DROP PO204 CYLINDER 4 INJ ECTOR CIRCUIT OVERCURRENT HIGH SIDE PO204 CYLINDER 4INJ ECTOR CIRCUIT OVERCURRENT LOW SIDE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will PO201 CYLINDER 1 INJ ECTOR CIRCUIT CURRENT DECREASE E When Monitored and Set Condition P0201 CYLINDER 1 INJ ECTOR CIRCUIT CURRENT DECREASE When Monitored With the engine running Set Condition The ECM detects an incorrect rate of current decrease after injection occurs P0201 CYLINDER 1 INJ ECTOR CIRCUIT LOAD DROP When Monitored With the engine running Set Condition The ECM detects insufficient current through the injector driver DRIVEABILITY DIESEL PO201 CYLINDER 1 1 ECTOR CIRCUIT CURRENT DECREASE Continued a P0O201 CYLINDER 1 INJ ECTOR CIRCUIT OVERCURRENT HIGH SIDE When Monitored With the engine running Set Condition The ECM detects excessive current on the common driver circuit P0201 CYLINDER 1 INJ ECTOR CIRCUIT OVERCURRENT LOW SIDE When Monitored With the engine running Set Condition The ECM detects excessive current on the injector driver circuit P0202 CYLINDER 2 INJ ECTOR CIRCUIT CURRENT DEC
85. DIESEL P0514 BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Battery Temperature Sensor harness connector Connect a jumper wire between the Battery Temperature Sensor harness connector cavities Turn the ignition on With the DRB read the Battery Temperature Sensor voltage 15 the voltage below 1 0 volt Yes Replace the Battery Temperature Sensor in accordance with the Service nformation Perform ROAD TEST VERIFICATION VER 2 GoTo 4 Turn the ignition off Disconnect the Battery Temperature Sensor harness connector Connect a jumper wire between ground and the Battery Temperature Sensor Signal circuit Turn the ignition on With the DRB read the Battery Temperature Sensor voltage 15 the voltage below 1 0 volt Yes Repair the Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 GoTo 5 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Battery Temperature Sensor harness connector Measure the resistance of the Battery Temperature Sensor Signal circuit Is the resistance below 5 0 ohms Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the Battery Temperature Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 88 DRIVEABILITY DIESEL
86. DORLESS CAUSES SLOWER REACTION TIME AND CAN LEAD TO SERIOUS INJURY WHEN THE ENGINE IS OPERATING KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL SYSTEM Set the parking brake and block the wheels before testing or repairing the vehicle It is especially important to block the wheels on front wheel drive vehicles the parking brake does not hold the drive wheels When servicing a vehicle always wear eye pro tection and remove any metal jewelry such as watchbands or bracelets that might make electrical contact When diagnosing a powertrain system problem it is important to follow approved procedures where applicable These procedures can be found in the service manual Following these procedures is very important to the safety of individuals performing diagnostic tests 4 2 2 VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery If it does not false diagnostic codes or error messages may occur 4 2 3 SERVICING SUB ASSEMBLIES Some components of the powertrain system are intended to be serviced as an assembly only At tempting to remove or repair certain system sub components may result in personal injury and or improper system operation Only those components with approved repair and installation procedures in the service manual should be serviced 4 2 4 DRBIII SAFETY INFORMATION WARNING EXCEEDING THE LIMITS OF THE DRBIII
87. DRB erase ECM DTCs Start the engine several times turning the ignition off for at least 30 seconds between each run cycle Monitor the DRB for ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 8 Turn the ignition off Disconnect the Fuel Pressure Solenoid harness connector Turn the ignition on Using a 12 volt test light connected to ground check the ASD Relay Output circuit Does the test light illuminate brightly Yes GoTo 3 No Repair the ASD Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the Fuel Pressure Solenoid Control circuit 15 the voltage below 1 0 volt Yes GoTo 4 No Repair the Fuel Pressure Solenoid Control circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Fuel Pressure Solenoid harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the Fuel Pressure Solenoid Control circuit NOTE The Fuel Pressure Solenoid Control circuit is duplicated at ECM cavities C2 80 and C2 81 15 the resistance above 100 kohms Yes GoTo 5 No Repair the Fuel Pressure Solenoid Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the Fuel Pressure Solenoid harness
88. Disconnect the Fuel Pressure Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the 5 Volt Supply circuit 15 the resistance below 5 0 ohms Yes GoTo 6 No Repair 5 volt Supply circuit for an open Perform ROAD TEST VERIFICATION VER 2 35 DRIVEABILITY DIESEL P0O190 FUEL PRESS SENSOR CIRCUIT SIGNAL VOLTAGE HIGH Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Fuel Pressure Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the Sensor Ground circuit at the Fuel Pressure Sensor and ECM harness connectors Is the voltage above 1 0 volt at either connector Yes Repair the Sensor Ground circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No GoTo 7 NOTE If the Sensor Ground circuit had a short to voltage on it the ECM may have been damaged Retest the Fuel Pressure Sensor circuit Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Connect a jumper wire between the Fuel Pressure Sensor Signal circuit and the Sensor Ground circuit in the Fuel Pressure Sensor harness connector Turn the ignition on and monitor the DRB for DTCs 15 DTC P0190 FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE
89. E ACCESS TO EEPROM FAILURE When Monitored With the ignition on Set Condition The ECM determines that the coded message from the PCM does not match the message programmed into memory POSSIBLE CAUSES SKIM INTERMITTENT CONDITION CHECK FOR SKIM COMMUNICATION AND DTCS APPLICABILITY Turn the ignition on All With the check for Sentry Key Immobilizer Module communication and DTCs Are SKIS problems or DTCs present Yes Refer tosymptom list for problems related to SKIM Communica tion and DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 No GoTo 2 Turn the ignition on With the DRBIII erase ECM DTCs Turn theignition on and off several times pausing 10 seconds between each key cycle With the DRBIII read the ECM DTCs Are any P1685 DTCs present Yes GoTo 3 GoTo 4 155 DRIVEABILITY DIESEL P1685 SKIM SYSTEM INVALID KEY CODE RECEIVED Continued ACTION APPLICABILITY Replace and program the SKIM in accordance with the Service Information All Turn the ignition on With the DRBIII erase ECM DTCs Turn the ignition on off several times pausing for 10 seconds between key cycles With the DRBIII read ECM DTCs there any P1685 DTC s present Yes Replace and program the ECM in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Test Complete WARNING WHEN THE ENGINE IS OPERATING
90. E CIRCUIT SIGNAL VOLTAGE HIGH Continued 1652 1850 COMMUNICATION BUS UNAUTHORIZED RESET When Monitored With the ignition on Set Condition An unauthorized reset of the 1850 hardware occurs during normal oper ation P1680 EEPROM PLAUSIBILITY CHECKSUM ERROR When Monitored With the ignition on Set Condition The ECM detects an internal failure P1680 EEPROM PLAUSIBILITY CODE WORD INCORRECT OR MISSING When Monitored With the ignition on Set Condition The ECM detects an internal failure P1680 EEPROM PLAUSIBILITY COMMUNICATION ERROR When Monitored With the ignition on Set Condition The ECM detects an internal failure P1680 EEPROM PLAUSIBILITY VARIATION NUMBER ERROR When Monitored With the ignition on Set Condition The ECM detects an internal failure P1680 EEPROM PLAUSIBILITY VIN CHECKSUM ERROR When Monitored With the ignition on Set Condition The ECM detects an internal failure P1680 EEPROM PLAUSIBILITY WRITE ERROR When Monitored With the ignition on Set Condition The ECM detects an internal failure POSSIBLE CAUSES ENGINE CONTROL MODULE INTERMITTENT CONDITION 21 DRIVEABILITY DIESEL P0O105 BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE HIGH Continued ACTION APPLICABILITY NOTE This DTC indicates an internal ECM problem All Turn the ignition on With the DRB erase ECM DTCs Perform several engine run cycles turning the ignition off for at least 20 seconds betwee
91. E VOLTAGE APP SENSOR WIDE OPEN THROTTLE VOLTAGE ECM 5 VOLT SUPPLY CIRCUIT LOW IDLE POSITION SWITCH SENSE CIRCUIT SHORTED TO GROUND SENSOR GROUND OPEN APP SENSOR SENSOR GROUND OPEN IDLE SWITCH INTERMITTENT CONDITION 5 VOLT SUPPLY CIRCUIT OPEN APP SENSOR SIGNAL CIRCUIT OPEN LOW IDLE POSITION SWITCH SENSE CIRCUIT OPEN 5 VOLT SUPPLY CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT VERIFY LOW IDLE POSITION SWITCH OPERATION APP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND 161 DRIVEABILITY DIESEL P2120 ACC PEDAL POSITION SENSOR 1CKT PLAUSIBILITY Continued POSSIBLE CAUSES 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND VERIFY APP SENSOR OPERATION APP SENSOR SIGNAL CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT LOW IDLE POSITION SWITCH SENSE CIRCUIT SHORTED TO THE SENSOR GROUND CIR CUIT 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE ECM SENSOR GROUND OPEN APP SENSOR CIRCUIT SHORTED TO VOLTAGE APP SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE LOW IDLE POSITION SWITCH SENSE CIRCUIT SHORTED TO VOLTAGE LOW IDLE POSITION SWITCH SENSE GROUND CIRCUIT SHORTED TO VOLTAGE VERIFY CORRECT SWITCHING ECM APP SENSOR SIGNAL CIRCUIT APPLICABILITY NOTE The brake switch must be operational for the result of this test to be All valid Turn the ignition off Disconnect the APP Sensor harness connector Connect one end of a jumper wire to the Low Idle Position Sense circuit at the APP Sensor harness connector Turn the ignition o
92. EABILITY DIESEL A C INOPERATIVE Continued ACTION APPLICABILITY Turn the ignition on All With the DRBIII actuate the A C Compressor Clutch Relay Observe the A C Compressor Clutch during actuation Is the A C Compressor Clutch clicking Yes GoTo 4 GoTo 10 Turn the ignition off Disconnect the A C High Pressure Switch harness connector Measure the resistance of the A C High Pressure Switch Is the resistance below 10 0 ohms Yes GoTo 5 No Replace the A C High Pressure Switch Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the A C Low Pressure Switch harness connector Measure the resistance of the A C Low Pressure Switch 15 the resistance below 10 0 ohms Yes GoTo 6 No Replace the A C Low Pressure Switch Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the A C High Pressure Switch harness connector Disconnect the ECM harness connectors Measure the resistance of the A C Pressure Signal circuit Is the resistance below 5 0 ohms Yes GoTo 7 No Repair the A C Pressure Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the A C Low Pressure Switch harness connector Disconnect the A C High Pressure Switch harness connector Measure the resistance of the A C Switch Sense circuit 15 the resistance below 5 0 ohms Yes GoTo 8 No Repair the A C Switch
93. ECKING THE ACCELERATOR PEDAL POSITION SENSOR CALIBRATION 175 CHECKING THE BOOST PRESSURE SENSOR CALIBRATION 176 CHECKING THE ECM POWER AND GROUND CIRCUITS 177 CHECKING THE EGR SYSTEM 178 THE ENGINE COOLANT TEMPERATURE SENSOR CALIBRATION 179 CHECKING THE ENGINE MECHANICAL 5 180 CHECKING THE GLOW PLUG OPERATION 25 181 CHECKING THE SPEED CONTROL OPERATION 183 CHECKING THE TRANSFER CASE POSITION 5 185 THE VISCOUS CABIN HEATER RELAY 186 ENGINE CRANKS BUT WILL NOT START 204224 e3044 Send ee bee Lk be ees 188 ENGINE WILL NOT dus oe 192 8 0 9 0 TABLE OF CONTENTS Continued VEHICLE THEFT SECURITY ANTENNA FAILURE OR Eee er eee 195 COP FAILURE lt 4 vases 6245 ux eax 195 EEPROM FAILURE s2cc ursue lense 195 INTERNAL FAUL T sien bowen Keven ees 195 RAM FAILURE Soi ee PENS E Eee ee 195 SERIAL LINK INTERNALIFAULYT ee meas Re 195 STACK OVERFLOW FAILURE exes or de oS 195
94. EM ECM ACTION APPLICABILITY With the DRBIII erase the SKIM All Turn the ignition off Wait 10 seconds Turn the ignition on and wait 2 minutes With the DRBIII read the SKIM DTC s Does the 2 display the DTC that was previously erased Yes GoTo 2 GoTo 4 199 VEHICLE THEFT SECURITY ROLLING CODE FAILURE Continued ACTION APPLICABILITY Turn the ignition on All With the DRBIII select Engine system from the main menu Display and record the Vehicle Identification Number NOTE Ensure that VIN has been programmed into the E CM Ifa VIN is not displayed attempt to program the ECM with the correct vehicle VIN before continuing Does the VIN recorded from the ECM match the VIN of the vehicle Yes GoTo 3 No Replace and program the Engine Control Module in accordance with the Service Information Perform SKIS VERIFICATION Turn the ignition off Replace and program the Sentry Key Immobilizer Module in accordance with the Service Information Turn the ignition on With the DRBIII display and clear all ECM and SKIM DTC s Perform 5 ignition key cycles leaving the ignition key on for 90 seconds per cycle With the DRBIII check SKIM Does the 2 display the same DTC Yes Replace and program the Engine Control Module in accordance with the Service Information Perform SKIS VERIFICATION Test Complete Turn the ignition of
95. ESEL Symptom P0235 BOOST PRESSURE SENSOR PLAUSIBILITY When Monitored and Set Condition P0235 BOOST PRESSURE SENSOR PLAUSIBILITY When Monitored With the engine speed below 850 rpm Set Condition When the engine is idling the boost pressure sensor input does not agree with the barometric pressure sensor input for at least 5 seconds POSSIBLE CAUSES INTERMITTENT CONDITION HIGH RESISTANCE IN THE BOOST PRESSURE SENSOR SIGNAL CIRCUIT HIGH RESISTANCE IN THE BOOST PRESSURE SENSOR GROUND CIRCUIT HIGH RESISTANCE IN THE 5 VOLT SUPPLY CIRCUIT BOOST PRESSURE INTAKE AIR TEMPERATURE SENSOR ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Turn the ignition off wait 30 seconds then start and idle the engine for at least 30 seconds NOTE Engine idle speed must be below 870 RPM With the DRB read ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 6 Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Boost Pressure Sensor Signal circuit 15 the resistance below 5 0 ohms Yes GoTo 3 No Repair the Boost Pressure Sensor Signal circuit for high resis tance Perform ROAD TEST VERIFICATION VER 2 46 DRIVEABILITY DIESEL P0235 BOOST PRESSURE SENSOR PLAUSIBILITY Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Boos
96. HE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 121 DRIVEABILITY DIESEL Symptom P0651 SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO LOW E When Monitored and Set Condition P0651 SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO LOW When Monitored With the ignition on Set Condition The ECM detects a short to ground on the Sensor Reference Voltage B circuit or a short to ground on the Accelerator Pedal Position Sensor 5 Volt Supply circuit POSSIBLE CAUSES INTERMITTENT CONDITION OIL PRESSURE BOOST PRESSURE OR ACCEL PEDAL POSITION SENSOR SHORT TO
97. IGNAL CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT CMP SENSOR CIRCUIT SHORTED TO VOLTAGE APPLICABILITY NOTE The Timing Belt must be correctly installed and operational before All diagnosis can be made Refer to the Service Information to ensure the timing belt is properly installed Turn the ignition on With the DRBIII erase the ECM DTCs Attempt to start the engine With the DRBIII read the ECM DTCs Does the DRB III display this DTC Yes GoTo 3 GoTo 2 61 DRIVEABILITY DIESEL 40 CORRECTION FOR MAIN ECTION Continued ACTION APPLICABILITY Turn the ignition on With the DRBIII erase the ECM DTCs Test drive the vehicle With the DRBIII read the ECM DTCs Does the DRB III display this DTC Yes GoTo 3 No GoTo 13 Turn the ignition off Disconnect the CMP Sensor harness connector Turn the ignition on Using a 12 volt test light connected to ground check the ASD Relay Output circuit in CMP Sensor harness connector Does the test light illuminate brightly Yes GoTo 4 No Repair the ASD Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the CMP Sensor harness connector Turn the ignition on Using a 12 volt test light connected to ground check the CMP Sensor Signal circuit Is the test light on Yes Repair the CMP Sensor Signal circuit for a short to voltage P
98. IGNAL CKTS PLAUS W REDUNDANT CONTACT AFTER INITIALIZATION Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be PO703 BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH REDUNDANT CONTACT a When Monitored and Set Condition 703 SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH REDUNDANT CONTACT When Monitored With the ignition on Set Condition TheECM detects the Primary Brake Switch Signal circuit and Secondary Brake Switch Signal circuit inputs to the ECM do not agree 703 SWITCH SIGNAL CKTS PLAUS W REDUNDANT CONTACT AF TER INITIALIZATION When Monitored With the ignition on Set Condition TheECM detects the Primary Brake Switch Signal circuit and Secondary Brake Switch Signal circuit inputs to the ECM do not agree POSSIBLE CAUSES INTERMITTENT CONDITION BRAKE LAMP SWITCH SECONDARY OPEN BRAKE LAMP SWITCH FUSED B CIRCUIT OPEN SECONDARY BRAKE SWITCH SIGNAL CIRCUIT SHORTED TO GROUND BRAKE LAMP SWITCH PRIMARY OPEN SECONDARY BRAKE SWITCH GROUND CIRCUIT OPEN SECONDARY BRAKE SWITCH SIGNAL CIRCUIT OPEN PRIMARY BRAKE SWITCH SIGNAL CIRCUIT SHORTED TO VOLTAGE PRIMARY BRAKE SWITCH SIGNAL CIRCUIT OPEN ENGINE CONTROL MODULE INTERNAL ENGINE CONTROL MODULE PRIMARY BRAKE SIGNAL ENGINE CONTROL MODULE SECONDARY BRAKE SIGNAL 129 DRIVEABILITY DIESEL 703 SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH DUNDANT CONTACT Continue
99. IM If all of the criteria for monitoring a circuit or function are met and a fault is detected a DTC will be stored in the SKIM memory 3 2 6 SKIS OPERATION When ignition power is supplied tothe SKIM the SKIM performs an internal self test After the self test is complete the SKIM energizes the antenna this activates the transponder chip and sends a challenge to the transponder chip The transponder chip responds to the challenge by generating an encrypted response message using the following Secret Key This is an electronically stored value identification number that is uniqueto each SKIS The secret key is stored in the SKIM ECM and all ignition key transponders Challenge This is a random number that is gen erated by the SKIM at each ignition key cycle The secret key and challenge are the two vari ables used in the algorithm that produces the encrypted response message The transponder uses the crypto algorithm to receive decode and respond to the message sent by SKIM After responding to the coded message the transponder sends a tran sponder ID message to the SKIM The SKIM com pares the transponder ID message to the available valid key codes in SKIM memory 8 key maximum at any one time After validating the ignition key the SKIM sends a PCI Bus message called a seed request to the ECM then waits for the ECM re sponse If the ECM does not respond the SKIM will send the seed request again After twenty faile
100. IM checks the circuit or function is an intermit tent code Most intermittent DTCs are caused by wiring or connector problems Problems that come and go like this are the most difficult to diagnose they must be looked for under specific conditions that cause them The following checks may assist you in identifying a possible intermittent problem e Visually inspect the related wire harness connec tors Look for broken bent pushed out or cor roded terminals e Visually inspect the related wire harness Look for chafed pierced or partially broken wire Refer to hotlines or technical service bulletins that may apply NOTE Electromagnetic radio interference can cause an intermittent system malfunction This interference can interrupt communication between the ignition key transponder and the SKIM 3 3 3 ECM DIAGNOSTIC TROUBLE CODES IMPORTANT NOTE Before replacing the ECM for a failed driver control circuit or ground circuit be sure to check the related component circuit in tegrity for failures not detected due toa double fault in the circuit Most ECM driver control circuit fail ures are caused by internal failures to components i e relays and solenoids and shorted circuits i e sensor pull ups drivers and ground circuits These faults are difficult to detect when a double fault has occurred and only one DTC has set If the DRBIII displays faults for multiple com ponents i e VSS ECT Batt Temp etc iden
101. ING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 94 DRIVEABILITY DIESEL Symptom P0520 OIL PRESS SENSOR MALF SUPPLY VOLTAGE HIGH OR LOW When Monitored and Set Condition P0520 O1IL PRESS SENSOR MALF SUPPLY VOLTAGE TOO HIGH OR LOW When Monitored With the ignition on Set Condition The Sensor Reference Voltage voltage to the Oil Pressure Sensor 15 below 4 8 volts or above 5 2 volts for at least 100 ms POSSIBLE CAUSES INTERMITTENT CONDITION 5 VO
102. ION SENSOR PLAUSIBILITY 133 TABLE OF CONTENTS Continued P0836 TRANSFER CASE POSITION SENSOR PLAUSIBILITY 2 133 P0836 TRANSFER CASE POSITION SENSOR SIGNAL VOLTAGE TOO HIGH 133 P0836 TRANSFER CASE POSITION SENSOR SIGNAL VOLTAGE TOO LOW 133 P1130 FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED 136 P1130 FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO HIGH SHUT see eee 136 P1130 FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO LOW 136 P1130 FUEL RAIL PRESSURE MALFUNCTION SOLENOID OPEN 136 P1131 FUEL PRESSURE SOLENOID OPEN CIRCUIT 139 P1131 FUEL PRESSURE SOLENOID PLAUSIBILITY IN AFTER RUN 139 P1131 FUEL PRESSURE SOLENOID SHORT CIRCUIT 139 P1511 BAT TERY SENSE LINE 1 VOLTAGE TOO 143 P1511 BAT TERY SENSE LINE 1 VOLTAGE TOO LOW 143 P1512 BATTERY SENSE LINE 2 VOLTAGE TOO 143 P1512 BATTERY SENSE LINE 2 VOLTAGE TOO LOW i002 508 eas dee 484 vans 143 P1605 IGNITION SWITCH PLAUSIBILITY 555225555555 5455556 wes 146 P1643 VISCOUS HEATER RELAY OPEN 2 854 55855 56465 148 P1643 VISCOUS HEATER RELAY SHORT CIRCUIT 148 P1651 MIL DIAG LAMP VIA J1850 BUS IN FRAME RESPONSE ERROR 151 P1651 MIL DIAG LAMP VIA J1850 BUS STATUS ERROR
103. IT IGNITION SWITCH START OUTPUT CIRCUIT OPEN INSPECT BATTERY CABLES MECHANICAL PROBLEM OPEN FUSED BATTERY CIRCUIT STARTER MOTOR STARTER RELAY STARTER RELAY GROUND CIRCUIT OPEN STARTER RELAY OUTPUT CIRCUIT OPEN ACTION APPLICABILITY Turn the ignition off All NOTE The battery must be fully charged before diagnosing a no crank condition Inspect the battery cables for corrosion looseness or other problems 15 there evidence of problems Yes Repair as necessary Perform NO START VERIFICATION VER 1 GoTo 2 Turn the ignition on With the DRBIII read the SKIM DTCs Does the DRBIII display any SKIM DTCs Yes Refer to symptom list for problems related to SKIM Perform NO START VERIFICATION VER 1 No GoTo 3 192 DRIVEABILITY DIESEL ENGINE WILL NOT CRANK Continued ACTION APPLICABILITY Turn the ignition off Remove the Starter Relay from the PDC WARNING THE TRANSMISSION MUST BE IN NEUTRAL AND THE PARK BRAKE MUST BE SET FOR THIS TEST WARNING THE ENGINE MAY CRANK IN THE NEXT STEP WHEN THE ENGINE IS CRANKING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Momentarily jumper Starter Relay connector cavities 30 and 87 in the PDC connector Did the engine crank Yes GoTo 4 GoTo 8 Remove the Starter Relay from the PDC All Using a 12 volt test light connected to ground check
