Dodge Cummins Articles: 3rd Generation - TSB Articleshttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/?d=4Dodge Cummins Articles: 3rd Generation - TSB ArticlesenP0016 Engine Speed Signal Mismatch (Diesel)https://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0016-engine-speed-signal-mismatch-diesel-r150/

P0016 ENGINE SPEED SIGNAL MISMATCH (DIESEL)

When Monitored and Set Condition

When Monitored: While Engine is running.
Set Condition: When the engine speed detected by the Engine Position Sensor (cam) and the Engine Speed
Sensor (crank) differ by a specified RPM amount.

POSSIBLE CAUSES

  • DAMAGE TO THE ESS OR EPS
  • MECHANICAL MISALIGNMENT OF THE ESS OR EPS
  • MECHANICAL MISALIGNMENT OF THE CAMSHAFT AND CRANKSHAFT GEARS
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Visually inspect the condition of the tone wheel, ESS, and EPS for damage.  Are any of the components damaged?
    Yes --> Repair or replace any damaged component. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 2
  2. Verify the speed indicator ring is properly positioned relative to the locating pin in the front face of the crankshaft. Is the speed indicator ring properly installed?
    Yes --> Go To 3
    No --> Repair the speed ring indicator ring installation. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  3. Check the mechanical alignment of the camshaft gear to the crankshaft gear. Refer to service information for assistance. Are the gear teeth in proper alignment?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Repair the gear alignment. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
]]>150Sat, 02 Jan 2016 00:33:00 +0000P0071 Inlet Air Temperature Sensor Rationalityhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0071-inlet-air-temperature-sensor-rationality-r151/

P0071 INLET AIR TEMPERATURE SENSOR RATIONALITY (DIESEL)

When Monitored and Set Condition:

When Monitored: While the engine is running.
Set Condition: The ECM does not read a change in value from the sensor over time.

POSSIBLE CAUSES

  • INLET AIR TEMPERATURE SENSOR
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

NOTE:Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Remove the temperature sensor and reconnect the wiring to the sensor. With the DRBIII® in Sensors, Monitor the inlet Air Temperature. While heating the sensor with an external heat source (DO NOT USE OPEN FLAME). Does the reading from the sensor increase at least 5 degrees F. on the DRBIII®?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Replace the inlet air temperature sensor Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
     
]]>151Sat, 02 Jan 2016 00:34:26 +0000P0072 Inlet Air Temperature Sensor Voltage Too Lowhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0072-inlet-air-temperature-sensor-voltage-too-low-r152/

P0072 INLET AIR TEMP SENSOR VOLTAGE TOO LOW (DIESEL)

When Monitored and Set Condition:

When Monitored: With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM falls below a calibrated threshold for a certain period of time.

POSSIBLE CAUSES

  • SENSOR OUT OF SPEC
  • INTERMITTENT CONDITION
  • HARNESS SHORTED
  • (Y501) 5-VOLT SUPPLY OPEN
  • HARNESS SHORTED (ECM SIDE)
  • INTERMITTENT CONDITION
  • ECM

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Turn the ignition off. Disconnect the Inlet Air Temp sensor harness connector. Check connectors - Clean/repair as necessary. Measure the resistance of the temperature sensor. Is the resistance between 300 and 90k ohms?
    Yes --> Go To 2
    No --> Replace the sensor. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  2. Reconnect the Inlet Air Temp Sensor harness connector. Turn the ignition on. With the DRBIII®, erase DTCs. With the DRBIII®, read DTCs. Did the DTC return?
    Yes --> Go To 3
    No --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  3. Turn the ignition off. Disconnect the inlet Air Temp sensor harness connector. Disconnect the ECM harness connector. Check connectors - Clean/repair as necessary. Measure the resistance between the engine ground and the (K69) temperature sensor signal circuit at the sensor connector. Is the resistance more than 100 k ohms?
    Yes --> Go To 4
    No --> Replace or Repair the shorted harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  4. Measure the resistance between the (K69) signal circuit and all other circuits at the ECM harness connector. Is the resistance more than 100 k ohms?
    Yes --> Go To 5
    No --> Repair or replace the ECM harness shorted. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  5. Reconnect the ECM harness connector. Turn the ignition on. Measure the voltage between the (Y501) supply circuit and the (Y502) return circuit in the Air Temp sensor harness connector. Is the voltage between 4.5 and 5.5 volts?
    Yes --> Go To 6
    No --> Go To 7
  6. Reconnect the Air Temp sensor harness connector. Reconnect the ECM harness connector. With the DRBIII®, erase DTCs. While monitoring with DRBIII®, disconnect the Air Temp sensor harness connector. Did the DTC P0073 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).
  7. Disconnect the ECM harness connectors. Measure the voltage at the (Y501) 5-volt supply circuit at he ECM harness connector. Is the voltage between 4.5 and 5.5 volts?
    Yes --> Fix or repair the (Y501) 5-volt supply circuit open. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Replace the ECM. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
]]>152Sat, 02 Jan 2016 00:35:42 +0000P0073 Inlet Air Temperature Sensor Voltag Too Highhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0073-inlet-air-temperature-sensor-voltag-too-high-r153/

P0073 INLET AIR TEMP SENSOR VOLTAGE TOO HIGH

When Monitored and Set Condition:

When Monitored: With ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM is above a calibrated threshold for a certain period of time.

POSSIBLE CAUSES

  • DTC RETURNS
  • INLET AIR TEMPERATURE SENSOR
  • (K69) SIGNAL CIRCUIT OPEN
  • (Y502) RETURN CIRCUIT OPEN
  • (K69) SIGNAL CIRCUIT SHORTED
  • INTERMITTENT CONDITION
  • ECM

DIAGNOSTIC PROCEDURE

NOTE:Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Turn the ignition on. With the DRBIII®, erase DTCs. With the DRBIII®, read DTCs. With the DRBIII®, record all Freeze frame data. Did the DTC return?
    Yes --> Go To 2
    No --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  2. Turn the ignition off. Disconnect the Inlet Air Temp sensor harness connector. Check connectors - Clean/repair as necessary. Measure the resistance of the Inlet Air temp sensor Is the resistance between 300 and 90k ohms?
    Yes --> Go To 3
    No --> Replace the Inlet air temperature sensor. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  3. Disconnect the ECM harness connector. Check connectors - Clean/repair as necessary. Reconnect the Inlet Air Temp sensor harness connector. Measure the resistance between the (K69) inlet air temperature sensor signal circuit and (Y502) return circuit at the ECM connector. Is the resistance between 300 and 90k ohms?
    Yes --> Go To 6
    No --> Go To 4
  4. Disconnect the inlet Air Temp sensor harness connector. Measure the resistance of the (K69) inlet air temperature sensor signal circuit between the sensor harness connector and the ECM harness connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 5
    No --> Repair or replace the harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  5. Measure the resistance of the sensor (Y502) return circuit between the sensor harness connector and the ECM harness connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 6
    No --> Repair or replace the harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  6. Check for a short circuit from the (K69) signal circuit to all other circuits at the ECM harness connector. Is the resistance more than 100 k ohms?
    Yes --> Go To 7
    No --> Repair or replace the harness for a short to ground in the signal circuit. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  7. Reconnect the ECM harness connector. Turn the ignition on. With the DRBIII®, erase DTCs. While monitoring with DRBIII®, use a jumper wire and connect the sensor (K69) signal circuit to the sensor (Y502) return circuit at the sensor connector. Did the DTC P0072 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).
]]>153Sat, 02 Jan 2016 00:36:50 +0000P0088 Fuel Rail Pressure Signal Is Above Maximum Limithttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0088-fuel-rail-pressure-signal-is-above-maximum-limit-r164/

P0088 FUEL RAIL PRESSURE SIGNAL IS ABOVE MAX LIMIT

When Monitored and Set Condition:

When Monitored: Engine running.
Set Condition: Fuel pressure is above a calibrated value for a calibrated amount of time.

