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1. FUEL ENGINE HEATER STARTER RELAY MOTOR RELAY RADIATOR AUTOMATIC FAN SHUT RELAY DOWN RELAY NOT CONTROLLER USED ANTI LOCK BRAKE RELAY COMPRESSOR LAMP CLUTCH RELAY RELAY F24 10 7 F23 15 9 22 20 11 21 20 13 20 20 15 F19 15 17 8 14 10 16 R 12 7 gt 2 Gb gt 28 30A 7 q 30A N 7 A 4 4 6 0 13 20 gt 27 6 2 3 5 012 40 26 5 5 A 2 4 D A 1 3 30A 710 74 40 24 3 Hp 0 2 2 50 77 5 40 23 N 7 GENERATOR BATTERY 261 R le 2 CONNECTOR PINOUTS FUSES DIESEL FUSE AMPS FUSED CIRCUIT FUNCTION NO 1 2 50A 54 12RD GY FUSED B 3 50A 54 12RD GY FUSED B 4 30A 16 12RD LG FUSED B 5 40A A1 12RD FUSED B 6 30A 61 14LG RD FUSED B 7 20A 41 16YL FUSED B 8 30A
2. 253 LOW PRESSURE SWITCH 2 253 ACCELERATOR PEDAL POSITION SENSOR DIESEL BLACK 10 WAY 253 BATTERY TEMPERATURE SENSOR DIESEL BLACK 2 254 BRAKE LAMP SWITCH GRAY 6 WAY 254 CLOCKSPRING C1 NATURAL 4 WAY 254 CLOCKSPRING C2 YELLOW 2 2 2 2 254 CLUTCH INTERLOCK SWITCH GREEN 2 254 DATA LINK CONNECTOR BLACK 16 WAY 255 EGR SOLENOID DIESEL 4 2 255 ENGINE CONTROL MODULE C1 DIESEL BLACK 51 256 ENGINE CONTROL MODULE C2 DIESEL BLACK 29 257 ENGINE COOLANT TEMPERATURE SENSOR NO 1 DIESEL ECM BLACK 2 UV tae a he pecans oad od ee en 257 ENGINE COOLANT TEMPERATURE SENSOR NO 2 DIESEL PCM BLACK 2 2 222 2222222 22 2 24 1 1 4 2 424 2 258 ENGINE SPEED SENSOR DIESEL BLACK 3 WAY 258 FUEL HEATER DIESEL 2 258 FUEL INJECTION PUMP DIESEL BLACK 10 258 FUEL LEVEL SENSOR DIESEL BLACK 6 WAY 259 GENERATOR BLACK 2 WAY 259 GEN
3. POWERTRAIN CONTROL MODULE C3 DIESEL 32 WAY CAV CIRCUIT FUNCTION 1 C103 18DG A C REQUEST OUTPUT 2 3 4 5 6 7 8 6154 18VT LG LOW COOLANT INDICATOR DRIVER 9 G86 18TN OR WATER IN FUEL INDICATOR DRIVER 10 11 12 A142 16DG OR AUTOMATIC HUT DOWN RELAY OUTPUT 13 14 15 118 18PK YL BATTERY TEMPERATURE SENSOR SIGNAL 16 G55 18 ENABLE DISABLE SIGNAL 17 18 19 20 21 22 K48 180R RD FAULT INDICATOR REQUEST INPUT 23 C90 18LG A C SWITCH SENSE 24 25 K72 18DG OR GENERATOR SOURCE 26 K226 18DB LG FUEL LEVEL SENSOR SIGNAL 27 021 18BK SCI TRANSMIT 28 02 18WT BK CCD BUS 29 D20 18LG BK SCI RECEIVE 30 01 18VT BR CCD BUS 31 32 RADIATOR FAN MOTOR LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C25 12LB RADIATOR FAN RELAY OUTPUT 2 21 12BK GROUND SENTRY KEY IMMOBILIZER MODULE BLACK 6 WAY CAV CIRCUIT FUNCTION 1 D1 20VT BR CCD BUS 2 D2 20WT BK CCD BUS 3 22 20BK LG GROUND 4 F87 20WT BK FUSED IGNITION SWITCH OUTPUT RUN START 5 Z2 20BK LG GROUND 6 F1 20DB GY FUSED 266 CONNECTOR PINOUTS BLACK TURBO BOOST PRESSURE SENSOR DIESEL BLACK 4 WAY 1 4 CAV CIRCUIT FUNCTION K4 20BK LB 1 SENSOR GROUND
4. 80acb0b4 252 9 0 CONNECTOR PINOUTS BLACK 1 CONNECTOR PINOUTS A C COMPRESSOR CLUTCH DIESEL BLACK 2 WAY CIRCUIT FUNCTION AA 1 C3 14DB BK A C COMPRESSOR CLUTCH RELAY OUTPUT 2 21 16BK GROUND A C COMPRESSOR CLUTCH DIESEL AIC HIGH PRESSURE SWITCH 4 WAY CAV CIRCUIT FUNCTION 1 C21 20DB PK A C SWITCH SENSE 2 C48 18 RADIATOR FAN REQUEST 3 C90 20LG GAS A C SWITCH SENSE A HIGH 3 21 18BK DIESEL GROUND PRESSURE 4 C22 20DB WT DIESEL A C PRESSURE SWITCH SENSE SWITCH 4 C90 20LG GAS A C SWITCH SENSE AIC LOW PRESSURE SWITCH 2 WAY CIRCUIT FUNCTION 1 Z1 20BK DIESEL GROUND A IC LOW 1 C22 18DB WT GAS PRESSURE SWITCH OUTPUT PRESSURE 2 C21 20DB PK A C SWITCH SENSE SWITCH ACCELERATOR PEDAL POSITION SENSOR DIESEL BLACK 10 WAY CAV CIRCUIT FUNCTION 1 2 3 K4 20BK LB SENSOR GROUND 4 5 K151 20WT LOW IDLE POSITION SWITCH SIGNAL 6 7 K22 200R DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL 8 K255 20WT DG ACCELERATOR PEDAL POSITION SENSOR GROUND 9 10 20VT WT 5V SUPPLY 253 R 4 2 R 4 2 CONNECTOR PINOUTS BLACK
5. 21 CHECKING THE CHARGING SYSTEM OPERATION 5 21 TABLE OF CONTENTS Continued COMMUNICATION P1685 3 55 56 yas dies Sesser 25 1686 NO SKIM BUS MESSAGE 27 0600 FAILURE SPI COMMUNICATIONS DIESEL 29 0601 INTERNAL CONTROLLER FAILURE 5 29 P1696 PCM FAILURE EEPROM WRITE 29 P1687 NO CLUSTER BUS MESSAGE 5 55 5 595588959 taeda ea 30 RESPONSE FROM ECM AND PCM DIESEL 32 RESPONSE FROM POWERTRAIN CONTROL MODULE DIESEL ONLY 35 DRIVEABILITY DIESEL P0115 TEMPERATURE OF ENGINE COOLANT SRC HIGH EXCEEDED 37 P0115 TEMPERATURE OF ENGINE COOLANT SRC LOW EXCEEDED 39 0117 SENSOR VOLTAGE 1 41 0118 SENSOR VOLTAGE TOO HIGH 43 P0180 FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED 45 P0180 FUEL TEMPERATURE SENSOR SRC LOW 48 P0235 TURBOCHARGER BOOST SENSOR PLAUSIBILITY 51 P0235 TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED 53 P0235 TURBOCHARGER BOOST SENSOR SIGNAL LOW EXCEEDED 56 P0235 TURBOCHARGER BOO
6. beans oer ad mde ee VEHICLE THEFT SECURITY ANTENNA FAILURE seuss COP FAILURE 616 cere endien EEPROM FAILURE ih INTERNAL FAULT sass die ewe paw awd pee SERIAL LINK INTERNAL STACK OVERFLOW FAILURE PCM STATUS FAILURE dees SERIAL LINK EXTERNAL FAULT ROLLING CODE FAILURE Hk 2s vane xt een ines te TRANSPONDER COMMUNICATION TRANSPONDER CYCLIC REDUNDANCY CHECK CRC FAILURE 5 ves TRANSPONDER RESPONSE MISMATCH VERIFICATION TESTS VERIFICATION stede kise Dika Peda pianta COMPONENT LOCATIONS 81 ENGINE CONTROL MODULE POWERTRAIN CONTROL MODULE AND SENTRY KEY IMMOBILIZER MODULE 9 0 10 0 TABLE OF CONTENTS Continued CONNECTOR 253 COMPRESSOR CLUTCH DIESEL BLACK 2 253 HIGH PRESSURE SWITCH 4
7. DIESEL Symptom 180 TEMPERATURE SENSOR SRC LOW EXCEEDED E When Monitored and Set Condition P0180 FUEL TEMPERATURE SENSOR SRC LOW EXCEEDED When Monitored With the ignition on Set Condition The fuel temperature sensor signal voltage is below 0 8 volt POSSIBLE CAUSES INTERMITTENT CONDITION FUEL TEMPERATURE SENSOR FUEL INJ ECTION PUMP SHORTED TO GROUND INTER NALLY FUEL TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND FUEL TEMPERATURE SENSOR SIGNAL AND GROUND CIRCUITS SHORTED TOGETHER INTERNAL FUEL INJECTION PUMP TEST ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 6 Turn the ignition off Disconnect the Fuel Injection Pump harness connector Turn the ignition on With the DRB erase ECM DTCs and then read ECM DTCs Did DTC P0180 FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED set Yes Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 3 48 DIESEL P0180 F VEL TEMPERATURE SENSOR SRC LOW EXCEEDED Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Fuel Injection Pump harness connector Measure the resistance between
8. PLA i F ESSAGE CENTER DIESEL EEDLE MOVEMENT SENSOR DIESEL INSTRUMENT CLUSTER C2 BLACK 10 WAY CAV CIRCUIT FUNCTION 1 D2 20WT BK CCD BUS 2 D1 20VT BR CCD BUS 3 C81 20LB WT REAR WINDOW DEFOGGER RELAY CONTROL 4 C80 20DB WT REAR WINDOW DEFOGGER SWITCH SENSE 5 G107 20BK RD 4WD SWITCH SENSE PART TIME 6 L60 20TN RIGHT TURN SIGNAL 7 G106 20BK WT 4WD SWITCH SENSE FULL TIME 8 G26 20LB KEY IN IGNITION SWITCH SENSE 9 Z2 18BK LG GROUND 10 G10 20LG RD SEAT BELT SWITCH SENSE LOW COOLANT SWITCH DIESEL 2 WAY CAV CIRCUIT FUNCTION 1 G18 18PK BK COOLANT LEVEL SWITCH SIGNAL 2 K167 20BR YL SENSOR GROUND MESSAGE CENTER DIESEL BLACK 8 WAY CAV CIRCUIT FUNCTION 1 F87 20WT BK FUSED IGNITION SWITCH OUTPUT RUN START 2 3 4 K185 200R LB WAIT TO START INDICATOR DRIVER 5 6 7 G86 20TN OR WATER IN FUEL INDICATOR DRIVER 8 G154 20VT LG LOW COOLANT INDICATOR DRIVER NEEDLE MOVEMENT SENSOR DIESEL 2 WAY CAV CIRCUIT FUNCTION K67 18BR BK NEEDLE MOVEMENT SENSOR K68 18LG YL NEEDLE MOVEMENT SENSOR 260 5 POWER DISTRIBUTION CENTER
9. APPLICABILITY Turn the ignition on All Connect the DRB to another vehicle Will the DRB communicate with this vehicle Yes gt GoTo 2 No or replace the or cable as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 Perform the symptom Checking ECM and PCM Power and Ground Circuits in the Driveability category Did the vehicle pass this test Yes gt GoTo 3 No as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 Turn the ignition off NOTE Reconnect all previously disconnected components Disconnect the PCM harness connectors Turn the ignition on With the DRB attempt to communicate with the ECM Was the DRB able to communicate with the ECM Yes Replace the Powertrain Control Module Perform POWERTRAIN VERIFICATION TEST VER 1 No gt GoTo 4 32 COMMUNICATION NO RESPONSE FROM ECM AND PCM DIESEL ONLY Continued ACTION APPLICABILITY Turn the ignition off Disconnect the CAB harness connector Turn the ignition on With the DRB attempt to communicate with the ECM Was the DRB able to communicate with the ECM Yes Replace the Controller Antilock Brake Perform POWERTRAIN VERIFICATION TEST VER 1 No gt GoTo 5 Turn the ignition off Disconnect the DRB from the DLC Disconnect the PCM harness connectors Disconnect the ECM harness connectors Disconnect the CAB harness connector Turn the ignition on Measu
10. Yes gt Test Complete No GoTo 6 Turn the ignition off Disconnect the Water In Fuel Sensor harness connector Disconnect the PCM harness connectors Measure the resistance of the Water In Fuel Sensor Signal circuit 15 the resistance below 5 0 ohms Yes gt GoTo 7 No Repair the Water In Fuel Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Water In Fuel Sensor harness connector Measure the resistance of the Sensor Ground circuit 15 the resistance below 5 0 ohms Yes gt Replace and program the PCM in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Repair the Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove and inspect the Water In Fuel Lamp bulb Is the bulb OK Yes Replace the Message Center Perform ROAD TEST VERIFICATION VER 2 No Replace the Water Fuel Lamp Bulb Perform ROAD TEST VERIFICATION VER 2 213 Symptom P1655 AC CONTROL OPEN CIRCUIT DIESEL When Monitored and Set Condition P1655 AC CONTROL OPEN CIRCUIT DIESEL When Monitored With the ignition on Set Condition With theA C clutch operation not requested the ECM detects low voltage on the A C Clutch Relay Control circuit NOTE AC is an option that may not be present on all vehicles POSSIBLE CAUSES INTERM
11. 4 Turn the ignition off All Disconnect the S C Switch 4 way harness connector Disconnect the ECM harness connector s Measure the resistance of the S C Switch Signal circuit Is the resistance below 10 0 ohms Yes gt GoTo 25 No Repair the S C Switch Signal circuit for an open Perform SPEED CONTROL VERIFICATION 4 227 STARTING Symptom NO CRANK CONDITION POSSIBLE CAUSES BATTERY CABLE HIGH RESISTANCE CHECKING SHIFTER LINKAGE CLUTCH INTERLOCK SWITCH CLUTCH INTERLOCK SWITCH SENSE CKT OPEN INSPECT BATTERY CABLES MECHANICAL PROBLEM OPEN FUSED BATTERY CIRCUIT OPEN IGNITION SWITCH START OUTPUT STARTER MOTOR STARTER RELAY STARTER RELAY OUTPUT CIRCUIT OPEN ACTION APPLICABILITY NOTE The Clutch Pedal must be depressed during any engine start All attempt Turn the ignition off NOTE The battery must be fully charged before diagnosing a no crank condition Inspect the battery cables for corrosion looseness or other problems 15 there evidence of problems Yes Repair as necessary Perform NO START VERIFICATION VER 1 No gt GoTo 2 Remove the Starter Relay from the PDC Using a 12 volt test light connected to ground check the Fused B circuit Is the test light on Yes gt GoTo 3 No Repair the Fused B circuit for an open Perform NO START VERIFICATION 1 Remove the Starter Relay from the PDC Using a 12 volt test light connected to ground check the Igniti
12. APPLICABILITY Refer to any Technical Service Bulletins TSB that may apply to this condition Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform SPEED CONTROL VERIFICATION VER 4 GoTo 13 Check the brake lamp switch for proper adjustment Is the brake lamp switch adjusted properly Yes Replace and program the Engine Control Module in accordance with the Service Information Perform SPEED CONTROL VERIFICATION 4 No Adjust or replace the brake lamp switch as necessary Perform SPEED CONTROL VERIFICATION VER 4 Turn the ignition off All Disconnect the Brake Lamp Switch harness connector Turn the ignition on Measure the voltage of the Secondary Brake Switch Signal circuit 15 the voltage above 9 0 volts Yes gt GoTo 15 No GoTo 17 Turn the ignition off Disconnect the Brake Switch harness connector With the DRB monitor the brake switch input Connect a jumper wire between the Brake Lamp Switch harness connector cavities 1 2 Did the display change from Pressed to Released Yes Adjust or replace the Brake Lamp Switch Perform SPEED CONTROL VERIFICATION VER 4 No GoTo 16 Disconnect the Brake Lamp Switch
13. BATTERY TEMPERATURE SENSOR DIESEL a All Lo BRAKE LAMP SWITCH ie M 88 88 4 CLOCKSPRING C1 YELLOW CLOCKSPRING C2 GREEN CLUTCH INTERLOCK SWITCH BATTERY TEMPERATURE SENSOR DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K118 18PK YL BATTERY TEMPERATURE SENSOR SIGNAL 2 K167 20BR YL SENSOR GROUND BRAKE LAMP SWITCH GRAY 6 WAY CAV CIRCUIT FUNCTION 1 K29 18WT PK GAS BRAKE LAMP SWITCH SENSE 1 K29 18WT PK DIESEL SECONDARY BRAKE SWITCH SIGNAL 2 21 18BK GROUND 2 21 20BK LHD BUILT UP GROUND EXPORT 3 V32 20YL RD SPEED CONTROL SUPPLY 4 V30 20DB RD SPEED CONTROL BRAKE SWITCH OUTPUT 5 L50 20WT TN LHD GAS BRAKE LAMP SWITCH OUTPUT 5 L50 20WT TN GAS BRAKE LAMP SWITCH OUTPUT 5 L50 20WT TN DIESEL PRIMARY BRAKE SWITCH SIGNAL 6 F32 20PK DB FUSED B CLOCKSPRING C1 NATURAL 4 WAY CAV CIRCUIT FUNCTION 1 20BK RD HORN RELAY CONTROL 2 V37 20RD LG SPEED CONTROL SWITCH SIGNAL 3 4 20BK RD SENSOR GROUND 4 CLOCKSPRING C2 YELLOW 2 WAY CAV CIRCUIT FUNCTION A R45 18DG LB DRIVER AIRBAG LINE 2 B R43 18BK LB DRIVER AIRBAG LINE 1 CLUTCH INTERLOCK SWITCH GREEN 2 WAY CAV CIRCUIT FUNCTION F4
14. Continued ACTION APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform CHARGING VERIFICATION VER 3 No Test Complete CHARGING Symptom P1493 AMBIENT BATT TEMP SEN VOLTS TOO LOW DIESEL When Monitored and Set Condition P1493 AMBIENT BATT TEMP SEN VOLTS TOO LOW DIESEL When Monitored With the ignition on Set Condition The PCM detects voltage on the ambient battery temperature sensor signal circuit below 0 08 volt for more than 3 seconds POSSIBLE CAUSES INTERMITTENT CONDITION AMBIENT BATTERY TEMPERATURE SENSOR AMBIENT BATTERY TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED
15. Connect a jumper wire between ground and the ECM ECT Sensor Signal circuit Turn the ignition on With the DRB read the ECM ECT Sensor voltage Is the voltage below 1 0 volt Yes Repair the ECM ECT Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 5 Turn the ignition off Disconnect the ECM harness connectors Disconnect the ECM ECT Sensor harness connector Measure the resistance of the ECM ECT Sensor Signal circuit 15 the resistance below 5 0 ohms Yes gt GoTo 6 No Repair the ECM ECT Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair All Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for a
16. DRIVEABILITY DIESEL P1515 ACCEL PEDAL SENSOR PLAUSIBILITY Continued ACTION APPLICABILITY Turn the ignition on All With the DRB III select Engine and with the custom display feature select Low Idle Switch input and the Accel Pedal Slowly depress and release the accelerator pedal several times while monitoring the DRB III display NOTE The Low Idle Switch state should change between 5 and 10 of Accelerator Pedal position Did the Low Idle Switch state change between 5 and 10 of Accelerator Pedal position Yes gt GoTo 17 Replace the Accelerator Pedal Position Sensor Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals
17. NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 105 DRIVEABILITY DIESEL Symptom List P1225 CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED P1225 CONTROL SLEEVE SENSOR SIGNAL LOW EXCEEDED Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P1225 CONTROL SLEEVE SEN SOR SIGNAL HIGH EXCEEDED eee When Monitored and Set Condition P1225 CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED When Monitored With the ignition on and during after run mode at key off Set Condition ECM does not receive a correct signal from the measure coil and or the sensor co
18. Repair the SCI Transmit circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 Turn the ignition off Disconnect the DRB from the DLC Disconnect the negative battery cable Measure the resistance between ground and both ground circuits at the DLC 15 the resistance below 5 0 ohms for each measurement Yes gt GoTo 10 No Repair the ground circuit that measured above 5 0 ohms for open Perform POWERTRAIN VERIFICATION TEST VER 1 If there are no possible causes remaining view repair Repair Replace the Engine Control Module Perform POWERTRAIN VERIFICATION TEST VER 1 34 COMMUNICATION Symptom NO RESPONSE FROM POWERTRAIN CONTROL MODULE DIE SEL ONLY POSSIBLE CAUSES ATTEMPT TO COMMUNICATE WITH THE ECM CHECK PCM POWERS AND GROUNDS SCI RECEIVE CIRCUIT SHORTED TO GROUND SCI RECEIVE CIRCUIT OPEN SCI TRANSMIT CIRCUIT OPEN POWERTRAIN CONTROL MODULE ACTION APPLICABILITY Turn the ignition on With the DRB attempt to communicate with the ECM Was the DRB able to communicate with the ECM Yes gt GoTo 2 No Refer tosymptom list for problems related to No Response From ECM and PCM Perform POWERTRAIN VERIFICATION TEST VER 1 Perform the symptom Checking ECM and PCM Power and Ground Circuits in the Driveability category Did the vehicle pass this test Yes gt GoTo 3 Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 Is the resistance below 5 0 oh
19. e Do not use the DRBIII if it has been damaged Do not use the test leads if the insulation is damaged or if metal is exposed To avoid electrical shock do not touch the test leads tips or the circuit being tested e Choose the proper range and function for the measurement Do not try voltage or current measurements that may exceed the rated capac ity e Do not exceed the limits shown in the table below FUNCTION INPUT LIMIT Volts 0 500 peak volts AC 500 volts DC Ohms resistance 0 1 12 megohms Frequency Measured 0 10 2 Temperature 58 1100F 50 600C Ohms cannot be measured if voltage is present Ohms can be measured only in a non powered circuit Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC e Use caution when measuring voltage above 25v DC or 25v AC The circuit being tested must be protected by a 10A fuse or circuit breaker e Usethelow current shunt to measure circuits up to 10A Use the high current clamp to measure circuits exceeding 10A e When testing for the presence of voltage or current make sure the meter is functioning correctly Take a reading of a known voltage or current before accepting a zero reading e When measuring current connect the meter in series with the load e Disconnect the live test lead before disconnect ing the common test lead 4 3 WARNINGS 4 3 1 VEHICLE DAMAGE WA
20. DIESEL Symptom CHECKING THE A C SYSTEM POSSIBLE CAUSES A C COMPRESSOR CLUTCH A C COMPRESSOR CLUTCH GROUND CIRCUIT OPEN A C COMPRESSOR CLUTCH RELAY OUTPUT CIRCUIT OPEN A C HIGH PRESSURE SWITCH OPEN A C LOW PRESSURE SWITCH OPEN A C PRESSURE SENSE CIRCUIT OPEN A C SELECT SWITCH SENSE CIRCUIT OPEN A C SELECT SWITCH SENSE CIRCUIT SHORT TO GROUND A C SELECT SWITCH SENSE CIRCUIT SHORT TO VOLTAGE A C SWITCH INPUT TO THE PCM A C SWITCH SIGNAL OPEN A C SWITCH SIGNAL SHORTED TO GROUND ACTUATOR TEST ECM ECM PRESSURE SIGNAL OPEN FUSED B CIRCUIT OPEN GROUND CIRCUIT OPEN PRESSURE SIGNAL CIRCUIT OPEN PCM A C SELECT SWITCH SENSE CIRCUIT OPEN PCM A C SWITCH INPUT PCM INTERNAL A C SELECT SWITCH CIRCUIT ACTION APPLICABILITY NOTE Prior to diagnosing the A C electrical system check for proper A C All system pressure Improper refrigerant charge can cause incorrect system diagnosis and unnecessary component replacement NOTE Refer the Service Information to check the A C mechanical system before continuing With the DRB select Engine J TEC then Inputs Outputs Start the engine and set the blower to Panel Turn theA C on With the DRB read the A C Select Switch Does the DRB display A C Select Switch YES Yes gt GoTo 2 No GoTo 16 165 DRIVEABILITY DIESEL CHECKING THE A C SYSTEM Continued ACTION APPLICABILITY With the DRB select Engine Bosch Controller then Inputs Outputs Start the eng
21. EVM genera tor hard start hesita tion sag stumble lack of power sluggish MIC MIL PCM PDC poor fuel economy fuel ignites in either the intake or the exhaust system a steady pulsation or the inability of the engine to maintain a consis tent rom data link connector previously called engine diagnostic connec tor a mild to severe ping especially under loaded engine conditions engine control module Bosch EDC15 engine coolant temperature sensor exhaust gas recirculation valve and system electric vacuum modulator previously called alternator The engine takes longer than usual to start even though it is able to crank normally There 15 a momentary lack of re sponse when the throttle is opened This can occur at all vehicle speeds If it is severe enough the engine may stall The engine has less than expected power with little or no increase in vehicle speed when the throttle is opened electro mechanical instrument clus ter malfunction indicator lamp powertrain control module power distribution center There is significantly less fuel mile age than other vehicles of the same design and configuration GENERAL INFORMATION rough The engine runs unevenly at idle unstable and causes the engine to shake if it or is severe enough The engine idle erratic rpm may vary called hunting idle This condition may cause stalling if stalli
22. HARNESS AA CONNECTOR 80 4 FUEL GAUGE FLOAT PIGTAIL WIRING HARNESS FUEL GAUGE SENDING UNIT 9 80ace654 249 2 L 5 5 8 4 SENSORS Continued BOOST PRESSURE SENSOR HARNESS BOOST __ PRESSURE SENSOR 80677056 SENSOR ELECTRICAL CONNECTOR Q ALS ee A CASE EXTENSION SPEED SENSOR 80b6b22c 8 5 RELAYS POWER DISTRIBUTION CENTER CLUTCH RELAY CONNECTOR 1 DB OR A C CLUTCH RELAY CONTROL 2 DG OR ASD RELAY OUTPUT 3 5 RD BK FUSED BATTERY SUPPLY DB BK A C CLUTCH RELAY OUTPUT 80 SENSOR FUEL INJECTOR NUMBER 1 CYLINDER ONLY UKE C xb ROY _ f we gt lt A 5 5 Y LL A Mae ae LY 4 60 ial Ta ae lt gt gt 7 z V Die FUEL HEATER WATER FUEL 4 HARNESS A4 SENSOR HARNESS CONNECTOR 77 CONNECTOR 8096236 POWER DISTRIBUTION ASD RELAY CONNECTOR 70 COLOR 30 RD LG FUSED BATTERY SUPPLY 85 RD LG FUSED BATTERY SUPP
23. While reading the A C Switch input use a jumper wire to connect the A C Switch Signal circuit to ground at the PCM harness connector Does the DRB display A C Switch ON Yes Replace and program the PCM in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 14 Turn the ignition off Disconnect the PCM harness connectors Disconnect the ECM harness connectors Measure the resistance between ground the A C Switch Signal circuit 15 the resistance below 100 0 ohms Yes Repair the A C Switch Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 No GoTo 15 Turn the ignition off Disconnect the PCM harness connectors Disconnect the ECM harness connectors Measure the resistance of the A C Switch Signal circuit 15 the resistance below 10 0 ohms Yes Replace and program the ECM in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Repair the A C Switch Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the A C Heater Control harness connectors Disconnect the PCM harness connectors Turn the ignition on Measure the voltage of the A C Select Switch Sense circuit Is the voltage below 1 0 volt Yes gt GoTo 17 No Repair theA C Select Switch Sense circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off D
24. fied locate the matching test in the Table of Contents and begin to diagnose the symptom All component location views are in Section 8 0 All connector pinouts are in Section 9 0 All system schematics are in Section 10 0 An placed before the symptom description indi cates ano DTC customer complaint 1 1 SYSTEM COVERAGE This diagnostic procedures manual covers the 2001 XJ equipped with the 2 5L VM diesel engine 1 2 SIX STEP TROUBLESHOOTING PROCEDURE Diagnosis of the engine control module ECM and powertrain control module PCM is done six basic steps e verification of complaint e verification of any related symptoms symptom analysis e problem isolation e repair of isolated problem GENERAL INFORMATION e verification of proper operation 2 0 IDENTIFICATION OF SYSTEM LHD ECM is located behind the lower instru ment panel to the right of the accelerator pedal RHD The ECM is located behind the lower instru ment panel to the left of the clutch pedal The PCM for both LHD and RHD is located in the engine compartment behind the air cleaner housing 3 0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION 3 1 GENERAL DESCRIPTION The 2 5L VM diesel engine system is equipped with the latest in technical advances The on board diagnostics incorporated with the powertrain con trol module and engine control module are intended to assist the field technician in repairing vehicle problems b
25. 115 DRIVEABILITY DIESEL P1515 ACCEL PEDAL SENSOR PLAUSIBILITY Continued POSSIBLE CAUSES 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE APP SENSOR CIRCUIT SHORTED TO VOLTAGE APP SENSOR IDLE VOLTAGE APP SENSOR WIDE OPEN THROTTLE VOLTAGE ECM SENSOR GROUND CIRCUIT OPEN LOW IDLE POSITION SWITCH SENSE CIRCUIT SHORTED TO VOLTAGE 5 VOLT SUPPLY CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT APP SENSOR SIGNAL CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT INTERMITTENT CONDITION LOW IDLE POSITION SWITCH SENSE CIRCUIT SHORTED TO THE SENSOR GROUND CIR CUIT 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND APP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND LOW IDLE POSITION SWITCH SENSE CIRCUIT SHORTED TO GROUND 5 VOLT SUPPLY CIRCUIT OPEN APP SENSOR SIGNAL CIRCUIT OPEN LOW IDLE POSITION SWITCH SENSE CIRCUIT OPEN 5 VOLT SUPPLY CIRCUIT ECM APP SENSOR SIGNAL CIRCUIT PCM SENSOR GROUND CIRCUIT OPEN PCM SENSOR GROUND CIRCUIT VERIFY LOW IDLE POSITION SWITCH OPERATION VERIFY APP SENSOR OPERATION ECM SENSOR GROUND OPEN VERIFY CORRECT SWITCHING ACTION APPLICABILITY Turn the ignition off All Disconnect the APP Sensor harness connector Connect one end of a jumper wire to APP Sensor harness connector cavity 4 Turn the ignition on With the DRB III monitor the Low Idle Position Switch input while tapping the other end of the jumper wire to APP Sensor harness connector cavity 5 Does the 111 change between IDLE and ABOVE IDLE when t
26. 14RD WT FUSED B 9 50 7 10RD BK FUSED B 10 40a A2 12 FUSED B 11 40a 111 12RD LG FUSED B 12 40 F141 12LG RD FUSED B 13 40 F141 12LG RD FUSED B 14 204 A20 12RD DB FUSED B 15 30A 4 12BK PK FUSED B 16 15a 1 20PK FUSED B 16 15a 1 20PK FUSED B 17 18 19 15a 2 20PK DB FUSED B 20 20 17 18RD BK FUSED B 20 20A 17 16RD BK FUSED B 21 20 F142 16DG OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 22 20 F75 16VT FUSED B 23 15 19 20BK PK FUSED B 24 10A F16 16RD LG FUSED B 25 15 F61 20WT OR FUSED B 26 20 4 18TN BK FUSED B 27 10 F1 20DB GY FUSED B AIC COMPRESSOR CLUTCH RELAY DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION B1 A17 16RD BK FUSED B B2 C3 16DB BK COMPRESSOR CLUTCH RELAY OUTPUT C13 20DB OR COMPRESSOR CLUTCH RELAY CONTROL B4 B5 A142 1806 AUTOMATIC SHUT DOWN RELAY OUTPUT AUTOMATIC SHUT DOWN RELAY DIESEL CAV CIRCUIT FUNCTION c2 A16 12RD LG FUSED B 16 12RD LG FUSED B c5 K51 20DB YL AUTOMATIC SHUT DOWN RELAY CONTROL 8 A142 16DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT A142 1806 AUTOMATIC SHUT DOWN RELAY OUTPUT 262 ENGINE STARTER MOTOR RELAY DIESEL CONNECTOR PINOUTS CAV CIRCUIT FUNCTION 010 A41 16YL FUSED 011 7141 20YL IGNITION
27. Continued ACTION APPLICABILITY Turn the ignition off All Remove the ASD Diesel Power Relay from the PDC Disconnect the ECM harness connectors Measure the resistance of the ASD Diesel Power Relay Control circuit while wiggling the wiring harness and connectors between the ECM and the PDC Was the resistance above 5 0 ohms at any time while wiggling the wiring harness and connectors Yes Repair the ASD Diesel Power Relay Control circuit for an inter mittent open Perform ROAD TEST VERIFICATION VER 2 GoTo 5 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness
28. GoTo 11 No Repair the 5 volt Supply circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 198 DRIVEABILITY DIESEL Symptom CHECKING THE SPEEDOMETER OPERATION POSSIBLE CAUSES CHECK FOR VEHICLE SPEED SENSOR DTCS CHECK GAUGES AND OTHER LAMPS KEY ON COMPARETHE DRB VEHICLE SPEED WITH THE SPEEDOMETER INSTRUMENT CLUSTER POWERTRAIN CONTROL MODULE 5 VOLT OPEN POWERTRAIN CONTROL MODULE INTERNAL FAULT 5 VOLT SUPPLY CIRCUIT OPEN CHECK VSS CIRCUITS FOR A SHORT TO VOLTAGE CHECK VSS CIRCUITS FOR A SHORT TO GROUND CHECK VSS CIRCUITS FOR A SHORT TOGETHER CHECK VSS CIRCUITS FOR AN OPEN VEHICLE SPEED SENSOR ACTION APPLICABILITY Turn the ignition on and observe gauge and lamp operation during bulb check All Did the gauges and other lamps operate properly during the bulb check Yes gt GoTo 2 Refer to symptom list for problems related to Vehicle Communi cation Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on With the DRB read ECM DTCs Are any Vehicle Speed Sensor DTCs present Yes Refer to symptom list for problems related to Vehicle Speed Sensor DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 3 With the DRB monitor Vehicle Speed in the PCM S
29. Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Turn the ignition on Connect a jumper wire between the Intake Air Temperature Sensor Signal circuit and ground Monitor the DRB for ECM DTCs Does the DRB display P1110 AIR TEMP SENSOR SRC LOW EXCEEDED Yes Repair the Intake Air Temperature Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 Replace and program the Engine Control Module in accordance with the Service Information No Test Complete 92 DRIVEABILITY DIESEL Symptom P1110 AIR TEMP SENSOR SRC LOW EXCEEDED When Monitored and Set Condition P1110 AIR TEMP SENSOR SRC LOW EXCEEDED When Monitored With the ignition on Set Condition Theintake air temperature sensor signal goes below 0 18 volt for at least 2 seconds POSSIBLE CAUSES INTERMI
30. NOTE The thermostat must be operating correctly for this test to be valid Start the engine Using a temperature probe measure the engine block temperature near the ECT Sensor When the engine temperature reaches 75 C 180 F use the DRB and read the engine coolant temperature Are the readings within 7 C 13 F of each other Yes gt Test Complete No Replace the Engine Coolant Temperature Sensor Perform ROAD TEST VERIFICATION VER 2 179 DRIVEABILITY DIESEL Symptom CHECKING THE ENGINE MECHANICAL SYSTEMS POSSIBLE CAUSES CHECKING ENGINE MECHANICAL SYSTEMS ACTION APPLICABILITY NOTE The following items should be checked as a possible cause of a All Driveability or No Start problem Engine Valve Timing must be within specification Engine Compression must be within specifications Camshaft Lobes check for abnormal wear Engine Speed Sensor Pick Up check the flywheel slots for debris and deterioration Engine Exhaust System must be free of any restriction Engine Drive Sprocket must be properly positioned Power Brake Booster must be free of any vacuum leaks Fuel must be free of contamination Fuel Injector must not be plugged or restricted Fuel Injection Pump must be properly timed NOTE Check for any Technical Service Bulletins that may relate to the problem Are there any problems evident Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Comp
31. No Repair the Low Coolant Switch Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the PCM harness connectors Disconnect the Low Coolant Switch harness connector Measure the resistance between the Low Coolant Switch Signal circuit and Switch Ground circuit Is the resistance above 100 kohms Yes gt GoTo 5 the Low Coolant Switch Signal and Switch Ground circuit for a short together Perform ROAD TEST VERIFICATION VER 2 Disconnect the Low Coolant Switch harness connector Turn the ignition on and wait 30 seconds Is the Low Coolant Lamp on Yes Replace the Low Coolant Switch Perform ROAD TEST VERIFICATION VER 2 No GoTo 6 If there no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the PCM harness connectors Turn the ignition on and observe the Low Coolant Lamp Did the Low Coolant Lamp illuminate and stay on continuously Yes gt GoTo 8 No gt GoTo 9 Turn the ignition off 193 DRIVEABILITY DIESEL CHECKING THE LOW COOLANT LAMP OPERATION Continued ACTION APPLICABILITY Turn the ignition off Disconnect the PCM harness connectors Disconnect the Message Center harness connector Measure the resistance between ground and t
32. P1615 MICROCONTROLLER GATE ARRAY 89 P1615 MICROCONTROLLER PREPARE FUEL QUANTITY 89 P1615 MICROCONTROLLER RECOVERY HAS 89 P1615 MICROCONTROLLER REDUNDANT OVERRUN MONITORING 89 620 UREF 89 P1680 EEPROM PLAUSIBILITY CHECKSUM ERROR FOR ADJ 89 P1680 EEPROM PLAUSIBILITY CHECKSUM ERROR IN 212 89 P1680 EEPROM PLAUSIBILITY COMMUNICATION WITH EEPROM 89 P1680 EEPROM PLAUSIBILITY FUNC SWITCH WRONG OR MISSING 89 P1680 EEPROM PLAUSIBILITY VER NUMBER NOT CORRESPONDING 89 P1680 EEPROM PLAUSIBILITY VIN CHECKSUM ERROR 89 P1110 AIR TEMP SENSOR SRC HIGH 91 1110 TEMP SENSOR SRC LOW 93 TABLE OF CONTENTS Continued P1201 NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED 95 P1201 NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED 98 P1220 FUEL QUANTITY ACTUATOR NEG GOV DEVIATION COLD 100 P1220 FUEL QUANTITY ACTUATOR NEG GOV DEVIATION WARM 102 P1220 FUEL QUANTITY ACTUATOR POS GOV DEVIATION COLD 104 P1220 FUEL QUANTITY ACTUATOR POS GOV DEVIATION WARM 104 P1225 CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED 106 P1225 CONTROL SLEEVE SENSOR SIGNAL LOW EXCEEDE
33. Perform ROAD TEST VERIFICATION VER 2 No Replace the Instrument Cluster in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 196 DRIVEABILITY DIESEL CHECKING THE OIL PRESSURE GAUGE OPERATION Continued APPLICABILITY Turn the ignition off Connect a 8 3 Bar 120 PSI oil pressure gauge to the engine Start the engine Observe the mechanical oil pressure gauge Is the engine oiling system functioning properly Yes gt GoTo 5 No Repair the engine oiling system in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Engine Oil Pressure Sensor harness connector Turn the ignition on Measure the voltage of the 5 volt Supply circuit in the Engine Oil Pressure Sensor harness connector 15 the voltage between 4 8 and 5 5 volts Yes gt GoTo 6 No gt GoTo 8 Turn the ignition off All Disconnect the Engine Oil Pressure Sensor harness connector Measure the voltage on the Sensor Ground circuit 15 the voltage below 0 5 volt Yes gt Replace the Engine Oil Pressure Sensor Perform ROAD TEST VERIFICATION VER 2 No GoTo 7 Turn the ignition off Disconnect the Engine Oil Pressure Sensor harness connector Disconnect the PCM harness connectors Turn the ignition on Measure the voltage of the Sensor Ground circuit Is the voltage below 0 5 volt Yes Replace and program the
34. TURBO BOOST TEMPERATURE SENSOR SIGNAL PRESSURE SENSOR 4 20DG RD BOOST PRESSURE SENSOR SIGNAL DIESEL VEHICLE SPEED SENSOR DIESEL 3 WAY 3 1 CIRCUIT FUNCTION 1 K7 180R 5V SUPPLY 2 67 18BR YL SENSOR GROUND VEHICLE SPEED G7 8WT OR VEHICLE SPEED SENSOR SIGNAL SENSOR DIESEL 2 1 WATER IN FUEL SENSOR DIESEL BLACK 2 WAY a CAV CIRCUIT FUNCTION 1 G123 18DG WT WATER IN FUEL SENSOR SIGNAL R WATER IN FUEL 2 167 20BR YL SENSOR GROUND SENSOR DIESEL U T S 267 NOTES SCHEMATIC DIAGRAMS 10 0 SCHEMATIC DIAGRAMS 10 1 ENGINE CONTROL MODULE TO PCM ASD A C INPUT EF RELAY SKIM INPUT C1 38 SPEED 30 AMP CONTROL IN SWITCH FUSE 11 gt IGNITION 20 SWITCH IN J BLOCK BRAKE RESUME ACCEL Le LAMP SWITCH EUSE 9 CANCEL 9 7 DECEL 2 l BOOST PRESSURE INTAKE AIR Z TO PCM ENGINE SPEED TEMP PCM S C INPUT FUSE 21 5 20 GLOW PLUG RELAY COOLING SPEED SENSOR o FUSE 3 NEEDLE C2 62 SENSOR C2 55 TO PCM VSS SIGNAL TO PCM VEHICLE ELECTRIC VACUUM SENSOR SPEED MODULATOR RETURN SENSOR TO PCM 7 5 VOLT TO P
35. VER 3 No Repair the Generator Source circuit for an open Perform CHARGING VERIFICATION VER 3 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform CHARGING VERIFICATION VER 3 No Test Complete 11 CHARGING Symptom P1492 AMBIENT BATT TEMP SEN VOLTS TOO HIGH DIESEL E When Monitored and Set Condition P1492 AMBIENT BATT TEMP SEN VOLTS TOO HIGH DIESEL When Monitored With the ignition on Set Condition The PCM detects voltage on the ambient battery temperature sensor signal circuit above 4 94 volts for more than 3 seconds POSSIBLE CAUSES POWERTRAIN CONTROL MODULE SHORTED TO VOLTAGE INT
36. VER 3 Repair the Ambient Battery Temperature Sensor Signal circuit for a short to voltage Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the Ambient Battery Temperature Sensor harness connector Measure the resistance of the Amb Batt Temp Sensor Is the resistance above 100 kohms Yes Replace the Ambient Battery Temperature Sensor Perform CHARGING VERIFICATION VER 3 No gt GoTo 5 Measure the resistance of the Amb Batt Temp Sensor Signal circuit Is the resistance below 5 0 ohms Yes gt GoTo 6 No Repair the Ambient Battery Temperature Sensor Signal circuit for an open Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the Ambient Battery Temperature Sensor harness connector Disconnect the PCM harness connectors Measure the resistance of the Amb Batt Temp Sensor Ground circuit 15 the resistance below 5 0 ohms Yes gt GoTo 7 No Repair the Ambient Battery Temperature Sensor Ground circuit for an open Perform CHARGING VERIFICATION VER 3 If there are no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform CHARGING VERIFICATION VER 3 Turn the ignition off All Disconnect the Ambient Battery Temperature Sensor harness connector Disconnect the PCM harness connectors 13 CHARGING P1492 AMBIENT BATT TEMP SEN VOLTS TOO HIGH DIESEL
37. When Monitored and Set Condition P1605 TERMINAL 15 PLAUSIBILITY AFTER START UP When Monitored During power up and in after run mode Set Condition The switched ignition voltage at ECM cavity C1 47 drops to 0 volt and battery voltage is present at an ECM cavity other than cavities C1 33 and C1 45 NOTE The Terminal 15 refers to the internal terminal the Bosch controller and not to the actual switched ignition cavity cavity C1 47 in the ECM harness connector POSSIBLE CAUSES INTERMITTENT CONDITION ASD DIESEL POWER RELAY ENGINE CONTROL MODULE ECM CIRCUIT SHORTED TO VOLTAGE ASD RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE ASD RELAY CONTROL CIRCUIT SHORTED TO GROUND APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Cycle the ignition switch on and off several times pausing for at least 10 seconds at each key off and key on Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 6 Turn the ignition off Disconnect the ECM harness connectors Measure the voltage of all cavities in the ECM harness connectors except cavities C1 33 and C1 45 Is the voltage above 2 0 volts on any of the cavity terminals except C1 33 and C1 45 Yes gt GoTo 3 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 124 DRIVEABILITY DIESEL P1605 TERMINAL
38. With the DRB erase ECM DTCs Turn the ignition off wait 30 seconds then turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 gt GoTo 3 Turn the ignition off Disconnect the Turbocharger Boost Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage between ground and the 5 volt Supply circuit 15 the voltage above 1 0 volt Yes Repair the 5 volt Supply circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 59 DRIVEABILITY DIESEL P0235 TURBOCHARGER BOOST SENSOR SUPPLY HIGH EXCEEDED Continued APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the condi
