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1. P1690 P1691 P1693 P1694 P1698 P1740 P1756 P1757 P1762 P1763 P1764 P1765 P1899 Fuel Level Unit No Change Over Miles Fuel Level Sending unit Volts Too Low Fuel Level Sending unit Volts Too High No Vehicle Speed Sensor Signal Oil Pressure Voltage Too Low Oil Pressure Voltage Too High Oil Pressure Too Low A C Clutch Relay Circuit Charging System Voltage Too Low Charging System Voltage Too Low PCM Internal Controller Failure Alternator Field Improper Switching Trans Temp Sensor Voltage Too Low Trans Temp Sensor Voltage Too High Low Output Speed Sensor RPM Above 15 MPH TCC Solenoid Trans Relay Circuits Governor Pressure Sol Control Trans Relay Circuits OD Switch Pressed Lo For More Than 5 Minutes Trans 3 4 Shift Sol Trans Relay Circuits Idle Select Signal Invalid Fuel Injection Pump Battery Voltage Out Of Range Fuel Injection Pump Controller Always On Accelerator Pedal Position Sensor Supply Voltage Too High Fuel Injection Pump Controller Supply Voltage Low No Temperature Rise Seen From Intake Air Heaters Accelerator Pedal Position Sensor Supply Voltage Too Low Auto Shutdown ASD Relay Control Circuit No Auto Shutdown ASD Relay Output Voltage At PCM Aux 5 Volt Output Too High Aux 5 Volt Output Too Low Battery Temperature Sensor Voltage Too High Battery Temperature Sensor Voltage Too Low Charging System Voltage Too High Speed Control Sol
2. Inlet air Temp Sensor Rationality Ambient Air Temperature Sensor Performance P1192 Inlet Air Temperature Sensor Too Low This DTC enhances the current DTC P0072 Inlet Air Temp Sensor Voltage Too Low P1193 Inlet Air Temperature Sensor Too High This DTC enhances the current DTC P0073 Inlet Air Temp Sensor Voltage Too High e New ECM and CCN software that together will improve the customer understanding of the exhaust aftertreatment system messages that can be displayed on the overhead Electronic Vehicle Information Center EVIC e Creation of a new DTC to address VGT actuator calibration event failures separate from other VGT actuator communication faults for P0046 The new DTC is POO3A Turbocharger Boost Control Module Position Exceeded Learning Limit 6 7 Liter DTC Code Retrieval Okay we have laid the ground work for your understanding of the engine and exhaust aftertreatment s current and future complexity What is an owner to do when you get the check engine light CEL aka malfunction indicator light MIL or electronic throttle control ETC illumination on your dash Better yet what is the used truck owner 10 years down the road going to do Can you say black electrical tape No black electrical tape is not the answer The answer is to find out what the dang blasted DTC number is and look up its meaning Then make an informed decision about whether you will drive thru the di
3. Recently the TDR s editor called me and asked me to explain the trouble code quandry that many of us will face as we drive computer controlled vehicles The call was prompted by an owner that had purchased a 2003 Dodge Shop Manual but was bewildered by the omission of the diagnostic trouble codes from the book As a benchmark consulted a 99 manual and was only able to see the code numbers and their meanings A call to a Dodge contact revealed that the purchase of an additional 2003 Powertrain book at 1300 pages would be necessary to access the codes their meanings probalby cause and action descriptives Wow that book would be another 40 Worth it At 1300 pages the book offers troubleshooting tests to help the technician trace the cause of the diagnostic trouble code This information was not available in the 10 pages of codes in the old 99 book So the question goes back to the truck s owner How much do you want to know A Publication of the TURBO DIESEL REGISTER I ll try and help you sort through the DTC dilemma But first lets take a quick trip back in time before there were electronic engine and powertrain management systems From the automobile s beginning the internal combustion engine was fueled with a mixture of air and fuel With stricter environmental legislation circa late 70s the manufacturers realized that mechanical engine fuel and spark controls were not reliable or durable enough to maintain t
4. Transfer pump Circuit Out Of Range Fuel Shut Off Voltage Too High Turbo Boost Limit Exceeded MAP Sensor Too High Too Long MAP Sensor Voltage Too Low MAP Sensor Voltage Too High Fuel Injection Pump Mechanical Failure Fuel Valve Feedback Circuit Fuel Injection Pump Fuel Valve Open Circuit Fuel Injection Pump Fuel Valve Current Too High Multiple Cylinder Misfire Misfire Detected Cylinder No Misfire Detected Cylinder No Misfire Detected Cylinder No Misfire Detected Cylinder No Misfire Detected Cylinder No Misfire Detected Cylinder No No RPM Signal To PCM Crankshaft Position Sensor Signal Camshaft Position Sensor Signal Fuel Injection Pump Speed Position Sensor Signal Lost Intake Air Heater Relay No 1 Control Circuit Wait To Start Lamp Inoperative Intake Air Heater Relay No 2 Control Circuit Crankshaft Position Sensor Supply Voltage Too Low Crankshaft Position Sensor Supply Voltage Too High Exhaust Gas Recirculation EGR Flow Malfunction OoahRWNDM A Publication of the TURBO DIESEL REGISTER P0460 P0462 P0463 P0500 P0522 P0523 P0524 P0545 P0562 P0563 P0601 P0622 P0712 P0713 P0720 P0743 P0748 P0751 P0753 P1283 P1284 P1285 P1286 P1287 P1291 P1295 P1388 P1389 P1475 P1488 P1492 P1493 P1594 P1595 P1597 P1682 P1683 P1688 P1689