104. L Symptom P0235 BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW When Monitored and Set Condition P0235 BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW When Monitored With the ignition on Set Condition Sensor Reference Voltage voltage to the Boost Pressure Sensor is below 4 8 volts or above 5 2 volts for at least 100 ms POSSIBLE CAUSES INTERMITTENT CONDITION 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND 5 VOLT SUPPLY CIRCUIT SHORTED TO SENSOR GROUND 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE APP SENSOR 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND APP SENSOR 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE ENGINE CONTROL MODULE ACTION APPLICABILITY NOTE If DTC P0641 or P0651 is present with this DTC diagnose DTCs All P0641 and P0651 before diagnosing this DTC Turn the ignition on With the DRB erase ECM DTCs Turn the ignition off wait 30 seconds then turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes GoTo 2 No GoTo 7 Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage between ground and the 5 volt Supply circuit at the Boost Pressure IAT Sensor harness connector 15 the voltage above 1 0 volt Yes Repair the 5 volt Supply circuit for a sh
105. L FUSED B 85 51 18DB YL AUTO SHUT DOWN RELAY CONTROL 86 9 14RD YL DIESEL FUSED B 86 18DB GAS FUSED IGNITION SWITCH OUTPUT RUN START 86 18DB GAS FUSED IGNITION SWITCH OUTPUT RUN START 87 142 14DG OR DIESEL AUTO SHUT DOWN RELAY OUTPUT 87 A142 14DG OR AUTO SHUT DOWN RELAY OUTPUT 87A CABIN HEATER RELAY DIESEL CAV CIRCUIT FUNCTION 30 17 18RD BK FUSED B 85 K132 18DG LB CABIN HEATER RELAY CONTROL 86 71 18DG RD FUSED AUTO SHUT DOWN RELAY OUTPUT 87 C151 18DB WT CABIN HEATER RELAY OUTPUT 87A CLUTCH SWITCH OVERRIDE RELAY M T CAV CIRCUIT FUNCTION 30 F45 18YL BR GAS FUSED IGNITION SWITCH OUTPUT START 30 F45 18YL BR FUSED IGNITION SWITCH OUTPUT START 85 90 18 CLUTCH SWITCH OVERRIDE RELAY CONTROL 86 21 12RD DB IGNITION SWITCH OUTPUT RUN START 87 1141 18YL RD CLUTCH SWITCH OVERRIDE RELAY OUTPUT 87 7141 18YL RD CLUTCH SWITCH OVERRIDE RELAY OUTPUT 87A FUEL HEATER RELAY DIESEL CAV CIRCUIT FUNCTION 30 A34 16LB RD FUSED B 85 7142 18BK WT GROUND 86 F20 18WT FUSED IGNITION SWITCH OUTPUT RUN 87 A93 16RD BK FUEL HEATER RELAY OUTPUT 87A GLOW PLUG RELAY NO 1 DIESEL CAV CIRCUIT FUNCTION 30 54 10RD FUSED B 85 K152 18WT GLOW PLUG RELAY NO 1 CONTROL 86 71 1800 80 FUSED AUTO SHUT DOWN RELAY OUTPUT 87 K154 10GY GLOW PLUG RELAY NO 1 RELAY OUTPUT 87A GLOW PLUG RELAY NO 2 DIESEL
106. LITY DIESEL Symptom 41 5 REFERENCE VOLTAGE VOLTAGE TOO HIGH When Monitored and Set Condition P0641 SENSOR REFERENCE VOLTAGE VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition The ECM detects a short to voltage on the Sensor Reference Voltage A circuit or the Fuel Pressure Sensor 5 Volt Supply circuit POSSIBLE CAUSES INTERMITTENT CONDITION FUEL PRESSURE SENSOR 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Monitor the DRB for ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 4 Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage on the Fuel Pressure Sensor 5 Volt Supply circuit 15 the voltage below 1 0 volt Yes GoTo 3 No Repair the Fuel Pressure Sensor 5 Volt Supply circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 NOTE Remove the jumper wire and reinstall the ASD Relay If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 112 DRIVEABILITY DIESEL
107. LT SUPPLY CIRCUIT SHORTED TO GROUND 5 VOLT SUPPLY CIRCUIT SHORTED TO SENSOR GROUND 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE ENGINE CONTROL MODULE ACTION APPLICABILITY NOTE If DTC P0641 or P0651 is present with this DTC diagnose DTCs All P0641 and P0651 before diagnosing this DTC Turn the ignition on With the DRB erase ECM DTCs Turn the ignition off wait 30 seconds then start and idle the engine With the DRB read ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 5 Turn the ignition off Disconnect the Oil Pressure Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage between ground and the 5 volt Supply circuit at the Oil Pressure Sensor harness connector 15 the voltage above 1 0 volt Yes Repair the 5 volt Supply circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 3 95 DRIVEABILITY DIESEL P0520 OIL PRESS SENSOR SUPPLY VOLTAGE TOO HIGH LOW Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Oil Pressure Sensor harness connector Measure the resistance between ground and the 5 volt Supply circuit at the Oil Pressure Sensor harness connector 15 the resistance above 1000 ohms Yes GoTo 4
108. MALF BAT TERY VOLTAGE TOO HIGH GENERATOR FIELD CONTROL CHARGING VOLTS TOO LOW GENERATOR FIELD CONTROL MALF OPEN CIRCUIT GENERATOR FIELD CONTROL MALF SHORT CIRCUIT GLOW PLUG CIRCUIT A OPEN CIRCUIT GLOW PLUG CIRCUIT A SHORT CIRCUIT GLOW PLUG CIRCUIT B OPEN CIRCUIT GLOW PLUG CIRCUIT B SHORT CIRCUIT IGNITION SWITCH PLAUSIBILITY INTAKE AIR TEMP SENSOR CIRCUIT SIG NAL VOLTAGE TOO HIGH INTAKE AIR TEMP SENSOR CIRCUIT SIG NAL VOLTAGE TOO LOW 11850 COMMUNICATION BUS LOST TRATION 11850 COMMUNICATION BUS SHORT GROUND MALF GENERAL INFORMATION 11850 COMMUNICATION BUS SHORT VOLTAGE 1 1850 COMMUNICATION BUS UNAUTHO RIZED RESET MIL DIAG LAMP VIA J 1850 BUS IN FRAME RESPONSE ERROR MIL DIAG LAMP VIA J 1850 BUS STATUS ERROR OIL PRESS SENSOR CKT MALF PLAUSIBIL ITY PRESS SENSOR CKT MALF SIGNAL VOLTAGE TOO HIGH PRESS SENSOR MALF SIGNAL VOLTAGE TOO LOW PRESS SENSOR MALF SUPPLY VOLTAGE TOO HIGH OR LOW S C SWITCH SIGNAL CIRCUIT PLAUSIBILITY S C SWITCH SIGNAL CIRCUIT SIGNAL VOLT AGE TOO HIGH S C SWITCH SIGNAL CIRCUIT SIGNAL VOLT AGE TOO LOW SENSOR REFERENCE VOLTAGE VOLT AGE TOO HIGH SENSOR REFERENCE VOLTAGE VOLT AGE TOO LOW SENSOR REFERENCE VOLTAGE VOLTAGE TOO HIGH SENSOR REFERENCE VOLTAGE VOLTAGE TOO LOW SKIM SYSTEM INVALID KEY CODE RE CEIVED SKIM SYSTEM INVALID SECRET KEY IN EE PROM SKIM SYSTEM KEY COMMUNICATI
109. N RELAY OUTPUT 6 7 1025 20 PCI BUS 8 20BK LB CAMSHAFT POSITION SENSOR GROUND 9 _ 20TN YL CAMSHAFT POSITION SENSOR SIGNAL 10 11 K37 20DB YL BOOST PRESSURE SENSOR SIGNAL 12 z 13 K78 20GY FUEL PRESSURE SENSOR SIGNAL 14 z 15 __ 20VT TN ACCELERATOR PEDAL POSITION SENSOR SIGNAL 16 20BK VT FUEL PRESSURE SENSOR GROUND 17 18 19 92 20YL BR BATTERY SENSE 20 2109 20BK DB BATTERY SENSE 21 _ 20BK LB SENSOR GROUND 22 Fl 2008 FUSED IGNITION SWITCH OUTPUT RUN START 23 20VT WT SENSOR REFERENCE VOLTAGE B 24 K3 20LB BK CRANKSHAFT POSITION SENSOR SIGNAL 2 25 26 27 BLACK 28 29 K77 20BR WT TRANSFER CASE POSITION SENSOR INPUT 30 _ 060 20GY YL ENGINE OIL PRESSURE SENSOR SIGNAL 31 _ 6123 2000 WATER IN FUEL SENSOR SIGNAL 32 K118 20PK YL BATTERY TEMPERATURE SENSOR SIGNAL N 33 34 K255 20WT DG ACCELERATOR PEDAL POSITION SENSOR GROUND 5 35 852 20VT WT ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY E 24 z 5 36 2 37 T 25 38 V37 2080 08 SPEED CONTROL SWITCH SIGNAL 39 K226 20DB WT FUEL LEVEL SENSOR SIGNAL 40 K2 20TN BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL R 55 41 K21 18BK RD INTAKE AIR TEMPERATURE SENSOR SIGNAL 55 42 Y101 20BK OR CRANKSHAFT POSITION SENSOR SHIELD 43 _ 2420 CRANKSHAFT POSITION SENSOR SIGNAL 1 44 6 25 44 63 25 46
110. NAL CIRCUIT SHORTED TO VOLTAGE VEHICLE SPEED SIGNAL CIRCUIT OPEN ENGINE CONTROL MODULE NO VOLTAGE ENGINE CONTROL MODULE NO VOLTAGE CHANGE ENGINE CONTROL MODULE VOLTAGE TOO HIGH 83 DRIVEABILITY DIESEL 5 SPEED SENSOR FREQUENCY TOO HIGH Continued APPLICABILITY Turn the ignition on With the DRB erase ECM DTCs Test drive the vehicle With the DRB read Vehicle Speed Does the DRB display an accurate Vehicle Speed Yes GoTo 2 GoTo 3 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions p
111. NE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Test drive the vehicle and activate the Speed Control At some point during the test drive actuate each of the S C Switch buttons With the DRB read ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 5 Turn the ignition off Disconnect the S C Switch harness connectors Disconnect the ECM harness connectors Measure the resistance of the S C Switch Signal circuit 15 the resistance below 5 0 ohms Yes GoTo 3 No Repair the S C Switch Signal circuit for high resistance Perform SPEED CONTROL VERIFICATION 4 Turn the ignition off Disconnect the S C Switch harness connectors Disconnect the ECM harness connectors Measure the resistance of the S C Switch Ground circuit 15 the resistance below 5 0 ohms Yes GoTo 4 No Repair the S C Switch Ground circuit for high resistance Perform SPEED CONTROL VERIFICATION 4 102 DRIVEABILITY DIESEL P0579 S C SWITCH SIGNAL CIRCUIT PLAUSIBILITY Continued ACTION APPLICABILITY Turn the ignition off All Replace the S C Switches Turn the ignition on With the DRB erase ECM DTCs Test drive the vehicle and activate the Speed Control At some point during the test drive actuate each of the S C Switch buttons Monitor the DRB for ECM DTCs Did this DTC reset Yes Replace and program the Engine Control Module in
112. NOTE Theidleswitch is designed totransition when the accel position is approximately 16 1 00 volt This code sets the ECM to Limp in Mode which includes a fixed engine speed of 1100 RPM 160 DRIVEABILITY DIESEL P2120 ACC PEDAL POSITION SENSOR 1CKT PLAUSIBILITY Continued P2120 ACC PEDAL POSITION SENSOR 1CKT PLAUSIBILITY WITH POTENTI OMETER When Monitored With the ignition on Set Condition TheAccelerator Pedal Position Sensor Signal is below 0 20 volts the idle switch transitions at too high a percentage intermittently or the idle switch is not in the correct state intermittently NOTE switch is designed totransition when the accel position is approximately 16 1 00 volt This code sets the ECM to Limp in Mode which includes a fixed engine speed of 1100 RPM P2120 ACC PEDAL POSITION SENSOR 1CKT SIGNAL VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition TheECM detects voltage on theAccelerator Pedal Position Sensor Signal circuit above 4 5 volts P2120 ACC PEDAL POSITION SENSOR 1CKT SIGNAL VOLTAGE TOO LOW When Monitored With the ignition on Set Condition TheECM detects voltage on theAccelerator Pedal Position Sensor Signal circuit 0 0 volt P2120 ACC PEDAL POSITION SENSOR 1CKT SUPPLY VOLTAGE TOO HIGH OR LOW When Monitored With the ignition on Set Condition TheAccelerator Pedal Position Sensor 5 Volt Supply voltage 15 too high too low POSSIBLE CAUSES APP SENSOR IDL
113. No Repair as necessary Perform NO START VERIFICATION VER 1 Turn the ignition off Disconnect the ECM harness connectors Disconnect all 4 Fuel Injector harness connectors Measure the resistance between Ground and each Fuel Injector Driver circuit at it s respective Fuel Injector harness connector 15 the resistance below 1000 ohms for any of the measurements Yes Repair the Fuel Injector Driver circuit s for a short to ground Perform NO START VERIFICATION 1 No GoTo 6 Inspect the fuel system lines for restrictions leaks or other problems 15 there any evidence of problems Yes Repair as necessary Perform NO START VERIFICATION 1 GoTo 7 Turn the ignition off Using the 119 lab scope the CMP Sensor Signal circuit at the ECM harness connector Start the engine if the engine will not start crank the engine for several seconds while monitoring the DRBIII NOTE Refer to Charts and Graphs to view a correct CMP Sensor signal Does the 2 display a steady clean CMP Signal pattern Yes GoTo 8 No Perform Test for DTC P0340 Camshaft Position Sensor Circuit Static Plausibility Perform NO START VERIFICATION VER 1 189 DRIVEABILITY DIESEL ENGINE CRANKS BUT WILL NOT START Continued ACTION APPLICABILITY Turn the ignition off All U sing the lab scope backprobe both of the CKP Sensor Signal circui
114. O LOW 19 0606 ERROR GATE ARRAY 19 0606 ERROR GATE ARRAY COMMUNICATION NOT VERIFIED 19 0606 ERROR GATE ARRAY QUANTITY 5 19 0606 ERROR RECOVERY HAS 19 0606 ERROR REDUNDANT OVERRUN MONITORING 19 P1206 CALCULATED INJECTOR VOLTAGE TOO HIGH 19 P1206 CALCULATED INJECTOR VOLTAGE TOO 19 P1601 CAPACITOR VOLTAGE 1 VOLTAGE TOO 19 P1601 GAPACITOR VOLTAGE 1 VOLTAGE TOO LOW seas oxen 19 1606 RUN SHUT OFF ERROR INJECTION POWERSTAGE 19 1606 RUN SHUT OFF ERROR ZERO 19 P1610 VOLTAGE REGULATOR SIGNAL VOLTAGE TOO HIGH 19 P1610 VOLTAGE REGULATOR SIGNAL VOLTAGE TOO LOW 19 P1652 J1850 COMMUNICATION BUS LOST ARBITRATION 19 P1652 J1850 COMMUNICATION BUS UNAUTHORIZED RESET 19 P1680 EEPROM PLAUSIBILITY CHECKSUM ERROR 19 1680 PLAUSIBILITY CODE WORD INCORRECT OR MISSING 19 P1680 EEPROM PLAUSIBILITY COMMUNICATION 19 P1680 EEPROM PLAUSIBILITY VARIATION NUMBER ERROR 19 P1680 EEPROM PLAUSIBILITY VIN CHECKSUM ERROR
115. O NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 25 DRIVEABILITY DIESEL Symptom PO1LO INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW When Monitored and Set Condition 0110 AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW When Monitored With the ignition on Set Condition Intake Air Temperature Sensor Signal voltage is below 0 21 volt POSSIBLE CAUSES INTERMITTENT CONDITION INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND BOOST PRESSURE IAT SENSOR ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB eras
116. OID CIRCUIT SHORT CIRCUIT When Monitored With the ignition on Set Condition The ECM detects excessive current draw on the EGR Solenoid Control circuit POSSIBLE CAUSES INTERMITTENT CONDITION EGR SOLENOID EGR SOLENOID CONTROL SHORTED TO VOLTAGE ENGINE CONTROL MODULE INTERNAL ENGINE CONTROL MODULE INTERNAL SHORT TO VOLTAGE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Test drive the vehide and monitor the DRB for ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 5 Turn the ignition off Disconnect the EGR Solenoid harness connector Turn the ignition on With the DRB erase ECM DTCs Monitor the DRB for ECM DTCs Does the DRB display P0403 EGR OPEN CIRCUIT Yes Replace the EGR Solenoid Perform ROAD TEST VERIFICATION VER 2 GoTo 3 Turn the ignition off Disconnect the EGR Solenoid harness connector Turn the ignition on Measure the voltage of the EGR Solenoid Control circuit at the EGR Solenoid harness connector 15 the voltage below 0 5 volt Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 4 76 DRIVEABILITY DIESEL P0403 EGR SOLENOID CIRCUIT SHORT CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the EGR Solenoid harness connector Disconnect the ECM harness connectors Remove the ASD Relay fro
117. ON TIMED OUT SKIM SYSTEM WRITE ACCESS TO EEPROM FAILURE SYSTEM VOLTAGE TOO HIGH TRANSFER CASE POSITION SENSOR PLAU SIBILITY TRANSFER CASE POSITION SENSOR PLAU SIBILITY 2 TRANSFER CASE POSITION SENSOR SIG NAL VOLTAGE TOO HIGH TRANSFER CASE POSITION SENSOR SIG NAL VOLTAGE TOO LOW VEHICLE SPEED SENSOR FREQUENCY TOO VEHICLE SPEED SENSOR PLAUSIBILITY VEHICLE SPEED SENSOR SIGNAL VOLTAGE TOO HIGH VISCOUS HEATER OPEN CIRCUIT VISCOUS HEATER SHORT CIRCUIT VOLTAGE REGULATOR SIGNAL VOLTAGE TOO HIGH VOLTAGE REGULATOR SIGNAL VOLTAGE TOO LOW GENERAL INFORMATION 3 3 4 SKIM DIAGNOSTIC TROUBLE CODES ANTENNA FAILURE COP FAILURE EEPROM FAILURE INTERNAL FAULT PCM STATUS FAILURE RAM FAILURE ROLLING CODE FAILURE SERIAL LINK EXTERNAL FAULT SERIAL LINK INTERNAL FAULT STACK OVERFLOW FAILURE TRANSPONDER COMMUNICATION FAILURE TRANSPONDER CYCLIC REDUN DANCY CHECK FAILURE TRANSPONDER ID MISMATCH TRANSPONDER RESPONSE MISMATCH VIN MISMATCH 3 3 5 HANDLING NO TROUBLE CODE PROBLEMS After reading Section 3 0 System Description and Functional Operation you should have a bet ter understanding of the theory and operation of the on board diagnostics and how this relates to the diagnosis of a vehicle that may have a driveability related symptom or complaint When there are no trouble codes present refer to the no trouble code tests 3 4 USING THE DRBIII Refer to the DRBIII user s
118. ORTED TO VOLTAGE ACTION APPLICABILITY Attempt to start the engine All Did the engine start Yes GoTo 2 GoTo 3 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 59 DRIVEABILITY DIESEL P0340 CKP POSITION SENSOR CIRCUIT DYNAMIC PLAUSIBILITY Continued APPLICABILITY Turn the ignition off Disconnect the CKP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between grou
119. P SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition Intake Air Temperature Sensor Signal voltage is above 4 85 volts POSSIBLE CAUSES INTERMITTENT CONDITION INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE INTAKE AIR TEMP SENSOR GROUND CIRCUIT OPEN INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT OPEN BOOST PRESSURE IAT SENSOR ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Monitor the DRB for ECM DTCs Did this DTC reset Yes GoTo 2 No GoTo 6 Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage on the IAT Sensor Signal circuit 15 the voltage below 1 0 volt Yes GoTo 3 No Repair the Intake Air Temperature Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 NOTE Remove the jumper wire 23 DRIVEABILITY DIESEL PO110 INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Boost Pressure IAT Sensor harness connector Measure the resistance of the Intake Air Temperature Sensor Signal circuit 15 the resistance below 5 0 o
120. PLICABILITY Turn the ignition off All Disconnect the S C ON OFF SET Switch harness connector Disconnect the ECM harness connectors Measure the resistance of the Sensor Ground circuit 15 the resistance below 10 0 ohms Yes Replace and program the Engine Control Module in accordance with the Service Information Perform SPEED CONTROL VERIFICATION 4 Repair the Sensor Ground circuit for an open Perform SPEED CONTROL VERIFICATION VER 4 Turn the ignition off Disconnect the S C ON OFF SET Switch harness connector Disconnect the ECM harness connectors Turn the ignition on Measure the voltage of the S C Switch Signal circuit 15 the voltage above 1 0 volt Yes Repair the S C ON OFF SET Switch Signal circuit for a short to voltage Perform SPEED CONTROL VERIFICATION VER 4 Replace and program the Engine Control Module in accordance with the Service Information Perform SPEED CONTROL VERIFICATION 4 105 DRIVEABILITY DIESEL Symptom P0579 S C SWITCH SIGNAL CIRCUIT SIGNAL VOLTAGE TOO LOW POSSIBLE CAUSES INTERMITTENT CONDITION 5 SWITCH S C RESUME ACCEL SWITCH S C SWITCH SIGNAL CIRCUIT SHORTED TO SENSOR GROUND S C SWITCH SIGNAL CIRCUIT SHORTED TO GROUND ECM ACTION APPLICABILITY Turn the ignition on With the read the S C Switch voltage Is the S C Switch voltage below 1 0 volt Yes GoTo 2 GoTo 7 Turn the ignition on With
121. PLY VOLTAGE TOO HIGH LOW When Monitored With the ignition on Set Condition TheFuel Pressure Sensor 5 Volt Supply voltage is below 4 7 volts or above 5 1 volts for 100 ms POSSIBLE CAUSES CHECK FOR SENSOR REFERENCE VOLTAGE A CIRCUIT DTCS ENGINE CONTROL MODULE ACTION APPLICABILITY WARNING THE FUEL INJ ECTION PUMP SUPPLIES HIGH PRESSURE All FUEL TO EACH INDIVIDUAL INJ ECTOR THROUGH HIGH PRESSURE FUEL LINES FUEL UNDER HIGH PRESSURE CAN PENETRATE SKIN AND CAUSE PERSONAL INJ URY WEAR SAFETY GOGGLES AND ADE QUATE PROTECTIVE CLOTHING Turn the ignition on With the DRB III read ECM DTCs Is the High or Low DTC for P0641 SENSOR REFERENCE VOLTAGE A CIRCUIT set with this DTC Yes Refer to the symptom list for the related symptom s Perform ROAD TEST VERIFICATION VER 2 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 40 DRIVEABILITY DIESEL Symptom List PO201 CYLINDER 1 INJ ECTOR CIRCUIT CURRENT DECREASE PO201 CYLINDER 1 INJ ECTOR CIRCUIT LOAD DROP PO201 CYLINDER 1 INJ ECTOR CIRCUIT OVERCURRENT HIGH SIDE PO201 CYLINDER 1 INJ ECTOR CIRCUIT OVERCURRENT LOW SIDE P0202 CYLINDER 2 ECTOR CIRCUIT CURRENT DECREASE P0202 CYLINDER 2 CIRCUIT LOAD DROP P0O202 CYLINDER 2 1 ECTOR CIRCUIT OVERCURRENT HIGH SIDE PO202 CYLINDER 2 1 CIRCUIT OVERCURRENT LOW SIDE P0203 CYLINDER 3 ECTOR CIR
122. PPLICABILITY Turn the ignition off All Disconnect the Viscous Heater harness connector Remove the Viscous Heater Relay Measure the resistance between ground and the Viscous H eater Relay Output circuit 15 the resistance above 1000 ohms Yes GoTo 5 No Repair the Viscous Heater Relay Output circuit for a short to ground Inspect the fuse or fuselink and replace as necessary Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Viscous Heater harness connector Remove the Viscous Heater Relay Connect a jumper wire across Viscous Heater Relay connector cavities 30 and 87 Using a 12 volt test light connected to ground check the Viscous Heater Relay Output circuit at each Viscous Heater harness connector Does the test light illuminate brightly Yes GoTo 6 No Repair the Viscous Heater Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there no possible causes remaining view repair Repair Replace the Viscous Heater Relay Perform ROAD TEST VERIFICATION VER 2 187 DRIVEABILITY DIESEL Symptom ENGINE CRANKS BUT WILL NOT START POSSIBLE CAUSES CHECK CAMSHAFT POSITION SENSOR SIGNAL CHECK CRANKSHAFT POSITION SENSOR SIGNAL CHECKING FOR ECM CODES CHECKING FOR SKIM CODES CHECKING THE ECT SENSOR CHECKING THE GLOW PLUG OPERATION ENGINE CONTROL MODULE ENGINE DRIVE BELT FUEL INJ ECTOR DRIVER CIRCUIT S SHORTED TO GROUND FUEL PRESS
123. Perform ROAD TEST VERIFICATION VER 2 No Test Complete 115 DRIVEABILITY DIESEL Symptom P0645 A C CLUTCH RELAY CIRCUIT OPEN CIRCUIT When Monitored and Set Condition 645 CLUTCH RELAY CIRCUIT OPEN CIRCUIT When Monitored With the ignition on Set Condition The ECM detects an open or short to ground on the A C Clutch Relay Control circuit POSSIBLE CAUSES INTERMITTENT CONDITION FUSED ASD RELAY OUTPUT CIRCUIT OPEN A C CLUTCH RELAY A C CLUTCH RELAY CONTROL CKT OPEN A C CLUTCH RELAY CONTROL CIRCUIT SHORT TO GROUND ECM ACTION APPLICABILITY Turn the ignition on All With the DRBIII actuate the A C Clutch Relay Is the A C Clutch Relay operating Yes GoTo 2 GoTo 3 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring ha
124. RANSFER CASE POSITION SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE 133 DRIVEABILITY DIESEL 836 5 CASE POSITION SENSOR PLAUSIBILITY Continued POSSIBLE CAUSES TRANSFER CASE POSITION SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIR CUIT ENGINE CONTROL MODULE ACTION APPLICABILITY NOTE The vehicle speedometer must be operational for the result of this test to be valid With the DRBIII record and erase DTC s Start the engine and cycle the Transfer Case through all positions With the DRBIII read the ECM DTCs Does the DRBII1 display this DTC Yes GoTo 2 No GoTo 7 Turn the ignition off to the lock position All Disconnect the ECM harness connectors Disconnect the Transfer Case Position Sensor harness connector Remove the ASD Relay Connect a jumper wire between cavities 30 and 87 of the ASD Relay connector in the PDC Turn the ignition on Measure the voltage of the Transfer Case Position Sensor Signal circuit 15 the voltage above 1 0 volt Yes Repair the Transfer Case Position Sensor Signal circuit for short to voltage Perform ROAD TEST VERIFICATION VER 2 No GoTo 3 Turn the ignition off to the lock position Disconnect the ECM harness connectors Disconnect the Transfer Case Position Sensor harness connector Measure the resistance of the Transfer Case Position Sensor Signal circuit 15 the resistance below 10 0 ohms Yes GoTo 4 No Repair the Transf
125. REASE When Monitored With the engine running Set Condition The ECM detects an incorrect rate of current decrease after injection occurs P0202 CYLINDER 2 INJ ECTOR CIRCUIT LOAD DROP When Monitored With the engine running Set Condition The ECM detects insufficient current through the injector driver P0202 CYLINDER 2 INJ ECTOR CIRCUIT OVERCURRENT HIGH SIDE When Monitored With the engine running Set Condition The ECM detects excessive current on the common driver circuit P0202 CYLINDER 2 INJ ECTOR CIRCUIT OVERCURRENT LOW SIDE When Monitored With the engine running Set Condition The ECM detects excessive current on the injector driver circuit P0203 CYLINDER 3 ECTOR CIRCUIT CURRENT DECREASE When Monitored With the engine running Set Condition The ECM detects an incorrect rate of current decrease after injection occurs P0203 CYLINDER 3 INJ ECTOR CIRCUIT LOAD DROP When Monitored With the engine running Set Condition The ECM detects insufficient current through the injector driver P0203 CYLINDER 3 INJ ECTOR CIRCUIT OVERCURRENT HIGH SIDE When Monitored With the engine running Set Condition The ECM detects excessive current on the common driver circuit P0203 CYLINDER 3 INJ ECTOR CIRCUIT OVERCURRENT LOW SIDE When Monitored With the engine running Set Condition The ECM detects excessive current on the injector driver circuit 42 DRIVEABILITY DIESEL PO201 CYLINDER 1 INJECTOR CIRCUIT CURRENT DECREASE
