DaimlerChrysler Jeep Grand Cherokee 2002 Service Manual

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1.0

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.1

SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2

SIX-STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . .1

2.0

IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.0

SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1

3.1

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.2

FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.2.1

3.2.2

3.2.3

3.2.4

3.2.5

3.2.6

3.3

DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3.3.1

3.3.2

3.3.3

3.3.4

3.3.5

3.4

USING THE DRBIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3.4.1

3.4.2

4.0

DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4.1

DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4.2

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4.2.1

4.2.2

4.2.3

4.2.4

4.3

WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

4.3.1

4.3.2

5.0

REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

6.0

GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

7.0

DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . .11

COMMUNICATION

*NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY . . . . . . . . . . . . . . . . . . . . . .12

*NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY . . . . . . . . . . . . . . . . . . . . .13

*PCI BUS COMMUNICATION FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

DRIVEABILITY - DIESEL

P0070-AMBIENT AIR TEMPERATURE CIRCUIT SIGNAL VOLTAGE TOO HIGH . . . .18

P0070-AMBIENT AIR TEMPERATURE CIRCUIT SIGNAL VOLTAGE TOO LOW . . . .18

P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH . . . . . . . . . . . . . . .20

ECM ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

ECM OPERATING MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

MONITORED CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

SKIS OVERIVEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

SKIS ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

SKIS OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

HARD CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

INTERMITTENT CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

ECM DIAGNOSTIC TROUBLE CODES. . . . . . . . . . . . . . . . . . . . . . . . . .3

SKIM DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . .6

HANDLING NO TROUBLE CODE PROBLEMS . . . . . . . . . . . . . . . . . . .7

DRBIII DOES NOT POWER UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

DISPLAY IS NOT VISIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

TECHNICIAN SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . .7

VEHICLE PREPARATION FOR TESTING. . . . . . . . . . . . . . . . . . . . . . . .8

SERVICING SUB-ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

DRBIII SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

ROAD TEST WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

VEHICLE DAMAGE CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Table of Contents