POSSIBLE CAUSES

  • FUEL CONTROL ACTUATOR (FCA)
  • FUEL PRESSURE SENSOR
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.
NOTE: This DTC will only clear by turning the ignition off. It is necessary to operate the engine for at least five seconds to verify the DTC will clear.

  1. Check for a mechanically stuck Fuel Control Actuator by turning the key switch on and off and listening for a click at the FCA. Do you hear a click from the actuator when the key is cycled off?
    Yes --> Go To 2
    No --> Check the electrical connector of the Fuel Control Actuator, if the connection is tight, replace the fuel control actuator. Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
  2. Using the DRBIII®, monitor the fuel pressure while operating the engine at several different RPM settings. Did the fuel pressure reading on the DRBIII® change?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
    No --> Replace the Fuel Pressure Sensor. Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
]]>164Tue, 05 Jan 2016 01:01:45 +0000P0106 Inlet Air Pressure Sensor Rationalityhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0106-inlet-air-pressure-sensor-rationality-r165/ P0106 INLET AIR PRESSURE SENSOR RATIONALITY

When Monitored and Set Condition:

When Monitored: When the ignition is on.
Set Condition: The Inlet air pressure is above a calibrated threshold.

POSSIBLE CAUSES

  • INLET AIR PRESSURE SENSOR
  • INTERMITTENT CONDITION
  • TROUBLESHOOT OTHER DTC'S FIRST

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.Using the DRBIII®, check for additional DTC's.

  1. Do you have any other air pressure related DTC's?
    Yes --> Troubleshoot other DTC's First. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 2
  2. Using the DRBIII®, monitor the Inlet air pressure sensor values. Do the readings on the DRBIII® fluctuate slightly?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Replace the Inlet Air Temperature/ Pressure sensor. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
]]>165Tue, 05 Jan 2016 01:03:33 +0000P0107 Inlet Air Pressure Sensor Voltage Too Lowhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0107-inlet-air-pressure-sensor-voltage-too-low-r166/

P0107 INLET AIR PRESSURE SENSOR VOLTAGE TOO LOW

When Monitored and Set Condition:

When Monitored: With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM falls below a calibrated threshold for a certain period of time.

POSSIBLE CAUSES

  • OTHER DTC'S PRESENT
  • INLET AIR PRESSURE SENSOR
  • INLET AIR SENSOR (K69) SIGNAL CIRCUIT SHORTED TO THE (Y502) RETURN CIRCUIT
  • INLET AIR PRESSURE SENSOR (Y501) SUPPLY CIRCUIT SHORTED TO THE RETURN
  • CIRCUIT
  • (K69) SIGNAL CIRCUIT OPEN
  • (Y501) 5-VOLT SUPPLY CIRCUIT OPEN
  • (K69) SIGNAL CIRCUIT SHORTED TO GROUND
  • (Y501) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
  • ECM
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Ignition on, engine not running. With the DRBIII®, read DTCs. Do you have multiple DTCs?
    Yes --> Repair other DTCs first. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 2
  2. Disconnect the Inlet Air Pressure sensor harness connector. Check connectors - Clean/repair as necessary. Measure the voltage between the (Y501) 5-volt supply circuit and (Y502) return circuit of the sensor harness connector. Is the voltage between 4.5 and 5.5 volts?
    Yes --> Go To 3
    No --> Go To 5
  3. While monitoring DRBIII®, use a jumper wire to connect the (Y501) 5-volt supply circuit with the (K69) signal circuit at the sensor harness connector. Does the DRBIII® show a pressure sensor out of range high DTC?
    Yes --> Replace the Inlet Air Temperature/Pressure sensor. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 4
  4. Turn the ignition off. Disconnect the ECM harness connector. Check connectors - Clean/repair as necessary. Measure the resistance between the (K69) signal circuit and (Y502) return circuit in the Inlet Air pressure sensor harness connector. Is the resistance greater than 100K Ohms?
    Yes --> Go To 5
    No --> Repair or replace wiring harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  5. Measure the resistance between the (Y501) 5-volt supply circuit and (Y502) return circuit in the Inlet Air Pressure sensor harness connector. Is the resistance greater than 100K Ohms?
    Yes --> Go To 6
    No --> Repair the short or replace the harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  6. Measure the resistance between the (K69) signal circuit in the Inlet Air Pressure sensor harness connector and the (K69) signal circuit in the ECM harness connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 7
    No --> Repair or replace the open wiring harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  7. 7. Measure the resistance between the (Y501) 5-volt supply circuit in the Inlet Air Pressure sensor harness connector with the (Y501) 5-volt supply circuit in the ECM harness connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 8
    No --> Repair or replace the Engine harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  8. Measure the resistance between the (K69) signal circuit in the inlet Air Pressure sensor connector and battery negative. Is the resistance greater than 100 K Ohms?
    Yes --> Go To 9
    No --> Repair the (K69) signal circuit shorted to ground or replace the wire harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  9. Measure the resistance between the (Y501) 5-volt supply Circuit in the Inlet Air Pressure sensor harness connector and battery negative. Is the resistance greater than 100 K Ohms?
    Yes --> Go To 10
    No --> Repair the (Y501) 5-volt supply circuit shorted to ground or replace the wire harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  10. Install the ECM harness connector. Turn the ignition on. While monitoring DRBIII®, use a jumper wire to connect the (Y501) 5-volt supply circuit with the (K69) signal circuit at the sensor harness connector. Does the DRBIII® show a pressure sensor out of range high DTC?
    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).
]]>166Tue, 05 Jan 2016 01:08:01 +0000P0108 Inlet Air Pressure Sensor Voltage Too Highhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0108-inlet-air-pressure-sensor-voltage-too-high-r167/

P0108 INLET AIR PRESSURE SENSOR VOLTAGE TOO HIGH

When Monitored and Set Condition:

When Monitored: With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM is above a calibrated threshold for a certain period of time.