126. RT CIRCUIT Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P1131 FUEL PRESSURE SOLE NOID OPEN CIRCUIT E When Monitored and Set Condition P1131 FUEL PRESSURE SOLENOID OPEN CIRCUIT When Monitored With the ignition on Set Condition TheECM detects an open or short to ground on the F uel Pressure Solenoid Control circuit P1131 FUEL PRESSURE SOLENOID PLAUSIBILITY IN AFTER RUN When Monitored When the ignition is turned off Set Condition The ECM detects engine speed does not fall below 650 RPM within 0 5 second after ignition off P1131 FUEL PRESSURE SOLENOID SHORT CIRCUIT When Monitored With the ignition on Set Condition TheECM detects a short to voltage on the F uel Pressure Solenoid Control circuit POSSIBLE CAUSES INTERMITTENT CONDITION ASD RELAY OUTPUT CIRCUIT OPEN FUEL PRESSURE SOLENOID CONTROL SHORTED TO VOLTAGE FUEL PRESSURE SOLENOID CONTROL CIRCUIT SHORTED TO GROUND FUEL PRESSURE SOLENOID CONTROL CIRCUIT OPEN FUEL PRESSURE SOLENOID ENGINE CONTROL MODULE 139 DRIVEABILITY DIESEL P1131 F PRESSURE SOLENOID OPEN CIRCUIT Continued ACTION APPLICABILITY WARNING THE FUEL INJ ECTION PUMP SUPPLIES HIGH PRESSURE FUEL TO EACH INDIVIDUAL INJECTOR THROUGH HIGH PRESSURE FUEL LINES FUEL UNDER HIGH PRESSURE CAN PENETRATE SKIN AND CAUSE PERSONAL INJ URY WEAR SAFETY GOGGLES AND ADE QUATE PROTECTIVE CLOTHING Turn the ignition on With the
127. ST VERIFICATION VER 2 No Test Complete 82 DRIVEABILITY DIESEL Symptom List PO500 VEHICLE SPEED SENSOR FREQUENCY TOO HIGH P0O500 VEHICLE SPEED SENSOR HIGH LEVEL DURATION P0O500 VEHICLE SPEED SENSOR PLAUSIBILITY P0O500 VEHICLE SPEED SENSOR SIGNAL VOLTAGE TOO HIGH Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will PO500 VEHICLE SPEED SEN SOR FREQUENCY TOO HIGH When Monitored and Set Condition P0500 VEHICLE SPEED SENSOR FREQUENCY TOO HIGH When Monitored With the engine running Set Condition ECM detects a vehicle speed greater than the vehicle is capable 0500 SPEED SENSOR PLAUSIBILITY When Monitored With the engine under load and engine speed greater than 2400 RPM while vehicle speed is below 20 km h 12 MPH Set Condition TheECM compares the amount of fuel the fuel injectors are delivering to the vehicle speed from the VSS The VSS indicates a vehicle speed that cannot be achieved with the present amount of fuel being delivered 500 SPEED SENSOR SIGNAL VOLTAGE TOO HIGH When Monitored With the engine running Set Condition The ECM detects a vehicle speed greater than 240 km h 149 POSSIBLE CAUSES INTERMITTENT CONDITION BODY CONTROL MODULE CHECK FOR RELATED BODY CONTROL MODULE DTCS CHECK FOR RELATED CONTROLLER ANTILOCK BRAKES DTCS VEHICLE SPEED SIGNAL CIRCUIT SHORTED TO GROUND VEHICLE SPEED SIG
128. Sense circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the A C Low Pressure Switch harness connector Measure the resistance between ground and the A C Low Pressure Switch Ground circuit 15 the resistance below 5 0 ohms Yes GoTo 9 No Repair theA C Low Pressure Switch Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 170 DRIVEABILITY DIESEL A C INOPERATIVE Continued APPLICABILITY If there are no possible causes remaining view repair Repair Replace and program the ECM in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 NOTE If the A C Clutch fuse is open refer to the system schematics for all circuits that are powered by the A C Clutch fuse to determine the cause of the blown fuse Turn the ignition off Remove the A C Clutch Relay from the PDC Usinga 12 volt test light connected to ground probe the Fused in the PDC Does the test light illuminate brightly Yes GoTo 11 No Repair the Fused B circuit Inspect fuse and replace as neces sary Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Install a substitute relay in place of the A C Clutch Relay Turn the ignition on With the DRBIII actuate the A C Clutch Relay Does the A C Clutch Relay cycle on and off Yes Replace the A C Clutch Relay Perform ROAD TEST VERIFICATION VER 2 N
129. T DECREASE 41 P0203 CYLINDER 3 INJECTOR CIRCUIT LOAD 41 P0203 CYLINDER 3 INJECTOR CIRCUIT OVERCURRENT HIGH SIDE 41 P0203 CYLINDER 3 INJECTOR CIRCUIT OVERCURRENT LOW SIDE 41 P0204 CYLINDER 4 INJECTOR CIRCUIT CURRENT DECREASE 41 P0204 CYLINDER 4 INJECTOR CIRCUIT LOAD 41 P0204 CYLINDER 4 INJECTOR CIRCUIT OVERCURRENT HIGH SIDE 41 P0204 CYLINDER 4 INJECTOR CIRCUIT OVERCURRENT LOW SIDE 41 P0235 BOOST PRESSURE SENSOR PLAUSIBILITY es caves 46 P0235 BOOST PRESSURE SENSOR SIGNAL VOLTAGE HIGH 48 TABLE OF CONTENTS Continued P0235 BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW 51 P0235 BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW 54 P0335 CKP POSITION SENSOR CIRCUIT OVERSPEED RECOGNITION 57 P0340 CKP POSITION SENSOR CIRCUIT DYNAMIC PLAUSIBILITY 59 P0340 CMP CORRECTION FOR MAIN INJECTION 61 P0340 CMP POSITION SENSOR CIRCUIT SIGNAL FREQUENCY TOO HIGH 61 P0340 CMP POSITION SENSOR CIRCUIT STATIC PLAUSIBILITY 61 P0340 CMP POSITION SENSOR CIRCUIT CMP CKP SYNC FAILURE 65 P0380 GLOW PLUG 1 CONTROL CIRCUIT OPEN CIRCUIT ceed 68 P0380 GLOW PLUG 1 CONTROL CIRCUIT SHORT CIRCUIT 68 P0382 GLOW PLUG 2 CONTROL CIRCUIT OPEN CIRCUIT
130. T OPEN VISCOUS HEATER RELAY APPLICABILITY Turn the ignition off All Disconnect the Viscous Heater harness connector Turn the ignition on With the DRB actuate the Viscous Heater Relay Using a 12 volt test light connected to ground probe the Viscous Heater Relay Output circuit at the Viscous Heater harness connector during actuator test Does the test light cycle on and off during the actuator test Yes Test Complete GoTo 2 NOTE If the Viscous Heater Relay fuse or fuselink is open refer to the system schematics for all circuits that are powered by the Cabin Heater Relay fuse or fuselink to determine the cause of the blown fuse fuselink Remove the Viscous Heater Relay Using 12 volt test light connected to ground probe the Fused B circuit in the Viscous Heater Relay connector Does the test light illuminate brightly Yes GoTo 3 No Repair the Fused B Fuse F uselink circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Viscous Heater harness connector Remove the Viscous Heater Relay Turn the ignition on Measure the voltage on the Viscous Heater Relay Output circuit 15 the voltage above 1 0 volt Yes Repair the Viscous Heater Relay Output circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 4 186 DRIVEABILITY DIESEL CHECKING THE VISCOUS CABIN HEATER RELAY Continued ACTION A
131. TCH 5 ON OFF SET SWITCH SIGNAL CIRCUIT OPEN S C SWITCH SIGNAL CIRCUIT SHORTED TO VOLTAGE SENSOR GROUND OPEN TOO APPLICABILITY Turn the ignition off All Disconnect the S C ON OFF SET button harness connector Turn the ignition on Measure the voltage of the S C Switch Signal circuit Select the appropriate voltage reading Below 4 5 volts GoTo 2 Between 4 5 and 5 5 volts GoTo 3 Above 5 5 volts GoTo 5 Turn the ignition off Disconnect the S C ON OFF SET Switch harness connector Disconnect the ECM harness connectors Measure the resistance of the S C Switch Signal circuit 15 the resistance below 10 0 ohms Yes Replace and program the Engine Control Module in accordance with the Service Information Perform SPEED CONTROL VERIFICATION 4 Repair the S C ON OFF SET Switch Signal circuit for an open Perform SPEED CONTROL VERIFICATION 4 Turn the ignition off Disconnect the 5 5 switch harness connector Turn the ignition on Connect jumper wire between the S C Switch Signal circuit and the Sensor Ground at the ON OFF SET Switch harness connector With the DRB 111 read the S C Switch volts Does the DRB 111 display below 0 5 volt Yes Replace the S C ON OFF SET Switch Perform SPEED CONTROL VERIFICATION VER 4 No GoTo 4 104 DRIVEABILITY DIESEL P0579 S C SWITCH SIGNAL CIRCUIT SIGNAL VOLTAGE TOO HIGH Continued ACTION AP
132. TION VER 2 No Test Complete 31 DRIVEABILITY DIESEL Symptom P0115 E NGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLT AGE TOO LOW When Monitored and Set Condition 0115 COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW When Monitored With the ignition on Set Condition The Engine Coolant Temperature Sensor Signal voltage is below 0 2 volt for more than 1 second POSSIBLE CAUSES INTERMITTENT CONDITION ECT SENSOR ECT SENSOR SIGNAL CIRCUIT SHORTED TO GROUND ECT SENSOR SIGNAL AND GROUND CIRCUITS SHORTED TOGETHER ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB monitor the Engine Coolant Temperature ECT Sensor voltage Is the ECT Sensor voltage below 0 3 volt Yes GoTo 2 No GoTo 6 Turn the ignition off Disconnect the ECT Sensor harness connector Turn the ignition on With the DRB read the ECT Sensor voltage Is the voltage above 4 0 volts Yes Replace the ECT Sensor in accordance with the Service Informa tion Perform ROAD TEST VERIFICATION VER 2 GoTo 3 Turn the ignition off Disconnect the ECM harness connectors Disconnect the ECT Sensor harness connector Measure the resistance between ground and the ECT Sensor Signal circuit 15 the resistance above 1000 ohms Yes GoTo 4 No Repair the ECT Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 32 DRIVEABILITY DIESEL
133. TION VER 2 No Test Complete 77 DRIVEABILITY DIESEL Symptom PO460 FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE HIGH When Monitored and Set Condition P0O460 F UEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition The Fuel Level Sensor Signal voltage is above 4 70 volts POSSIBLE CAUSES INTERMITTENT CONDITION FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE FUEL LEVEL SENSOR SIGNAL CIRCUIT OPEN FUEL LEVEL SENSOR GROUND CIRCUIT OPEN FUEL LEVEL SENSOR ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes GoTo 2 No GoTo 7 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Fuel Level Sensor harness connector Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage on the Fuel Level Sensor Signal circuit 15 the voltage below 0 5 volt Yes GoTo 3 No Repair the Fuel Level Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 78 DRIVEABILITY DIESEL P0O460 F UEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the ECM har
134. TOO HIGH P0620 GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVIATION TOO LOW P0620 GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO HIGH P0620 GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO LOW P0620 GENERATOR FIELD CONTROL MALF CHARGING VOLTS TOO LOW P0620 GENERATOR FIELD CONTROL MALF OPEN CIRCUIT P0620 GENERATOR FIELD CONTROL MALF SHORT CIRCUIT P0620 GENERATOR FIELD CONTROL MALF UNSTABLE CUR RENT Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will PO620 GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVIATION TOO HIGH E When Monitored and Set Condition P0620 GE RATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO HIGH When Monitored With the engine running Set Condition The ECM senses battery voltage above 16 5 volts P0620 GE NERATOR FIELD CONTROL MALF CHARGING VOLTS TOO LOW When Monitored With the engine running Set Condition The ECM senses battery voltage that is 1volt or more below desired charging voltage P0620 GE NERATOR FIELD CONTROL MALF OPEN CIRCUIT When Monitored With the ignition on Set Condition The ECM detects an open or short to ground on the Generator Field Control circuit 108 DRIVEABILITY DIESEL P0620 GE NE FIELD CONTROL BATTERY VOLTAGE DEVI ATION TOO HIGH Continued 620 FIELD CONTROL SHORT CIRCUIT When Monitored With the ignition on Set Condition TheECM detects short
135. TOO LOW P1512 BATTERY SENSE LINE 2 VOLTAGE TOO HIGH P1512 BATTERY SENSE LINE 2 VOLTAGE TOO LOW Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P1511 BATTERY SENSE LINE 1 VOLTAGE TOO HIGH When Monitored and Set Condition P1511 BATTERY SENSE LINE 1 VOLTAGE TOO HIGH When Monitored With the ignition on or the engine running Set Condition The ECM detects Battery Sense circuit voltage above 17 50 volts P1511 BATTERY SENSE LINE 1 VOLTAGE TOO LOW When Monitored With the ignition on or the engine running Set Condition The ECM detects Battery Sense circuit voltage below 7 98 volts P1512 BATTERY SENSE LINE 2 VOLTAGE TOO HIGH When Monitored With the ignition on or the engine running Set Condition The ECM detects Battery Sense circuit voltage above 17 50 volts P1512 BATTERY SENSE LINE 2 VOLTAGE TOO LOW When Monitored With the ignition on or the engine running Set Condition The ECM detects Battery Sense circuit voltage below 7 98 volts POSSIBLE CAUSES INTERMITTENT CONDITION FUSE 26 OPEN ECM GROUND CIRCUIT S OPEN BATTERY SENSE CIRCUIT SHORTED TO VOLTAGE BATTERY SENSE CIRCUIT OPEN BATTERY SENSE CIRCUIT SHORTED TO GROUND BATTERY SENSE CIRCUIT OPEN ENGINE CONTROL MODULE 143 DRIVEABILITY DIESEL 1511 SENSE LINE 1 VOLTAGE TOO HIGH Continued ACTION APPLICABILITY NOTE If DTC 560 5 5 VOLTAGE TOO HIGH is present wit
136. TTERY VOLTAGE DEVIATION TOO 7 108 P0620 GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVIATION TOO DOW snd aaa 108 P0620 GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO HIGH 108 P0620 GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO LOW 108 P0620 GENERATOR FIELD CONTROL MALF CHARGING VOLTS TOO LOW 108 P0620 GENERATOR FIELD CONTROL MALF OPEN CIRCUIT 108 P0620 GENERATOR FIELD CONTROL MALF SHORT 108 P0620 GENERATOR FIELD CONTROL MALF UNSTABLE CURRENT 108 P0641 SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO HIGH 112 P0641 SENSOR REFERENCE VOLTAGE VOLTAGE TOO LOW 114 P0645 A C CLUTCH RELAY CIRCUIT OPEN CIRGUIT 116 P0645 A C CLUTCH RELAY CIRCUIT SHORT CIRCUIT 02 000 050006 118 P0651 SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO HIGH 120 P0651 SENSOR REFERENCE VOLTAGE VOLTAGE LOW 122 P0685 ASD RELAY CONTROL CIRCUIT SHUTS OFF TOO EARLY 125 P0685 ASD RELAY CONTROL CIRCUIT SHUTS OFF LATE 127 P0703 BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH REDUNDANT CONTACT 129 P0703 BRAKE SWITCH SIGNAL CKTS PLAUS W REDUNDANT CONTACT AFTER INITIALIZATION oe Khe bene neta ds 129 P0836 TRANSFER CASE POSIT
137. Temperature Sensor Signal circuit a 1850 Bus message is sent to the ECM to set this DTC 70 AIR TEMPERATURE CIRCUIT SIGNAL VOLTAGE TOO LOW When Monitored With the ignition on Set Condition When the BCM detects low voltage on the Ambient Air Temperature Sensor Signal circuit a 1850 Bus message is sent to the ECM to set this DTC POSSIBLE CAUSES REFER TO COMPASS MINI TRIP COMPUTER SYMPTOM INTERMITTENT CONDITION ACTION APPLICABILITY NOTE The Ambient Air Temperature Sensor is hardwired to the Body All Control Module BCM The Ambient Air Temperature Circuit DTCs are set in the ECM via the J 1850 Bus by the BCM Turn the ignition on With the DRBIII erase the ECM DTCs Cycle the ignition switch from OFF to ON Monitor the DRBIII for ECM DTCs Does the 2 display this DTC Yes Refer tosymptom TEMP DISPLAY OR WRONG in the Compass Mini Trip Computer category in the Body Diag nostic Information Perform ROAD TEST VERIFICATION VER 2 GoTo 2 DRIVEABILITY DIESEL 070 AIR TEMPERATURE CIRCUIT SIGNAL VOLTAGE HIGH Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identif
138. Turn the ignition on With the III erase ECM DTCs Cycle the ignition key on and off several times leaving the key on for at least 10 seconds at a time With the DRB III read ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 6 Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Measure the voltage of the Fuel Pressure Sensor Signal circuit Is the voltage between 4 7 and 5 3 volts Yes Replace the Fuel Pressure Sensor Perform ROAD TEST VERIFICATION VER 2 GoTo 3 38 DRIVEABILITY DIESEL P0O190 FUEL PRESS SENSOR CIRCUIT SIGNAL VOLTAGE LOW Continued ACTION APPLICABILITY Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the Fuel Pressure Sensor Signal circuit Is the resistance above 100 kohms Yes GoTo 4 No Repair the Fuel Pressure Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between the Sensor Ground circuit and the Fuel Pressure Sensor Signal circuit 15 the resistance above 100 kohms Yes GoTo 5 No Repair the Fuel Pressure Sensor Signal circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION
139. UEL INJECTOR NO 4 CONTROL 116 2 5mmDB BK COMMON INJECTOR DRIVER 117 4 7 118 2 5mmWT DB FUEL INJECTOR NO 1 CONTROL 119 K12 2 5mmTN FUEL INJECTOR NO 2 CONTROL 120 K13 2 5mmYL WT FUEL INJECTOR NO 3 CONTROL 121 a LT GRAY 8 ENGINE COOLANT LEVEL SENSOR DIESEL LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 G18 18PK BK COOLANT LEVEL SENSOR SIGNAL ENGINE COOLANT 2 7246 18BK GY SENSOR GROUND LEVEL SENSOR DIESEL 220 ENGINE COOLANT TEMP SENSOR DIESEL 3 25 1 ENGINE OIL PRESSURE SENSOR FUEL HEATER DIESEL FUEL INJECTOR NO 1 DIESEL CONNECTOR PINOUTS ENGINE COOLANT TEMP SENSOR DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K2 20TN BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 2 18BK LB SENSOR GROUND ENGINE OIL PRESSURE SENSOR BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K6 18VT WT SENSOR REFERENCE VOLTAGE B 2 G60 20GY YL DIESEL ENGINE OIL PRESSURE SENSOR SIGNAL 2 G60 18GY YL GAS ENGINE OIL PRESSURE SENSOR SIGNAL 3 K4 18BK LB SENSOR GROUND N N E T FUEL HEATER DIESEL BLACK 2 WAY o CAV CIRCUIT FUNCTION 1 A93 16RD BK FUEL HEATER RELAY OUTPUT R 2 Z246 16BK GY GRO
140. UND P U T 5 FUEL INJECTOR NO 1 DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K63 2 5mmDB BK COMMON INJECTOR DRIVER 2 11 2 5mmWT DB FUEL INJECTOR NO 1 CONTROL 221 CONNECTOR PINOUTS FUEL INJECTOR DIESEL N N E R 4 7 FUEL PRESSURE SENSOR DIESEL FUEL INJECTOR NO 2 DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 2 5mmDB BK COMMON INJECTOR DRIVER 2 12 2 5 FUEL INJECTOR NO 2 CONTROL FUEL INJECTOR NO 3 DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 2 5mmDB BK COMMON INJECTOR DRIVER 2 K13 2 5mm YL WT FUEL INJECTOR NO 3 CONTROL FUEL INJECTOR NO 4 DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 2 5mm DB BK COMMON INJECTOR DRIVER 2 K14 2 5mmLB BR FUEL INJECTOR NO 4 CONTROL FUEL PRESSURE SENSOR DIESEL BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K80 20BK VT FUEL PRESSURE SENSOR GROUND 2 K78 20GY FUEL PRESSURE SENSOR SIGNAL 3 K7 200R FUEL PRESSURE SENSOR 5 VOLT SUPPLY 222 FUEL PRESSURE SOLENOID DIESEL LT GRAY GENERATOR BLACK GENERATOR FUEL PRESSURE SOLENOID DIESEL BLACK 2 WAY CONNECTOR PINOUTS
141. URE SENSOR FUEL PRESSURE SENSOR 5 VOLT SUPPLY CIRCUIT OPEN FUEL PRESSURE SENSOR SIGNAL CIRCUIT OPEN FUEL SUPPLY CONTAMINATION FUEL SYSTEM PRESSURE MECHANICAL FUEL SYSTEM RESTRICTION SENSOR GROUND OPEN ACTION APPLICABILITY Turn the ignition on All With the DRBIII read the ECM DTCs Does the DRBII display ECM DTCs Yes Refer to symptom list for problems related to ECM DTC Perform NO START VERIFICATION 1 GoTo 2 Turn the ignition on With the DRBIII read the SKIM DTCs Does the DRBIII display any SKIM DTCs Yes Refer to symptom list for problems related to SKIM DTC Perform NO START VERIFICATION 1 No GoTo 3 188 DRIVEABILITY DIESEL ENGINE CRANKS BUT WILL NOT START Continued ACTION APPLICABILITY Using a temperature probe check the vehicle temperature near the ECT Sensor All Turn the ignition on With the DRBIII in Sensors read the ECT Sensor temperature Compare the temperature probe reading with the DRBIII reading Are the two readings within 10 C of each other Yes GoTo 4 No Repair as necessary Perform NO START VERIFICATION VER 1 NOTE Prior to performing this test be sure to check the Glow Plug Relay operation Refer to CHECKING GLOW PLUG OPERATION for the related sympton s Refer to the Service Information and check the Glow Plugs for proper operation Are the Glow Plugs operating properly Yes GoTo 5
142. VER 1 Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Fuel Pressure Sensor Signal circuit 15 the resistance below 10 0 ohms Yes GoTo 14 No Repair the Fuel Pressure Sensor Signal circuit an open Perform NO START VERIFICATION VER 1 190 DRIVEABILITY DIESEL ENGINE CRANKS BUT WILL NOT START Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Fuel Pressure Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Fuel Pressure Sensor 5 volt Supply circuit Is the resistance below 10 0 ohms Yes GoTo 15 No Repair theFuel Pressure Sensor 5 volt Supply circuit for an open Perform NO START VERIFICATION VER 1 Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Sensor Ground circuit 15 the resistance below 10 0 ohms Yes Replace the Fuel Pressure Sensor in accordance with the Service Information Perform NO START VERIFICATION 1 Repair the Sensor Ground circuit for an open Perform NO START VERIFICATION VER 1 191 DRIVEABILITY DIESEL Symptom ENGINE WILL NOT CRANK POSSIBLE CAUSES BATTERY CABLE HIGH RESISTANCE CHECKING FOR SKIM CODES CLUTCH INTERLOCK SWITCH CLUTCH INTERLOCK SWITCH OUTPUT CIRCU
143. VER 2 If there no possible causes remaining view repair All Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 39 DRIVEABILITY DIESEL Symptom P0O190 FUEL PRESS SENSOR CIRCUIT MALF SUPPLY VOLTAGE TOO HIGH OR LOW When Monitored and Set Condition 0190 PRESS SENSOR CIRCUIT SUP
144. VER 2 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the BCM harness connectors Turn the ignition on Connect one end of a jumper wire to the Vehicle Speed Signal circuit With the DRB select isolate and observe the Vehicle Speed status while tapping the other end of the jumper wire to ground Does the DRB display a vehicle speed change while tapping the jumper wire to ground Yes Replace and program the Body Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the BCM harness connectors Disconnect the ECM harness connectors Measure the resistance between ground and the Vehicle Speed Signal circuit 15 the resistance above 100 kohms Yes GoTo 9 No Repair the Vehicle Speed Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 85 DRIVEABILITY DIESEL 5 SPEED SENSOR FREQUENCY TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the BCM harness connectors Disconnect the ECM harness connectors Measure the resistance of the Vehicle Speed Signal circuit Is the resistance below 5 0 ohms
145. W PLUG RELAY 2 CONTROL CIRCUIT SHORTED TO VOLTAGE GLOW PLUG RELAY 2 CONTROL CIRCUIT SHORTED TO GROUND GLOW PLUG RELAY 2 CONTROL CIRCUIT OPEN ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB actuate Glow Plug Relay 2 Is Glow Plug Relay 2 clicking Yes GoTo 2 GoTo 3 71 DRIVEABILITY DIESEL P0382 GLOW PLUG 2 CONTROL CIRCUIT OPEN CIRCUIT Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER
146. With the DRB read the Boost Pressure Sensor voltage 15 the Boost Pressure Sensor voltage above 4 5 volts Yes Replace the Boost Pressure Intake Air Temperature Sensor Perform ROAD TEST VERIFICATION VER 2 GoTo 4 51 DRIVEABILITY DIESEL P0235 BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the Boost Pressure Sensor Signal circuit Is the resistance above 100 kohms Yes GoTo 5 No Repair the Boost Pressure Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between the Boost Pressure Sensor Signal circuit and Sensor Ground circuit 15 the resistance above 100 kohms Yes GoTo 6 Repair the Boost Pressure Sensor Signal circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Boost Pressure Sensor Signal circuit 15 the resistance below 5 0 ohms Yes GoTo 7 No Repair the Boost Pressure Sensor Signal circu
147. YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Start the engine Is the voltage on the voltmeter below 0 4 volt Yes GoTo 3 No Repair the Generator Fused B circuit for high resistance Perform CHARGING VERIFICATION VER 3 Connect the positive lead of a voltmeter to the generator case housing and the negative lead to the battery negative post WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Start the engine Is the voltage on the voltmeter below 0 4 volt Yes GoTo 4 No Repair the Generator Ground circuit for high resistance Perform CHARGING VERIFICATION VER 3 No GoTo 6 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually in