Summary of Contents for DaimlerChrysler Jeep Grand Cherokee 2002

Page 1: Table Of Contents
TABLE OF CONTENTS INTRODUCTION ............1 SYSTEM COVERAGE .
Page 2 TABLE OF CONTENTS - Continued P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO LOW ....20 P0100-MASS AIR FLOW SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW ..20 P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH .
Page 3 TABLE OF CONTENTS - Continued P0204-CYLINDER 4-INJECTOR CIRCUIT OVERCURRENT LOW SIDE ...47 P0205-CYLINDER 5-INJECTOR CIRCUIT CURRENT DECREASE ....47 P0205-CYLINDER 5-INJECTOR CIRCUIT LOAD DROP .
Page 4 TABLE OF CONTENTS - Continued P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO LOW..131 P0620-GENERATOR FIELD CONTROL MALF CHARGING VOLTS TOO LOW ..131 P0620-GENERATOR FIELD CONTROL MALF HIGH GENERATOR CURRENT ..131 P0620-GENERATOR FIELD CONTROL MALF OPEN CIRCUIT ....131 P0620-GENERATOR FIELD CONTROL MALF SHORT CIRCUIT .
Page 5 TABLE OF CONTENTS - Continued P1242-CAN BUS MESSAGE MISSING ........174 P1242-CAN BUS MESSAGE MISSING FROM TCM .
Page 6 TABLE OF CONTENTS - Continued *ENGINE CRANKS BUT WILL NOT START ....... . .234 *ENGINE WILL NOT CRANK .
Page 7 TABLE OF CONTENTS - Continued FUEL PRESSURE SOLENOID (DIESEL) - BLACK 2 WAY .....265 FUEL TANK MODULE (DIESEL) - BLACK 6 WAY ......265 GENERATOR (DIESEL) - LT.
Page 8 NOTES viii...
Page 9: Introduction
GENERAL INFORMATION 1.0 INTRODUCTION 2.0 IDENTIFICATION OF SYSTEM The procedures contained in this manual include all specifications, instructions and graphics needed The ECM is located in the left side of the engine to diagnose engine control module (ECM) and sen- compartment attached to the left inner fender be- try key immobilizer system (SKIS) problems;...
Page 10: Ecm Operating Modes
GENERAL INFORMATION 3.2.2 ECM OPERATING MODES circuitry. In addition, the ECM monitors the voltage state of some circuits and compares those states As input signals to the ECM change, the ECM with expected values. Other systems are monitored adjusts its response to the output devices. For indirectly when the ECM conducts a rationality test example, the ECM must calculate a different fuel to identify problems.
Page 11: Diagnostic Trouble Codes
GENERAL INFORMATION to the message sent by SKIM. After responding to 3.3 DIAGNOSTIC TROUBLE CODES the coded message, the transponder sends a tran- sponder ID message to the SKIM. The SKIM com- Each diagnostic trouble code (DTC) is diagnosed pares the transponder ID message to the available by following a specific procedure.
Page 12 GENERAL INFORMATION (i.e. relays and solenoids) and shorted circuits (i.e. BATTERY SENSE LINE 2 VOLTAGE TOO LOW sensor pull-ups, drivers and ground circuits). These BATTERY TEMP SENSOR CIRCUIT SIGNAL faults are difficult to detect when a double fault has VOLTAGE TOO HIGH occurred and only one DTC has set.
Page 13 GENERAL INFORMATION CYLINDER 3-INJECTOR CIRCUIT OVERCUR- FUEL PRESS SENSOR CIRCUIT MALF SIG- RENT LOW SIDE NAL VOLTAGE TOO LOW CYLINDER 4-INJECTOR CIRCUIT CURRENT FUEL PRESS SENSOR CIRCUIT MALF SUP- DECREASE PLY VOLTAGE TOO HIGH OR LOW CYLINDER 4-INJECTOR CIRCUIT LOAD FUEL PRESSURE SOLENOID OPEN CIRCUIT DROP FUEL PRESSURE SOLENOID POWER STAGE...
Page 14: Skim Diagnostic Trouble Codes
GENERAL INFORMATION INTAKE PORT SWIRL ACTUATOR OPEN CIR- SYSTEM VOLTAGE TOO LOW CUIT TRANSFER CASE POSITION SENSOR PLAU- INTAKE PORT SWIRL ACTUATOR SHORT SIBILITY CIRCUIT TRANSFER CASE POSITION SENSOR PLAU- J1850 COMMUNICATION BUS LOST ARBI- SIBILITY 2 TRATION TRANSFER CASE POSITION SENSOR SIG- J1850 COMMUNICATION BUS RECEIVE TIM- NAL VOLTAGE TOO HIGH EOUT...
Page 15: Handling No Trouble Code Problems
GENERAL INFORMATION 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...
Page 16: Vehicle Preparation For Testing
GENERAL INFORMATION 4.2.2 VEHICLE PREPARATION FOR • Use the low current shunt to measure circuits up to 10 amps. Use the high current shunt to mea- TESTING sure circuits exceeding 10 amps. Make sure the vehicle being tested has a fully •...
Page 17: Glossary Of Terms
GENERAL INFORMATION 6.0 GLOSSARY OF TERMS intake air temperature (sensor) lack of the engine power output has been air conditioning power, reduced sluggish accelerator pedal position (sensor) mass air flow (sensor) automatic shut down malfunction indicator lamp backfire, fuel ignites in either the intake or popback the exhaust system millisecond(s)
Page 18 NOTES...
Page 19: Diagnostic Information And Procedures
DIAGNOSTIC INFORMATION AND PROCEDURES...
Page 20: Communication
COMMUNICATION Symptom: *NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY POSSIBLE CAUSES ECM PCI NO RESPONSE PCI BUS CIRCUIT OPEN ENGINE CONTROL MODULE TEST ACTION APPLICABILITY Turn the ignition on. NOTE: As soon as one or more module communicates with the DRB, answer the question.
Page 21: Response From Ecm (Sci Only) - Diesel Only
COMMUNICATION Symptom: *NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY POSSIBLE CAUSES CHECK ECM POWERS AND GROUNDS SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE TRANSMISSION CONTROL MODULE SCI TRANSMIT CIRCUIT SHORTED TO GROUND SCI TRANSMIT CIRCUIT OPEN ENGINE CONTROL MODULE TEST ACTION APPLICABILITY...
Page 22 COMMUNICATION *NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY — Continued TEST ACTION APPLICABILITY 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.
Page 23: Pci Bus Communication Failure
COMMUNICATION Symptom: *PCI BUS COMMUNICATION FAILURE POSSIBLE CAUSES WITH THE DRB PERFORM A MODULE SCAN OPEN PCI BUS CIRCUIT AT THE DATA LINK 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...
Page 24 COMMUNICATION *PCI BUS COMMUNICATION FAILURE — Continued TEST ACTION APPLICABILITY Note: Determine which modules this vehicle is equipped with before begin- ning. Connect the Diagnostic Junction Port Tester #8339 to the DRB and to the Diagnostic Junction Port. Using the DRB, along with the Diagnostic Junction Port Tester #8339, select Junction Port Tool then PCI Bus Control Mode and follow the instructions on the DRB.
Page 25 COMMUNICATION *PCI BUS COMMUNICATION FAILURE — Continued TEST ACTION APPLICABILITY Disconnect the negative battery cable. Measure the resistance between ground and the PCI Bus circuit at the Diagnostic Junction Port tester that previously measured below 100.0 ohms. Disconnect the module harness connector(s). NOTE: If the problem occurred on a bus circuit that has more than one module on the same circuit, observe the ohmmeter while disconnecting each module connector one at a time.
Page 26: P0070-Ambient Air Temperature Circuit Signal Voltage Too High
DRIVEABILITY - DIESEL Symptom List: P0070-AMBIENT AIR TEMPERATURE CIRCUIT SIGNAL VOLTAGE TOO HIGH P0070-AMBIENT AIR TEMPERATURE CIRCUIT SIGNAL VOLTAGE TOO LOW Test Note: All symptoms listed above are diagnosed using the same tests. The title for the tests will be P0070-AMBIENT AIR TEMPER- ATURE CIRCUIT SIGNAL VOLTAGE TOO HIGH.
Page 27 DRIVEABILITY - DIESEL P0070-AMBIENT AIR TEMPERATURE CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.
Page 28: P0100-Mass Air Flow Sensor Signal Voltage Too High
DRIVEABILITY - DIESEL Symptom List: P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO LOW P0100-MASS AIR FLOW SENSOR SUPPLY VOLTAGE TOO HIGH OR Test Note: All symptoms listed above are diagnosed using the same tests. The title for the tests will be P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH.
Page 29 DRIVEABILITY - DIESEL P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH — Continued POSSIBLE CAUSES SENSOR REFERENCE VOLTAGE A CIRCUIT SHORTED TO GROUND MAF SENSOR SIGNAL CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT FUEL PRESSURE SENSOR 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE SENSOR REFERENCE VOLTAGE A CIRCUIT SHORTED TO VOLTAGE MAF SENSOR CIRCUIT SHORTED TO VOLTAGE ECM - MAF SENSOR SIGNAL CIRCUIT...
Page 30 DRIVEABILITY - DIESEL P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the MAF Sensor harness connector. Disconnect the ECM harness connectors. Measure the resistance of the MAF Sensor Signal circuit. Is the resistance below 10.0 ohms? Yes →...
Page 31 DRIVEABILITY - DIESEL P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the MAF Sensor harness connector. Turn the ignition on. Measure the voltage between the 5-volt Supply circuit and the Sensor Ground circuit at the MAF Sensor harness connector.
Page 32 DRIVEABILITY - DIESEL P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the MAF Sensor harness connector. Disconnect the ECM harness connectors. Measure the resistance between ground and the Sensor Reference Voltage A circuit at the MAF harness connector.
Page 33 DRIVEABILITY - DIESEL P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY 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.
Page 34 DRIVEABILITY - DIESEL Symptom List: P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO P0606-ECM ERROR GATE ARRAY - COMMUNICATION P0606-ECM ERROR GATE ARRAY - COMMUNICATION NOT VERI- FIED P0606-ECM ERROR GATE ARRAY - QUANTITY STOP P0606-ECM ERROR RECOVERY HAS OCCURRED P0606-ECM ERROR REDUNDANT OVERRUN MONITORING P1206-CALCULATED INJECTOR VOLTAGE TOO HIGH...
Page 35 DRIVEABILITY - DIESEL P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO LOW When Monitored: With the ignition on. Set Condition: The Barometric Pressure Sensor Signal is below 0.22 volts. P0606-ECM ERROR GATE ARRAY - COMMUNICATION When Monitored: With the ignition on.
Page 36 DRIVEABILITY - DIESEL P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued 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 the codeword test routine not yet performed (for injector classification).
Page 37 DRIVEABILITY - DIESEL P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY NOTE: This DTC indicates an internal ECM problem. Turn the ignition on. With the DRBIII , erase ECM DTCs. Perform several engine run cycles, turning the ignition off for at least 20 seconds between each engine run cycle.
Page 38 DRIVEABILITY - DIESEL Symptom: P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH When Monitored and Set Condition: P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH When Monitored: With the ignition on. Set Condition: The Intake Air Temperature Sensor Signal voltage is above 4.83 volts. POSSIBLE CAUSES INTERMITTENT CONDITION INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE...
Page 39 DRIVEABILITY - DIESEL P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the ECM harness connectors. Disconnect the IAT Sensor harness connector. Measure the resistance of the Intake Air Temperature Sensor Signal circuit. Is the resistance below 5.0 ohms? Yes →...
Page 40 DRIVEABILITY - DIESEL P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN.