39. Yes gt GoTo 9 No Repair the S C Lamp Signal circuit for an open Perform SPEED CONTROL VERIFICATION 4 Turn the ignition off All Disconnect the ECM harness connectors Disconnect the PCM harness connectors Measure the resistance between ground and the S C Lamp Signal circuit 15 the resistance below 100 0 ohms Yes gt Repair the S C Lamp Signal circuit for a short to ground Perform SPEED CONTROL VERIFICATION VER 4 No GoTo 10 Turn the ignition off Disconnect the ECM harness connectors Disconnect the PCM harness connectors Disconnect the ASD Relay from the PDC Connect a jumper wire across ASD Relay connector cavities 30 and 87 in the PDC Turn the ignition on Measure the voltage of the S C Lamp Signal circuit 15 the voltage below 8 0 volts Yes gt GoTo 11 No Repair the S C Lamp Signal circuit for a short to voltage Perform SPEED CONTROL VERIFICATION VER 4 Turn the ignition off Disconnect the ECM harness connectors Turn the ignition on Connect a jumper wire between the S C Lamp Signal circuit and ground Observe the S C Lamp Is the S C Lamp on Yes Replace and program the ECM in accordance with the Service Information Perform SPEED CONTROL VERIFICATION VER 4 Replace and program the PCM in accordance with the Service Information Perform SPEED CONTROL VERIFICATION VER 4 224 SPEED CONTROL CHECKING THE SPEED CONTROL OPERATION Continued
40. nformation Perform ROAD TEST VERIFICATION VER 2 GoTo 6 Turn the ignition off Disconnect the Brake Lamp Switch harness connector Measure the resistance between ground and the Secondary Brake Switch Ground circuit Is the resistance below 5 0 ohms Yes gt GoTo 7 No Repair the Secondary Brake Switch Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 159 DRIVEABILITY DIESEL P1703 BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT Continued ACTION APPLICABILITY Turn the ignition off Disconnect the Brake Lamp Switch harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the Secondary Brake Switch Signal circuit Is the resistance above 100 kohms Yes gt GoTo 9 Repair the Secondary Brake Switch Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Brake Lamp Switch harness connector Disconnect the ECM harness connectors Measure the resistance of the Secondary Brake Switch Signal circuit Is the resistance below 5 0 ohms Yes gt GoTo 10 No Repair the Secondary Brake Switch Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 Disconnect the Brake L
41. 136 DRIVEABILITY DIESEL P1635 GLOW RELAY 1 CONTROLLER OPEN CIRCUIT Continued APPLICABILITY Turn the ignition off Remove the Glow Plug Relay from the PDC Turn the ignition on Using a 12 volt Test Light connected to ground check the ASD Diesel Power Relay Output circuit Did the test light illuminate brightly Yes gt GoTo 4 No Repair the ASD Diesel Power Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Install a substitute relay in place of the Glow Plug Relay Turn the ignition on With the DRB actuate the Glow Plug Relay 15 the Glow Plug Relay dicking Yes Replace the Glow Plug Relay Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 5 Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Remove the Glow Plug Relay from the PDC Measure the resistance of the Glow Plug Relay Control circuit Is the resistance below 5 0 ohms Yes gt GoTo 7 No Repair the Glow Plug Relay Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 there no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the ECM harness connectors Remove the Glow Plug Relay from the PDC Measure the resistanc
42. 500 SPEED SENSOR PLAUSIBILITY 500 SPEED SENSOR SRC HIGH EXCEEDED Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will PO500 VEH SPEED SENSOR PEC FREQUENCY TOO HIGH When Monitored and Set Condition P0500 VEH SPEED SENSOR PEC FREQUENCY TOO HIGH When Monitored With the engine running Set Condition The ECM detects a vehicle speed greater than 220 km h 137 500 SPEED SENSOR PLAUSIBILITY When Monitored With the engine running Set Condition The ECM compares the amount of fuel the fuel quantity actuator is delivering to the vehicle speed from the vehicle speed sensor VSS The VSS indicates a vehicle speed that cannot be achieved with the present amount of fuel being delivered P0500 VEH SPEED SENSOR SRC HIGH EXCEEDED When Monitored With the engine running Set Condition The ECM detects a vehicle speed greater than 220 km h 137 POSSIBLE CAUSES VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND POWERTRAIN CONTROL MODULE 5 VOLT SUPPLY HIGH POWERTRAIN CONTROL MODULE AFTER 5 VOLT SUPPLY SHORTED TO VOLTAGE REPAIR THE 5 VOLT SUPPLY CIRCUIT AND CHECK THE PCM INTERMITTENT CONDITION 5 VOLT SUPPLY CIRCUIT OPEN POWERTRAIN CONTROL MODULE SHORTED TO VOLTAGE SPEEDOMETER PINION AND DRIVE TEETH DAMAGED VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO 5 VOLT SUPPLY CIRCUIT 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND ENGINE CON
43. APPLICABILITY Turn the ignition off Disconnect the ECM harness connectors Disconnect the Fuel Injection Pump harness connector Measure the resistance between ground and the Fuel Timing Solenoid Control circuit Is the resistance above 100 kohms Yes gt GoTo 4 No Repair the Fuel Timing Solenoid Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Fuel Injection Pump harness connector Measure the resistance of the Fuel Timing Solenoid Control circuit Is the resistance below 5 0 ohms Yes gt GoTo 5 No Repair the Fuel Timing Solenoid Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the Fuel Injection Pump harness connector Measure the resistance of the Fuel Timing Solenoid at the Fuel Injection Pump connector fuel pump side between cavities 5 and 10 Is the resistance between 12 0 and 20 0 ohms Yes gt GoTo 6 Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Disconnect the Fuel Injection Pump harness connector Measure the resistance between the following cavities in the Fuel Injection Pump connector fuel pump side Cavity 1 to cavities 4 5 6 7 8 9 and 10 Cavity 4 to cavities 5 6 7 8 9 and 10 Cavity 5 to cavities 6 7 8 and 9 Cavity 7 to cavities
44. C Compressor Clutch harness connector Using a 12 volt test light connected to 12 volts check the A C Compressor Clutch Ground circuit Is the test light on Yes Replace the A C Compressor Clutch in accordance with the Service nformation Perform ROAD TEST VERIFICATION VER 2 No Repair the A C Compressor Clutch Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 166 DRIVEABILITY DIESEL CHECKING THE A C SYSTEM Continued ACTION APPLICABILITY Turn the ignition on Connect one end of a jumper wire to ground and back probe the A C Pressure Signal circuit at the ECM harness connector With the DRB select Engine Bosch Controller then Inputs Outputs Read the A C H L Press Sw Does the DRB display A C H L Press Sw ON Yes gt GoTo 9 No Replace and program the ECM in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Disconnect the A C High Pressure Switch harness connector Turn the ignition on Connect one end of a jumper wire to ground and back probe the A C Pressure Signal circuit at the A C High Pressure Switch harness connector With the DRB select Engine Bosch Controller then Inputs Outputs Read the A C H L Press Sw Does the DRB display A C H L Press Sw ON Yes gt GoTo 10 No Repair the A C Pressure Signal circuit for an open between the ECM and theA C High Pressure Switch Perform ROAD TEST VERIFICATION VER 2 Turn the
45. Cavity 5 to cavities 6 7 8 and 9 Cavity 7 to cavities 6 8 9 and 10 Cavity 8 to cavities 6 and 10 NOTE The resistance should be above 100 ohms for all measurements 15 the resistance above 100 ohms for each of the measurements Yes gt Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 101 DRIVEABILITY
46. Control Resume Accel Switch harness connector Did the volt change to above 4 7 volts Yes Replace the Speed Control Resume Accel Switch Perform SPEED CONTROL VERIFICATION VER 4 gt GoTo 4 220 SPEED CONTROL P1597 SPEED CONTROL SWITCH ALWAYS LOW DIESEL Continued ACTION APPLICABILITY Turn the ignition off Disconnect the Speed Control On Off Switch harness connector Disconnect the Speed Control Resume Accel Switch harness connector Disconnect the PCM harness connector Measure the resistance between the Speed Control Switch circuit and the Sensor ground circuit the PCM harness connector Is the resistance below 5 0 ohms Yes Repair the Speed Control Switch Signal circuit shorted to Sensor ground circuit Perform SPEED CONTROL VERIFICATION 4 No gt GoTo 5 Turn the ignition off Disconnect the Speed Control On Off Switch harness connector Disconnect the Speed Control Resume Accel Switch harness connector Disconnect the PCM harness connector Measure the resistance of the Speed Control Switch circuit in PCM harness connector to ground 15 the resistance below 5 0 ohms Yes Repair the Speed Control Switch Signal circuit shorted to ground Perform SPEED CONTROL VERIFICATION 4 No gt GoTo 6 Repair Replace the Powertrain Control Module in accordance with the Service Information Perform SPEED CONTROL VERIFICATION VER 4 WARNING KEEP CLEAR OF THE
47. DIESEL Symptom P1220 FUEL QUANTITY ACTUATOR NEG GOV DEVIATION WARM When Monitored and Set Condition P1220 FUEL QUANTITY ACTUATOR NEG GOV DEVIATION WARM When Monitored With the engine running Set Condition TheECM has attempted to compensate for a rich condition and the engine coolant temperature is above 60 C 140 F POSSIBLE CAUSES INTERMITTENT CONDITION FUEL INJ ECTION PUMP SHORTED INTERNALLY FUEL QUANTITY ACTUATOR CONTROL CIRCUIT SHORTED TO GROUND INTERNAL FUEL INJ ECTION PUMP TEST ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Start the engine and vary the engine speed from idle to 3500 RPM several times With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 5 Turn the ignition off Disconnect the Fuel Injection Pump harness connector Measure the resistance between ground and Fuel Injection Pump connector fuel pump side cavity 8 Is the resistance above 100 kohms Yes gt GoTo 3 No Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Fuel Injection Pump harness connector Measure the resistance between ground and the Fuel Quantity Actuator Control circuit in ECM harness connector C2 cavities 59 66 and 80 Is the resistance above 100 kohms Yes gt GoTo 4 No Re
48. DRIVER CIRCUIT INTERMITTENT CONDITION GENERATOR BELT CONDITION OR TENSION HIGH RESISTANCE IN THE FUSED B CIRCUIT TO THE PCM GENERATOR FIELD DRIVER CIRCUIT SHORTED TO VOLTAGE GENERATOR FUSED B CIRCUIT HIGH RESISTANCE ASD RELAY OUTPUT CIRCUIT OPEN GENERATOR GROUND CIRCUIT HIGH RESISTANCE GENERATOR FIELD DRIVER CIRCUIT OPEN POWERTRAIN CONTROL MODULE ACTION APPLICABILITY NOTE Inspect the vehicle for aftermarket accessories that may exceed the All Generator capacity NOTE The battery must be fully charged before continuing Inspect the generator belt condition and tension Is the generator belt in good condition and tensioned properly Yes gt GoTo 2 as necessary Perform CHARGING VERIFICATION VER 3 21 CHARGING P1682 CHARGING SYSTEM VOLTAGE TOO LOW DIESEL Continued ACTION APPLICABILITY Turn the ignition on With the DRB actuate the Generator Field Measure the voltage between ground and the Generator Field Driver circuit by back probing the Generator Field harness connector with a voltmeter NOTE The voltage should cycle from Battery voltage to below 2 0 volts every 1 4 seconds While monitoring the voltmeter wiggle the generator field harness and connectors between the generator PCM and the ASD Diesel Power Relay in the PDC Was there any interruption of the normal voltage cycling Yes Repair the harness as necessary where the wiggling caused the interruption Perform CHARGI
49. FUEL QUANTITY ACTUATOR POS GOV DEVIATION COLD FUEL QUANTITY ACTUATOR POS GOV DEVIATION WARM FUEL TEMPERATURE SENSOR SRC HIGH EXCEEDED FUEL TEMPERATURE SENSOR SRC LOW EXCEEDED GLOW DISPLAY OPEN CIRCUIT GLOW DISPLAY SHORT CIRCUIT GLOW RELAY CONTROLLER OPEN CIRCUIT GLOW RELAY CONTROLLER SHORT CIRCUIT INDUCTIVE AUX SPEED SENSOR DYN PLAUSIBILITY INDUCTIVE AUX SPEED SENSOR OVER SPEED RECOGNITION INDUCTIVE AUX SPEED SENSOR PLAUSIBILITY INDUCTIVE AUX SPEED SENSOR STATIC PLAUSIBILITY MICROCONTROLLER GATE ARRAY MONITORING MICROCONTROLLER GATE ARRAY WATCHDOG MICROCONTROLLER PREPARE FUEL QUANTITY STOP MICROCONTROLLER RECOVERY WAS OCCURRED MICROCONTROLLER REDUNDANT OVERRUN MONITORING NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED REDUNDANT EMER STOP PLAUSIBILITY IN AFTER RUN REDUNDANT EMER STOP POWERSTAGE DEFECTIVE REGULATOR LOWER REGULATOR LIMIT REGULATOR UPPER REGULATOR LIMIT SOLENOID VALVE CONTROLLER OPEN CIRCUIT SOLENOID VALVE CONTROLLER SHORT CIRCUIT GENERAL INFORMATION TEMPERATURE OF ENGINE COOLANT SRC HIGH EXCEEDED TEMPERATURE OF ENGINE COOLANT SRC LOW EXCEEDED TERMINAL 15 PLAUSIBILITY AFTER START UP TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION TIMING GOVERNING POSITIVE GOVERNOR DEVIATION TURBOCHARGER BOOST SENSOR PLAUSIBILITY TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED TURBOCHARGER BOOST SENSOR SIGNAL LOW EXCEEDED TURBOCHARGER BOOST SENSOR SUPPLY HIGH EXCEEDED TURBOCHARGER BOOST S
50. IAT Sensor harness connector and the sensor The repair is complete Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 55 DRIVEABILITY DIESEL Symptom P0235 TURBOCHARGER BOOST SENSOR SIGNAL LOW EX CEEDED When Monitored and Set Condition P0235 TURBOCHARGER BOOST SENSOR SIGNAL LOW EXCEEDED When Monitored With the ignition on Set Condition The turbocharger boost pressure sensor signal voltage stays below 0 15 volt for at least 2 seconds POSSIBLE CAUSES INTERMITTENT CONDITION 5 VOLT SUPPLY CIRCUIT OPEN
51. IMMOBILIZER SIGNAL CIRCUIT SHORTED TO VOLTAGE IMMOBILIZER SIGNAL CIRCUIT SHORTED TO GROUND ENGINE CONTROL MODULE IMMOBILIZER SIGNAL CIRCUIT OPEN ENGINE CONTROL MODULE INTERNAL SHORT POWERTRAIN CONTROL MODULE INTERNAL SHORT APPLICABILITY Turn the ignition on All With the check for Sentry Key Immobilizer Module communication and DTCs Are SKIS problems or DTCs present Yes Refer tosymptom list for problems related to SKIM Communica tion and DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 GoTo 2 151 DRIVEABILITY DIESEL P1685 VEHICLE THEFT ALARM IMMOBILIZER SIG LOST Continued ACTION APPLICABILITY With the DRB select ENGINE then BOSCH 3 1L VM DIESEL CONTROLLER from All the menu Display the Vehicle dentification Number VIN Compare the programmed VIN to the vehicle VIN Does the programmed VIN match the vehicle VIN Yes gt GoTo 3 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 With the DRB select ENGINE then J TEC CONTROLLER from the menu Display the Vehicle Identification Number VIN Compare the programmed VIN to the vehicle VIN Does the programmed VIN match the vehicle VIN Yes gt GoTo 4 No Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the igniti
52. IN THE BOOST PRESSURE SENSOR SIGNAL CIRCUIT HIGH RESISTANCE IN THE BOOST PRESSURE SENSOR GROUND CIRCUIT HIGH RESISTANCE IN THE 5 VOLT SUPPLY CIRCUIT TURBOCHARGER BOOST PRESSURE INTAKE AIR TEMPERATURE SENSOR ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Turn the ignition off wait 30 seconds then start and idle the engine for at least 30 seconds NOTE Engine idle speed must be below 870 RPM With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 6 Turn the ignition off Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Boost Pressure Sensor Signal circuit Is the resistance below 5 0 ohms Yes gt GoTo 3 No Repair the Boost Pressure Sensor Signal circuit for high resis tance Perform ROAD TEST VERIFICATION VER 2 51 DRIVEABILITY DIESEL P0235 TURBOCHARGER BOOST SENSOR PLAUSIBILITY Continued ACTION APPLICABILITY Turn the ignition off Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Sensor Ground circuit 15 the resistance below 5 0 ohms Yes gt GoTo 4 No Repair the Boost Pressure Sensor Ground circuit for high resis tance Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Turbocharger B
53. Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 112 DRIVEABILITY DIESEL Symptom P1230 TIMING GOVERNING POSITIVE GOVERNOR DEVIATION I When Monitored and Set Condition 1230 GOVERNING POSITIVE GOVERNOR DEVIATION When Monitored With the engine speed between 1000 and 4800 RPM Set Condition The ECM detects 3 degrees of excess timing advance for at least 10 seconds POSSIBLE CAUSES ENGINE CONTROL MODULE REPLACE THE FUEL INJ ECTION PUMP INTERMITTENT CONDITION FUEL SYSTEM RESTRICTIONS FUE
54. Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 147 DIESEL Symptom P1660 REDUNDANT EMERG STOP POWERSTAGE DEFECTIVE E When Monitored and Set Condition P1660 REDUNDANT EMERG STOP POWERSTAGE DEFECTIVE When Monitored With the ignition on Set Condition The ECM detects an open short to ground on the fuel shutdown solenoid control circuit POSSIBLE CAUSES INTERMITTENT CONDITION FUEL SHUTDOWN SOLENOID CONTROL CIRCUIT OPEN FUEL SHUTDOWN SOLENOID CONTROL CIRCUIT SHORTED TO GROUND
55. Plug connector Does the test light cycle on and off for each Glow Plug connector during actuator test Yes gt GoTo 2 gt GoTo 3 Refer to the Service Information and perform the Glow Plug Test all the Glow Plugs operating properly Yes Test Complete No Replace the Glow Plug s as necessary in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Remove the Glow Plug Relay from the PDC All Turn the ignition on Usinga 12 volt test light connected to ground check the used B circuit in the Glow Plug Relay connector in the PDC Is the test light on Yes gt GoTo 4 No Repair the Fused B circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect all the Glow Plug connectors Remove the Glow Plug Relay from the PDC Connect a jumper wire across the Glow Plug Relay connector cavities 30 and 87 Using a 12 volt test light connected to ground check each Glow Plug Relay Output circuit at each Glow Plug connector 15 the test light on at each of the Glow Plug connectors Yes Replace the Glow Plug Relay Perform ROAD TEST VERIFICATION VER 2 No Repair the Glow Plug Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 191 DRIVEABILITY DIESEL Symptom CHECKING THE LOW COOLANT LAMP OPERATION POSSIBLE CAUSES CHECK THE LOW COOLANT SWITCH POWERTRAIN CONTROL MODULE CONTROL OPEN POWERTRAIN C
56. RELAY RADIATOR FAN RELAY CONTROL CIRCUIT SHORTED TO GROUND RADIATOR FAN RELAY CONTROL CIRCUIT OPEN ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB actuate the Radiator Fan Relay Does the Radiator Fan cycle on and off Yes gt GoTo 2 No gt GoTo 3 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored Set Conditions If possible try to duplicatethe conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 154 DIESEL P1690 FAN CONTROL OPEN CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off Remove the Radiator Fan Relay from the PDC Turn the ignition on Using a 12 volt test l
57. Reassemble and reconnect components as necessary 2 If the PCM has been replaced perform step 3 Otherwise continue with step 4 3 If the vehicle is equipped with a factory theft alarm start the engine at least 20 times order to be able to activate the alarm system when desired 4 With the DRB erase all diagnostic trouble codes DTCs 5 Road test the vehicle at a speed above 58 km h 35 MPH 6 Turn the speed control ON OFF switch on 7 Depress and release the SET switch If the speed control does not engage the repair is not complete continue with step 15 8 Quickly depress and release the RESUME ACCEL switch If the vehicle speed does not increase by 3 km h 2 MPH the repair is not complete continue with step 15 9 Using caution depress and release the brake pedal If the speed control does not disengage the repair is not complete continue with step 15 10 With the vehicle speed at least 56 km h 35 MPH depress the RESUME ACCEL switch If the speed control does not resume at the previously set speed the repair is not complete continue with step 15 11 Hold down the COAST switch If the vehicle does not decelerate the repair is not complete continue with step 15 12 Whilestill holding down the COAST switch ensure the vehicle speed is at least 56 km h 35 MPH and release the COAST switch If the vehicle does not adjust and set a new vehicle speed the repair is not complete continue with step 15 13 With
58. SECRET KEY transfers tothe PCM Set Condition When the 5 does not receive an expected BUS message trans mission acknowledgement from the PCM after 3 transmit attempts POSSIBLE CAUSES INTERMITTENT WIRING HARNESS PROBLEM WIRING HARNESS INSPECTION SKIM PCM APPLICABILITY NOTE Ensure the PCM has proper power and ground connections before All continuing With the III read and record the SKIM then erase the SKIM Turn the ignition off Wait 2 minutes Turn the ignition on With the DRB III read the SKIM DTC s Does the DRB III display the DTC that was previously erased Yes gt GoTo 2 gt GoTo 4 236 VEHICLE THEFT SECURITY PCM STATUS FAILURE Continued ACTION APPLICABILITY Turn the ignition off All NOTE Visually inspect the related wiring harness and CCD PCI Bus whichever applicable circuits Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any Technical Service Bulletins TSB that may apply Were any problems found Yes Repair as necessary Perform SKIS VERIFICATION GoTo 3 NOTE Before proceeding it will be necessary to obtain the SKIM PIN number Turn the ignition on With the DRB III display and erase all PCM and SKIM Perform 5 ignition key cycles leaving the ignit
59. SENSOR NO 2 DIESEL PCM BLACK ENGINE SPEED SENSOR DIESEL R FUEL HEATER DIESEL 4 2 FUEL INJECTION PUMP DIESEL BLACK ENGINE COOLANT TEMPERATURE SENSOR NO 2 DIESEL PCM BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K222 18TN RD PCM ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 2 K167 18BR YL SENSOR GROUND ENGINE SPEED SENSOR DIESEL BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K3 20LG BK ENGINE SPEED SENSOR GROUND 2 3 K24 20GY BK ENGINE SPEED SENSOR SIGNAL FUEL HEATER DIESEL 2 WAY CAV CIRCUIT FUNCTION 1 A93 14RD BK FUEL HEATER RELAY OUTPUT 2 71 16BK GROUND FUEL INJECTION PUMP DIESEL BLACK 10 WAY CAV CIRCUIT FUNCTION 1 K134 20LB BK CONTROL SLEEVE POSITION SENSOR SIGNAL 2 57 20LG OR CONTROL SLEEVE POSITION SENSOR MIDDLE TAP SIGNAL 3 K135 20WT BK CONTROL SLEEVE POSITION SENSOR MEASURE COIL 4 K4 20BK LB SENSOR GROUND 5 K126 18LG FUEL TIMING SOLENOID CONTROL 6 K153 180R FUEL SHUT DOWN SOLENOID CONTROL 7 K156 20GY FUEL TEMPERATURE SENSOR SIGNAL 8 K140 16TN WT FUEL QUANTITY ACTUATOR CONTROL 9 A142 16DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT 10 F142 16DG OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 258 CONNECTOR PINOUTS FUEL LEVEL SENSOR DIESEL BLACK 6 W
60. SENSOR PLAUSIBILITY When Monitored With the engine running Set Condition The ECM has determined that the needle movement sensor input is incorrect P1725 INDUCTIVE AUX SPEED SENSOR STATIC PLAUSIBILITY When Monitored With the engine running Set Condition TheECM has determined that the inductive auxiliary speed sensor values are incorrect POSSIBLE CAUSES INTERMITTENT CONDITION CHECK THE NEEDLE MOVEMENT SENSOR CONNECTOR TERMINALS MIS ROUTED WIRING HARNESS NEEDLE MOVEMENT SENSOR SIGNAL CIRCUIT OPEN NEEDLE MOVEMENT SENSOR GROUND CIRCUIT OPEN ENGINE CONTROL MODULE 162 DIESEL P1725 INDUCTIVE AUX SPEED SENSOR DYN PLAUSIBILITY Continued POSSIBLE CAUSES NEEDLE MOVEMENT SENSOR SIGNAL CIRCUIT SHORTED TO GROUND NEEDLE MOVEMENT SENSOR ACTION APPLICABILITY Turn the ignition on With the DRB erase ECM DTCs Start the engine and vary the engine speed from idle to 3500 RPM several times With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 GoTo 8 Turn the ignition off Disconnect the Needle Movement Sensor harness connector Check the Needle Movement Sensor connector terminals in the harness side connector and the sensor side connector 15 there any damage or corrosion to any of the terminals in either connector Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 3 Turn the ignition off Disconnect the ECM harness connect
61. SIGNAL CIRCUIT SHORTED TO VOLTAGE PCM PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE PCM OIL PRESSURE SENSOR SIGNAL OPEN SENSOR GROUND CIRCUIT OPEN INTERMITTENT CONDITION APPLICABILITY Turn the ignition on All With the DRB III erase PCM DTCs Cycle the ignition key on and off several times leaving the key on for at least 10 seconds at a time With the III read PCM DTCs Did this DTC reset Yes gt GoTo 2 gt GoTo 6 Turn the ignition off Disconnect the Oil Pressure Sensor harness connector Turn the ignition on Measure the voltage of the Oil Pressure Sensor Signal circuit Select the appropriate voltage reading Voltage is above 5 5 volts GoTo 3 Voltage is between 4 7 and 5 4 volts GoTo 4 Voltage is below 4 7 volts GoTo 5 81 DRIVEABILITY DIESEL P0523 OIL PRESSURE VOLTAGE TOO HIGH Continued APPLICABILITY Turn the ignition off All Disconnect the Oil Pressure Sensor harness connector Disconnect the PCM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage of the Oil Pressure Sensor Signal circuit 15 the voltage below 1 0 volt Yes gt Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair
62. SWITCH OUTPUT START 012 013 271 20 GROUND 013 71 20BK YL GROUND 014 740 16BR ENGINE STARTER MOTOR RELAY OUTPUT FUEL HEATER RELAY DIESEL CAV CIRCUIT FUNCTION D2 A61 14LG RD FUSED B D4 F12 18DB WT FUSED IGNITION SWITCH OUTPUT RUN START 05 06 21 20 GROUND D8 A93 14RD BK FUEL HEATER RELAY OUTPUT RADIATOR FAN RELAY CAV CIRCUIT FUNCTION C10 F141 12LG RD FUSED B C11 A142 18DG AUTOMATIC SHUT DOWN RELAY OUTPUT C11 A142 18DG AUTOMATIC SHUT DOWN RELAY OUTPUT C12 C13 C27 18DB PK RHD RADIATOR FAN RELAY CONTROL C13 C27 20DB PK LHD RADIATOR FAN RELAY CONTROL C14 C25 12LB RADIATOR FAN RELAY OUTPUT 010 F141 12LG RD FUSED B 011 F20 18WT FUSED IGNITION SWITCH OUTPUT RUN START 011 F20 18WT FUSED IGNITION SWITCH OUTPUT RUN START 012 013 C27 18DB PK RADIATOR FAN RELAY CONTROL 014 C25 12LB RADIATOR FAN RELAY OUTPUT 263 R 4 2 CONNECTOR PINOUTS 22 32 12 21 1 00000000000 11 0 1 2 POWERTRAIN CONTROL MODULE C1 DIESEL R 4 2 POWERTRAIN CONTROL MODULE 1 DIESEL 32 WAY CAV CIRCUIT FUNCTION 1 2 A142 16DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT 3 4 K167 18BR YL SENSOR GROUND 5 6 7 8 K15
63. Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 GoTo 21 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage of the 5 volt Supply circuit in the ECM harness connector 15 the voltage above 1 0 volt Yes Repair the 5 volt Supply circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 gt GoTo 24 Turn the ignition off All Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the APP Sensor Signal circuit 15 the resistance below 5 0 ohms Yes gt GoTo 22 No Repair the APP Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 121 DRIVEABILITY DIESEL P1515 ACCEL PEDAL SENSOR PLAUSIBILITY Continued APPLICABILITY Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between the 5 volt Supply circuit and the Sensor Ground circuits at cavities 4
64. TO GROUND AMB BATT TEMP SENSOR SIGNAL AND SENSOR GROUND CIRCUITS SHORTED TOGETHER POWERTRAIN CONTROL MODULE SHORT TO GROUND INTERNALLY ACTION APPLICABILITY Turn the ignition on All With the DRB read the voltage of the Ambient Battery Temperature Sensor Is the voltage below 0 4 volt Yes gt GoTo 2 gt GoTo 6 Turn the ignition off Disconnect the Ambient Battery Temperature Sensor harness connector Turn the ignition on With the DRB read the voltage of the Ambient Battery Temperature Sensor Is the voltage above 4 0 volts Yes Replace the Ambient Battery Temperature Sensor Perform CHARGING VERIFICATION VER 3 No gt GoTo 3 Turn the ignition off Disconnect the Ambient Battery Temperature Sensor harness connector Disconnect the PCM harness connectors Measure the resistance between ground and the Amb Batt Temp Sensor Signal circuit 15 the resistance above 100 kohms Yes gt GoTo 4 No Repair the Ambient Battery Temperature Sensor Signal circuit for a short to ground Perform CHARGING VERIFICATION VER 3 CHARGING P1493 AMBIENT BATT TEMP SEN VOLTS TOO LOW DIESEL Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Ambient Battery Temperature Sensor harness connector Disconnect the PCM harness connectors Measure the resistance between theAmb Batt Temp Sensor Signal circuit and Sensor Ground circuit 15 the resistance above 100 kohms Yes gt GoTo
65. Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage of the APP Sensor Signal circuit Is the voltage above 1 0 volt Yes Repair the APP Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 19 120 DRIVEABILITY DIESEL P1515 ACCEL PEDAL SENSOR PLAUSIBILITY Continued APPLICABILITY Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between the APP Sensor Signal circuit and the Sensor Ground circuits at cavity 4 and 8 of the APP Sensor harness connector 15 the resistance below 10 kohms for any of the measurements Yes Repair the APP Sensor Signal and Sensor Ground circuits for a short together Perform ROAD TEST VERIFICATION VER 2 GoTo 20 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the APP Sensor Signal circuit Is the resistance below 10 kohms Yes gt Repair the APP Sensor
66. When Monitored With the ignition on Set Condition ThePCM receives a vehicle speed signal for an extended duration without a change in fuel level signal voltage POSSIBLE CAUSES CHECK FOR OTHER DTCS FUEL TANK OBSTRUCTING THE FUEL LEVEL SENSOR POWERTRAIN CONTROL MODULE FUEL LEVEL SENSOR ACTION APPLICABILITY Turn the ignition on All With the DRB check for additional PCM DTCs Are other Fuel Level Sensor DTCs present Yes Refer to the Symptom List for diagnosis of other Fuel Level Sensor related DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 gt GoTo 2 Turn the ignition off Disconnect the Fuel Level Sensor harness connector Turn the ignition on With the DRB read and record the Fuel Level Sensor voltage NOTE The DRB should read 10 0 volts with the Fuel Level Sensor harness connector disconnected Connect a 12 volt test light between Fuel Level Sensor harness connector cavities 3 and 4 With the DRB read the Fuel Level Sensor voltage Did the voltage change to less than 10 0 volts Yes gt GoTo 3 Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 67 DRIVEABILITY DIESEL 0460 LEVEL UNIT NO CHANGE OVER MILES Continued ACTION APPLICABILITY Turn the ignition off All Remove the Fuel Level Sensor from the Fuel Tank in accordance with the Service Information Inspect
67. Yes gt GoTo 3 gt GoTo 4 53 DRIVEABILITY DIESEL P0235 TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage between ground and the 5 volt Supply circuit 15 the voltage above 1 0 volt Yes Repair the 5 volt Supply circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Turn the ignition on Measure the voltage between ground and the Boost Pressure Sensor Signal circuit 15 the voltage above 1 0 volt Yes gt GoTo 5 No gt GoTo 6 Turn the ignition off Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage between ground and the Boost Pressure Sensor Signal circ
68. and 8 of the APP Sensor harness connector 15 the resistance above 100 kohms for both of the measurements Yes gt GoTo 25 No Repair 5 volt Supply circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the 5 volt Supply circuit Is the resistance below 10 kohms Yes Repair the 5 volt Supply circuit for short to ground Perform ROAD TEST VERIFICATION VER 2 No GoTo 26 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the 5 volt Supply circuit 15 the resistance below 5 0 ohms Yes gt GoTo 27 No Repair the 5 volt Supply circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 122 DRIVEABILITY DIESEL Symptom P1520 VEHICLE SPEED GOV ANALOG CTRL CONTROL CON TACT ALONE POSSIBLE CAUSES PERFORM SYMPTOM CHECKING THE SPEED CONTROL OPERATION INTERMITTENT CONDITION ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Turn the ignition off wait 10 seconds then turn the ig
69. below 0 2 volt 4 or above 4 5 volts 90 and the idle switch is not in the correct state NOTE The idle switch is designed to transition when the accel position is approximately 16 1 00 volt This code sets the ECM to Limp in Mode which includes a fixed engine speed of 1100 RPM P1515 ACCEL PEDAL SENSOR PWG PLAUS WITH POTENTIOMETER When Monitored With the ignition on Set Condition The accelerator pedal position sensor signal is below 0 20 volts the idle switch transitions at too high a percentage intermittently or the idle switch is not in the correct state intermittently NOTE Theidle switch is designed to transition when the accel position is approximately 16 1 00 volt This code sets the ECM to Limp in Mode which includes a fixed engine speed of 1100 RPM P1515 ACCEL PEDAL SENSOR SIGNAL HIGH EXCEEDED When Monitored With the ignition on Set Condition The accelerator pedal position sensor signal voltage is above 4 5 volts NOTE This code sets the ECM to Limp in Mode which includes a fixed engine speed of 1100 RPM P1515 ACCEL PEDAL SENSOR SUPPLY HIGH EXCEEDED When Monitored With the ignition on Set Condition The ECM detects voltage on the accelerator pedal position sensor 5 volt supply circuit above 5 2 volts P1515 ACCEL PEDAL SENSOR SUPPLY LOW EXCEEDED When Monitored With the ignition on Set Condition The ECM detects voltage the accelerator pedal position sensor 5 volt supply circuit below 4 75 volts
70. conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 156 DIESEL P1690 FAN CONTROL SHORT CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Install a substitute relay in place of the Radiator Fan Relay Turn the ignition on With the DRB actuate the Radiator Fan Relay Does the Radiator Fan cycle on and off Yes Replace the Radiator Fan Relay Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 4 Turn the ignition off Remove the Radiator Fan Relay from the PDC Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage of the Radiator Fan Relay Control circuit 15 the voltage below 1 0 volt Yes gt GoTo 5 No Repair the Radiator Fan Relay Control circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 157 DRIVEABILITY DIESEL Symptom P1703 BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT When Monitored and Set Condition P1703 BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT When Monitored With the ignition on Set Condition The ECM detects the brake switch
71. cycle on and off Yes gt Thetest is complete Perform ROAD TEST VERIFICATION VER 2 Radiator Fan inoperative GoTo 3 Radiator Fan always on GoTo 8 Turn the ignition off Remove the Radiator Fan Relay from the PDC Using a 12 volt test light connected to ground check the Fused B circuit Did the test light illuminate brightly Yes gt GoTo 4 No Repair the Fused circuit for an open Perform ROAD TEST VERIFICATION VER 2 177 DIESEL THE ELECTRIC RADIATOR OPERATION Continued ACTION APPLICABILITY Turn the ignition off Install a substitute relay in place of the Radiator Fan Relay Turn the ignition on With the DRB actuate the Radiator Fan Relay Does the Radiator Fan cycle on and off Yes Replace the Radiator Fan Relay Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 5 Turn the ignition off Remove the Radiator Fan Relay from the PDC Disconnect the Radiator Fan harness connector Connect a fused jumper wire between the Fused B circuit cavity and the Radiator Fan Relay Output circuit cavity in the Radiator Fan Relay connector Using a 12 volt test light connected to ground check the Radiator Fan Relay Output circuit in the Radiator Fan harness connector Did the test light illuminate brightly Yes gt GoTo 6 Repair the Radiator Fan Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 If
72. found Yes Repair wiring harness connectors as necessary Perform SKIS VERIFICATION No Test Complete 242 VERIFICATION TESTS Verification Tests CHARGING VERIFICATION VER 3 1 Inspect the vehicle to ensure that all engine components are properly installed and connected Reassemble and reconnect components as necessary 2 If the PCM has been replaced perform step 3 Otherwise continue with step 4 3 If the vehicle is equipped with a factory theft alarm start the engine at least 20 times order to be able to activate the alarm system when desired 4 With the DRB erase all diagnostic trouble codes DTCs 5 Start the engine 6 Raise the engine speed to 2000 RPM for at least 30 seconds 7 Allow the engine to idle 8 Turn the ignition off for 20 seconds 9 Turn the ignition on 10 With the DRB read ECM and PCM DTCs 11 If this DTC has reset or another DTC has set look for any Technical Service Bulletins TSBs that may relate to this condition Return to the Symptom List if necessary 12 If the charging system is functioning correctly and there no DTCs the repair is now complete Are any DTCs or symptoms remaining Yes Repair is not complete refer to appropriate symptom No Repair is complete NO START VERIFICATION VER 1 1 NOTE IMPORTANT If the Engine Control Module Sentry Key Immobilizer Module or Powertrain Control Module have been replaced ensure the prog
73. ground and the Fuel Temperature Sensor Signal circuit 15 the resistance above 100 kohms Yes gt GoTo 4 No Repair the Fuel Temperature Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Fuel Injection Pump harness connector Measure the resistance between the Fuel Temperature Sensor Signal circuit and Sensor Ground circuit 15 the resistance above 100 kohms Yes gt GoTo 5 Repair the Fuel Temperature Sensor Signal and Ground circuits for a short together Perform ROAD TEST VERIFICATION VER 2 Disconnect the Fuel Injection Pump harness connector Measure the resistance between the following cavities in the Fuel Injection Pump connector fuel pump side Cavity 1 to cavities 4 5 6 7 8 9 and 10 Cavity 4 to cavities 5 6 7 8 9 and 10 Cavity 5 to cavities 6 7 8 and 9 Cavity 7 to cavities 6 8 9 and 10 Cavity 8 to cavities 6 and 10 NOTE The resistance should be above 100 ohms for all measurements 15 the resistance above 100 ohms for each of the measurements Yes gt Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 49 DRIVEABILITY DIESEL P0180 F VEL TEMPERATURE SE
74. harness connector Measure the resistance between ground and the Brake Lamp Switch harness connector cavity 2 Is the resistance below 5 0 ohms Yes Replace and program the ECM in accordance with the Service Information Perform SPEED CONTROL VERIFICATION VER 4 No the Ground circuit for an open Perform SPEED CONTROL VERIFICATION VER 4 225 SPEED CONTROL CHECKING THE SPEED CONTROL OPERATION Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Brake Lamp Switch harness connector Disconnect the ECM harness connectors Measure the resistance of the Secondary Brake Switch Signal between the Brake Lamp Switch and the PCM 15 the resistance below 10 0 ohms Yes gt GoTo 18 No Repair the Secondary Brake Switch Signal circuit for an open Perform SPEED CONTROL VERIFICATION 4 Turn the ignition off Disconnect the Brake Lamp Switch harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the Secondary Brake Switch Signal circuit 15 the resistance below 100 0 ohms Yes Repair the Secondary Brake Switch Signal circuit for a short to ground Perform SPEED CONTROL VERIFICATION 4 No Replace and program the ECM in accordance with the Service Information Perform SPEED CONTROL VERIFICATION VER 4 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Brake Lamp Switch ha
75. identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform CHARGING VERIFICATION VER 3 No Test Complete Turn the ignition off Disconnect PCM harness connector C2 Disconnect the Generator Field harness connector Measure the resistance between ground and the Generator Field Driver circuit 15 the resistance above 100 kohms Yes gt GoTo 5 No Repair the Generator Field Driver circuit for a short to ground Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the Generator Field harness connector Measure the resistance between ground and the Generator Field Driver terminal on the back of the Generator 15 the resistance above 100 kohms Yes gt GoTo 6 No Repair or replace the Generator as necessary Perform CHARGING VERIFIC
