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  • P0542 High Voltage On The #1 Intake Air Heater Relay

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    Mopar1973Man

    P0542 HIGH VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY

    When Monitored: When the ignition is on.
    Set Condition: When the signal from the #1 Intake Air Heater output does not match the signal from the #1
    Intake Air Heater feedback.

    POSSIBLE CAUSES

    • LOOSE CONNECTION
    • INTAKE AIR HEATER RELAY
    • SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE
    • ECM
    • INTERMITTENT CONDITION

    DIAGNOSTIC PROCEDURE

    1. Ignition on, engine not running.

    With the DRBIII®, actuate the Intake Air Heater relay.
    Can you hear the Relay clicking?
    Yes --> Go To 2
    No --> Go To 3
    2. While the relay is clicking, wiggle the wiring harness and connectors.
    Does this interrupt the clicking?
    Yes --> Repair the poor connection.
    Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 3
    3. Turn the ignition off.
    Remove the Intake Air Heater Relay.
    Check connectors - Clean/repair as necessary.
    Measure the resistance between the signal and return posts of the intake air heater relay.
    Is the resistance between 15 and 25 Ohms?
    Yes --> Go To 4
    No --> Replace the Intake Air Heater relay.
    Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    4. Disconnect the ECM harness connector(s).
    Check connectors - Clean/repair as necessary.
    Measure the resistance between the signal circuit of the intake air heater relay and battery negative.
    Is the resistance greater than 100 K ohms?
    Yes --> Go To 5
    No --> Repair signal circuit shorted to battery negative.
    Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).

    5. Reconnect the ECM harness connectors.
    Turn the ignition on.
    Disconnect the intake air heater relay signal wire.
    Did DTC P0542 or 2608 set?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic
    Procedure).
    Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Replace the ECM.
    Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).



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