POSSIBLE CAUSES

  • OTHER DTC'S PRESENT
  • INLET AIR PRESSURE SENSOR
  • INLET AIR PRESSURE SENSOR (K69) SIGNAL CIRCUIT SHORTED TO VOLTAGE
  • INLET AIR SENSOR (Y501) 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
  • (K69) SIGNAL CIRCUIT SORTED TO (Y501) 5-VOLT SUPPLY
  • (Y502) RETURN CIRCUIT OPEN
  • ECM
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Ignition on, engine not running. With the DRBIII®, read DTCs. Do you have multiple DTCs?
    Yes --> Repair other DTCs first. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 2
  2. Disconnect the Inlet Air Pressure sensor harness connector. Measure the voltage between the (Y501) 5-volt supply circuit and (Y502) return circuit of the Inlet Air Pressure sensor harness connector. Is the voltage between 4.5 and 5.5 volts?
    Yes --> Go To 3
    No --> Go To 4
  3. While monitoring DRBIII®, use a jumper wire to connect the (Y502) Return circuit to the (K69) signal circuit at the Inlet Air Pressure sensor harness connector. Does the DRBIII® show a P0107 Inlet Air Pressure Sensor Low DTC.
    Yes --> Replace the Inlet Air Temperature/Pressure sensor. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 4
  4. Disconnect the ECM harness connectors. NOTE: Check connectors - Clean/repair as necessary. Measure the voltage between the (K69) signal circuit of the Inlet Air Pressure sensor connector and battery negative. Is the voltage less than 1 volt?
    Yes --> Go To 5
    No --> Repair or replace short to voltage. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  5. Measure the voltage between the (Y501) 5-volt supply circuit of the sensor connector and battery negative. Is the voltage less than 1 volt?
    Yes --> Go To 6
    No --> Repair the short to voltage or replace the harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  6. Turn the ignition off. Measure the resistance between the (K69) signal circuit and the (Y501) 5-volt supply circuit of the Inlet Air Pressure sensor harness connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 7
    No --> Repair or replace the shorted wiring harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  7. Disconnect the ECM harness connector. Check connectors - Clean/repair as necessary. Measure the resistance between the (Y502) return circuit in the Inlet Air Pressure sensor harness connector with the (Y502) return circuit in the ECM harness connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 8
    No --> Repair or replace the Engine harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  8. Install the ECM harness connector. Turn the ignition on. While monitoring DRBIII®, use a jumper wire to connect the (Y501) 5-volt supply circuit with the (K69) signal circuit at the Inlet Air Pressure sensor harness connector. Did DTC P0107 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).
]]>167Tue, 05 Jan 2016 01:17:09 +0000P0111 Intake Air Temperature (IAT) Sensor Rationalityhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0111-intake-air-temperature-iat-sensor-rationality-r168/ P0111 INTAKE AIR TEMPERATURE (IAT) SENSOR RATIONALITY

When Monitored and Set Condition:

When Monitored: While the engine is running.
Set Condition: The ECM does not read a change in value from the sensor over time.

POSSIBLE CAUSES

  • FAILED IAT SENSOR
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Remove the temperature sensor and reconnect the wiring to the sensor. Monitor DRBIII®, while heating the sensor with an external heat source (DO NOT USE OPEN FLAME). Does the reading from the sensor increase at least 5 degrees F. on the DRB?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Replace the Intake air temp sensor/MAP sensor. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
]]>168Tue, 05 Jan 2016 01:18:12 +0000P0112 Intake Air Temperature (IAT) Sensor Voltage Too Lowhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0112-intake-air-temperature-iat-sensor-voltage-too-low-r169/

P0112 INTAKE AIR TEMPERATURE (IAT) SENSOR VOLTAGE TOO LOW

When Monitored and Set Condition:

When Monitored: With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM falls below a calibrated threshold for a certain period of time.

POSSIBLE CAUSES

  • INTAKE AIR TEMP SENSOR OUT OF SPEC
  • INTERMITTENT CONDITION
  • (K21) SENSOR SIGNAL CIRCUIT SHORTED TO GROUND CIRCUIT
  • WIRING HARNESS SHORTED
  • (K72E) 5-VOLT SUPPLY CIRCUIT OPEN
  • ECM

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Disconnect the Intake Air Temperature sensor harness connector. Check connectors - Clean/repair as necessary. Measure the resistance of the Intake Air Temp sensor. Is the resistance between 300 and 90k ohms?
    Yes --> Go To 2
    No --> Replace the Intake Air temperature sensor/MAP sensor. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  2. Reconnect the circuit. Turn the ignition on. With the DRBIII®, erase DTCs. With the DRBIII®, read DTCs. Did the DTC reappear?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 3
  3. Turn the ignition off. Disconnect the ECM harness connector. Check connectors - Clean/repair as necessary. Measure the resistance between the engine ground and the temperature sensor (K21) signal circuit at the sensor harness connector. Is the resistance more than 100 k ohms?
    Yes --> Go To 4
    No --> Repair or replace the engine wiring harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  4. Measure the resistance between the (K21) signal circuit and all other circuits at the ECM harness connector. Is the resistance more than 100 k ohms?
    Yes --> Go To 5
    No --> Repair or replace the shorted wiring harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  5. Reconnect the ECM harness connector connected. Turn the ignition on. Measure the voltage between the (K72E) 5-volt supply circuit and the (K55) return circuit the sensor harness connector. Is the voltage between 4.5 and 5.5 volts?
    Yes --> Go To 7
    No --> Go To 6
  6. Turn the ignition off. Disconnect the ECM harness connector. Measure the voltage at the (K72E) 5-volt supply circuit of the sensor harness connector. Is the voltage between 4.5 and 5.5 volts?
    Yes --> Repair the open (K72E) 5-volt supply circuit. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 7
  7. Reconnect the ECM harness connector. Reconnect the intake air temp sensor harness connector. Turn the ignition on. While monitoring with DRBIII®, disconnect the temperature sensor Did the DTC P0113 set?
    Yes --> Clear DTC's, repair complete. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Replace the ECM. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
]]>169Tue, 05 Jan 2016 01:19:30 +0000P0113 Intake Air Temperature (IAT) Sensor Voltage Too Highhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0113-intake-air-temperature-iat-sensor-voltage-too-high-r170/

P0113 INTAKE AIR TEMPERATURE (IAT) SENSOR VOLTAGE TOO HIGH

When Monitored and Set Condition:

When Monitored: With ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM is above a calibrated threshold for a certain period of time.

POSSIBLE CAUSES

  • FAILED SENSOR
  • INTERMITTENT CONDITION
  • (K21) SENSOR SIGNAL CIRCUIT OPEN
  • (K55) RETURN CIRCUIT OPEN
  • SHORT IN HARNESS
  • ECM

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Turn the ignition off. Disconnect the IAT sensor harness connector. Check connectors - Clean/repair as necessary. Measure the resistance of the IAT sensor. Is the resistance between 300 and 90k ohms?
    Yes --> Go To 2
    No --> Replace the Intake Air Temperature Sensor/map sensor. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  2. Reconnect the IAT harness connector. Turn the ignition on. With the DRBIII®, erase DTCs. With the DRBIII®, read DTCs. Is P0113 still set?
    Yes --> Go To 3
    No --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  3. Turn the ignition off. Disconnect the ECM harness connector(s). Measure the resistance between the temperature sensor (K21) signal and (K55) return circuit at the ECM harness connector with the sensor connected Is the resistance between 300 and 90k ohms?
    Yes --> Go To 6
    No --> Go To 4
  4. Measure the resistance of the sensor (K21) signal circuit between the sensor harness connector and the ECM harness connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 5
    No --> Repair the open Sensor (K21) signal circuit or the harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  5. Measure the resistance of the sensor (K55) Return circuit between the sensor harness connector and the ECM harness connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 6
    No --> Repair the open (K55) return circuit or the harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  6. Check for a short circuit from (K21) signal circuit to all other circuits at the ECM harness connector. Is the resistance more than 100 k ohms?
    Yes --> Go To 7
    No --> Repair the short in the wiring harness or replace the harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  7. Reconnect the ECM harness connectors. Turn the ignition on. With the DRBIII®, erase DTCs. While monitoring with DRBIII®, use a jumper wire and connect the sensor (K21) signal circuit to the sensor (K55) return circuit at the sensor harness connector. Did the DTC P0112 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).
]]>170Tue, 05 Jan 2016 01:20:53 +0000P0116 Engine Coolant Temperature (ECT) Sensor Rationalityhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0116-engine-coolant-temperature-ect-sensor-rationality-r171/

P0116 ENGINE COOLANT TEMPERATURE (ECT) SENSOR RATIONALITY

When Monitored and Set Condition:

When Monitored: While the engine is running.
Set Condition: The ECM does not read a change in value from the sensor over time.