Page 41 DRIVEABILITY - DIESEL Symptom: P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW When Monitored and Set Condition: P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW When Monitored: With the ignition on. Set Condition: The Intake Air Temperature Sensor Signal voltage is below 0.073 volt. POSSIBLE CAUSES INTERMITTENT CONDITION IAT SENSOR...
Page 42 DRIVEABILITY - DIESEL P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the ECM harness connectors. Disconnect the IAT Sensor harness connector. Measure the resistance between the Intake Air Temperature Sensor Signal circuit and the Sensor Ground circuit.
Page 43 DRIVEABILITY - DIESEL Symptom: P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLT- AGE TOO HIGH When Monitored and Set Condition: P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH When Monitored: With the ignition on. Set Condition: The Engine Coolant Temperature Sensor Signal voltage is above 4.98 volts for more than 3 seconds.
Page 44 DRIVEABILITY - DIESEL P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued TEST 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.
Page 45 DRIVEABILITY - DIESEL P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN.
Page 46 DRIVEABILITY - DIESEL Symptom: P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLT- AGE TOO LOW When Monitored and Set Condition: P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO When Monitored: With the ignition on. Set Condition: The Engine Coolant Temperature Sensor Signal voltage is below 0.073 volt for more than 3 seconds.
Page 47 DRIVEABILITY - DIESEL P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the ECM harness connectors. Disconnect the ECT Sensor harness connector. Measure the resistance between the ECT Sensor Signal circuit and Sensor Ground circuit.
Page 48 DRIVEABILITY - DIESEL Symptom: P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH 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...
Page 49 DRIVEABILITY - DIESEL P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. 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.
Page 50 DRIVEABILITY - DIESEL P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY 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.
Page 51 DRIVEABILITY - DIESEL P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN.
Page 52 DRIVEABILITY - DIESEL Symptom: P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW When Monitored and Set Condition: P0190-FUEL 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...
Page 53 DRIVEABILITY - DIESEL P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW — Continued TEST 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 →...
Page 54 DRIVEABILITY - DIESEL Symptom: P0190-FUEL PRESS SENSOR CIRCUIT MALF SUPPLY VOLTAGE TOO HIGH OR LOW When Monitored and Set Condition: P0190-FUEL PRESS SENSOR CIRCUIT MALF SUPPLY VOLTAGE TOO HIGH OR When Monitored: With the ignition on. Set Condition: The Fuel Pressure Sensor 5-Volt Supply voltage is below 4.9 volts or above 5.1 volts for 100 ms.
Page 55: P0204-Cylinder 4-Injector Circuit Overcurrent Low Side
DRIVEABILITY - DIESEL Symptom List: P0201-CYLINDER 1-INJECTOR CIRCUIT CURRENT DECREASE P0201-CYLINDER 1-INJECTOR CIRCUIT LOAD DROP P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT LOW SIDE P0202-CYLINDER 2-INJECTOR CIRCUIT CURRENT DECREASE P0202-CYLINDER 2-INJECTOR CIRCUIT LOAD DROP P0202-CYLINDER 2-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE P0202-CYLINDER 2-INJECTOR CIRCUIT OVERCURRENT LOW SIDE...
Page 56 DRIVEABILITY - DIESEL P0201-CYLINDER 1-INJECTOR CIRCUIT CURRENT DECREASE — Continued P0201-CYLINDER 1-INJECTOR CIRCUIT LOAD DROP When Monitored: With the engine running. Set Condition: The ECM detects insufficient current through the injector driver when on. P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE When Monitored: With the engine running.
Page 57 DRIVEABILITY - DIESEL P0201-CYLINDER 1-INJECTOR CIRCUIT CURRENT DECREASE — Continued P0203-CYLINDER 3-INJECTOR CIRCUIT OVERCURRENT LOW SIDE When Monitored: With the engine running. Set Condition: The ECM detects excessive current on the injector driver circuit. P0204-CYLINDER 4-INJECTOR CIRCUIT CURRENT DECREASE When Monitored: With the engine running. Set Condition: The ECM detects an incorrect rate of current decrease after injection occurs.
Page 58 DRIVEABILITY - DIESEL P0201-CYLINDER 1-INJECTOR CIRCUIT CURRENT DECREASE — Continued POSSIBLE CAUSES ENGINE CONTROL MODULE INTERMITTENT CONDITION FUEL INJECTOR CONTROL CIRCUIT SHORTED TO VOLTAGE COMMON DRIVER CIRCUIT SHORTED TO VOLTAGE FUEL INJECTOR CONTROL CIRCUIT SHORTED TO GROUND COMMON DRIVER CIRCUIT SHORTED TO GROUND FUEL INJECTOR CIRCUITS SHORTED TOGETHER FUEL INJECTOR CONTROL CIRCUIT OPEN COMMON DRIVER CIRCUIT OPEN...
Page 59 DRIVEABILITY - DIESEL P0201-CYLINDER 1-INJECTOR CIRCUIT CURRENT DECREASE — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the ECM harness connectors. Disconnect the Cylinder Fuel Injector harness connector. Measure the resistance between ground and the Fuel Injector Control circuit. Is the resistance below 1000 ohms? Yes →...
Page 60 DRIVEABILITY - DIESEL P0201-CYLINDER 1-INJECTOR CIRCUIT CURRENT DECREASE — Continued TEST ACTION APPLICABILITY Turn the ignition off. Replace the Cylinder Fuel Injector in accordance with the Service Information. With the DRBIII , erase the ECM DTCs. Test drive the vehicle. With the DRBIII , read the ECM DTCs.
Page 61: P0235-Boost Pressure Sensor Plausibility
DRIVEABILITY - DIESEL Symptom: P0235-BOOST PRESSURE SENSOR PLAUSIBILITY When Monitored and Set Condition: P0235-BOOST PRESSURE SENSOR PLAUSIBILITY When Monitored: With the engine speed below 800 rpm. Set Condition: When the engine is idling, the boost pressure sensor input differs from the barometric pressure sensor input by 2.17 psi for at least 6 seconds.
Page 62 DRIVEABILITY - DIESEL P0235-BOOST PRESSURE SENSOR PLAUSIBILITY — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the Boost Pressure Sensor harness connector. Disconnect the ECM harness connectors. Measure the resistance of the Sensor Ground circuit. Is the resistance below 5.0 ohms? Yes →...
Page 63: P0235-Boost Pressure Sensor Signal Voltage Too High
DRIVEABILITY - DIESEL Symptom: P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH 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 4.85 volts for at least 2 seconds.
Page 64 DRIVEABILITY - DIESEL P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the Boost 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.
Page 65 DRIVEABILITY - DIESEL P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. 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.
Page 66: P0235-Boost Pressure Sensor Signal Voltage Too Low
DRIVEABILITY - DIESEL Symptom: P0235-BOOST 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 0.30 volt for at least 2 seconds.
Page 67 DRIVEABILITY - DIESEL P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the Boost Pressure Sensor harness connector. Disconnect the ECM harness connectors. Measure the resistance between ground and the Boost Pressure Sensor Signal circuit.
Page 68 DRIVEABILITY - DIESEL P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.
Page 69: P0235-Boost Pressure Sensor Supply Voltage Too High Or Low
DRIVEABILITY - DIESEL 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: The Sensor Reference Voltage B voltage to the Boost Pressure Sensor is below 4.8 volts or above 5.2 volts for at least 100 ms.
Page 70 DRIVEABILITY - DIESEL P0235-BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the Boost Pressure Sensor harness connector. Disconnect the ECM harness connectors. Measure the resistance between ground and the Sensor Reference Voltage B circuit at the Boost Pressure Sensor harness connector.
Page 71 DRIVEABILITY - DIESEL P0235-BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN.
Page 72: P0243-Turbocharger Wastegate Solenoid Circuit Open Circuit
DRIVEABILITY - DIESEL Symptom: P0243-TURBOCHARGER WASTEGATE SOLENOID CIRCUIT OPEN CIRCUIT When Monitored and Set Condition: P0243-TURBOCHARGER WASTEGATE SOLENOID CIRCUIT OPEN CIRCUIT When Monitored: With the ignition on. Set Condition: The ECM detects an open or short to ground on the Turbocharger Wastegate Solenoid Control circuit.
Page 73 DRIVEABILITY - DIESEL P0243-TURBOCHARGER WASTEGATE SOLENOID CIRCUIT OPEN CIR - CUIT — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the Turbocharger Wastegate Solenoid harness connector. Disconnect the ECM harness connectors. Measure the resistance between ground and the Turbocharger Wastegate Solenoid Control circuit.
Page 74 DRIVEABILITY - DIESEL P0243-TURBOCHARGER WASTEGATE SOLENOID CIRCUIT OPEN CIR - CUIT — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.The following list may help in identifying the intermittent condition.
Page 75: P0243-Turbocharger Wastegate Solenoid Circuit Short Circuit
DRIVEABILITY - DIESEL Symptom: P0243-TURBOCHARGER WASTEGATE SOLENOID CIRCUIT SHORT CIRCUIT When Monitored and Set Condition: P0243-TURBOCHARGER WASTEGATE SOLENOID CIRCUIT SHORT CIRCUIT When Monitored: With the ignition on. Set Condition: The ECM detects a short to battery on the Turbocharger Wastegate Solenoid Control circuit.
Page 76 DRIVEABILITY - DIESEL P0243-TURBOCHARGER WASTEGATE SOLENOID CIRCUIT SHORT CIRCUIT — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the Turbocharger Wastegate Solenoid 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.
Page 77: P0335-Ckp Sensor Circuit Dynamic Plausibility
DRIVEABILITY - DIESEL Symptom: P0335-CKP SENSOR CIRCUIT DYNAMIC PLAUSIBILITY When Monitored and Set Condition: P0335-CKP SENSOR CIRCUIT DYNAMIC PLAUSIBILITY When Monitored: With the engine cranking or running. Set Condition: The ECM detects a change in engine speed that has occurred more rapidly than is physically possible by the engine.
Page 78 DRIVEABILITY - DIESEL P0335-CKP SENSOR CIRCUIT DYNAMIC PLAUSIBILITY — Continued TEST ACTION APPLICABILITY Replace the Crankshaft Position Sensor in accordance with the Service Information. With the DRB, erase ECM DTCs. Perform several drive cycles, turning the ignition off for at least 10 seconds between each drive cycle.
Page 79: P0340-Cmp/Ckp Position Sensor Circuit - Ckp Dynamic Plausibility
DRIVEABILITY - DIESEL Symptom: P0340-CMP/CKP POSITION SENSOR CIRCUIT - CKP DYNAMIC PLAUSIBILITY When Monitored and Set Condition: P0340-CMP/CKP POSITION SENSOR CIRCUIT - CKP DYNAMIC PLAUSIBILITY When Monitored: The engine speed is above 790 RPM. Set Condition: The ECM compares the current crankshaft RPM to the last calculated crankshaft RPM and the acceleration or deceleration is greater than is physically possible.
Page 80 DRIVEABILITY - DIESEL P0340-CMP/CKP POSITION SENSOR CIRCUIT - CKP DYNAMIC PLAUSI - BILITY — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN.
Page 81 DRIVEABILITY - DIESEL P0340-CMP/CKP POSITION SENSOR CIRCUIT - CKP DYNAMIC PLAUSI - BILITY — Continued TEST ACTION APPLICABILITY 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.