76. ignition off All Disconnect the A C High Pressure Switch harness connector Measure the resistance of the A C High Pressure Switch 15 the Resistance below 10 0 ohms Yes gt GoTo 11 No Replace the A C High Pressure Switch Perform ROAD TEST VERIFICATION VER 2 Disconnect the A C Low Pressure Switch harness connector Turn the ignition on Connect end of a jumper wire to ground and the other end to the A C Pressure Sense circuit at the A C Low Pressure Switch harness connector With the DRB select Engine Bosch Controller then Inputs Outputs Read the A C H L Press Sw Does the DRB display A C H L Press Sw ON Yes gt GoTo 12 No Repair the A C Pressure Sense circuit for an open between the A C High Pressure Switch and the A C Low Pressure Switch Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the A C Low Pressure Switch harness connector Measure the resistance of the A C Low Pressure Switch 15 the Resistance below 10 0 ohms Yes Repair the ground circuit at the A C Low Pressure Switch for an open Perform ROAD TEST VERIFICATION VER 2 No Replace the A C Low Pressure Switch Perform ROAD TEST VERIFICATION VER 2 167 DRIVEABILITY DIESEL CHECKING THE A C SYSTEM Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the PCM harness connectors Turn the ignition on With the DRB select Engine Bosch Controller then Inputs Outputs
77. measured below 100 kohms for a short together Perform ROAD TEST VERIFICATION VER 2 Measure the resistance of the Vehicle Speed Sensor Ground circuit 15 the resistance below 5 0 ohms for each measurement Yes gt GoTo 11 No Repair the circuit that measured above 5 0 ohms for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Yes Replace the Vehicle Speed Sensor Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Vehicle Speed Sensor harness connector Disconnect the PCM C2 harness connector Check connectors Clean repair as necessary Measure the resistance of the 5 volt Supply circuit between the Vehicle Speed Sensor harness connector and the PCM C2 harness connector 15 the resistance below 5 0 ohms Yes gt Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Repair the 5 volt Supply circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the PCM harness connectors Disconnect the Vehicle Speed Sensor harness connector Measure the resistance of the Vehicle Speed Sensor Signal circuit 201 DRIVEABILITY DIESEL Symptom CHECKING THE TACHOMETER OPERATION POSSIBLE CAUSES CHECK OPERATION OF OTHER GAUGES INSTRUMENT CLUSTER INOPERATIVE TACHOMETER ENGINE CONTROL MODULE INCORR
78. possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for chafed pierced pinched partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 103 DRIVEABILITY DIESEL Symptom List P1220 FUEL QUANTITY ACTUATOR POS GOV DEVIATION COLD P1220 F UEL QUANTITY ACTUATOR POS GOV DEVIATION WARM Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P1220 FUEL QUANTITY ACTU ATOR POS GOV DEVIATION COLD When Monitored and Set Condition P1220 FUEL QUANTITY ACTUATOR POS GOV DEVIATION COLD When Monitored With the engine running Set Condition has attempted to compensate for lean condition and the engine coolant temperature is below 60 C 140 F P1220 FUEL QUANTITY ACTUATOR POS GOV DEVIATION WARM When Monitored With the engine running Set Condition has attempted to compensate for a lean condition and the engine coolant temperature is above 60 C 140 F POSSIBLE CAUSES INTERMITTENT CONDITION CHECK THE FUEL INJ ECTION PUMP TIMING CHECK FORA FUEL RESTRICTION REPLACE THE FUEL INJ ECTIO
79. same tests The title for the tests will 1105 PRES SURE SENSOR SRC HIGH EXCEEDED POSSIBLE CAUSES ENGINE CONTROL MODULE INTERMITTENT CONDITION ACTION APPLICABILITY NOTE This DTC indicates an internal ECM problem All Turn the ignition on With the DRB erase ECM DTCs Perform several engine run cycles turning the ignition off for at least 20 seconds between each engine run cycle Monitor the DRB for ECM DTCs Did this DTC reset Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 2 89 DIESEL P1105 ATMOSPHERE PRESSURE SENSOR SRC HIGH EXCEEDED Continued APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visu
80. sense circuit and brake lamp switch output circuit inputs to the ECM do not agree NOTE An out of adjustment brake lamp switch may also cause a reduction in engine power POSSIBLE CAUSES INTERMITTENT CONDITION BRAKE LAMP SWITCH SECONDARY OPEN BRAKE LAMP SWITCH FUSED B CIRCUIT OPEN SECONDARY BRAKE SWITCH SIGNAL CIRCUIT SHORTED TO GROUND BRAKE LAMP SWITCH PRIMARY OPEN SECONDARY BRAKE SWITCH GROUND CIRCUIT OPEN SECONDARY BRAKE SWITCH SIGNAL CIRCUIT OPEN PRIMARY BRAKE SWITCH SIGNAL CIRCUIT SHORTED TO VOLTAGE PRIMARY BRAKE SWITCH SIGNAL CIRCUIT OPEN ENGINE CONTROL MODULE INTERNAL ENGINE CONTROL MODULE PRIMARY BRAKE SIGNAL ENGINE CONTROL MODULE SECONDARY BRAKE SIGNAL APPLICABILITY Turn the ignition on All 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 gt GoTo 2 No gt GoTo 11 Turn the ignition on While observing the SEC BRAKE SWITCH status on the DRB display press and release the brake pedal several times Does the DRB display SEC BRAKE SWITCH PRESSED and RELEASED for the appropriate pedal position Yes gt GoTo 3 gt GoTo 4 158 DRIVEABILITY DIESEL 1703 SIGNAL PLAUS WITH REDUNDANT CONTACT Continued ACTION APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions th
81. the correct change of state from Released to Pressed Yes gt GoTo 4 GoTo 14 With the DRB select Engine then Bosch Controller and monitor the Vehicle Speed Signal while test driving the vehicle Does the DRB display accurate vehicle speed Yes gt GoTo 5 No Refer to symptom list for problems related to Vehicle Speed Sensor Signal Perform SPEED CONTROL VERIFICATION VER 4 Drive the vehicle and generate a vehicle speed above 55 Km h 35 mph Attempt to set the speed control Did vehicle speed control maintain set vehicle speed Yes gt GoTo 6 No GoTo 12 Drive the vehicle and generate a vehicle speed above 55 Km h 35 mph Set the speed control and observe the Speed Control Lamp Does the Speed Control Lamp illuminate when speed control is on Yes Test Complete No GoTo 7 223 SPEED CONTROL CHECKING THE SPEED CONTROL OPERATION Continued APPLICABILITY Turn the ignition on With the DRB select Engine J TEC then Actuators With the DRB actuate the S C Lamp while observing the S C Lamp 15 the S C Lamp turning on and off during actuation Yes gt GoTo 8 No Refer tosymptom list for problems related to S C Lamp operation Perform SPEED CONTROL VERIFICATION 4 Turn the ignition off Disconnect the ECM harness connectors Disconnect the PCM harness connectors Measure the resistance of the S C Lamp Signal circuit 15 the resistance below 10 0 ohms
82. the speed control engaged depress the ON OFF switch If the speed control does not disengage the repair is not complete continue with step 15 14 If the vehicle did not successfully perform all of the previous steps check for Technical Service Bulletins TSBs that pertain to this speed control problem and then if necessary return to the Symptom List 15 If the vehicle successfully performed all of the previous steps the speed control system is now functioning as designed The repair is now complete Are any DTCs or symptoms remaining Yes Repair is not complete refer to appropriate symptom No Repair is complete 246 APPLICABILITY All 8 0 COMPONENT LOCATIONS 8 1 ENGINE CONTROL MODULE POWERTRAIN CONTROL MODULE AND SENTRY KEY COMPONENT LOCATIONS IMMOBILIZER MODULE Engine Control Module NN N AY ENGINE CONTROL MODULE N NG ECM HARNESS CONNECTOR C2 80b5cbb1 Sentry Key Immobilizer Module ANTENNA PART OF THE SKIM Powertrain Control Module 2 2 MODULE EN 2 2 2 EES Ys FN HARNESS L 5 4 2 HARNESS CONNECTOR SENTRY KEY IMMOBILIZER MODULE 247 SKIM 8057706a COMPONENT LOCATIONS
83. there are no possible causes remaining view repair Repair Replace the Radiator Fan Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove the Radiator Fan Relay from the PDC Disconnect the Radiator Fan harness connector Turn the ignition on Measure the voltage of the Radiator Fan Relay Output circuit Is the voltage above 0 5 volt Yes Repair the Radiator Fan Reay Output circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Replace the Radiator Fan Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the Radiator Fan harness connector Using 12 test light connected to 12 volts check the Radiator Fan Ground circuit Did the test light illuminate brightly Yes gt GoTo 7 No Repair the Radiator Fan Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 178 DRIVEABILITY DIESEL Symptom CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR CALIBRATION POSSIBLE CAUSES ECT SENSOR COLD ECT SENSOR HOT ACTION APPLICABILITY NOTE The thermostat must be operating correctly for this test to be valid All With the DRB read and note the engine coolant temperature Using a temperature probe measure the engine block temperature near the ECT Sensor Are readings within 7 C 13 F of each other Yes gt GoTo 2 Replace the Engine Coolant Temperature Sensor Perform ROAD TEST VERIFICATION VER 2
84. this DTC to reset Did this DTC reset Yes gt GoTo 6 No Replace the EGR Solenoid Perform ROAD TEST VERIFICATION VER 2 If there no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 64 DRIVEABILITY DIESEL Symptom P0400 EGR SHORT CIRCUIT When Monitored and Set Condition P0400 EGR SHORT CIRCUIT When Monitored With the ignition on Set Condition
85. wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 42 DRIVEABILITY DIESEL Symptom 0118 SENSOR VOLTAGE TOO HIGH When Monitored and Set Condition 0118 SENSOR VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition The voltage on the PCM engine coolant temperature sensor signal circuit is above 4 9 volts for more than 3 seconds POSSIBLE CAUSES INTERMITTENT CONDITION PCM ECT SENSOR GROUND CIRCUIT OPEN PCM ECT SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE PCM ECT SENSOR PCM ECT SENSOR SIGNAL CIRCUIT OPEN POWERTRAIN CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB monitor the PCM Engine Coolant Temperature ECT Sensor voltage Is the PCM ECT Sensor voltage above 4 98 volts Yes gt GoTo 2 gt GoTo 7 Turn the ignition off Disconnect the PCM ECT Sensor harness connector Turn the ignit
86. 0 F NOTE If the engine temperature is above 70 C 160 F allow the engine to cool down to 70 C 160 F Start the engine and allow engine to reach operating temperature of 90 C 195 F Does the Fuel Temperature increase smoothly to 40 60 C 100 140 F Yes Test Complete No Replacethe Fuel Injection Pump Assembly in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 188 DRIVEABILITY DIESEL Symptom CHECKING THE GLOW PLUG LAMP OPERATION POSSIBLE CAUSES ACTUATE THE GLOW PLUG LAMP WITH THE DRB MESSAGE CENTER LAMP NEVER ON MESSAGE CENTER LAMP ON CONTINUOUSLY ENGINE CONTROL MODULE FAILS TO ACTIVATE LAMP ENGINE CONTROL MODULE LAMP ON CONTINUOUSLY GLOW PLUG LAMP CONTROL CIRCUIT SHORTED TO GROUND GLOW PLUG LAMP CONTROL CIRCUIT SHORTED TO VOLTAGE GLOW PLUG LAMP CONTROL CIRCUIT OPEN MESSAGE CENTER IGNITION FEED OPEN GLOW PLUG LAMP BULB APPLICABILITY Turn the ignition on and observe the Glow Plug Lamp Did the Glow Plug Lamp illuminate and stay on longer than 20 seconds Yes gt GoTo 2 No gt GoTo 4 Turn the ignition off Disconnect the ECM harness connectors Turn the ignition on 15 the Glow Plug Lamp Yes gt GoTo 3 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 15 the resistance above 100 kohms Yes gt Replace the Message Center
87. 00rpm 48 kPa 7 PSI 2500rpm 69 kPa 10 1 3000 90 kPa 13 PSI 3500rpm NOTE SECOND GEAR The following numbers are a comparison of Boost Pressure and Engine Speed PSI RPM for the Second Gear test 28 kPa 4 PSI 1500rpm 28 kPa 4 PSI 2000rpm 48 kPa 7 5 2500 76 kPa 11 5 3000 97 kPa 14 PSI 3500rpm Test drive the vehicle in First gear Increase engine RPM in 500 RPM increments slowly until engine speed is 3500 RPM NotetheAir Pressure Gauge reading at each 500 RPM increment Repeat this step with the vehicle in Second Gear Compare the two sets of readings to the appropriate GEAR NOTE Do theAir Pressure Gauge readings match the values indicated in the NOTE 0061 14 kPa 2 PSI Yes Test Complete No Replace the Turbocharger Assembly in accordance with the Ser vice Information Perform ROAD TEST VERIFICATION VER 2 Remove the E clip and disconnect the Wastegate Actuator Rod from the Wastegate Actuator Arm Manually move the Wastegate Actuator Arm from closed to fully open Does the Wastegate Actuator Arm move easily without restriction Yes Replace the Wastegate Actuator in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Clean Wastegate Actuator Arm or Wastegate Actuator Shaft as necessary If OK replace Turbocharger Assembly in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 206 DRIVEABILIT
88. 1 0 2 0 3 0 4 0 5 0 6 0 7 0 TABLE CONTENTS INTRODUCTION aa Sue pe Sw Meee ese dl ee ee 1 11 SYSTEM COVERAGE an 1 12 SIX STEP TROUBLESHOOTING PROCEDURE 1 IDENTIFICATION OF 5 5 2 lt 5 42 1 SYSTEM DESCRIPTION AND FUNCTIONAL 1 2 1 GENERALE DESCRIPTION E a 1 3 2 1 321 ON BOARD DIAGNOSTICS 1 3 2 2 ECM OPERATING 2 323 MONITORED CIRCUITS 2 3 2 4 SKIS ON BOARD DIAGNOSTICS 535555555 99 5 2 3 2 5 Sree webs 2 3 2 6 SKIS 2 855655 5545 pag 2 3 3 DIAGNOSTIC TROUBLE 3 33 1 HARD CODE Shaheen Sen oe ne 3 3 3 2 INTERMITTENT 2555554 56 3 3 3 4 ECM DIAGNOSTIC TROUBLE 4 3 3 5 HANDLING NO TROUBLE CODE PROBLEMS 5 3 4 USING THE ori ER 5 3 5 ERROR MESSAGES AND BLANK 5 351 DRBIII
89. 15 PLAUSIBILITY AFTER START UP Continued ACTION APPLICABILITY Turn the ignition off Disconnect the ECM harness connectors Measure the voltage of ECM harness connector C1 cavities 2 and 28 Is voltage present on ECM harness connector C1 cavities 2 and 28 Yes gt GoTo 4 No Repair the ECM circuit that measured above 2 0 volts for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Measure the voltage on ECM harness connector C1 cavity 2 Is the voltage below 2 0 volts Yes gt GoTo 5 Repair the ASD Relay Output circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Measure the resistance between ground and the ASD Relay Control circuit 15 the resistance above 100 kohms Yes Replace the ASD Diesel Power Relay Perform ROAD TEST VERIFICATION VER 2 No Repair the ASD Relay Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggli
90. 2 Repair the Oil Pressure Sensor Signal circuit for a short to Sensor Ground Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 80 DRIVEABILITY DIESEL Symptom P0523 OIL PRESSURE VOLTAGE TOO HIGH When Monitored and Set Condition P0523 OIL PRESSURE VOLTAGE TOO HIGH When Monitored With the ignition on Set Condition ThePCM detects voltage on the oil pressure sensor signal circuit above 4 8 volts POSSIBLE CAUSES OIL PRESSURE SENSOR FAILURE OIL PRESSURE SENSOR SIGNAL CIRCUIT OPEN OIL PRESSURE SENSOR
91. 5 No gt Repair the Ambient Battery Temperature Sensor Signal Sensor Ground circuits for a short together Perform CHARGING VERIFICATION VER 3 there no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform CHARGING VERIFICATION VER 3 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform CHARGING VERIFICATION VER 3 No Test Complete CHARGING Symptom P1594 CHARGING SYSTEM VOLTAGE TOO HIGH DIESEL When Monitored and Set Condition P1594 CHARGING SYSTEM VOLTAGE TOO HIGH DIESEL W
92. 5 20YL RD LHD DISEL FUSED IGNITION SWITCH OUTPUT START T141 20YL EXCEPT LHD DIESEL IGNITION SWITCH OUTPUT START F45 20YL RD EXCEPT LHD DIESEL FUSED IGNITION SWITCH OUTPUT START T141 20YL LHD DIESEL IGNITION SWITCH OUTPUT START 254 BLACK ECTOR R SOLENOID DIESEL CONNECTOR PINOUTS DATA LINK CONNECTOR BLACK 16 WAY 255 CAV CIRCUIT FUNCTION 1 2 3 D1 18VT BR CCD BUS 4 71 18BK GROUND 5 712 18BK TN GROUND 6 1020 20LG BK SCI RECEIVE 7 1021 20PK SCI TRANSMIT 8 9 10 ccbBUs 12 13 14 15 16 F34 18TN BK FUSED EGR SOLENOID DIESEL 4 WAY CAV CIRCUIT FUNCTION F142 18DG OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K35 18GY YL EGR SOLENOID CONTROL D 21 18 GROUND R le i CONNECTOR PINOUTS ENGINE CONTROL MODULE C1 DIESEL BLACK 51 WAY CAV CIRCUIT FUNCTION 1 712 14BK TN GROUND 2 142 16DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT 3 4 5 C13 20DB 0R AIC COMPRESSOR CLUTCH RELAY
93. 6 8 9 and 10 Cavity 8 to cavities 6 and 10 NOTE The resistance should be above 100 ohms for all measurements 15 the resistance above 100 ohms for each of the measurements Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Remove and inspect the ASD Relay Output Fuse from the PDC 15 the fuse OK Yes Repair the Fused ASD Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 8 132 DRIVEABILITY DIESEL P1630 SOLENOID VALVE CONTROLLER OPEN CIRCUIT Continued APPLICABILITY Turn the ignition off All Remove the ASD Relay Output Fuse Measure the resistance between ground and the Fused ASD Relay Output circuit 15 the resistance above 100 kohms Yes Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Repair the Fused ASD Relay Output circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related
94. 9 18VT RD ENGINE SPEED SENSOR SIGNAL 9 10 1 12 618 18 COOLANT LEVEL SWITCH SIGNAL 13 14 15 16 K222 18TN RD ENGINE COOLANT TEMP SENSOR SIGNAL 17 K7 180R 5V SUPPLY 18 G8 18LB BK FUEL MONITOR OUTPUT SIGNAL 19 20 21 22 F16 16RD LG FUSED B 23 24 25 26 27 0123 18DG WT WATER IN FUEL SENSOR SIGNAL 28 29 30 31 Z12 14BK TN GROUND 32 212 14BK TN GROUND 264 CONNECTOR PINOUTS POWERTRAIN CONTROL MODULE C2 DIESEL 32 WAY CAV CIRCUIT FUNCTION 1 2 3 4 5 6 7 8 9 10 K20 1806 GENERATOR FIELD 11 12 22 32 13 12 0000080000 21 14 1 00000000000 11 15 17 POWERTRAIN 18 V66 18RD LG SPEED CONTROL INDICATOR SIGNAL CONTROL MODULE C2 DIESEL 20 21 22 23 G60 18GY YL ENGINE OIL PRESSURE SENSOR SIGNAL N 24 E 25 26 27 G7 18WT OR VEHICLE SPEED SENSOR SIGNAL 28 29 30 U T S 265 CONNECTOR PINOUTS GRAY 22 32 12 0000000000 21 1 11 POWERTRAIN CONTROL MODULE C3 DIESEL R 4 2 RADIATOR FAN MOTOR BLACK
95. AL CIRCUIT OPEN PRIMARY BRAKE SWITCH SIGNAL CIRCUIT SHORTED TO GROUND S C LAMP SIGNAL OPEN S C LAMP SIGNAL SHORTED TO GROUND S C LAMP SIGNAL SHORTED TO VOLTAGE S C SWITCH SIGNAL CIRCUIT OPEN S C SWITCH SIGNAL CIRCUIT SHORTED TO GROUND S C SWITCHES SECONDARY BRAKE SWITCH SIGNAL CIRCUIT OPEN SECONDARY BRAKE SWITCH SIGNAL CIRCUIT SHORTED TO GROUND SENSOR GROUND CIRCUIT OPEN INTERMITTENT CONDITION 222 SPEED CONTROL CHECKING THE SPEED CONTROL OPERATION Continued ACTION APPLICABILITY Start the engine With the DRB select Engine Bosch Controller then Sensor Display Observe the cruise switch volts on the DRB while pressing and holding each cruise button separately NOTE Pressing each cruise button should result in the following voltages ON OFF 0 55 1 15 SET 3 15 3 6v RE SUME ACCEL 3 9 4 15v CANCEL 1 55 2 05v COAST 2 5 3 0v No Button Pressed 4 4 4 7v Does each switch provide the correct voltage Yes gt GoTo 2 GoTo 23 Turn the ignition on With the DRB select Engine Bosch Inputs Outputs Observe the Brake Switch input while pressing and releasing the brake pedal several times Does the DRB indicate the correct change of state from Released to Pressed Yes gt GoTo 3 No GoTo 19 Turn the ignition on All With the DRB select Engine Bosch Inputs Outputs Observe the Brake Switch input while pressing and releasing the brake pedal several times Does the DRB indicate
96. ATION VER 2 If there are possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 76 DRIVEABILITY DIESEL 5 SPEED SENSOR PEC FREQUENCY TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the Vehicle Speed Sensor harness connector Disconnect the PCM harness connectors Check connectors Clean repair as necessary Turn the ignition on Measure the voltage between ground and the 5 volt Supply circuit Is the voltage below 0 5 volt Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 16 Turn the ignition off All Repair the 5 volt Supply circuit for a short to voltage Reconnect all harness connectors except the Vehicle Speed Sensor harness connector Turn the ignition on Measure the voltage of the 5 volt Supply circuit Is the voltage above 4 8 volts Yes gt repair is complete Perform ROAD TEST VERIFICATION VER 2 No Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Vehicle Speed Sensor harness connector Disconnect the PCM C1 harness connector Check connectors Clean repair as necessary Measure the resis
97. ATION VER 3 If there are no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform CHARGING VERIFICATION VER 3 18 CHARGING Symptom P1600 BATTERY VOLTAGE SRC HIGH EXCEEDED DIESEL When Monitored and Set Condition P1600 BATTERY VOLTAGE SRC HIGH EXCEEDED DIESEL When Monitored With the ignition on Set Condition ECM detects the system voltage has exceeded 20 volts for at least 5 seconds POSSIBLE CAUSES CHECK THE CHARGING VOLTAGE AT 2000 RPM CLEAR THE DTC AND RETEST INTERMITTENT CONDITION ACTION APPLICABILITY Start the engine All Set the engine speed to 2000 RPM Measure the voltage at the battery Is the voltage above 17 0 volts Yes Refer to symptom list for problems related to the charging system Perform CHARGING VERIFICATION VER 3 No gt GoTo 2 Turn the ignition on With the DRB erase ECM DTCs Start the engine and vary the engine speed between idle and 2500 RPM for several minutes With the DRB read ECM DTCs Did this DTC reset Yes Replace and program the Engine Control Module in accordance with the Service Information Perform CHARGING VERIFICATION VER 3 No gt GoTo 3 CHARGING P1600 BATTERY VOLTAGE SRC HIGH EXCEEDED DIESEL Continued APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that
98. AY FUEL LEVEL SENSOR DIESEL BLACK QU GENERATOR 4 GLOW PLUG RELAY DIESEL CAV CIRCUIT FUNCTION 1 141 16DG WT NOT USED 2 K226 20DB LG FUEL LEVEL SENSOR SIGNAL 4 167 20BR YL SENSOR GROUND 5 6 Z1 16BK NOT USED GENERATOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K72 16DG OR GAS GENERATOR SOURCE 1 72 1800 DIESEL GENERATOR SOURCE 2 20 1600 GAS GENERATOR FIELD 2 K20 1800 DIESEL GENERATOR FIELD GENERATOR 3 WAY CAV CIRCUIT FUNCTION 1 FIELD WIRES 2 FIELD WIRE CONNECTOR 3 B OUTPUT TERMINALS GLOW PLUG RELAY DIESEL 4 WAY CAV CIRCUIT FUNCTION 1 10RD GY FUSED B 2 F142 18DG OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K152 18WT GLOW PLUG RELAY CONTROL 4 K154 10GY GLOW PLUG RELAY OUTPUT 259 R ie 2 CONNECTOR PINOUTS R E 2 BLACK q 1 6 4 INSTRUMENT CLUSTER C2 LOW COOLANT SWITCH DIESEL
99. BUS MESSAGE DIESEL Continued APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 31 COMMUNICATION Symptom NO RESPONSE FROM ECM AND PCM DIESEL ONLY POSSIBLE CAUSES ATTEMPT TO COMMUNICATE WITH ANOTHER VEHICLE CHECK ECM POWERS AND GROUNDS POWERTRAIN CONTROL MODULE SCI TRANSMIT CONTROLLER ANTILOCK BRAKE SCI TRANSMIT SCI TRANSMIT CIRCUIT SHORTED TO VOLTAGE SCI CIRCUITS SHORTED TOGETHER SCI TRANSMIT CIRCUIT SHORTED TO GROUND SCI TRANSMIT CIRCUIT OPEN GROUND CIRCUITS AT DLC OPEN ENGINE CONTROL MODULE
100. C CONTROL OPEN CIRCUIT DIESEL Continued ACTION APPLICABILITY Turn the ignition off Remove the A C Compressor Clutch Relay from the PDC Turn the ignition on Using a 12 volt Test Light connected to ground check the ASD Diesel Power Relay Output circuit Did the test light illuminate brightly Yes gt GoTo 4 Repair the ASD Diesel Power Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Install a substitute relay in place of the A C Compressor Clutch Relay Turn the ignition on With the DRB actuate the A C Compressor Clutch Relay Is the A C Compressor Clutch dicking Yes Replace the A C Compressor Clutch Relay Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 5 Turn the ignition off Disconnect the ECM harness connector s Remove the A C Compressor Clutch Relay from the PDC Measure the resistance of the A C Compressor Clutch Relay Control circuit Is the resistance below 5 0 ohms Yes gt GoTo 7 gt Repair the A C Compressor Clutch Relay Control circuit for open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the ECM harness connector s Remove the A C Compressor Clutch Relay from the PDC Measur
101. CM FUEL COMPUTER ECT SENSOR TO DATA LINK CONNECTOR ISO K LINE TO PCM MIL REQUEST ACCEL PEDAL POSITION SENSOR FUEL PUMP ASSEMBLY LOW IDLE POSITION SWITCH 2554 FUEL TIMING SOLENOID FUEL QUANTITY 6 ACTUATOR CONTROL H SLEEVE POSITION E SENSOR TO M IGNITION SWITCH A T Low PRESSURE PRESSURE 5 SWITCH SWITCH e TEND SENSOR COMPRESSOR RELAY 809db637 269 SCHEMATIC DIAGRAMS 10 2 POWERTRAIN CONTROL MODULE VEHICLE SPEED SENSOR PRESSURE SENSOR CCD TOW 4 COOLANT SWITCH TO DLC 79 FUEL SENSOR 2 LOW COOLANT 2 LAMP IGNITION 9 SWITCH 4 WATER 8 FUEL LAMP z 5 TEMPERATURE SENSOR Engine Speed MIL Request TO ECM CONTROLLER S C Input Fuel Computer 5 A C 2 H SELECT SWITCH E A TO ASD 5 270 80946845 NOTES 271 NOTES 272
102. CONTROL 6 K159 18VT RD ENGINE SPEED SENSOR SIGNAL 7 C103 1806 REQUEST INPUT 9 K29 20WT PK BRAKE LAMP SWITCH SENSE 10 C22 20DB WT AIC PRESSURE SWITCH SENSE 11 20VT WT 5V SUPPLY 12 20WT LOW IDLE POSITION SWITCH SIGNAL 13 K21 20BK RD INTAKE AIR TEMPERATURE SENSOR SIGNAL 14 15 BLACK T gt 17 C27 18DB PK RADIATOR FAN RELAY CONTROL 18 G8 18LB BK FUEL MONITOR OUTPUT SIGNAL 19 41 1 20 150 20WT TN BRAKE LAMP SWITCH OUTPUT 21 3 22 N 23 55 20WT DG ACCELERATOR PEDAL POSITION SENSOR GROUND E 2 2 24 22 200R DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL 25 DE p 26 5 lt 27 212 16 GROUND R T 229 28 A142 16DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT 29 K35 18GY YL EGR SOLENOID CONTROL 30 66 18RD LG SPEED CONTROL INDICATOR SIGNAL 31 N ENGINE CONTROL 32 185 200R LB WAIT START INDICATOR DRIVER 1 33 51 20DB YL AUTOMATIC SHUT DOWN RELAY CONTROL DIESEL 34 180R RD FAULT INDICATOR REQUEST INPUT T 35 5 36 37 38 G55 18 ENGINE DISABLE SIGNAL 39 20LB 5V SUPPLY 40 20DG RD BOOST PRESSURE SENSOR SIGNAL 41 42 K152 18WT GLOW PLUG RELAY CONTROL 43 44 45 021 20PK SCI TRANSMIT 46 47 Fi2 18DB WT FUSED IGNITION SWITCH OUTPUT RUN START 48 C48 18TN RADIATOR FAN REQUEST 49 50 51 G7 20 VEHICLE SPEED SENSOR SIGNAL 256 CONNECTOR P
103. Cs Did DTC P0180 FUEL TEMPERATURE SENSOR SRC LOW EXCEEDED set Yes Repair the Fuel Temperature Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 gt GoTo 4 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Fuel Injection Pump harness connector Measure the resistance of the Fuel Temperature Sensor Signal circuit Is the resistance below 5 0 ohms Yes gt GoTo 5 No Repair the Fuel Temperature Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Fuel Injection Pump harness connector Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage of the Fuel Temperature Sensor Signal circuit 15 the voltage above 1 0 volt Yes Repair the Fuel Temperature Sensor Signal circuit for short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 6 Disconnect the Fuel Injection Pump harness connector Measure the resistance between the following cavities in the Fuel Injection Pump connector fuel pump side Cavity 1 to cavities 4 5 6 7 8 9 and 10 Cavity 4 to cavities 5 6 7 8 9 and 10 Cavity 5 to cavities 6 7 8 and 9 Cavity 7 to cavities 6 8 9 and 10 Cavity 8 to cavities 6 and 10 NOTE The resistance shou
104. D 106 P1225 CONTROL SLEEVE SENSOR START END POS NOT ATTAINED 109 P1225 CONTROL SLEEVE SENSOR STOP END POS ATTAINED 109 P1230 TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION 111 P1230 TIMING GOVERNING POSITIVE GOVERNOR DEVIATION 113 P1515 ACCEL PEDAL SENSOR 5 115 P1515 ACCEL PEDAL SENSOR PWG PLAUS WITH POTENTIOMETER 115 P1515 ACCEL PEDAL SENSOR SIGNAL HIGH EXCEEDED 115 P1515 ACCEL PEDAL SENSOR SUPPLY HIGH EXCEEDED 115 P1515 ACCEL PEDAL SENSOR SUPPLY LOW EXCEEDED 119 P1520 VEHICLE SPEED GOV ANALOG CTRL CONTROL CONTACT ALONE 123 P1605 TERMINAL 15 PLAUSIBILITY AFTER START UP 124 P1625 ASD DIESEL POWER RELAY SHUTS OFF TOO LATE 126 P1625 ASD DIESEL POWER RELAY SHUTS OFF 129 P1630 SOLENOID VALVE CONTROLLER OPEN CIRCUIT 131 P1630 SOLENOID VALVE CONTROLLER SHORT CIRCUIT 134 P1635 GLOW RELAY 1 CONTROLLER OPEN 1 136 P1635 GLOW RELAY 1 CONTROLLER SHORT 138 P1645 GLOW DISPLAY OPEN CIRCUIT eee 140 1645 GLOW DISPLAY SHORT CIRCUIT 143 P1660 REDUNDANT EMERG STOP PLAUSIBILITY IN AFTER RUN 146 P1660 REDUNDANT EMERG ST
105. DOES NOT POWER 5 352 DISPLAY IS VISIBLE 5 DISCLAIMERS SAFETY 5 6 4 1 DISCLAIMERS 6 SAFETY 6 4 2 1 TECHNICIAN SAFETY 6 4 2 2 VEHICLE PREPARATION FOR 5 6 4 2 3 SERVICING SUB ASSEMBLIES 6 424 DRBIII SAFETY INFORMATION 6 4 3 5 222222220 45551 ieee Seay 7 4 3 1 VEHICLE DAMAGE WARNINGS seeetereeeeoates es 7 4 3 2 ROAD TESTING A COMPLAINT 7 REQUIRED TOOLS AND EQUIPMENT 7 GLOSSARY OF TERMS vas cscs ances cies eee 7 DIAGNOSTIC INFORMATION AND 9 CHARGING P0622 GENERATOR FIELD NOT SWITCHING PROPERLY DIESEL 10 1492 TEMP SEN VOLTS TOO HIGH DIESEL 12 1493 TEMP SEN VOLTS LOW DIESEL 19 P1594 CHARGING SYSTEM VOLTAGE TOO HIGH DIESEL 17 P1600 BATTERY VOLTAGE SRC HIGH EXCEEDED 5 19 P1682 CHARGING SYSTEM VOLTAGE LOW DIESEL
106. ECM detects an open or a short to ground on the glow plug relay 1 control circuit POSSIBLE CAUSES INTERMITTENT CONDITION ASD DIESEL POWER RELAY OUTPUT CIRCUIT OPEN SUBSTITUTE GLOW PLUG RELAY GLOW PLUG RELAY CONTROL CIRCUIT SHORTED TO GROUND GLOW PLUG RELAY CONTROL CIRCUIT OPEN ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB actuate the Glow Plug Relay Is the Glow Plug Relay dicking Yes gt GoTo 2 No gt GoTo 3 NOTE Stop the Glow Plug Relay actuation by the DRB WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete
107. ECT SIGNAL PROCESSING ENGINE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE ENGINE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO GROUND ENGINE SPEED SENSOR SIGNAL CIRCUIT OPEN POWERTRAIN CONTROL MODULE APPLICABILITY Turn the ignition on All Observe gauge and bulb operation during cluster initialization check Do the other gauges operate properly Yes gt GoTo 2 No Refer tosymptom list for problems related to Instrument Cluster Communication Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect jumper wire between ASD Diesel Power Relay connector cavities 30 87 in PDC Turn the ignition on Measure the voltage on the Engine Speed Sensor Signal circuit Is the voltage between 4 0 and 6 0 volts Yes gt GoTo 3 No gt GoTo 5 Start the engine With the DRB select Body from the Systems menu Electro Mech Cluster MIC Monitor Display then PCI Bus Engine Info Monitor the DRB and Instrument Cluster Tachometer engine speed with the engine idling then raise the engine speed to 2500 RPM and release it back to idle NOTE The DRB engine speed should be approximately 850 RPM at idle increase with actual engine speed and match the Instrument Cluster Tachometer reading Did the Instrument Cluster Tachometer perform as it should Yes gt GoTo 4 No Replace the Instrument Cluster in accordance wit
108. EL CHECKING THE VEHICLE SPEED SIGNAL Continued ACTION APPLICABILITY Turn the ignition off Repair the 5 volt Supply circuit for a short to voltage Reconnect all harness connectors except the Vehicle Speed Sensor harness connector Turn the ignition on Measure the voltage of the 5 volt Supply circuit Is the voltage above 4 8 volts Yes repair is complete Perform ROAD TEST VERIFICATION VER 2 No Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Vehicle Speed Sensor harness connector Disconnect the PCM C1 harness connector Check connectors Clean repair as necessary Measure the resistance of the 5 volt Supply circuit between the Vehicle Speed Sensor harness connector and the PCM C1 harness connector 15 the resistance below 5 0 ohms Yes gt GoTo 19 No Repair the 5 volt Supply circuit for an open Perform ROAD TEST VERIFICATION VER 2 Yes gt GoTo 20 No Repair the 5 volt Supply circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Vehicle Speed Sensor harness connector Disconnect the PCM harness connectors Check connectors Clean repair as necessary Measure the resistance between the 5 volt Supply circuit and the Sensor Ground circuit in the Vehicle Speed Sensor harness connector 15 the resi
109. ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform SPEED CONTROL VERIFICATION VER 4 No Test Complete If there are no possible causes remaining view repair 221 SPEED CONTROL Symptom CHECKING THE SPEED CONTROL OPERATION POSSIBLE CAUSES BRAKE LAMP SWITCH PRIMARY CIRCUIT BRAKE LAMP SWITCH SECONDARY CKT CHECKING BRAKE LAMP SWITCH ADJ USTMENT CHECKING THE S C LAMP OPERATION CHECKING THE VEHICLE SPEED SIGNAL ECM BRAKE SWITCH SIGNAL ECM PRIMARY BRAKE SWITCH CIRCUIT S C LAMP CONTROL ECM S C SIGNAL ECM SPEED CONTROL FUSED B CIRCUIT OPEN GROUND CIRCUIT OPEN S C LAMP CONTROL PRIMARY BRAKE SWITCH SIGN
110. ENSOR SUPPLY LOW EXCEEDED U_REF 2 5V VEHICLE SPEED GOV ANALOG CTRL CONTROL CONTACT ALONE VEHICLE SPEED SENSOR PEC FREQUENCY TOO HIGH VEHICLE SPEED SENSOR SRC HIGH EXCEEDED VEHICLE SPEED SENSOR PLAUSIBILITY VEHICLE THEFT ALARM IMMOBILIZER SIGNAL LOST VEHICLE THEFT ALARM INVALID SKIM MESSAGE 3 3 5 HANDLING NO TROUBLE CODE PROBLEMS After reading Section 3 0 System Description and Functional Operation you should have a better understanding of the theory and operation of the on board diagnostics and how this relates to the diagnosis of a vehicle that may have a driveability related symptom or complaint 3 4 USING THE DRBIII Refer to the user s guide for instructions and assistance with reading trouble codes erasing trouble codes and other DRBIII functions 3 5 DRBIII ERROR MESSAGES AND BLANK SCREEN Under normal operation the DRBII will display one of only two error messages User Requested WARM Boot Requested COLD Boot This is a sample of such an error message dis play ver 2 14 date 26 J ul93 file key itf cc date J ul 26 1993 line 548 err 0 1 User Requested COLD Boot User Press MORE to switch between this display and the application screen Press F4 when done noting information 3 5 1 DOES NOT POWER UP If the LEDs donot light or no sound is emitted at start up check for loose cable connections or a bad cable Check the vehicle battery voltage
111. ERATOR 3 259 GLOW PLUG RELAY DIESEL 4 WAY 259 INSTRUMENT CLUSTER C2 BLACK 10 260 LOW COOLANT SWITCH DIESEL 2 260 MESSAGE CENTER DIESEL BLACK 8 260 NEEDLE MOVEMENT SENSOR DIESEL 2 260 FUSES DIESEL 262 A C COMPRESSOR CLUTCH RELAY DIESEL BLACK 2 WAY 262 AUTOMATIC SHUT DOWN RELAY 1 262 ENGINE STARTER MOTOR RELAY 0 1 263 FUEL HEATER RELAY 5 2 263 RADIATOR FAN 22 2 263 POWERTRAIN CONTROL MODULE C1 DIESEL 32 264 POWERTRAIN CONTROL MODULE C2 DIESEL 32 265 POWERTRAIN CONTROL MODULE DIESEL 32 266 RADIATOR FAN MOTOR LT GRAY 2 266 SENTRY KEY IMMOBILIZER MODULE BLACK 6 WAY 266 TURBO BOOST PRESSURE SENSOR DIESEL BLACK 4 267 VEHICLE SPEED SENSOR DIESEL 267 WATER IN FUEL SENSOR DIESEL BLACK 2 267 SCHEMAT
112. ERNALLY INTERMITTENT CONDITION AMB BATT TEMP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE AMBIENT BATTERY TEMPERATURE SENSOR AMBIENT BATTERY TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN AMBIENT BATTERY TEMPERATURE SENSOR GROUND CIRCUIT OPEN POWERTRAIN CONTROL MODULE OPEN INTERNALLY ACTION APPLICABILITY Turn the ignition on All With the DRB erase PCM DTCs Cycle the ignition on for five seconds then off for five seconds several times With the DRB read PCM DTCs Did this DTC reset Yes gt GoTo 2 GoTo 8 Turn the ignition off Disconnect the Ambient Battery Temperature Sensor harness connector Turn the ignition on Measure the voltage between ground and the Ambient Battery Temperature Sensor Signal circuit Is the voltage above 5 5 volts Yes gt GoTo 3 gt GoTo 4 CHARGING P1492 AMBIENT BATT TEMP SEN VOLTS TOO HIGH DIESEL Continued ACTION APPLICABILITY Turn the ignition off Disconnect the Ambient Battery Temperature Sensor harness connector Disconnect the PCM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage between ground and the Amb Batt Temp Sensor Signal circuit 15 the voltage below 0 5 volt Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform CHARGING VERIFICATION
113. ESEL Symptom P1690 FAN CONTROL SHORT CIRCUIT E When Monitored and Set Condition P1690 FAN CONTROL SHORT CIRCUIT When Monitored With the ignition on and the ECM attempting to enable the radiator fan relay Set Condition The ECM detects excessive current draw the radiator fan relay control circuit POSSIBLE CAUSES INTERMITTENT CONDITION SUBSTITUTE RADIATOR FAN RELAY RADIATOR FAN RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB actuate the Radiator Fan Relay Does the Radiator Fan cycle on and off Yes gt GoTo 2 gt GoTo 3 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above
114. EST VERIFICATION VER 2 The repair is complete Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 110 DRIVEABILITY DIESEL Symptom P1230 TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION MMMM When Monitored and Set Condition 1230 GOVERNING NEGATIVE GOVERNOR DEVIATION When Monitored With the engine speed between 1000 and 4800 RPM Set Condition TheECM detects 3 degrees of excess timing retard for at least 10 seconds POSSIBLE CAUSES CHECK FOR OTHER DTCS ENGINE CONTROL MODULE REPLACE THE FUE
115. Engine Lamp bulb Perform ROAD TEST VERIFICATION VER 2 173 DRIVEABILITY DIESEL Symptom CHECKING THE ECM AND PCM POWER AND GROUND CIR CUITS POSSIBLE CAUSES ASD RELAY OUTPUT CIRCUIT OPEN AT ECM ASD RELAY OUTPUT OPEN AT PCM ECM GROUND CIRCUIT OPEN FUSED ASD BATTERY SUPPLY CIRCUIT OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN PCM BATTERY SUPPLY CIRCUIT OPEN PCM GROUND CIRCUIT OPEN ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Using a 12 volt test light connected to 12 volts check both of the ECM ground circuits in ECM harness connector C1 cavities 1 and 27 Did the test light illuminate for both cavities Yes gt GoTo 2 Repair the ECM Ground circuit s for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Turn the ignition on Using a 12 volt test light connected to ground check the Fused Ignition Switch Output circuit in ECM harness connector C1 cavity 47 Is the test light on Yes gt GoTo 3 Repair the Fused Ignition Switch Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove the ASD Diesel Power Relay from the PDC Using a 12 volt test light connected to ground check the F used ASD Battery Supply circuit in ASD Diesel Power Relay connector cavity 30 Is the test light on Yes gt GoTo 4 Repair the Fused ASD Batte
116. FUEL SHUTDOWN SOLENOID FUEL INJ ECTION PUMP SHORTED INTERNALLY INTERNAL FUEL INJECTION PUMP TEST ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Cycle the ignition on and off several times pausing for 10 seconds at key off each time Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 gt GoTo 6 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Fuel Injection Pump harness connector Measure the resistance of the Fuel Shutdown Solenoid Control circuit 15 the resistance below 5 0 ohms Yes gt GoTo 3 No Repair the Fuel Shutdown Solenoid Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 148 DRIVEABILITY DIESEL P1660 REDUNDANT EMERG STOP POWERSTAGE DEFECTIVE Continued APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Fuel Injection Pump harness connector Measure the resistance between ground and the Fuel Shutdown Solenoid Control circuit 15 the resistance above 100 kohms Yes gt GoTo 4 No Repair the Fuel Shutdown Solenoid Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Fuel Injection Pump harness connector Turn the ignition on With the DRB actuate the Fuel Shutdown Solenoid Measure the voltage on the Fuel S
117. Fuel Injection Pump 10 way harness connector pump side Resistance on these measurements should be greater than 100 0 ohms each Measure the resistance between cavity 1 and cavities 4 5 6 7 8 9 10 and case ground Measure the resistance between cavity 4 and cavities 5 6 8 9 10 and case ground Measure the resistance between cavity 5 and cavities 6 7 8 and case ground Measure the resistance between cavity 6 and cavities 7 8 9 and 10 Measure the resistance between cavity 7 and cavities 8 9 10 and case ground 15 the resistance below 100 0 ohms for any of the measurements Yes ReplacetheFuel Injection Pump Assembly in accordance with the Service nformation Perform ROAD TEST VERIFICATION VER 2 No Test Complete 185 DRIVEABILITY DIESEL Symptom CHECKING THE FUEL LEVEL GAUGE OPERATION POSSIBLE CAUSES FUEL LEVEL SENSOR FUEL LEVEL SENSOR SIGNAL CIRCUIT OPEN FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND INSTRUMENT CLUSTER ACTION APPLICABILITY Turn the ignition on All With the DRB perform the Instrument Cluster Self Test NOTE The 5 calibration points 1 mpty Stop 2 Empty 3 1 2 Full 4 Full 5 Full Stop Observe the gauge during the Self Test and compare the readings with the readings described in the NOTE NOTE With the DRB ensure there are no PCM Fuel Level Sensor DTCs If there are DTCs they must be r