POSSIBLE CAUSES

  • LOW COOLANT LEVEL
  • COOLANT TEMPERATURE SENSOR
  • THERMOSTAT
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. With the engine cold, verify the level of coolant in the radiator. Is the radiator full of coolant?
    Yes --> Go To 2
    No --> Fill the radiator with coolant- refer to the owners manual for assistance. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  2. Remove the temperature sensor and reconnect the wiring to the sensor. Turn the ignition on. Monitor DRBIII®, while heating the sensor with an external heat source (DO NOT USE OPEN FLAME). Does the reading from the sensor increase at least 5 degrees F. on the DRBIII®?
    Yes --> Go To 3
    No --> Replace the coolant temp sensor. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). NOTE: Refer to the Symptom: *FUEL HEATER THERMOSTAT TEST to ensure the thermostat is operating properly.
  3. Is the thermostat operating properly?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Replace the Thermostat. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
]]>171Tue, 05 Jan 2016 01:22:28 +0000P0117 Engine Coolant Temperature (ECT) Sensor Voltage Too Lowhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0117-engine-coolant-temperature-ect-sensor-voltage-too-low-r172/

P0117 ENGINE COOLANT TEMPERATURE (ECT) SENSOR VOLTAGE TOO LOW

When Monitored and Set Condition:

When Monitored: With ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM falls below a calibrated threshold for a certain period of time.

POSSIBLE CAUSES

  • COOLANT TEMPERATURE SENSOR
  • INTERMITTENT CONDITION
  • (K2) SENSOR SIGNAL CIRCUIT SHORTED TO GROUND OR (K104) RETURN CIRCUIT
  • WIRING HARNESS SHORTED
  • ECM

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Turn the ignition off. Disconnect the Coolant Temp sensor harness connector. Check connectors - Clean/repair as necessary. Measure the resistance of the Temp sensor. Is the resistance between 300 and 90k ohms?
    Yes --> Go To 2
    No --> Replace the Coolant Temperature sensor. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  2. Reconnect the coolant temp sensor connected. Turn the ignition on. With the DRBIII®, erase DTCs. With the DRBIII®, read DTCs. Did the DTC reset?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 3
  3. Turn the ignition off. Disconnect the ECM harness connector. Check connectors - Clean/repair as necessary. Measure the resistance between the engine ground and the (K2) temperature sensor signal circuit at the sensor harness connector. Is the resistance more than 100 k ohms?
    Yes --> Go To 4
    No --> Repair or replace the short harness. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  4. Measure the resistance between the (K2) signal circuit and all other circuits at the ECM harness connector. Is the resistance more than 100k ohms?
    Yes --> Go To 5
    No --> Repair or replace shorted wiring harness Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  5. Reconnect the ECM harness connectors. Turn the ignition on. With the DRBIII®, erase DTCs. While monitoring the DRBIII®, Disconnect the temperature sensor harness connector. Did the DTC P0118 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)
]]>172Tue, 05 Jan 2016 01:23:41 +0000P0118 Engine Coolant Temperature Sensor (ECT) Sensor Voltage Too Highhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0118-engine-coolant-temperature-sensor-ect-sensor-voltage-too-high-r173/

P0118 ENGINE COOLANT TEMPERATURE (ECT) SENSOR VOLTAGE TOO HIGH

When Monitored and Set Condition:

When Monitored: With ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM is above a calibrated threshold for a certain period of time.

POSSIBLE CAUSES

  • COOLANT TEMPERATURE SENSOR
  • INTERMITTENT CONDITION
  • (K2) SIGNAL CIRCUIT OPEN
  • (K104) SENSOR RETURN CIRCUIT OPEN
  • (K2) SIGNAL CIRCUIT SHORTED
  • ECM

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Disconnect the coolant temperature sensor harness connector. Check connectors - Clean/repair as necessary. Measure the resistance of the coolant temperature sensor. Is the resistance between 300 and 90k ohms?
    Yes --> Go To 2
    No --> Replace the coolant temperature sensor. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  2. Reconnect the disconnected coolant temp sensor harness connector. With the DRBIII®, erase DTCs. With the DRBIII®, read DTCs. Did the DTC return?
    Yes --> Go To 3
    No --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  3. Turn the ignition off. Disconnect the ECM harness connector. Check connectors - Clean/repair as necessary. Measure the resistance between the (K2) temperature sensor signal and (K104) return circuit at the ECM harness connector with the coolant temp sensor harness connected. Is the resistance between 300 and 90k ohms?
    Yes --> Go To 6
    No --> Go To 4
  4. Disconnect the coolant temperature sensor harness connector. Measure the resistance of the (K2) coolant temperature sensor signal circuit between the coolant temperature sensor connector and the ECM connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 5
    No --> Repair or replace the open (K2) signal circuit. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  5. Measure the resistance of the (K104) coolant temperature sensor return circuit between the coolant temperature sensor connector and the ECM connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 6
    No --> Repair or replace the open (K104) sensor return circuit. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  6. Measure the resistance of (K2) signal circuit to all other circuits at the ECM harness connector. Is the resistance more than 100k ohms?
    Yes --> Go To 7
    No --> Repair or replace the (K2) coolant temperature sensor signal circuit. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  7. Reconnect the ECM harness connectors. Turn the ignition on. With the DRBIII®, erase DTCs. While monitoring with DRBIII®, use a jumper wire and connect the sensor (K2) signal circuit to the (K104) sensor return circuit at the sensor connector. Did the DTC P0117 set?
    Yes --> Test Complete.
    No --> Replace the ECM. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
]]>173Tue, 05 Jan 2016 01:24:54 +0000P0122 TPS / APPS Lowhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0122-tps-apps-low-r174/

P0122 TPS/APPS LOW

When Monitored and Set Condition:

When Monitored: Continuously with the ignition on and engine running.
Set Condition: This DTC will set if the monitored TPS voltage drops below .078 volts for the period of 0.48
seconds.

POSSIBLE CAUSES

  • RELATED TPS ENGINE DTC'S PRESENT
  • POWERTRAIN CONTROL MODULE
  • INTERMITTENT WIRING AND CONNECTORS

DIAGNOSTIC PROCEDURE

NOTE: Low fluid level can be the cause of many transmission problems. If the fluid level is low locate and repair the leak then check and adjust the fluid level. Refer to appropriate AUTOMATIC TRANSMISSION article.

NOTE: Always perform diagnostics with a fully charged battery to avoid false symptoms.

NOTE: Diagnose 1 Trip Failures as a fully matured DTC.

NOTE: Verify flash level of Powertrain Controller. Some problems are corrected by software upgrades to the Transmission and Engine Systems.

NOTE: Due to the integration of the Powertrain and Transmission control modules - if a controller flash is performed it is necessary to perform STANDARD PROCEDURE - TCM QUICK LEARN and the STANDARD PROCEDURE - DRIVE LEARN . Failure to do so may result in shift quality complaints.

NOTE: Check for applicable TSB's that may apply.