Page 82: P0340-Cmp/Ckp Position Sensor Circuit - Cmp/Ckp Sync Failure
DRIVEABILITY - DIESEL Symptom: P0340-CMP/CKP POSITION SENSOR CIRCUIT - CMP/CKP SYNC FAILURE When Monitored and Set Condition: P0340-CMP/CKP 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.
Page 83 DRIVEABILITY - DIESEL P0340-CMP/CKP POSITION SENSOR CIRCUIT - CMP/CKP SYNC FAIL - URE — Continued TEST 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 →...
Page 84 DRIVEABILITY - DIESEL P0340-CMP/CKP POSITION SENSOR CIRCUIT - CMP/CKP SYNC FAIL - URE — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN.
Page 85: P0340-Cmp/Ckp Position Sensor Circuit - Signal Frequency Too
DRIVEABILITY - DIESEL Symptom List: P0340-CMP/CKP POSITION SENSOR CIRCUIT - SIGNAL FRE- QUENCY TOO HIGH P0340-CMP/CKP POSITION SENSOR CIRCUIT - STATIC PLAUSI- BILITY Test Note: All symptoms listed above are diagnosed using the same tests. The title for the tests will be P0340-CMP/CKP POSITION SENSOR CIRCUIT - SIGNAL FREQUENCY TOO HIGH.
Page 86 DRIVEABILITY - DIESEL P0340-CMP/CKP POSITION SENSOR CIRCUIT - SIGNAL FREQUENCY TOO HIGH — Continued TEST ACTION APPLICABILITY NOTE: The Timing Belt must be correctly installed and operational before diagnosis can be made. Refer to the Service Information to ensure the timing belt is properly installed.
Page 87 DRIVEABILITY - DIESEL P0340-CMP/CKP POSITION SENSOR CIRCUIT - SIGNAL FREQUENCY TOO HIGH — Continued TEST ACTION APPLICABILITY 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.
Page 88 DRIVEABILITY - DIESEL P0340-CMP/CKP POSITION SENSOR CIRCUIT - SIGNAL FREQUENCY TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the CMP Sensor harness connector. Disconnect the ECM harness connectors. Measure the resistance of the CMP Sensor Signal circuit. Is the resistance below 10.0 ohms? Yes →...
Page 89: P0380-Glow Plug 1 Control Circuit - Open Circuit
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 P0380-GLOW PLUG 1 CONTROL CIRCUIT - OPEN CIRCUIT.
Page 90 DRIVEABILITY - DIESEL P0380-GLOW PLUG 1 CONTROL CIRCUIT - OPEN CIRCUIT — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.
Page 91 DRIVEABILITY - DIESEL P0380-GLOW PLUG 1 CONTROL CIRCUIT - OPEN CIRCUIT — Continued TEST ACTION APPLICABILITY Turn the ignition off. 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? Yes →...
Page 92: P0382-Glow Plug 2 Control Circuit - Open Circuit
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 be P0382-GLOW PLUG 2 CONTROL CIRCUIT - OPEN CIRCUIT.
Page 93 DRIVEABILITY - DIESEL P0382-GLOW PLUG 2 CONTROL CIRCUIT - OPEN CIRCUIT — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.
Page 94 DRIVEABILITY - DIESEL P0382-GLOW PLUG 2 CONTROL CIRCUIT - OPEN CIRCUIT — Continued TEST ACTION APPLICABILITY Turn the ignition off. Remove Glow Plug Relay 2 from the PDC. Disconnect the ECM harness connectors. Measure the resistance between ground and the Glow Plug Relay 2 Control circuit. Is the resistance above 1000 ohms? Yes →...
Page 95: P0403-Egr Solenoid Circuit Negative Deviation
DRIVEABILITY - DIESEL Symptom: P0403-EGR SOLENOID CIRCUIT NEGATIVE DEVIATION When Monitored and Set Condition: P0403-EGR SOLENOID CIRCUIT NEGATIVE DEVIATION When Monitored: With the engine running. Set Condition: The ECM detects EGR flow is less than the requested flow. POSSIBLE CAUSES EGR VALVE INTERMITTENT CONDITION CHECKING VACUUM SUPPLY...
Page 96 DRIVEABILITY - DIESEL P0403-EGR SOLENOID CIRCUIT NEGATIVE DEVIATION — Continued TEST ACTION APPLICABILITY NOTE: The engine must be at operating temperature for this test to be valid. Turn the ignition off. Disconnect the vacuum line at the EGR Valve. Connect a vacuum gauge to the EGR Solenoid Output line at the EGR Valve Start the engine and observe the vacuum gauge reading for 1 minute.
Page 97: P0403-Egr Solenoid Circuit Open Circuit
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: The ECM detects an open or short to ground on the EGR Solenoid Control circuit.
Page 98 DRIVEABILITY - DIESEL P0403-EGR SOLENOID CIRCUIT OPEN CIRCUIT — Continued TEST ACTION 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. Is the resistance below 5.0 ohms? Yes →...
Page 99: P0403-Egr Solenoid Circuit Short Circuit
DRIVEABILITY - DIESEL Symptom: P0403-EGR SOLENOID CIRCUIT SHORT CIRCUIT When Monitored and Set Condition: P0403-EGR SOLENOID 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...
Page 100 DRIVEABILITY - DIESEL P0403-EGR SOLENOID CIRCUIT SHORT CIRCUIT — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the EGR Solenoid 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.
Page 101: P0460-Fuel Level Sensor Circuit Signal Voltage Too High
DRIVEABILITY - DIESEL Symptom: P0460-FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH When Monitored and Set Condition: P0460-FUEL 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...
Page 102 DRIVEABILITY - DIESEL P0460-FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the ECM harness connectors. Disconnect the Fuel Level Sensor harness connector. Measure the resistance of the Fuel Level Sensor Signal circuit. Is the resistance below 5.0 ohms? Yes →...
Page 103 DRIVEABILITY - DIESEL P0460-FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.
Page 104: P0460-Fuel Level Sensor Circuit Signal Voltage Too Low
DRIVEABILITY - DIESEL Symptom: P0460-FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO When Monitored and Set Condition: P0460-FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW When Monitored: With the ignition on. Set Condition: The Fuel Level Sensor Signal voltage is below 0.15 volt. POSSIBLE CAUSES INTERMITTENT CONDITION FUEL LEVEL SENSOR...
Page 105 DRIVEABILITY - DIESEL P0460-FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the ECM harness connectors. Disconnect the Fuel Level Sensor harness connector. Measure the resistance between the Fuel Level Sensor Signal circuit and Sensor Ground circuit.
Page 106: P0500-Vehicle Speed Sensor Frequency Too High
DRIVEABILITY - DIESEL Symptom List: P0500-VEHICLE SPEED SENSOR FREQUENCY TOO HIGH P0500-VEHICLE SPEED SENSOR HIGH LEVEL DURATION P0500-VEHICLE SPEED SENSOR PLAUSIBILITY P0500-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 be P0500-VEHICLE SPEED SEN- SOR FREQUENCY TOO HIGH.
Page 107 DRIVEABILITY - DIESEL P0500-VEHICLE SPEED SENSOR FREQUENCY TOO HIGH — Continued TEST ACTION 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 →...
Page 108 DRIVEABILITY - DIESEL P0500-VEHICLE SPEED SENSOR FREQUENCY TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the CAB 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.
Page 109: P0514-Battery Temp Sensor Circuit Signal Voltage Too High
DRIVEABILITY - DIESEL Symptom: P0514-BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO 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 4.9 volts.
Page 110 DRIVEABILITY - DIESEL P0514-BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. 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.
Page 111: P0514-Battery Temp Sensor Circuit Signal Voltage Too Low
DRIVEABILITY - DIESEL Symptom: P0514-BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO When Monitored and Set Condition: P0514-BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW When Monitored: With the ignition on. Set Condition: The ECM detects Battery Temperature Sensor Signal voltage below 0.151 volt.
Page 112 DRIVEABILITY - DIESEL P0514-BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY Turn the ignition off. 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.
Page 113: P0520-Oil Press Sensor Ckt Malf Signal Voltage Too High
DRIVEABILITY - DIESEL Symptom: P0520-OIL PRESS SENSOR CKT MALF SIGNAL VOLTAGE TOO HIGH When Monitored and Set Condition: P0520-OIL PRESS SENSOR CKT MALF SIGNAL VOLTAGE TOO HIGH When Monitored: With the engine running. Set Condition: The ECM detects the Oil Pressure Sensor Signal above 4.9 volts for more than 3 seconds.
Page 114 DRIVEABILITY - DIESEL P0520-OIL PRESS SENSOR CKT MALF SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY 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.
Page 115 DRIVEABILITY - DIESEL P0520-OIL PRESS SENSOR CKT MALF SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN.
Page 116: P0520-Oil Press Sensor Ckt Malf Signal Voltage Too Low
DRIVEABILITY - DIESEL Symptom: P0520-OIL PRESS SENSOR CKT MALF SIGNAL VOLTAGE TOO When Monitored and Set Condition: P0520-OIL PRESS SENSOR CKT MALF SIGNAL VOLTAGE TOO LOW When Monitored: With the engine running. Set Condition: The ECM detects the Oil Pressure Sensor Signal voltage below 0.1 volt for more than 3 seconds.
Page 117 DRIVEABILITY - DIESEL P0520-OIL PRESS SENSOR CKT MALF SIGNAL VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY 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.
Page 118 DRIVEABILITY - DIESEL Symptom: P0520-OIL PRESS SENSOR CKT MALF SUPPLY VOLTAGE TOO HIGH OR LOW When Monitored and Set Condition: P0520-OIL PRESS SENSOR CKT MALF SUPPLY VOLTAGE TOO HIGH OR LOW When Monitored: With the ignition on. Set Condition: The Sensor Reference Voltage A voltage to the Oil Pressure Sensor is below 4.8 volts or above 5.2 volts for at least 100 ms.
Page 119 DRIVEABILITY - DIESEL P0520-OIL PRESS SENSOR CKT MALF SUPPLY VOLTAGE TOO HIGH OR LOW — Continued TEST ACTION APPLICABILITY Turn the ignition off. 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.
Page 120: P0530-A/C Pressure Sensor Circuit Signal Voltage Too High
DRIVEABILITY - DIESEL Symptom List: P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO P0530-A/C PRESSURE SENSOR CIRCUIT 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 P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH.
Page 121 DRIVEABILITY - DIESEL P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued POSSIBLE CAUSES ECM - A/C PRESSURE SENSOR SIGNAL ECM - SENSOR REFERENCE VOLTAGE B CIRCUIT ECM - SIGNAL VOLTAGE HIGH TEST ACTION APPLICABILITY NOTE: If DTC P0641 or P0651 is present with this DTC, diagnose DTCs P0641 and P0651 before diagnosing this DTC.
Page 122 DRIVEABILITY - DIESEL P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the A/C Pressure Sensor harness connector. Turn the ignition on. Measure the voltage of the A/C Pressure Sensor Signal circuit in the A/C Pressure Sensor harness connector.
Page 123 DRIVEABILITY - DIESEL P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.
Page 124 DRIVEABILITY - DIESEL P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the A/C Pressure Sensor harness connector. Disconnect the ECM harness connectors. Measure the resistance between the A/C Pressure Sensor Signal circuit and the Sensor Ground circuit.
Page 125: P0560-System Voltage Too High
DRIVEABILITY - DIESEL Symptom: P0560-SYSTEM 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 15.5 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...