5. Here are a few more tips The emission system warranty on most new vehicles gasoline or diesel is 80 000 miles You should read your Owner s Manual and emission warranty information to see just exactly what is covered You will be very surprised The other thing to keep in mind is to either fix the problem or have the problem fixed at the first indication before the problem becomes into a big deal promise you if you drive it with the light on you are asking for trouble Happy Motoring Sam Memmolo TDR Writer CODES CAUSES AND CONCERNS got together with Dario Scafidi one of Carson Dodge s top diesel technicians to try to outline the most common codes out of the hundreds of them that he and the other techs see frequently The next question was whether it should be of concern to the owner or if you should not worry about it One of the interesting things ran into from the technicians that had worked in other states was how the frequency and type of code varies with different parts of the country That makes sense because there can t be much greater contrast in environments than there is between our high desert location in Nevada and our Hill Country location in Texas Altitude temperature swings humidity fuel formulas etc all impact the vehicle s operation In general if the check engine light is blinking shut it down and get it directly to your dealer before doing further damage If it stays on steady be
6. Engine Coolant Temperature Sensor Performance or P0071 Inlet Air Temp Sensor Rationality ECM Are you going to drive thru the diagnostic glitch and feel comfortable that you ll not be stranded in Boondocks New Mexico Were it my truck would continue onward But as you can see by the different code definitions there are some that will require your immediate attention For that matter the above P0116 and P0071 example that would drive thru may cause you too much alarm If left unattended I ve no doubt that the malfunction s will have other cause effect consequences But driving thru a DTC and the malfunction 215 216 indicator light MIL or electronic throttle control ETC is not something that has an easy yes or no answer Ultimately it is your judgment call For help with that judgment call looked up both the MIL and ETC meanings in my Owner s Manual Unfortunately the text is just as vague as my judgment call response If this light comes on and remains on while driving it suggests a potential engine control problem and the need for system service Although your vehicle will usually be drivable and not need towing see your dealer for service as soon as possible CAUTION Prolonged driving with the MIL on could cause damage to the engine control system It also could affect fuel economy and drivability The Seriousity of the EVIC Say what Yes seriousity have
7. High Bank 1 Sensor 3 P242f diesel Particulate Filter Restriction Ash Accumulation P244a diesel Particulate Filter Differential Pressure Too Low P244d exhaust Temperature Too High For Particulate Filter Regeneration Bank 1 P2453 diesel Particulate Filter Pressure Sensor A Circuit Performance P2454 diesel Particulate Filter Pressure Sensor A Circuit Low P2455 diesel Particulate Filter Pressure Sensor A Circuit High P2457 exhaust Gas Recirculation Cooling System Performance P245a egr Cooler Bypass Control Circuit Open P245c egr Cooler Bypass Control Circuit Low P245d egr Cooler Bypass Control Circuit High P2463 diesel Particulate Filter Soot Accumulation P2503 charging System Output Low P2504 charging System Output High P2509 ecm pcm Power Input Signal Intermittent P254c pto Speed Selector Sensor Circuit Low P254d pto Speed Selector Sensor Circuit High P2579 turbocharger Speed Sensor Circuit Performance P2580 turbocharger Speed Sensor Circuit Low P2609 intake Air Heater System Performance P268c cylinder 1 Injector Data Incompatible P268d cylinder 2 Injector Data Incompatible P268e cylinder 3 Injector Data Incompatible P268f cylinder 4 Injector Data Incompatible P2690 cylinder 5 Injector Data Incompatible P2691 cylinder 6 Injector Data Incompatible P2a00 02 Sensor 1 1 Circuit Performance P2a01 02 Sensor 1 2 Circuit Performance What is Next Okay it is decision time Lets say you ve noted a P0116
8. In rare cases typically due to difficult drive cycles a regeneration may not be possible In those cases you may see a message on the overhead console EVIC regarding the aftertreatment system stating either CATALYST FULL or EXHAUST SYSTEM REGENERATION REQUIRED NOW depending on the level of software As long as the percent full message is less than 100 the system can complete a regeneration if you change your drive cycle to allow it to happen The most effective drive cycle for regeneration is highway cruise Some trucks depending on the level of software will display REGENERATION IN PROCESS if your drive cycle has changed such that regeneration has been started Note that this message will occur only after the system has gotten full enough to display the EXHAUST SYSTEM REGENERATION REQUIRED NOW meaning you will not see it on every regeneration A visit to your dealer is necessary only if a message regarding the exhaust aftertreatment system reading SEE DEALER or SERVICE REQD is displayed on the EVIC In that case getting the truck to the dealer sooner rather than later may prevent further damage to the system Ni J A Publication of the TURBO DIESEL REGISTER OBD II DIAGNOSTIC TROUBLE CODES FOR 1998 UP TURBO DIESELS In TDR Issue 51 Sam Memmolo referred to these codes page 91 as did John Holmes page 107 John noted that you can t pull up the codes on your odometer with 2006