  1. With the DRBIII(R), read the engine DTC's. Check and repair all Engine DTC's prior to performing Transmission symptom diagnostics. With the DRBIII(R), read Transmission DTC's. Record all DTC's and 1 Trip Failures. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors. Repair as necessary. Perform the Shift Lever Position Test. If the test does not pass, refer to Symptom test for SYMPTOM: P0706-CHECK SHIFTER SIGNAL . For Gear Ratio DTC's, check and record all CVI's. Most DTC's set on start up but some must be set by driving the vehicle to ensure that all diagnostic monitors have run. Perform this procedure prior to Symptom diagnosis. Continue Go To 2. With the DRBIII(R), check Engine DTC's, this includes all one trip failures.
  2. Are there any Engine TPS DTCs present?
    Yes --> Refer to the Powertrain category and perform the appropriate symptom. Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1 .
    No --> Go To 3
  3. With the DRBIII(R), record the EATX EVENT DATA to help identify the conditions in which the DTC was set. With the DRBIII(R), erase Transmission DTCs.
    NOTE: To erase EATX EVENT DATA information, a BATTERY DISCONNECT must be performed. Performing a BATTERY DISCONNECT will reset all learned Transmission values to controller defaults which may lead to erratic shift schedules. Drive the vehicle and try to duplicate the conditions in which the DTC was reported by the EATX EVENT DATA. With the DRBIII(R), read Transmission DTCs. Did the DTC P0122 THROTTLE POSITION SENSOR LOW, reset?
    Yes --> Go To 4
    No --> Go To 5
    NOTE: Due to the integration of the Powertrain and Transmission Control Modules, bus communication between the modules is internal.
  4. Using the schematics as a guide, inspect the wiring and connectors. Repair as necessary. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, view repair. Repair Replace the Powertrain Control Module and perform STANDARD PROCEDURE - TCM QUICK LEARN . Refer to ELECTRONIC CONTROL MODULES . Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1 .
  5. The conditions necessary to set this DTC are not present at this time. Using the schematics as a guide, inspect the wiring and connectors specific to this circuit. Wiggle the wires while checking for shorted and open circuits. Pay particular attention to the TPS signal and sensor ground circuits. With the DRBIII(R), check the EATX DTC EVENT DATA to help identify the conditions in which the DTC was set. Were there any problems found?
    Yes --> Repair as necessary. Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1 .
    No --> Test Complete.
]]>174Tue, 05 Jan 2016 01:26:27 +0000P0123 TPS/APPS Highhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0123-tpsapps-high-r175/

P0123 TPS/APPS HIGH

When Monitored and Set Condition:

When Monitored: Continuously with the ignition on and engine running.
Set Condition: This DTC will set if the monitored TPS voltage rises above 4.94 volts for the period of 0.48 seconds.

POSSIBLE CAUSES

  • RELATED TPS ENGINE DTC'S PRESENT
  • POWERTRAIN CONTROL MODULE
  • INTERMITTENT WIRING AND CONNECTORS

DIAGNOSTIC PROCEDURE

NOTE: Low fluid level can be the cause of many transmission problems. If the fluid level is low locate and repair the leak then check and adjust the fluid level. Refer to appropriate AUTOMATIC TRANSMISSION article.

NOTE: Always perform diagnostics with a fully charged battery to avoid false symptoms.

NOTE: Diagnose 1 Trip Failures as a fully matured DTC.

NOTE: Verify flash level of Powertrain Controller. Some problems are corrected by software upgrades to the Transmission and Engine Systems.

NOTE: Due to the integration of the Powertrain and Transmission control modules - if a controller flash is performed it is necessary to perform STANDARD PROCEDURE - TCM QUICK LEARN and the STANDARD PROCEDURE - DRIVE LEARN . Failure to do so may result in shift quality complaints.

NOTE: Check for applicable TSB's that may apply.

  1. With the DRBIII(R), read the engine DTC's. Check and repair all Engine DTC's prior to performing Transmission symptom diagnostics. With the DRBIII(R), read Transmission DTC's. Record all DTC's and 1 Trip Failures. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors. Repair as necessary. Perform the Shift Lever Position Test. If the test does not pass, refer to Symptom test for SYMPTOM: P0706-CHECK SHIFTER SIGNAL . For Gear Ratio DTC's, check and record all CVI's. Most DTC's set on start up but some must be set by driving the vehicle to ensure that all diagnostic monitors have run. Perform this procedure prior to Symptom diagnosis. Continue Go To 2
  2. With the DRBIII(R), check Engine DTC's, this includes all one trip failures. Are there any Engine TPS DTCs present?
    Yes --> Refer to the Powertrain category and perform the appropriate symptom. Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1 .
    No --> Go To 3
  3. 3. With the DRBIII(R), record the EATX EVENT DATA to help identify the conditions in which the DTC was set. With the DRBIII(R), erase Transmission DTCs.
    NOTE: To erase EATX EVENT DATA information, a BATTERY DISCONNECT must be performed. Performing a BATTERY DISCONNECT will reset all learned Transmission values to controller defaults which may lead to erratic shift schedules.
    Drive the vehicle and try to duplicate the conditions in which the DTC was reported by the EATX EVENT DATA. With the DRBIII(R), read Transmission DTCs. Did the DTC P0123 THROTTLE POSITION SENSOR HIGH, reset?
    Yes --> Go To 4
    No --> Go To 5
    NOTE: Due to the integration of the Powertrain and Transmission Control Modules, communication between the modules is internal.
  4. Using the schematics as a guide, inspect the wiring and connectors. Repair as necessary. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, view repair.
    Repair Replace the Powertrain Control Module and perform STANDARD PROCEDURE - TCM QUICK LEARN . Refer to ELECTRONIC CONTROL MODULES . Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1 .
  5. The conditions necessary to set this DTC are not present at this time. Using the schematics as a guide, inspect the wiring and connectors specific to this circuit. Wiggle the wires while checking for shorted and open circuits. Pay particular attention to the TPS signal and sensor ground circuits. With the DRBIII(R), check the EATX DTC EVENT DATA to help identify the conditions in which the DTC was set. Were there any problems found?
    Yes --> Repair as necessary. Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1 .
    No --> Test Complete.
]]>175Tue, 05 Jan 2016 01:27:59 +0000P0124 TPS/APPS Intermittenthttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0124-tpsapps-intermittent-r176/

P0124 TPS/APPS INTERMITTENT

When Monitored and Set Condition:

When Monitored: Continuously with the ignition on and engine running.
Set Condition: This DTC will set if the monitored TPS throttle angle between the angles of 6° and 120° and the degree change is greater than 5° within a period of less than 7.0 ms.

POSSIBLE CAUSES

  • RELATED TPS ENGINE DTC'S PRESENT
  • THROTTLE POSITION SENSOR
  • POWERTRAIN CONTROL MODULE
  • INTERMITTENT WIRING AND CONNECTORS

DIAGNOSTIC PROCEDURE

NOTE: Low fluid level can be the cause of many transmission problems. If the fluid level is low locate and repair the leak then check and adjust the fluid level. Refer to appropriate AUTOMATIC TRANSMISSION article.

NOTE: Always perform diagnostics with a fully charged battery to avoid false symptoms.

NOTE: Diagnose 1 Trip Failures as a fully matured DTC.

NOTE: Verify flash level of Powertrain Controller. Some problems are corrected by software upgrades to the Transmission and Engine Systems.

NOTE: Due to the integration of the Powertrain and Transmission control modules - if a controller flash is performed it is necessary to perform STANDARD PROCEDURE - TCM QUICK LEARN and the STANDARD PROCEDURE - DRIVE LEARN . Failure to do so may result in shift quality complaints.

NOTE: Check for applicable TSB's that may apply.