Page 126 DRIVEABILITY - DIESEL P0560-SYSTEM VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect ECM harness connectors. Disconnect the Generator Field harness connector. Measure the resistance between ground and the Generator Field Control circuit. Is the resistance above 100 kohms? Yes →...
Page 127: P0560-System Voltage Too Low
DRIVEABILITY - DIESEL Symptom List: P0560-SYSTEM VOLTAGE TOO LOW P1536-GENERATOR FIELD CURRENT TOO HIGH *CHECKING THE CHARGING SYSTEM OPERATION - DIESEL Test Note: All symptoms listed above are diagnosed using the same tests. The title for the tests will be P0560-SYSTEM VOLTAGE TOO LOW.
Page 128 DRIVEABILITY - DIESEL P0560-SYSTEM VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY NOTE: If there are any Battery Sense DTCs (P1511 or P1512) present with this DTC, diagnose the Battery Sense DTCs first. NOTE: Inspect the vehicle for aftermarket accessories that may exceed the Generator capacity.
Page 129 DRIVEABILITY - DIESEL P0560-SYSTEM VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the Generator Field harness connector. Measure the resistance of the Field Control terminals on the back of the Generator. Is the resistance between 2 and 6 ohms? Yes →...
Page 130 DRIVEABILITY - DIESEL P0560-SYSTEM VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY 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 →...
Page 131: P0579-S/C Switch Signal Circuit Plausibility
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 ENGINE CONTROL MODULE TEST ACTION APPLICABILITY Turn the ignition on. With the DRB, erase ECM DTCs.
Page 132 DRIVEABILITY - DIESEL P0579-S/C SWITCH SIGNAL CIRCUIT PLAUSIBILITY — Continued TEST ACTION APPLICABILITY Turn the ignition off. 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.
Page 133: P0579-S/C Switch Signal Circuit Signal Voltage Too High
DRIVEABILITY - DIESEL Symptom: P0579-S/C SWITCH SIGNAL CIRCUIT SIGNAL VOLTAGE TOO HIGH POSSIBLE CAUSES ECM - S/C SIGNAL CIRCUIT OPEN ECM - S/C SIGNAL CIRCUIT SHORTED TO VOLTAGE ECM - SENSOR GROUND OPEN S/C ON/OFF/SET SWITCH S/C ON/OFF/SET SWITCH SIGNAL CIRCUIT OPEN S/C SWITCH SIGNAL CIRCUIT SHORTED TO VOLTAGE SENSOR GROUND OPEN TEST...
Page 134 DRIVEABILITY - DIESEL P0579-S/C SWITCH SIGNAL CIRCUIT SIGNAL VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the S/C ON/OFF/SET Switch harness connector. Disconnect the ECM harness connectors. Measure the resistance of the Sensor Ground circuit. Is the resistance below 10.0 ohms? Yes →...
Page 135: P0579-S/C Switch Signal Circuit Signal Voltage Too Low
DRIVEABILITY - DIESEL Symptom: P0579-S/C SWITCH SIGNAL CIRCUIT SIGNAL VOLTAGE TOO LOW POSSIBLE CAUSES INTERMITTENT CONDITION S/C ON/OFF/SET SWITCH S/C RESUME/ACCEL SWITCH S/C/ SWITCH SIGNAL CIRCUIT SHORTED TO SENSOR GROUND S/C SWITCH SIGNAL CIRCUIT SHORTED TO GROUND TEST ACTION APPLICABILITY Turn the ignition on.
Page 136 DRIVEABILITY - DIESEL P0579-S/C SWITCH SIGNAL CIRCUIT SIGNAL VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY Turn the ignition off. 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. Is the resistance below 5.0 ohms? Yes →...
Page 137: P0615-Starter Relay Circuit Short Circuit
DRIVEABILITY - DIESEL Symptom: P0615-STARTER RELAY CIRCUIT SHORT CIRCUIT When Monitored and Set Condition: P0615-STARTER RELAY CIRCUIT SHORT CIRCUIT When Monitored: With the ignition on. Set Condition: The ECM detects excessive current on the Starter Relay Control circuit. POSSIBLE CAUSES INTERMITTENT CONDITION SUBSTITUTE ECM/PCM RELAY STARTER RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE...
Page 138 DRIVEABILITY - DIESEL P0615-STARTER RELAY CIRCUIT SHORT CIRCUIT — Continued TEST ACTION APPLICABILITY Turn the ignition off. Remove the Starter Relay from the PDC. 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.
Page 139: P0620-Generator Field Control Malf Battery Voltage Deviation
DRIVEABILITY - DIESEL Symptom List: P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVIATION 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 HIGH GENERATOR CURRENT...
Page 140 DRIVEABILITY - DIESEL P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVI - ATION TOO HIGH — Continued P0620-GENERATOR 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.
Page 141 DRIVEABILITY - DIESEL P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVI - ATION TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition on. With the DRB, erase ECM DTCs. Start the engine several times. Allow the engine to run for at least 30 seconds each run cycle while turning the ignition off for at least 10 seconds between each run cycle.
Page 142 DRIVEABILITY - DIESEL P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVI - ATION TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the ECM harness connectors. Remove Fuse 26 from the PDC. Measure the resistance of the Battery(+) Sense circuit. Is the resistance below 5.0 ohms? Yes →...
Page 143 DRIVEABILITY - DIESEL Symptom: P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO HIGH When Monitored and Set Condition: P0641-SENSOR REFERENCE VOLTAGE A CKT 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.
Page 144 DRIVEABILITY - DIESEL P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY 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.
Page 145 DRIVEABILITY - DIESEL Symptom: P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO LOW 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 A circuit or a short to ground on the Fuel Pressure Sensor 5-Volt Supply circuit.
Page 146 DRIVEABILITY - DIESEL P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the MAF Sensor harness connector. Turn the ignition on. Measure the voltage of the Sensor Reference Voltage A circuit. Is the voltage above 4.8 volts? Yes →...
Page 147 DRIVEABILITY - DIESEL P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY 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.
Page 148 DRIVEABILITY - DIESEL Symptom: P0645-A/C CLUTCH RELAY CIRCUIT OPEN CIRCUIT When Monitored and Set Condition: P0645-A/C CLUTCH RELAY CIRCUIT OPEN CIRCUIT When Monitored: With the ignition on. Set Condition: The ECM does not detect voltage on the A/C Clutch Relay Control circuit. POSSIBLE CAUSES INTERMITTENT CONDITION FUSED ASD RELAY OUTPUT CIRCUIT OPEN...
Page 149 DRIVEABILITY - DIESEL P0645-A/C CLUTCH RELAY CIRCUIT OPEN CIRCUIT — Continued TEST 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.
Page 150 DRIVEABILITY - DIESEL Symptom: P0645-A/C CLUTCH RELAY CIRCUIT SHORT CIRCUIT When Monitored and Set Condition: P0645-A/C CLUTCH RELAY CIRCUIT SHORT CIRCUIT When Monitored: With the ignition off. Set Condition: The ECM detects excessive current on the A/C Clutch Relay Control circuit.
Page 151 DRIVEABILITY - DIESEL P0645-A/C CLUTCH RELAY CIRCUIT SHORT CIRCUIT — Continued TEST 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 12-volts, probe the A/C Clutch Relay Control circuit in the PDC.
Page 152 DRIVEABILITY - DIESEL Symptom: P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO HIGH When Monitored and Set Condition: P0651-SENSOR REFERENCE VOLTAGE B CKT 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.
Page 153 DRIVEABILITY - DIESEL P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. 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.
Page 154 DRIVEABILITY - DIESEL Symptom: P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO LOW 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.
Page 155 DRIVEABILITY - DIESEL P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY Turn the ignition on. With the DRBIII in Sensors, monitor the Accelerator Pedal Position and Boost Pressure Sensors only. One at a time while monitoring the DRB sensor readings, disconnect then reconnect the Boost Pressure, Accelerator Pedal Position, A/C Pressure and Engine Oil Pressure Sensor harness connectors.
Page 156 DRIVEABILITY - DIESEL P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO LOW — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the ECM harness connectors. Disconnect the Accelerator Pedal Position Sensor harness connector. Measure the resistance between ground and the Accelerator Pedal Position Sensor 5-Volt Supply circuit.
Page 157 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.
Page 158 DRIVEABILITY - DIESEL P0685-ASD RELAY CONTROL CIRCUIT SHUTS OFF TOO EARLY — Continued TEST ACTION APPLICABILITY Turn the ignition off. 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.
Page 159 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 on for more than 2.0 seconds after the ECM has turned off the ASD Relay.
Page 160 DRIVEABILITY - DIESEL P0685-ASD RELAY CONTROL CIRCUIT SHUTS OFF TOO LATE — Continued TEST ACTION 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.
Page 161 DRIVEABILITY - DIESEL Symptom List: P0700-TRANS CONTROL 1-2/4-5 SOLENOID CIRCUIT P0700-TRANS CONTROL 2-3 SOLENOID CIRCUIT P0700-TRANS CONTROL 3-4 SOLENOID CIRCUIT P0700-TRANS CONTROL INTERNAL CONTROLLER P0700-TRANS CONTROL MOD. PRESS SOLENOID CIRCUIT P0700-TRANS CONTROL SHIFT PRESSURE SOLENOID CIRCUIT P0700-TRANS CONTROL SOLENOID SUPPLY VOLTAGE P0700-TRANS CONTROL TCC SOLENOID CIRCUIT P0702-TRANS CONTROL ABS SENSOR MESSAGE P0702-TRANS CONTROL ENGINE T-CASE SWITCH MESSAGE...
Page 162 DRIVEABILITY - DIESEL Symptom List: P0703-BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH REDUNDANT CONTACT P0703-BRAKE SWITCH SIGNAL 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 P0703-BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH REDUNDANT CONTACT.
Page 163 DRIVEABILITY - DIESEL P0703-BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH RE - DUNDANT CONTACT — Continued TEST ACTION 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 →...
Page 164 DRIVEABILITY - DIESEL P0703-BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH RE - DUNDANT CONTACT — Continued TEST 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.
Page 165 DRIVEABILITY - DIESEL P0703-BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH RE - DUNDANT CONTACT — Continued TEST ACTION APPLICABILITY Disconnect the Brake Lamp Switch harness connector. Using a 12-volt test light connected to ground, check the Fused B+ circuit. Does the test light illuminate brightly? Yes →...
Page 166 DRIVEABILITY - DIESEL Symptom List: P0836-TRANSFER CASE POSITION SENSOR PLAUSIBILITY P0836-TRANSFER CASE POSITION SENSOR PLAUSIBILITY 2 P0836-TRANSFER CASE POSITION SENSOR SIGNAL VOLTAGE TOO HIGH P0836-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 be P0836-TRANSFER CASE POSI- TION SENSOR PLAUSIBILITY.
Page 167 DRIVEABILITY - DIESEL P0836-TRANSFER CASE POSITION SENSOR PLAUSIBILITY — Continued POSSIBLE CAUSES TRANSFER CASE POSITION SENSOR SIGNAL CIRCUIT SHORT TO SENSOR GROUND CIR- CUIT ENGINE CONTROL MODULE TEST ACTION APPLICABILITY With the DRBIII , record and erase DTCs. Start the engine and cycle the Transfer Case through all positions. With the DRBIII , read the ECM DTCs.