118. IC 269 10 1 ENGINE CONTROL 2 269 10 2 POWERTRAIN CONTROL MODULE 270 NOTES 1 0 INTRODUCTION The procedures contained in this manual include all the specifications instructions and graphics needed to diagnose engine control module ECM powertrain control module PCM and sentry key immobilizer module SKIM problems they are no start diagnostic trouble code and no trouble code problems The diagnostics in this manual are based on the trouble condition or symptom being present at the time of diagnosis When repairs are required refer to the appropri ate volume of the service manual for the proper removal and repair procedure Diagnostic procedures change every year New diagnostic systems may be added carryover sys tems may be enhanced 15 RECOMMENDED THAT YOU REVIEW THE ENTIRE MANUAL TO BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES Please follow the recommendations below when choosing your diagnostic path 1 First make sure the DRBIII is communicating with the appropriate modules ie if the DRBII displays a No Response condition you must diagnose this first before proceeding 2 Read DTC s diagnostic trouble codes with the DRBIII 3 If no DTC s are present identify the customer complaint 4 Once the DTC or customer complaint is identi
119. ICATION VER 2 NOTE The Vacuum Output Hose must not be leaking or restricted for the result of this test to be valid Turn the ignition off Disconnect the Vacuum Supply and Vacuum Output Hoses in the EGR Solenoid vacuum connector Connect the Vacuum Supply Hose to the Vacuum Output Hose Test drive the vehicle and observe vehicle performance Is there a power reduction on vehicle acceleration Yes gt Test Complete No Replace the EGR Valve Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the EGR Solenoid harness connector Using a 12 volt test light connected to 12 volts check the Ground circuit the EGR 176 DRIVEABILITY DIESEL Symptom CHECKING THE ELECTRIC RADIATOR FAN OPERATION POSSIBLE CAUSES ACTUATE THE RADIATOR FAN RELAY WITH THE DRB CHECK FOR FAN CONTROL DTCS RADIATOR FAN RELAY SHORTED RADIATOR FAN RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE FUSED B CIRCUIT OPEN SUBSTITUTE RADIATOR FAN RELAY RADIATOR FAN RELAY OUTPUT CIRCUIT OPEN RADIATOR FAN GROUND CIRCUIT OPEN RADIATOR FAN OPEN ACTION APPLICABILITY Turn the ignition on All With the DRB check for ECM Fan Control DTCs Are any Fan Control DTCs present Yes Refer to symptom list for problems related to the Fan Control DTCs Perform ROAD TEST VERIFICATION VER 2 GoTo 2 Turn the ignition on With the DRB actuate the Radiator Fan Relay and observe the Radiator Fan Did the Radiator Fan
120. ICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 78 DRIVEABILITY DIESEL Symptom P0522 OIL PRESSURE VOLTAGE TOO LOW When Monitored and Set Condition P0522 O1IL PRESSURE VOLTAGE TOO LOW When Monitored With the ignition on Set Condition ThePCM detects voltage on the oil pressure sensor signal circuit below 0 1 volt POSSIBLE CAUSES CHECKING THE OIL PRESSURE SENSOR OIL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND OIL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND PCM OIL PRESSURE SENSOR SIGNAL SHORT TO GROUND INTER
121. INOUTS ENGINE CONTROL MODULE C2 DIESEL BLACK 29 WAY CAV CIRCUIT FUNCTION 52 53 K156 20GY FUEL TEMPERATURE SENSOR SIGNAL 54 20TN BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 55 K68 18LG YL NEEDLE MOVEMENT SENSOR GROUND 56 K134 20LB BK CONTROL SLEEVE POSITION SENSOR SIGNAL 57 K57 20LG OR CONTROL SLEEVE POSITION SENSOR MIDDLE TAP 58 K135 20WT BK CONTROL SLEEVE POSITION SENSOR MEASURE COIL 59 140 18TN WT FUEL QUANTITY ACTUATOR CONTROL 4 60 7 2080 9 SPEED CONTROL SWITCH SIGNAL 61 20BK LB SENSOR GROUND 59 80 62 K67 18BR BK NEEDLE MOVEMENT SENSOR SIGNAL 63 64 65 p 5 66 140 18TN WT FUEL QUANTITY ACTUATOR CONTROL 53 T 72 67 24 20GY BK ENGINE SPEED SENSOR SIGNAL 68 69 K3 20LG BK ENGINE SPEED SENSOR GROUND ENGINE CONTROL MODULE C2 a DIESEL 73 74 75 76 77 K153 1808 FUEL SHUTDOWN SOLENOID CONTROL T 78 79 126 1816 FUEL TIMING SOLENOID CONTROL R 80 K140 18TN WT FUEL QUANTITY ACTUATOR CONTROL P BLACK N ENGINE COOLANT TEMPERATURE SENSOR 1 DIESEL ECM BLACK 2 WAY T CAV CIRCUIT FUNCTION 5 ENGINE 1 2 18TN BK ECM ENGINE COOLANT TEMPERATURE SENSOR SIGNAL COOLANT 2 18BK LB SENSOR GROUND TEMPERATURE SENSOR 1 DIESEL ECM 257 CONNECTOR PINOUTS ENGINE COOLANT TEMPERATURE
122. IR CLEANER HOUSING EVM HARNESS L T 5 HARNESS 7 zA D go 1 G3 2 AWK VES 622 MA A 80b6b23b 8 3 DATA LINK CONNECTOR LHD RHD Symmetrically Opposite 16 WAY DATA LINK CONNECTOR lt lt 80248351 248 CONNECTOR MODULATOR EVM SOLENOID 8 2 CONTROLS AND SOLENOIDS POWERTRAIN CONTROL MODULE A Ee Ce TORN E ING gt N Z m D 1225 il FUEL SUPPLY Alk INE i fA FUEL INJECTION 04 R PUMP 10 WAY 7 80665189 5 8 4 SENSORS M AMBIENT BATTERY N 11 TEMPERATURE SENSOR j N ACCELERATOR PEDAL POSITION SENSOR L 5 80aafb0o bs PCM sd ECM OIL PRESSURE ENGINE COOLANT x ENGINE COOLANT _ SENSOR TEMPERATURE TEMPERATURE 4 ECT gt SENSOR SENSOR 4 lt gt 7 A RN 7 5 n SENSOR HARNESS N BELLHOUSING
123. IT SHORT TO VOLTAGE FUEL SUPPLY CONTAMINATION FUEL SYSTEM PRESSURE FUEL SYSTEM RESTRICTION IMMOBILIZER SIGNAL CIRCUIT OPEN IMMOBILIZER SIGNAL CIRCUIT SHORTED TO GROUND IMMOBILIZER SIGNAL CIRCUIT SHORTED TO VOLTAGE VERIFYING IMMOBILIZER SIGNAL ACTION APPLICABILITY NOTE Check for SKIM ECM and DTCs Return to the Symptom List All to diagnose any DTCs that are present before continuing With the DRB select Engine TEC Miscellaneous and View SKIM Status While observing the DRB attempt to start the engine Does the DRB display Fuel Shut Off Activated Yes gt GoTo 2 gt GoTo 7 Turn the ignition off Disconnect the PCM harness connector Disconnect the ECM harness connector Remove the ASD Relay from the PDC Connect a jumper wire between ASD Relay connector cavity 30 and cavity 87 the PDC Turn the ignition on Measure the voltage of the Immobilizer Signal circuit 15 the voltage above 1 0 volt Yes Repair the Immobilizer Signal circuit for a short to voltage Perform NO START VERIFICATION VER 1 No gt GoTo 3 231 STARTING NO START CONDITION Continued ACTION APPLICABILITY Turn the ignition off Disconnect the PCM harness connector Disconnect the ECM harness connector Measure the resistance of the Immobilizer Signal circuit between the PCM harness connector and the ECM harness connector Is the resistance below 5 0 ohms Yes gt GoTo 4 Repair the Immob
124. ITTENT CONDITION ASD DIESEL POWER RELAY OUTPUT CIRCUIT OPEN SUBSTITUTE A C COMPRESSOR CLUTCH RELAY A C COMPRESSOR CLUTCH RELAY CONTROL CIRCUIT SHORTED TO GROUND A C COMPRESSOR CLUTCH RELAY CONTROL CIRCUIT OPEN ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB actuate the A C Compressor Clutch Relay 15 the A C Compressor Clutch Relay clicking Yes gt GoTo 2 No gt GoTo 3 NOTE Stop the A C Compressor Clutch Relay actuation by the DRB WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 214 HEATING amp A C P1655 A
125. Injection Pump timing correct Yes Check the fuel supply for contamination Perform NO START VERIFICATION VER 1 No Refer to the Service Information to correctly time the Fuel Injection Pump Perform NO START VERIFICATION VER 1 233 VEHICLE THEFT SECURITY Symptom List ANTENNA FAILURE COP FAILURE EEPROM FAILURE INTERNAL FAULT RAM FAILURE SERIAL LINK INTERNAL FAULT STACK OVERFLOW FAILURE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be ANTENNA FAILURE j lt lt When Monitored and Set Condition ANTENNA FAILURE When Monitored Every 250 milliseconds with the ignition on Set Condition TheSKIM s microcontroller determines that an antenna circuit fault has occurred for 2 0 consecutive seconds COP FAILURE When Monitored With the ignition on Set Condition TheCOP timer is not reset by the microcontroller every 65 5 milliseconds EEPROM FAILURE When Monitored With the ignition on Set Condition When the value written to EEPROM memory does not equal the value read back after the write operation INTERNAL FAULT When Monitored With the ignition on Set Condition 5 has detected a fault during an internal self test RAM FAILURE When Monitored With the ignition on Set Condition The RAM fails a test that checks the 5 ability to retain memory SERIAL LINK INTERNAL FAULT When Mo
126. L INJ ECTION PUMP INTERMITTENT CONDITION FUEL INJ ECTION PUMP TIMING INCORRECT ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Turn the ignition off wait 30 seconds then attempt to start the engine With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 5 NOTE This DTC will set due to noise on the Needle Movement Sensor circuit Turn the ignition on With the DRB check for additional DTCs Are other DTCs present Yes Refer tothe Symptom List for diagnosis of the other DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 gt GoTo 3 Check the Fuel Injection Pump timing using the Service Information Is the Fuel Injection Pump timed correctly Yes gt GoTo 4 No Rese the Fuel Injection Pump timing in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 111 DRIVEABILITY DIESEL P1230 TIMING GOVERNING NEGATIVE GOVERNOR DEVIATION Continued APPLICABILITY Replace the Fuel Injection Pump in accordance with the Service Information All With the DRB erase ECM DTCs Perform several drive cycles turning the ignition off for at least 10 seconds between each drive cycle Monitor the DRB for ECM DTCs Did this DTC reset Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 The repair is complete
127. L INJ ECTION PUMP TIMING INCORRECT ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Turn the ignition off wait 30 seconds then attempt to start the engine With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 5 NOTE This DTC will set due to low fuel volume to the Fuel Injection Pump Check the fuel system for restrictions Were any problems found Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 gt GoTo 3 Check the Fuel Injection Pump timing using the Service Information Is the Fuel Injection Pump timed correctly Yes gt GoTo 4 No Rese the Fuel Injection Pump timing in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 113 DRIVEABILITY DIESEL P1230 TIMING GOVERNING POSITIVE GOVERNOR DEVIATION Continued ACTION APPLICABILITY Replace the Fuel Injection Pump in accordance with the Service Information All With the DRB erase ECM DTCs Perform several drive cycles turning the ignition off for at least 10 seconds between each drive cycle Monitor the DRB for ECM DTCs Did this DTC reset Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 The repair is complete Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC ar
128. LAMP OPERATION POSSIBLE CAUSES ACTUATE CHECK ENGINE LAMP CHECK ENGINE CONTROL CIRCUIT SHORTED TO VOLTAGE CHECK ENGINE LAMP BULB ENGINE CONTROL MODULE INSTRUMENT CLUSTER INSTRUMENT CLUSTER LAMP NEVER ON POWERTRAIN CONTROL MODULE CONTROL SHORTED TO VOLTAGE POWERTRAIN CONTROL MODULE INTERNAL FAULT CHECK ENGINE LAMP CONTROL CIRCUIT SHORTED TO GROUND CHECK ENGNINE LAMP CONTROL CIRCUIT OPEN POWERTRAIN CONTROL MODULE CONTROL SHORTED TO GROUND ACTION APPLICABILITY Turn the ignition on and observe the Check Engine Lamp All Did the Check Engine Lamp illuminate for approximately 2 seconds then go out for a bulb check Yes gt GoTo 2 gt GoTo 10 Turn the ignition on With the DRB actuate the Diag Glow Plug Lamp Did the Check Engine Lamp illuminate Yes Check Engine Lamp System is working properly Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 3 Turn the ignition off Disconnect the ECM harness connectors Turn the ignition on Measure the voltage of the Check Engine Lamp Control circuit Is the voltage between 4 8 and 5 5 volts Yes gt GoTo 4 Above GoTo 6 Below GoTo 7 171 DRIVEABILITY DIESEL CHECKING THE CHECK ENGINE LAMP OPERATION Continued APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Pow
129. LY 86 DB YL ASD RELAY CONTROL 87 DG OR ASD RELAY OUTPUT 5 POWER DISTRIBUTION P POWER DISTRIBUTION CENTER CENTER FUEL HEATER RELAY RADIATOR FAN RELAY CONNECTOR CONNECTOR l engh 1 TI 5 FUNCTION FUSED BATTERY SUPPLY RADIATOR FAN RELAY CONTROL ASD RELAY OUTPUT RADIATOR FAN RELAY OUTPUT 80 9 2 80 9 3 POWER DISTRIBUTION MOUNTING GLOW 9 BOLT PLUG STARTER RELAY CONNECTOR Tena 5 FUSED BATTERY SUPPLY GROUND CLUTCH INTERLOCK SWITCH OUTPUT ELECTRICAL STARTER RELAY OUTPUT re CONNECTOR 80ad08f8 8 6 SWITCHES BRAKE LAMP SWITCH LOW COOLANT LEVEL SWITCH EN RE 5 LOW COOLANT LEVEL SWITCH HARNESS CONNECTOR 059 80 2 6 251 2 L 5 5 9 8 6 SWITCHES Continued P CLUTCH CLUTCH PEDAL CABLE SWITCH N E N T L CLUTCH q S DASH PANEL PEDAL BRACKET 80ab248d 8 7 LAMPS XJ BODY SPEED CONTROL GLOW PLUG tA LAMP INSTRUMENT CLUSTER WATER IN FUEL LAMP LOW COOLANT
130. MED IN THE PCM PCM SKIM TROUBLE CODES SET APPLICABILITY With the DRB III read the PCM DTCs Look for P1685 All Turn the ignition on 15 the Starts Since Set counter for DTC P1685 displayed and equal to 0 Yes gt GoTo 2 gt GoTo 7 Turn the ignition on With the III attempt to communicate with the SKIM Can you communicate with the SKIM Yes gt GoTo 3 No Refer to symptom BUS SIGNAL OPEN FROM SKIM the COMMUNICATION category Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on With the 111 check for SKIM Are there any trouble codes set in the SKIM Yes Repair all SKIM DTC s Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 4 25 COMMUNICATION P 1685 INVALID SKIM KEY Continued ACTION APPLICABILITY NOTE If a VIN has not been programmed into the PCM program VIN into the PCM and retest Turn the ignition on With the DRB 111 display the VIN that is programmed in the PCM Is there VIN programmed the PCM Yes gt GoTo 5 No Program the correct VIN into the PCM and retest Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on With the DRB III display the VIN that is programmed in the PCM 15 the correct VIN programmed in the PCM Yes gt GoTo 6 No Replace and program the PCM in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Replac
131. MITTENT CONDITION ACTION APPLICABILITY Turn the ignition on All With the DRB III erase PCM DTCs Cycle the ignition key on and off several times leaving the key on for at least 10 seconds at a time With the DRB III read PCM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 5 Turn the ignition off Disconnect the Oil Pressure Sensor harness connector Measure the voltage of the Oil Pressure Sensor Signal circuit 15 the voltage between 4 7 and 5 3 volts Yes Replace the Oil Pressure Sensor Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 3 Turn the ignition off Disconnect the Oil Pressure Sensor harness connector Disconnect the PCM harness connectors Measure the resistance between ground and the Oil Pressure Sensor Signal circuit 15 the resistance above 100 kohms Yes gt GoTo 4 No Repair the Oil Pressure Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 79 DRIVEABILITY DIESEL P0522 OIL PRESSURE VOLTAGE TOO LOW Continued APPLICABILITY Turn the ignition off All Disconnect the Oil Pressure Sensor harness connector Disconnect the PCM harness connectors Measure the resistance between Sensor Ground and the Oil Pressure Sensor Signal circuit 15 the resistance above 100 kohms Yes Replace and program the Powertrain Control Module accor dance with the Service Information Perform ROAD TEST VERIFICATION VER
132. N PUMP ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Start the engine and vary the engine speed from idle to 3500 RPM several times With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 5 Check the Fuel Injection Pump timing using the Service Information Is the Fuel Injection Pump timing correct Yes gt GoTo 3 Set the Fuel Injection Pump timing in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 104 DRIVEABILITY DIESEL P1220 FUEL QUANTITY ACTUATOR POS GOV DEVIATION COLD Continued ACTION APPLICABILITY Turn the ignition off All Inspect the fuel system for restrictions in the delivery lines filter and or at the fuel level sensor module Was a restriction found Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 4 Turn the ignition off Replace the Fuel Injection Pump in accordance with the Service nformation Turn the ignition on With the DRB erase ECM DTCs Start the engine and vary the engine speed from idle to 3500 RPM several times With the DRB read ECM DTCs Did this DTC reset Yes gt Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 The repair is complete Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS
133. NG VERIFICATION VER 3 GoTo 3 With the DRB stop the Generator Field actuation Connect the positive lead of a voltmeter to the generator 12V terminal and the All negative lead to the battery positive post WARNING KEEP EVERYTHING CLEAR OF THE ENGINE S MOVING PARTS Start the engine Is the voltage on the voltmeter below 0 4 volt Yes gt GoTo 4 No Repair the Generator Fused B for high resistance Perform CHARGING VERIFICATION VER 3 Connect the positive lead of a voltmeter to the generator case housing and the negative lead to the battery negative post WARNING KEEP EVERYTHING CLEAR OF THE ENGINE S MOVING PARTS Start the engine 15 the voltage on the voltmeter below 0 4 volt Yes gt GoTo 5 No Repair the Generator Ground circuit for high resistance Perform CHARGING VERIFICATION VER 3 Turn the ignition off then on With the DRB read and record the Battery Voltage With a voltmeter measure and record the voltage between the Battery terminals Compare the DRB Battery Voltage reading to the voltmeter reading Is the difference between the two readings less than 0 5 volt Yes gt GoTo 6 No gt GoTo 7 22 CHARGING P1682 CHARGING SYSTEM VOLTAGE TOO LOW DIESEL Continued ACTION APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list
134. NSOR SRC LOW EXCEEDED Continued ACTION APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 50 DRIVEABILITY DIESEL Symptom P0235 TURBOCHARGER BOOST SENSOR PLAUSIBILITY When Monitored and Set Condition P0235 TURBOCHARGER BOOST SENSOR PLAUSIBILITY When Monitored With the engine speed between 600 and 870 RPM Set Condition When the engine is idling the turbocharger boost pressure sensor input does not agree with the atmospheric pressure sensor input for at least 7 seconds POSSIBLE CAUSES INTERMITTENT CONDITION HIGH RESISTANCE
135. OAD TEST VERIFICATION VER 2 208 DRIVEABILITY DIESEL CHECKING THE VEHICLE SPEED SIGNAL Continued ACTION APPLICABILITY Turn the ignition off Disconnect the ECM harness connectors Disconnect the Vehicle Speed Sensor harness connector Note Check connectors Clean repair as necessary Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between ASD Diesel Power Relay cavities 30 and 87 in PDC Turn the ignition on Measure the voltage of the Vehide Speed Sensor Signal circuit Is the voltage above 5 5 volts Yes gt GoTo 8 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Repair the Vehide Speed Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the Vehicle Speed Sensor harness connector Disconnect the PCM C1 and C2 harness connectors Check connectors Clean repair as necessary Measure the resistance between the Vehicle Speed Sensor Signal circuit and the 5 volt Supply circuit Is the resistance above 100 kohms Yes GoTo 10 Repair the Vehicle Speed Sensor Signal circuit for a short to the 5 volt Supply circuit Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Vehicle Speed S
136. ONTROL MODULE CONTROL SHORTED TO GROUND LOW COOLANT LAMP CONTROL SHORTED TO VOLTAGE LOW COOLANT SWITCH SIGNAL CIRCUIT OPEN LOW COOLANT SWITCH SIGNAL CIRCUIT SHORTED TO GROUND LOW COOLANT LAMP CONTROL CIRCUIT SHORTED TO GROUND LOW COOLANT SWITCH OPEN LOW COOLANT SWITCH SIGNAL CIRCUIT SHORTED TO SWITCH GROUND LOW COOLANT LAMP CONTROL CIRCUIT OPEN LOW COOLANT SWITCH INTERNAL SHORT POWERTRAIN CONTROL MODULE SIGNAL OPEN LOW COOLANT LAMP BULB POWERTRAIN CONTROL MODULE SIGNAL SHORT TO GROUND MESSAGE CENTER ACTION NOTE Ensure the engine coolant is at the proper level before continuing Turn the ignition on and observe the Low Coolant Lamp Select the outcome of this operation Lamp on for 2 seconds then off GoTo 2 Lamp on continuously GoTo 7 Lamp inoperative GoTo 12 Turn the ignition off Remove the coolant from the coolant reservoir Turn the ignition on Did the Low Coolant Lamp illuminate and stay on Yes The Low Coolant Lamp System is working properly Perform ROAD TEST VERIFICATION VER 2 gt GoTo 3 192 APPLICABILITY All DIESEL THE LOW COOLANT LAMP OPERATION Continued ACTION APPLICABILITY Turn the ignition off Disconnect the PCM harness connectors Disconnect the Low Coolant Switch harness connector Measure the resistance between ground and the Low Coolant Switch Signal circuit Is the resistance above 100 kohms Yes gt GoTo 4
137. OP POWERSTAGE DEFECTIVE 148 P1685 VEHICLE THEFT ALARM IMMOBILIZER SIG 1 5 151 P1685 VEHICLE THEFT ALARM INVALID 151 P1690 FAN CONTROL OPEN CIRCUIT 154 P1690 FAN CONTROL SHORT CIRCUIT ode 156 P1703 BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT 158 P1725 INDUCTIVE AUX SPEED SENSOR DYN PLAUSIBILITY 162 P1725 INDUCTIVE AUX SPEED SENSOR OVERSPEED RECOGNITION 162 P1725 INDUCTIVE AUX SPEED SENSOR PLAUSIBILITY 162 P1725 INDUCTIVE AUX SPEED SENSOR STATIC PLAUSIBILITY 162 CHECKING THE AIG SYSIEM 00ccuesees ds oun sewed es bande ed sawed ex 165 CHECKING THE ACCELERATOR PEDAL POSITION SENSOR CALIBRATION 170 CHECKING THE CHECK ENGINE LAMP 171 CHECKING THE ECM AND PCM POWER AND GROUND CIRCUITS 174 CHECKING THE EGR SYSTEM rares goanian Pees weed Phe cee ee we 176 CHECKING THE ELECTRIC RADIATOR FAN OPERATION 177 CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR CALIBRATION 179 CHECKING THE ENGINE MECHANICAL 180 CHECKING THE FUEL COMPUTER Of see Seaweed 181 CHECKING THE FUEL HEATER OPERATION ve seu Sense doen tex 183 CHECKING THE FUEL INJECTION PUM
138. OR SHORTED TO GROUND TURBOCHARGER BOOST PRESSURE INTAKE AIR TEMPERATURE SENSOR BOOST PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND BOOST PRESSURE SENSOR SIGNAL AND GROUND CIRCUITS SHORTED TOGETHER BOOST PRESSURE SENSOR SIGNAL CIRCUIT OPEN ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB read the Turbocharger Boost Pressure Sensor voltage Is the voltage below 0 2 volt Yes gt GoTo 2 GoTo 8 Turn the ignition off Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Turn the ignition on Measure the voltage between ground and the 5 volt Supply circuit 15 the voltage above 4 9 volt Yes gt GoTo 3 No Repair the 5 volt Supply circuit for an open or short to ground Perform ROAD TEST VERIFICATION VER 2 56 DRIVEABILITY DIESEL P0235 TURBOCHARGER BOOST SENSOR SIGNAL LOW EXCEEDED Continued APPLICABILITY Turn the ignition off All Disconnect the Turbocharger Boost Sensor harness connector Turn the ignition on Connect a jumper wire between the Boost Pressure Sensor Signal and 5 volt Supply circuits With the DRB read the Turbocharger Boost Pressure Sensor voltage 15 the Boost Pressure Sensor voltage above 4 5 volts Yes Replace the Turbocharger Boost Pressure Intake Air Tempera ture Sensor Perform ROAD TEST VERIFICATION VER 2 GoTo 4 Turn the ignition off Disconnect the Turbocharg
139. P 185 CHECKING THE FUEL LEVEL GAUGE 186 CHECKING THE FUEL TEMPERATURE SENSOR CALIBRATION 188 CHECKING THE GLOW PLUG LAMP 189 CHECKING THE GLOW PLUG 24 55 65 bos 191 8 0 TABLE OF CONTENTS Continued CHECKING THE LOW COOLANT LAMP CHECKING THE OIL PRESSURE GAUGE CHECKING THE SPEEDOMETER OPERATION ved CHECKING THE TACHOMETER CHECKING THE TURBOCHARGER BOOST PRESSURE SENSOR CALIBRATION lt 2 0 05 Gee ween CHECKING THE TURBOCHARGER CHECKING THE VEHICLE SPEED SIGNAL 5 5655 CHECKING THE WATER IN FUEL LAMP HEATING amp A C P1655 AC CONTROL OPEN CIRCUIT DIESEL 1655 CONTROL SHORT CIRCUIT DIESEL 4 6555458 9 51 bene bebo SPEED CONTROL P1596 SPEED CONTROL SWITCH ALWAYS HIGH DIESEL P1597 SPEED CONTROL SWITCH ALWAYS LOW 5 CHECKING THE SPEED CONTROL OPERATION STARTING NO CRANK CONDMION ste oka eke sue NO START
140. Perform ROAD TEST VERIFICATION VER 2 No Repair the Glow Plug Lamp Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on With the DRB actuate the Glow Plug Lamp Does the Glow Plug Lamp cycle on and off Yes gt TheGlow PlugLamp System is operating properly Test complete Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 5 Turn the ignition off All Disconnect the PCM harness connectors Disconnect the ECM harness connectors Measure the resistance between ground and the Glow Plug Lamp Control circuit 189 DRIVEABILITY DIESEL CHECKING THE GLOW PLUG LAMP OPERATION Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Turn the ignition on a jumper wire between ground and the Glow Plug Lamp Control circuit in the ECM C1 harness connector Is the Glow Plug Lamp on Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 6 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Message Center harness connector Remove the ASD Diesel Power Relay from the PDC Connect jumper wire between ASD Diesel Power Relay connector cavities 30 87 in PDC Turn the ignition on Measure the voltage of the Glow Plug Lamp Control circuit 15 the voltage below 0 5 volt Yes gt GoT
141. Position Switch Sense circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Low Idle Position Switch Sense circuit 15 the resistance below 5 0 ohms Yes gt GoTo 6 No Repair the Low Idle Position Switch Sense circuit for an open Perform ROAD TEST VERIFICATION VER 2 117 DRIVEABILITY DIESEL P1515 ACCEL PEDAL SENSOR PLAUSIBILITY Continued APPLICABILITY Turn the ignition off All Disconnect the APP Sensor harness connector Disconnect the PCM harness connectors Measure the resistance of the Sensor Ground circuit between APP Sensor harness connector cavity 4 and the PCM harness connector 15 the resistance below 5 0 ohms Yes gt GoTo 7 No the PCM APP Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on With the observe the Low Idle Position Switch input Press and release the accelerator pedal several times while observing the 111 display NOTE The Low Idle Position Switch input should change from IDLE to ABOVE IDLE when pressing and releasing the accele
142. Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Repair the Sensor Ground circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Engine Oil Pressure Sensor harness connector Disconnect the PCM harness connectors Measure the resistance between ground and the 5 volt Supply circuit 15 the resistance above 100 kohms Yes gt GoTo 9 No Repair the 5 volt Supply circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 197 DIESEL CHECKING THE PRESSURE GAUGE OPERATION Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Engine Oil Pressure Sensor harness connector Disconnect the PCM harness connectors Measure the resistance between the 5 volt Supply circuit and the Sensor Ground circuit in the Engine Oil Pressure Sensor harness connector Is the resistance above 100 kohms Yes gt GoTo 10 Repair 5 volt Supply circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Engine Oil Pressure Sensor harness connector Disconnect the PCM harness connectors Measure the resistance of the 5 volt Supply circuit between the Engine Oil Pressure Sensor harness connector and the PCM harness connector 15 the resistance below 5 0 ohms Yes gt
143. Pump may also set this DTC All Turn the ignition on With the DRB erase ECM DTCs Turn the ignition off wait 10 seconds then attempt to start and idle the engine With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 5 Turn the ignition off Disconnect the Fuel Injection Pump harness connector Measure the resistance between ground and Fuel Injection Pump connector fuel pump side cavity 8 Is the resistance above 100 kohms Yes gt GoTo 3 No Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 100 DRIVEABILITY DIESEL P1220 FUEL QUANTITY ACTUATOR NEG GOV DEVIATION COLD Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Fuel Injection Pump harness connector Measure the resistance between ground and the Fuel Quantity Actuator Control circuit in ECM harness connector C2 cavities 59 66 and 80 Is the resistance above 100 kohms Yes gt GoTo 4 Repair the Fuel Quantity Actuator Control circuit for short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Fuel Injection Pump harness connector Measure the resistance between the following cavities in the Fuel Injection Pump connector fuel pump side Cavity 1 to cavities 4 5 6 7 8 9 and 10 Cavity 4 to cavities 5 6 7 8 9 and 10
144. RMITTENT CONDITION FUEL TEMPERATURE SENSOR FUEL INJ ECTION PUMP OPEN INTERNALLY FUEL TEMPERATURE SENSOR GROUND CIRCUIT OPEN FUEL TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN INTERNAL FUEL INJ ECTION PUMP TEST FUEL TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 7 Turn the ignition off Disconnect the Fuel Injection Pump harness connector Connect jumper wire between the Fuel Temperature Sensor Signal circuit and the Sensor Ground circuit in the Fuel Injection Pump harness connector vehicle side Turn the ignition on With the DRB erase ECM DTCs and then read ECM DTCs Did DTC P0180 FUEL TEMPERATURE SENSOR SRC LOW EXCEEDED set Yes Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 3 45 DRIVEABILITY DIESEL P0180 F VEL TEMPERATURE SENSOR SRC HIGH EXCEEDED Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Fuel Injection Pump harness connector Connect a jumper wire between ground and the Fuel Temperature Sensor Signal circuit in the Fuel Injection Pump harness connector vehicle side Turn the ignition on With the DRB erase ECM DTCs and then read ECM DT
145. RNINGS Before disconnecting any control module make sure the ignition is off Failure to so could damage the module When testing voltage or continuity at any control module use the terminal side not the wire end of the connector Do not probe a wire through the insulation this will damage it and eventually cause it to fail because of corrosion careful when performing electrical tests so as to prevent accidental shorting of terminals Such mistakes can damage fuses or components Also a second code could be set making diagnosis of the original problem more difficult 4 3 2 ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition CAUTION BEFORE ROAD TESTING A VEHICLE BE SURE THAT ALL COMPONENTS ARE REASSEMBLED DURING THE TEST DRIVE DO NOT TRY TO READ THE SCREEN WHILE MOTION DO NOT HANG THE FROM THE REAR VIEW MIRROR OR OPERATE IT YOURSELF HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII 5 0 REQUIRED TOOLS AND EQUIPMENT ammeter DRBIII diagnostic read out box scan tool high impedance 12 volt test light jumper wires and probes ohmmeter vacuum gauge voltmeter GENERAL INFORMATION 6 0 GLOSSARY OF TERMS backfire popback cuts out misses DLC detona tion pre ignition ECM ECT EGR
146. ROAD TEST VERIFICATION VER 2 No gt GoTo 2 Check the wastegate actuator supply hose for loose connection damage restriction Are any of these conditions evident Yes Repair or replace as necessary Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 3 Disconnect the Wastegate Actuator Supply Hose from the intake manifold Using an air pressure regulator connect an air hose to the disconnected end of the Wastegate Actuator Supply Hose Start at 0 kPa 0 PSI and slowly increase air pressure to 310 kPa 45 PSI while monitoring the Wastegate Actuator Arm NOTE The Wastegate Actuator Arm should remain closed until air pressure reaches 117 138 kPa 17 20 PSI and fully open when the air pressure reaches 234 276 kPa 34 40 PSI Did the Wastegate Actuator unseat and fully open as described Yes gt GoTo 4 No gt GoTo 5 205 All DRIVEABILITY DIESEL CHECKING THE TURBOCHARGER OPERATION Continued APPLICABILITY Connect an air pressure gauge in line with the Wastegate Actuator Supply Hose All NOTE Air pressure gauge must be rated above 276 kPa 40 PSI NOTE The vehicle must be on flat level ground to perform this test Failure to drive vehicle on flat level ground could result in incorrect boost pressure readings NOTE FIRST GEAR The following numbers are a comparison of Boost Pressure and Engine Speed PSI RPM for the First Gear test 21 kPa 3 PSI 1500rpm 28 kPa 4 PSI 20
147. ROL MODULE INTERMITTENT CONDITION ENGINE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO GROUND ENGINE SPEED SENSOR CIRCUITS SHORTED TOGETHER ENGINE SPEED SENSOR SIGNAL CIRCUIT OPEN ENGINE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE ENGINE SPEED SENSOR ACTION APPLICABILITY Attempt to start the engine All Did the engine start Yes gt GoTo 2 No GoTo 3 84 DRIVEABILITY DIESEL P0725 E NGINE SPEED SENSOR DYN PLAUSIBILITY Continued APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete Turn the ignition off All Disconnect t
148. Repair the Engine Speed Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 NOTE Ensure the ECM and Engine Speed Sensor harness connectors are connected Connect by back probing a voltmeter capable of reading frequency to ECM harness connector C2 cavity 67 Crank the engine while monitoring the voltmeter Is the frequency between 16 and 20 Hz at 270 300 cranking RPM Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace the Engine Speed Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 86 DIESEL Symptom P0725 E NGINE SPEED SENSOR OVERSPEED RECOGNITION When Monitored and Set Condition 725 SPEED SENSOR OVERSPEED RECOGNITION When Monitored With the engine running Set Condition The engine speed sensor signal indicates engine speed is above 5100 RPM for at least 500 milliseconds NOTE Engine damage is possible when the engine speed exceeds 5100 RPM POSSIBLE CAUSES CHECK FOR OTHER DTCS ENGINE CONTROL MODULE REPLACE THE ENGINE SPEED SENSOR INTERMITTENT CONDITION ACTION APPLICABILITY CAUTION Engine damage is possible when engine speed exceeds 5100 All RPM NOTE This DTC indicates the Engine Speed Sensor has seen an engine speed above 5100 RPM Turn the ignition on With the DRB check for other Eng
149. SIGNAL Continued ACTION APPLICABILITY Turn the ignition off Remove the Vehide Speed Sensor Inspect the Speedometer Pinion and drive teeth on the Output Shaft located in the transmission Are both components OK Yes gt GoTo 4 No Repair or replace the Speedometer Pinion or internal components as necessary in accordance with the Service nformation Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the Vehicle Speed Sensor harness connector Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the 5 volt Supply circuit in the Vehicle Speed Sensor harness connector 15 the voltage between 4 8 and 5 5 volts Yes gt GoTo 5 Above GoTo 16 Below GoTo 18 Turn the ignition off Disconnect the Vehicle Speed Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Vehicle Speed Sensor Signal circuit Is the voltage above 5 5 volts Yes gt GoTo 6 No gt GoTo 9 Turn the ignition off Disconnect the PCM harness connectors Disconnect the Vehicle Speed Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Vehicle Speed Sensor Signal circuit 15 the voltage above 5 5 volts Yes gt GoTo 7 No Replace and program the Powertrain Control Module in accor dance with the Service Information Perform R
150. ST SENSOR SUPPLY HIGH EXCEEDED 59 P0235 TURBOCHARGER BOOST SENSOR SUPPLY LOW EXCEEDED 61 PO400 EGR OPEN CIRCUIT 222222222 2 63 0400 SHORT 22 65 P0460 FUEL LEVEL UNIT NO CHANGE OVER 8 67 P0462 FUEL LEVEL SENDING UNIT VOLTS TOO 69 P0463 FUEL LEVEL SENDING UNIT VOLTS 71 0500 SPEED SENSOR FREQUENCY TOO HIGH 73 500 SPEED SENSOR 73 500 SPEED SENSOR SRC HIGH EXCEEDED 73 P0522 OlL PRESSURE VOLTAGE LOW 79 523 PRESSURE VOLTAGE 81 0725 SPEED SENSOR DYN 84 0725 SPEED SENSOR STATIC PLAUSIBILITY 84 0725 SPEED SENSOR OVERSPEED RECOGNITION 87 P1105 ATMOSPHERE PRESSURE SENSOR SRC HIGH EXCEEDED 89 P1105 ATMOSPHERE PRESSURE SENSOR SRC LOW EXCEEDED 89 P1610 REGULATOR LOWER REGULATOR LIMIT 89 P1610 REGULATOR UPPER REGULATOR 89 P1615 MICROCONTROLLER GATE ARRAY 89
151. Set Condition The voltage the ECM engine coolant temperature sensor signal circuit is above 4 9 volts for more than 3 seconds POSSIBLE CAUSES INTERMITTENT CONDITION ECM ECT SENSOR GROUND CIRCUIT OPEN ECM ECT SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE ECM ECT SENSOR ECM ECT SENSOR SIGNAL CIRCUIT OPEN ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB monitor the ECM Engine Coolant Temperature Sensor voltage Is the ECM ECT Sensor voltage above 4 5 volts Yes gt GoTo 2 gt GoTo 7 Turn the ignition off Disconnect the ECM ECT Sensor harness connector Turn the ignition on Measure the voltage on the ECM ECT Sensor Signal circuit 15 the voltage above 5 5 volts Yes Repair the ECM ECT Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No GoTo 3 Turn the ignition off Disconnect the ECM ECT Sensor harness connector Connect a jumper wire between the ECM ECT Sensor harness connector cavities Turn the ignition on With the DRB read the ECM ECT Sensor voltage 15 the voltage below 1 0 volt Yes Replace the ECM ECT Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 4 37 DRIVEABILITY DIESEL 115 OF ENGINE COOLANT SRC HIGH EXCEEDED Continued ACTION APPLICABILITY Turn the ignition off Disconnect the ECM ECT Sensor harness connector
152. TARTING NO START CONDITION Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Fuel Injection Pump 10 way harness connector Measure the resistance between cavity 8 and cavity 9 of the Fuel Injection Pump 10 way harness connector Is the resistance between 0 7 and 1 6 ohms Yes gt GoTo 8 Replace the Fuel Injection Pump assembly Perform NO START VERIFICATION VER 1 Turn the ignition off Disconnect the ECM harness connector Remove the ASD Relay from the PDC Connect a jumper wire between ASD Relay connector cavity 30 and cavity 87 in the PDC Turn the ignition on Measure the voltage of the Fuel Quantity Actuator circuit at ECM harness connector C2 cavity 59 15 the voltage above 1 0 volt Yes Repair the Fuel Quantity Actuator circuit for a short to voltage Perform NO START VERIFICATION VER 1 No gt GoTo 9 Inspect and fuel system lines for restrictions leaks or other problems 15 there any evidence of problems Yes Repair as necessary Perform NO START VERIFICATION VER 1 gt GoTo 10 Refer to the Service Information and perform the fuel pressure test 15 the fuel pressure within specification Yes gt GoTo 11 No Check the Fuel Injection Pump drive If the drive is working properly replace the Fuel Injection Pump Perform NO START VERIFICATION VER 1 Refer to the Service Information and check the Fuel Injection Pump Timing 15 the Fuel
153. TC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 83 DIESEL Symptom List P0725 E NGINE SPEED SENSOR DYN PLAUSIBILITY 725 SPEED SENSOR STATIC PLAUSIBILITY Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be PO725 ENGINE SPEED SENSOR DYN PLAUSIBILITY When Monitored and Set Condition 0725 SPEED SENSOR DYN PLAUSIBILITY When Monitored The engine speed is above 790 RPM Set Condition TheECM detects a change in engine speed that has occurred more rapidly than the engine is capable of changing speed 0725 SPEED SENSOR STATIC PLAUSIBILITY When Monitored With the engine speed above 700 RPM Set Condition The engine speed sensor signal indicates engine speed below 75 RPM the needle movement sensor signal injector 1 indicates engine speed above 700 RPM POSSIBLE CAUSES ENGINE CONT