9. Sensor Circuit Low P040b exhaust Gas Recirculation Temperature Sensor 1 Circuit Performance P040c exhaust Gas Recirculation Temperature Sensor 1 Circuit Low P040d exhaust Gas Recirculation Temperature Sensor 1 Circuit High P0420 catalyst Efficiency Bank 1 P042e exhaust Gas Recirculation Control Stuck Open P0461 fuel Level Sensor 1 Performance P0462 fuel Level Sensor 1 Circuit Low P0463 fuel Level Sensor 1 Circuit High P0471 Exhaust Pressure Sensor 1 Performance P0472 Exhaust Pressure Sensor 1 Low P0473 Exhaust Pressure Sensor 1 High P0480 cooling Fan 1 Control Circuit open P0483 cooling Fan Speed P0487 egr Airflow Throttle Control Circuit A Open P0488 egr Airflow Throttle Control Circuit Performance P0489 egr Control Circuit Low P0501 vehicle Speed Sensor 1 Performance P0505 engine Speed At Idle Data Erratic Intermittent Or Incorrect P0513 invalid Skim Key P0514 battery Temperature Sensor Performance P0516 battery Temperature Sensor Circuit Low P0517 battery Temperature Sensor Circuit High P051b crankcase Pressure Sensor Circuit Range performance P051c crankcase Pressure Sensor Circuit Low P051d crankcase Pressure Sensor Circuit High P0521 engine Oil Pressure Sensor Performance P0524 engine Oil Pressure Too Low P0532 a c Pressure Sensor Circuit Low P0533 a c Pressure Sensor Circuit High P0541 intake Air Heater Control Circuit 1 Low P0542 intake Air Heater Control Circuit 1 High P0545 exhaust Gas Te
10. Turbo Diesels Issue 52 page 42 although you can do so on earlier Turbo Diesels Here are the commonly used On Board Diagnostic II Trouble Codes They can be accessed on electronic odometers by cycling the key on off on off on P0112 P0113 P0117 P0118 P0121 P0122 P0123 P0125 P0168 P0177 P0181 P0215 P0216 P0217 P0219 P0222 P0223 P0230 P0232 P0234 P0236 P0237 P0238 P0251 P0253 P0254 P0300 P0301 P0302 P0303 P0304 P0305 P0306 P0320 P0336 P0341 P0370 P0380 P0381 P0382 P0387 P0388 P0400 Intake Air Temperature Sensor Voltage Low Intake Air Temperature Sensor Voltage High ECT Sensor Voltage Too Low ECT Sensor Voltage Too High Accelerator Pedal Position Sensor Signal Volts Do Not Agree w ldle Validation Signal Accelerator Pedal Position Sensor Signal Voltage Too Low Accelerator Pedal Position Sensor Signal Voltage Too High Engine Is Cold Too Long Decreased Engine Performance Due To High Injection Pump Fuel Temperature Water In Fuel Sensor Voltage Too Low Fuel Injection Pump Failure Fuel Injection Pump Control Circuit Fuel Injection Pump Timing Failure Decreased Engine Performance Due To Engine Overheating Condition Camshaft Position Sensor Overspeed Signal Idle Validation Signals Both Low Idle Validation Signals Both High Above 5 Volts
11. automobiles too Go to your local mechanic and clear the fault Go to the auto parts store and clear the fault Clear the fault but does it reappear Time for a trip to the Dodge dealership Will the DTC go away on its own Perhaps A look at the industry wide guidelines for on board diagnostics OBD reveals that it takes four drive cycles of non malfunction to turn off the MIL light 40 cycles and the code is cleared from the OBD memory Did it go away Conclusion What have we learned e In the future DTCs will continue in greater numbers and scope e You can retrieve DTCs using the key trick e You have the codes listed in this magazine Copy and carry them with you e You have a judgment decision to make should you encounter a DTC e If your problem is minor and does not reoccur the MIL light will turn off and the code will be cleared from OBD memory Robert Patton TDR Staff Notes on exhaust system regeneration The ECM continuously monitors the level of particulates soot and other substances in the exhaust aftertreatment system As needed the ECM triggers a regeneration to remove them This is completely transparent to the driver There are no indicators on the instrument cluster or EVIC and there is no difference in sound or feel of the engine In other words when things are operating as normal as they do for the majority of owners you will not know that a regeneration is needed or in process
12. codes how serious the code may be to you and make it go away As a refresher here is a reprint from Issue 64 on how to retrieve the DTCs What is an owner to do when you get the check engine light CEL aka malfunction indicator light MIL or electronic throttle control ETC illumination on your dash Better yet what is the used truck owner 10 years down the road going to do Can you say black electrical tape No black electrical tape is not the answer The answer is to find out what the dang blasted DTC number is and look up its meaning Then make an informed decision about whether you will drive thru the diagnostic glitch or whether trouble looms on the horizon First how do you retrieve the code Internet myth has it that the codes cannot be brought up on the 07 5 and newer trucks some say since 06 On the flip side internet research will show you how to pull up the codes on a photobucket video PII save you the time finding the photobucket video The technique is the same as it has been since 1994 I think it is that long ago Here is a diagram from your owner s Manual so that we re using the same words 2n 272 geen OFF i ON E bd RU LOCK Using Dodge s vernacular here is the method e Insert key e Move it from Lock to Off pause e Move to On Run e Back to Off e Move to On Run e Back to Off e Move to On Run and stop The three movements from Off to On Run shoul