Page 168 DRIVEABILITY - DIESEL P0836-TRANSFER CASE POSITION SENSOR PLAUSIBILITY — Continued TEST ACTION APPLICABILITY 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 the Transfer Case Position Sensor circuit and the Sensor Ground circuit.
Page 169 DRIVEABILITY - DIESEL Symptom: P0850-P/N SWITCH PLAUSIBILITY When Monitored and Set Condition: P0850-P/N SWITCH PLAUSIBILITY When Monitored: With the engine running at >3700 RPM, accelerator pedal position sensor >70%, fuel quantity >60 mm , and the transmission physically not in Park or Neutral.
Page 170 DRIVEABILITY - DIESEL P0850-P/N SWITCH PLAUSIBILITY — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the TCM harness connector. Disconnect the ECM harness connectors. Remove the ASD Relay from the PDC. Connect a jumper wire between cavities 30 and 87 in the ASD connector in the PDC. Turn the ignition on.
Page 171 DRIVEABILITY - DIESEL Symptom List: P1130-FUEL RAIL PRESSURE MALFUNCTION ACTUATOR STICK- P1130-FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DE- TECTED P1130-FUEL RAIL PRESSURE MALFUNCTION POSITIVE DEVIA- TION P1130-FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO HIGH-SHUT OFF P1130-FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO P1130-FUEL RAIL PRESSURE MALFUNCTION SOLENOID OPEN Test Note: All symptoms listed above are diagnosed using the same tests.
Page 172 DRIVEABILITY - DIESEL P1130-FUEL RAIL PRESSURE MALFUNCTION ACTUATOR STICKING — Continued 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.
Page 173 DRIVEABILITY - DIESEL P1130-FUEL RAIL PRESSURE MALFUNCTION ACTUATOR STICKING — Continued TEST ACTION APPLICABILITY Turn the ignition off. Inspect the entire fuel system for leakage. Is there any evidence of leakage? Yes → Repair as necessary in accordance with the Service Information. Perform ROAD TEST VERIFICATION - VER-2.
Page 174 DRIVEABILITY - DIESEL P1130-FUEL RAIL PRESSURE MALFUNCTION ACTUATOR STICKING — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.
Page 175 DRIVEABILITY - DIESEL Symptom List: P1131-FUEL PRESSURE SOLENOID OPEN CIRCUIT P1131-FUEL PRESSURE SOLENOID POWERSTAGE ERROR P1131-FUEL PRESSURE SOLENOID SHORT 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.
Page 176 DRIVEABILITY - DIESEL P1131-FUEL PRESSURE SOLENOID OPEN CIRCUIT — Continued TEST ACTION APPLICABILITY WARNING: THE FUEL INJECTION PUMP SUPPLIES HIGH-PRESSURE FUEL TO EACH INDIVIDUAL INJECTOR THROUGH HIGH-PRESSURE FUEL LINES. FUEL UNDER HIGH PRESSURE CAN PENETRATE SKIN AND CAUSE PERSONAL INJURY. WEAR SAFETY GOGGLES AND ADE- QUATE PROTECTIVE CLOTHING.
Page 177 DRIVEABILITY - DIESEL P1131-FUEL PRESSURE SOLENOID OPEN CIRCUIT — Continued TEST ACTION APPLICABILITY Turn the ignition off. 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.
Page 178 DRIVEABILITY - DIESEL P1131-FUEL PRESSURE SOLENOID OPEN CIRCUIT — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.The following list may help in identifying the intermittent condition.
Page 179 DRIVEABILITY - DIESEL Symptom List: P1205-INJECTOR CLASSIFICATION ERROR P1205-INJECTOR CLASSIFICATION ERROR CHECKSUM ERROR Test Note: All symptoms listed above are diagnosed using the same tests. The title for the tests will be P1205-INJECTOR CLASSIFICA- TION ERROR. POSSIBLE CAUSES VERIFY INJECTOR CLASSIFICATIONS TEST ACTION APPLICABILITY...
Page 180 DRIVEABILITY - DIESEL Symptom List: P1235-EXTERNAL FUEL QUANTITY BIT ERROR P1235-EXTERNAL FUEL QUANTITY DEMAND ERROR P1235-EXTERNAL FUEL QUANTITY PARITY ERROR P1235-EXTERNAL FUEL QUANTITY TORQUE ERROR Test Note: All symptoms listed above are diagnosed using the same tests. The title for the tests will be P1235-EXTERNAL FUEL QUAN- TITY BIT ERROR.
Page 181 DRIVEABILITY - DIESEL P1235-EXTERNAL FUEL QUANTITY BIT ERROR — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.
Page 182: P1242-Can Bus Message Missing
DRIVEABILITY - DIESEL Symptom List: P1242-CAN BUS MESSAGE MISSING P1242-CAN BUS MESSAGE MISSING FROM TCM Test Note: All symptoms listed above are diagnosed using the same tests. The title for the tests will be P1242-CAN BUS MESSAGE MISSING. When Monitored and Set Condition: P1242-CAN BUS MESSAGE MISSING When Monitored: With the ignition on.
Page 183 DRIVEABILITY - DIESEL P1242-CAN BUS MESSAGE MISSING — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the ECM harness connectors. Disconnect the TCM harness connectors. Measure and note the resistance of the CAN C Bus (+) circuit between the ECM harness connector and the TCM harness connector.
Page 184 DRIVEABILITY - DIESEL P1242-CAN BUS MESSAGE MISSING — Continued TEST ACTION APPLICABILITY Turn the ignition off. Replace and program the Transmission Control Module in accordance with the Service Information. Turn the ignition on. With the DRB, erase all ECM and TCM DTC’s. Perform several engine run cycles, turning the engine off for at least 20 seconds between each cycle.
Page 185: P1242-Can Bus Mute
DRIVEABILITY - DIESEL Symptom: P1242-CAN BUS MUTE When Monitored and Set Condition: P1242-CAN BUS MUTE When Monitored: With the ignition on. Set Condition: The ECM does not detect any CAN Bus messages. POSSIBLE CAUSES ENGINE CONTROL MODULE INTERMITTENT CONDITION CAN C BUS CIRCUIT OPEN TEST ACTION APPLICABILITY...
Page 186 DRIVEABILITY - DIESEL P1242-CAN BUS MUTE — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.The following list may help in identifying the intermittent condition.
Page 187: P1270-Intake Port Swirl Actuator Short Circuit
DRIVEABILITY - DIESEL Symptom: P1270-INTAKE PORT SWIRL ACTUATOR SHORT CIRCUIT When Monitored and Set Condition: P1270-INTAKE PORT SWIRL ACTUATOR SHORT CIRCUIT When Monitored: With the ignition on and the ECM attempting to actuate the Intake Port Swirl Actuator. Set Condition: The ECM detects excessive current on the Intake Port Swirl Actuator Control circuit.
Page 188 DRIVEABILITY - DIESEL P1270-INTAKE PORT SWIRL ACTUATOR SHORT CIRCUIT — Continued TEST ACTION APPLICABILITY Turn the ignition off. Install a substitute Swirl Solenoid. Turn the ignition on. With the DRB, erase ECM DTCs. With the DRBIII , actuate the Swirl Solenoid. With the DRBIII , read the ECM DTCs.
Page 189: P1270-Intake Port Swirl Actuator Ground X
DRIVEABILITY - DIESEL Symptom: P1270-INTAKE PORT SWIRL ACTUATOR GROUND X When Monitored and Set Condition: P1270-INTAKE PORT SWIRL ACTUATOR GROUND X When Monitored: With the ignition on. Set Condition: The ECM detects an internal fault with the Intake Port Swirl Actuator. POSSIBLE CAUSES INTAKE PORT SWIRL ACTUATOR Repair Instructions:...
Page 190: P1270-Intake Port Swirl Actuator Open Circuit
DRIVEABILITY - DIESEL Symptom: P1270-INTAKE PORT SWIRL ACTUATOR OPEN CIRCUIT When Monitored and Set Condition: P1270-INTAKE PORT SWIRL ACTUATOR OPEN CIRCUIT When Monitored: With the ignition on. Set Condition: The ECM does not detect voltage on the Intake Port Swirl Actuator Control circuit.
Page 191 DRIVEABILITY - DIESEL P1270-INTAKE PORT SWIRL ACTUATOR OPEN CIRCUIT — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the Swirl Solenoid harness connector. Disconnect the ECM harness connectors. Measure the resistance of the Swirl Solenoid Control circuit. Is the resistance below 10.0 ohms? Yes →...
Page 192: P1499-Hydraulic Cooling Fan Solenoid Circuit Open Circuit
DRIVEABILITY - DIESEL Symptom: P1499-HYDRAULIC COOLING FAN SOLENOID CIRCUIT OPEN CIRCUIT When Monitored and Set Condition: P1499-HYDRAULIC COOLING FAN SOLENOID CIRCUIT OPEN CIRCUIT When Monitored: With the ignition on. Set Condition: The ECM does not detect voltage on the Hydraulic Cooling Fan Solenoid Control circuit.
Page 193 DRIVEABILITY - DIESEL P1499-HYDRAULIC COOLING FAN SOLENOID CIRCUIT OPEN CIRCUIT — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the Hydraulic Cooling Fan Solenoid harness connector. Disconnect the ECM harness connectors. Measure the resistance between ground and the Swirl Solenoid Control circuit. Is the resistance above 1000 ohms? Yes →...
Page 194 DRIVEABILITY - DIESEL P1499-HYDRAULIC COOLING FAN SOLENOID CIRCUIT OPEN CIRCUIT — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.The following list may help in identifying the intermittent condition.
Page 195: P1499-Hydraulic Cooling Fan Solenoid Circuit Short Circuit
DRIVEABILITY - DIESEL Symptom: P1499-HYDRAULIC COOLING FAN SOLENOID CIRCUIT SHORT CIRCUIT When Monitored and Set Condition: P1499-HYDRAULIC COOLING FAN SOLENOID CIRCUIT SHORT CIRCUIT When Monitored: With the ignition on and the ECM attempting to actuate the Hydraulic Cooling Fan Soleniod. Set Condition: The ECM detects excessive current on the Hydraulic Cooling Fan Solenoid Control circuit.
Page 196 DRIVEABILITY - DIESEL P1499-HYDRAULIC COOLING FAN SOLENOID CIRCUIT SHORT CIR - CUIT — Continued TEST ACTION APPLICABILITY Turn the ignition off. Install a substitute Hydraulic Cooling Fan Solenoid. Turn the ignition on. With the DRB, erase ECM DTCs. With the DRBIII , actuate the Hydraulic Cooling Fan Solenoid. With the DRBIII , read the ECM DTCs.
Page 197: P1511-Battery Sense Line 1 Voltage Too High
DRIVEABILITY - DIESEL Symptom List: P1511-BATTERY SENSE LINE 1 VOLTAGE TOO HIGH P1511-BATTERY SENSE LINE 1 VOLTAGE 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.
Page 198 DRIVEABILITY - DIESEL P1511-BATTERY SENSE LINE 1 VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY NOTE: If DTC P0560-SYSTEM VOLTAGE TOO HIGH is present with this DTC, perform diagnostics for P0560 first. Turn the ignition on. With the DRBIII , erase the ECM DTCs. Test drive the vehicle.
Page 199 DRIVEABILITY - DIESEL P1511-BATTERY SENSE LINE 1 VOLTAGE TOO HIGH — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the ECM harness connectors. Measure the resistance between the Battery negative terminal and the Battery(-) Sense circuit in ECM harness connector cavity C1-20. Is the resistance below 5.0 ohms? Yes →...
Page 200: P1605-Ignition Switch Plausibility
DRIVEABILITY - DIESEL Symptom: P1605-IGNITION SWITCH PLAUSIBILITY When Monitored and Set Condition: P1605-IGNITION SWITCH PLAUSIBILITY When Monitored: When the ignition is first turned on. Set Condition: The ECM detects the Ignition Switch Sense momentarily return to the OFF state during ECM initialization. POSSIBLE CAUSES INTERMITTENT CONDITION ENGINE CONTROL MODULE...
Page 201 DRIVEABILITY - DIESEL P1605-IGNITION SWITCH PLAUSIBILITY — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the ECM harness connectors. Disconnect the ignition switch harness connector. Measure the resistance between ground and the Fused Ignition Switch Output (RUN/START) circuit. Is the resistance above 100 kohms? Yes →...
Page 202: P1643-Viscous Heater Relay Open Circuit
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 RELAY OPEN CIRCUIT. When Monitored and Set Condition: P1643-VISCOUS HEATER RELAY OPEN CIRCUIT When Monitored: With the ignition on.
Page 203 DRIVEABILITY - DIESEL P1643-VISCOUS HEATER RELAY OPEN CIRCUIT — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.