148. Yes GoTo 10 No Repair the Vehicle Speed Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 86 DRIVEABILITY DIESEL Symptom 0514 TEMP SENSOR CIRCUIT SIGNAL VOLTAGE HIGH When Monitored and Set Condition P0514 BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition The ECM detects Battery Temperature Sensor Signal voltage above 4 72 volts POSSIBLE CAUSES INTERMITTENT CONDITION BATTERY TEMPERATURE SENSOR GROUND CIRCUIT OPEN BATTERY TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE BATTERY TEMPERATURE SENSOR BATTERY TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB monitor the Battery Temperature Sensor voltage 15 the voltage above 4 5 volts Yes GoTo 2 GoTo 6 Turn the ignition off Disconnect the Battery Temperature Sensor harness connector Turn the ignition on Measure the voltage on the Battery Temperature Sensor Signal circuit 15 the voltage above 5 5 volts Yes Repair the Battery Temperature Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 3 87 DRIVEABILITY
149. Yes GoTo 2 No GoTo 10 34 DRIVEABILITY DIESEL P0O190 FUEL PRESS SENSOR CIRCUIT SIGNAL VOLTAGE HIGH Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Fuel Pressure Sensor harness connector Turn the ignition on Measure the voltage of the Fuel Pressure Sensor Signal circuit Select the appropriate voltage reading Voltage is above 5 5 volts GoTo 3 Voltage is between 4 7 and 5 4 volts GoTo 4 Voltage is below 4 7 volts GoTo 9 Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the Fuel Pressure Sensor Signal circuit 15 the voltage below 1 0 volt Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the Fuel Pressure Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Fuel Pressure Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Sensor Ground circuit 15 the resistance below 5 0 ohms Yes GoTo 5 No Repair the Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off
150. Yes GoTo 7 No Repair theGlow Plug Relay 1 Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove Glow Plug Relay 1 from the PDC Disconnect the ECM harness connectors Measure the resistance of the Glow Plug Relay 1 Control circuit Is the resistance below 10 0 ohms Yes GoTo 8 No Repair the Glow Plug Relay 1 Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 70 DRIVEABILITY DIESEL Symptom List P0382 GLOW PLUG 2 CONTROL CIRCUIT OPEN CIRCUIT P0382 GLOW PLUG 2 CONTROL CIRCUIT SHORT CIRCUIT Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will PO382 GLOW PLUG 2 CONTROL CIRCUIT OPEN CIRCUIT When Monitored and Set Condition P0382 GLOW PLUG 2 CONTROL CIRCUIT OPEN CIRCUIT When Monitored With the ignition on Set Condition TheECM does not detect voltage on the Glow Plug Relay 2 Control circuit P0382 GLOW PLUG 2 CONTROL CIRCUIT SHORT CIRCUIT When Monitored With the ignition off Set Condition The ECM detects excessive current on the Glow Plug Relay 2 Control circuit POSSIBLE CAUSES INTERMITTENT CONDITION ASD RELAY OUTPUT CIRCUIT OPEN SUBSTITUTE GLOW PLUG RELAY 2 GLO
151. accordance with the Service Information Perform SPEED CONTROL VERIFICATION 4 No Therepair is complete Perform SPEED CONTROL VERIFICATION 4 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform SPEED CONTROL VERIFICATION VER 4 No Test Complete 103 DRIVEABILITY DIESEL Symptom P0579 S C SWITCH SIGNAL CIRCUIT SIGNAL VOLTAGE HIGH POSSIBLE CAUSES ECM S C SIGNAL CIRCUIT OPEN ECM S C SIGNAL CIRCUIT SHORTED TO VOLTAGE ECM SENSOR GROUND OPEN S C 5 SWI
152. accordance with the Service Information With the DRBIII erase the ECM DTCs Test drive the vehicle With the DRBIII read the ECM DTCs Does the DRBIII display this DTC Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Therepair is complete Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 45 DRIVEABILITY DI
153. age below 0 5 volt Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the ASD Relay Output circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 128 DRIVEABILITY DIESEL Symptom List 703 SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH REDUNDANT CONTACT 703 SWITCH S
154. ail pressure sensor indicates fuel pressure above 21 000 PSI with the engine off P1130 FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO LOW When Monitored With the engine running Set Condition The ECM determines that the fuel rail pressure is too low for a given engine speed P1130 FUEL RAIL PRESSURE MALFUNCTION SOLENOID OPEN When Monitored With the engine running Set Condition The ECM detects a higher rate of fuel pressure than the target pressure POSSIBLE CAUSES CHECKING FOR OTHER DTC S CHECKING THE FUEL PRESSURE FUEL INJ ECTOR CONTROL CIRCUIT SHORTED TO GROUND FUEL PRESSURE SENSOR FUEL SYSTEM LEAK DRIVEABILITY DIESEL P1130 FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED Continued POSSIBLE CAUSES INJ ECTOR COMMON DRIVER CIRCUIT OPEN INTERMITTENT CONDITION APPLICABILITY WARNING THE FUEL INJ ECTION PUMP SUPPLIES HIGH PRESSURE FUEL TO EACH INDIVIDUAL INJ ECTOR THROUGH HIGH PRESSURE FUEL LINES FUEL UNDER HIGH PRESSURE CAN PENETRATE SKIN AND CAUSE PERSONAL URY WEAR SAFETY GOGGLES AND ADE QUATE PROTECTIVE CLOTHING Turn the ignition on With the DRBIII read the ECM DTCs Are there any other DTC s present Yes Refer tosymptom list for problems related to the DTC other than P1130 No GoTo 2 Turn the ignition on With the DRBIII erase the ECM DTCs Test drive the vehicle under various load and speed conditions to attempt to duplicate the fault With the DRBIII
155. and with the DRBIII erase all Diagnostic Trouble Codes from ALL modules Start the engine and allow it to run for 2 minutes and fully operate the system that was malfunctioning 17 Turn the ignition off and wait 5 seconds Turn the ignition on and using the DRBIII read DTC s from ALL modules present or is the original complaint still present Yes Repair is not complete refer to the appropriate symptom No Repair is complete 205 VERIFICATION TESTS VERIFICATION TESTS Continued CHARGING VERIFICATION VER 3 APPLICABILITY 1 Inspect the vehicle to ensure that all engine components are properly installed and All connected Reassemble and reconnect components as necessary 2 With the DRB erase all diagnostic trouble codes DTCs 3 Start the engine 4 Raise the engine speed to 2000 RPM for at least 30 seconds 5 Allow the engine to idle 6 Turn the ignition off for 20 seconds 7 Turn the ignition on 8 With the DRB read ECM DTCs 9 If this DTC has reset or another DTC has set look for any Technical Service Bulletins TSBs that may relate to this condition Return to the Symptom List if necessary 10 If the charging system is functioning correctly and there are no DTCs the repair is now complete DTCs or symptoms remaining Yes Repair is not complete refer to appropriate symptom No Repair is complete NO START VERIFICATION VER 1 APPLICABILITY
156. arness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 96 DRIVEABILITY DIESEL Symptom 560 5 VOLTAGE TOO HIGH When Monitored and Set Condition P0560 SYSTEM VOLTAGE TOO HIGH When Monitored With the engine running Set Condition The ECM detects battery voltage is above 16 5 volts POSSIBLE CAUSES GROUND CIRCUIT HIGH RESISTANCE BATTERY SUPPLY OR ASD RELAY OUTPUT CIRCUIT HIGH RESISTANCE GENERATOR FIELD CONTROL CIRCUIT SHORTED TO GROUND GENERATOR INTERNALLY SHORTED TO GROUND ENGINE CONTROL MODULE APPLICABILITY NOTE The battery must be fully charged and the generator belt must be in All good condition and tensioned properly before continuing Turn the ignition off Disconnect the ECM harness connectors Using a 12 volt test light connected to 12 volts check all of the ECM Ground circuits including the Battery Sense circuit Does the test light illuminate brightly for each circuit Yes GoTo 2 No Repair the Ground circuit s for high resistance Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Using a 12 volt test light conne
157. between the Fuel Injector Control circuit and the Common Driver circuit 15 the resistance below 1000 ohms Yes Repair the Fuel Injector Control circuit and Common Driver circuit for a short together Perform ROAD TEST VERIFICATION VER 2 GoTo 7 Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Cylinder Fuel Injector harness connector Measure the resistance between ground and the Fuel Injector Control circuit 15 the resistance below 1000 ohms Yes Repair the Fuel Injector Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 44 DRIVEABILITY DIESEL PO201 CYLINDER 1 1 CIRCUIT CURRENT DECREASE Continued ACTION APPLICABILITY Turn the ignition off Disconnect the ECM harness connectors Disconnect the Cylinder Fuel Injector harness connector Measure the resistance of the Fuel Injector Control circuit Is the resistance below 10 ohms Yes GoTo 8 No Repair the Fuel Injector Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Cylinder Fuel Injector harness connector Measure the resistance of the Common Driver circuit 15 the resistance below 10 ohms Yes GoTo 9 No Repair the Common Driver circuit an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Replace the Cylinder Fuel Injector in
158. ch cycle Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes GoTo 3 GoTo 5 Turn the ignition off Install a substitute relay in place of the ASD Relay Perform several ignition key cycles pausing for at least 10 seconds between each cycle Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes GoTo 4 No Replace theASD Relay Perform ROAD TEST VERIFICATION VER 2 125 DRIVEABILITY DIESEL PO0685 ASD RELAY CONTROL CIRCUIT SHUTS OFF TOO EARLY Continued ACTION APPLICABILITY Turn the ignition off All Remove the ASD Relay from the PDC Disconnect the ECM harness connectors Measure the resistance of the ASD Relay Control circuit while wiggling the wiring harness and connectors between the ECM and the PDC Was the resistance above 5 0 ohms at any time while wiggling the wiring harness and connectors Yes Repair the ASD Relay Control circuit for an intermittent open Perform ROAD TEST VERIFICATION VER 2 Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent c
159. change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete Turn the ignition off All Disconnect the Viscous Heater Relay from the PDC Turn the ignition on Using a 12 volt test light connected to ground check the ASD Relay Output circuit at the Viscous Heater Relay connector in the PDC Does the test light illuminate brightly Yes GoTo 4 Repair the ASD Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Install a substitute relay in place of the Viscous Heater Relay Turn the ignition on With the DRB actuate the Viscous Cabin Heater Relay for at least 20 seconds With the DRB read ECM DTCs Did this DTC reset Yes GoTo 5 No Replace the Viscous Heater Relay Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Remove the Viscous Heater Relay Remove the ASD Relay from the PDC Connect a jum
160. circuit 15 the voltage above 1 0 volt Yes GoTo 5 No GoTo 6 Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage between ground and the Boost Pressure Sensor Signal circuit 15 the voltage above 1 0 volt Yes Repair the Boost Pressure Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Sensor Ground circuit 15 the resistance below 5 0 ohms Yes GoTo 7 No Repair the Boost Pressure Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors 49 DRIVEABILITY DIESEL P0235 BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off All NOTE Ensure all harness connectors are connected Turn the ignition on Measure the voltage of the Boost Pressure Sensor Signal circuit by back probing ECM harness connector C1 cavity 11 Is the voltage above 4 5 volts Yes Replace the Boost Pressure
161. cope backprobe both of the CKP Sensor Signal circuits at the ECM harness connector NOTE Refer to Charts and Graphs to view a correct CKP Sensor signal Start the engine if the engine will not start crank the engine for several seconds while monitoring the DRB Does the DRB display a steady clean CKP Signal pattern for each circuit Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace the Crankshaft Position Sensor Perform ROAD TEST VERIFICATION VER 2 60 DRIVEABILITY DIESEL Symptom List 40 CORRECTION FOR MAIN ECTION 40 POSITION SENSOR CIRCUIT SIGNAL FREQUENCY TOO HIGH 40 POSITION SENSOR CIRCUIT STATIC PLAUSIBILITY Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be 40 CORRECTION FOR MAIN INJ ECTION When Monitored and Set Condition P0340 CMP POSITION SENSOR CIRCUIT SIGNAL FREQUENCY TOO HIGH When Monitored With the engine running Set Condition detects more than three camshaft sensor signals within 10 ms time period POSSIBLE CAUSES CHECKING FOR DAMAGE ECM SENSOR GROUND CIRCUIT OPEN INTERMITTENT CONDITION VERIFY ASD RELAY OUTPUT CMP SENSOR SIGNAL CIRCUIT OPEN CMP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND CMP SENSOR OPERATION DURING CRANKING CRANK ECM SENSOR GROUND CIRCUIT OPEN CMP SENSOR S
162. ct the Starter Relay Output wire at the Starter to ground Using a 12 volt test light connected to 12 volts check the Starter Relay Output circuit at the Starter Relay connector in the PDC 194 VEHICLE THEFT SECURITY Symptom List ANTENNA FAILURE COP FAILURE EEPROM FAILURE INTERNAL FAULT RAM FAILURE SERIAL LINK INTERNAL FAULT STACK OVERFLOW FAILURE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be ANTENNA FAILURE When Monitored and Set Condition ANTENNA FAILURE When Monitored Every 250 milliseconds with the ignition on Set Condition TheSKIM s microcontroller determines that an antenna circuit fault has occurred for 2 0 consecutive seconds COP FAILURE When Monitored With the ignition on Set Condition TheCOP timer is not reset by the microcontroller every 65 5 milliseconds EEPROM FAILURE When Monitored With the ignition on Set Condition When the value written to EEPROM memory does not equal the value read back after the write operation INTERNAL FAULT When Monitored With the ignition on Set Condition 5 has detected a fault during an internal self test RAM FAILURE When Monitored With the ignition on Set Condition The RAM fails a test that checks the 5 ability to retain memory SERIAL LINK INTERNAL FAULT When Monitored With the ignition on Set Condition The SKIM fails an internal J 1850 communication self test
163. cted to ground check all of the ECM Battery Supply and ASD Relay Output circuits induding the Battery Sense circuit Does the test light illuminate brightly for each circuit Yes GoTo 3 No Repair the Battery Supply or ASD Relay Output circuit s for high resistance Perform CHARGING VERIFICATION VER 3 97 DRIVEABILITY DIESEL 560 5 VOLTAGE TOO HIGH Continued APPLICABILITY Turn the ignition off All Disconnect ECM harness connectors Disconnect the Generator Field harness connector Measure the resistance between ground and the Generator Field Control circuit 15 the resistance above 100 kohms Yes GoTo 4 No Repair the Generator Field Control circuit for a short to ground Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the Generator Field harness connector Measure the resistance between ground and the Generator Field Control terminal on the back of the Generator 15 the resistance above 100 kohms Yes Replace and program the Engine Control Module in accordance with the Service Information Perform CHARGING VERIFICATION VER 3 Repair or replace the Generator as necessary Perform CHARGING VERIFICATION VER 3 98 DRIVEABILITY DIESEL Symptom List 560 5 VOLTAGE TOO LOW CHECKING THE CHARGING SYSTEM OPERATION DIESEL Test Note All symptoms listed above are diagnosed using the same tests The
164. cuits at the CKP Sensor harness connector NOTE Refer to Charts and Graphs to view a correct CKP Sensor signal Start the engine if the engine will not start crank the engine for several seconds while monitoring the DRB Does the DRB display a steady clean CKP Signal pattern for each circuit Yes GoTo 7 No Perform Test for DTC P0340 Crankshaft Position Sensor Circuit Dynamic Plausibility Perform ROAD TEST VERIFICATION VER 2 Refer to the Service Information and check alignment of the camshaft sprocket crankshaft sprocket and injection pump sprocket Are all of the sprockets aligned correctly Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair or adjust as necessary Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off 66 DRIVEABILITY DIESEL 40 POSITION SENSOR CIRCUIT CMP CKP SYNC FAILURE Continued APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter
165. d APPLICABILITY Turn the ignition on While observing the PRIM BRAKE SWITCH status on the DRB display press and release the brake pedal several times Does the DRB display PRIM BRAKE SWITCH PRESSED and RELEASED for the appropriate pedal position Yes GoTo 2 No GoTo 11 Turn the ignition on While observing the SEC BRAKE SWITCH status on the DRB display press and release the brake pedal several times Does the DRB display SEC BRAKE SWITCH PRESSED and RELEASED for the appropriate pedal position Yes GoTo 3 GoTo 4 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed ou
166. d attempts the SKIM will stop sending the seed request and store a trouble code in memory If the ECM sends a seed response the SKIM sends a valid invalid key message to the ECM This is an encrypted message that is generated using the following e VIN Vehicle Identification Number e Seed a random number that is generated by the ECM at each ignition key The VIN and seed are two variables used in the rolling code algorithm that encrypts the valid invalid key message The ECM uses the rolling code algorithm to receive decode and respond to the valid invalid key message sent by the SKIM After sending the valid invalid key message the SKIM waits 3 5 seconds for an ECM status message from the ECM If the ECM does not respond with valid key message to the SKIM a fault is detected and a code is stored The SKIS incorporates warning lamp located in the instrument cluster The SKIS lamp is actuated when the SKIM sends a PCI Bus message to the instrument cluster requesting the lamp on off or flashing The SKIM will request lamp operation for the following bulb check at ignition on to alert the vehicle operator to a SKIS malfunc tion when the SKIM isin customer key programming mode For all faults except transponder faults the lamp remains on steady the event of a transponder fault the lamp will flash at a rate of 1Hz once per second If a fault is present the lamp will remain on or flashing for
167. d cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the 5 volt Supply circuit in the ECM harness connector Is the voltage above 1 0 volt Yes Repair the 5 volt Supply circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Low Idle Position Switch Sense circuit 15 the resistance below 10 0 ohms Yes GoTo 21 No Repair the Low Idle Position Switch Sense circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the Low Idle Position Switch Sense circuit 15 the resistance above 1000 ohms Yes GoTo 22 No Repair the Low Idle Position Switch Sense circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between the Low Idle Position Switch Sense circuit and the Sensor Ground circuit at the APP Sensor harness connector 15 the resistance above 1000 ohms Yes GoTo 23 No Repair
168. d result in severe bodily injury or death Engine Valve Timing must be within specification Engine Compression must be within specifications Camshaft Lobes check for abnormal wear Camshaft Position Sensor check the camshaft position sensor tooth for debris and deterioration Crankshaft Position Sensor check the crankshaft tone wheel for debris and deterioration Engine Exhaust System must be free of any restriction Engine Drive Sprocket must be properly positioned Power Brake Booster must be free of any vacuum leaks Fuel must have adequate supply and must be free of contamination and gasoline Fuel Injectors must not be plugged or restricted Fuel Injection Pump must be producing the correct output volume and pressure Inspect the Fuel Lines Fuel Filter and Fuel Pressure Relief Valve for signs of restriction and leaks NOTE Check for any Technical Service Bulletins that may relate to the problem Are there any problems evident Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 180 DRIVEABILITY DIESEL Symptom CHECKING THE GLOW PLUG OPERATION POSSIBLE CAUSES CHECKING THE GLOW PLUGS FUSED B CIRCUIT OPEN GLOW PLUG RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE GLOW PLUG RELAY OUTPUT CIRCUIT SHORTED TO GROUND GLOW PLUG RELAY OUTPUT CIRCUIT OPEN GLOW PLUG RELAY ACTION APPLICABILITY Turn the ignition off All Disconnect the Glow Plug harness connectors for al
169. e ECM DTCs Monitor the DRB for ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 5 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Boost Pressure IAT Sensor harness connector Measure the resistance between ground and the Intake Air Temperature Sensor Signal circuit 15 the resistance above 100 kohms Yes GoTo 3 No Repair the Intake Air Temperature Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Turn the ignition on Monitor the DRB for ECM DTCs Does the display P0110 INTAKE AIR TEMP SIGNAL VOLTAGE TOO HIGH Yes Replace the Boost Air Temperature Sensor Perform ROAD TEST VERIFICATION VER 2 GoTo 4 26 DRIVEABILITY DIESEL PO110 INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW Continued ACTION APPLICABILITY If there are no possible causes remaining view repair All Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the int
170. e between the Fuel Pressure Sensor 5 Volt Supply circuit and the Sensor Ground circuit 15 the resistance above 100 kohms Yes GoTo 5 Repair the Fuel Pressure Sensor 5 Volt Supply circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary
171. ector Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the Generator Field Control circuit 15 the voltage below 1 0 volt Yes GoTo 8 No Repair the Generator Field Control circuit for a short to voltage Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Generator Field harness connector Measure the resistance of the Generator Field Control circuit 15 the resistance below 5 0 ohms Yes GoTo 9 No Repair the Generator Field Control circuit for an open Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the generator harness connector Turn the ignition on Measure the voltage of the Fused ASD Relay Output circuit Is the voltage above 10 0 volts Yes GoTo 10 No Repair the Fused ASD Relay Output circuit for an open Perform CHARGING VERIFICATION VER 3 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform CHARGING VERIFICATION VER 3 101 DRIVEABILITY DIESEL Symptom P0579 S C SWITCH SIGNAL CIRCUIT PLAUSIBILITY POSSIBLE CAUSES INTERMITTENT CONDITION HIGH RESISTANCE IN THE S C SWITCH SIGNAL CIRCUIT HIGH RESISTANCE IN THE S C SWITCH GROUND CIRCUIT S C SWITCHES ENGI
172. ely dies stalls engine rpm fluctuation without cor responding change in accelerator pedal position signal range check water in fuel sensor vehicle speed sensor 7 0 DIAGNOSTIC INFORMATION AND PROCEDURES COMMUNICATION Symptom NO RESPONSE FROM ECM PCI BUS DIESEL ONLY POSSIBLE CAUSES ECM NO RESPONSE PCI BUS CIRCUIT OPEN ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All NOTE As soon as one or more module communicates with the DRB answer the question With the DRB enter Body then Body Computer With the DRB enter Anti Lock Brakes With the DRB enter Body then Electro M echanical Cluster MIC With the DRB enter Passive Restraints then Airbag Were you able to establish communications with any of the modules Yes GoTo 2 Refer to symptom PCI Bus Communication Failure in the Com munications category Perform ROAD TEST VERIFICATION VER 2 With the DRB read ECM Diagnostic Trouble Codes This is to ensure power and grounds to the ECM are operational NOTE If the DRB will not read DTC s follow the NO RESPONSE ECM SCI only symptom path Turn the ignition off Disconnect the ECM harness connectors Use Scope input cable CH 7058 Cable to Probe adapter CH 7062 and the red and black test probes Connect the scope input cable to the channel one connector on the Attach the red and black leads and the cable to probe adapter to the scope input