13. 00 nox Absorber Efficiency Below Threshold Bank 1 P2002 diesel Particulate Filter Efficiency Below Threshold P200c diesel Particulate Filter Over Temperature Bank 1 P200e catalyst System Over Temperature Bank 1 P2032 exhaust Gas Temperature Sensor Circuit Low Bank 1 Sensor 2 P2033 exhaust Gas Temperature Sensor Circuit High Bank 1 Sensor 2 P2080 exhaust Gas Temp Sensor Circuit Performance Bank 1 Sensor 1 P2084 exhaust Gas Temp Sensor Circuit Performance Bank 1 Sensor 2 P2121 accelerator Pedal Position Sensor 1 Performance P2122 accelerator Pedal Position Sensor 1 Circuit Low P2123 accelerator Pedal Position Sensor 1 Circuit High P2127 accelerator Pedal Position Sensor 2 Circuit Low P2128 accelerator Pedal Position Sensor 2 Circuit High P2141 egr Airflow Throttle Control Circuit Low P2142 egr Airflow Throttle Control Circuit High P2227 barometeric Pressure Sensor Rationality P2228 barometric Pressure Circuit Low P2229 barometric Pressure Circuit High P2262 turbocharger Boost Pressure Not Detected Mechanical A Publication of the TURBO DIESEL REGISTER P2266 water In Fuel Sensor Circuit Low P2267 water In Fuel Sensor Circuit High P2269 water In Fuel Condition P2299 brake Pedal Position Accelerator Pedal Position Incompatible P242b exhaust Gas Temp Sensor Circuit Performance Bank 1 Sensor 3 P242c exhaust Gas Temperature Sensor Circuit Low Bank 1 Sensor 3 P242d exhaust Gas Temperature Sensor Circuit
14. DTCs and You You have got to love abbreviations What is a DTC Better yet what is a CEL a SES or an MIL DTC diagnostic trouble code CEL check engine light SES service engine soon light MIL malfunction indicator light All four abbreviations mean the same there is some kind of a problem under the hood But how much of a concern should the glowing red light GRL be to you and how do you retrieve the trouble code and determine its meaning As is the case with most things related to the Doge Cummins Turbo Diesel truck our membership group has been there and done that Therefore the following is a collection of articles that I ve arranged in a sequence for the best understanding e Issue 51 Author Sam Memmolo gives us background information on DTCs e Issue 55 Author Joe Donnelly discusses DTCs for 98 5 to 2007 vehicles e Issue 64 Editor Robbert Patton gives the audience an update eon DTCs for the 07 5 and newer 6 7 liter engine e Issue 66 Author John Holmes tells us about the most common DTCs that dealership technicians encounter This article also has a discussion about the severity or lack thereof of DTCs DTCs and You am hopeful this collection of articles will shed some light pun intended_ on the subject Seriously tell your fellow Turbo Diesel owners about your new found understanding of codes and about the TDR magazine WHAT DOES THE CODE MEAN Decoding your warning light
15. agnostic glitch or whether trouble looms on the horizon First how do you retrieve the code Internet myth has it that the codes cannot be brought up on the 07 5 and newer trucks some say since 06 On the flip side internet research will show you how to pull up the codes on a photobucket video I ll save you the time finding the photobucket video The technique is the same as it has been since 1994 I think itis that long ago Here is a diagram from your owner s Manual so that we re using the same words A Publication of the TURBO DIESEL REGISTER Cees Using Dodge s vernacular here is the method e Insert key e Move it from Lock to Off pause e Move to On Run e Back to Off e Move to On Run e Back to Off e Move to On Run and stop The three movements from Off to On Run should be done in less than say 5 seconds Read the codes where the truck s odometer shows total miles not trip miles Make note of the code s and continue your research with the TDR magazine in hand What Do the Codes Mean With apologies in advance to Chuck Berry No Particular Place to Go Ridin along in my diesel truck A code comes up I m outta luck What does it mean well don t know Hoping the truck it doesn t slow FII check it out when I get home With no particular place to go So now I m home and the computer is logged on to www tdr1 com My thanks to Kilo who posted the 6 7 liter engine c