154. TER APPLICABILITY Turn the ignition on All With the DRB check for additional DTCs Are other DTCs present Yes Refer tothe Symptom List for diagnosis of the other DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 2 Turn the ignition on With the DRB actuate the Glow Plug Lamp 15 the Glow Plug Lamp on and off Yes gt GoTo 3 No gt GoTo 4 143 DRIVEABILITY DIESEL P1645 GLOW DISPLAY SHORT CIRCUIT Continued APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test C
155. THER DTCS POWERTRAIN CONTROL MODULE POWERTRAIN CONTROL MODULE SENSOR GROUND SHORTED TO VOLTAGE INSTRUMENT CLUSTER CHECK ENGINE OIL PRESSURE WITH EXTERNAL GAUGE 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND 5 VOLT SUPPLY CIRCUIT SHORTED TO SENSOR GROUND 5 VOLT SUPPLY CIRCUIT OPEN ENGINE OIL PRESSURE SENSOR POWERTRAIN CONTROL MODULE 5 VOLT SUPPLY CIRCUIT LOW SENSOR GROUND CIRCUIT SHORTED TO VOLTAGE ACTION APPLICABILITY Turn the ignition on All With the DRB check for Oil Pressure Sensor related DTCs Are any Oil Pressure Sensor DTCs present Yes Refer tosymptom list for problems related to Pressure Sensor DTCs Perform ROAD TEST VERIFICATION VER 2 GoTo 2 CAUTION Ensure the engine oil is at the proper level before proceeding Start the engine With the DRB in Sensors read the Oil Pressure Sensor voltage 15 the voltage between 1 0 and 4 0 volts Yes gt GoTo 3 gt GoTo 4 Turn the ignition off wait 30 seconds then turn the ignition on With the DRB select BODY from the SYSTEM menu then select ELECTRO MECH CLUSTER MIC ACTUATOR TESTS and SELF TEST Perform the Instrument Cluster Self Test Observe the Oil Pressure Gauge NOTE The Oil Pressure Gauge should stop at 0 Bar 0 PSI 3 0 Bar 40 PSI 5 0 Bar 80 PSI and 8 3 Bar 120 PSI Did the gauge reach the proper calibration points Yes gt Replace and program the Powertrain Control Module in accor dance with the Service Information
156. TROL MODULE SHORTED TO VOLTAGE VEHICLE SPEED SENSOR SIGNAL CIRCUIT OPEN 5 VOLT SUPPLY CIRCUIT SHORTED TO SENSOR GROUND 73 DRIVEABILITY DIESEL 5 SPEED SENSOR PEC FREQUENCY TOO HIGH Continued POSSIBLE CAUSES VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO GROUND VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE POWERTRAIN CONTROL MODULE 5 VOLT SUPPLY CIRCUIT LOW SENSOR GROUND CIRCUIT OPEN VEHICLE SPEED SENSOR ENGINE CONTROL MODULE INTERNAL FAULT APPLICABILITY Turn the ignition on With the DRB erase ECM DTCs Test drive the vehicle With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 GoTo 21 Turn the ignition off Remove the Vehicle Speed Sensor Inspect the Speedometer Pinion and drive teeth on the Output Shaft located in the transmission Are both components OK Yes gt GoTo 3 No Repair or replace the Speedometer Pinion or internal components as necessary in accordance with the Service nformation Perform ROAD TEST VERIFICATION VER 2 15 the voltage between 4 8 and 5 5 volts Yes gt GoTo 4 Above GoTo 15 Below GoTo 17 Turn the ignition off Disconnect the Vehicle Speed Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Vehicle Speed Sensor Signal circuit 15 the voltage above 5 5 volts Yes gt GoTo 5 Turn the ignition off All Disco
157. TTENT CONDITION INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND TURBOCHARGER BOOST PRESSURE IAT SENSOR ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Monitor the DRB for ECM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 5 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Measure the resistance between ground and the Intake Air Temperature Sensor Signal circuit Is the resistance above 100 kohms Yes gt GoTo 3 No Repair the Intake Air Temperature Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Turbocharger Boost Sensor harness connector Turn the ignition on Monitor the DRB for ECM DTCs Does the DRB display P1110 AIR TEMP SENSOR SRC HIGH EXCEEDED Yes Replace the Turbocharger Boost Pressure Intake Air Tempera ture Sensor Perform ROAD TEST VERIFICATION VER 2 gt GoTo 4 93 DRIVEABILITY DIESEL P1110 AIR TEMP SENSOR SRC LOW EXCEEDED Continued ACTION APPLICABILITY If there are no possible causes remaining view repair All Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE
158. TY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 58 DIESEL Symptom P0235 TURBOCHARGER BOOST SENSOR SUPPLY HIGH EX CEEDED When Monitored and Set Condition P0235 TURBOCHARGER BOOST SENSOR SUPPLY HIGH EXCEEDED When Monitored With the ignition on Set Condition The turbocharger boost pressure sensor supply voltage exceeds 5 2 volts for at least 2 seconds POSSIBLE CAUSES INTERMITTENT CONDITION 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All
159. TY DIESEL Symptom CHECKING THE ACCELERATOR PEDAL POSITION SENSOR CALIBRATION POSSIBLE CAUSES APP SENSOR APP SENSOR IDLE APP SENSOR WOT ACTION APPLICABILITY NOTE Ensure the Accelerator pedal is free from any restriction or binding All before continuing Turn the ignition on While back probing measure the voltage of the APP Sensor Signal circuit at the ECM NOTE The accelerator pedal must be released for this step 15 the voltage below 1 0 volt Yes gt GoTo 2 No Replace theAccelerator Pedal Position Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on While back probing measure the voltage of the APP Sensor Signal circuit at the ECM Monitor the voltmeter while slowly pressing the accelerator pedal completely down Did the voltage increase smoothly with pedal travel Yes gt GoTo 3 No ReplacetheAccelerator Pedal Position Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on While back probing measure the voltage of the APP Sensor Signal circuit at the ECM Press the accelerator pedal completely down Is the voltage above 3 5 volts Yes gt Test Complete No Replace theAccelerator Pedal Position Sensor in accordance with the Service nformation Perform ROAD TEST VERIFICATION VER 2 170 DRIVEABILITY DIESEL Symptom CHECKING THE CHECK ENGINE
160. Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 138 DIESEL P1635 GLOW RELAY 1 CONTROLLER SHORT CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Install a substitute relay in place of the Glow Plug Relay Turn the ignition on With the DRB actuate the Glow Plug Relay Is the Glow Plug Relay dicking Yes Replace the Glow Plug Relay Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 4 Turn the ignition off Disconnect the ECM harness connector s Remove the Glow Plug Relay from the PDC Remove the ASD Diesel Power Relay from the PDC Connec a jumper wire between ASD Diesel Power Relay cavities 30 and 87 in PDC Turn the ignition on Measure the voltage of the Glow Plug Relay Control circuit Is the voltage above 1 0 volt Yes Repair the Glow Plug Relay Control circuit for short to voltage Perform ROAD TEST VERIFICATION VER 2 gt GoTo 5 If there no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service I
161. The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for chafed pierced pinched partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 94 DRIVEABILITY DIESEL Symptom P1201 NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED When Monitored and Set Condition P1201 NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED When Monitored With the ignition on Set Condition The ECM detects high voltage on the needle movement sensor signal circuit POSSIBLE CAUSES INTERMITTENT CONDITION NEEDLE MOVEMENT SENSOR GROUND CIRCUIT OPEN NEEDLE MOVEMENT SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE NEEDLE MOVEMENT SENSOR NEEDLE MOVEMENT SENSOR SIGNAL CIRCUIT OPEN ENGINE CONTROL MODULE APPLICABILITY Turn the igniti
162. TheECM detects excessive current draw on the electric vacuum modula tor control circuit POSSIBLE CAUSES INTERMITTENT CONDITION EGR SOLENOID EGR SOLENOID CONTROL SHORTED TO VOLTAGE ENGINE CONTROL MODULE INTERNAL ENGINE CONTROL MODULE INTERNAL SHORT TO VOLTAGE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Test drive the vehide and monitor the DRB for ECM DTCs Did this DTC reset Yes gt GoTo 2 No GoTo 5 Turn the ignition off Disconnect the EGR Solenoid harness connector Turn the ignition on With the DRB erase ECM DTCs Monitor the DRB for ECM DTCs Does the DRB display P0400 EGR OPEN CIRCUIT Yes Replace the EGR Solenoid Perform ROAD TEST VERIFICATION VER 2 No GoTo 3 Turn the ignition off Disconnect the EGR Solenoid harness connector Turn the ignition on Measure the voltage of the EGR Solenoid Control circuit Is the voltage below 0 5 volt Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 4 65 DRIVEABILITY DIESEL 0400 SHORT CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the EGR Solenoid harness connector Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ig
163. US CIRCUIT S OPEN FROM PCM TO SKIM LOSS OF SKIM COMMUNICATION ACTION APPLICABILITY Turn the ignition on All With the DRB III read PCM DTCs LOOK for P1686 Is the Starts Since Set counter for DTC P1686 displayed and equal to 0 Yes gt GoTo 2 No gt GoTo 4 Turn the ignition on With the DRB 111 attempt to communicate with the SKIM With the DRB IIl select Theft Alarm and read the SKIM DTCs NOTE This test will indicate if the Bus is operational from the DLC to the SKIM Can the DRB communicate with the SKIM Yes gt GoTo 3 gt Refer to the appropriate symptom the COMMUNICATION category Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the PCM harness connectors Disconnect the SKIM harness connector Measure the resistance of both CCD Bus circuits between the PCM and the SKIM Is the resistance below 5 0 ohms for each measurement Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the CCD Bus circuit s for an open Perform ROAD TEST VERIFICATION VER 2 27 COMMUNICATION P 1686 NO SKIM BUS MESSAGE RECEIVED Continued APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engin
164. VERIFICATION VER 2 Turn the ignition off Disconnect the Fuel Injection Pump harness connector Measure the resistance between ground and Fuel Injection Pump connector fuel pump side cavities 1 2 then 3 15 the resistance above 100 kohms for each measurement Yes gt GoTo 4 No Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Fuel Injection Pump harness connector Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage on ECM harness connector C2 cavity 56 Measure the voltage on ECM harness connector C2 cavity 57 Measure the voltage on ECM harness connector C2 cavity 58 Is the voltage above 0 5 volt for any of the measurements Yes gt Repair the Control Sleeve Position Sensor circuit s that mea sured above 0 5 volt for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 5 NOTE Remove the jumper wire Turn the ignition off Disconnect the Fuel Injection Pump harness connector Disconnect the ECM harness connectors Measure the resistance between ground and ECM harness connector C2 cavities 56 57 and 58 15 the resistance above 100 kohms for each of the measurements Yes gt GoTo 6 No Repair the Cont
165. XCEEDED set Yes Replace the Needle Movement Sensor in accordance with the Service nformation Perform ROAD TEST VERIFICATION VER 2 No GoTo 3 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Needle Movement Sensor harness connector Measure the resistance between ground and the Needle Movement Sensor Signal circuit 15 the resistance above 100 kohms Yes gt GoTo 4 No Repair the Needle Movement Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 98 DIESEL P1201 NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED Continued APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Needle Movement Sensor harness connector Measure the resistance between the Needle Movement Sensor Signal circuit and Sensor Ground circuit 15 the resistance above 100 kohms Yes gt GoTo 5 No Repair the Needle Movement Sensor Signal and Ground circuits for a short together Perform ROAD TEST VERIFICATION VER 2 there no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermi
166. Y DIESEL Symptom CHECKING THE VEHICLE SPEED SIGNAL POSSIBLE CAUSES VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND CHECK FOR VSS DTC POWERTRAIN CONTROL MODULE 5 VOLT SUPPLY HIGH POWERTRAIN CONTROL MODULE AFTER 5 VOLT SUPPLY SHORTED TO VOLTAGE REPAIR THE 5 VOLT SUPPLY CIRCUIT AND CHECK THE PCM 5 VOLT SUPPLY CIRCUIT OPEN POWERTRAIN CONTROL MODULE SHORTED TO VOLTAGE SPEEDOMETER PINION AND DRIVE TEETH DAMAGED VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO 5 VOLT SUPPLY CIRCUIT 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND ENGINE CONTROL MODULE SHORTED TO VOLTAGE VEHICLE SPEED SENSOR SIGNAL CIRCUIT OPEN 5 VOLT SUPPLY CIRCUIT SHORTED TO SENSOR GROUND VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO GROUND VEHICLE SPEED SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE POWERTRAIN CONTROL MODULE 5 VOLT SUPPLY CIRCUIT LOW SENSOR GROUND CIRCUIT OPEN VEHICLE SPEED SENSOR ENGINE CONTROL MODULE INTERNAL FAULT ACTION APPLICABILITY Turn the ignition on All With the DRB select Engine J TEC then Sensors Note the Vehicle Speed reading the while test driving the vehicle Does the DRB display an accurate vehicle speed reading Yes Test Complete No GoTo 2 Turn the ignition on With the DRB read ECM DTCs Are any VSS DTCs present Yes Refer to symptom list for problems related to VSS DTCs Perform ROAD TEST VERIFICATION VER 2 No GoTo 3 207 DRIVEABILITY DIESEL CHECKING THE VEHICLE SPEED
167. Yes gt GoTo 9 No Repair the Generator Field Driver circuit for a short to voltage Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the PCM harness connectors Turn the ignition on Measure the voltage of the ASD Relay Output circuit in PCM harness connector C3 cavity 12 15 the voltage above 10 0 volts Yes gt GoTo 10 No Repair the ASD Relay Output circuit for an open Perform CHARGING VERIFICATION VER 3 23 CHARGING P1682 CHARGING SYSTEM VOLTAGE TOO LOW DIESEL Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the PCM harness connectors Disconnect the Generator Field harness connector Measure the resistance of the Generator Field Driver circuit Is the resistance below 5 0 ohms Yes gt GoTo 11 No Repair the Generator Field Driver circuit for an open Perform CHARGING VERIFICATION VER 3 If there are no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform CHARGING VERIFICATION VER 3 24 COMMUNICATION Symptom P 1685 INVALID SKIM KEY When Monitored and Set Condition P 1685 INVALID SKIM KEY When Monitored With the ignition on Set Condition The PCM does not receive a valid key message from the SKIM POSSIBLE CAUSES INCORRECT VIN IN PCM INVALID SKIM KEY NOT PRESENT NO COMMUNICATION WITH SKIM NO VIN PROGRAM
168. ally inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 90 DRIVEABILITY DIESEL Symptom P1110 AIR TEMP SENSOR SRC HIGH EXCEEDED When Monitored and Set Condition P1110 AIR TEMP SENSOR SRC HIGH EXCEEDED When Monitored With the ignition on Set Condition Theintake air temperature sensor signal goes above 4 7 volts for at least 2 seconds POSSIBLE CAUSES INTERMITTENT CONDITION INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE INTAKE AIR TEMP SENSOR GROUND CIRCUIT OPEN INTAKE AIR TEMP SENSOR SIGNAL CIRCUIT OPEN TURBOCHARGER BOOST PRESSURE IAT SENSOR ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Monitor the DRB for ECM DTCs Did this DTC reset Yes gt GoTo 2 gt GoTo 6 Turn the ignition off Disconnect the Turbocharger Boost Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage the IAT Sensor Signal circuit Is the voltage below 1 0 volt Yes gt GoTo 3 No Repair the Intake Air Temperature Sensor Signal circuit
169. amp Switch harness connector Using a 12 volt test light connected to ground check the Fused B circuit Does the test light illuminate brightly Yes gt GoTo 12 Repair the Brake Lamp Switch Fused B circuit for an open Perform ROAD TEST VERIFICATION VER 2 Disconnect the Brake Lamp Switch harness connector Turn the ignition on While monitoring the PRIM BRAKE SWITCH status with the DRB connect a jumper wire between the Primary Brake Switch Signal circuit and the Fused circuit Does the DRB display change from RELEASED to PRESSED Yes Adjust or replace the Brake Lamp Switch in accordance with the Service nformation Perform ROAD TEST VERIFICATION VER 2 GoTo 13 If there are no possible causes remaining view repair All Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 160 DIESEL 1703 SIGNAL PLAUS WITH REDUNDANT CONTACT Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Brake Lamp Switch harness connector Disconnect the ECM harness connectors Turn the ignition on Measure the voltage between the Primary Brake Switch Signal circuit and ground 15 the voltage above 1 0 volt Yes Repair the Primary Brake Switch Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 14 Turn the ignition
170. ange and or a DTC to set Review the DTC When Monitored Set Conditions If possible try toduplicatethe conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 216 1655 CONTROL SHORT CIRCUIT DIESEL Continued APPLICABILITY Turn the ignition off All Install a substitute relay in place of the A C Compressor Clutch Relay Turn the ignition on With the DRB actuate the A C Compressor Clutch Relay Is the A C Compressor Clutch clicking Yes Replace the A C Compressor Clutch Relay Perform ROAD TEST VERIFICATION VER 2 gt GoTo 4 Turn the ignition off Disconnect the ECM harness connector s Remove the A C Compressor Clutch Relay from the PDC Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between ASD Diesel Power Relay cavities 30 and 87 in PDC Turn the ignition on Measure the voltage of the A C Compressor Clutch Relay Control circuit 15 the voltage above 1 0 volt Yes Repair the A C Compressor Clutch Relay Control
171. apping the jumper wire Yes gt GoTo 2 No GoTo 8 116 DIESEL P1515 ACCEL PEDAL SENSOR PLAUSIBILITY Continued APPLICABILITY Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 ASD Diesel Power Relay connector Turn the ignition on Measure the voltage of the Low Idle Position Switch Sense circuit 15 the voltage above 1 0 volt Yes Repair the Low Idle Position Switch Sense circuit for short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 3 Turn the ignition off All Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between the Low Idle Position Switch Sense circuit and the Sensor Ground circuits at cavity 4 and 8 of the APP Sensor harness connector 15 the resistance above 100 kohms for both measurements Yes gt GoTo 4 No Repair the Low Idle Position Switch Sense circuit and Sensor Ground circuit for a short together Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the Low Idle Position Switch Sense circuit 15 the resistance above 100 kohms Yes gt GoTo 5 No Repair the Low Idle
172. are sent to the SKIM with the correct message format but with invalid data TRANSPONDER ID MISMATCH When Monitored At ignition on and during Key Programming Mode Set Condition When the transponder ID read by the SKIM does not match any of the transponder D s stored in the 5 5 memory TRANSPONDER RESPONSE MISMATCH When Monitored At ignition on and during Key Programming Mode Set Condition When thetransponder s crypto algorithm result fails to match the SKIM s result POSSIBLE CAUSES CHECKING MULTIPLE KEY OPERATION SKIM INTERMITTENT WIRING HARNESS PROBLEM REPLACE IGNITION KEY 240 VEHICLE THEFT SECURITY TRANSPONDER COMMUNICATION FAILURE Continued APPLICABILITY With the III read and record the SKIM DTC s With the III erase the SKIM DTC s NOTE Perform the following test several times to ensure the DTC is current Turn the ignition off Wait 10 seconds Turn the ignition on With the III read the SKIM DTC s Does the DRB display the DTC that was previously erased Yes GoTo 2 gt GoTo 7 Are there multiple vehicle ignition keys available Yes gt GoTo 3 gt GoTo 4 NOTE Perform the following steps using one of the vehicle ignition keys All When finished repeat the procedure using each of the other vehicle keys one at a time With the III erase the SKIM Turn the ignition off Wait 10 seconds Turn the ignitio
173. arious input signals Ignition Switch On Engine Off Mode When the ignition switch activates the diesel fuel injection system the following actions occur 1 The ECM determines atmospheric air pressure from the atmospheric pressure sensor located in the ECM 2 The ECM energizes the fuel quantity actuator and the fuel shutdown solenoid if no faults are present If the engine is not started within 5 seconds of ignition on the ECM deactivates the fuel quantity actuator and the fuel shutdown solenoid to prevent overheating Engine Start up Mode The ECM uses the engine temperature sensor fuel temperature sen sor atmospheric pressure sensor intake air temper ature sensor and the engine speed sensor to deter mine fuel delivery during this mode Normal Driving Modes Engine idle warm up acceleration deceleration and wide open throttle modes are all controlled based on the sensor inputs to the ECM and are modified based on engine temperature boost pressure intake air tempera ture and engine speed Overheat Protection Mode If engine temper ature becomes too hot the ECM limits fuel quantity for engine protection Limp In Modes The ECM operates limp in mode when certain system faults are detected The ECM operates in one of the following modes based on the type and severity of the fault 1 10 torque reduction 2 50 torque reduction 3 Engine speed set to 1100 rpm After Run When fused ignition switch
174. at set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete Turn the ignition off All Disconnect the Brake Lamp Switch harness connector Turn the ignition on Measure the voltage between the Secondary Brake Switch Signal circuit and ground 15 the voltage above 9 0 volts Yes gt GoTo 5 No GoTo 8 Disconnect the Brake Lamp Switch harness connector Turn the ignition on While monitoring the SEC BRAKE SWITCH status with the DRB connect a jumper wire between ground and the Secondary Brake Switch Signal circuit Does the DRB display change from PRESSED to RELEASED Yes Adjust or replace the Brake Lamp Switch in accordance with the Service
175. ce the Glow Plug Lamp bulb Perform ROAD TEST VERIFICATION VER 2 145 DIESEL Symptom P1660 RE DUNDANT EMERG STOP PLAUSIBILITY IN AFTER RUN When Monitored and Set Condition P1660 REDUNDANT EMERG STOP PLAUSIBILITY IN AFTER RUN When Monitored During after run when the engine speed is below 800 RPM and vehicle speed is below 2 5 MPH Set Condition The fuel shutdown solenoid is turned off and engine speed does not drop below 500 RPM POSSIBLE CAUSES INTERMITTENT CONDITION FUEL SHUTDOWN SOLENOID CONTROL CIRCUIT SHORTED TO VOLTAGE FUEL SHUTDOWN SOLENOID FUEL INJ ECTION PUMP SHORTED INTERNALLY INTERNAL FUEL INJ ECTION PUMP TEST ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Start and stop the engine several times pausing for 10 seconds at key off each time Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 5 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Fuel Injection Pump harness connector Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage on the Fuel Shutdown Solenoid Control circuit 15 the voltage below 0 5 volt Yes gt GoTo 3 No Repair the Fuel Shutdown Solenoid Control circuit for a short to voltag
176. circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No GoTo 5 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 217 SPEED CONTROL Symptom P1596 SPEED CONTROL SWITCH ALWAYS HIGH DIESEL When Monitored and Set Condition P1596 SPEED CONTROL SWITCH ALWAYS HIGH DIESEL When Monitored With the ignition on and battery voltage above 10 4 volts Set Condition The PCM detects voltage above 4 8 volts on the S C switch signal circuit for at least 2 minutes POSSIBLE CAUSES CHECKING S C ON OFF SET SWITCH S C SIGNAL CIRCUIT OPEN PCM S C SIGNAL CIRCUIT SHORTED TO VOLTAGE PCM SENSOR GROUND OPEN S C ON OFF SET SWITCH SIGNAL CIRCUIT OPEN S C SWITCH SIGNAL CIRCUIT SHORTED TO VOLTAGE SENSOR GROUND OPEN ACTION APPLICABILITY Turn the ignition off All Disconnect the S C ON OFF SET button harness connector Turn the ignition on Measure the voltage of the S C Switch Signal circuit Select the appropriate voltage reading Below 4 5 volts GoTo 2 Between 4 5 and 5 5 volts GoTo 3 Above 5 5 volts GoTo 5 Turn the ignition off Disconnect the S C ON OFF SET Switch harness connector Disconnect the PCM harness connectors Measure the resistance of the S C Switch Signal circuit 15 the resistance below 10 0 ohms Yes gt Replace and progra
177. connectors Disconnect the ECM ECT Sensor harness connector Measure the resistance between ground and the ECM ECT Sensor Signal circuit 15 the resistance above 100 kohms Yes gt GoTo 4 No Repair the ECM ECT Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 39 DRIVEABILITY DIESEL 115 OF ENGINE COOLANT SRC LOW EXCEEDED Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the ECM ECT Sensor harness connector Measure the resistance between the ECM ECT Sensor Signal circuit and Sensor Ground circuit Is the resistance above 100 kohms Yes gt GoTo 5 Repair the ECM ECT Sensor Signal and Ground circuits for a short together Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Condi
178. connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 130 DIESEL Symptom P1630 SOLENOID VALVE CONTROLLER OPEN CIRCUIT When Monitored and Set Condition P1630 SOLENOID VALVE CONTROLLER OPEN CIRCUIT When Monitored With the ignition on Set Condition ECM detects an open or short to ground the fuel timing solenoid control circuit POSSIBLE CAUSES FUEL INJ ECTION PUMP INTERMITTENT CONDITION FUEL TIMING SOLENOID CONTROL CIRCUIT SHORTED TO GROUND FUSED ASD RELAY OUTPUT CIRCUIT SHORTED TO GROUND FUSED ASD RELAY OUTPUT OPEN FUEL TIMING SOLENOID CONTROL CIRCUIT OPEN FUEL TIMING SOLENOID FUEL INJ ECTION PUMP INTERNAL INTERNAL FUEL INJ ECTION PUMP TEST ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Turn the ignition off wait 30 seconds then turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 gt GoTo 9 Turn the ignition off Disconnect the Fuel Injection Pump harness connector Turn the ignition on Measure the voltage on the Fused ASD Relay Output circuit 15 the voltage above 10 5 volts Yes gt GoTo 3 gt GoTo 7 131 DRIVEABILITY DIESEL P1630 SOLENOID VALVE CONTROLLER OPEN CIRCUIT Continued ACTION
179. data link connector cavity 16 minimum of 11 volts at DLC cavity 16 is required to adequately power the DRBIII Check for proper ground connection at DLC cavities 4 and 5 If all connections are proper between the and the vehicle or other devices and the vehicle battery is fully charged an inoperative may result of a faulty cable or vehicle wiring For a blank screen refer to the appropriate body diagnostics manual 3 5 2 DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display Adjust the contrast to compensate for this condition DISPLAY REPLACEABLE LENS ENTER KEYS LEDs CONTRAST Oe D with YES key BACK LIGHTING with YES key KEYPAD SHIFT KEY LED 80b57566 GENERAL INFORMATION 4 0 DISCLAIMERS SAFETY WARNINGS 4 1 DISCLAIMERS All information illustrations and specifications contained in this manual are based on the latest information available at the time of publication The right is reserved to make changes at any time without notice 4 2 SAFETY 4 2 1 TECHNICIAN SAFETY INFORMATION WARNING ENGINES PRODUCE CARBON MONOXIDE THAT IS ODORLESS CAUSES SLOWER REACTION TIME AND CAN LEAD TO SERIOUS INJURY WHEN THE ENGINE IS OPERATING KEEP SERVICE AREAS WELL VENTILATED OR ATTACH THE VEHICLE EXHAUST SYSTEM TO THE SHOP EXHAUST REMOVAL SYSTEM Set the parking brake and block the wheels before testin
180. dition P1687 NO CLUSTER BUS MESSAGE DIESEL When Monitored With the ignition on Set Condition ThePCM has not received an expected Cluster Status Bus message from the instrument cluster within the last 20 seconds POSSIBLE CAUSES CCD BUS CIRCUIT S OPEN CHECKING CLUSTER COMMUNICATION PCM INTERNAL FAILURE INTERMITTENT CONDITION ACTION APPLICABILITY Turn the ignition on All With the DRB III erase PCM DTCs Cycle the ignition key on and off several times leaving the key on for at least 10 seconds at a time With the DRB III read PCM DTCs Did this DTC reset Yes gt GoTo 2 gt GoTo 4 Turn the ignition on With the DRB III attempt to communicate with the instrument duster Can the DRB communicate with the instrument cluster Yes gt GoTo 3 No gt Refer COMMUNICATION for the related symptom s Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the PCM harness connectors Disconnect the instrument cluster harness connector Measure the resistance of both CCD Bus circuits between the PCM and the instrument cluster Is the resistance below 5 0 ohms for both measurements Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the CCD Bus circuit s that measured above 5 0 ohms for an open Perform ROAD TEST VERIFICATION VER 2 30 COMMUNICATION P1687 NO CLUSTER
181. dle Movement Sensor harness connector Connect a jumper wire between ground and the Needle Movement Sensor Signal circuit Turn the ignition on With the DRB read ECM DTCs Did DTC P1201 NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED set Yes Repair the Needle Movement Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 No GoTo 5 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Needle Movement Sensor harness connector Measure the resistance of the Needle Movement Sensor Signal circuit 15 the resistance below 5 0 ohms Yes gt GoTo 6 No Repair the Needle Movement Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 96 DRIVEABILITY DIESEL P1201 NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED Continued ACTION APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Condit
182. e Perform ROAD TEST VERIFICATION VER 2 NOTE Remove the jumper wire from the ASD Diesel Power Relay connec tor reinstall the ASD Diesel Power Relay in the PDC and reconnect the ECM harness connectors 146 DRIVEABILITY DIESEL P1660 REDUNDANT EMERG STOP PLAUSIBILITY IN AFTER RUN Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Fuel Injection Pump harness connector Turn the ignition on With the DRB actuate the Fuel Shutdown Solenoid Measure the voltage on the Fuel Shutdown Solenoid Control circuit Does the voltage cycle from B to below 1 0 volt Yes Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 4 Disconnect the Fuel Injection Pump harness connector Measure the resistance between the following cavities in the Fuel Injection Pump connector fuel pump side Cavity 1 to cavities 4 5 6 7 8 9 and 10 Cavity 4 to cavities 5 6 7 8 9 and 10 Cavity 5 to cavities 6 7 8 and 9 Cavity 7 to cavities 6 8 9 and 10 Cavity 8 to cavities 6 and 10 NOTE The resistance should be above 100 ohms for all measurements 15 the resistance above 100 ohms for each of the measurements Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace the Fuel Injection Pump in accordance with the Service Information
183. e DTC Yes gt Replace and program the Powertrain Control Module in accor dance with the Service Information Perform SKIS VERIFICATION No Therepair is complete Perform SKIS VERIFICATION Turn the ignition off Note Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any Technical Service Bulletins TSB that may apply Were any problems found Yes Repair wiring harness connectors as necessary Perform SKIS VERIFICATION No Test Complete 239 VEHICLE THEFT SECURITY Symptom List TRANSPONDER COMMUNICATION FAILURE TRANSPONDER CYCLIC REDUNDANCY CHECK CRC FAILURE TRANSPONDER ID MISMATCH TRANSPONDER RESPONSE MISMATCH Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be TRANSPONDER COMMUNICA TION FAILURE When Monitored and Set Condition TRANSPONDER COMMUNICATION FAILURE When Monitored At ignition on and during Key Programming Mode Set Condition When the SKIM does not receive a transponder response after 8 consec utive transponder read attempts within 2 0 seconds TRANSPONDER CYCLIC REDUNDANCY CHECK CRC FAILURE When Monitored At ignition on and during Key Programming Mode Set Condition When 5 consecutive transponder signal transmissions
184. e Fuel Heater Relay Using a 12 volt test light connected to ground check the Fused B circuit Is the test light on Yes gt GoTo 6 No Repair the Fused B circuit for an open Perform ROAD TEST VERIFICATION VER 2 circuit Is the test light on Yes gt GoTo 7 No Repair the Ignition Switch Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove the Fuel Heater Relay Turn the ignition on Using a 12 volt test light connected to 12 volts check the Ground circuit at the Fuel Heater Relay connector Is the test light on Yes Repair the Fuel Heater Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 No the Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Remove the Fuel Heater Relay Turn the ignition on Using 12 volt test light connected to ground check the Switch Output 184 DRIVEABILITY DIESEL Symptom CHECKING THE FUEL INJ ECTION PUMP POSSIBLE CAUSES CHECKING THE FUEL INJ ECTION PUMP APPLICABILITY NOTE This test should be performed before replacing the ECM during fault All code diagnostics NOTE This test checks for shorted circuits internal to the Fuel Injection Pump assembly Turn the ignition off Disconnect the Fuel Injection Pump 10 way harness connector NOTE The following resistance measurements are performed on the
185. e and program the Sentry Key Immobilizer Module in accordance with the Service Information Turn the ignition on With the DRB III erase all DTCs Attempt to start and idle the engine With the III read the PCM DTCs Does the DRB III display this code Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Test Complete NOTE This DTC could have been set if the SKIM harness connector was disconnected or if the SKIM was replaced recently NOTE All keys that the customer uses for this vehicle must be tested to verify they are operating properly Verify the correct VIN is programmed in both the PCM and SKIM modules Turn the ignition off With the next customer key turn the ignition key on and crank the engine to start With the III read the PCM DTCs Look for P1685 15 the Starts Since Set Counter for DTC P1685 displayed and equal to 0 Yes Replace the Ignition Key Perform ROAD TEST VERIFICATION VER 2 No Test Complete NOTE If this DTC can not be reset it may have been an actual theft attempt 26 COMMUNICATION Symptom P 1686 NO SKIM BUS MESSAGE RECEIVED When Monitored and Set Condition P 1686 NO SKIM BUS MESSAGE RECEIVED When Monitored With the ignition on Set Condition The PCM does not receive a CCD Bus message from the SKIM when expected POSSIBLE CAUSES PCM INTERMITTENT CONDITION CCD B
186. e below 0 5 volt Yes gt GoTo 6 No Repair the ASD Diesel Power Relay Output circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 127 DRIVEABILITY DIESEL P1625 ASD DIESEL POWER RELAY SHUTS OFF TOO LATE Continued ACTION APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 128 DRIVEABILITY DIESEL Sympto
187. e between ground and the Glow Plug Relay Control circuit 15 the resistance above 100 kohms Yes gt GoTo 6 No Repair the Glow Plug Relay Control circuit for a short to ground 137 DIESEL Symptom P1635 GLOW RELAY 1 CONTROLLER SHORT CIRCUIT E When Monitored and Set Condition P1635 GLOW RELAY 1 CONTROLLER SHORT CIRCUIT When Monitored When the ECM attempts to activate glow plug relay 1 Set Condition The ECM detects excessive current draw on the glow plug relay 1 control circuit when attempting to activate the glow plug relay POSSIBLE CAUSES INTERMITTENT CONDITION SUBSTITUTE GLOW PLUG RELAY GLOW PLUG RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB actuate the Glow Plug Relay Is the Glow Plug Relay dicking Yes gt GoTo 2 gt GoTo 3 NOTE Stop the Glow Plug Relay actuation by the DRB WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any
188. e not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 114 DIESEL Symptom List P1515 ACCEL PEDAL SENSOR PLAUSIBILITY P1515 ACCEL PEDAL SENSOR PWG PLAUS WITH POTENTIOME TER P1515 ACCEL PEDAL SENSOR SIGNAL HIGH EXCEEDED P1515 ACCEL PEDAL SENSOR SUPPLY HIGH EXCEEDED P1515 ACCEL PEDAL SENSOR SUPPLY LOW EXCEEDED Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P1515 ACCEL PEDAL SENSOR PLAUSIBILITY When Monitored and Set Condition P1515 ACCEL PEDAL SENSOR PLAUSIBILITY When Monitored With the ignition on Set Condition Theaccelerator pedal position sensor signal is
189. e running and at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 28 COMMUNICATION Symptom List 600 FAILURE SPI COMMUNICATIONS DIESEL 601 INTERNAL CONTROLLER FAILURE DIESEL P1696 PCM FAILURE EEPROM WRITE DENIED Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be PO600 PCM FAILURE SPI COMMUNICATIONS DIESEL POSSIBLE CAUSES POWERTRAIN CONTROL MODULE ACTION APPLICABILITY NOTE This DTC indicates an internal PCM problem All View repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 29 COMMUNICATION Symptom P1687 NO CLUSTER BUS MESSAGE DIESEL When Monitored and Set Con
190. e the resistance between ground and the A C Compressor Clutch Relay Control circuit Is the resistance above 100 kohms Yes gt GoTo 6 Repair the A C Compressor Clutch Relay Control circuit for short to ground Perform ROAD TEST VERIFICATION VER 2 215 Symptom P1655 AC CONTROL SHORT CIRCUIT DIESEL ETE When Monitored and Set Condition P1655 AC CONTROL SHORT CIRCUIT DIESEL When Monitored With the ignition on Set Condition The ECM detects excessive current draw on theA C clutch relay control circuit when attempting to activate the A C clutch NOTE is an option that may not be present on all vehicles POSSIBLE CAUSES INTERMITTENT CONDITION SUBSTITUTE A C COMPRESSOR CLUTCH RELAY A C COMPRESSOR CLUTCH RELAY CONTROL CIRCUIT SHORTED TO VOLTAGE ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB actuate the A C Compressor Clutch Relay Is the A C Compressor Clutch Relay dicking Yes gt GoTo 2 gt GoTo 3 NOTE Stop the A C Compressor Clutch Relay actuation by the DRB WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to ch
191. e voltage above 1 0 volt Yes Repair the S C Switch Signal circuit for a short to voltage Perform SPEED CONTROL VERIFICATION 4 No Replace and program the Powertrain Control Module accor dance with the Service Information Perform SPEED CONTROL VERIFICATION VER 4 219 SPEED CONTROL Symptom P1597 SPEED CONTROL SWITCH ALWAYS LOW DIESEL When Monitored and Set Condition P1597 SPEED CONTROL SWITCH ALWAYS LOW DIESEL When Monitored With the ignition on and battery voltage above 10 4 volts Set Condition The PCM detects voltage below 0 39 volt on the S C switch signal circuit for at least 2 minutes POSSIBLE CAUSES INTERMITTENT CONDITION SPEED CONTROL ON OFF SWITCH SPEED CONTROL RESUME ACCEL SWITCH SPEED CONTROL SWITCH CONTROL CIRCUIT SHORTED TO SENSOR GROUND SPEED CONTROL SWITCH CONTROL CIRCUIT SHORTED TO GROUND PCM ACTION APPLICABILITY Turn the ignition on All With the DRBIII read the Speed Control voltage 15 the Speed Control voltage below 1 0 volts Yes gt GoTo 2 gt GoTo 7 Turn the ignition on With the DRBIII monitor the Speed Control Switch voltage Disconnect the Speed Control On Off Switch harness connector Did the volt change to above 4 7 volts Yes Replace the Speed Control On Off Switch Perform SPEED CONTROL VERIFICATION VER 4 No GoTo 3 Turn the ignition on With the DRBIII monitor the Speed Control Switch voltage Disconnect the Speed
192. each of the measurements Yes gt Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicatethe conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 135 DIESEL Symptom P1635 GLOW RELAY 1 CONTROLLER OPEN CIRCUIT E When Monitored and Set Condition P1635 GLOW RELAY 1 CONTROLLER OPEN CIRCUIT When Monitored With the ignition on Set Condition The