  1. With the DRBIII(R), read the engine DTC's. Check and repair all Engine DTC's prior to performing Transmission symptom diagnostics. With the DRBIII(R), read Transmission DTC's. Record all DTC's and 1 Trip Failures. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors. Repair as necessary. Perform the Shift Lever Position Test. If the test does not pass, refer to Symptom test for SYMPTOM: P0706-CHECK SHIFTER SIGNAL . For Gear Ratio DTC's, check and record all CVI's. Most DTC's set on start up but some must be set by driving the vehicle to ensure that all diagnostic monitors have run. Perform this procedure prior to Symptom diagnosis. Continue Go To 2
  2. With the DRBIII(R), check Engine DTC's, this includes all one trip failures. Are there any Engine TPS DTCs present?
    Yes --> Refer to the Powertrain category and perform the appropriate symptom. Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1 .
    No --> Go To 3
  3. With the DRBIII(R), record the EATX EVENT DATA to help identify the conditions in which the DTC was set. With the DRBIII(R), erase Transmission DTCs.
    NOTE: To erase EATX EVENT DATA information, a BATTERY DISCONNECT must be performed. Performing a BATTERY DISCONNECT will reset all learned Transmission values to controller defaults which may lead to erratic shift schedules.
    Drive the vehicle and try to duplicate the conditions in which the DTC was reported by the EATX EVENT DATA. With the DRBIII(R), read Transmission DTCs. Did the DTC P0124 THROTTLE POSITION SENSOR INTERMITTENT, reset?
    Yes --> Go To 4
    No --> Go To 6
  4. Ignition On, Engine Not Running. With the DRBIII(R), under Transmission Sensors, monitor the TPS voltage in the following step. Slowly open and close the throttle while checking for erratic voltage changes. Did the TPS voltage change smooth and consistent?
    Yes --> Go To 5
    No --> Replace the Throttle Position Sensor. See appropriate FUEL INJECTION article. Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1 .
    NOTE: Due to the integration of the Powertrain and Transmission Control Modules, communication between the modules is internal.
  5. Using the schematics as a guide, inspect the wiring and connectors. Repair as necessary. Pay particular attention to all power and ground circuits. If there are no possible causes remaining, view repair. Repair Replace the Powertrain Control Module and perform STANDARD PROCEDURE - TCM QUICK LEARN . Refer to ELECTRONIC CONTROL MODULES . Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1 .
  6. The conditions necessary to set this DTC are not present at this time. Using the schematics as a guide, inspect the wiring and connectors specific to this circuit. Wiggle the wires while checking for shorted and open circuits. Pay particular attention to the TPS signal and sensor ground circuits. With the DRBIII(R), check the EATX DTC EVENT DATA to help identify the conditions in which the DTC was set. Were there any problems found?
    Yes --> Repair as necessary. Perform (NGC) 45RFE/545RFE TRANSMISSION VERIFICATION TEST - VER 1 .
    No --> Test Complete.
]]>176Tue, 05 Jan 2016 01:40:58 +0000P0128 Thermostat Rationalityhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0128-thermostat-rationality-r177/

P0128 THERMOSTAT RATIONALITY

When Monitored and Set Condition:

When Monitored: While the engine is running.
Set Condition: The coolant temperature does not rise by a calibrated amount over a calibrated amount of time.

POSSIBLE CAUSES

  • COOLING FAN
  • COOLANT TEMPERATURE SENSOR
  • THERMOSTAT

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.
NOTE: refer to the no trouble code test "*Fan Operation Test" to ensure the fan is operating properly.

  1. Is the cooling fan operating properly?
    Yes --> Go To 2
    No --> Repair the cooling fan. Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
  2. Operate the engine for 10 minutes while monitoring the coolant temperature with the DRBIII®. Did the coolant temperature change over time while the engine was running?
    Yes --> Go To 3
    No --> Replace the coolant temperature sensor. Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
    NOTE: Refer to Symptom: *FUEL HEATER THERMOSTAT TEST to ensure the thermostat is operating properly.
  3. is the thermostat operating properly?
    Yes --> Test Complete.
    No --> Replace the thermostat. Perform POWERTRAIN VERIFICATION TEST VER - 2 (DIESEL).
]]>177Tue, 05 Jan 2016 01:42:57 +0000P0148 High Pressure Common Rail (HPCR) Checksumhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0148-high-pressure-common-rail-hpcr-checksum-r178/

P0148 HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM

When Monitored and Set Condition:

When Monitored: While the engine is running.
Set Condition: A deviation between the fuel pressure set point and the actual fuel pressure.

POSSIBLE CAUSES

  • OTHERS DTC'S PRESENT
  • FUEL LEAKS
  • FUEL CONTROL ACTUATOR
  • FUEL PRESSURE SENSOR
  • CASCADE OVERFLOW VALVE
  • CHECK VALVE DAMAGED OR BLOCKED
  • FUEL RETURN LINES OBSTRUCTION, DAMAGE, OR DEBRIS.
  • LIFT PUMP FLOW
  • AIR IN FUEL SYSTEM
  • LEAKING FUEL INJECTORS OR HIGH PRESSURE CONNECTORS
  • PRESSURE LIMITING VALVE
  • HIGH PRESSURE FUEL PUMP
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. With the DRBIII®, read DTCs. Are any other DTCs present?
    Yes --> Repair other DTCs first. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 2
  2. Ensure that the fuel level is above 15% using the DRBIII®. Visually inspect the low and high pressure side of the fuel system for fuel leaks or damaged components. Do you have any fuel leaks or damaged components?
    Yes --> Repair the fuel leak. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 3
  3. Check for a mechanically stuck Fuel Control Actuator (FCA). Using the DRBIII®, actuate the fuel control actuator. Note: The fuel control actuator will only click when cycled off. Do you hear a click from the actuator when you cycle the actuator off with the DRBIII®?
    Yes --> Go To 4
    No --> Replace the fuel control actuator. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  4. Using the DRBIII®, monitor the fuel pressure reading from the fuel rail pressure sensor at idle and at 2000 RPM Is the fuel rail pressure reading higher at 2000 RPM than at idle?
    Yes --> Go To 5
    No --> Replace the fuel pressure sensor. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  5. Using the DRBIII® compare the fuel rail pressure set point with the actual fuel rail pressure. Is the actual fuel rail pressure higher than the fuel rail pressure set point?
    Yes --> Go To 6
    No --> Go To 9
  6. Perform the no trouble code test "SYMPTOM: *FUEL PUMP RETURN FLOW TEST". Did the fuel injection pump pass the test?
    Yes --> Go To 7
    No --> Replace the Fuel pump. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  7. Check the fuel drain line check valve in the rear of the cylinder head for signs of damage, blockage, or debris. Is the check valve damaged or blocked?
    Yes --> Repair the cause of the damaged or blocked check valve or replace the valve. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 8
  8. Check the fuel return lines for signs of obstruction, damage, or debris. Are the fuel drain lines damaged or blocked?
    Yes --> Repair cause of high fuel drain line restriction. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 9
  9. Perform the no trouble code "SYMPTOM: *FUEL LIFT PUMP FLOW AND INLET RESTRICTION TEST". Did the Lift pump pass the test?
    Yes --> Go To 10
    No --> Replace the Lift Pump. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  10. Perform the no trouble code test "Fuel system vacuum test". Is there air in the fuel system?
    Yes --> Go To 11
    No --> Repair cause of air in fuel system. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  11. Perform the no trouble code test "SYMPTOM: *CHECKING PRESSURE LIMITING VALVE ON THE FUEL RAIL FOR INTERNAL LEAKS". Did the pressure limiting valve pass the test procedure?
    Yes --> Go To 12
    No --> Replace the Pressure Limiting Valve. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
  12. Perform the no trouble test "SYMPTOM: *INJECTOR RETURN FLOW TEST". Are any Injectors leaking or high pressure connectors leaking?
    Yes --> Replace or repair the leaking fuel injectors or high pressure connectors. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Go To 13
  13. Perform the no trouble code test "SYMPTOM: *HIGH PRESSURE FUEL PUMP PERFORMANCE TEST" Did the fuel pump pass the high pressure fuel pump performance test?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure). Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Replace the High pressure fuel pump. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
]]>178Tue, 05 Jan 2016 01:44:20 +0000P0169 Water In Fuel (WIF) Light On Too Longhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0169-water-in-fuel-wif-light-on-too-long-r179/ P0169 WATER IN FUEL (WIF) LIGHT ON TOO LONG

When Monitored and Set Condition:

When Monitored: While the engine is running.
Set Condition: Water in fuel light was on for a calibrated amount of time.