173. epressed Yes Test Complete No Replace theAccelerator Pedal Position Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 175 DRIVEABILITY DIESEL Symptom CHECKING THE BOOST PRESSURE SENSOR CALIBRATION POSSIBLE CAUSES TURBOCHARGER BOOST PRESSURE SENSOR CALIBRATION ACTION APPLICABILITY Allow the engine to idle All With the DRBIII select Engine then Sensors Read the Boost Pressure Voltage 15 the Boost Pressure Voltage between 1 50 and 2 00 volts Yes Test Complete No Replace the Turbocharger Boost Pressure Sensor Perform ROAD TEST VERIFICATION VER 2 176 DRIVEABILITY DIESEL Symptom CHECKING THE ECM POWER AND GROUND CIRCUITS POSSIBLE CAUSES ASD RELAY OUTPUT CIRCUIT S OPEN ECM GROUND CIRCUIT S OPEN FUSED ASD RELAY BATTERY SUPPLY CIRCUIT OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN APPLICABILITY Turn the ignition off Disconnect the ECM harness connectors Using a 12 volt test light connected to 12 volts check both of the ECM ground circuits in ECM harness connector C1 cavities 1 and 2 Did the test light illuminate for both cavities Yes GoTo 2 No Repair the ECM Ground circuit s for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Turn the ignition on Using a 12 volt test light connected to ground check the Fused Ignition Switch
174. er Case Position Sensor Signal circuit for open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off to the lock position Disconnect the ECM harness connectors Disconnect the Transfer Case Position Sensor harness connector Measure the resistance between ground and the Transfer Case Position Sensor Signal circuit 15 the resistance below 1000 0 ohms Yes Repair the Transfer Case Position Sensor Signal circuit for short to ground Perform ROAD TEST VERIFICATION VER 2 GoTo 5 134 DRIVEABILITY DIESEL 836 5 CASE POSITION SENSOR PLAUSIBILITY Continued ACTION APPLICABILITY Turn the ignition off to the lock position All Disconnect the ECM harness connectors Disconnect the Transfer Case Position Sensor harness connector Measure the resistance between the Transfer Case Position Sensor circuit and the Sensor Ground circuit Is the resistance below 1000 0 ohms Yes Repair the Transfer Case Position Sensor Signal circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 GoTo 6 Turn the ignition on With the DRBIII read the T case Sensor Observe the T case volts on the DRB while moving the transfer case selector lever in each of the transfer case positions NOTE When shifting the transfer case selector to each position the Sensor voltage should result in the following voltages 4WD Low 0 15 0 40 Neutral 0 68 0 98 4WD
175. erform ROAD TEST VERIFICATION VER 2 No GoTo 6 Turn the ignition off Disconnect the CMP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Sensor Ground circuit between the CMP Sensor harness connector and the ECM harness connector 15 the resistance below 10 0 ohms Yes GoTo 7 No Repair the Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the CMP Sensor harness connector Turn the ignition on Measure the voltage of the CMP Sensor Signal circuit 15 the voltage above 10 0 volts Yes GoTo 5 No GoTo 10 62 DRIVEABILITY DIESEL 40 CORRECTION FOR MAIN ECTION Continued ACTION APPLICABILITY Turn the ignition on All Disconnect the IAT Boost Pressure Sensor harness connector Disconnect the Camshaft Position Sensor harness connector Connect one of a jumper wire to the ATSensor signal circuit in the AT Boost Pressure Sensor harness connector Connect the other end of the jumper wire to the Sensor Ground circuit in the Camshaft Position Sensor harness connector With the III in Engine Sensors read the Intake Air Temp volts 15 the voltage below 1 0 volt Yes GoTo 8 No Replace and program the ECM in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove the CMP Sensor Inspec
176. ermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 27 DRIVEABILITY DIESEL Symptom 115 COOLANT TEMP SENSOR CIRCUIT ENGINE 15 COLD TOO LONG When Monitored and Set Condition 0115 COOLANT TEMP SENSOR CIRCUIT ENGINE IS COLD TOO LONG When Monitored With the engine running Set Condition The engine temperature fails to reach 80 C 176 within 20 minutes of startup POSSIBLE CAUSES ENGINE COLD TOO LONG APPLICABILITY Note The best way to diagnose this DTC is to allow the vehicle to remain All outside overnight in order to have a completely cold soaked engine Note Extremely cold outside ambient temperatures may cause this DTC to set Verify that the coolant
177. es Replace the Sensor that when disconnected caused the sensor readings to rise Perform ROAD TEST VERIFICATION VER 2 GoTo 3 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Boost Pressure Sensor and Engine Oil Pressure Sensor harness connectors Measure the resistance between ground and the Sensor Reference Voltage B circuit 15 the resistance above 100 kohms Yes GoTo 4 No Repair the Sensor Reference Voltage circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Engine Oil Pressure Sensor harness connector Measure the resistance between the Sensor Reference Voltage B circuit and the Oil Pressure Sensor Ground circuit Disconnect the Boost Pressure Sensor harness connector Measure the resistance between the Sensor Reference Voltage circuit and the Boost Pressure Sensor Ground circuit Is the resistance above 100 kohms for both measurements Yes GoTo 5 No Repair the Sensor Reference Voltage circuit for a short to the Sensor Ground circuit that measured below 100 kohms Perform ROAD TEST VERIFICATION VER 2 123 DRIVEABILITY DIESEL P0651 SENSOR REFERENCE VOLTAGE VOLTAGE TOO LOW Continued ACTION APPLICABILITY Turn the ignition off Disconnect the ECM harness connectors Disconnect the Accelerator Pedal Position Sensor harness con
178. es Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 33 DRIVEABILITY DIESEL Symptom P0O190 FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH I When Monitored and Set Condition P0190 FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition The Fuel Rail Pressure Sensor Signal voltage is above 4 8 volts POSSIBLE CAUSES ECM FUEL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE ECM FUEL PRESSURE SENSOR SIGNAL OPEN FUEL PRESSURE SENSOR SIGNAL CIRCUIT OPEN FUEL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE SENSOR GROUND CIRCUIT OPEN INTERMITTENT CONDITION 5 VOLT SUPPLY CIRCUIT OPEN SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE FUEL PRESSURE SENSOR ENGINE CONTROL MODULE ACTION APPLICABILITY WARNING THE FUEL INJ ECTION PUMP SUPPLIES HIGH PRESSURE All FUEL TO EACH INDIVIDUAL INJECTOR THROUGH HIGH PRESSURE FUEL LINES FUEL UNDER HIGH PRESSURE CAN PENETRATE SKIN AND CAUSE PERSONAL INJ URY WEAR SAFETY GOGGLES AND ADE QUATE PROTECTIVE CLOTHING Turn the ignition on With the DRB III erase ECM DTCs Cycle the ignition key on and off several times leaving the key on for at least 10 seconds at a time With the III read ECM DTCs Did this DTC reset
179. f Note Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any Technical Service Bulletins TSB that may apply Were any problems found Yes Repair wiring harness connectors as necessary Perform SKIS VERIFICATION No Test Complete 200 VEHICLE THEFT SECURITY Symptom List TRANSPONDER COMMUNICATION FAILURE TRANSPONDER CYCLIC REDUNDANCY CHECK CRC FAILURE TRANSPONDER ID MISMATCH TRANSPONDER RESPONSE MISMATCH Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be TRANSPONDER COMMUNICA TION FAILURE When Monitored and Set Condition TRANSPONDER COMMUNICATION FAILURE When Monitored At ignition on and during Key Programming Mode Set Condition When the SKIM does not receive a transponder response after 8 consec utive transponder read attempts within 2 0 seconds TRANSPONDER CYCLIC REDUNDANCY CHECK CRC FAILURE When Monitored At ignition on and during Key Programming Mode Set Condition When 5 consecutive transponder signal transmissions are sent to the SKIM with the correct message format but with invalid data TRANSPONDER ID MISMATCH When Monitored At ignition on and during Key Programming Mode Set Condition When the transponder ID read by the SKIM does not ma
180. g Relay 2 Control circuit Is the resistance above 1000 ohms Yes GoTo 7 No Repair theGlow Plug Relay 2 Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove Glow Plug Relay 2 from the PDC Disconnect the ECM harness connectors Measure the resistance of the Glow Plug Relay 2 Control circuit Is the resistance below 10 0 ohms Yes GoTo 8 No Repair the Glow Plug Relay 2 Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 73 DRIVEABILITY DIESEL Symptom P0403 EGR SOLENOID CIRCUIT OPEN CIRCUIT When Monitored and Set Condition P0403 EGR SOLENOID CIRCUIT OPEN CIRCUIT When Monitored With the ignition on Set Condition TheECM detects an open or short to ground on the EGR Solenoid Control circuit POSSIBLE CAUSES INTERMITTENT CONDITION ASD RELAY OUTPUT CIRCUIT OPEN EGR SOLENOID CONTROL CIRCUIT SHORTED TO GROUND EGR SOLENOID CONTROL CIRCUIT OPEN SUBSTITUTE EGR SOLENOID ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Perform several ignition cycles turning the ignition off for at least 10 seconds between each ignition cycle Monitor the DRB for ECM DTCs Did thi
181. ge on the Clutch Relay Control circuit when the relay is commanded off P1830 CLUTCH OVER RIDE RELAY CIRCUIT SHORTED When Monitored When the ignition on Set Condition TheECM detects too much current on the Clutch Interlock Relay Control circuit when attempting to command the relay on POSSIBLE CAUSES INTERMITTENT CONDITION IGNITION SWITCH OUTPUT CIRCUIT OPEN SUBSTITUTE CLUTCH INTERLOCK RELAY CLUTCH INTERLOCK RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE CLUTCH INTERLOCK RELAY CONTROL CIRCUIT SHORTED TO GROUND CLUTCH INTERLOCK RELAY CONTROL CIRCUIT OPEN ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB actuate the Clutch Interlock Relay Is the Clutch Interlock Relay clicking Yes GoTo 2 GoTo 3 157 DRIVEABILITY DIESEL P1830 CLUTCH OVER RIDE RELAY CIRCUIT OPEN Continued APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the
182. guide for instructions and assistance with reading the DTCs erasing the DTCs lab scope usage and other DRBIII func tions 3 4 1 DRBIII DOES NOT POWER UP If the LEDs do not light no sound is emitted at start up check for loose cable connections or a bad cable Check the vehicle battery voltage at data link connector cavity 16 A minimum of 11 0 volts is required to adequately power the DRBIII Check for proper ground connection at data link connector cavities 4 and 5 If all connections are proper between the DRBIII and the vehicle or other devices and the vehicle battery is fully charged an inoperative DRBIII may be the result of a faulty cable or vehicle wiring For a blank screen refer to the appropriate diagnostic manual 3 4 2 DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display Adjust the contrast to compensate for this condition DRB III DISPLAY REPLACEABLE LENS ENTER KEYS LEDs CONTRAST gt with YES key QOS with YES key KEYPAD SHIFT KEY LED 80b57566 BACK LIGHTING 4 0 DISCLAIMERS SAFETY WARNINGS 4 1 DISCLAIMERS All information illustrations and specifications contained in this manual are based on the latest information available at the time of publication The right is reserved to make changes at any time without notice 4 2 SAFETY 4 2 1 TECHNICIAN SAFETY INFORMATION WARNING ENGINES PRODUCE CARBON MONOXIDE THAT IS O
183. h this DTC perform diagnostics for P0560 first Turn the ignition on With the DRBIII erase the ECM DTCs Test drive the vehicle With the DRBIII read the ECM DTCs Does the 2 display this DTC Yes GoTo 2 GoTo 9 Turn the ignition off Remove and inspect Fuse 26 from the PDC Is the fuse OK Yes GoTo 3 No Repair theshort that caused the fuse to open and replace the fuse Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the ECM harness connectors Using a 12 volt test light connected to 12 volts check both of the ECM ground circuits in ECM harness connector 1 cavities 1 and 2 Did the test light illuminate for both cavities Yes GoTo 4 No Repair the ECM Ground circuit s for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the Battery Sense circuit 15 the voltage below 1 0 volt Yes GoTo 5 No Repair the Battery Sense circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Measure the resistance between the Battery negative terminal and the Battery Sense circuit Is the resistance below 5 0 ohms Yes GoTo 6 N
184. he DLC and the Diagnostic J unction Port connector for a short to voltage or to ground repair as necessary Perform BODY VERIFICATION TEST VER 1 Disconnect the Diagnostic J unction Port Tester cable from the DRBIII Keep the tester connected to the Diagnostic J unction Port Turn the ignition on Measure the voltage of the PCI Bus circuit on the Diagnostic J unction Port Tester that the DRBIII displayed No Modules Responding Is the voltage steadily above 7 0 volts Yes GoTo 5 GoTo 6 Measure the voltage of the PCI Bus circuit the Diagnostic J unction Port tester that previously measured above 7 0 volts Note Turn the ignition off before disconnecting any module harness connector then turn the ignition on Disconnect the module harness connector s Note If the problem occurred pins 1 2 or 3 of the Diagnostic J unction Port tester observe the voltmeter while discon necting each module connector one at a time Is the voltage steadily above 7 0 volts with the module s disconnected Yes Repair the PCI Bus circuit that measured over 7 0 volts for a short to voltage Perform BODY VERIFICATION TEST VER 1 Replace the module that when disconnected the short to voltage was eliminated Perform BODY VERIFICATION TEST VER 1 Disconnect the Diagnostic unction Port Tester cable from the DRBIII Keep the tester connected to the Diagnostic J unction Port Turn the ignition off Disconnect the
185. he ignition on Set Condition The Fuel Level Sensor Signal voltage is below 0 15 volt POSSIBLE CAUSES INTERMITTENT CONDITION FUEL LEVEL SENSOR FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND FUEL LEVEL SENSOR SIGNAL AND GROUND CIRCUITS SHORTED TOGETHER ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes GoTo 2 No GoTo 6 Turn the ignition off Disconnect the Fuel Level Sensor harness connector Turn the ignition on With the DRB read the Fuel Level Sensor voltage Is the voltage above 4 8 volts Yes Replace the Fuel Level Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 3 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Fuel Level Sensor harness connector Measure the resistance between ground and the Fuel Level Sensor Signal circuit 15 the resistance above 100 kohms Yes GoTo 4 No Repair the Fuel Level Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 81 DRIVEABILITY DIESEL P0O460 FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE LOW Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Fuel Level Sensor harness connector Meas
186. hms Yes GoTo 4 No Repair the Intake Air Temperature Sensor Signal circuit for open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Connect a jumper wire between the IAT Sensor Signal and IAT Sensor Ground circuits in the Boost Pressure IAT Sensor harness connector Turn the ignition on Monitor the DRB for ECM DTCs Does the display P0110 INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW Yes Replace the Boost Pressure Intake Air Temperature Sensor Perform ROAD TEST VERIFICATION VER 2 GoTo 5 Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Sensor Ground circuit between the ECM harness connector and the Boost Pressure Sensor harness connector 15 the resistance below 10 0 ohms Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the Intake Air Temperature Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 24 DRIVEABILITY DIESEL 110 1 AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE HIGH Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN D
187. ing view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 141 DRIVEABILITY DIESEL P1131 F PRESSURE SOLENOID OPEN CIRCUIT Continued APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 142 DRIVEABILITY DIESEL Symptom List P1511 BATTERY SENSE LINE 1 VOLTAGE TOO HIGH P1511 BATTERY SENSE LINE 1 VOLTAGE
188. ion Perform ROAD TEST VERIFICATION VER 2 Disconnect the ECM harness connectors Measure the resistance between ground and the Secondary Brake Switch Signal circuit 15 the resistance above 1000 ohms Yes GoTo 9 Repair the Secondary Brake Switch Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Brake Lamp Switch harness connector Disconnect the ECM harness connectors Measure the resistance of the Secondary Brake Switch Signal circuit 15 the resistance below 10 0 ohms Yes GoTo 10 No Repair the Secondary Brake Switch Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the Brake Lamp Switch harness connector 131 DRIVEABILITY DIESEL 703 SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH DUNDANT CONTACT Continued ACTION APPLICABILITY Disconnect the Brake Lamp Switch harness connector Using 12 volt test light connected to ground check the Fused B circuit Does the test light illuminate brightly Yes GoTo 12 No Repair the Brake Lamp Switch Fused B circuit for an open Perform ROAD TEST VERIFICATION VER 2 Disconnect the Brake Lamp Switch harness co
189. ions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete DRIVEABILITY DIESEL Symptom List 070 AIR TEMPERATURE CIRCUIT SIGNAL VOLTAGE TOO HIGH 070 AIR TEMPERATURE CIRCUIT SIGNAL VOLTAGE TOO LOW SSS Eee Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be 70 AIR TEMPER ATURE CIRCUIT SIGNAL VOLTAGE TOO HIGH When Monitored and Set Condition 70 AIR TEMPERATURE CIRCUIT SIGNAL VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition When the BCM detects high voltage on the Ambient Air
190. ir was successful and testing is now complete 4 If the initial or another symptom exists the repair is not complete Check all pertinent Technical Service Bulletins TSBs and return to the Symptom List if necessary 5 For previously read DTCs that have not been dealt with return to the Symptom List and follow the diagnostic path for that DTC otherwise continue 6 If the Engine Control Module ECM has not been changed perform steps 7 and 8 otherwise continue with step 9 7 With the DRB erase all diagnostic trouble codes DTCs then disconnect the 8 Turn the ignition off for at least 10 seconds 9 If equipped with a Transfer Case Position Switch perform step 10 otherwise continue with step 11 10 With the ignition switch on place the Transfer Case Shift Lever in each gear position stopping for 15 seconds in each position 11 Ensure no DTCs remain by performing steps 12 through 15 12 Road test the vehicle For some of the road test at least 64 km h 40 If this test is for an A C Relay Control Circuit drive the vehicle for at least 5 minutes with the A C on 13 At some point stop the vehicle and turn the engine off for at least 10 seconds then restart the engine and continue 14 Upon completion of the road test turn the engine off and check for DTCs with the DRB 15 If the repaired DTC has reset the repair is not complete Check for any pertinent Technical Service Bulletins TSBs and return t
191. it for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 52 DRIVEABILITY DIESEL P0235 BOOST PRESSURE SENSOR SIGNAL VOLTAGE LOW Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 53 DRIVEABILITY DIESE
192. ition than it would for a wide open throttle condition There are several different modes of operation that determine how the ECM responds to the various input signals Ignition Switch On Engine Off When the ignition switch is turned on the ECM activates the glow plug relay for a time period that is determined by engine coolant temperature atmo spheric temperature and battery voltage The ECM also activates the lift pump to prime the fuel sys tem Engine Start up Mode The ECM uses the engine temperature sensor and the crankshaft position sensor engine speed inputs to determine fuel injection quantity Normal Driving Modes Engine idle warm up acceleration deceleration and wide open throttle modes are controlled based on all of the sensor inputs to the ECM The ECM uses these sensor inputs to adjust fuel quantity and fuel injector timing Limp In Mode If there is fault detected with the accelerator pedal position sensor the ECM will set the engine speed at 1100 RPM Overspeed Detection Mode If the ECM detects engine RPM that exceeds 5200 RPM the ECM will set a DTC in memory and illuminate the MIL until the DTC is cleared After Run Mode The ECM transfers RAM information to ROM and performs an Input Output state check 3 2 3 MONITORED CIRCUITS The ECM is able to monitor and identify most driveability related trouble conditions Some cir cuits are directly monitored through ECM feedback circuitry addi
193. ity are controlled by the ECM based on inputs from the various sensors The precision control of the injectors by the ECM helps to reduce the engine noise odor and smoke 3 2 FUNCTIONAL OPERATION 3 2 1 ON BOARD DIAGNOSTICS TheECM has been programmed to monitor many different circuits of the diesel fuel injection system This monitoring is called on board diagnostics Certain criteria must be met for a trouble code to be entered into the ECM memory The criteria may be a range of engine rpm engine temperature time or other input signals to the ECM If all of the criteria for monitoring a system or circuit are met and a problem is sensed then a DTC will be stored in the ECM memory It is possible that a DTC for a monitored circuit may not be entered into the ECM memory even though a malfunction has occurred This may hap pen when the monitoring criteria has not been met The ECM compares input signal voltages from each input device with specifications the estab lished high and low limits of the input range that are programmed into it for that device If the input voltage is not within the specifications and other trouble code criteria are met a DTC will be stored in the ECM memory GENERAL INFORMATION 3 2 2 ECM OPERATING MODES As input signals to the ECM change the ECM adjusts its response to the output devices For example the ECM must calculate a different fuel quantity and fuel timing for engine idle cond
194. l cylinders Turn the ignition on With the DRBIII actuate the Glow Plug 1 Relay Using a 12 volt test light connected to ground probe 1 and 2 Glow Plug harness connectors during actuator test With the DRBIII actuate the Glow Plug 2 Relay Using 12 volt test light connected to ground probe 3 and 4 Glow Plug harness connectors during actuator test Does the test light on and off at each Glow Plug harness connector during actuation Yes GoTo 2 GoTo 3 Refer to the Service Information and perform the Glow Plug Test Are all Glow Plugs operating properly Yes Test Complete No Replace the Glow Plug s as necessary Perform ROAD TEST VERIFICATION VER 2 NOTE If the Glow Plug Relay fuse or fuselink is open refer to the system schematics for all circuits that are powered by the Glow Plug Relay fuse or fuselink to determine the cause of the blown fuse fuselink Remove the Glow Plug Relay of the affected cylinder s Usinga 12 volt test light connected to ground probe used B circuit the Glow Plug Relay connector Does the test light illuminate brightly Yes GoTo 4 No Repair the Fused B Fuse F uselink circuit for an open Perform ROAD TEST VERIFICATION VER 2 181 DRIVEABILITY DIESEL CHECKING THE GLOW PLUG OPERATION Continued ACTION APPLICABILITY Turn the ignition off Disconnect the Glow Plug harness connectors of the affected cylinder