193. ed and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 70 DRIVEABILITY DIESEL Symptom P0463 F UEL LEVEL SENDING UNIT VOLTS TOO HIGH When Monitored and Set Condition P0463 FUEL LEVEL SENDING UNIT VOLTS TOO HIGH When Monitored With the ignition on Set Condition The fuel level sensor signal voltage on PCM cavity C3 26 is above 9 50 volts POSSIBLE CAUSES INTERMITTENT CONDITION FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE FUEL LEVEL SENSOR SIGNAL CIRCUIT OPEN FUEL LEVEL SENSOR GROUND CIRCUIT OPEN FUEL LEVEL SENSOR POWERTRAIN CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB erase PCM DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRB read PCM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 7 Turn the ignition off Disconnect the PCM harness connectors Disconnect the Fuel Level Sensor harness connector Turn the ignition on Measure the voltage on the Fuel Lev
194. el Sensor Signal circuit 15 the voltage below 0 5 volt Yes gt GoTo 3 No Repair the Fuel Level Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the PCM 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 gt GoTo 4 No Repair the Fuel Level Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 71 DRIVEABILITY DIESEL P0463 F VEL LEVEL SENDING UNIT VOLTS TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the PCM harness connectors Disconnect the Fuel Level Sensor harness connector Measure the resistance of the Fuel Level Sensor Ground circuit 15 the resistance below 5 0 ohms Yes gt GoTo 5 No Repair the Fuel Level Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Fuel Level Sensor harness connector Turn the ignition on With the DRB read and record the Fuel Level Sensor voltage NOTE The Fuel Level Sensor voltage should be 10 0 volts with the sensor harness connector disconnected Connect a jumper wire between Fuel Level Sensor harness connector cavities 3 and 4 With the DRB read the Fuel Level Sensor voltage NOTE The Fuel Level Sensor voltage should be less then 1 0 volt
195. enerated by the SKIM at each ignition key cyde The secret key and challenge are the two vari ables used in the algorithm that produces the encrypted response message The transponder uses the crypto algorithm to receive decode and respond to the message sent by SKIM After responding to the coded message the transponder sends a tran sponder ID message to the SKIM The SKIM com pares the transponder ID to the available valid key codes in SKIM memory 8 key maximum After validating the ignition key the SKIM sends a CCD Bus message called a Seed Request to the power train controller then waits for a powertrain control ler response If the powertrain controller does not respond the SKIM will send the seed request again After three failed attempts the SKIM will stop sending the seed request and store a trouble code If the powertrain controller sends a seed response the SKIM sends a valid invalid key message to the powertrain controller This is encrypted message that is generated using the following VIN Vehicle Identification Number Seed This is a random number that is generated by the PCM at each ignition key cycle The VIN and seed are the two variables used in the rolling code algorithm that encrypts the valid invalid key message The powertrain controller uses the rolling code algorithm to receive decode and respond to the valid invalid key message sent by SKIM After sending the valid invalid key mes
196. ensor Display menu Test drive the vehicle and observe the Vehicle Speed on the DRB Does the Vehicle Speed reading on the DRB increase with vehicle speed Yes gt GoTo 4 No gt GoTo 6 199 DRIVEABILITY DIESEL CHECKING THE SPEEDOMETER OPERATION Continued ACTION APPLICABILITY With the DRB monitor Vehicle Speed the PCM Sensor Display menu Test drive the vehicle and observe the Vehicle Speed on the DRB Compare the DRB reading with the vehicle s Speedometer Are the readings within 5 km h 3 MPH of each other Yes gt The Speedometer System is working properly Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 5 With the DRB select BODY from the Systems menu ELECTRO MECH INSTRU MENT CLUSTER MONITOR DISPLAY then CCD BUS ENGINE INFO Monitor Vehicle Speed while driving the vehicle Does the Vehicle Speed Sensor reading increase with vehicle speed Yes Replace the Instrument Cluster in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 connector Is the voltage above 4 5 volts Yes gt GoTo 7 No GoTo 12 Turn the ignition off Disconnect the ECM harness connectors Disconnect the PCM harness connectors Turn the ignition on Disconnect the Vehicle Speed Sensor harness connector Measure the voltage between grou
197. ensor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Vehicle Speed Sensor Signal circuit 15 the resistance below 5 0 ohms Yes gt GoTo 11 No Repair the Vehicle Speed Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Vehicle Speed Sensor harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Vehicle Speed Sensor Signal circuit 15 the resistance above 100 kohms Yes gt GoTo 12 No Repair the Vehicle Speed Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 209 DRIVEABILITY DIESEL CHECKING THE VEHICLE SPEED SIGNAL Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Vehicle Speed Sensor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Vehicle Speed Sensor Ground circuit Is the resistance below 5 0 ohms Yes gt GoTo 13 Repair the Vehicle Speed Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Vehicle Speed Sensor harness connector NOTE E nsure the ECM and PCM harness connectors are connected before continuing Turn the ignition on Connec a jumper wire t
198. epaired before continuing Did the gauge reach the proper calibration points Yes gt GoTo 2 No Replace the Instrument Cluster Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Fuel Level Sensor harness connector Disconnect the PCM harness connectors Measure the resistance of the Fuel Level Sensor Signal circuit 15 the resistance below 10 0 ohms Yes gt GoTo 3 Repair the Fuel Level Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Fuel Level Sensor harness connector Disconnect the PCM harness connectors Measure the resistance between ground and the Fuel Level Sensor Signal circuit Is the resistance below 1000 0 ohms Yes Repair the Fuel Level Sensor Signal circuit for short to ground Perform ROAD TEST VERIFICATION VER 2 gt GoTo 4 186 DRIVEABILITY DIESEL CHECKING THE FUEL LEVEL GAUGE OPERATION Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Fuel Level Sensor harness connector Disconnect the PCM harness connectors Measure the resistance between Sensor Ground and the Fuel Level Sensor Signal circuit Is the resistance below 1000 0 ohms Yes Repair the Fuel Level Sensor Signal circuit for a short to Sensor Ground Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 5 Turn the ignition off Completely drain the fuel tank Refer to Se
199. er Relay connector Turn the ignition on Connect a jumper wire between the Check Engine Lamp Control circuit and ground Did the Check Engine Lamp illuminate Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 5 Turn the ignition off Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Connect a jumper wire between the Check Engine Lamp Control circuit and ground With the DRB select Body from the System menu then Monitor CCD Bus Info Does the DRB display Engine Lamp Status On Yes Replace the Instrument Cluster in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the PCM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between ASD Diesel Power Relay connector cavities 30 and 87 in PDC Turn the ignition on Measure the voltage of the Check Engine Lamp Control circuit 15 the voltage below 0 5 volt Yes gt Replace and program the Powertrain Control Module in accor dance with the Serv
200. er Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the Boost Pressure Sensor Signal circuit 15 the resistance above 100 kohms Yes gt GoTo 5 No Repair the Boost Pressure Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between the Boost Pressure Sensor Signal circuit and Sensor Ground circuit 15 the resistance above 100 kohms Yes gt GoTo 6 No Repair the Boost Pressure Sensor Signal circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Boost Pressure Sensor Signal circuit Is the resistance below 5 0 ohms Yes gt GoTo 7 No the Boost Pressure Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 57 DRIVEABILITY DIESEL P0235 TURBOCHARGER BOOST SENSOR SIGNAL LOW EXCEEDED Continued ACTION APPLICABILI
201. f input voltage CCD Bus messages or coded messages to the SKIS If all of the criteria for monitoring a circuit or function are met and a fault is sensed a diagnostic trouble code will be stored in the SKIS memory 3 2 5 SKIS OVERVIEW The Sentry Key Immobilizer System SKIS is an immobilizer system designed to prevent unautho rized vehicle operation The system consists of a Sentry Key Immobilizer Module SKIM ignition 5 equipped with a transponder chip engine controller and powertrain controller When the ig nition switch is turned on the SKIM interrogates the ignition key If the ignition key is Valid the SKIM sends a CCD Bus message to the powertrain controller indicating the presence of a valid ignition key The PCM then supplies the ECM with a valid immobilizer signal allowing the engine to continue to operate 3 2 6 SKIS OPERATION When ignition power is supplied tothe SKIM the SKIM performs an internal self test After the self test is completed the SKIM energizes the antenna this activates the transponder chip and sends a challenge to the transponder chip The transponder chip responds to the challenge by generating an encrypted response message using the following Secret Key This is an electronically stored value identification number that is unique to each SKIS secret key is stored the SKIM PCM and all ignition key transponders Challenge This is a random number that is g
202. f the tests in this book to diagnose an individual code Always begin by reading the diagnostic trouble codes using the This procedure begins in DTC TEST Checking the System for Diagnostic Trouble Codes This will direct you to the specific test s that must be performed 3 3 1 HARD CODE A diagnostic trouble code that comes back within one cycle of the ignition key is a hard code This means that the fault is there every time the power train control module engine control module sentry key immobilizer system SKIS checks that circuit or function Procedures in this manual verify if the trouble code is a hard code at the beginning of each test When it is not a hard code an intermittent test must be performed 3 3 2 INTERMITTENT CODE A diagnostic trouble code that is not there every time the powertrain control module engine control module sentry key immobilizer sytem SKIS checks the circuit is an intermittent code Most intermittent codes are caused by wiring or connec tor problems Faults that come and go like this the most difficult to diagnose they must be looked for under specific conditions that cause them The following checks may assist you in identifying a possible intermittent problem e Visually inspect related wire harness connectors Look for broken bent pushed out or corroded terminals e Visually inspect the related harnesses Look for chafed pierced or partially br
203. for a short to voltage Perform ROAD TEST VERIFICATION VER 2 NOTE Remove the jumper wire 91 DRIVEABILITY DIESEL P1110 AIR TEMP SENSOR SRC HIGH EXCEEDED Continued ACTION APPLICABILITY Turn the ignition off Disconnect the ECM harness connectors Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Measure the resistance of the Intake Air Temperature Sensor Signal circuit Is the resistance below 5 0 ohms Yes gt GoTo 4 No gt Repair the Intake Air Temperature Sensor Signal circuit for open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Connect a jumper wire between the IAT Sensor Signal and IAT Sensor Ground circuits the Turbocharger Boost Pressure IAT Sensor harness connector Turn the ignition on Monitor the DRB for ECM DTCs Does the DRB display P1110 AIR TEMP SENSOR SRC LOW EXCEEDED Yes Replace the Turbocharger Boost Pressure Intake Air Tempera ture Sensor Perform ROAD TEST VERIFICATION VER 2 GoTo 5 Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness
204. form ROAD TEST VERIFICATION VER 2 No gt GoTo 2 Turn the ignition on With the DRB erase ECM DTCs Perform several ignition key cycles pausing for at least 10 seconds between each cycle Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 3 gt GoTo 7 126 DRIVEABILITY DIESEL P1625 ASD DIESEL POWER RELAY SHUTS OFF TOO LATE Continued ACTION APPLICABILITY Turn the ignition off Install a substitute relay in place of the ASD Diesel Power Relay Perform several ignition key cycles pausing for at least 10 seconds between each Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 4 No Replace theASD Diesel Power Relay Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Remove the ASD Diesel Power Relay from the PDC Disconnect the ECM harness connectors Measure the resistance between ground and the ASD Diesel Power Relay Control circuit while wiggling the wiring harness and connectors Was the resistance below 5 0 ohms at any time while wiggling the wiring harness and connectors Yes Repair the ASD Diesel Power Relay Control circuit for an inter mittent short to ground Perform ROAD TEST VERIFICATION VER 2 GoTo 5 Turn the ignition off Remove the ASD Diesel Power Relay from the PDC Turn the ignition on Measure the voltage of the ASD Diesel Power Relay Output circuit 15 the voltag
205. g or repairing the vehicle It is espe cially important to block the wheels on front wheel drive vehicles the parking brake does not hold the drive wheels When servicing a vehicle always wear eye pro tection and remove any metal jewelry such as watchbands or bracelets that might make an inad vertent electrical contact When diagnosing a powertrain system problem it is important to follow approved procedures where applicable These procedures can be found in the service manual procedures Following these procedures is very important to the safety of indi viduals performing diagnostic tests 4 2 2 VEHICLE PREPARATION FOR TESTING Make sure the vehicle being tested has a fully charged battery If it does not false diagnostic codes or error messages may occur 4 2 3 SERVICING SUB ASSEMBLIES Some components of the powertrain system are intended to be serviced in assembly only Attempt ing to remove or repair certain system sub components may result in personal injury and or improper system operation Only those compo nents with approved repair and installation proce dures in the service manual should be serviced 4 2 4 DRBIII SAFETY INFORMATION WARNING EXCEEDING THE LIMITS OF THE DRBIIIe MULTIMETER IS DANGEROUS CAN EXPOSE YOU TO SERIOUS OR POSSIBLY FATAL INJURY CAREFULLY READ AND UNDERSTAND THE CAUTIONS AND THE SPECIFICATION LIMITS Follow the vehicle manufacturer s service speci fications at all times
206. h the Service Information Perform ROAD TEST VERIFICATION VER 2 202 DRIVEABILITY DIESEL CHECKING THE TACHOMETER OPERATION Continued APPLICABILITY Turn the ignition off NOTE Ensure the ECM harness connectors are connected Start the engine With a voltmeter set to measure frequency Hz measure the frequency of the Engine Speed Sensor Signal circuit by back probing ECM C1 cavity 6 15 the frequency between 26 0 34 0 Hz at idle Yes gt Test Complete No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the PCM harness connectors Turn the ignition on Measure the voltage on the Engine Speed Sensor Signal circuit Is the voltage above 6 0 volts Yes Repair the Engine Speed Sensor Signal circuit for short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 6 15 the resistance above 100 kohms Yes gt GoTo 7 No Repair the Engine Speed Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the PCM harness connectors Measure the resistance of the Engine Speed Sensor Signal circuit 15 the resistance below 5 0 ohms Yes gt GoTo 8 No GoTo 8 If there are no possible causes remaining view re
207. he conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Check the Engine Speed Sensor wiring harness for incorrect routing which may cause interference Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 88 DIESEL Symptom List 1105 PRESSURE SENSOR SRC HIGH EXCEEDED P1105 ATMOSPHERE PRESSURE SENSOR SRC LOW EXCEEDED P1610 REGULATOR LOWER REGULATOR LIMIT P1610 REGULATOR UPPER REGULATOR LIMIT P1615 MICROCONTROLLER GATE ARRAY MONITORING P1615 MICROCONTROLLER GATE ARRAY WATCHDOG P1615 MICROCONTROLLER PREPARE FUEL QUANTITY STOP P1615 MICROCONTROLLER RECOVERY HAS OCCURRED P1615 MICROCONTROLLER REDUNDANT OVERRUN MONITOR ING P1620 U REF 2 5V P1680 EEPROM PLAUSIBILITY CHECKSUM ERROR FOR ADJ EGR P1680 EEPROM PLAUSIBILITY CHECKSUM ERROR IN CC212 P1680 EEPROM PLAUSIBILITY COMMUNICATION WITH PROM P1680 EEPROM PLAUSIBILITY FUNC SWITCH WRONG OR MISS ING P1680 EEPROM PLAUSIBILITY VER NUMBER NOT CORRE SPONDING P1680 EEPROM PLAUSIBILITY VIN CHECKSUM ERROR Test Note All symptoms listed above are diagnosed using the
208. he Engine Speed Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the Engine Speed Sensor Signal circuit 15 the resistance above 100 kohms Yes gt GoTo 4 No Repair the Engine Speed Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Engine Speed Sensor harness connector Disconnect the ECM harness connectors Measure the resistance between the Engine Speed Sensor Signal and Sensor Ground circuits 15 the resistance above 100 kohms Yes gt GoTo 5 No Repair the Engine Speed Sensor Signal and Sensor Ground circuits for a short together Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Engine Speed Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Engine Speed Sensor Signal circuit Is the resistance below 5 0 ohms Yes gt GoTo 6 No Repair the Engine Speed Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 85 DRIVEABILITY DIESEL P0725 E NGINE SPEED SENSOR DYN PLAUSIBILITY Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Engine Speed Sensor harness connector Disconnect the ECM harness connectors Turn the ignition on Measure the voltage of the Engine Speed Sensor Signal circuit Is the voltage below 0 5 volt Yes gt GoTo 7 No
209. he Low Coolant Lamp Control circuit 15 the resistance above 100 kohms Yes gt Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the Low Coolant Lamp Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the PCM harness connectors Disconnect the Low Coolant Switch harness connector Measure the resistance of the Low Coolant Switch Signal circuit 15 the resistance below 5 0 ohms Yes gt GoTo 10 No Repair the Low Coolant Switch Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the PCM harness connectors Disconnect the Message Center harness connector Turn the ignition on Measure the voltage of the Low Coolant Lamp Control circuit 15 the voltage above 0 5 volt Yes Repair the Low Coolant Lamp Control circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 GoTo 13 NOTE Ensure the PCM harness connectors are connected All Disconnect the Low Coolant Switch harness connector Connect a high impedance test light between the Low Coolant Switch harnes
210. he ignition off Replace the Needle Movement Sensor in accordance with the Service Information Turn the ignition on With the DRB erase ECM DTCs Start the engine and vary the engine speed from idle to 3500 RPM several times With the DRB read ECM DTCs Did this DTC reset Yes gt Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Therepair is complete Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicatethe conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 164
211. hen Monitored With the engine running Set Condition The voltage at PCM cavity C1 22 is 1 0 volt or more above the target charging voltage for at least 3 seconds POSSIBLE CAUSES INTERMITTENT CONDITION GENERATOR FIELD DRIVER CIRCUIT SHORTED TO GROUND POWERTRAIN CONTROL MODULE TARGET CHARGING VOLTAGE TOO LOW GENERATOR SHORTED TO GROUND INTERNALLY POWERTRAIN CONTROL MODULE FIELD DRIVER SHORTED TO GROUND ACTION APPLICABILITY NOTE The battery must be fully charged and the generator belt must be in All good condition and tensioned properly before continuing Turn the ignition on With the DRB actuate the Generator Field Measure the voltage between ground and the Generator Field Driver circuit by back probing the Generator Field harness connector with a voltmeter Does the voltage cycle from to below 2 0 volts Yes gt GoTo 2 No GoTo 4 NOTE With the DRB stop the Generator Field actuation Start the engine With the DRB read the Target Charging voltage Is the Target Charging voltage above 13 0 volts Yes gt GoTo 3 Replace and program the Powertrain Control Module in accor dance with the Service Information Perform CHARGING VERIFICATION VER 3 CHARGING P1594 CHARGING SYSTEM VOLTAGE TOO HIGH DIESEL Continued ACTION APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list may help in
212. his time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete Turn the ignition off Disconnect the ECM harness connectors Disconnect the Message Center harness connector Measure the resistance between ground and the Glow Plug Lamp Control circuit 15 the resistance above 100 kohms Yes gt GoTo 5 No Repair the Glow Plug Lamp Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Message Center harness connector Measure the resistance of the Glow Plug Lamp Control circuit 15 the resistance below 5 0 ohms Yes gt GoTo 6 Repair the Glow Plug Lamp Control ci
213. hutdown Solenoid Control circuit Does the voltage cycle from B to below 1 0 volt Yes Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 5 Disconnect the Fuel Injection Pump harness connector Measure the resistance between the following cavities in the Fuel Injection Pump connector fuel pump side Cavity 1 to cavities 4 5 6 7 8 9 and 10 Cavity 4 to cavities 5 6 7 8 9 and 10 Cavity 5 to cavities 6 7 8 and 9 Cavity 7 to cavities 6 8 9 and 10 Cavity 8 to cavities 6 and 10 NOTE The resistance should be above 100 ohms for all measurements 15 the resistance above 100 ohms for each of the measurements Yes gt Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 149 DRIVEABILITY DIESEL P1660 REDUNDANT EMERG STOP POWERSTAGE DEFECTIVE Continued ACTION APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values
214. ice Information Perform ROAD TEST VERIFICATION VER 2 Repair the Check Engine Lamp Control circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 172 DIESEL THE CHECK ENGINE LAMP OPERATION Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the PCM harness connectors Disconnect the ECM harness connectors Measure the resistance between ground and the Check Engine Lamp Control circuit Is the resistance above 100 kohms Yes gt GoTo 8 No Repair the Check Engine Lamp Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the PCM harness connectors Measure the resistance of the Check Engine Lamp Control circuit Is the resistance below 5 0 ohms Yes gt GoTo 9 No Repair the Check Engine Lamp Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove and inspect the Check Engine Lamp bulb from the Instrument Cluster Is the bulb OK Yes Replace the Instrument Cluster in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Replace the Check
215. ight connected to ground check the ASD Diesel Power Relay Output circuit Did the test light illuminate brightly Yes gt GoTo 4 Repair the ASD Diesel Power Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Install a substitute relay in place of the Radiator Fan Relay Turn the ignition on With the DRB actuate the Radiator Fan Relay Does the Radiator Fan cycle on and off Yes Replace the Radiator Fan Relay Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 5 GoTo 6 Turn the ignition off Remove the Radiator Fan Relay from the PDC Disconnect the ECM harness connectors Measure the resistance of the Radiator Fan Relay Control circuit Is the resistance below 5 0 ohms Yes gt GoTo 7 No Repair the Radiator Fan Relay Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Remove the Radiator Fan Relay from the PDC Disconnect the ECM harness connectors Measure the resistance between ground and the Radiator Fan Relay Control circuit 15 the resistance below 100 kohms Yes Repair the Radiator Fan Relay Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 155 DRIVEABILITY DI
216. il NOTE This fault will cause the engine to stumble and or stall P1225 CONTROL SLEEVE SENSOR SIGNAL LOW EXCEEDED When Monitored With the ignition on and during after run mode at key off Set Condition The ECM does not receive a correct signal from the measure coil and or the sensor coil POSSIBLE CAUSES INTERMITTENT CONDITION FUEL INJ ECTION PUMP CONTROL SLEEVE POSITION SENSOR OPEN FUEL INJ ECTION PUMP CONTROL SLEEVE POSITION SENSOR SHORTED TO GROUND CONTROL SLEEVE POSITION SENSOR CIRCUITS SHORTED TO VOLTAGE CONTROL SLEEVE POSITION SENSOR CIRCUIT SHORTED TO GROUND CONTROL SLEEVE POSITION SENSOR CIRCUITS SHORTED TOGETHER CONTROL SLEEVE POSITION SENSOR CIRCUITS OPEN ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Turn the ignition off and wait for at least 30 seconds Turn the ignition on Monitor the DRB for ECM DTCs Did this DTC reset Yes gt GoTo 2 gt GoTo 9 106 DRIVEABILITY DIESEL P1225 CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Fuel Injection Pump harness connector Measure the resistance between Fuel Injection Pump connector fuel pump side cavities 1 and 2 then 2 and 3 Is the resistance between 5 0 and 7 0 ohms for each measurement Yes gt GoTo 3 No Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST
217. ilizer Signal circuit for an open Perform NO START VERIFICATION VER 1 Turn the ignition off Disconnect the PCM harness connector Disconnect the ECM harness connector Measure the resistance between ground and the Immobilizer Signal circuit at the PCM harness connector 15 the resistance above 100 kohms Yes gt GoTo 5 No Repair the Immobilizer Signal circuit for a short to ground Perform NO START VERIFICATION 1 Information Perform NO START VERIFICATION With the DRBIII select the Lab Scope function Set the voltage range to 20 0V Set the probe to X10 Set the time range to 0 1S Div Turn the ignition on Using the oscilloscope lead backprobe the PCM harness connector C3 cavity 16 NOTE A valid immobilizer signal will cycle high and low similar to the pattern shown in Charts and Graphs Does the DRB display show the 12 volt signal cycling high and low Yes gt Replace and program the ECM in accordance with the Service Information Perform NO START VERIFICATION VER 1 No Replace the PCM in accordance with the Service Information Perform NO START VERIFICATION 1 Turn the ignition off All Disconnect the PCM harness connector Turn the ignition on Measure the amperage between PCM harness connector C 3 cavity 16 and ground Is the amperage between 1 0 and 1 4 milliamperes Yes gt GoTo 6 No Replace and program the ECM in accordance with the Service 232 S
218. in the SKIM s EEPROM POSSIBLE CAUSES VERIFYING PCM VIN REPLACE SKIM AND CHECK DTC S INTERMITTENT WIRING HARNESS PROBLEM PCM APPLICABILITY Turn the ignition on All With the DRB III erase the SKIM DTC s Turn the ignition off Wait 10 seconds Turn the ignition on and wait 2 minutes With the III read the SKIM Does the 111 display the DTC that was previously erased Yes gt GoTo 2 gt GoTo 4 238 VEHICLE THEFT SECURITY ROLLING CODE FAILURE Continued APPLICABILITY NOTE Ensure that a VIN has been programmed into the PCM If a VIN isnot All displayed attempt to program the PCM with the correct vehicle VIN before continuing Turn the ignition on With the DRB III select Engine system from the main menu Display and record the Vehicle dentification Number Does the VIN recorded from the PCM match the VIN of the vehicle Yes gt GoTo 3 No Replace and program the Powertrain Control Module accor dance with the Service Information Perform SKIS VERIFICATION Turn the ignition off Replace and program the Sentry Key Immobilizer Module in accordance with the Service Information Turn the ignition on With the III display and erase all PCM SKIM Perform 5 ignition key cycles leaving the ignition on for 90 seconds per cycle With the 111 check for SKIM Does the 111 display the sam
219. ine set the blower to Panel Turn the A C on With the DRB read the A C Switch Does the DRB display A C Switch ON Yes gt GoTo 3 No gt GoTo 13 Turn the ignition on With the DRB select Engine Bosch Controller then Inputs Outputs Read the A C H L Press Sw Does the DRB display A C H L Press Sw ON Yes gt GoTo 4 No GoTo 8 Turn the ignition on With the actuate the A C Compressor Clutch Relay Observe the A C Compressor Clutch during actuation 15 the A C Compressor Clutch clicking Yes The electrical portion of the A C System is operating properly Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 5 Remove the A C Compressor Clutch Relay from the PDC All Using a 12 volt test light connected to ground check the Fused B circuit Is the test light on Yes gt GoTo 6 No Repair the Fused B circuit for an open Perform ROAD TEST VERIFICATION VER 2 Remove the A C Compressor Clutch Relay from the PDC Disconnect the A C Compressor Clutch harness connector Connect a jumper wire across theA C Compressor Clutch Relay connector cavities 30 and 87 in the PDC Using a 12 volt test light connected to ground check the A C Compressor Clutch Relay Output circuit in the A C Compressor Clutch harness connector Is the test light on Yes gt GoTo 7 Repair the A C Compressor Clutch Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Disconnect the A
220. ine Speed Sensor DTCs Are other Engine Speed Sensor DTCs present Yes Refer to symptom list for problems related to other DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 GoTo 2 Turn the ignition on With the DRB erase ECM DTCs Test drive the vehicle and monitor the DRB for ECM DTCs Did this DTC reset Yes gt GoTo 3 gt GoTo 4 87 DIESEL 725 SPEED SENSOR OVERSPEED RECOGNITION Continued ACTION APPLICABILITY Replace the Engine Speed Sensor in accordance with the Service Information All With the DRB erase ECM DTCs Perform several drive cycles turning the ignition off for at least 10 seconds between each drive cycle Monitor the DRB for ECM DTCs Did this DTC reset Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 The repair is complete Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate t
221. ion key on for a minimum of 90 seconds per cycle With the DRB 111 read the SKIM DTC s Does the code appear Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform SKIS VERIFICATION Test Complete Turn the ignition off Note Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires NOTE Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any Technical Service Bulletins TSB that may apply Were any problems found Yes Repair wiring harness connectors as necessary Perform SKIS VERIFICATION Test Complete 237 VEHICLE THEFT SECURITY Symptom List ROLLING CODE FAILURE VIN MISMATCH Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be ROLLING CODE FAILURE ee 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 PCM due toa SKIM or PCM reset Set Condition When a PCM STATUS message with a Valid K ey status is not received by the SKIM within 3 5 seconds of transmitting the last Valid Key Code message to the PCM VIN MISMATCH When Monitored With the ignition on Set Condition When the VIN received from the PCM does not match the VIN stored
222. ion on Measure the voltage on the PCM ECT Sensor Signal circuit Is the voltage above 5 5 volts Yes Repair the PCM ECT Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 3 Turn the ignition off Disconnect the PCM ECT Sensor harness connector Connect a jumper wire between the PCM ECT Sensor harness connector cavities Turn the ignition on With the DRB read the PCM ECT Sensor voltage 15 the voltage below 1 0 volt Yes Replace the PCM ECT Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 4 43 DRIVEABILITY DIESEL 0118 SENSOR VOLTAGE TOO HIGH Continued APPLICABILITY Turn the ignition off Disconnect the PCM ECT Sensor harness connector Connect a jumper wire between ground and the PCM ECT Sensor Signal circuit Turn the ignition on With the DRB read the PCM ECT Sensor voltage 15 the voltage below 1 0 volt Yes Repair the PCM ECT Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 5 Turn the ignition off Disconnect the PCM harness connectors Disconnect the PCM ECT Sensor harness connector Measure the resistance of the PCM ECT Sensor Signal circuit 15 the resistance below 5 0 ohms Yes gt GoTo 6 No Repair the PCM ECT Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there no po
223. ions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 97 DRIVEABILITY DIESEL Symptom P1201 NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED When Monitored and Set Condition P1201 NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED When Monitored With the ignition on Set Condition TheECM detects the voltage on the needle movement sensor signal circuit below 0 141 volt POSSIBLE CAUSES INTERMITTENT CONDITION NEEDLE MOVEMENT SENSOR NEEDLE MOVEMENT SENSOR SIGNAL CIRCUIT SHORTED TO GROUND NEEDLE MOVEMENT SENSOR SIGNAL AND GROUND CIRCUITS SHORTED TOGETHER ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Turn the ignition off wait 30 seconds then turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 gt GoTo 6 Turn the ignition off Disconnect the Needle Movement Sensor harness connector Turn the ignition on With the DRB read ECM DTCs Did DTC P1201 NEEDLE MOVEMENT SENSOR SRC HIGH E
224. isconnect the A C Heater Control harness connectors Disconnect the PCM harness connectors Measure the resistance between ground and the A C Select Switch Sense circuit 15 the resistance below 100 0 ohms Yes Repair the A C Select Switch Sense circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 GoTo 18 168 DIESEL THE A C SYSTEM Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the A C Heater Control harness connectors Disconnect the PCM harness connectors Measure the resistance of the A C Select Switch Sense circuit Is the resistance below 10 0 ohms Yes gt GoTo 19 Repair the A C Select Switch Sense circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the A C Heater Control harness connectors Turn the ignition on With the DRB select Engine J TEC then Inputs Outputs Start the Engine Connect a jumper wire between theA C Select Switch Sense circuit and ground at the A C Heater Control harness connector With the DRB read the A C Select Switch Does the DRB display A C Select Switch YES Yes Refer to symptom list for problems related to A C Select Switch operation Perform ROAD TEST VERIFICATION VER 2 No Replace and program the PCM in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 169 DRIVEABILI
225. isually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 52 DIESEL Symptom P0235 TURBOCHARGER BOOST SENSOR SIGNAL HIGH EX CEEDED I When Monitored and Set Condition P0235 TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED When Monitored With the ignition on Set Condition The turbocharger boost pressure sensor signal voltage exceeds 4 80 volts for at least 2 seconds POSSIBLE CAUSES INTERMITTENT CONDITION 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE BOOST PRESSURE SENSOR GROUND CIRCUIT OPEN BOOST PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE TURBOCHARGER BOOST PRESSURE INTAKE AIR TEMPERATURE SENSOR POOR CONNECTOR TERMINAL CONTACT ENGINE CONTROL MODULE 5 VOLT SUPPLY SHORTED TO VOLTAGE ENGINE CONTROL MODULE INTERNAL ENGINE CONTROL MODULE SENSOR SIGNAL SHORTED TO VOLTAGE ACTION APPLICABILITY Turn the ignition on All With the DRB read the Turbocharger Boost Pressure Sensor voltage Is the voltage above 4 5 volts Yes gt GoTo 2 No gt GoTo 9 Turn the ignition off Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Turn the ignition on Measure the voltage between ground and the Turbocharger Boost Pressure Sensor 5 volt Supply circuit Is the voltage above 5 2 volts
226. ith the DRB read PCM DTCs Did this DTC reset Yes gt GoTo 3 gt GoTo 7 Turn the ignition off then on Measure the voltage of the Generator Field Driver circuit in PCM harness connector C2 by back probing Is the voltage above 10 0 volts Yes gt Replace and program the Powertrain Control Module in accor dance with the Service Information Perform CHARGING VERIFICATION VER 3 GoTo 4 CHARGING P0622 GENERATOR FIELD NOT SWITCHING PROPERLY DIESEL Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Generator Field harness connector Turn the ignition on Measure the voltage of the Generator Source circuit Is the voltage above 10 0 volts Yes gt GoTo 5 gt GoTo 6 Turn the ignition off Disconnect the Generator Field harness connector Disconnect the PCM harness connectors Measure the resistance of the Generator Field circuit 15 the resistance below 5 0 ohms Yes Replace the Generator Perform CHARGING VERIFICATION VER 3 No Repair the Generator Field circuit for an open Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the Generator Field harness connector Disconnect the PCM harness connectors Measure the resistance of the Generator Source circuit 15 the resistance below 5 0 ohms Yes gt Replace and program the Powertrain Control Module in accor dance with the Service Information Perform CHARGING VERIFICATION
227. ition off Disconnect the Vehicle Speed Sensor harness connector Disconnect the PCM C1 and C2 harness connectors Check connectors Clean repair as necessary Measure the resistance between the Vehicle Speed Sensor Signal circuit and the 5 volt Supply circuit 15 the resistance above 100 kohms Yes gt GoTo 9 Repair the Vehicle Speed Sensor Signal circuit for a short to the 5 volt Supply circuit Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Vehicle Speed Sensor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Vehicle Speed Sensor Signal circuit Is the resistance below 5 0 ohms Yes gt GoTo 10 No Repair the Vehicle Speed Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair All Repair Repair the Vehicle Speed Sensor Signal circuit for a short to 75 DRIVEABILITY DIESEL 5 SPEED SENSOR PEC FREQUENCY TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the ECM harness connectors Disconnect the Vehicle Speed Sensor harness connector Note Check connectors Clean repair as necessary Measure the resistance between ground and the Vehicle Speed Sensor Signal circuit Is the resistance above 100 kohms Yes gt GoTo 1 No Repair the Vehicle Speed Sen
228. ld be above 100 ohms for all measurements 15 the resistance above 100 ohms for each of the measurements Yes gt Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 46 DIESEL P0180 F VEL TEMPERATURE SENSOR SRC HIGH EXCEEDED Continued ACTION APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 47
229. le pressing and releasing the Brake Pedal Yes Replace and program the ECM in accordance with the Service Information Perform SPEED CONTROL VERIFICATION VER 4 Replace the Brake Lamp Switch Perform SPEED CONTROL VERIFICATION VER 4 Turn the ignition off Disconnect the S C Switch 4 way harness connector Turn the ignition on With the DRB read the cruise switch voltage while connecting a jumper wire between the Sensor Ground circuit and the S C Switch Signal circuit Did the voltage change from approximately 5 0 volts to below 0 3 volts Yes gt Replace the S C Switches Perform SPEED CONTROL VERIFICATION VER 4 gt GoTo 24 Turn the ignition off Disconnect the S C Switch 4 way harness connector Disconnect the ECM harness connector s Measure the resistance of the S C Sensor Ground circuit 15 the resistance below 10 0 ohms Yes gt GoTo 26 No Repair the Sensor Ground circuit for an open Perform SPEED CONTROL VERIFICATION 4 Turn the ignition off Disconnect the S C Switch 4 way harness connector Disconnect the ECM harness connector s Measure the resistance between ground and the S C Switch Signal circuit Is the resistance below 100 0 ohms Yes Repair the S C Switch Signal circuit for a short to ground Perform SPEED CONTROL VERIFICATION VER 4 No Replace and program the ECM in accordance with the Service Information Perform SPEED CONTROL VERIFICATION