16. be to the further operation of your truck Today s conclusion is the same as it was in Issue 64 Each DTC has a unique meaning and each owner has to make a judgment call based on their situation mechanical aptitude and tolerance for repair Robert Patton TDR Staff FUTURE ECM COMPLEXITY AND CURRENT DIAGNOSTIC TROUBLE CODES In Issue 63 s Blowin in the Wind column there were quotes from the trade publication Transportation Topics that discussed future diesel emissions regulations Titled Ex EPA Official Sees No New Rules on Diesel Exhaust Emissions After 2010 the article was examined for its meaning to the TDR audience At the end of the quoted material from Transportation Topics concluded the following In trying to interpret what the No New Rules headline might actually mean for the 6 7 liter engine called one of my contacts at Cummins What took away from the phone exchange is the confident declaration that the engine is very well positioned The emissions from the 6 7 liter engine are on par with gasoline engines and the emissions horizon for gasoline is stable Reassuring Nevertheless the current notice of proposed rule NPR making has a deadline of 2013 The 2013 rules will have Dodge and Cummins further continuing modifications to meet on board diagnostics OBD requirements The bottomline more sensors and greater ECM complexity as more engine parameters are monitored controlled and rep
17. d be done in less than say 5 seconds Read the codes where the truck s odometer shows total miles not trip miles Make note of the code s and continue your research as you look up the codes and their meanings The underlying question that neither John nor have answered How serious is the code to the continuation of a trip to the convenience store or a cross country journey The cop out answer Mr Turbo Diesel owner it depends on the code and the nature of the problem We do not know the answer My conclusion from Issue 64 remains the same What have we learned In the future DTCs will continue in greater numbers and scope e You can retrieve DTCs using the key trick e You have the codes listed in this magazine Copy and carry them with you e You have a judgment decision to make should you encounter a DTC e If your problem is minor and does not reoccur the MIL light will turn off foiur drive cycles and the code will be cleared from OBD memory 40 drive cycles Editor s Update and Final Thoughts If you flipped to this text as directed in the discussion about DTCs on page 53 you can see that do not have any further updates about 5 9 liter or 6 7 liter engine derate or damage implications to share with you Author Holmes and technician Scafidi presented a good article on what codes are most common Collectively we re still looking for the answer s to how serious a code can
18. de refers to a defective exhaust gas recirculation EGR circuit Some would think that you could just replace the EGR valve and bingo the problem is solved Not so easy The EGR or exhaust gas recirculation system is composed of several components The EGR valve the vacuum or electric source that supplies the energy to open and close modulate the valve and the controls that allow the electricity or vacuum to flow to the valve Some systems even have EGR sensors Not yet convinced that it is a complicated system Add to all of the above the circuit in the microprocessor the wiring and connections the physical plugging up or carboning up of the EGR gas passages and you have a treat in store when it comes to diagnosing the problem In order to properly diagnose and repair a problem signaled by the MILs illumination you will also need a diagnostic flow chart These diagnostic charts take you through a regimen of tests specific to the code Step by step it directs you through a procedure that should bring you to a diagnosis and pinpoint the problem Then you can effectively perform the repairs needed Diagnostic charts will not fix every problem but they will teach you a tremendous amount about how that particular circuit works and the possibilities of component failure So the only way to accurately and professionally diagnose and repair the malfunction without shot gunning it with expensive components which often cannot b
19. e returned to the parts house or the dealer is to have a decent scan tool with the capability to interface with your particular application and the appropriate manual with the diagnostic flow charts You may also need some additional equipment such as a good digital multimeter a hand operated vacuum pump and even a heat gun From the scenario have presented using an automotive EGR problem as an example you can see that the answer to How much do you want to know is as unique as each Turbo Diesel owner The factory manuals are available see Issue 50 page 51 and www techauthority com The code number is easy to retrieve using the on off on off on technique that was described on page 10 There are affordable good scanners available from Auto X Ray and Actron These devices are suitable for the do it yourselfer and work well If you understand the system follow the charts and use a little common sense you should be able to keep things humming yourself and avoid the costly trips to the dealer Purchasing these tools manuals and electronic devices is not inexpensive but when a club or a few owners get together and pool their resources the cost becomes manageable If you opt for an independent repair shop be sure to question them as to what types of equipment and information systems they have in house that apply to your vehicle If they are not able to make you feel warm and fuzzy be sure to check alternative shops