195. lace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Refer to Body Diagnostic Information for problems related to Communication with ECM Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 152 DRIVEABILITY DIESEL Symptom List 1652 1850 COMMUNICATION BUS SHORT TO GROUND 1652 1850 COMMUNICATION BUS SHORT TO VOLTAGE Test
196. lay Perform ROAD TEST VERIFICATION VER 2 No Repair the ASD Relay Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 147 DRIVEABILITY DIESEL Symptom List P1643 VISCOUS HEATER RELAY OPEN CIRCUIT P1643 VISCOUS HEATER RELAY SHORT CIRCUIT Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P1643 VISCOUS HEATER
197. le does not adjust and set a new vehicle speed the repair is not complete continue with step 12 11 With the speed control engaged depress the ON OFF switch If the speed control does not disengage the repair is not complete continue with step 12 12 If the vehicle did not successfully perform all of the previous steps check for Technical Service Bulletins TSBs that pertain to this speed control problem and then if necessary return to the Symptom List 13 If the vehicle successfully performed all of the previous steps the speed control system is now functioning as designed The repair is now complete Are any DTCs or symptoms remaining Yes Repair is not complete refer to appropriate symptom No Repair is complete 208 APPLICABILITY All COMPONENT LOCATIONS 8 0 COMPONENT LOCATIONS 8 1 CONTROL MODULES 4AZmZ00zZ00 pf Y AA RS p gt gt gt SENTRY KEY IMMOBILIZER L MODULE AND HARNESS CONNECTOR 5 EGR SOLENOID AND HARNESS 25 VISCOUS HEATER HARNESS CONNECTOR 80cd 116d 209 COMPONENT LOCATIONS 8 3 DATA LINK CONNECTOR nO DATA LINK CONNECTOR L N 5 80014811 8 4 FUEL SYSTEM KAA AHUATE ZDA S7 Ln af LN ALE FUEL Sima z INJECTORS 5 S gt
198. m the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the EGR Solenoid Control circuit 15 the voltage below 0 5 volt Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the EGR Solenoid Control circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICA
199. n With the DRB read ECM DTCs Did this DTC reset Yes GoTo 2 No GoTo 6 Turn the ignition off Disconnect the ECM harness connectors Measure the voltage of all cavities in the ECM harness connectors Is the voltage above 2 0 volts on any of the cavities Yes GoTo 3 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Measure the voltage on ECM harness connector C1 cavity 22 Is voltage present on ECM harness connector C1 cavity 22 Yes Repair the Ignition Switch Sense circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 4 146 DRIVEABILITY DIESEL P1605 IGNITION SWITCH PLAUSIBILITY Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Turn the ignition on Measure the voltage on ECM harness connector C1 cavities 4 and 5 Is the voltage below 2 0 volts on both circuits Yes GoTo 5 No Repair the ASD Relay Output circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Measure the resistance between ground and the ASD Relay Control circuit 15 the resistance above 100 kohms Yes Replace the ASD Re
200. n With the DRB III monitor the Low dle Position Switch input while tapping the other end of the jumper wire to the Sensor Ground circuit at the APP Sensor harness connector Does the III change between LOW IDLE and ABOVE IDLE when tapping the jumper wire Yes GoTo 2 No GoTo 20 Turn the ignition on With the III observe the Low Idle Position Switch input Press and release the accelerator pedal several times while observing the 111 display NOTE The Low Idle Position Switch input should change from IDLE to ABOVE IDLE when pressing and releasing the accelerator pedal Did Low Idle Position Switch input change between LOW IDLE and ABOVE IDLE Yes GoTo 3 No ReplacetheAccelerator Pedal Position Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 162 DRIVEABILITY DIESEL P2120 ACC PEDAL POSITION SENSOR 1CKT PLAUSIBILITY Continued ACTION APPLICABILITY NOTE If DTC P0641 or P0651 is present with this DTC diagnose DTCs All P0641 and P0651 before diagnosing this DTC Turn the ignition off Disconnect the APP Sensor harness connector Turn the ignition on Measure the voltage of the 5 volt Supply circuit in APP Sensor harness connector Is the voltage between 4 7 and 5 3 volts Yes GoTo 4 No GoTo 16 Turn the ignition off Disconnect the APP Sensor harness connector Connect a jumper wire between APP Sensor Signal circuit and
201. n cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the A C Clutch Relay Control circuit 15 the voltage above 1 0 volt Yes Repair theA C Clutch Relay Control circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No GoTo 5 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 119 DRIVEABILITY DIESEL Symptom 51 REFERENCE VOLTAGE VOLTAGE TOO HIGH When Monitored and Set Condition P0651 SENSOR REFERENCE VOLTAGE VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition The ECM detects a short to voltage on the Sensor Reference Voltage B circuit or the Accelerator Pedal Position Sensor 5 Volt Supply circuit POSSIBLE CAUSES INTERMITTENT CONDITION SENSOR REFERENCE VOLTAGE B CIRCUIT SHORTED TO VOLTAGE ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Monitor the DRB for ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 5 Turn the ignition off Disconnect the Boost Pressure Sensor harness connector Disconnect the Engine Oil Pressure Sensor harness connector Disconnect the ECM harness connectors Remove the
202. n each engine run cycle With the DRBIII read the ECM DTC s Did this DTC reset Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No GoTo 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 22 DRIVEABILITY DIESEL Symptom PO1LO INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH When Monitored and Set Condition 0110 AIR TEM
203. nd and the both of the CKP Sensor Signal circuits 15 the resistance above 1000 ohms for both measurements Yes GoTo 4 No Repair the Sensor Signal circuit s for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the CKP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between the CKP Sensor Signal circuits 15 the resistance above 1000 ohms Yes GoTo 5 No Repair the Sensor Signal circuits for a short together Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the CKP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of CKP Sensor Signal circuits 15 the resistance below 10 0 ohms for both measurements Yes GoTo 6 No Repair the Sensor Signal circuit s for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the CKP Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of both CKP Sensor Signal circuits Is the voltage below 1 0 volt for both measurements Yes GoTo 7 No Repair the Sensor Signal circuit s for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Using the DRB lab s
204. nect the ECM harness connectors Measure the resistance between ground and the CMP Sensor Signal circuit Is the resistance below 1000 ohms Yes Repair the CMP Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 GoTo 12 Turn the ignition off Disconnect the CMP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between the CMP Sensor Signal circuit and the Sensor Ground circuit at of the CMP Sensor harness connector 15 the resistance below 1000 ohms Yes Repair the CMP Sensor Signal and Sensor Ground circuits for a short together Perform ROAD TEST VERIFICATION VER 2 Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Remove the CMP Sensor and the CKP Sensor checking for loose mounting screws and debris on the sensor magnets that can corrupt the sensor signal Revie
205. nector Measure the resistance between ground and the Accelerator Pedal Position Sensor 5 Volt Supply circuit Is the resistance above 100 kohms Yes GoTo 6 No Repair theAccelerator Pedal Position Sensor 5 Volt Supply circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Accelerator Pedal Position Sensor harness connector Measure the resistance between theAccelerator Pedal Position Sensor 5 Volt Supply circuit and the Sensor Ground circuit 15 the resistance above 100 kohms Yes GoTo 7 No Repair theAccelerator Pedal Position Sensor 5 Volt Supply circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair All Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set
206. negative battery cable Measure the resistance between ground and the PCI Bus circuit on the Diagnostic J unction Port Tester that the DRBIII displayed No Modules Responding Is the resistance below 100 0 ohms Yes GoTo 7 GoTo 8 13 COMMUNICATION PCI BUS COMMUNICATION FAILURE Continued ACTION APPLICABILITY Disconnect the negative battery cable All Measure the resistance between ground and the PCI Bus circuit at the Diagnostic J unction Port tester that previously measured below 100 0 ohms Disconnect the module harness connector s Note If the problem occurred on pins 1 2 or 3 of the Diagnostic J unction Port tester observe the ohmmeter while discon necting each module connector one at a time 15 the resistance below 100 0 ohms with the module s disconnected Yes Repair the PCI Bus circuit that measured below 100 0 ohms for a short to ground Perform BODY VERIFICATION TEST VER 1 Replace the module that when disconnected the short to ground was eliminated Perform BODY VERIFICATION TEST VER 1 Turn the ignition off Note Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Note Visually inspect the related wire harness connectors Look for broken bent pushed out or corroded terminals Were any problems found Yes Repair wiring harness connectors as necessary Perform BODY VERIFICATION TEST VER 1 No Test C
207. ness connectors Disconnect the Fuel Level Sensor harness connector Measure the resistance of the Fuel Level Sensor Signal circuit 15 the resistance below 5 0 ohms Yes GoTo 4 No Repair the Fuel Level Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Fuel Level Sensor harness connector Measure the resistance of the Fuel Level Sensor Ground circuit 15 the resistance below 5 0 ohms Yes GoTo 5 No Repair the Fuel Level Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 sensor harness connector disconnected Connect a jumper wire between Fuel Level Sensor harness connector cavities 3 and 4 With the DRB read the Fuel Level Sensor voltage NOTE The Fuel Level Sensor voltage should be less then 1 0 volt with the jumper wire connected Are the voltage readings the expected voltages Yes Replace the Fuel Level Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 6 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the Fuel Level Sensor harness connector Turn the ignition on With the DRB read and record the Fuel Level Sensor voltage NOTE The F
208. nition on Measure the voltage on the Clutch Interlock Relay Control circuit 15 the voltage above 1 0 volt Yes Repair the Clutch Interlock Relay Control circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No GoTo 6 158 DRIVEABILITY DIESEL P1830 CLUTCH OVER RIDE RELAY CIRCUIT OPEN Continued ACTION APPLICABILITY Turn the ignition off All Remove the Clutch Interlock Relay from the PDC Disconnect the ECM harness connectors Measure the resistance between ground and the Clutch Interlock Relay Control circuit Is the resistance above 1000 ohms Yes GoTo 7 Repair the Clutch Interlock Reay Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove the Clutch Interlock Relay from the PDC Disconnect the ECM harness connectors Measure the resistance of the Clutch Interlock Relay Control circuit Is the resistance below 10 0 ohms Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the Clutch Interlock Relay Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 159 DRIVEABILITY DIESEL Symptom List P2120 ACC PEDAL POSITION SENSOR 1 PLAUSIBILITY P2120 ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH BRAKE SWITCH P2120 ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH LOW IDLE SWITCH P2120 ACC PEDAL
209. nnect the appropriate Cylinder Fuel Injector harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connec a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the appropriate Fuel Injector Control circuit Is the voltage above 1 0 volt Yes Repair the Fuel Injector Control circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 3 Turn the ignition off Disconnect the Cylinder Fuel Injector harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the Common Driver circuit 15 the voltage above 1 0 volt Yes Repair the Common Driver circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 4 No GoTo 5 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Cylinder Fuel Injector harness connector Measure the resistance between ground and the Common Driver circuit 15 the resistance below 1000 ohms Yes Repair the Common Driver circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 GoTo 6 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Cylinder Fuel Injector harness connector Measure the resistance
210. nnector Turn the ignition on While monitoring the PRIM BRAKE SWITCH status with the DRB connect a jumper wire between the Primary Brake Switch Signal circuit the Fused circuit Does the DRB display change from RELEASED to PRESSED Yes Adjust or replace the Brake Lamp Switch in accordance with the Service nformation Perform ROAD TEST VERIFICATION VER 2 No GoTo 13 15 the voltage above 1 0 volt Yes Repair the Primary Brake Switch Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 14 Turn the ignition off Disconnect the Brake Lamp Switch harness connector Disconnect the ECM harness connectors Measure the resistance of the Primary Brake Switch Signal circuit Is the resistance below 5 0 ohms Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the Primary Brake Switch Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the Brake Lamp Switch harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage between the Primary Brake Switch Signal circuit and ground 132 DRIVEABILITY DIESEL Symptom List P0O836 TRANSFER CASE POSITION SENSOR
211. nning and at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 145 DRIVEABILITY DIESEL Symptom 1605 SWITCH PLAUSIBILITY When Monitored and Set Condition 1605 SWITCH PLAUSIBILITY When Monitored With the ignition off Set Condition The ECM detects a short to voltage on the Ignition Switch Sense circuit POSSIBLE CAUSES INTERMITTENT CONDITION ASD RELAY ENGINE CONTROL MODULE IGNITION SWITCH SENSE CIRCUIT SHORTED TO VOLTAGE ASD RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE ASD RELAY CONTROL CIRCUIT SHORTED TO GROUND APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Cycle the ignition switch on and off several times pausing for at least 10 seconds at each key off and key on Turn the ignition o
212. ntifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 118 DRIVEABILITY DIESEL P0645 A C CLUTCH RELAY CIRCUIT SHORT CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Remove the A C Clutch Relay from the PDC Turn the ignition on Using a 12 volt test light connected to 12 volts probe the A C Clutch Relay Control circuit in the PDC With the DRBIII actuate the A C Clutch Relay Does the test light cycle on and off Yes Replace the A C Clutch Relay Perform ROAD TEST VERIFICATION VER 2 GoTo 4 Turn the ignition off Remove the A C Clutch Relay from the PDC Disconnect the ECM harness connector Remove the ASD Relay from the PDC Connect a jumper wire betwee
213. o GoTo 12 Turn the ignition off Remove the A C Clutch Relay from the PDC Disconnect the A C Clutch harness connector Measure the resistance between ground and the A C Clutch Relay Output circuit Is the resistance above 100 kohms Yes GoTo 13 No Repair theA C Clutch Relay Output circuit for a short to ground Inspect fuse and replace as necessary Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove the A C Clutch Relay from the PDC Disconnect the A C Clutch harness connector Measure the resistance of the A C Clutch Relay Output circuit Is the resistance below 5 0 ohms Yes GoTo 14 No Repair the A C Clutch Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 171 DRIVEABILITY DIESEL A C INOPERATIVE Continued ACTION APPLICABILITY Turn the ignition off Disconnect the A C Clutch harness connector Using 12 volt test light connected to 12 volts check the A C Clutch Ground circuit Does the test light illuminate brightly Yes GoTo 15 No Repair the A C Clutch Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace the A C Clutch in accordance with the Service nforma tion Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the A C Heater Control C1 harness connector Turn the ignition on Measure the voltage of
214. o Repair the Battery Sense circuit for an open Perform ROAD TEST VERIFICATION VER 2 144 DRIVEABILITY DIESEL 1511 SENSE LINE 1 VOLTAGE TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the ECM harness connectors Remove Fuse 26 from the PDC NOTE A short to ground on any circuit associated with Fuse 6 or 26 may cause this DTC to set Measure the resistance between ground and the Battery Sense circuit Is the resistance above 100 kohms Yes GoTo 7 No Repair the Battery Sense circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Remove F use 26 from the PDC Measure the resistance of the Battery Sense circuit 15 the resistance below 5 0 ohms Yes GoTo 8 No Repair the Battery Sense circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair All Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine ru
215. o the Symptom List If there DTCs the repair was successful and is now complete Are any DTCs or symptoms remaining Yes Repair is not complete refer to appropriate symptom No Repair is complete SKIS VERIFICATION APPLICABILITY 1 Reconnect all previously disconnected components and connectors All 2 Obtain the vehicle s unique Personal Identification Number PIN assigned to it s original SKIM This number can be obtained from the vehicle s invoice or Chrysler s Customer Center 1 800 992 1997 3 NOTE When entering the PIN care should be taken because the SKIM will only allow 3 consecutive attempts to enter the correct PIN If 3 consecutive incorrect PINs are entered the SKIM will Lock Out the DRB III for 1 hour 4 To exit Lock Out mode the ignition key must remain in the Run position continually for 1 hour Turn off all accessories and connect a battery charger if necessary 5 With the DRBIII select Theft Alarm SKIM and Miscellaneous Then select the desired procedure and follow the steps that will be displayed 6 If the SKIM has been replaced ensure all of the vehicle ignition keys are programmed to the new 5 7 NOTE Prior to returning vehicle to the customer perform a module scan to be sure that all DTCs are erased Erase any DTCs that are found 8 With the DRBIII erase all DTCs Perform 5 ignition key cycles leaving the key on for at least 90 seconds per cycle 9 With the DR
216. o voltage Perform CHARGING VERIFICATION VER 3 109 DRIVEABILITY DIESEL P0620 GE FIELD CONTROL BATTERY VOLTAGE DEVI ATION TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off All Disconnect ECM harness connectors Disconnect the Generator Field harness connector Measure the resistance between ground and the Generator Field Control circuit 15 the resistance above 100 kohms Yes GoTo 5 No Repair the Generator Field Control circuit for a short to ground Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Generator Field harness connector Measure the resistance of the Generator Field Control circuit 15 the resistance below 5 0 ohms Yes GoTo 6 No Repair the Generator Field Control circuit an open Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the ECM harness connectors Remove F use 26 from the PDC Measure the resistance of the Battery Sense circuit 15 the resistance below 5 0 ohms Yes GoTo 7 No Repair the Battery Sense circuit for high resistance Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the ECM harness connectors Measure the resistance of the Battery Sense circuit 15 the resistance below 5 0 ohms Yes GoTo 8 No Repair the Battery Sense circuit for high resistance Perform
217. oTo 6 No Repair the ECT Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 30 DRIVEABILITY DIESEL 0115 COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICA
218. of a known voltage or current before accepting a zero reading e When measuring current connect the meter in series with the load e Disconnect the live test lead before disconnecting the common test lead 4 3 WARNINGS AND CAUTIONS 4 3 1 ROAD TEST WARNINGS Some complaints will require a test drive as part of the repair verification procedure The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition CAUTION Before road testing a vehicle be sure that all components are reassembled During the test drive do not hang the DRBIII from the rear view mirror Do not attempt to read the DRBIII while driving Have assistant available to operate the DRBIII 4 3 2 VEHICLE DAMAGE CAUTIONS Before disconnecting any control module make sure the ignition is off Failure to do so could damage the module When testing voltage or circuit integrity at any control module use the terminal side not the wire end of the harness connector Do not probe through the insulation this will damage it and eventually cause it to fail because of corro sion Becareful when performing electrical test so as to prevent accidental shorting of terminals Such a mistake can damage fuses or components Also a second code could be set making diagnosis of the original problem more difficult 5 0 REQUIRED TOOLS AND EQUIPMENT DRBIII diagnostic read out box scan tool vacuum gauge ammeter ohmmeter j
219. omplete DRIVEABILITY DIESEL Symptom 0 70 AIR TEMPERATURE CIRCUIT RECEIVE TIME OUT When Monitored and Set Condition 070 AIR TEMPERATURE CIRCUIT RECEIVE TIMEOUT When Monitored With the ignition on Set Condition When an expected BCM J 1850 Bus message to the ECM is missing POSSIBLE CAUSES INTERMITTENT CONDITION COMMUNICATE WITH BCM ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRBIII erase ECM DTCs Cycle the ignition key on and off several times With the DRBIII read ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 3 Turn the ignition on With the DRBIII attempt to communicate with the Body Control Module Can communication be established with the Body Control Module Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Refer to the Communication Category of the Body Diagnostic Procedures and perform the appropriate symptom related to no communication with Body Control Module Perform ROAD TEST VERIFICATION VER 2 DRIVEABILITY DIESEL 0 070 AIR TEMPERATURE CIRCUIT RECEIVE TIMEOUT Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The condit
220. ondition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 126 DRIVEABILITY DIESEL Symptom P0685 ASD RELAY CONTROL CIRCUIT SHUTS OFF TOO LATE When Monitored and Set Condition P0685 ASD RELAY CONTROL CIRCUIT SHUTS OFF TOO LATE When Monitored During after run Set Condition The internal ECM timer determines that the ASD Relay remains too long when AFTER RUN mode of operation has been completed POSSIBLE CAUSES CHECK FOR OTHER DTCS INTERMITTENT CONDITION SUBSTITUTE ASD RELAY ASD RELAY CONTROL CIRCUIT SHORTED TO GROUND INTERMITTENTLY ASD RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB check for additional DTCs Are other DTCs present Yes