Page 204 DRIVEABILITY - DIESEL P1643-VISCOUS HEATER RELAY OPEN CIRCUIT — Continued TEST ACTION APPLICABILITY Turn the ignition off. 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.
Page 205: P1651-Mil/Diag Lamp Via J1850 Bus In Frame Response Error
DRIVEABILITY - DIESEL Symptom List: P1651-MIL/DIAG LAMP VIA J1850 BUS IN FRAME RESPONSE ER- P1651-MIL/DIAG LAMP VIA J1850 BUS STATUS ERROR Test Note: All symptoms listed above are diagnosed using the same tests. The title for the tests will be P1651-MIL/DIAG LAMP VIA J1850 BUS IN FRAME RESPONSE ERROR.
Page 206 DRIVEABILITY - DIESEL P1651-MIL/DIAG LAMP VIA J1850 BUS IN FRAME RESPONSE ERROR — Continued TEST ACTION APPLICABILITY Start and idle the engine. 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 →...
Page 207: P1652-J1850 Communication Bus Lost Arbitration
DRIVEABILITY - DIESEL Symptom List: P1652-J1850 COMMUNICATION BUS LOST ARBITRATION P1652-J1850 COMMUNICATION BUS RECEIVE TIMEOUT P1652-J1850 COMMUNICATION BUS SHORT TO GROUND P1652-J1850 COMMUNICATION BUS SHORT TO VOLTAGE P1652-J1850 COMMUNICATION BUS SPI ERROR P1652-J1850 COMMUNICATION BUS TRANSMIT BUFFER OVER- P1652-J1850 COMMUNICATION BUS UNAUTHORIZED RESET Test Note: All symptoms listed above are diagnosed using the same tests.
Page 208 DRIVEABILITY - DIESEL P1652-J1850 COMMUNICATION BUS LOST ARBITRATION — Continued P1652-J1850 COMMUNICATION BUS UNAUTHORIZED RESET When Monitored: With the ignition on. Set Condition: An unauthorized reset of the J1850 hardware occurs during normal operation. POSSIBLE CAUSES VERIFY ACTIVE DTC VERIFY INSTRUMENT CLUSTER COMMUNICATION INTERMITTENT CONDITION TEST ACTION...
Page 209 DRIVEABILITY - DIESEL P1652-J1850 COMMUNICATION BUS LOST ARBITRATION — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.
Page 210: P1685-Skim System Invalid Key Code Received
DRIVEABILITY - DIESEL Symptom: P1685-SKIM SYSTEM INVALID KEY CODE RECEIVED When Monitored and Set Condition: P1685-SKIM SYSTEM INVALID KEY CODE RECEIVED When Monitored: With the ignition on. Set Condition: The ECM receives a message from the SKIM indicating an incorrect message was received from the ignition key.
Page 211: P1685-Skim System Key Communication Timed Out
DRIVEABILITY - DIESEL Symptom: P1685-SKIM SYSTEM KEY COMMUNICATION TIMED OUT When Monitored and Set Condition: P1685-SKIM SYSTEM KEY COMMUNICATION TIMED OUT When Monitored: With the ignition on. Set Condition: Communication between the ECM and the SKIM is not completed within 2.0 seconds POSSIBLE CAUSES SKIM...
Page 212 DRIVEABILITY - DIESEL P1685-SKIM SYSTEM KEY COMMUNICATION TIMED OUT — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.
Page 213: P2120-Acc Pedal Position Sensor 1 Ckt Plausibility
DRIVEABILITY - DIESEL Symptom List: P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH BRAKE SWITCH P2120-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE TOO HIGH P2120-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE TOO LOW P2120-ACC PEDAL POSITION SENSOR 1 CKT SUPPLY VOLTAGE TOO HIGH OR LOW...
Page 214 DRIVEABILITY - DIESEL P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY — Continued P2120-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE TOO LOW When Monitored: With the ignition on. Set Condition: The ECM detects voltage on the Accelerator Pedal Position Sensor Signal circuit 0.0 volt.
Page 215 DRIVEABILITY - DIESEL P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY — Continued POSSIBLE CAUSES VERIFY APP SENSOR OPERATION APP SENSOR SIGNAL CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT 5-VOLT SUPPLY OR SENSOR REF VOLTAGE A CIRCUIT SHORTED TO VOLTAGE ECM - SENSOR GROUND OPEN APP SENSOR CIRCUIT SHORTED TO VOLTAGE APP SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE ECM - APP SENSOR SIGNAL CIRCUIT...
Page 216 DRIVEABILITY - DIESEL P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY — Continued TEST ACTION APPLICABILITY WARNING: WHEN THE ENGINE IS OPERATING, 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. NOTE: The conditions that set the DTC are not present at this time.
Page 217 DRIVEABILITY - DIESEL P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the APP Sensor harness connector. Disconnect the ECM harness connectors. Measure the resistance of the Sensor Ground circuit between the APP Sensor and the ECM.
Page 218 DRIVEABILITY - DIESEL P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY — Continued TEST 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 and cavity 87 of the ASD Relay connector. Turn the ignition on.
Page 219 DRIVEABILITY - DIESEL P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY — Continued TEST 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 and cavity 87 of the ASD Relay connector. Turn the ignition on.
Page 220: A/C Inoperative
DRIVEABILITY - DIESEL Symptom: *A/C INOPERATIVE POSSIBLE CAUSES CHECK FOR ECM DTCS FUSED B+ CIRCUIT OPEN A/C CLUTCH RELAY A/C CLUTCH RELAY OUTPUT CIRCUIT SHORTED TO GROUND A/C CLUTCH RELAY OUTPUT CIRCUIT OPEN A/C CLUTCH GROUND CIRCUIT OPEN A/C CLUTCH ECM - INTERNAL FAULT AZC MODULE OR A/C - HEATER CONTROL MODULE BCM - NO SWITCH STATE CHANGE...
Page 221 DRIVEABILITY - DIESEL *A/C INOPERATIVE — Continued TEST ACTION APPLICABILITY 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.
Page 222 DRIVEABILITY - DIESEL *A/C INOPERATIVE — Continued TEST ACTION APPLICABILITY If there are no possible causes remaining, view repair. Repair Replace the A/C Clutch in accordance with the Service Informa- tion. Perform ROAD TEST VERIFICATION - VER-2. Turn the ignition off. Disconnect the AZC Module C2 harness connector or the A/C - Heater Control C1 harness connector.
Page 223: A/C Operates In All Mode Switch Positions
DRIVEABILITY - DIESEL Symptom: *A/C OPERATES IN ALL MODE SWITCH POSITIONS POSSIBLE CAUSES CHECK FOR ECM DTCS A/C CLUTCH A/C CLUTCH RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE A/C CLUTCH RELAY ENGINE CONTROL MODULE A/C SWITCH SIGNAL CIRCUIT SHORTED TO GROUND AZC MODULE OR A/C - HEATER CONTROL MODULE BODY CONTROL MODULE TEST...
Page 224 DRIVEABILITY - DIESEL *A/C OPERATES IN ALL MODE SWITCH POSITIONS — Continued TEST ACTION APPLICABILITY Turn the ignition off. Remove the A/C Clutch Relay from the PDC. Disconnect the A/C Clutch harness connector. Turn the ignition on. Measure the voltage of the A/C Clutch Relay Output circuit. Is the voltage above 1.0 volt? Yes →...
Page 225: Checking The Accelerator Pedal Position Sensor Calibration
DRIVEABILITY - DIESEL Symptom: *CHECKING THE ACCELERATOR PEDAL POSITION SENSOR CALIBRATION POSSIBLE CAUSES APP SENSOR IDLE VOLTAGE APP SENSOR WIDE OPEN THROTTLE VOLTAGE VERIFY APP SENSOR OPERATION TEST ACTION APPLICABILITY NOTE: The APP Sensor is a device that contains 2 separate potentiometer type sensors.
Page 226: Checking The Boost Pressure Sensor Calibration
DRIVEABILITY - DIESEL Symptom: *CHECKING THE BOOST PRESSURE SENSOR CALIBRATION POSSIBLE CAUSES TURBOCHARGER BOOST PRESSURE SENSOR CALIBRATION TEST ACTION APPLICABILITY Allow the engine to idle. With the DRBIII , select Engine, then Sensors. Read the Boost Pressure Voltage. Is the Boost Pressure Voltage between 1.50 and 2.00 volts? Yes →...
Page 227: Checking The Ecm Power And Ground Circuits
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 TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the ECM harness connectors.
Page 228: Checking The Egr System
DRIVEABILITY - DIESEL Symptom: *CHECKING THE EGR SYSTEM POSSIBLE CAUSES EGR VALVE CHECKING VACUUM SUPPLY EGR SOLENOID TEST ACTION APPLICABILITY Turn the ignition off. Disconnect both vacuum lines at the EGR Solenoid. Using a vacuum line connection tee, connect the vacuum supply line to the EGR Solenoid Output line at the EGR Solenoid.
Page 229: Checking The Engine Coolant Temperature Sensor Calibration
DRIVEABILITY - DIESEL Symptom: *CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR CALIBRATION POSSIBLE CAUSES ECT SENSOR - COLD ECT SENSOR - HOT TEST ACTION APPLICABILITY NOTE: The thermostat must be operating correctly for this test to be valid. 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.
Page 230: Checking The Engine Mechanical Systems
DRIVEABILITY - DIESEL Symptom: *CHECKING THE ENGINE MECHANICAL SYSTEMS POSSIBLE CAUSES CHECKING ENGINE MECHANICAL SYSTEMS TEST ACTION APPLICABILITY NOTE: The following items should be checked as a possible cause of a Driveability or No-Start problem. WARNING: Do not attempt to remove or separate high pressure fuel line. Attempting to do so could result in severe bodily injury or death.
Page 231: Checking The Glow Plug Operation
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 TEST ACTION...
Page 232 DRIVEABILITY - DIESEL *CHECKING THE GLOW PLUG OPERATION — Continued TEST ACTION APPLICABILITY 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). Turn the ignition on. Measure the voltage on the Glow Plug Relay Output circuit of the affected cylinder(s).
Page 233: Checking The Park Neutral Switch Signal
DRIVEABILITY - DIESEL Symptom: *CHECKING THE PARK NEUTRAL SWITCH SIGNAL POSSIBLE CAUSES CHECK FOR TRANSMISSION CONTROL MODULE DTCS ENGINE CONTROL MODULE P/N SENSE CIRCUIT SHORTED TO VOLTAGE P/N SWITCH SENSE CIRCUIT OPEN P/N SWITCH SENSE CIRCUIT SHORTED TO GROUND TEST ACTION APPLICABILITY Turn the ignition on.
Page 234 DRIVEABILITY - DIESEL *CHECKING THE PARK NEUTRAL SWITCH SIGNAL — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the TCM harness connector. Disconnect the ECM harness connectors. Measure the resistance of the P/N Switch Sense circuit. Is the resistance below 10.0 ohms? Yes →...
Page 235: Checking The Speed Control Operation
DRIVEABILITY - DIESEL Symptom: *CHECKING THE SPEED CONTROL OPERATION POSSIBLE CAUSES BRAKE SWITCH SIGNAL ECM DTC(S) PRESENT ENGINE CONTROL MODULE SPEED CONTROL SWITCHES VSS SIGNAL INTERMITTENT CONDITION TEST ACTION APPLICABILITY Turn the ignition on. With the DRBIII , read the ECM DTCs. Are there any ECM DTCs present? Yes →...
Page 236 DRIVEABILITY - DIESEL *CHECKING THE SPEED CONTROL OPERATION — Continued TEST ACTION APPLICABILITY Turn the ignition on. With the DRBIII in Inputs/Outputs, read the Primary and Secondary brake 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 →...
Page 237: Checking The Transfer Case Position Sensor
DRIVEABILITY - DIESEL Symptom: *CHECKING THE TRANSFER CASE POSITION SENSOR POSSIBLE CAUSES CHECKING THE TRANSFER CASE POSITION SENSOR TEST ACTION APPLICABILITY 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.
Page 238: Checking The Viscous/Cabin Heater Relay
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 CIRCUIT OPEN VISCOUS HEATER RELAY TEST ACTION APPLICABILITY...
Page 239 DRIVEABILITY - DIESEL *CHECKING THE VISCOUS/CABIN HEATER RELAY — Continued TEST ACTION APPLICABILITY 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 in the Viscous Heater harness connector.