20. e trade calls these malfunction indicator lights MIL Most 95 and later vehicles are controlled by the second generation computer systems called on board diagnostics ll or OBD II There are many codes in use now as compared to just a handful in the early systems OBD II systems have much greater diagnostic ability and can even track misfires down to an individual cylinder With this background information out of the way let me suggest how the diagnostic trouble codes are of benefit to the average Joe First just getting a scan tool and retrieving DTCs has never fixed a problem Even if you have a reference manual that explains what the numerical codes mean that is simply not enough to fix a car or truck If it were we would all be in much better shape 269 270 If you experience a MIL illumination and or amessage in the driver information panel the first step is to perform a good visual inspection Step two would be to retrieve the trouble code using a scan tool Once you have the code and get the definition you are now ready to start troubleshooting Let s take this example you are driving along and everything is normal Then the dreaded MIL illuminates You determine that the oil is fine the coolant is okay no belts or hoses broken and no obvious signs of a major vacuum leak or any other problem You get the scan tool out and it tells you the code number You look in the service manual and the co
21. enoid Circuits Speed Control Switch Always Low Charging System Voltage Too Low Speed Control Power Relay Or Speed Control 12 Volt Driver Circuit Internal Fuel Injection Pump Controller Failure No Communication Between ECM amp Injection Pump Module Fuel injection pump CKP Sensor Does Not Agree With ECM CKP Sensor Fuel Injection Pump Controller Calibration Failure DTC Detected In ECM Or PCM No CCD Messages Received From ECM No CCD Messages Received From PCM TCC Or OD Solenoid Performance Governor Pressure Not Equal To Target At 15 20 PSI Governor Pressure Above 3 PSI When Request Is 0 PSI Governor Pressure Sensor Offset Improper Voltage Governor Pressure Sensor Voltage Too High Governor Pressure Sensor Voltage Too Low Trans 12 Volt Supply Relay Control Circuit PNP Switch Failure Joe Donnelly TDR Writer 271
22. he optimal 14 7 1 air fuel ratio dubbed by engineers as stoichiometric This 14 7 1 air fuel mixture is critical for proper operation of the catalyst in gasoline fueled engines With the advances in microprocessor reliability manu facturers decided that using electronics to control fuel distribution and spark timing would provide more efficient engine operation over a longer period of time and thereby lower tailpipe emissions and provide better fuel economy as well as increased performance While electronic ignition provided a hotter longer duration ignition spark at the plugs it also dramatically reduced the need for periodic maintenance Replacing points every 12 thousand miles or so became ancient history in a matter of a few years The early computer systems were basic with very little intelligence and provided little or no diagnostic functions In 1981 GM introduced its first fully controlled system with diagnostic trouble codes This was the GM or Computer Command Control system To alert the operator and the technician to a possible malfunction a light on the instrument panel would illuminate The first diagnostic trouble codes DTCs were now in place The light initially read Check Engine That was confusing so now many read Service Engine Soon This can still be misleading because the light can illuminate when there is a transmission problem a suspension problem and even A C and heater malfunctions Th
23. intake Air Temperature Sensor 1 Performance P0112 intake Air Temperature Sensor Circuit Low P0113 intake Air Temperature Sensor 1 Circuit High P0116 engine Coolant Temperature Sensor Performance P0117 engine Coolant Temperature Sensor Circuit Low P0118 engine Coolant Temperature Sensor Circuit High P0128 thermostat Rationality P0131 02 Sensor 1 1 Circuit Low P0135 02 Sensor 1 1 Heater Performance P0137 02 Sensor 1 2 Circuit Low P0141 02 Sensor 1 2 Heater Performance P0148 fuel Delivery Error P0169 water In Fuel Detected For Too Long P0191 fuel Rail Pressure Sensor Circuit Performance P0192 fuel Pressure Sensor Low P0193 fuel Pressure Sensor High P0201 fuel Injector 1 Circuit open P0202 fuel Injector 2 Circuit open P0203 fuel Injector 3 Circuit open P0204 fuel Injector 4 Circuit open P0205 fuel Injector 5 Circuit open P0206 fuel Injector 6 Circuit open P0217 coolant Temperature Too High P0219 engine Overspeed P0251 injection Pump Fuel Valve Feedback P0300 multiple Cylinder Misfire P0335 crankshaft Position Sensor Circuit P0336 crankshaft Position Sensor Performance P0340 camshaft Position Sensor Circuit Bank 1 Sensor 1 P0341 camshaft Position Sensor Performance Bank 1 Sensor 1 P0381 wait To Start Lamp Inoperative P0400 egr System Flow Malfunction P0401 egr System Performance P0402 egr Flow Excessive Detected P0403 egr Control Circuit open P0404 egr Position Sensor Performance Diesel P0405 egr Position