221. onnectors Disconnect the CKP Sensor harness connector Measure the resistance of the Shield circuit 15 the resistance below 10 0 ohms Yes GoTo 3 No Repair the Shield circuit for an open Perform ROAD TEST VERIFICATION VER 2 57 DRIVEABILITY DIESEL 5 POSITION SENSOR CIRCUIT OVERSPEED RECOGNITION Continued ACTION APPLICABILITY Replace the Crankshaft Position Sensor in accordance with the Service Information All With the DRB erase ECM DTCs Perform several drive cycles turning the ignition off for at least 10 seconds between each drive cycle Monitor the DRB for ECM DTCs Did this DTC reset Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 repair is complete Refer to the Service Information to check for engine mechanical problems that may have occurred due to excessive engine speed Perform ROAD TEST VERIFICATION VER 2 CAUTION Refer to the Service Information to check for engine mechanical problems that may have occurred due to excessive engine RPM WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal
222. operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicatethe conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Check the CKP Sensor wiring harness for incorrect routing which may cause EMI interference Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 58 DRIVEABILITY DIESEL Symptom 40 POSITION SENSOR CIRCUIT DYNAMIC PLAUSIBIL ITY When Monitored and Set Condition 40 POSITION SENSOR CIRCUIT DYNAMIC PLAUSIBILITY When Monitored The engine speed is above 790 RPM Set Condition TheECM detects a change engine speed that has occurred more rapidly than the engine is capable of changing speed POSSIBLE CAUSES CHECK CRANKSHAFT POSITION SENSOR SIGNAL ENGINE CONTROL MODULE INTERMITTENT CONDITION CRANKSHAFT POSITION SENSOR SIGNAL CIRCUIT S SHORTED TO GROUND CKP SENSOR CIRCUITS SHORTED TOGETHER CKP SENSOR SIGNAL CIRCUITS OPEN CKP SENSOR SIGNAL CIRCUIT S SH
223. orm ROAD TEST VERIFICATION VER 2 Repair the Battery Temperature Sensor Signal and Ground circuits for a short together Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 91 DRIVEABILITY DIESEL Symptom P0520 OIL PRESS SENSOR CIRCUIT MALF PLAUSIBILITY E When Monitored and Set Condition P0520 OIL PRESS SENSOR CIRCUIT MALF PLAUSIBILITY When Monitored At engine start up Set Condition The oil
224. ort to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 3 54 DRIVEABILITY DIESEL P0235 BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW Continued ACTION APPLICABILITY Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the 5 volt Supply circuit at the Boost Pressure IAT Sensor harness connector 15 the resistance above 1000 ohms Yes GoTo 4 No Repair 5 volt Supply circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between Sensor Ground and the 5 volt Supply circuit at the Boost AT Sensor harness connector 15 the resistance above 1000 ohms Yes GoTo 5 No Repair the 5 volt Supply circuit for a short to Sensor Ground Perform ROAD TEST VERIFICATION VER 2 Yes GoTo 6 No Repair theAPP Sensor 5 volt Supply circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage between ground and the 5
225. ound Perform ROAD TEST VERIFICATION VER 2 GoTo 3 Turn the ignition off Disconnect the ECM harness connectors Disconnect the DRB from the DLC Measure the resistance of the SCI Transmit circuit between the ECM connector and the DLC 15 the resistance below 5 0 ohms Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the SCI Transmit circuit for an open Perform ROAD TEST VERIFICATION VER 2 3 Turn the ignition off All Disconnect the DRB from the DLC Disconnect the ECM harness connectors Turn the ignition on Measure the voltage of the SCI Transmit circuit at the DLC connector cav 7 15 the voltage above 1 0 volt Yes Repair the SCI Transmit circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No GoTo 4 COMMUNICATION Symptom BUS COMMUNICATION FAILURE POSSIBLE CAUSES WITH THE DRB PERFORM A MODULE SCAN OPEN PCI BUS CIRCUIT AT THE DATALINK CONNECTOR USING THE DRB PERFORM THE PCI BUS CONTROL MODE DISCONNECT THE MODULE S HARNESS CONNECTOR PCI BUS CIRCUIT SHORTED TO VOLTAGE DISCONNECT THE MODULE S HARNESS CONNECTOR PCI BUS CIRCUIT SHORTED TO GROUND WIRING HARNESS INTERMITTENT FAILURE APPLICABILITY Note Determine which modules this vehicle is equipped with before begin All ning Connect the Diagnostic unction Port Tester 8339 to the DRBIII and to
226. pect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 56 DRIVEABILITY DIESEL Symptom P0335 CKP POSITION SENSOR CIRCUIT OVERSPEED RECOGNI TION When Monitored and Set Condition P0335 CKP POSITION SENSOR CIRCUIT OVERSPEED RECOGNITION When Monitored With the engine running Set Condition The engine speed sensor signal indicates engine speed is above 5200 RPM for at least 500 milliseconds NOTE Engine damage is possible when the engine speed exceeds 5200 RPM POSSIBLE CAUSES ENGINE CONTROL MODULE OPEN SHIELD CIRCUIT REPLACE THE CRANKSHAFT POSITION SENSOR INTERMITTENT CONDITION ACTION APPLICABILITY CAUTION Engine damage is possible when engine speed exceeds 5200 All RPM NOTE This DTC indicates the Engine Speed Sensor has seen an engine speed above 5200 RPM This can occur if the vehicle is in 5th gear and the vehicle operator performs a downshift and accidentally downshifts from 5th gear to 2nd gear Turn the ignition on With the DRB erase ECM DTCs Test drive the vehicle and monitor the DRB for ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 4 Turn the ignition off Disconnect the ECM harness c
227. per wire between cavity 30 and cavity 87 of the ASD Relay connector in the PDC Turn the ignition on Measure the voltage on the Viscous Heater Relay Control circuit Is the voltage above 1 0 volt Yes Repair the Viscous Heater Relay Control circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 6 149 DRIVEABILITY DIESEL P1643 VISCOUS HEATER RELAY OPEN CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Remove the Viscous Heater Relay from the PDC Disconnect the ECM harness connectors Measure the resistance between ground and the Viscous Heater Relay Control circuit Is the resistance above 1000 ohms Yes GoTo 7 No Repair the Viscous Heater Relay Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove the Viscous Heater Relay from the PDC Disconnect the ECM harness connectors Measure the resistance of the Viscous Heater Relay Control circuit Is the resistance below 10 0 ohms Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the Viscous Heater Relay Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 150 DRIVEABILITY DIESEL Symptom List P1651 MIL DIAG LAMP VIA J 1850 BUS FRAME RESPONSE ER ROR P1651 MIL DIAG LAMP VIAJ 1850 BUS STATUS ERROR Test Note All symp
228. perature ECT Sensor voltage Is the ECT Sensor voltage above 4 5 volts Yes GoTo 2 No GoTo 7 Turn the ignition off Disconnect the ECT Sensor harness connector Turn the ignition on Measure the voltage on the ECT Sensor Signal circuit 15 the voltage above 5 5 volts Yes Repair the ECT Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 3 29 DRIVEABILITY DIESEL 115 NGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the ECT Sensor harness connector Connect a jumper wire between the ECT Sensor harness connector cavities Turn the ignition on With the DRB read the ECT Sensor voltage 15 the voltage below 1 0 volt Yes Replace the ECT Sensor in accordance with the Service nforma tion Perform ROAD TEST VERIFICATION VER 2 GoTo 4 Turn the ignition off All Disconnect the ECT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the ECT Sensor Ground circuit 15 the resistance below 10 0 ohms Yes GoTo 5 No Repair the ECT Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the ECT Sensor harness connector Measure the resistance of the ECT Sensor Signal circuit 15 the resistance below 10 0 ohms Yes G
229. perature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 47 DRIVEABILITY DIESEL Symptom P0235 BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH A When Monitored and Set Condition P0235 BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition The Boost Pressure Sensor Signal voltage exceeds 4 5 volts for at least 2 seconds POSSIBLE CAUSES INTERMITTENT CONDITION 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE BOOST PRESSURE SENSOR GROUND CIRCUIT OPEN BOOST PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE BOOST PRESSURE INTAKE AIR TEMPERATURE SENSOR POOR CONNECTOR TERMINAL CONTACT ENGINE CONTROL MODULE 5 VOLT SUPPLY SHORTED TO VOLTAGE ENGINE CONTROL MODULE INTERNAL ENGINE CONTROL MODULE SENSOR SIGNAL SHORTED TO VOLTAGE ACTION APPLICABILITY Turn
230. pressure signal is below the lower limit for 8 seconds after engine start up POSSIBLE CAUSES 5 VOLT SUPPLY CIRCUIT OPEN ECM OIL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE ECM OIL PRESSURE SENSOR SIGNAL SHORT TO GROUND INCORRECT OIL PRESSURE OIL PRESSURE SENSOR FAILURE OIL PRESSURE SENSOR SIGNAL CIRCUIT OPEN OIL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND OIL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND OIL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE SENSOR GROUND CIRCUIT OPEN INTERMITTENT CONDITION ACTION APPLICABILITY NOTE If DTC P0641 or P0651 is present with this DTC diagnose these All DTC s before diagnosing this DTC Turn the ignition on With the DRB III erase ECM DTCs Cycle the ignition key on and off several times leaving the key on for at least 10 seconds at a time Test drive the vehicle With the 111 read ECM DTCs Did this DTC reset Yes GoTo 2 GoTo 10 Refer to the Service Information and perform the Oil Pressure Test 15 the oil pressure within specification Yes GoTo 3 No Repair as necessary Perform ROAD TEST VERIFICATION VER 2 92 DRIVEABILITY DIESEL P0520 OIL PRESS SENSOR CIRCUIT MALF PLAUSIBILITY Continued ACTION APPLICABILITY Turn the ignition off Disconnect the Oil Pressure Sensor harness connector Turn the ignition on Measure the voltage of the Oil Pressure Sensor Signal circuit Select the appropriate
231. pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform SPEED CONTROL VERIFICATION VER 4 No Replace and program the ECM in accordance with the Service Information Perform SPEED CONTROL VERIFICATION 4 184 DRIVEABILITY DIESEL Symptom CHECKING THE TRANSFER CASE POSITION SENSOR POSSIBLE CAUSES CHECKING THE TRANSFER CASE POSITION SENSOR APPLICABILITY Turn the ignition on All With the DRBIII read the T case Sensor Observe the T case volts on the DRB while moving the transfer case selector lever in each of the transfer case positions NOTE When shifting the transfer case selector to each position the Sensor voltage should result in the following voltages 4WD Low 0 15 0 40 Neutral 0 68 0 98 4WD Part Time 1 78 2 12 2WD 2 43 2 77 Does each position provide the correct voltage Yes Test Complete No Using the wiring diagram schematic as a guide inspect the wiring and connectors between the Transfer Case Position Sensor and the ECM If wiring and connectors are ok replace the Transfer Case Position Sensor Perform ROAD TEST VERIFICATION VER 2 185 DRIVEABILITY DIESEL Symptom CHECKING THE VISCOUS CABIN HEATER RELAY POSSIBLE CAUSES FUSED B CIRCUIT OPEN VISCOUS HEATER RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE VISCOUS HEATER RELAY OUTPUT CIRCUIT SHORTED TO GROUND VISCOUS HEATER RELAY OUTPUT CIRCUI
232. r options as necessary 5 BUX only If the Intrusion Transceiver was replaced use the DRBIII to enable ITM and Program Interior Type 6 BUX only If the Siren was replaced perform the Siren Replacement procedure 7 Proceed to number 15 8 Obtain the Vehicle s unique PIN assigned to it s original SKIM from either the vehicles invoice or from Chryslers Customer Assistance Center 1 800 992 1997 9 NOTE Once Secured Access Mode is active the SKIM will remain in that mode for 60 seconds 10 With the DRBIII select THEFT ALARM SKIM MISCELLANEOUS and select SKIM REPLACED Enter the 4 digit PIN to put the SKIM in Secured Access Mode 11 The 2 will prompt for the following steps 12 Using the DRBIII program all customer keys into the SKIM memory This requires that the SKIM be in Secured Access Mode using the 4 digit PIN 13 Note If the PCM is replaced the VIN and the unique Secret Key data must be transferred from the SKIM to the PCM This procedure requires the 5 to be placed in Secured Access Mode using the 4 digit PIN 14 Note If 3 attempts are made to enter Secured Access M ode using an incorrect PIN Secured Access M ode will be locked out for 1 hour which causes the to display Signals Open To exit this mode turn ignition to Run for 1 hour 15 Ensure all accessories are turned off and the battery is fully charged 16 Turn the Ignition
233. resent Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete Turn the ignition on With the DRB check for Body Control Module DTCs related BCM DTCs present Yes Refer to symptom list for problems related to BCM DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 GoTo 4 Turn the ignition on With the DRB check for Controller Antilock Brakes DTCs Are any related CAB DTCs present Yes Refer to symptom list for problems related to CAB DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 GoTo 5 84 DRIVEABILITY DIESEL 5 SPEED SENSOR FREQUENCY TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the BCM harness connectors Turn the ignition on Measure the voltage of the Vehicle Speed Signal circuit Select the range that the voltage reading falls into Above 5 4 volts GoTo 6 Between 4 5 and 5 4 volts GoTo 7 Below 4 5 volts GoTo 8 Turn the ignition off All Disconnect the BCM harness connectors Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage on the Vehicle Speed Signal circuit 15 the voltage above 1 0 volt Yes Repair the Vehicle Speed Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION
234. rness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 116 DRIVEABILITY DIESEL P0645 A C CLUTCH RELAY CIRCUIT OPEN CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off Remove the A C Clutch Relay from the PDC Turn the ignition on Using a 12 volt test light connected to ground probe the Fused ASD Relay Output circuit in the PDC Does the test light illuminate Yes GoTo 4 No Repair the Fused ASD Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove the A C Clutch Relay from the PDC Turn the ignition on Using a 12 volt test light connected to 12 volts probe the A C Clutch Relay Control circuit in the PDC With the DRBIII actuate the A C Clutch Relay Does the test light cycle on and off Yes Replace the A C Clutch Reay Perform ROAD TEST VERIFICATION VER 2 No GoTo 5 15 the resistance below 5 0 ohms Yes GoTo 6 No Repair the A C Clutch Relay Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove the A C Clutch Relay from the PDC Disconnect the ECM harness connector Measure the resistance be
235. round circuit for an open Perform ROAD TEST VERIFICATION VER 2 93 DRIVEABILITY DIESEL P0520 OIL PRESS SENSOR CIRCUIT MALF PLAUSIBILITY Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Oil Pressure Sensor harness connector Measure the resistance of the Oil Pressure Sensor Signal circuit Is the resistance below 10 0 ohms Yes GoTo 8 No Repair the Oil Pressure Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Oil Pressure Sensor harness connector Measure the resistance between ground and the Oil Pressure Sensor Signal circuit 15 the resistance above 1000 ohms Yes GoTo 9 No Repair the Oil Pressure Sensor Signal circuit a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Oil Pressure Sensor harness connector Measure the resistance between Sensor Ground and the Oil Pressure Sensor Signal circuit Is the resistance above 1000 ohms Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the Oil Pressure Sensor Signal circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERAT
236. s DTC reset Yes GoTo 2 No GoTo 7 Turn the ignition off Disconnect the EGR Solenoid harness connector Turn the ignition on Using a 12 volt test light connected to ground check the ASD Relay Output circuit Does the test light illuminate brightly Yes GoTo 3 No Repair the ASD Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the EGR Solenoid harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the EGR Solenoid Control circuit 15 the resistance above 100 kohms Yes GoTo 4 No Repair the EGR Solenoid Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 74 DRIVEABILITY DIESEL P0403 EGR SOLENOID CIRCUIT OPEN CIRCUIT Continued APPLICABILITY Turn the ignition off Disconnect the EGR Solenoid harness connector Disconnect the ECM harness connectors Measure the resistance of the EGR Solenoid Control circuit 15 the resistance below 5 0 ohms Yes GoTo 5 No Repair the EGR Solenoid Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Install a substitute EGR Solenoid in place of the vehicle s EGR Solenoid NOTE Ensure the ECM and EGR Solenoid harness connectors are con nected Turn the ignition on With the DRB check for this DTC to reset Did this DTC reset Yes GoTo 6
237. s necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 50 DRIVEABILITY DIESEL Symptom 235 PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW When Monitored and Set Condition P0235 BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW When Monitored With the ignition on Set Condition The Turbocharger Boost Pressure Sensor Signal voltage is below 0 15 volt for at least 2 seconds POSSIBLE CAUSES INTERMITTENT CONDITION 5 VOLT SUPPLY CIRCUIT OPEN OR SHORTED TO GROUND BOOST PRESSURE INTAKE AIR TEMPERATURE SENSOR BOOST PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND BOOST PRESSURE SENSOR SIGNAL AND GROUND CIRCUITS SHORTED TOGETHER BOOST PRESSURE SENSOR SIGNAL CIRCUIT OPEN ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB read the Turbocharger Boost Pressure Sensor voltage 15 the voltage below 0 2 volt Yes GoTo 2 GoTo 8 Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Turn the ignition on Measure the voltage between ground and the 5 volt Supply circuit Is the voltage above 4 9 volt Yes GoTo 3 Repair the 5 volt Supply circuit for an open or short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Turn the ignition on Connect a jumper wire between the Boost Pressure Sensor Signal and 5 volt Supply circuits
238. sistance below 10 0 ohms Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the Low Idle Switch Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 168 DRIVEABILITY DIESEL Symptom A C INOPERATIVE POSSIBLE CAUSES A C HIGH PRESSURE SWITCH OPEN CHECK FOR ECM DTCS FUSED B CIRCUIT OPEN A C CLUTCH RELAY A C LOW PRESSURE SWITCH OPEN A C CLUTCH RELAY OUTPUT CIRCUIT SHORTED TO GROUND PRESSURE SIGNAL CIRCUIT OPEN A C CLUTCH RELAY OUTPUT CIRCUIT OPEN A C SWITCH SENSE CIRCUIT OPEN A C HEATER CONTROL MODULE A C CLUTCH GROUND CIRCUIT OPEN GROUND CIRCUIT OPEN BCM NO SWITCH STATE CHANGE A C CLUTCH A C ON OFF CONTROL CIRCUIT OPEN ECM PRESSURE SIGNAL OPEN BCM ON OFF CONTROL CIRCUIT OPEN ACTION APPLICABILITY With the DRBIII check for ECM DTCs All Are any DTCs present Yes Return tothe symptom list and choose the symptom s Perform ROAD TEST VERIFICATION VER 2 GoTo 2 Position the Mode switch on the A C Heater Control Module to the Panel position A C off Turn the ignition on With the DRBIII in BCM select Inputs Outputs Monitor the A C Select Switch state while turning the Mode switch from Panel A C off to Bi Level A C on then back to Panel A C off Does the switch state change from Off to On then back to Off Yes GoTo 3 No GoTo 16 169 DRIV
239. spect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform CHARGING VERIFICATION VER 3 Turn the ignition off then on All With the DRB read and record the Battery Voltage With a voltmeter measure and record the voltage between the Battery terminals Compare the DRB Battery Voltage reading to the voltmeter reading Is the difference between the two readings less than 0 5 volt Yes GoTo 5 No Test Complete 100 DRIVEABILITY DIESEL 560 5 VOLTAGE LOW Continued ACTION APPLICABILITY Turn the ignition off All With a voltmeter measure and record the voltage between the Battery terminals Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the ASD Relay Output circuits Battery Sense circuit in the ECM C1 harness connector all voltage measurements within 0 5 volt of each other Yes GoTo 7 No Repair the circuit that had high resistance Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Generator Field harness conn
240. system failed fuel sending unit gelled fuel faulty injector 15 the fuel pressure within specification Yes Replace the Fuel Pressure Sensor in accordance with the Service Information No Repair as necessary in accordance with the Service Information WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary No Test Complete 138 DRIVEABILITY DIESEL Symptom List P1131 FUEL PRESSURE SOLENOID OPEN CIRCUIT P1131 FUEL PRESSURE SOLENOID PLAUSIBILITY IN AFTER RUN P1131 FUEL PRESSURE SOLENOID SHO
241. t or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete Turn the ignition off Disconnect the Brake Lamp Switch harness connector Turn the ignition on Measure the voltage between the Secondary Brake Switch Signal circuit and ground 15 the voltage above 9 0 volts Yes GoTo 5 GoTo 8 130 DRIVEABILITY DIESEL 703 SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH DUNDANT CONTACT Continued ACTION APPLICABILITY Disconnect the Brake Lamp Switch harness connector Turn the ignition on While monitoring the SEC BRAKE SWITCH status with the DRB connect a jumper wire between ground and the Secondary Brake Switch Signal circuit Does the DRB display change from PRESSED to RELEASED Yes Adjust or replace the Brake Lamp Switch in accordance with the Service nformation Perform ROAD TEST VERIFICATION VER 2 GoTo 6 Turn the ignition off Disconnect the Brake Lamp Switch harness connector Measure the resistance between ground and the Secondary Brake Switch Ground circuit Is the resistance below 10 0 ohms Yes GoTo 7 No Repair the Secondary Brake Switch Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Informat
242. t Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Sensor Ground circuit 15 the resistance below 5 0 ohms Yes GoTo 4 No Repair the Boost Pressure Sensor Ground circuit for high resis tance Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the 5 Volt Supply circuit 15 the resistance below 5 0 ohms Yes GoTo 5 No Repair the 5 Volt Supply circuit for high resistance Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Replace the Boost Pressure I ntake Air Temperature Sensor Turn the ignition on With the DRB erase ECM DTCs Test drive the vehicle pausing several times to cycle the ignition Monitor the DRB for ECM DTCs Did this DTC reset Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Therepair is complete Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating tem
243. t the camshaft for conditions such as loose mounting screws damage debris or cracked teeth 15 there any evidence of these conditions Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 GoTo 9 Turn the ignition off With the DRB III lab scope lead backprobe the CMP Signal circuit Set the DRB lab scope settings as follows Time 0 1s Div 20 volts scale Offset 0 00volts Probe X10 Coupling DC While observing the III display crank the engine NOTE The DRB III should display a digital signal square wave similar to that shown in the support material Does the DRB display an uninterrupted digital signal square wave Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace the Camshaft Position Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the CMP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the CMP Sensor Signal circuit 15 the resistance below 10 0 ohms Yes GoTo 11 No Repair the CMP Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 63 DRIVEABILITY DIESEL 40 CORRECTION FOR MAIN ECTION Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the CMP Sensor harness connector Discon
244. tch Signal circuit for a short to ground Perform SPEED CONTROL VERIFICATION VER 4 No GoTo 6 If there are no possible causes remaining view repair Repair Replace the Engine Control Module in accordance with the Ser vice Information Perform SPEED CONTROL VERIFICATION 4 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FANS DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FANS DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform SPEED CONTROL VERIFICATION VER 4 No Test Complete 107 DRIVEABILITY DIESEL Symptom List P0620 GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVIATION
245. tch any of the transponder D s stored in the 5 5 memory TRANSPONDER RESPONSE MISMATCH When Monitored At ignition on and during Key Programming Mode Set Condition When thetransponder s crypto algorithm result fails to match the SKIM s result POSSIBLE CAUSES CHECKING MULTIPLE KEY OPERATION SKIM INTERMITTENT WIRING HARNESS PROBLEM REPLACE IGNITION KEY 201 VEHICLE THEFT SECURITY TRANSPONDER COMMUNICATION FAILURE Continued ACTION APPLICABILITY With the DRBIII read and record the SKIM DTCs With the DRBIII erase the SKIM DTCs NOTE Perform the following test several times to ensure the DTC is current Turn the ignition off Wait 10 seconds Turn the ignition on With the DRBIII read the SKIM DTCs Does the DRBII1 display the DTC that was previously erased Yes GoTo 2 No GoTo 7 Are there multiple vehicle ignition keys available Yes GoTo 3 GoTo 4 NOTE Perform the following steps using one of the vehicle ignition keys All When finished repeat the procedure using each of the other vehicle keys one at a time With the DRBIII erase the SKIM DTC s Turn the ignition off Wait 10 seconds Turn the ignition on With the DRBIII read the SKIM Is the DTC present for all ignition keys Yes Replace and program the Sentry Key Immobilizer Module accordance with the Service Information Perform SKIS VERIFICATION Replace the ignition key s
246. ter Control C1 harness connector Measure the resistance between ground and the A C On Off Control circuit 15 the resistance above 100 kohms Yes GoTo 7 No Repair the A C On Off Control circuit for a short to ground 174 DRIVEABILITY DIESEL Symptom CHECKING THE ACCELERATOR PEDAL POSITION SENSOR CALIBRATION POSSIBLE CAUSES APP SENSOR APP SENSOR IDLE APP SENSOR WOT ACTION APPLICABILITY NOTE Ensure the Accelerator pedal is free from any restriction or binding All before continuing Turn the ignition on With the DRBIII in Engine Sensors read the APP Output Volt NOTE The accelerator pedal must be released Idle for this step 15 the voltage below 1 0 volt Yes GoTo 2 No Replace the Accelerator Pedal Position Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on While back probing measure the voltage of the APP Sensor Signal circuit at the ECM Monitor the voltmeter while slowly pressing the accelerator pedal completely down Did the voltage increase smoothly with pedal travel Yes GoTo 3 No Replace theAccelerator Pedal Position Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on With the DRBIII in Engine Sensors read the APP Output Volt Press the accelerator pedal completely down 15 the voltage above 3 7 volts with the accelerator pedal fully d
247. the Diagnostic J unction Port Using the DRBIII along with the Diagnostic J unction Port Tester 8339 select J unction Port Tool then PCI Bus Module Scan and follow the instructions on the DRBIII Was the DRBIII able to scan 1 0 or communicate with any modules Yes Refer tothe Communication category for the related symptom s Individual module no responses Perform BODY VERIFICATION TEST VER 1 GoTo 2 Turn the ignition off Measure the resistance of the PCI Bus circuit between the Data Link Connector and the Diagnostic J unction Port connector 15 the resistance below 5 0 ohms Yes GoTo 3 No Repair thePCI Bus circuit for an open between the DLC and the Diagnostic J unction Port Perform BODY VERIFICATION TEST VER 1 COMMUNICATION PCI BUS COMMUNICATION FAILURE Continued APPLICABILITY Note Determine which modules this vehicle is equipped with before begin All ning Connect the Diagnostic J unction Port Tester 8339 to the DRBIII and to the Diagnostic J unction Port Using the DRBIII along with the Diagnostic J unction Port Tester 8339 select J unction Port Tool then PCI Bus Control Mode and follow the instructions on the DRBIII Note Perform this function on each pin that is equipped with a PCI Bus circuit Did the DRB display No Modules Responding from any of the pins that were scanned Yes GoTo 4 No Check the PCI Bus circuit between t
248. the A C On Off Control circuit 15 the voltage greater than 11 0 volts Yes GoTo 17 GoTo 18 and the A C On Off Control circuit Does the A C Select Switch state change from Off to On when the jumper wire is connected Yes Replace theA C Heater Control Module in accordance with the Service nformation Perform BODY VERIFICATION TEST VER 1 Replace and program the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 Turn the ignition off Disconnect the BCM C1 harness connector Disconnect the A C Heater Control C1 harness connector Measure the resistance of the A C On Off Control circuit 15 the resistance below 5 0 ohms Yes Replace and program the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 Repair the A C On Off Control circuit for an open Perform BODY VERIFICATION TEST VER 1 Turn the ignition off All Disconnect the A C Heater Control C1 harness connector Turn the ignition on With the DRBIII in BCM select Inputs Outputs Monitor the A C Select Switch state while connecting a jumper wire between ground 172 DRIVEABILITY DIESEL Symptom A C OPERATES IN ALL MODE SWITCH POSITIONS POSSIBLE CAUSES A C CLUTCH CHECK FOR ECM DTCS A C CLUTCH RELAY A C CLUTCH RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE ENGINE CONTROL MODULE A C ON OFF CONTROL CIRCUIT SHORTED TO GROUND A
249. the DRBIII monitor the S C Switch voltage Disconnect the S C ON OFF SET Switch harness connector Did the DRB reading change to above 4 7 volts Yes Replace the S C ON OFF SET Switch Perform SPEED CONTROL VERIFICATION VER 4 GoTo 3 Turn the ignition on All With the DRBIII monitor the S C Switch voltage Disconnect the S C Resume Accel Switch harness connector Did the volt change to above 4 7 volts Yes Replace the S C Resume Accel Switch Perform SPEED CONTROL VERIFICATION VER 4 No GoTo 4 Turn the ignition off Disconnect the S C ON OFF SET Switch harness connector Disconnect the 5 RESUME ACCEL Switch harness connector Disconnect the ECM harness connectors Measure the resistance between the S C Switch Signal circuit the Sensor Ground circuit in the ECM harness connector 15 the resistance below 5 0 ohms Yes Repair the S C Switch Signal circuit shorted to the Sensor Ground circuit Perform SPEED CONTROL VERIFICATION 4 GoTo 5 106 DRIVEABILITY DIESEL P0579 S C SWITCH SIGNAL CIRCUIT SIGNAL VOLTAGE TOO LOW Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the S C ON OFF SET Switch harness connector Disconnect the S C RESUME ACCEL Switch harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the S C Switch Signal circuit 15 the resistance below 5 0 ohms Yes Repair the S C Swi
250. the Ignition Switch Start Output circuit while fully depressing the clutch pedal and turning theignition switch to the START position Does the test light illuminate with the ignition switch in the START position Yes GoTo 5 GoTo 6 Turn the ignition off Remove the Starter Relay From the PDC Install a substitute relay in place of the Starter Relay Attempt to start the engine Does the engine crank Yes Replace the Starter Relay Perform NO START VERIFICATION VER 1 No Repair the Starter Relay Ground Circuit for an open Perform NO START VERIFICATION VER 1 Turn the ignition off Remove the Starter Relay from the PDC Disconnect the Clutch Interlock Switch harness connector Connect a jumper wire across the Clutch Interlock Switch harness connector Using a 12 volt test light connected to ground check the Ignition Switch Start Output circuit at the Starter Relay connector in the PDC and turning the ignition switch to the Start position Does the test light illuminate with the ignition switch in the Start position Yes Replace the Clutch Interlock Switch Perform NO START VERIFICATION VER 1 GoTo 7 193 DRIVEABILITY DIESEL ENGINE WILL NOT CRANK Continued ACTION APPLICABILITY Turn the ignition off Disconnect the Clutch Interlock Switch harness connector Remove the Starter Relay from the PDC Measure the resistance of the Clutch Interlock Switch Output circuit between
251. the Low Idle Position Switch Sense circuit and Sensor Ground circuit for a short together Perform ROAD TEST VERIFICATION VER 2 167 DRIVEABILITY DIESEL P2120 ACC PEDAL POSITION SENSOR 1CKT PLAUSIBILITY Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the Low Idle Position Switch Sense circuit 15 the voltage above 1 0 volt Yes Repair the Low Idle Position Switch Sense circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 24 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the Low Idle Position Switch Ground circuit 15 the voltage above 1 0 volt Yes Repair the Low Idle Position Switch Sense Ground circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 25 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Low Idle Switch Sensor Ground circuit between the APP Sensor and the ECM 15 the re
252. the ignition on All With the DRB read the Boost Pressure Sensor voltage NOTE Ensure the turbocharger wastegate is operating properly This code can be set if turbocharger boost pressure is too high Is the voltage above 4 5 volts Yes GoTo 2 GoTo 9 Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Turn the ignition on Measure the voltage between ground and the Boost Pressure Sensor 5 volt Supply circuit Is the voltage above 5 2 volts Yes GoTo 3 GoTo 4 48 DRIVEABILITY DIESEL P0235 BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage between ground and the 5 volt Supply circuit 15 the voltage above 1 0 volt Yes Repair the 5 volt Supply circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Boost 1 Sensor harness connector Turn the ignition on Measure the voltage between ground and the Boost Pressure Sensor Signal
253. tify and check the shared circuits for possible problems before continuing i e sensor grounds or 5 volt supply circuits Refer to the appropriate wiring diagrams to identify shared circuits GENERAL INFORMATION A C CLUTCH RELAY CIRCUIT OPEN CIRCUIT A C CLUTCH RELAY CIRCUIT SHORT CIR CUIT ACC PEDAL POSITION SENSOR 1 CKT PLAU SIBILITY ACC PEDAL POSITION SENSOR 1 CKT PLAU SIBILITY WITH BRAKE SWITCH ACC PEDAL POSITION SENSOR 1 CKT PLAU SIBILITY WITH LOW IDLE SWITCH ACC PEDAL POSITION SENSOR 1 CKT PLAU SIBILITY WITH POTENTIOMETER ACC PEDAL POSITION SENSOR 1 CKT SIG NAL VOLTAGE TOO HIGH ACC PEDAL POSITION SENSOR 1 CKT SIG NAL VOLTAGE TOO LOW ACC PEDAL POSITION SENSOR 1 CKT SUP PLY VOLTAGE TOO HIGH OR LOW AFTER RUN SHUT OFF ERROR INJ POWER STAGE AFTER RUN SHUT OFF ERROR ZERO QUAN TITY AMBIENT AIR TEMPERATURE CIRCUIT RE CEIVE TIMEOUT AMBIENT AIR TEMPERATURE CIRCUIT SIG NAL VOLTAGE TOO HIGH AMBIENT AIR TEMPERATURE CIRCUIT SIG NAL VOLTAGE TOO LOW ASD RELAY CONTROL CIRCUIT SHUTS OFF TOO EARLY ASD RELAY CONTROL CIRCUIT SHUTS OFF TOO LATE BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO LOW BATTERY SENSE LINE 1 VOLTAGE TOO HIGH BATTERY SENSE LINE 1 VOLTAGE TOO LOW BATTERY SENSE LINE 2 VOLTAGE TOO HIGH BATTERY SENSE LINE 2 VOLTAGE TOO LOW BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW BOOST
254. tion the ECM monitors the voltage state of some circuits and compares those states with expected values Other systems are monitored indirectly when the ECM conducts a rationality test to identify problems Although most subsystems of the engine control module are either directly or indirectly monitored there may be occasions when diagnostic trouble codes are not immediately identified For a trouble code to set a specific set of conditions must occur and unless these conditions occur a DTC will not set 3 2 4 SKIS OVERIVEW The sentry key immobilizer system SKIS is designed to prevent unauthorized vehicle opera tion The system consists of a sentry key immobi lizer module SKIM ignition key s equipped with a transponder chip and the ECM When theignition switch is turned on the SKIM interrogates the ignition key If the ignition key is Valid or Invalid the SKIM sends a PCI Bus message to the ECM indicating ignition key status Upon receiving this message the ECM will terminate engine operation or allow the engine to continue to operate 3 2 5 SKIS ON BOARD DIAGNOSTICS The sentry key immobilizer module SKIM has been programmed to transmit and monitor many different coded messages as well as PCI Bus mes sages This monitoring is called On Board Diagnos tics Certain criteria must be met for a DTC to be entered into SKIM memory The criteria may be a range of input voltage Bus message or coded messages to the SK
255. title for the tests will PO560 SYSTEM VOLTAGE LOW E When Monitored and Set Condition P0560 SYSTEM VOLTAGE TOO LOW When Monitored With the engine running Set Condition The ECM detects battery voltage is below 10 0 volts POSSIBLE CAUSES INTERMITTENT CONDITION GENERATOR BELT CONDITION OR TENSION HIGH RESISTANCE IN THE VOLTAGE SUPPLY CIRCUIT S TO THE ECM GENERATOR FIELD CONTROL CIRCUIT SHORTED TO VOLTAGE GENERATOR FUSED B CIRCUIT HIGH RESISTANCE GENERATOR FIELD CONTROL CIRCUIT OPEN GENERATOR GROUND CIRCUIT HIGH RESISTANCE FUSED ASD RELAY OUTPUT CIRCUIT TO GENERATOR OPEN ENGINE CONTROL MODULE ACTION APPLICABILITY NOTE If there are any Battery Sense DTCs P1511 or P1512 present with All this DTC diagnose the Battery Sense DTCs first NOTE Inspect the vehicle for aftermarket accessories that may exceed the Generator capacity NOTE The battery must be fully charged before continuing Inspect the generator belt condition and tension Is the generator belt in good condition and tensioned properly Yes GoTo 2 No Repair as necessary Perform CHARGING VERIFICATION VER 3 99 DRIVEABILITY DIESEL 560 5 VOLTAGE TOO LOW Continued ACTION APPLICABILITY Connect the positive lead of a voltmeter to the generator B 12V terminal and the negative lead to the battery positive post WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT
256. to voltage on the Generator Field Control circuit POSSIBLE CAUSES INTERMITTENT CONDITION GENERATOR FIELD GENERATOR FIELD CONTROL CIRCUIT SHORTED TO VOLTAGE GENERATOR FIELD CONTROL CIRCUIT SHORTED TO GROUND GENERATOR FIELD CONTROL CIRCUIT OPEN HIGH RESISTANCE ON THE BATTERY SENSE CIRCUIT HIGH RESISTANCE ON THE BATTERY SENSE CIRCUIT ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Start the engine several times Allow the engine to run for at least 30 seconds each run cycle whileturning the ignition off for at least 10 seconds between each Monitor the DRB for ECM DTCs Did this DTC reset Yes GoTo 2 No GoTo 9 Turn the ignition off Disconnect the Generator Field harness connector Measure the resistance of the Field Control terminals on the back of the Generator 15 the resistance between 2 and 6 ohms Yes GoTo 3 No Repair or replace the Generator as necessary Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Generator Field harness connector Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the Generator Field Control circuit Is the voltage below 1 0 volt Yes GoTo 4 No Repair the Generator Field Control circuit for a short t
257. toms listed above are diagnosed using the same tests The title for the tests will be P1651 MIL DIAG LAMP VIA 1850 BUS IN FRAME RESPONSE ERROR _ When Monitored and Set Condition P1651 MIL DIAG LAMP VIA J 1850 BUS IN FRAME RESPONSE ERROR When Monitored With the ignition on Set Condition TheECM does not receive a response from the instrument cluster when a J 1850 message to actuate the MIL is transmitted P1651 MIL DIAG LAMP VIA J 1850 BUS STATUS ERROR When Monitored With the ignition on Set Condition The ECM has not received any 1850 messages from the instrument cluster POSSIBLE CAUSES REFER TO COMMUNICATION SECTION VERIFY INSTRUMENT CLUSTER COMMUNICATION INTERMITTENT CONDITION APPLICABILITY Turn the ignition on All With the DRBIII erase the ECM DTCs Cycle the ignition switch from OFF to ON Monitor the 2 for ECM DTCs Does the DRBIII display this DTC Yes GoTo 2 GoTo 3 151 DRIVEABILITY DIESEL P1651 MIL DIAG LAMP VIAJ 1850 BUS IN FRAME RESPONSE ERROR Continued ACTION APPLICABILITY Start and idle the engine All With the DRBIII select Instrument Cluster and read the PCM ECM Monitors NOTE If the DRB is unable to communicate with the Instrument cluster refer to the appropriate symptom in the Body Diagnostic Information Does the DRB display accurate monitors Yes Rep
258. ts at the ECM harness connector NOTE Refer to Charts and Graphs to view a correct CKP Sensor signal Start the engine if the engine will not start crank the engine for several seconds while monitoring the DRBIII Does the DRBIII display a steady clean Signal pattern for each circuit Yes GoTo 9 No Perform Test for DTC P0340 Crankshaft Position Sensor Circuit Dynamic Plausibility Perform NO START VERIFICATION VER 1 Refer to the Service Information and perform the fuel pressure test 15 the fuel pressure within specification Yes GoTo 10 No Repair as necessary Perform NO START VERIFICATION VER 1 Refer to the Service Information and perform the fuel pressure test Note the test results Using the DRBIII read the Fuel Pressure PSI and compare the two readings Are the two readings within 500 psi of each other Yes GoTo 11 GoTo 13 Refer to the Service Information to ensure the Engine Drive Belt is installed correctly and the camshaft and crankshaft gears are timed correctly Were any problems found Yes Repair as necessary Perform NO START VERIFICATION 1 No GoTo 12 Inspect the fuel supply for contamination 15 the fuel contaminated Yes Check the fuel supply for contamination Perform NO START VERIFICATION VER 1 No Replace and program the Engine Control Module in accordance with the Service Information Perform NO START VERIFICATION
259. tween ground and the A C Clutch Relay Control circuit Is the resistance below 5 0 ohms Yes Repair theA C Clutch Relay Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 No GoTo 7 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Remove the A C Clutch Relay from the PDC Disconnect the ECM harness connector Measure the resistance of the A C Clutch Relay Control circuit 117 DRIVEABILITY DIESEL Symptom 645 CLUTCH RELAY CIRCUIT SHORT CIRCUIT When Monitored and Set Condition 645 CLUTCH RELAY CIRCUIT SHORT CIRCUIT When Monitored With the ignition off Set Condition The ECM detects a short to voltage on the A C Clutch Relay Control circuit POSSIBLE CAUSES INTERMITTENT CONDITION A C CLUTCH RELAY A C CLUTCH RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE ECM ACTION APPLICABILITY Turn the ignition on All With the DRBIII actuate the A C Clutch Relay Is the A C Clutch Relay operating Yes GoTo 2 GoTo 3 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in ide
260. uel Level Sensor voltage should be 5 0 0 3 volts with the 79 DRIVEABILITY DIESEL 460 LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 80 DRIVEABILITY DIESEL Symptom PO460 FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE LOW When Monitored and Set Condition P0460 FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW When Monitored With t
261. umper wires and probes oscilloscope GENERAL INFORMATION 6 0 GLOSSARY OF TERMS AIC APP backfire popback BCM BP CKP CMP cuts out misses DLC detona tion spark knock ECM ECT EGR hard start IAT air conditioning accelerator pedal position sensor fuel ignites in either the intake or the exhaust system body control module boost pressure sensor crankshaft position Sensor camshaft position sensor a steady pulsation or the inability of the engine to maintain a consistent rpm data link connector a mild to severe ping especially un der loaded engine conditions engine control module engine coolant temperature sensor exhaust gas recirculation sol enoid val ve the engine takes longer than usual to start even though it is able to crank at normal speed intake air temperature sensor lack of power sluggish MAF MIL ms PDC poor fuel economy runs rough unstable idle S C SKIM SKIS start and stall surge SRC WIF VSS the engine power output has been reduced mass air flow sensor malfunction indicator lamp millisecond s power distribution center there is significantly less fuel mile age than other vehicles of the same design and configuration the engine runs unevenly at idle causing the engine to shake if it is severe enough speed control sentry key immobilizer module sentry key immobilizer system The engine starts but immediat
262. und Perform ROAD TEST VERIFICATION VER 2 No GoTo 14 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between the APP Sensor Signal circuit and the Sensor Ground circuit at of the APP Sensor harness connector 15 the resistance below 1000 ohms Yes Repair the APP Sensor Signal and Sensor Ground circuits for short together Perform ROAD TEST VERIFICATION VER 2 GoTo 15 Turn the ignition off All Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the APP Sensor Signal circuit 15 the resistance below 10 0 ohms Yes GoTo 13 No Repair the APP Sensor Signal circuit an open Perform ROAD TEST VERIFICATION VER 2 165 DRIVEABILITY DIESEL P2120 ACC PEDAL POSITION SENSOR 1CKT PLAUSIBILITY Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Relay connector Turn the ignition on Measure the voltage of the APP Sensor Signal circuit 15 the voltage above 1 0 volt Yes Repair the APP Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No Replace and program the Engine Control Module in accordance with the Service
263. ure the resistance between the Fuel Level Sensor Signal circuit and Sensor Ground circuit Is the resistance above 100 kohms Yes GoTo 5 Repair the Fuel Level Sensor Signal and Ground circuits for a short together Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TE
264. volt Supply circuit at the APP Sensor harness connector 15 the voltage above 1 0 volt Yes Repair theAPP Sensor 5 volt Supply circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the 5 volt Supply circuit at the Boost Sensor harness connector 15 the resistance above 1000 ohms 55 DRIVEABILITY DIESEL P0235 BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH LOW Continued ACTION APPLICABILITY WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND INA All DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually ins
265. w the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 64 DRIVEABILITY DIESEL Symptom 40 POSITION SENSOR CIRCUIT CMP CKP SYNC FAIL URE When Monitored and Set Condition 40 POSITION SENSOR CIRCUIT CMP CKP SYNC FAILURE When Monitored With the engine running Set Condition The ECM determines that the camshaft position sensor signal frequency is not plausible with the crankshaft position sensor signal frequency POSSIBLE CAUSES CHECK CAMSHAFT POSITION SENSOR SIGNAL CHECK CRANKSHAFT POSITION SENSOR SIGNAL CHECKING CKP SENSOR FOR DAMAGE CHECKING CMP SENSOR FOR DAMAGE ENGINE CONTROL MODULE GEAR ALIGNMENT INTERMITTENT CONDITION ACTION APPLICABILITY Turn the ignition on All With the DRBIII erase the ECM DTCs Attempt to start the engine With the DRBIII read the ECM DTCs Does the III display this DTC Yes GoTo 3 GoTo 2 Turn the ignition on With the DRBIII erase the ECM DTCs
266. ying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete DRIVEABILITY DIESEL Symptom List 0105 PRESSURE CIRCUIT SIGNAL VOLTAGE HIGH P0105 BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE LOW 606 ERROR GATE ARRAY COMMUNICATION 606 ERROR GATE ARRAY COMMUNICATION VERI FIED 606 ERROR GATE ARRAY QUANTITY STOP 606 ERROR RECOVERY HAS OCCURRED 606 ERROR REDUNDANT OVERRUN MONITORING P1206 CALCULATED INJ ECTOR VOLTAGE TOO HIGH P1206 CALCULATED INJ ECTOR VOLTAGE TOO LOW P1601 CAPACITOR VOLTAGE 1 VOLTAGE TOO HIGH P1601 CAPACITOR VOLTAGE 1 VOLTAGE TOO LOW P1606 AFTER RUN SHUT OFF ERROR IN J POWERSTAGE P1606 AFTER RUN SHUT

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