POSSIBLE CAUSES

  • OTHER DTCS PRESENT
  • WATER IN FUEL

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. With the DRBIII®, read DTCs. Is P2269 displayed?
    Yes --> Repair P2269 DTC first. Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
    No --> Drain water in fuel.
]]>179Tue, 05 Jan 2016 01:46:06 +0000P0192 Fuel Pressure Sensor Voltage Too Lowhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0192-fuel-pressure-sensor-voltage-too-low-r180/

P0192 FUEL PRESSURE SENSOR VOLTAGE TOO LOW

When Monitored and Set Condition:

When Monitored: With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM falls below a calibrated threshold for a certain period of time.

POSSIBLE CAUSES

  • OTHER DTC'S
  • FUEL PRESSURE SENSOR
  • (K72E) 5-VOLT SUPPLY CIRCUIT SHORTED TO (G910) RETURN CIRCUIT
  • (K102) SIGNAL CIRCUIT SHORTED TO (G910) RETURN CIRCUIT
  • (K102) SIGNAL CIRCUIT OPEN
  • (K72E) 5-VOLT SUPPLY CIRCUIT OPEN
  • (K102) SIGNAL CIRCUIT SHORTED TO GROUND
  • (K72E) 5-VOLT SUPPLY CIRCUIT SHORTED TO GROUND
  • ECM
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Ignition on, engine not running. With the DRBIII®, read DTCs. Do you have multiple DTCs?
    Yes --> Repair other DTCs first.
    No --> Go To 2
  2. Turn the ignition off. Disconnect the Fuel Pressure sensor harness connector. Check connectors - Clean/repair as necessary. Measure the voltage between the (K72E) 5-volt supply and (G910) return circuits of the Fuel pressure sensor harness connector. Is the voltage between 4.5 and 5.5 volts?
    Yes --> Go To 3
    No --> Go To 4
  3. Reconnect the disconnected Fuel Pressure Sensor harness connector. Ignition on, engine not running.While monitoring DRBIII®, disconnect the Fuel Pressure sensor harness connector. Does the DTC P0193 set?
    Yes --> Replace the Fuel Pressure Sensor.
    No --> Go To 4
  4. Turn the ignition off. Disconnect the ECM harness connectors. Disconnect the Fuel Pressure sensor harness connector. Check connectors - Clean/repair as necessary. Measure the resistance between the (K72E) 5-volt supply circuit and (G910) return circuit in the sensor harness connector. Is the resistance greater than 100 K Ohms?
    Yes --> Go To 5
    No --> Repair the shorted circuits.
  5. Measure the resistance between the (K102) signal circuit and (G910) return circuit in the sensor connector. Is the resistance greater than 100 K Ohms?
    Yes --> Go To 6
    No --> Repair the shorted circuits.
  6. Measure the resistance between the signal (K102) circuit in the sensor harness connector with the (K102) signal circuit in the ECM harness connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 7
    No --> Repair the open (K102) signal circuit.
  7. Measure the resistance between the supply (K72E) circuit in the sensor harness connector with the (K72E) 5-volt supply circuit in the ECM harness connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 8
    No --> Repair the open (K72E) 5-volt supply circuit.
  8. Measure the resistance between the (K102) signal circuit in the sensor harness connector and battery negative. Is the resistance greater than 100 K Ohms?
    Yes --> Go To 9
    No --> Repair (K102) signal circuit shorted to ground.
  9. Measure the resistance between the (K72E) 5-volt supply circuit in the sensor harness connector and battery negative. Is the resistance greater than 100 K Ohms?
    Yes --> Go To 10
    No --> Repair (K72E) 5-volt Supply circuit shorted to ground.
  10. Reconnect the disconnected Fuel pressure sensor harness connector and ECM harness connectors. While monitoring DRBIII®, disconnect the Fuel Pressure sensor connector. Does the DTC P0193 set?
    Yes --> Test Complete.
    No --> Replace the ECM.
]]>180Tue, 05 Jan 2016 01:47:08 +0000P0193 Fuel Pressure Sensor Voltage Too Highhttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0193-fuel-pressure-sensor-voltage-too-high-r181/

P0193 FUEL PRESSURE SENSOR VOLTAGE TOO HIGH

When Monitored and Set Condition:

When Monitored: With the ignition on and battery voltage greater than 10.4 volts.
Set Condition: The circuit voltage to the ECM is above a calibrated threshold for a certain period of time.

POSSIBLE CAUSES

  • OTHER DTC'S
  • FUEL PRESSURE SENSOR
  • (K102) SIGNAL CIRCUIT SHORTED TO VOLTAGE
  • (K72E) 5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
  • (K102) SIGNAL CIRCUIT SHORTED TO (K72E) 5-VOLT SUPPLY CIRCUIT
  • (G910) RETURN CIRCUIT OPEN
  • ECM
  • INTERMITTENT CONDITION

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. Ignition on, engine not running. With the DRBIII®, read DTCs. Do you have multiple DTCs?
    Yes --> Refer to multiple fault troubleshooting tree.
    No --> Go To 2
  2. Turn the ignition off. Disconnect the Fuel Pressure sensor harness connector. Check connectors - Clean/repair as necessary. Measure the voltage between the (K72E) 5-volt supply and (G910) return circuits of the Fuel pressure sensor harness connector. Is the voltage between 4.5 and 5.5 volts?
    Yes --> Go To 3
    No --> Go To 4
  3. Ignition on, engine not running. While monitoring DRBIII®, connect a jumper wire between the (K102) signal circuit and the (G910) return circuit of the Fuel Pressure sensor connector. Does the DTC P0192 set?
    Yes --> Replace the Fuel Pressure Sensor.
    No --> Go To 4
  4. Turn the ignition off. Disconnect the Fuel Pressure sensor harness connector. Disconnect the ECM harness connectors. Check connectors - Clean/repair as necessary. Turn the ignition on. Measure the voltage between the (K102) signal circuit of the sensor harness connector and battery negative. Is the voltage less than 1 volt?
    Yes --> Go To 5
    No --> Repair the (K102) signal circuit shorted to voltage.
  5. Measure the voltage between the (K72E) 5-volt supply circuit of the sensor harness connector and battery negative. Is the voltage less than 1 volt?
    Yes --> Go To 6
    No --> Repair the (K72E) 5-volt supply circuit shorted to voltage.
  6. Turn the ignition off. Measure the resistance between the (K102) signal circuit and (K72E) 5-volt supply circuit in the sensor connector. Is the resistance greater than 10 K Ohms?
    Yes --> Go To 7
    No --> Repair the shorted circuits.
  7. Measure the resistance between the (G910) return circuit in the sensor harness connector with the (G910) return circuit in the ECM harness connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 8
    No --> Repair the open (G910) return circuit.
  8. Reconnect the disconnected ECM harness connectors. While monitoring DRBIII®, connect a jumper wire between the (K102) signal circuit of the sensor connector and the (G910) return circuit of the sensor connector. Does the DTC P0192 set?
    Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
    No --> Replace the ECM.
]]>181Tue, 05 Jan 2016 01:48:10 +0000P0201 Injector #1 Control Circuithttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0201-injector-1-control-circuit-r182/

P0201 INJECTOR #1 CONTROL CIRCUIT

NOTE: All symptoms listed above are diagnosed using the same tests. The title for the tests will be P0201-INJECTOR #1 CONTROL CIRCUIT.