24. l flash turbo clean or replacement Moving backward to the 03 07 Third Generation 5 9 liter common rail diesels P0148 Fuel Delivery Error restriction fuel filter transfer pump injectors P0191 Fuel Rail Pressure Sensor Circuit Performance flash P0201 through P0206 Fuel Injector 1 through 6 Circuit Open engine miss electrical valve cover gasket P0301 through P0306 Cylinder 1 through 6 Misfire engine miss mechanical P0606 Internal Control Processor PCM failure this one can also apply to the 6 7L P0341 Camshaft Position Sensor Performance Bank 1 Sensor 1 Sensor ECM wiring or even a cam shaft The above items are important to get fixed but P0514 Battery Temperature Sensor Performance is a just a nuisance flash A flash will also take care of P0111 Intake Air Temperature Sensor 1 Performance An aftermarket performance box can set these P0335 and P0336 Crankshaft Position Sensor Circuit and Performance no fix light will eventually go out Some units like to set P0513 Invalid Skim Key vehicle runs fine Watch out for P0628 Low Voltage Detected at Lift Pump generally means the pump is going out sometimes shows up on the 24 valves too Again trotting backwards to the 98 5 02 Second Generation 24 valve engines P0216 Injection Pump Timing Failure bad news may mean replacement check transfer pump VOLUME
25. made up a new entry in the Webster Dictionary And EVIC was defined earlier as an acronym for the overhead electronic vehicle information center EVIC If you will look back at Issue 63 pages 38 39 you will find TSB 18 013 08 Revision A dated 12 04 08 which describes a reflash for 07 09 DH D1 that s Dodge speak for 2500 3500 pickup trucks If you will look at our summary of TSB 18 001 09 you will see that there is another reflash program for the 6 7 liter engine that is used in 07 09 DC DM Dodge speak for 3500 4500 5500 Cab and Chassis trucks These twoTSB revisions use the overhead EVIC to warn the owner of Do Not Pass Go Do Not Collect 200 messages that will disable the engine due to emissions related problems For examples of these messages see the sidebar that we are reprinting from Issue 62 All vehicles built after March 2008 or those fully updated per TSBs 18 013 08 and 18 001 09 have the software for the new messages that will appear on the EVIC should there be emissions problems The EVIC display of an impending engine problem is serious news and owners should take immediate corrective action at a Dodge dealership Make It Go Away Will your DTC simply go away Sure that s what black electrical tape is used for Seriously look back at TDR Issue 61 page 88 and John Holmes write up on an inexpensive scan tool monitor system Purchase the Scan Gauge and clear the fault It will work on
26. mperature Sensor Circuit Low Bank 1 Sensor 1 P0546 exhaust Gas Temperature Sensor Circuit High Bank 1 Sensor 1 P0562 battery Voltage Low P0563 battery Voltage High P0571 brake Switch 1 Performance P0572 brake Switch 1 Stuck On P0573 brake Switch 1 Stuck Off P0580 speed Control Switch 1 Circuit Low P0581 speed Control Switch 1 Circuit High P0585 speed Control Switch 1 2 Correlation P0592 speed Control Switch 2 Circuit Low P0593 speed Control Switch 2 Circuit High P0601 internal Memory Checksum Invalid P0604 internal Control Module Ram P0606 internal Control Processor P0607 Ecu Internal Performance P061a etc Level 2 Torque Performance P061c etc Level 2 Rpm Performance P0622 generator Field Control Circuit open P0628 fuel Pump Control Circuit Low P0629 fuel Pump Control Circuit High P062c etc Level 2 Mph Performance P0630 vin Not Programmed In Pem P0633 skim Secret Key Not Stored In Pem P063c generator Voltage Sense Low P063d generator Voltage Sense High P0642 sensor Reference Voltage 1 Circuit Low P0643 sensor Reference Voltage 1 Circuit High P0646 a c Control Circuit Low P0647 a c Control Circuit High P0652 sensor Reference Voltage 2 Low A Publication of the TURBO DIESEL REGISTER P0653 sensor Reference Voltage 2 High P065a generator System Performance P0698 sensor Reference Voltage 3 Circuit Low P0699 sensor Reference Voltage 3 Circuit High P06a4 sensor Reference Voltage 4 Circuit Low P0Q6a5 sens
27. not pressure fuel gauge can help prevent this A Publication of the TURBO DIESEL REGISTER P0234 Turbo Boost Limit Exceeded usually occurs with the use of a boost elbow on the turbo that comes with a power enhancement package you ll have to live with it or go back to stock In the dealership the technicians use a DRB III for trucks up through 2005 They use a StarScan StarMobile or the new Witech for trucks 2006 and newer These devices are specific Chrysler diagnostic tools and are pricey Today the average owner can buy an aftermarket scan tool for a very reasonable price although it won t beas sophisticated as those mentioned above One example is the ScanGauge Il that wrote about in Issue 61 on page 88 However that one does a whole bunch of things more than read and clear codes Companies that make units of varying sophistication and pricing levels are AutoXray Actron Equus Products CarMD check the Internet and if you drop by Harbor Freight Tools you ll discover it s a good source for similar items Any of the tool peddlers like Snap on Mac Cornwell or Matco will also have similar types of scanners Put this in your next letter to Santa John Holmes TDR Writer Editor s note John s article on diagnostic trouble codes DTCs goes hand in hand with my article on DTCs in Issue 64 pages 46 49 In that article listed the codes that are applicable for the 6 7 liter engine how to retrieve the