Page 240: Checking The Water In Fuel Lamp Operation
DRIVEABILITY - DIESEL Symptom: *CHECKING THE WATER IN FUEL LAMP OPERATION POSSIBLE CAUSES ASD RELAY OUTPUT CIRCUIT OPEN SENSOR GROUND CIRCUIT OPEN VERIFY WIF INDICATOR OPERATION WATER IN FUEL SENOR SIGNAL CIRCUIT OPEN WATER IN FUEL SENOR SIGNAL CIRCUIT SHORTED TO GROUND WATER IN FUEL SENOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND WATER IN FUEL SENSOR TEST...
Page 241 DRIVEABILITY - DIESEL *CHECKING THE WATER IN FUEL LAMP OPERATION — Continued TEST ACTION APPLICABILITY Turn the ignition off. Disconnect the Water In Fuel Sensor harness connector. Disconnect the ECM harness connectors. Measure the resistance of the Water In Fuel Sensor Signal circuit. Is the resistance below 5.0 ohms? Yes →...
Page 242: Engine Cranks But Will Not Start
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 GEAR/SPROCKET FUEL INJECTOR DRIVER CIRCUIT(S) SHORTED TO GROUND FUEL PRESSURE SENSOR...
Page 243 DRIVEABILITY - DIESEL *ENGINE CRANKS BUT WILL NOT START — Continued TEST ACTION APPLICABILITY Using a temperature probe, check the vehicle temperature near the ECT Sensor. Turn the ignition on. With the DRBIII in Sensors, read the ECT Sensor temperature. Compare the temperature probe reading with the DRBIII reading.
Page 244 DRIVEABILITY - DIESEL *ENGINE CRANKS BUT WILL NOT START — Continued TEST ACTION APPLICABILITY Turn the ignition off. Using the DRBIII lab scope, 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 DRBIII .
Page 245 DRIVEABILITY - DIESEL *ENGINE CRANKS BUT WILL NOT START — Continued TEST ACTION APPLICABILITY Turn the ignition off. 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 →...
Page 246: Engine Will Not Crank
DRIVEABILITY - DIESEL Symptom: *ENGINE WILL NOT CRANK POSSIBLE CAUSES BATTERY CABLE HIGH RESISTANCE CHECKING FOR SKIM OR TCM CODES INSPECT BATTERY CABLES MECHANICAL PROBLEM OPEN FUSED BATTERY (+) CIRCUIT OPEN IGNITION SWITCH START CIRCUIT OPEN IGNITION SWITCH START OUTPUT AT THE ECM STARTER MOTOR STARTER RELAY STARTER RELAY CONTROL CIRCUIT OPEN...
Page 247 DRIVEABILITY - DIESEL *ENGINE WILL NOT CRANK — Continued TEST ACTION APPLICABILITY WARNING: The transmission must be in Neutral and the parking break must be engaged for this test. WARNING: The engine may be cranked in this test. Keep away from moving engine parts.
Page 248 DRIVEABILITY - DIESEL *ENGINE WILL NOT CRANK — Continued TEST ACTION APPLICABILITY Using a 12-volt test light connected to ground, check the Ignition Switch Start Output circuit at ECM C1 harness connector cavity 22 while turning the ignition switch to the START position. Does the test light illuminate with the ignition switch in the START position? Yes →...
Page 249: Sentry Key Immobilizer
SENTRY KEY IMMOBILIZER 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.
Page 250 SENTRY KEY IMMOBILIZER ANTENNA FAILURE — Continued POSSIBLE CAUSES SKIM INTERNAL DTC FAILURE TEST ACTION APPLICABILITY Note: This trouble code indicates an internal SKIM fault. With the DRBIII , 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.
Page 251: Pcm Status Failure
SENTRY KEY IMMOBILIZER 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. When Monitored and Set Condition: PCM STATUS FAILURE When Monitored: With the ignition on.
Page 252 SENTRY KEY IMMOBILIZER PCM STATUS FAILURE — Continued TEST ACTION APPLICABILITY Turn the ignition off. 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.
Page 253: Rolling Code Failure
SENTRY KEY IMMOBILIZER 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 to a SKIM or ECM reset.
Page 254 SENTRY KEY IMMOBILIZER ROLLING CODE FAILURE — Continued TEST ACTION APPLICABILITY Turn the ignition on. With the DRBIII , select Engine system from the main menu. Display and record the Vehicle Identification Number. NOTE: Ensure that a VIN has been programmed into the ECM. If a VIN is not displayed, attempt to program the ECM with the correct vehicle VIN before continuing.
Page 255: Transponder Communication Failure
SENTRY KEY IMMOBILIZER 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.
Page 256 SENTRY KEY IMMOBILIZER TRANSPONDER COMMUNICATION FAILURE — Continued TEST 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.
Page 257 SENTRY KEY IMMOBILIZER TRANSPONDER COMMUNICATION FAILURE — Continued TEST ACTION APPLICABILITY If there are no possible causes remaining, view repair. 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.
Page 258: Verification Tests
VERIFICATION TESTS Verification Tests BODY VERIFICATION TEST - VER 1 APPLICABILITY 1. Disconnect all jumper wires and reconnect all previously disconnected components and connectors. 2. If the Sentry Key Immobilizer Module (SKIM) or the Engine Control Module (ECM) was replaced, proceed to number 5. If the SKIM or ECM was not replaced, continue to the next number.
Page 259 VERIFICATION TESTS Verification Tests — Continued NO START VERIFICATION - VER-1 APPLICABILITY 1. NOTE: IMPORTANT! If the Engine Control Module or Sentry Key Immobilizer Module has been replaced, ensure the programming procedure for the module has been performed in accordance with the Service Information. 2.
Page 260 VERIFICATION TESTS Verification Tests — Continued SKIS VERIFICATION APPLICABILITY 1. Reconnect all previously disconnected components and connectors. 2. Obtain the vehicle’s unique Personal Identification Number (PIN) assigned to it’s original SKIM. 3. NOTE: When entering the PIN, care should be taken because the SKIM will only allow 3 consecutive attempts to enter the correct PIN.
Page 261 VERIFICATION TESTS Verification Tests — Continued W5J400 TRANSMISSION VERIFICATION TEST - VER 1 APPLICABILITY 1. NOTE: If the TCM was replaced, use the DRBIII to program the VIN information into the TCM 2. Reconnect any disconnected components. 3. Connect the DRBIII to the Data Link Connector. 4.
Page 262 NOTES...
Page 263: Component Locations
COMPONENT LOCATIONS 8.0 COMPONENT LOCATIONS 8.1 CONTROL MODULES 8.2 CONTROLS AND SOLENOIDS...
Page 264: Data Link Connector
COMPONENT LOCATIONS 8.3 DATA LINK CONNECTOR 8.4 FUEL SYSTEM 8.5 SENSORS...
Page 265 COMPONENT LOCATIONS...
Page 266: Switches
COMPONENT LOCATIONS 8.5 SENSORS (Continued) 8.6 SWITCHES...
Page 267: Connector Pinouts
CONNECTOR PINOUTS 9.0 CONNECTOR PINOUTS A/C COMPRESSOR CLUTCH - BLACK 2 WAY CIRCUIT FUNCTION C2 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT Z18 18BK GROUND A/C PRESSURE TRANSDUCER - BLACK 4 WAY CIRCUIT FUNCTION K4 18BK/LB SENSOR GROUND K6 18VT/WT (DIESEL) SENSOR REFERENCE VOLTAGE B K6 18VT/BK (GAS) 5 VOLT SUPPLY...
Page 268: Boost Pressure Sensor (Diesel) - Black 3 Way
CONNECTOR PINOUTS BOOST PRESSURE SENSOR (DIESEL) - BLACK 3 WAY CIRCUIT FUNCTION K4 20BK/LB SENSOR GROUND Y53 20VT/WT BOOST PRESSURE SENSOR SIGNAL K6 20BK/YL SENSOR REFERENCE VOLTAGE B BRAKE LAMP SWITCH - GRAY 6 WAY CIRCUIT FUNCTION K29 18WT/PK SECONDARY BRAKE SWITCH SIGNAL Z238 18BK (LHD) GROUND Z243 18BK (RHD)
Page 269: Data Link Connector - Black 16 Way
CONNECTOR PINOUTS DATA LINK CONNECTOR - BLACK 16 WAY CIRCUIT FUNCTION D25 20YL/VT PCI BUS Z305 20BK/OR GROUND Z306 20BK/LG GROUND D32 20LG/DG SCI RECEIVE D21 20PK SCI TRANSMIT D19 20VT/OR BODY CONTROL MODULE FLASH ENABLE D20 20LG SCI RECEIVE F33 20PK/RD FUSED B(+) EGR SOLENOID (DIESEL) - BLACK 2 WAY...
Page 270: Engine Control Module C1 (Diesel) - Black 81 Way
CONNECTOR PINOUTS ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY CIRCUIT FUNCTION Z108 14BK/DG GROUND Z108 14BK/DG GROUND K20 14DB GENERATOR FIELD CONTROL F142 14RD/DG FUSED AUTO SHUT DOWN RELAY OUTPUT F142 14RD/DG FUSED AUTO SHUT DOWN RELAY OUTPUT D52 18DG/WT CAN C BUS(+) D25 20VT/YL...
Page 271: Engine Control Module C2 (Diesel) - Black 40 Way
CONNECTOR PINOUTS ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAY CIRCUIT FUNCTION D21 20PK SCI TRANSMIT K35 20GY/YL EGR SOLENOID CONTROL G123 20DG/WT WATER IN FUEL SIGNAL T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE K14 14BK/YL FUEL INJECTOR NO. 4 CONTROL K63 14BK COMMON INJECTOR DRIVER K11 14BK/DB...
Page 272: Engine Oil Pressure Sensor (Diesel) - Black 3 Way
CONNECTOR PINOUTS ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY CIRCUIT FUNCTION K6 18VT/WT SENSOR REFERENCE VOLTAGE B G60 20BR/DB ENGINE OIL PRESSURE SENSOR SIGNAL K4 18BK/LB SENSOR GROUND FUEL INJECTOR NO. 1 (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION K11 14BK/DB FUEL INJECTOR NO.
Page 273: Fuel Injector No. 5 (Diesel) - Black 2 Way
CONNECTOR PINOUTS FUEL INJECTOR NO. 5 (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION K38 14BK/DG FUEL INJECTOR NO. 5 CONTROL K63 14BK COMMON INJECTOR DRIVER FUEL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY CIRCUIT FUNCTION Y100 20BR/GY FUEL PRESSURE SENSOR GROUND Y40 20DG/VT FUEL PRESSURE SENSOR SIGNAL K7 20RD/WT...
Page 274: Generator (Diesel) - Lt. Gray 2 Way
CONNECTOR PINOUTS GENERATOR (DIESEL) - LT. GRAY 2 WAY CIRCUIT FUNCTION F15 14DB/WT FUSED AUTO SHUT DOWN RELAY OUTPUT K20 14DB GENERATOR FIELD CONTROL INTAKE AIR TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION K4 20BK/LB SENSOR GROUND K21 20DG/WT INTAKE AIR TEMPERATURE SENSOR SIGNAL INTAKE PORT SWIRL ACTUATOR (DIESEL) - BLACK 3 WAY CIRCUIT...
Page 275 CONNECTOR PINOUTS...
Page 276: Fuses (Diesel)
CONNECTOR PINOUTS FUSES (DIESEL) FUSE AMPS FUSED CIRCUIT FUNCTION C1 12DG FUSED B(+) A149 12RD/TN FUSED B(+) A145 10WT/RD FUSED B(+) A10 12RD/DG FUSED B(+) A105 10DB/RD FUSED B(+) A147 10RD/GY FUSED B(+) A1 12RD FUSED B(+) A110 10VT/RD FUSED B(+) A146 10OR/WT FUSED B(+) A14 14RD/WT...
Page 277: Engine Starter Motor Relay (Diesel)
CONNECTOR PINOUTS ENGINE STARTER MOTOR RELAY (DIESEL) CIRCUIT FUNCTION A1 12RD FUSED B(+) T752 18DG/OR ENGINE STARTER MOTOR RELAY CONTROL F45 18YL/RD FUSED IGNITION SWITCH OUTPUT (START) T40 12BR ENGINE STARTER MOTOR RELAY OUTPUT GLOW PLUG RELAY NO. 1 (DIESEL) CIRCUIT FUNCTION A105 10DB/RD...
Page 278: Sentry Key Immobilizer Module - Black 6 Way
CONNECTOR PINOUTS SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) Z132 20BK/OR GROUND G5 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) D25 20YL/VT/BK PCI BUS SPEED CONTROL SWITCH NO. 1 - BLACK 4 WAY CIRCUIT FUNCTION K4 20BK/LB SENSOR GROUND...
Page 279: Transmission Control Module C1 (Diesel) - Black 18 Way
CONNECTOR PINOUTS TRANSMISSION CONTROL MODULE C1 (DIESEL) - BLACK 18 WAY CIRCUIT FUNCTION D21 20PK SCI TRANSMIT W4 20PK/OR SHIFTER C5 SENSE Y1 20DB/PK PARK LOCKOUT SOLENOID CONTROL T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE W0 20DB/WT SHIFTER C1 SENSE W1 20VT/WT SHIFTER C2 SENSE W2 20VT SHIFTER C3 SENSE...
Page 280 NOTES...
Page 281: Schematic Diagrams
SCHEMATIC DIAGRAMS 10.0 SCHEMATIC DIAGRAMS 10.1 ENGINE CONTROL MODULE...
Page 282 NOTES...
Page 283: Charts And Graphs
CHARTS AND GRAPHS 11.0 CHARTS AND GRAPHS...
Page 284 NOTES...

DaimlerChrysler Jeep Grand Cherokee 2002 Service Manual

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