230. lete 180 DIESEL Symptom CHECKING THE FUEL COMPUTER POSSIBLE CAUSES ECM FUEL COMPUTER OUTPUT CIRCUIT FUEL COMP OUPUT CIRCUIT SHORTED TO VOLTAGE FUEL COMPUTER OUTPUT CIRCUIT OPEN FUEL COMPUTER OUTPUT CIRCUIT SHORT TO GROUND OVERHEAD CONSOLE PCM PCM FUEL COMPUTER OUTPUT CIRCUIT ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Turn the ignition on Measure the voltage of the Fuel Computer Output circuit at the ECM harness connector 15 the voltage between 4 5 and 5 5 volts Yes gt GoTo 2 Below 4 5 volts GoTo 4 Above 5 5 volts Repair the Fuel Computer Output circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Turn the ignition on Connect a jumper wire between ground and ECM harness connector C1 cavity 18 while observing the Overhead Fuel Computer Did the Overhead Fuel Computer status change Yes Replace the ECM in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 3 Turn the ignition off Disconnect the ECM harness connectors Turn the ignition on Connect one end of a jumper wire to ECM harness connector 1 cavity 18 while observing the Overhead Fuel Computer With the select Body System and monitor Bus I nfo while connecting and disconnecting the other end of the jumper wire to grou
231. m P1625 ASD DIESEL POWER RELAY SHUTS OFF TOO SOON When Monitored and Set Condition P1625 ASD DIESEL POWER RELAY SHUTS OFF TOO SOON When Monitored During after run Set Condition Theinternal ECM timer determines that the ASD Diesel Power Relay has shut off before the AFTER RUN mode of operation has been completed POSSIBLE CAUSES CHECK FOR OTHER DTCS INTERMITTENT CONDITION SUBSTITUTE ASD DIESEL POWER RELAY ASD DIESEL POWER RELAY CONTROL CIRCUIT OPEN INTERMITTENTLY ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB check for additional DTCs Are other DTCs present Yes Refer tothe Symptom List for diagnosis of the other DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 2 Turn the ignition on With the DRB erase ECM DTCs Perform several ignition key cycles pausing for at least 10 seconds between each cycle Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 3 No gt GoTo 6 Turn the ignition off Install a substitute relay in place of the ASD Diesel Power Relay Perform several ignition key cycles pausing for at least 10 seconds between each cycle Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 4 No Replace the ASD Diesel Power Relay Perform ROAD TEST VERIFICATION VER 2 129 DRIVEABILITY DIESEL P1625 ASD DIESEL POWER RELAY SHUTS OFF TOO SOON
232. m the Powertrain Control Module in accor dance with the Service Information Perform SPEED CONTROL VERIFICATION 4 No Repair the S C ON OFF SET Switch Signal circuit for an open Perform SPEED CONTROL VERIFICATION 4 218 SPEED CONTROL P1596 SPEED CONTROL SWITCH ALWAYS HIGH DIESEL Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the S C ON OFF SET button harness connector Turn the ignition on Connect a jumper wire between the S C Switch Signal circuit the Sensor Ground at the ON OFF SET Switch harness connector With the DRB III read the S C Switch Volts Does the 111 display below 0 5 volts Yes Replace the S C ON OFF SET Switch Perform SPEED CONTROL VERIFICATION VER 4 No gt GoTo 4 Turn the ignition off Disconnect the S C ON OFF SET Switch harness connector Disconnect the PCM harness connectors Measure the resistance of the Sensor Ground circuit 15 the resistance below 10 0 ohms Yes gt Replace and program the Powertrain Control Module in accor dance with the Service Information Perform SPEED CONTROL VERIFICATION 4 No the Sensor Ground circuit for an open Perform SPEED CONTROL VERIFICATION 4 Turn the ignition off Disconnect the S C ON OFF SET Switch harness connector Disconnect the PCM harness connectors Turn the ignition on Measure the voltage of the S C Switch Signal circuit 15 th
233. may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform CHARGING VERIFICATION VER 3 No Test Complete Turn the ignition off With a voltmeter measure and record the voltage between the Battery terminals Disconnect the PCM harness connectors Measure the voltage of the Fused B circuit in the PCM harness connector Are the voltage measurements within 0 5 volt of each other Yes gt GoTo 8 No gt Repair the Fused B circuit to the Powertrain Control Module for high resistance Perform CHARGING VERIFICATION VER 3 Turn the ignition off Disconnect the PCM harness connectors Disconnect the Generator Field harness connector Turn the ignition on Measure the voltage of the Generator Field Driver circuit Is the voltage below 0 5 volt
234. ms Yes Repair the SCI Receive circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 1 gt GoTo 4 Turn the ignition off Disconnect the PCM C3 harness connector Measure the resistance of the SCI Receive circuit between the PCM connector and the DLC 15 the resistance below 5 0 ohms Yes gt GoTo 5 No Repair the SCI Receive circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 Turn the ignition off All Disconnect the PCM C3 harness connector Disconnect the DRB from the DLC Measure the resistance between ground and the SCI Receive circuit 35 COMMUNICATION NO RESPONSE FROM POWERTRAIN CONTROL MODULE DIESEL ONLY Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the PCM C3 harness connector Measure the resistance of the SCI Transmit circuit between the PCM C3 connector and the DLC 15 the resistance below 5 0 ohms Yes gt GoTo 6 No Repair the SCI Transmit circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 If there are no possible causes remaining view repair Repair Replace the Powertrain Control Module Perform POWERTRAIN VERIFICATION TEST VER 1 36 DIESEL Symptom 115 OF ENGINE COOLANT SRC HIGH EX CEEDED When Monitored and Set Condition PO115 TEMPERATURE OF ENGINE COOLANT SRC HIGH EXCEEDED When Monitored With the ignition on
235. n cycle Monitor the DRB for ECM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 7 Turn the ignition off Disconnect the EGR Solenoid harness connector Turn the ignition on Using 12 volt test light connected to ground check the Fused ASD Relay Output circuit Does the test light illuminate brightly Yes gt GoTo 3 No Repair the Fused ASD Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 63 DRIVEABILITY DIESEL 0400 OPEN CIRCUIT Continued APPLICABILITY Turn the ignition off All Disconnect the EGR Solenoid harness connector Disconnect the ECM harness connectors Measure the resistance between ground and the EGR Solenoid Control circuit 15 the resistance above 100 kohms Yes gt GoTo 4 No Repair the EGR Solenoid Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the EGR Solenoid harness connector Disconnect the ECM harness connectors Measure the resistance of the EGR Solenoid Control circuit 15 the resistance below 5 0 ohms Yes gt GoTo 5 No Repair the EGR Solenoid Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Install a substitute EGR Solenoid in place of the vehicle s EGR Solenoid NOTE Ensure the ECM and EGR Solenoid harness connectors are con nected Turn the ignition on With the DRB check for
236. n off Disconnect the Fuel Injection Pump harness connector Turn the ignition on With the DRB erase ECM DTCs and then read ECM DTCS Did DTC P1630 SOLENOID VALVE CONTROLLER OPEN CIRCUIT set Yes Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 3 134 DIESEL P1630 SOLENOID VALVE CONTROLLER SHORT CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Fuel Injection Pump harness connector Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage of the Fuel Timing Solenoid Control circuit 15 the voltage below 0 5 volt Yes gt GoTo 4 No Repair the Fuel Timing Solenoid Control circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Disconnect the Fuel Injection Pump harness connector Measure the resistance between the following cavities in the Fuel Injection Pump connector fuel pump side Cavity 1 to cavities 4 5 6 7 8 9 and 10 Cavity 4 to cavities 5 6 7 8 9 and 10 Cavity 5 to cavities 6 7 8 and 9 Cavity 7 to cavities 6 8 9 and 10 Cavity 8 to cavities 6 and 10 NOTE The resistance should be above 100 ohms for all measurements 15 the resistance above 100 ohms for
237. n on With the IIl read the SKIM DTC s 15 the DTC present for all ignition keys Yes Replace the Sentry Key Immobilizer Module in accordance with the Service Information Perform SKIS VERIFICATION Test Complete With the DRB III attempt to reprogram the ignition keys to the SKIM With the DRB III erase the SKIM DTC s Wait 10 seconds Turn the ignition on With the III read the SKIM DTC s Does the DTC reset Yes gt GoTo 5 No Test Complete Replace the ignition key with a new key With the DRB III program the new ignition key to the SKIM With the III erase the SKIM DTC s Turn the ignition off Wait 10 seconds Turn the ignition on With the IIl read the SKIM DTC s Does the DTC reset Yes gt GoTo 6 No Test Complete 241 VEHICLE THEFT SECURITY TRANSPONDER COMMUNICATION FAILURE Continued APPLICABILITY If there are no possible causes remaining view repair All Repair Replace and program the Sentry Key Immobilizer Module in accordance with the Service Information Perform SKIS VERIFICATION Turn the ignition off Note Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Note Visually inspect the related wire harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any Technical Service Bulletins TSB that may apply Were any problems
238. n the ignition on Using a 12 volt test light connected to ground check the Fuel Heater Relay Output circuit at the Fuel Heater harness connector Is the test light on Yes gt GoTo 2 No gt GoTo 4 Turn the ignition off Disconnect the Fuel Heater harness connector Turn the ignition on Using a 12 volt test light connected to 12 volts check the Ground circuit at the Fuel Heater harness connector Is the test light on Yes gt GoTo 3 No the Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Fuel Heater harness connector Turn the ignition on With the DRB read the Fuel Temperature Sensor NOTE The Fuel temperature must be below 4 5 C 40 F Measure the resistance of the Fuel Heater 15 the resistance between 0 7 and 2 0 ohms Yes gt Test Complete No Replace the Fuel Heater Perform ROAD TEST VERIFICATION VER 2 183 DRIVEABILITY DIESEL CHECKING THE FUEL HEATER OPERATION Continued ACTION APPLICABILITY Turn the ignition off Install a substitute relay in place of the Fuel H eater Relay Disconnect the Fuel Heater harness connector Turn the ignition on Using a 12 test light connected to ground check the Fuel Heater Relay Output circuit Is the test light on Yes Replace the initial Fuel Heater Relay Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 5 Turn the ignition off Remove th
239. nd Does the display a change Fuel Computer Status Yes gt Replace the Overhead Console in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Test Complete 181 DIESEL THE FUEL COMPUTER Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the PCM and ECM harness connectors Measure the resistance of the Fuel Computer Output circuit between the ECM and PCM harness connectors 15 the resistance below 10 0 ohms Yes gt GoTo 5 No Repair the Fuel Computer Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the PCM and ECM harness connectors Measure the resistance between ground and the Fuel Computer Output circuit 15 the resistance below 100 0 ohms Yes Repair the Fuel Computer Output circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 No Replace the PCM in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 182 DIESEL Symptom CHECKING THE FUEL HEATER OPERATION POSSIBLE CAUSES FUEL HEATER RELAY FUEL HEATER RELAY OUTPUT CIRCUIT OPEN FUEL HEATER RESISTANCE FUSED B CIRCUIT OPEN GROUND CIRCUIT OPEN IGNITION SWITCH OUTPUT CIRCUIT OPEN RELAY GROUND CIRCUIT OPEN ACTION APPLICABILITY Turn the ignition off All Disconnect the Fuel Heater harness connector Tur
240. nd and Vehicle Speed Sensor harness connector cavities 1 2 and 3 15 the voltage below 1 0 volt on each circuit Yes gt GoTo 8 No Repair the circuit that measured above 1 0 volt for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the Vehicle Speed Sensor harness connector Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the 5 volt Supply circuit in the Vehicle Speed Sensor harness 200 DIESEL THE SPEEDOMETER OPERATION Continued APPLICABILITY Turn the ignition off Disconnect the ECM harness connectors Disconnect the PCM harness connectors Disconnect the Vehicle Speed Sensor harness connector Measure the resistance between ground and Vehicle Speed Sensor harness connector cavities 1 2 and 3 15 the resistance above 100 kohms on each circuit Yes gt GoTo 9 No Repair the circuit that measured below 100 kohms for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the PCM harness connectors Disconnect the Vehicle Speed Sensor harness connector Measure the resistance between VSS harness connector cavity 1 and cavities 2 and 3 then between cavity 2 and 3 15 the resistance above 100 kohms for each measurement Yes gt GoTo 10 No Repair the circuit that
241. nd mileage have not been programmed DTC will be set in ABS and Air Bag modules In addition if vehicle is equipped with a Sentry Key Immobilizer Module SKIM Secret Key data must be updated to enable start 5 For ABS and Air Bag systems Enter correct VIN and Mileage in PCM Erase codes in ABS and Air Bag modules 6 For SKIM theft alarm Connect to data link conn Go to Theft Alarm SKIM Misc and place SKIM in secured access mode by using the appropriate PIN code for this vehicle Select Update the Secret Key data Data will be transferred from SKIM to PCM 7 Attempt to start the engine 8 If the engine is unable to start look for any Technical Service Bulletins that may relate to this condition Return to Symptom List if necessary 9 If the engine starts and stays running the repair is now complete ROAD TEST VERIFICATION VER 2 1 Inspect the vehicle to ensure that all engine components are properly installed and connected Reassemble and reconnect components as necessary 2 If this verification procedure is being performed after a non DTC test perform steps 3 and 4 3 Check to see if the initial symptom still exists If there are no trouble codes and the symptom no longer exists the repair was successful and testing is now complete 4 If the initial or another symptom exists the repair is not complete Check all pertinent Technical Service Bulletins TSBs and return to the Symptom List if necessary 5 For
242. ndition P1225 CONTROL SLEEVE SENSOR START END POS NOT ATTAINED When Monitored With the ignition on Set Condition control sleeve sensor signal indicates the control sleeve did not reach its start position P1225 CONTROL SLEEVE SENSOR STOP END POS NOT ATTAINED When Monitored With the ignition on Set Condition The control sleeve position sensor signal indicates the control sleeve is not at its ending position POSSIBLE CAUSES ENGINE CONTROL MODULE REPLACE THE FUEL INJ ECTION PUMP INTERMITTENT CONDITION ACTION APPLICABILITY NOTE If other Control Sleeve Position Sensor or Fuel Quantity Actuator All DTCs are present diagnose the other DTCs before continuing Turn the ignition on With the DRB erase ECM DTCs Perform several drive cycles turning the ignition off for at least 10 seconds between each drive cycle Monitor the DRB for ECM DTCs Did this DTC reset Yes gt GoTo 2 GoTo 3 109 DIESEL P1225 CONTROL SLEEVE SENSOR START END POS ATTAINED Continued ACTION APPLICABILITY Replace the Fuel Injection Pump in accordance with the Service Information All With the DRB erase ECM DTCs Perform several drive cycles turning the ignition off for at least 10 seconds between each drive cycle Monitor the DRB for ECM DTCs Did this DTC reset Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD T
243. nformation Perform ROAD TEST VERIFICATION VER 2 139 DRIVEABILITY DIESEL Symptom P1645 GLOW DISPLAY OPEN CIRCUIT When Monitored and Set Condition P1645 GLOW DISPLAY OPEN CIRCUIT When Monitored During wait to start lamp operation Set Condition ECM detects an open short to ground the wait to start lamp control circuit NOTE This code may set if the ASD Diesel Power Relay contacts stick together or the ASD Diesel Power Relay control circuit shorts to ground after key off POSSIBLE CAUSES CHECK FOR OTHER DTCS INTERMITTENT CONDITION GLOW PLUG LAMP CONTROL CIRCUIT SHORTED TO GROUND GLOW PLUG LAMP CONTROL CIRCUIT OPEN ENGINE CONTROL MODULE CHECK THE GLOW PLUG LAMP BULB MESSAGE CENTER ACTION APPLICABILITY NOTE This DTC may set if the ASD Diesel Power Relay contacts stick All together after ignition off Turn the ignition on With the DRB check for additional DTCs Are other DTCs present Yes Refer tothe Symptom List for diagnosis of the other DTCs before continuing Perform ROAD TEST VERIFICATION VER 2 No GoTo 2 Turn the ignition on With the DRB actuate the Glow Plug Lamp 15 the Glow Plug Lamp on and off Yes gt GoTo 3 gt GoTo 4 140 DRIVEABILITY DIESEL P1645 GLOW DISPLAY OPEN CIRCUIT Continued ACTION APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at t
244. ng view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 108 DIESEL Symptom List P1225 CONTROL SLEEVE SENSOR START END POS NOT AT TAINED P1225 CONTROL SLEEVE SENSOR STOP END POS NOT AT TAINED Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P1225 CONTROL SLEEVE SEN SOR START END POS NOT ATTAINED When Monitored and Set Co
245. ng it is severe enough SKIM sentry key immobilizer module SKIS sentry key immobilizer system start amp stall surge VSS The engine starts but immediately dies engine rpm fluctuation without cor responding change in throttle posi tion sensor vehicle speed sensor 7 0 DIAGNOSTIC INFORMATION AND PROCEDURES CHARGING Symptom P0622 GENERATOR FIELD NOT SWITCHING PROPERLY DIESEL ee When Monitored and Set Condition P0622 GENERATOR FIELD NOT SWITCHING PROPERLY DIESEL When Monitored With the engine speed greater than 1500 RPM for at least 25 seconds Set Condition When the PCM tries to regulate the generator output with no result during monitoring POSSIBLE CAUSES INTERMITTENT CONDITION CHECK FOR OTHER CHARGING SYSTEM DTCS GENERATOR FIELD CIRCUIT OPEN GENERATOR SOURCE CIRCUIT OPEN POWERTRAIN CONTROL MODULE INTERNAL DRIVER FAULT GENERATOR FIELD OPEN POWERTRAIN CONTROL MODULE GENERATOR SOURCE OPEN ACTION APPLICABILITY Turn the ignition on All With the DRB read PCM DTCs Are there any other Charging System related DTCs Yes Refer to the symptom list for the related symptom s Perform CHARGING VERIFICATION VER 3 No GoTo 2 NOTE The battery must be fully charged the generator belt must be good condition and tensioned properly before continuing Turn the ignition on With the DRB erase PCM DTCs Turn the ignition off for 10 seconds then start the engine W
246. ng the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 125 DIESEL Symptom P1625 ASD DIESEL POWER RELAY SHUTS OFF TOO LATE E When Monitored and Set Condition P1625 ASD DIESEL POWER RELAY SHUTS OFF TOO LATE When Monitored During after run Set Condition The internal ECM timer determines that the ASD Diesel Power Relay remains on too long when AFTER RUN mode of operation has been completed POSSIBLE CAUSES CHECK FOR OTHER DTCS INTERMITTENT CONDITION SUBSTITUTE ASD DIESEL POWER RELAY ASD DIESEL POWER RELAY CONTROL CIRCUIT SHORTED TO GROUND INTERMITTENTLY ASD DIESEL POWER RELAY OUTPUT CIRCUIT SHORTED TO VOLTAGE ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB check for additional DTCs Are other DTCs present Yes Refer tothe Symptom List for diagnosis of the other DTCs before continuing Per
247. nition on Measure the voltage of the EGR Solenoid Control circuit 15 the voltage below 0 5 volt Yes gt Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the EGR Solenoid Control circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 66 DRIVEABILITY DIESEL Symptom 460 LEVEL UNIT NO CHANGE OVER MILES When Monitored and Set Condition PO460 FUEL LEVEL UNIT NO CHANGE OVER MILES
248. nition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 gt GoTo 3 Perform symptom CHECKING THE SPEED CONTROL OPERATION in the Symptom List Were any problems found Yes Repair as necessary Perform SPEED CONTROL VERIFICATION VER 4 No Replace and program the Engine Control Module in accordance with the Service Information Perform SPEED CONTROL VERIFICATION VER 4 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform SPEED CONTROL VERIFICATION VER 4 No Test Complete 123 DRIVEABILITY DIESEL Symptom P1605 TERMINAL 15 PLAUSIBILITY AFTER START UP
249. nitored With the ignition on Set Condition The SKIM fails an internal J 1850 communication self test STACK OVERFLOW FAILURE When Monitored With the ignition on Set Condition The microcontroller has exceeded its stack space limit 234 VEHICLE THEFT SECURITY ANTENNA FAILURE Continued POSSIBLE CAUSES SKIM INTERNAL DTC FAILURE ACTION APPLICABILITY Note This trouble code indicates an internal SKIM fault All With the DRB III read and record the SKIM and then erase the SKIM 5 Perform 10 ignition key cycles leaving the ignition key on for a minimum of 90 seconds per cycle With the III read the SKIM Did the same SKIM DTC return Yes gt Replace and program the Sentry Key Immobilizer Module in accordance with the Service Information Perform SKIS VERIFICATION Test Complete 235 VEHICLE THEFT SECURITY Symptom List PCM STATUS FAILURE SERIAL LINK EXTERNAL FAULT Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be PCM STATUS FAILURE When Monitored and Set Condition PCM STATUS FAILURE When Monitored With the ignition on Set Condition This DTC exists when PCM STATUS message was not received from the PCM for at least 20 0 consecutive seconds SERIAL LINK EXTERNAL FAULT When Monitored At ignition on after ignition on during any rolling code handshake that occurs with the PCM due toa SKIM reset or during
250. nnect the Vehicle Speed Sensor harness connector Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the 5 volt Supply circuit in the Vehicle Speed Sensor harness connector No GoTo 8 74 DRIVEABILITY DIESEL 5 SPEED SENSOR PEC FREQUENCY TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off Disconnect the PCM harness connectors Disconnect the Vehicle Speed Sensor harness connector Note Check connectors Clean repair as necessary Turn the ignition on Measure the voltage of the Vehicle Speed Sensor Signal circuit 15 the voltage above 5 5 volts Yes gt GoTo 6 No Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Vehicle Speed Sensor harness connector Note Check connectors Clean repair as necessary Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between ASD Diesel Power Relay cavities 30 and 87 in PDC Turn the ignition on Measure the voltage of the Vehicle Speed Sensor Signal circuit 15 the voltage above 5 5 volts Yes gt GoTo 7 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ign
251. nnectors Disconnect the Fuel Level Sensor harness connector Measure the resistance between ground and the Fuel Level Sensor Signal circuit Is the resistance above 100 kohms Yes gt GoTo 4 Repair the Fuel Level Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 69 DRIVEABILITY DIESEL P0462 FUEL LEVEL SENDING UNIT VOLTS TOO LOW Continued APPLICABILITY Turn the ignition off All Disconnect the PCM harness connectors Disconnect the Fuel Level Sensor harness connector Measure the resistance between the Fuel Level Sensor Signal circuit and Sensor Ground circuit 15 the resistance above 100 kohms Yes gt GoTo 5 No the Fuel Level Sensor Signal and Ground circuits for a short together Perform ROAD TEST VERIFICATION VER 2 there no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitor
252. ny chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 38 DIESEL Symptom 115 OF ENGINE COOLANT SRC LOW CEEDED When Monitored and Set Condition PO115 TEMPERATURE OF ENGINE COOLANT SRC LOW EXCEEDED When Monitored With the ignition on Set Condition The voltage the ECM engine coolant temperature sensor signal circuit is below 0 5 volt for more than 3 seconds POSSIBLE CAUSES INTERMITTENT CONDITION ECM ECT SENSOR ECM ECT SENSOR SIGNAL CIRCUIT SHORTED TO GROUND ECM ECT SENSOR SIGNAL AND GROUND CIRCUITS SHORTED TOGETHER ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB monitor the ECM Engine Coolant Temperature ECT Sensor voltage Is the ECM ECT Sensor voltage below 0 3 volt Yes gt GoTo 2 gt GoTo 6 Turn the ignition off Disconnect the ECM ECT Sensor harness connector Turn the ignition on With the DRB read the ECM ECT Sensor voltage 15 the voltage above 4 0 volts Yes Replace the ECM ECT Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 3 Turn the ignition off Disconnect the ECM harness
253. o 7 No Repair the Glow Plug Lamp Control circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Message Center harness connector Measure the resistance of the Glow Plug Lamp Control circuit 15 the resistance below 5 0 ohms Yes gt GoTo 8 Repair the Glow Plug Lamp Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Message Center harness connector Turn the ignition on Measure the voltage of the Ignition Feed circuit 15 the voltage above 10 0 volts Yes gt GoTo 9 No Repair the Ignition Feed circuit to the Message Center for open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove and inspect the Glow Plug Lamp bulb from the Message Center Is the bulb OK Yes Replace the Message Center Perform ROAD TEST VERIFICATION VER 2 No Replace the Glow Plug Lamp bulb Perform ROAD TEST VERIFICATION VER 2 190 DRIVEABILITY DIESEL Symptom CHECKING THE GLOW PLUG OPERATION POSSIBLE CAUSES CHECKING THE GLOW PLUGS FUSED B CIRCUIT OPEN GLOW PLUG RELAY GLOW PLUG RELAY OUTPUT CIRCUIT OPEN APPLICABILITY Turn the ignition off Disconnect all four Glow Plug connectors Turn the ignition on With the DRB actuate Glow Relay 1 Using 12 volt test light connected to ground probe each Glow
254. o the Vehicle Speed Sensor Signal circuit in the VSS harness connector With the DRB monitor the VEHICLE SPEED while tapping the other end of the jumper wire to ground Does the DRB display km h MPH greater than 0 Yes Replace the Vehicle Speed Sensor Perform ROAD TEST VERIFICATION VER 2 gt GoTo 14 Turn the ignition off Disconnect the Vehicle Speed Sensor harness connector Disconnect the PCM harness connectors Check connectors Clean repair as necessary Measure the resistance between the Vehicle Speed Sensor Signal circuit and the Sensor Ground circuit Is the resistance above 100 kohms Yes gt GoTo 15 Repair the Vehicle Speed Sensor Signal circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 there no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Vehicle Speed Sensor harness connector Disconnect the PCM harness connectors Check connectors Clean repair as necessary Turn the ignition on Measure the voltage between ground and the 5 volt Supply circuit 15 the voltage below 0 5 volt Yes gt Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 17 210 DRIVEABILITY DIES
255. off Disconnect the Brake Lamp Switch harness connector Disconnect the ECM harness connectors Measure the resistance of the Primary Brake Switch Signal circuit Is the resistance below 5 0 ohms Yes gt GoTo 15 Repair the Primary Brake Switch Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 161 DIESEL Symptom List P1725 INDUCTIVE AUX SPEED SENSOR DYN PLAUSIBILITY P1725 INDUCTIVE AUX SPEED SENSOR OVERSPEED RECOGNI TION P1725 INDUCTIVE AUX SPEED SENSOR PLAUSIBILITY P1725 INDUCTIVE AUX SPEED SENSOR STATIC PLAUSIBILITY Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P1725 INDUCTIVE AUX SPEED SENSOR DYN PLAUSIBILITY aa When Monitored and Set Condition P1725 INDUCTIVE AUX SPEED SENSOR DYN PLAUSIBILITY When Monitored With the engine running Set Condition TheECM has determined that the inductive auxiliary speed sensor values are incorrect during an engine speed transition P1725 INDUCTIVE AUX SPEED SENSOR OVERSPEED RECOGNITION When Monitored With the engine running Set Condition The ECM detects the engine speed signal from the needle movement sensor has exceeded 6600 RPM P1725 INDUCTIVE AUX SPEED
256. oken wire e Refer to any hotlines or technical service bulle tins that may apply NOTE Electro magnetic Radio interference can cause intermittent system malfunction GENERAL INFORMATION 3 3 4 ECM DIAGNOSTIC TROUBLE CODES AC CONTROL OPEN CIRCUIT AC CONTROL SHORT CIRCUIT ACCEL PEDAL SENSOR PLAUSIBILITY ACCEL PEDAL SENSOR PWG PLAUS WITH POTENTIOMETER ACCEL PEDAL SENSOR SIGNAL HIGH EXCEEDED ACCEL PEDAL SENSOR SUPPLY HIGH EXCEEDED ACCEL PEDAL SENSOR SUPPLY LOW EXCEEDED AIR TEMP SENSOR SIGNAL HIGH EXCEEDED AIR TEMP SENSOR SIGNAL LOW EXCEEDED ATMOSPHERE PRESSURE SENSOR SRC HIGH EXCEEDED ATMOSPHERE PRESSURE SENSOR SRC LOW EXCEEDED BATTERY VOLTAGE SRC HIGH EXCEEDED BRAKE SIGNAL PLAUS WITH REDUNDANT CONTACT CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED CONTROL SLEEVE SENSOR START END POS NOT ATTAINED CONTROL SLEEVE SENSOR STOP END POS NOT ATTAINED EEPROM PLAUSIBILITY CHECKSUM ERROR FOR EGR EEPROM PLAUSIBILITY CHECKSUM ERROR IN CC212 EEPROM PLAUSIBILITY COMMUNICATION WITH EEPROM EEPROM PLAUSIBILITY FUNC SWITCH WRONG OR MISSING EEPROM PLAUSIBILITY VER NUMBER NOT CORRESPONDING EEPROM PLAUSIBILITY VIN CHECKSUM ERROR EGR OPEN CIRCUIT EGR SHORT CIRCUIT ENGINE SPEED SENSOR DYN PLAUSIBILITY ENGINE SPEED SENSOR OVER SPEED RECOGNITION ENGINE SPEED SENSOR STATIC PLAUSIBILITY FAN CONTROL OPEN CIRCUIT FAN CONTROL SHORT CIRCUIT FUEL QUANTITY ACTUATOR NEG GOV DEVIATION COLD FUEL QUANTITY ACTUATOR NEG GOV DEVIATION WARM
257. om the Starter Solenoid Measure the resistance of the Starter Relay Output circuit between the PDC and the Starter Solenoid Is the resistance below 5 0 ohms Yes gt GoTo 9 No Repair the Starter Relay Output circuit for an open Perform NO START VERIFICATION 1 Turn the ignition off All Disconnect the Clutch Interlock Switch harness connector Connect a jumper wire between the Clutch Interlock Switch Sense circuit and ground Attempt to start the engine Does the engine crank Yes Repair the Clutch Interlock Switch Sense circuit for an open Perform NO START VERIFICATION VER 1 No GoTo 7 229 STARTING NO CRANK CONDITION Continued ACTION Using the Service Information check the battery cables for high resistance Did either battery cable have a voltage drop greater than 0 2 volts Yes Replace the battery cable s Perform NO START VERIFICATION VER 1 GoTo 10 Turn the ignition off Attempt to manually rotate the crankshaft 360 Is the crankshaft able to rotate 360 Yes Replace the Starter Motor Perform NO START VERIFICATION VER 1 Repair the engine mechanical problem Perform NO START VERIFICATION VER 1 230 APPLICABILITY All STARTING Symptom NO START CONDITION POSSIBLE CAUSES CHECKING FUEL QUANTITY ACTUATOR IMMOBILIZER SIGNAL IMMOBILIZER SIGNAL OUTPUT FUEL INJ ECTION PUMP TIMING FUEL QUANTITY ACTUATOR CIRCU
258. omplete Turn the ignition off Disconnect the ECM harness connectors Disconnect the Message Center harness connector Measure the resistance between ground and the Glow Plug Lamp Control circuit 15 the resistance above 100 kohms Yes gt GoTo 5 No Repair the Glow Plug Lamp Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Message Center harness connector Measure the resistance of the Glow Plug Lamp Control circuit 15 the resistance below 5 0 ohms Yes gt GoTo 6 Repair the Glow Plug Lamp Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 NOTE Ensure the Message Center harness connector is connected Turn the ignition off Disconnect the ECM harness connectors Turn the ignition on Connect a jumper wire between ground and the Glow Plug Lamp Control circuit in ECM harness connector C1 Did the Glow Plug Lamp illuminate Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 7 144 DRIVEABILITY DIESEL P1645 GLOW DISPLAY SHORT CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Remove and check the Glow Plug Lamp bulb from the Instrument Cluster Is the bulb OK Yes Replace the Message Center Perform ROAD TEST VERIFICATION VER 2 Repla
259. on Switch Start Output circuit while turning the ignition switch to the crank position Does the test light illuminate with the ignition switch in the crank position Yes gt GoTo 4 No Repair the Ignition Switch Start Output circuit Perform NO START VERIFICATION VER 1 228 STARTING NO CRANK CONDITION Continued ACTION APPLICABILITY WARNING The transmission must be in Neutral and the parking break must be engaged for this test WARNI NG The engine may be cranked in this test Keep away from moving engine parts Briefly connect a jumper wire between the Starter Relay Output circuit and the Fused circuit at the starter relay connector in the Did the engine crank Yes gt GoTo 5 GoTo 8 Turn the ignition off Remove the Starter Relay F rom the PDC Install a substitute relay in place of the Starter Relay Attempt to start the engine Does the engine crank Yes Replace the Starter Relay Perform NO START VERIFICATION VER 1 No gt GoTo 6 Check the shifter and associated linkage for proper adjustment between shifter and transmission Were any problems found Yes Repair or replace as necessary Perform NO START VERIFICATION VER 1 No Replace the Clutch Interlock Switch in accordance with the Service Information Perform NO START VERIFICATION VER 1 Turn the ignition off Remove the Starter Relay from the PDC Disconnect the Starter Relay Output wire fr
260. on off Disconnect the ECM harness connectors Disconnect the PCM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage of the Immobilizer Signal circuit 15 the voltage below 1 0 volt Yes gt GoTo 5 No Repair the Immobilizer Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 NOTE Remove the jumper wire and install the ASD Diesel Power Relay Turn the ignition off Disconnect the ECM harness connectors Disconnect the PCM harness connectors Measure the resistance between ground and the Immobilizer Signal circuit 15 the resistance above 100 kohms Yes gt GoTo 6 No Repair the Immobilizer Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the PCM harness connectors Measure the resistance of the Immobilizer Signal circuit 15 the resistance below 5 0 ohms Yes gt GoTo 7 No Repair the Immobilizer Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 152 DIESEL P1685 VEHICLE THEFT ALARM IMMOBILIZER SIG LOST Continued ACTION APPLICABILITY Turn the ignition off All NOTE Ensure the ECM harness connectors are connected Measure the amperage between ground and the Immobili
261. on on All With the DRB erase ECM DTCs Turn the ignition off wait 30 seconds then turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 7 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Needle Movement Sensor harness connector Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 of the ASD Diesel Power Relay connector Turn the ignition on Measure the voltage on the Needle Movement Sensor Signal circuit Is the voltage below 0 5 volt Yes gt GoTo 3 No Repair the Needle Movement Sensor Signal circuit for short to voltage Perform ROAD TEST VERIFICATION VER 2 NOTE Remove the jumper wire 95 DRIVEABILITY DIESEL P1201 NEEDLE MOVEMENT SENSOR SRC HIGH EXCEEDED Continued ACTION APPLICABILITY NOTE Ensure the ECM harness connectors are connected and the ASD Diesel Power Relay is installed before continuing Turn the ignition off Disconnect the Needle Movement Sensor harness connector Connect a jumper wire between the Needle Movement Sensor harness connector cavities Turn the ignition on With the DRB read ECM DTCs Did DTC P1201 NEEDLE MOVEMENT SENSOR SRC LOW EXCEEDED set Yes Replace the Needle Movement Sensor in accordance with the Service nformation Perform ROAD TEST VERIFICATION VER 2 GoTo 4 Turn the ignition off All Disconnect the Nee
262. on while observing the Water In Fuel Lamp Does the Water In Fuel Lamp turn on and stay on Yes gt GoTo 3 No Replace the Water Fuel Sensor Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the PCM harness connectors Disconnect the Water In Fuel Sensor harness connector Measure the resistance between engine ground and the Water In Fuel Sensor Signal circuit Is the resistance above 100 kohms Yes gt GoTo 4 No Repair the Water In Fuel Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 212 DRIVEABILITY DIESEL CHECKING THE WATER IN FUEL LAMP OPERATION Continued APPLICABILITY Turn the ignition off All Disconnect the PCM harness connectors Disconnect the Water In Fuel Sensor harness connector Measure the resistance between the Sensor Ground circuit and the Water In Fuel Sensor Signal circuit 15 the resistance above 100 kohms Yes Replace and program the PCM in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Repair the Water In Fuel Sensor Signal circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Water Fuel Sensor harness connector Turn the ignition on Connect jumper wire across the Water Fuel Sensor harness connector cavities 1 and 2 Observe the Water In Fuel Lamp 15 the lamp
263. oost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the 5 volt Supply circuit 15 the resistance below 5 0 ohms Yes gt GoTo 5 No Repair the 5 volt Supply circuit for high resistance Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Replace the Turbocharger Boost Pressure I ntake Air Temperature Sensor Turn the ignition on With the DRB erase ECM DTCs Test drive the vehicle pausing several times to cycle the ignition Monitor the DRB for ECM DTCs Did this DTC reset Yes gt Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Therepair is complete Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires V
264. ordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 3 Turn the ignition off Disconnect the PCM harness connectors Disconnect the PCM ECT Sensor harness connector Measure the resistance between ground and the PCM ECT Sensor Signal circuit Is the resistance above 100 kohms Yes gt GoTo 4 Repair the PCM ECT Sensor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 41 DRIVEABILITY DIESEL 0117 SENSOR VOLTAGE TOO LOW Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the PCM harness connectors Disconnect the PCM ECT Sensor harness connector Measure the resistance between the PCM ECT Sensor Signal circuit and Sensor Ground circuit Is the resistance above 100 kohms Yes gt GoTo 5 No Repair the PCM ECT Sensor Signal and Ground circuits for a short together Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the
265. ors Disconnect the Needle Movement Sensor harness connector Measure the resistance of the Needle Movement Sensor Signal circuit 15 the resistance below 5 0 ohms Yes gt GoTo 5 No Repair the Needle Movement Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Needle Movement Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Needle Movement Sensor Ground circuit 15 the resistance below 5 0 ohms Yes gt GoTo 6 No Repair the Needle Movement Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 NOTE EMI interference can be caused by high current carrying wires or All the Alternator Check the wiring harness for mis routing that could cause interference 15 the wiring harness mis routed Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 4 163 DRIVEABILITY DIESEL P1725 INDUCTIVE AUX SPEED SENSOR DYN PLAUSIBILITY Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Needle Movement Sensor harness connector Measure the resistance between ground and the Needle Movement Sensor Signal circuit 15 the resistance above 100 kohms Yes gt GoTo 7 No Repair the Needle Movement Sensor Signal circuit for short to ground Perform ROAD TEST VERIFICATION VER 2 Turn t