28. ode numbers and descriptions last October The table P0016 Crankshaft camshaft Timing Misalignment Bank 1 Sensor 1 P0031 O2 Sensor 1 1 Heater Circuit Low P0037 O2 Sensor 1 2 Heater Circuit Low P003a Turbocharger Boost Control Module Position Exceeded Learning Limit P0046 Turbocharger Boost Control Circuit Performance P0049 Turbocharger Turbine Overspeed P006e Turbocharger Boost Control Module Supply Voltage Circuit Low POO6f Turbocharger Boost Control Supply Voltage Circuit High P0071 Inlet Air Temp Sensor Rationality ECM 213 214 P0071 ambient Air Temperature Sensor Performance tipm P0072 inlet Air Temp Sensor Voltage Too Low Ecm P0072 ambient Air Temperature Sensor Circuit Low tipm P0073 inlet Air Temp Sensor Voltage Too High Ecm P0073 ambient Air Temperature Sensor Circuit High tipm P007c charge Air Cooler Temperature Sensor Circuit Low P007d charge Air Cooler Temperature Sensor Circuit High P007e charge Air Cooler Temperature Sensor Circuit Intermittent erratic P0087 fuel Rail Pressure Too Low P0088 fuel Rail Pressure Too High POOaf turbocharger Boost Control Module Performance P0101 mass Air Flow Sensor a Circuit Performance P0102 mass Air Flow Sensor a Circuit Low P0103 mass Air Flow Sensor a Circuit High P0106 manifold Absolute Pressure Sensor Performance P0107 manifold Absolute Pressure Sensor Circuit Low P0108 manifold Absolute Pressure Sensor Circuit High P0111
29. or Reference Voltage 4 Circuit High P0700 transmission Control System mil Request P0850 park neutral Switch Performance P1011 Fuel Pump Delivery Pressure Too Low P1012 Fuel Pump Delivery Pressure Too High P1191 Inlet Air Temperature Sensor Rational performance P1192 Inlet Air Temperature Sensor Low P1193 Inlet Air Temperature Sensor High P113c 02 Sensor Power Supply Circuit Performance P125a power Enable Control Circuit Low P125b power Enable Control Circuit High P1272 a c Clutch Control Circuit 2 Low tipm P1273 a c Clutch Control Circuit 2 High tipm P1274 a c Clutch Control Circuit 2 Open tipm P1275 a c Clutch Control Circuit 2 Overcurrent tipm P1277 starter Control Circuit 2 Low tipm P1278 starter Control Circuit 2 High tipm P1279 starter Control Circuit 2 Open tipm P127a starter Control Circuit 2 Overcurrent tipm P127c fuel Pump Control Circuit 2 Low tipm P127d fuel Pump Control Circuit 2 High tipm P127e fuel Pump Control Circuit 2 Open tipm P127f fuel Pump Control Circuit 2 Overcurrent tipm P141a exhaust Gas Temperature Sensor 1 And 2 Signals Swapped P144e egr Cooler Bypass Status Line Circuit Low P144f egr Cooler Bypass Status Line Circuit High P1451 diesel Particulate Filter System Performance P1484 catalyst Overheat Detection P1506 crankcase Depression Regulator Valve Performance P1507 crankcase Filter Restriction P1508 crankcase Filter Restriction Replace Filter P20
30. orted through OBD read outs No rest for the weary Do you need further evidence of the greater ECM complexity and more items being monitored and reported Well you did not have to look any further than the summary of the latest technical service bulletin TSB 18 013 08 Revision A which was released in December and applies to all 6 7 liter engines produced prior to November 27 2008 The summary was in Issue 63 on pages 38 and 39 Did you miss the correlation of further diagnostics and the implementation of modifications on the 6 7 liter engine I ll save you from searching through your TDR library Here is the text Owners should also note that with the revised software of TSB 18 013 08 Revision A a number of improvements have been made to the engine diagnostics Performing this service bulletin completely will enable these diagnostic improvements e Improved Fuel Level Sensor diagnostics in the ECM e Improvement to the single diagnostic DTC P0148 Fuel Delivery Error This DTC is now addressed by the following two DTC diagnostics P1011 Fuel Pump Delivery Pressure Too Low P1012 Fuel Pump Delivery Pressure Too High A Publication of the TURBO DIESEL REGISTER e Creation of three new DTC s to address the inlet air temperature sensor separate from the ambient air temperature sensor The new DTC s are P1191 Inlet Air Temperature Sensor Rationality Performance This DTC enhances the current DTC P0071
31. tter check it out and see if there s cause for concern If it goes out after about five restarts that generally indicates no reason for concern However the code will still be stored in the PCM ECM The codes can sort of be deciphered as follows P Powertrain B Body C Chassis On the second digit its either 0 Standard or 1 Manufacturer specific Generally the third digit breaks down this way 1 A Publication of the TURBO DIESEL REGISTER Emissions management 2 Injector circuit 3 Ignition 4 Auxiliary emissions 5 Vehicle speed and idle control 6 Computer and output circuit 7 Transmission The ones Dario highlighted on the 6 7 liter engines are P1451 Diesel Particulate Filter System Performance emissions re clean needed maybe replace DPF P2000 NOx Absorber Efficiency Below Threshold Bank 1 emissions O2 sensors P2002 Diesel Particulate Filter Efficiency Below Threshold emissions P200C Diesel Particulate Filter Over Temperature Bank 1 emissions P200E Catalyst System Over Temperature Bank 1 emissions P2463 Diesel Particulate Filter Soot Accumulation DPF full possible regeneration or replacement As you can see these all pertain to the emissions system and they should be checked right away to avoid expensive repairs or replacements The other serious 6 7 liter code often seen is P2262 Turbocharger Boost Pressure Not Detected Mechanica

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