When Monitored and Set Condition:

When Monitored: While the engine is running.
Set Condition: When the injector current falls below a calibrated threshold.

POSSIBLE CAUSES

PASS TROUGH CONNECTORS OPEN
FUEL INJECTOR
INJECTOR HARNESS OPEN
HIGH SIDE DRIVER HARNESS OPEN
LOW SIDE DRIVER HARNESS OPEN
ECM

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. With the DRBIII®, read DTCs. Are all 6 of the injector DTCs (P0201 - P0206) present?
    Yes --> Go To 2
    No --> Go To 3
  2. Inspect wiring harness for signs of multiple open circuits between the ECM and the injector pass through connectors. Inspect the wiring harness between the pass through connectors to the injectors. Are there open circuits in the wiring harness?
    Yes --> Repair or replace the open connectors or wiring.
    No --> Go To 3
  3. Turn the ignition off. Disconnect the pigtail nuts from the suspect injector. Using an Ohmmeter, measure the resistance between the solenoid posts of the injector. NOTE: Be sure to zero the ohm meter prior to checking the injector circuit. Is the resistance less than 1 ohm and greater than 0 ohms?
    Yes --> Go To 4
    No --> Replace the fuel injector.
  4. Connect the pigtail nuts for the suspect injector. Disconnect the injector harness connector for the suspect injector. Measure the resistance of the injector harness circuit between the high side driver circuit and the low side driver circuit for the suspect injector at the injector harness connector. NOTE: Be sure to zero the ohm meter prior to checking the injector circuit. Is the resistance less than 1 ohm and greater than 0 ohms?
    Yes --> Go To 5
    No --> Replace or repair the injector harness.
  5. Disconnect the ECM harness connectors. Disconnect the Injector harness connector. Check connectors - Clean/repair as necessary. Measure the resistance of the Bank 1 high side driver circuit between the ECM connector and the injector harness connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 6
    No --> Replace or repair the open engine harness.
  6. Measure the resistance of the Bank 1 low side driver circuit between the ECM connector and the injector harness connector. Is the resistance less than 10 Ohms?
    Yes --> Test Complete.
    No --> Replace or repair the open engine harness.
]]>182Tue, 05 Jan 2016 01:49:10 +0000P0202 Injector #2 Control Circuithttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0202-injector-2-control-circuit-r183/

P0202 INJECTOR #2 CONTROL CIRCUIT

NOTE: All symptoms listed above are diagnosed using the same tests. The title for the tests will be P0202-INJECTOR #2 CONTROL CIRCUIT.

When Monitored and Set Condition:

When Monitored: While the engine is running.
Set Condition: When the injector current falls below a calibrated threshold.

POSSIBLE CAUSES

PASS TROUGH CONNECTORS OPEN
FUEL INJECTOR
INJECTOR HARNESS OPEN
HIGH SIDE DRIVER HARNESS OPEN
LOW SIDE DRIVER HARNESS OPEN
ECM

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. With the DRBIII®, read DTCs. Are all 6 of the injector DTCs (P0201 - P0206) present?
    Yes --> Go To 2
    No --> Go To 3
  2. Inspect wiring harness for signs of multiple open circuits between the ECM and the injector pass through connectors. Inspect the wiring harness between the pass through connectors to the injectors. Are there open circuits in the wiring harness?
    Yes --> Repair or replace the open connectors or wiring.
    No --> Go To 3
  3. Turn the ignition off. Disconnect the pigtail nuts from the suspect injector. Using an Ohmmeter, measure the resistance between the solenoid posts of the injector. NOTE: Be sure to zero the ohm meter prior to checking the injector circuit. Is the resistance less than 1 ohm and greater than 0 ohms?
    Yes --> Go To 4
    No --> Replace the fuel injector.
  4. Connect the pigtail nuts for the suspect injector. Disconnect the injector harness connector for the suspect injector. Measure the resistance of the injector harness circuit between the high side driver circuit and the low side driver circuit for the suspect injector at the injector harness connector. NOTE: Be sure to zero the ohm meter prior to checking the injector circuit. Is the resistance less than 1 ohm and greater than 0 ohms?
    Yes --> Go To 5
    No --> Replace or repair the injector harness.
  5. Disconnect the ECM harness connectors. Disconnect the Injector harness connector. Check connectors - Clean/repair as necessary. Measure the resistance of the Bank 1 high side driver circuit between the ECM connector and the injector harness connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 6
    No --> Replace or repair the open engine harness.
  6. Measure the resistance of the Bank 1 low side driver circuit between the ECM connector and the injector harness connector. Is the resistance less than 10 Ohms?
    Yes --> Test Complete.
    No --> Replace or repair the open engine harness.
]]>183Tue, 05 Jan 2016 01:56:44 +0000P0203 Injector #3 Control Circuithttps://mopar1973man.com/cummins/articles.html/3rd-generation/engine/obdii-error-codes/p0203-injector-3-control-circuit-r184/

P0203 INJECTOR #3 CONTROL CIRCUIT

NOTE: All symptoms listed above are diagnosed using the same tests. The title for the tests will be P0203-INJECTOR #3 CONTROL CIRCUIT.

When Monitored and Set Condition:

When Monitored: While the engine is running.
Set Condition: When the injector current falls below a calibrated threshold.

POSSIBLE CAUSES

PASS TROUGH CONNECTORS OPEN
FUEL INJECTOR
INJECTOR HARNESS OPEN
HIGH SIDE DRIVER HARNESS OPEN
LOW SIDE DRIVER HARNESS OPEN
ECM

DIAGNOSTIC PROCEDURE

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

  1. With the DRBIII®, read DTCs. Are all 6 of the injector DTCs (P0201 - P0206) present?
    Yes --> Go To 2
    No --> Go To 3
  2. Inspect wiring harness for signs of multiple open circuits between the ECM and the injector pass through connectors. Inspect the wiring harness between the pass through connectors to the injectors. Are there open circuits in the wiring harness?
    Yes --> Repair or replace the open connectors or wiring.
    No --> Go To 3
  3. Turn the ignition off. Disconnect the pigtail nuts from the suspect injector. Using an Ohmmeter, measure the resistance between the solenoid posts of the injector. NOTE: Be sure to zero the ohm meter prior to checking the injector circuit. Is the resistance less than 1 ohm and greater than 0 ohms?
    Yes --> Go To 4
    No --> Replace the fuel injector.
  4. Connect the pigtail nuts for the suspect injector. Disconnect the injector harness connector for the suspect injector. Measure the resistance of the injector harness circuit between the high side driver circuit and the low side driver circuit for the suspect injector at the injector harness connector. NOTE: Be sure to zero the ohm meter prior to checking the injector circuit. Is the resistance less than 1 ohm and greater than 0 ohms?
    Yes --> Go To 5
    No --> Replace or repair the injector harness.
  5. Disconnect the ECM harness connectors. Disconnect the Injector harness connector. Check connectors - Clean/repair as necessary. Measure the resistance of the Bank 1 high side driver circuit between the ECM connector and the injector harness connector. Is the resistance less than 10 Ohms?
    Yes --> Go To 6
    No --> Replace or repair the open engine harness.
  6. Measure the resistance of the Bank 1 low side driver circuit between the ECM connector and the injector harness connector. Is the resistance less than 10 Ohms?
    Yes --> Test Complete.
    No --> Replace or repair the open engine harness.
]]>184Tue, 05 Jan 2016 01:58:01 +0000