266. output is removed from the ECM cavity C1 47 the ECM performs a self diagnostic check in the following order 1 Electrical shut off test Fuel quantity actuator test Monitoring module test Voltage regulator test Main relay test if tests 1 4 pass If any of tests 1 4 fail the fault is stored memory and can be retrieved during the next igni tion cycle using the amp WN 3 2 3 MONITORED CIRCUITS The PCM and ECM are able to monitor and identify most driveability related trouble condi tions Some circuits are directly monitored through feedback circuitry addition the PCM ECM monitor the voltage state of some circuits and compare those states with expected values Other systems are monitored indirectly when the PCM and ECM conduct a rationality test to identify problems Although most engine control subsystems are either directly or indirectly monitored there may be occasions when diagnostic trouble codes are not immediately identified For a trouble code to set specific conditions must be met and unless these conditions are encountered a code will not set 3 2 4 SKIS ON BOARD DIAGNOSTICS The SKIS has been programmed to transmit and monitor many different coded messages as well as CCD Bus messages This monitoring is called On Board Diagnosis Certain criteria must be met for a diagnostic trouble code to be entered in to the SKIS memory The criteria may be a range o
267. pair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the ECM harness connectors Disconnect the PCM harness connectors Measure the resistance between ground and the Engine Speed Sensor Signal circuit 203 DRIVEABILITY DIESEL Symptom CHECKING THE TURBOCHARGER BOOST PRESSURE SENSOR CALIBRATION POSSIBLE CAUSES TURBOCHARGER BOOST PRESSURE SENSOR CALIBRATION ACTION APPLICABILITY Turn the ignition on All With the DRB select Engine Bosch then Sensors Read the Boost Pressure Voltage Is the Boost Pressure Voltage between 1 70 and 1 95 volts Yes Test Complete Replace the Turbocharger Boost Pressure Sensor Perform ROAD TEST VERIFICATION VER 2 204 DRIVEABILITY DIESEL Symptom CHECKING THE TURBOCHARGER OPERATION POSSIBLE CAUSES CHECKING THE TURBOCHARGER HOSES CHECKING THE WASTEGATE HOSE TURBOCHARGER WASTEGATE ACTUATOR ARM OPERATION WASTEGATE RESTRICTION ACTION APPLICABILITY NOTE The exhaust system must be free from any restriction to perform this test Check the turbocharger outlet hose between the turbocharger and the intake manifold and the turbocharger inlet hose between the turbocharger and the air cleaner for loose connection damage or restriction Are any of these conditions evident Yes Repair or replace as necessary Perform
268. pair the Fuel Quantity Actuator Control circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 102 DRIVEABILITY DIESEL P1220 FUEL QUANTITY ACTUATOR NEG GOV DEVIATION WARM Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Fuel Injection Pump harness connector Measure the resistance between the following cavities in the Fuel Injection Pump connector fuel pump side Cavity 1 to cavities 4 5 6 7 8 9 and 10 Cavity 4 to cavities 5 6 7 8 9 and 10 Cavity 5 to cavities 6 7 8 and 9 Cavity 7 to cavities 6 8 9 and 10 Cavity 8 to cavities 6 and 10 NOTE The resistance should be above 100 ohms for all measurements Is the resistance above 100 ohms for each of the measurements Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace the Fuel Injection Pump in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored Set Conditions If
269. previously read DTCs that have not been dealt with return to the Symptom List and follow the diagnostic path for that DTC otherwise continue 6 If the engine control module ECM has not been changed perform steps 7 and 8 otherwise continue with step 9 7 With the DRB erase all diagnostic trouble codes DTCs then disconnect the 8 Turn the ignition off for at least 10 seconds 9 Ensure no DTCs remain by performing steps 10 through 13 10 Road test the vehicle For some of the road test go at least 64 km h 40 MPH If this test is for an A C Relay Control Circuit drive the vehicle for at least 5 minutes with the A C on 11 At some point stop the vehicle and turn the engine off for at least 10 seconds then restart the engine and continue 12 Upon completion of the road test turn the engine off and check for DTCs with the DRB 13 If the repaired DTC has reset the repair is not complete Check for any pertinent Technical Service Bulletins TSBs and return to the Symptom List If there are no DTCs the repair was successful and is now complete Are any DTCs or symptoms remaining Yes Repair is not complete refer to appropriate symptom No Repair is complete 244 APPLICABILITY All APPLICABILITY All VERIFICATION TESTS Verification Tests Continued SKIS VERIFICATION APPLICABILITY 1 Reconnect all previously disconnected components and connectors All 2 Obtain the vehicle s unique Pe
270. ramming procedures for these modules have been performed in accordance with the Service Information 2 Inspect the vehicle to ensure that all engine components are properly installed and connected Reassemble and reconnect components as necessary 3 Inspect the engine oil for contamination If it is contaminated change the oil and filter 4 With the DRB erase all diagnostic trouble codes DTCs 5 Turn the ignition off for at least 10 seconds 6 Attempt to start the engine 7 If the engine is unable to start look for any Technical Service Bulletins TSBs that may relate to this condition Return to the Symptom List if necessary 8 If the engine starts and continues to run the repair is now complete Are any DTCs or symptoms remaining Yes is not complete refer to appropriate symptom No Repair is complete 243 APPLICABILITY All APPLICABILITY All VERIFICATION TESTS Verification Tests Continued POWERTRAIN VERIFICATION TEST VER 1 1 Inspect the vehicle to ensure that all engine components are properly installed and connected Reassemble and reconnect components as necessary 2 Inspect the engine oil for contamination If it is contaminated change the oil and filter 3 Perform the steps 4 through 6 if the PCM has been replaced Then proceed with the verification If the PCM has not been replaced skip those steps and continue verification 4 PCM has been changed and correct VIN a
271. rator pedal Did Low Idle Position Switch input change between IDLE and ABOVE IDLE Yes gt GoTo 9 ReplacetheAccelerator Pedal Position Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the APP Sensor harness connector Turn the ignition on Measure the voltage of the 5 volt Supply circuit in APP Sensor harness connector cavity 10 Is the voltage between 4 7 and 5 3 volts Yes gt GoTo 10 No GoTo 23 Turn the ignition off Disconnect the APP Sensor harness connector Connect a jumper wire between APP Sensor harness connector cavities 7 and 10 With the DRBIII read the PEDAL OUTPUT VOLTS Does the display between 4 0 and 5 5 volts Yes gt GoTo 11 No gt GoTo 18 118 DRIVEABILITY DIESEL P1515 ACCEL PEDAL SENSOR PLAUSIBILITY Continued APPLICABILITY Turn the ignition off All Disconnect the APP Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Sensor Ground circuit between APP Sensor harness connector cavity 8 and ECM harness connector C1 15 the resistance below 5 0 ohms Yes gt GoTo 12 No Repair the ECM APP Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the APP Sensor harness connector Turn the ignition on Connect a voltmeter between the 5 volt Supply circuit ca
272. rcuit for an open Perform ROAD TEST VERIFICATION VER 2 NOTE Ensure the Message Center harness connector is connected Turn the ignition off Disconnect the ECM harness connectors Turn the ignition on Connect a jumper wire between ground and the Glow Plug Lamp Control circuit in ECM harness connector C1 Did the Glow Plug Lamp illuminate Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 7 141 DRIVEABILITY DIESEL P1645 GLOW DISPLAY OPEN CIRCUIT Continued ACTION APPLICABILITY Turn the ignition off All Remove and check the Glow Plug Lamp bulb from the Instrument Cluster Is the bulb OK Yes Replace the Message Center Perform ROAD TEST VERIFICATION VER 2 Replace the Glow Plug Lamp bulb Perform ROAD TEST VERIFICATION VER 2 142 DIESEL Symptom P1645 GLOW DISPLAY SHORT CIRCUIT When Monitored and Set Condition P1645 GLOW DISPLAY SHORT CIRCUIT When Monitored During wait to start lamp operation Set Condition detects excessive current draw on the wait to start lamp control circuit when attempting to activate the wait to start lamp POSSIBLE CAUSES CHECK FOR OTHER DTCS INTERMITTENT CONDITION GLOW PLUG LAMP CONTROL CIRCUIT SHORTED TO GROUND GLOW PLUG LAMP CONTROL CIRCUIT OPEN ENGINE CONTROL MODULE CHECK THE GLOW PLUG LAMP BULB MESSAGE CEN
273. re the voltage of the SCI Transmit circuit at the DLC connector 15 the voltage above 1 0 volt Yes Repair the SCI Transmit circuit for a short to voltage Perform POWERTRAIN VERIFICATION TEST VER 1 No gt GoTo 6 Measure the resistance between the SCI Transmit circuit and the SCI Receive circuit at the PCM connector 15 the resistance below 5 0 ohms Yes Repair the short between the SCI Transmit and the SCI Receive circuits Perform POWERTRAIN VERIFICATION TEST VER 1 GoTo 7 Turn the ignition off Disconnect the DRB from the DLC Disconnect the PCM harness connectors Disconnect the ECM harness connectors Disconnect the CAB harness connector Measure the resistance between ground and the SCI Transmit circuit at the DLC 15 the resistance below 5 0 ohms Yes Repair the SCI Transmit circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 1 No gt GoTo 8 Turn the ignition off All Disconnect the DRB from the DLC Disconnect the PCM harness connectors Disconnect the ECM harness connectors Disconnect the CAB harness connector 33 COMMUNICATION NO RESPONSE FROM ECM AND PCM DIESEL ONLY Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the DRB from the DLC Disconnect the ECM harness connectors Measure the resistance of the SCI Transmit circuit between the ECM connector and the DLC 15 the resistance below 5 0 ohms Yes gt GoTo 9 No
274. rness connector Measure the resistance between ground and the Primary Brake Switch Sense circuit Is the resistance below 100 0 ohms Yes Repair the Primary Brake Switch Signal circuit for a short to ground Perform SPEED CONTROL VERIFICATION VER 4 GoTo 20 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Brake Lamp Switch harness connector Measure the resistance of the Primary Brake Switch Sense circuit 15 the resistance below 10 0 ohms Yes gt GoTo 21 No Repair the Primary Brake Switch Signal circuit for an open Perform SPEED CONTROL VERIFICATION VER 4 Disconnect the Brake Lamp Switch harness connector Turn the ignition on Using a 12 volt test light connected to ground check the Fused circuit at the Brake Lamp Switch harness connector Does the test light illuminate brightly Yes gt GoTo 22 No Repair the Fused B circuit for an open Perform SPEED CONTROL VERIFICATION VER 4 226 SPEED CONTROL CHECKING THE SPEED CONTROL OPERATION Continued ACTION APPLICABILITY NOTE The Brake Switch must be properly adjusted before performing this test Turn the ignition off Disconnect the ECM harness connectors Usinga 12 volt test light connected to ground probe the Primary Brake Switch Sense circuit at the ECM harness connector While observing the test light press and release the Brake Pedal several times Does the test light turn on and off whi
275. rol Sleeve Position Sensor circuit s that mea sured below 100 kohms for a short to ground Perform ROAD TEST VERIFICATION VER 2 107 DRIVEABILITY DIESEL P1225 CONTROL SLEEVE SENSOR SIGNAL HIGH EXCEEDED Continued APPLICABILITY Turn the ignition off All Disconnect the Fuel Injection Pump harness connector Disconnect the ECM harness connectors Measure the resistance between ECM harness connector C2 cavities 56 and 57 then 56 and 58 then 57 and 58 15 the resistance below 100 kohms for any of the measurements Yes Repair the Control Sleeve Position Sensor circuits that measured below 100 kohms for a short together Perform ROAD TEST VERIFICATION VER 2 GoTo 7 Turn the ignition off Disconnect the Fuel Injection Pump harness connector Disconnect the ECM harness connectors Measure the resistance between ECM harness connector C2 cavity 56 and Fuel Injection Pump harness connector cavity 1 Measure the resistance between ECM harness connector C2 cavity 57 and Fuel Injection Pump harness connector cavity 2 Measure the resistance between ECM harness connector C2 cavity 58 and Fuel Injection Pump harness connector cavity 3 Is the resistance below 5 0 ohms for each of the measurements Yes gt GoTo 8 No Repair the Control Sleeve Position Sensor circuit s that mea sured above 5 0 ohms for an open Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaini
276. rsonal Identification Number PIN assigned to it s original SKIM This number can be obtained from the vehicle s invoice or Chrysler s Customer Center 1 800 992 1997 3 NOTE When entering the PIN care should be taken because the SKIM will only allow 3 consecutive attempts to enter the correct PIN If 3 consecutive incorrect PIN s are entered the SKIM will Lock Out the DRB III for 1 hour 4 To exit Lock Out mode the ignition key must remain in the Run position continually for 1 hour Turn off all accessories and connect a battery charger if necessary 5 With the DRB III select Theft Alarm SKIM and Miscellaneous Then select desired procedure and follow the steps that will be displayed 6 Ifthe SKIM has been replaced ensure all of the vehicle ignition keys are programmed to the new SKIM 7 NOTE Prior to returning vehicle to the costumer perform a module scan to be sure that all DTC s are erased Erase any DTC s that are found 8 With the DRB III erase Perform 5 ignition key cycles leaving the key for at least 90 seconds per cycle 9 With the III read the SKIM Are there SKIM Yes Repair is not complete refer to appropriate symptom No Repair is complete 245 VERIFICATION TESTS Verification Tests Continued SPEED CONTROL VERIFICATION VER 4 1 Inspect the vehicle to ensure that all engine components are properly installed and connected
277. rvice Information for proper procedure NOTE It is necessary to know the fuel tank capacity for this test Fill the fuel tank to 1 4 of its capacity then turn the ignition and note the instrument cluster fuel gauge reading Turn the ignition off Fill the fuel tank to 3 4 of its capacity then turn the ignition on and note the instrument cluster fuel gauge reading Does the Fuel Gauge read the fuel tank levels accurately Yes Test Complete Replace the Fuel Level Sensor Perform ROAD TEST VERIFICATION VER 2 187 DRIVEABILITY DIESEL Symptom CHECKING THE FUEL TEMPERATURE SENSOR CALIBRATION POSSIBLE CAUSES FUEL TEMPERATURE SENSOR COLD FUEL TEMPERATURE SENSOR HOT ACTION APPLICABILITY Disconnect the Fuel Heater harness connector All With the DRB monitor the engine coolant temperature and fuel temperature Start and idle the engine until engine temperature reaches 70 C 1609 NOTE If the engine temperature is above 70 C 160 F allow the engine to cool down to 70 C 160 F 15 the fuel temperature between 20 C 70 F and 50 C 120 F Yes gt GoTo 2 No Fuel Injection Pump Assembly in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Disconnect the Fuel Heater harness connector With the DRB monitor the engine coolant temperature and fuel temperature Start and idle the engine until engine temperature reaches 70 C 16
278. ry Supply circuit for an open Perform ROAD TEST VERIFICATION VER 2 174 DRIVEABILITY DIESEL CHECKING THE ECM AND PCM POWER AND GROUND CIRCUITS Continued APPLICABILITY Turn the ignition off Disconnect the ECM harness connectors Remove the ASD Diesel Power Relay from the PDC Connect a jumper wire between cavity 30 and cavity 87 in the ASD Diesel Power Relay connector Using a 12 test light connected to ground check theASD Relay Output circuit in ECM harness connector C1 cavities 2 and 28 Did the test light illuminate for both circuits Yes gt GoTo 5 Repair the ASD Relay Output circuit s for an open Perform ROAD TEST VERIFICATION VER 2 Disconnect the PCM harness connectors Usinga 12 volt test light connected to ground check the PCM Battery Supply circuit in PCM harness connector C1 cavity 22 Is the test light on Yes gt GoTo 6 No Repair the PCM Battery Supply circuit s for an open Perform ROAD TEST VERIFICATION VER 2 Using a 12 volt test light connected to 12 volts check both PCM Ground circuits in PCM harness connector 1 cavities 31 and 32 Did the test light illuminate for both cavities Yes gt GoTo 7 No Repair the PCM Ground circuit s for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove the ASD Diesel Power Relay from the PDC Disconnect the PCM harness connectors Connect a jumper wire between cavit
279. s connector cavities Turn the ignition on After 30 seconds is the Low Coolant Lamp on steady Yes gt GoTo 11 No Replace the Low Coolant Switch 194 DIESEL THE LOW COOLANT LAMP OPERATION Continued APPLICABILITY Turn the ignition off Disconnect the PCM harness connectors Connect a jumper wire between the Low Coolant Lamp Control circuit and ground Turn the ignition on Is the Low Coolant Lamp illuminated Yes gt Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 14 Turn the ignition off All Disconnect the PCM harness connectors Disconnect the Message Center harness connector Measure the resistance of the Low Coolant Lamp Control circuit Is the resistance below 5 0 ohms Yes gt GoTo 15 No Repair the Low Coolant Lamp Control circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Remove the Message Center Remove and inspect the Low Coolant Lamp bulb Is the bulb OK Yes gt GoTo 16 No Replace the Low Coolant Lamp bulb Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace the Message Center Perform ROAD TEST VERIFICATION VER 2 195 DRIVEABILITY DIESEL Symptom CHECKING THE OIL PRESSURE GAUGE OPERATION POSSIBLE CAUSES CHECK FOR O
280. sage the SKIM waits 3 5 seconds for a PCM status message from the powertrain controller If the PCM does not respond with a valid key message to the SKIM a fault is detected and a trouble code stored The SKIS incorporates a SKIS indicator lamp located in the instrument cluster The lamp is actuated when the SKIM sends a CCD Bus message to the electro mechanical instrument cluster MIC requesting the lamp on The MIC then provides the power and ground for the lamp The SKIM will request lamp operation for the following bulb check at ignition on to alert the vehicle operator to a SKIS mal function For all faults except transponder faults and VIN mismatch the lamp remains on steady the event of a transponder fault the light flashes at the rate of 1Hz once per second If a fault is present the lamp will remain on or flashing for the complete ignition cycle If a fault is stored in SKIM memory which GENERAL INFORMATION prevents the system from operating properly the ECM will allow the engine to start and run for 2 seconds up tosix times After the sixth attempt the ECM disables fuel delivery until the fault is cor rected 3 3 DIAGNOSTIC TROUBLE CODES Each diagnostic trouble code is diagnosed by following a specific testing procedure The diagnos tic test procedures contain step by step instructions for determining the cause of trouble codes as well as no trouble code problems It is not necessary to perform all o
281. set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform CHARGING VERIFICATION VER 3 No Test Complete 20 CHARGING Symptom List P1682 CHARGING SYSTEM VOLTAGE TOO LOW DIESEL 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 P1682 CHARGING SYSTEM VOLTAGE TOO LOW DIESEL When Monitored and Set Condition P1682 CHARGING SYSTEM VOLTAGE TOO LOW DIESEL When Monitored With the engine running Set Condition The voltage at PCM cavity C1 22 is 0 5 volt or more below the target charging voltage for at least 3 seconds POSSIBLE CAUSES CHECK FOR CYCLING VOLTAGE ON THE GENERATOR FIELD
282. sor 5 volt Supply circuit 15 the voltage above 4 7 volts Yes Replace the Turbocharger Boost Pressure Intake Air Tempera ture Sensor Perform ROAD TEST VERIFICATION VER 2 GoTo 3 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Turbocharger Boost Sensor harness connector Measure the resistance between ground and the 5 volt Supply circuit 15 the resistance above 100 kohms Yes gt GoTo 4 No Repair the 5 volt Supply circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 61 DRIVEABILITY DIESEL P0235 TURBOCHARGER BOOST SENSOR SUPPLY LOW EXCEEDED Continued APPLICABILITY Turn the ignition off All Disconnect the ECM harness connectors Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Measure the resistance between the 5 volt Supply circuit and the Sensor Ground circuit 15 the resistance above 100 kohms Yes gt GoTo 5 No Repair the 5 volt Supply and Sensor Ground circuits for a short together Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in iden
283. sor Signal circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the ECM harness connectors Disconnect the Vehicle Speed Sensor harness connector Note Check connectors Clean repair as necessary Measure the resistance of the Vehicle Speed Sensor Ground circuit Is the resistance below 5 0 ohms Yes gt GoTo 12 No the Vehicle Speed Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the Vehicle Speed Sensor harness connector NOTE Ensure the ECM and PCM harness connectors are connected before continuing Turn the ignition on Connect jumper wire to the Vehicle Speed Sensor Signal circuit in the VSS harness connector With the DRB monitor the VEHICLE SPEED while tapping the other end of the jumper wire to ground Does the DRB display km h MPH greater than 0 Yes Replace the Vehicle Speed Sensor Perform ROAD TEST VERIFICATION VER 2 No GoTo 13 Turn the ignition off Disconnect the Vehicle Speed Sensor harness connector Disconnect the PCM harness connectors Check connectors Clean repair as necessary Measure the resistance between the Vehicle Speed Sensor Signal circuit and the Sensor Ground circuit 15 the resistance above 100 kohms Yes gt GoTo 14 No Repair the Vehicle Speed Sensor Signal circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFIC
284. ssible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 44 DIESEL Symptom 180 TEMPERATURE SENSOR SRC HIGH EXCEEDED mT When Monitored and Set Condition P0O180 F UEL TEMPERATURE SENSOR SRC HIGH EXCEEDED When Monitored With the ignition on Set Condition The fuel temperature sensor signal voltage is above 4 7 volts POSSIBLE CAUSES INTE
285. stance above 100 kohms Yes gt GoTo 21 No Repair 5 volt Supply circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off All Disconnect the Vehicle Speed Sensor harness connector Disconnect the PCM harness connectors Check connectors Clean repair as necessary Measure the resistance between ground and the 5 volt Supply circuit 15 the resistance above 100 kohms 211 DRIVEABILITY DIESEL Symptom CHECKING THE WATER IN FUEL LAMP OPERATION POSSIBLE CAUSES MESSAGE CENTER PCM WATER IN FUEL SIGNAL CIRCUIT SENSOR GROUND OPEN WATER IN FUEL LAMP BULB WATER IN FUEL SENOR SIGNAL CIRCUIT OPEN WATER IN FUEL SENSOR WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND WATER IN FUEL SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND ACTION APPLICABILITY NOTE Be sure a water in fuel condition does not exist before continuing All Turn the ignition on while monitoring the Water In Fuel Lamp Choose the appropriate answer The lamp turns on and stays on GoTo 2 The lamp turns on for 2 seconds then off GoTo 5 The lamp does not turn on at all GoTo 8 Turn the ignition off Disconnect the Water In Fuel Sensor harness connector Turn the ignition
286. tance of the 5 volt Supply circuit between the Vehicle Speed Sensor harness connector and the PCM harness connector 15 the resistance below 5 0 ohms Yes gt GoTo 18 No Repair the 5 volt Supply circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Vehicle Speed Sensor harness connector Disconnect the PCM harness connectors Check connectors Clean repair as necessary Measure the resistance between ground and the 5 volt Supply circuit 15 the resistance above 100 kohms Yes gt GoTo 19 No Repair the 5 volt Supply circuit for a short to ground Perform ROAD TEST VERIFICATION VER 2 77 DRIVEABILITY DIESEL 5 SPEED SENSOR PEC FREQUENCY TOO HIGH Continued ACTION APPLICABILITY Turn the ignition off All Disconnect the Vehicle Speed Sensor harness connector Disconnect the PCM harness connectors Check connectors Clean repair as necessary Measure the resistance between the 5 volt Supply circuit and the Sensor Ground circuit in the Vehicle Speed Sensor harness connector Is the resistance above 100 kohms Yes gt GoTo 20 Repair 5 volt Supply circuit for a short to the Sensor Ground circuit Perform ROAD TEST VERIFICATION VER 2 If there are no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIF
287. the Oil Pressure Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Oil Pressure Sensor harness connector Disconnect the PCM harness connectors Measure the resistance of the Sensor Ground circuit 15 the resistance below 5 0 ohms Yes Replace the Oil Pressure Sensor Perform ROAD TEST VERIFICATION VER 2 No Repair the Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Oil Pressure Sensor harness connector Disconnect the PCM harness connectors Measure the resistance of the Oil Pressure Sensor Signal circuit 15 the resistance below 5 0 ohms Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Repair the Oil Pressure Sensor Signal circuit for an open Perform ROAD TEST VERIFICATION VER 2 82 DIESEL P0523 OIL PRESSURE VOLTAGE HIGH Continued ACTION APPLICABILITY WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS All NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a D
288. the inside of the Fuel Tank for any obstructions or deformities 15 the Fuel Tank OK Yes Replace the Fuel Level Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No Repair or replace the Fuel Tank in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 68 DRIVEABILITY DIESEL Symptom 462 LEVEL SENDING UNIT VOLTS TOO LOW When Monitored and Set Condition P0462 FUEL LEVEL SENDING UNIT VOLTS TOO LOW When Monitored With the ignition on Set Condition The fuel level sensor signal voltage on PCM cavity C3 26 is below 0 25 volt POSSIBLE CAUSES INTERMITTENT CONDITION FUEL LEVEL SENSOR FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND FUEL LEVEL SENSOR SIGNAL AND GROUND CIRCUITS SHORTED TOGETHER POWERTRAIN CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB erase PCM DTCs Turn the ignition off wait 10 seconds then turn the ignition on With the DRB read PCM DTCs Did this DTC reset Yes gt GoTo 2 gt GoTo 6 Turn the ignition off Disconnect the Fuel Level Sensor harness connector Turn the ignition on With the DRB read the Fuel Level Sensor voltage Is the voltage above 9 0 volts Yes Replace the Fuel Level Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 No gt GoTo 3 Turn the ignition off Disconnect the PCM harness co
289. tifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 62 DRIVEABILITY DIESEL Symptom 0400 OPEN CIRCUIT When Monitored and Set Condition 0400 OPEN CIRCUIT When Monitored With the ignition on Set Condition The ECM detects an open or short to ground on the electric vacuum modulator control circuit POSSIBLE CAUSES INTERMITTENT CONDITION FUSED ASD RELAY OUTPUT CIRCUIT OPEN EGR SOLENOID CONTROL CIRCUIT SHORTED TO GROUND EGR SOLENOID CONTROL CIRCUIT OPEN SUBSTITUTE EGR SOLENOID ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Perform several ignition cycles turning the ignition off for at least 10 seconds between each ignitio
290. tions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 40 DRIVEABILITY DIESEL Symptom 117 SENSOR VOLTAGE TOO LOW When Monitored and Set Condition 0117 SENSOR VOLTAGE LOW When Monitored With the ignition on Set Condition The voltage on the PCM engine coolant temperature sensor signal circuit is below 0 25 volt for more than 3 seconds POSSIBLE CAUSES INTERMITTENT CONDITION PCM ECT SENSOR PCM ECT SENSOR SIGNAL CIRCUIT SHORTED TO GROUND PCM ECT SENSOR SIGNAL AND GROUND CIRCUITS SHORTED TOGETHER POWERTRAIN CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB monitor the PCM Engine Coolant Temperature Sensor voltage Is the PCM ECT Sensor voltage below 0 25 volt Yes gt GoTo 2 gt GoTo 6 Turn the ignition off Disconnect the PCM ECT Sensor harness connector Turn the ignition on With the DRB read the PCM ECT Sensor voltage Is the voltage above 4 0 volts Yes Replace the PCM ECT Sensor in acc
291. tions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 60 DRIVEABILITY DIESEL Symptom P0235 TURBOCHARGER BOOST SENSOR SUPPLY LOW EX CEEDED When Monitored and Set Condition P0235 TURBOCHARGER BOOST SENSOR SUPPLY LOW EXCEEDED When Monitored With the ignition on Set Condition turbocharger boost pressure sensor supply voltage stays below 4 75 volts for at least 2 seconds POSSIBLE CAUSES INTERMITTENT CONDITION TURBOCHARGER BOOST PRESSURE INTAKE AIR TEMPERATURE SENSOR 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND 5 VOLT SUPPLY AND SENSOR GROUND CIRCUITS SHORTED TOGETHER ENGINE CONTROL MODULE ACTION APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Turn the ignition off wait 30 seconds then turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 gt GoTo 6 Turn the ignition off Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Turn the ignition on Measure the voltage between ground and the Turbocharger Boost Pressure Sen
292. to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 150 DIESEL Symptom List P1685 VEHICLE THEFT ALARM IMMOBILIZER SIG LOST P1685 VEHICLE THEFT ALARM INVALID SKIM MESSAGE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests will be P1685 VEHICLE THEFT ALARM IMMOBILIZER SIG LOST When Monitored and Set Condition P1685 VEHICLE THEFT ALARM IMMOBILIZER SIG LOST When Monitored With the ignition on the immobilizer disarmed Set Condition The ECM detects an open short to ground or short to voltage on the immobilizer signal circuit P1685 VEHICLE THEFT ALARM INVALID SKIM MESSAGE When Monitored With the ignition on Set Condition The ECM determines that the coded message from the PCM does not match the message programmed into memory POSSIBLE CAUSES CHECK FOR SKIM COMMUNICATION AND DTCS ECM VIN MISMATCH PCM VIN MISMATCH
293. to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 133 DRIVEABILITY DIESEL Symptom P1630 SOLENOID VALVE CONTROLLER SHORT CIRCUIT When Monitored and Set Condition P1630 SOLENOID VALVE CONTROLLER SHORT CIRCUIT When Monitored With the ignition on Set Condition The ECM detects excessive current draw on the fuel timing solenoid control circuit POSSIBLE CAUSES INTERMITTENT CONDITION FUEL TIMING SOLENOID FUEL INJ ECTION PUMP SHORTED TO VOLTAGE INTERNALLY FUEL TIMING SOLENOID CONTROL CIRCUIT SHORTED TO VOLTAGE INTERNAL FUEL INJ ECTION PUMP TEST ENGINE CONTROL MODULE APPLICABILITY Turn the ignition on All With the DRB erase ECM DTCs Turn the ignition off wait 30 seconds then turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes gt GoTo 2 No gt GoTo 5 Turn the ignitio
294. ttent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes gt Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 99 DRIVEABILITY DIESEL Symptom P1220 FUEL QUANTITY ACTUATOR NEG GOV DEVIATION COLD When Monitored and Set Condition P1220 FUEL QUANTITY ACTUATOR NEG GOV DEVIATION COLD When Monitored With the engine running Set Condition TheECM has attempted to compensate for a rich condition and the engine coolant temperature is below 60 C 140 F NOTE An improperly timed fuel injection pump may also set this code POSSIBLE CAUSES INTERMITTENT CONDITION FUEL INJ ECTION PUMP SHORTED INTERNALLY FUEL QUANTITY ACTUATOR CONTROL CIRCUIT SHORTED TO GROUND INTERNAL FUEL INJ ECTION PUMP TEST ENGINE CONTROL MODULE ACTION APPLICABILITY NOTE An improperly timed Fuel Injection
295. uit 15 the voltage above 1 0 volt Yes Repair the Boost Pressure Sensor Signal circuit for a short to voltage Perform ROAD TEST VERIFICATION VER 2 Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the Turbocharger Boost Pressure IAT Sensor harness connector Disconnect the ECM harness connectors Measure the resistance of the Sensor Ground circuit 15 the resistance below 5 0 ohms Yes gt GoTo 7 No Repair the Boost Pressure Sensor Ground circuit for an open Perform ROAD TEST VERIFICATION VER 2 54 DIESEL P0235 TURBOCHARGER BOOST SENSOR SIGNAL HIGH EXCEEDED Continued APPLICABILITY Turn the ignition off All NOTE Ensure all harness connectors are connected Turn the ignition on Measure the voltage of the Boost Pressure Sensor Signal circuit by backprobing ECM harness connector C1 cavity 40 Is the voltage above 4 5 volts Yes Replace the Turbocharger Boost Pressure Intake Air Tempera ture Sensor Perform ROAD TEST VERIFICATION VER 2 No GoTo 8 Turn the ignition on With the DRB read ECM DTCs Did this DTC reset Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Ensure good terminal contact between the Turbocharger Boost Pressure
296. vity 10 and the Sensor Ground circuit cavity 8 in the APP Sensor harness connector 15 the voltage between 4 5 and 5 5 volts Yes gt GoTo 13 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on With the 111 read the PEDAL OUTPUT VOLTS with the accelerator pedal in the at rest position Does the 111 display between 0 28 and 0 38 volt Yes gt GoTo 14 Replace theAccelerator Pedal Position Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on Fully depress the accelerator pedal With the DRBIII read the PEDAL OUTPUT VOLTS Does the 111 display between 4 1 and 4 6 volts Yes gt GoTo 15 ReplacetheAccelerator Pedal Position Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition on With the III read the PEDAL OUTPUT VOLTS With the accelerator pedal in the idle position slowly depress the accelerator pedal until the pedal is fully depressed NOTE The PEDAL OUTPUT VOLTS should increase smoothly as the pedal is depressed Does the voltage increase smoothly with the accelerator pedal travel Yes gt GoTo 16 ReplacetheAccelerator Pedal Position Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 119
297. with the jumper wire connected Are the voltage readings the expected voltages Yes Replace the Fuel Level Sensor in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 GoTo 6 If there are no possible causes remaining view repair Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 WARNING KEEP CLEAR OF THE ENGINE S MOVING PARTS NOTE The conditions that set the DTC are not present at this time The following list may help in identifying the intermittent condition With the engine running at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wiring harness Look for param eter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wiring harness connectors Look for broken bent pushed out or corroded terminals Were any of the above conditions present Yes Repair as necessary Perform ROAD TEST VERIFICATION VER 2 No Test Complete 72 DRIVEABILITY DIESEL Symptom List 500 SPEED SENSOR PEC FREQUENCY TOO HIGH
298. y 30 and cavity 87 of the ASD Diesel Power Relay connector Using a 12 volt test light connected to ground check theASD Relay Output circuit in PCM harness connectors C1 cavity 2 and C3 cavity 12 Did the test light illuminate for both circuits Yes Test Complete No Repair the ASD Relay Output circuit s for an open Perform ROAD TEST VERIFICATION VER 2 Disconnect the PCM harness connectors 175 DRIVEABILITY DIESEL Symptom CHECKING THE EGR SYSTEM POSSIBLE CAUSES ASD RELAY OUTPUT CIRCUIT OPEN EGR VALVE GROUND CIRCUIT OPEN VACUUM SUPPLY HOSE ACTION APPLICABILITY Disconnect the Vacuum Supply Hose at the EGR solenoid Connect a vacuum gauge to the Vacuum Supply Hose Start the engine and allow the engine to idle Is the vacuum above 10 inches of mercury at idle Yes gt GoTo 2 gt Repair leaking restricted Vacuum Supply Hose or faulty Vacuum Supply Pump Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off Disconnect the EGR Solenoid harness connector Turn the ignition on Using a 12 volt test light connected to ground check the ASD Relay Output circuit at the EGR Solenoid harness connector Is the test light on Yes gt GoTo 3 No Repair the ASD Relay Output circuit for an open Perform ROAD TEST VERIFICATION VER 2 Solenoid harness connector Is the test light on Yes gt GoTo 4 No Repair the Ground circuit for an open Perform ROAD TEST VERIF
299. y the quickest means 3 2 FUNCTIONAL OPERATION 3 2 1 PCM ON BOARD DIAGNOSTICS The PCM and ECM have been programmed to monitor many different circuits of the diesel fuel injection system This monitoring is called on board diagnosis Certain criteria must be met for a trouble code to be entered into the PCM or ECM memory The criteria may be a range of engine rpm engine temperature and or input voltage If all of the criteria for monitoring a system or circuit are met and a problem is sensed then a trouble code will be stored in the PCM or the ECM It is possible that a trouble code for a monitored circuit may not be entered into memory even though a malfunction has occurred This may hap pen when the monitoring criteria have not been met The PCM and ECM compare input signal volt ages from each input device with specifications the established high and low limits of the range that are programmed into it for that device If the input voltage is not within specifications and other trou ble code criteria are met a trouble code will be stored in the PCM or ECM memory GENERAL INFORMATION 3 2 2 ECM OPERATING MODES As input signals to the ECM change the ECM adjusts its response to output devices F or example the ECM must calculate a different fuel quantity and fuel timing for idle than it does for wide open throttle There are several different modes of oper ation that determine how the ECM responds to the v
300. zer Signal circuit in PCM harness connector C3 Turn the ignition on 15 the amperage between 1 0 and 1 4 milliamps Yes gt GoTo 8 No Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Turn the ignition off NOTE Ensure all connectors are connected With the oscilloscope function select LAB SCOPE and set the oscilloscope to the following specifications Voltage Range to 20 0V Probe to X10 Time Range to 0 1s Div Turn the ignition on With the DRB oscilloscope lead back probe PCM harness connector C3 cavity 16 NOTE A valid Immobilizer Signal voltage will cycle high and low Does the display show the 12 volt Immobilizer Signal voltage cycling high and low Yes Replace and program the Engine Control Module in accordance with the Service Information Perform ROAD TEST VERIFICATION VER 2 Replace and program the Powertrain Control Module in accor dance with the Service Information Perform ROAD TEST VERIFICATION VER 2 153 DRIVEABILITY DIESEL Symptom P1690 FAN CONTROL OPEN CIRCUIT When Monitored and Set Condition P1690 FAN CONTROL OPEN CIRCUIT When Monitored With the ignition on Set Condition The ECM detects an open or short to ground on the radiator fan relay control circuit POSSIBLE CAUSES INTERMITTENT CONDITION ASD DIESEL POWER RELAY OUTPUT CIRCUIT OPEN SUBSTITUTE RADIATOR FAN

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