Jeep XJ. Manual — part 621
Symptom:
P1635-GLOW RELAY 1 CONTROLLER OPEN CIRCUIT
When Monitored and Set Condition:
P1635-GLOW RELAY 1 CONTROLLER OPEN CIRCUIT
When Monitored:
With the ignition on.
Set Condition:
The 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
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
With the DRB, actuate the Glow Plug Relay.
Is the Glow Plug Relay clicking?
All
Yes
→
No
→
NOTE: Stop the Glow Plug Relay actuation by the DRB.
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?
All
Yes
→
Repair as necessary
Perform ROAD TEST VERIFICATION - VER-2.
No
→
Test Complete.
136
DRIVEABILITY - DIESEL
TEST
ACTION
APPLICABILITY
3
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?
All
Yes
→
No
→
Repair the ASD/Diesel Power Relay Output circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
4
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.
Is the Glow Plug Relay clicking?
All
Yes
→
Replace the Glow Plug Relay.
Perform ROAD TEST VERIFICATION - VER-2.
No
→
5
Turn the ignition off.
Disconnect the ECM harness connectors.
Remove the Glow Plug Relay from the PDC.
Measure the resistance between ground and the Glow Plug Relay Control circuit.
Is the resistance above 100 kohms?
All
Yes
→
No
→
Repair the Glow Plug Relay Control circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
6
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?
All
Yes
→
No
→
Repair the Glow Plug Relay Control circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
7
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.
137
DRIVEABILITY - DIESEL
P1635-GLOW RELAY 1 CONTROLLER OPEN CIRCUIT —
Continued
Symptom:
P1635-GLOW RELAY 1 CONTROLLER SHORT CIRCUIT
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
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
With the DRB, actuate the Glow Plug Relay.
Is the Glow Plug Relay clicking?
All
Yes
→
No
→
NOTE: Stop the Glow Plug Relay actuation by the DRB.
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?
All
Yes
→
Repair as necessary
Perform ROAD TEST VERIFICATION - VER-2.
No
→
Test Complete.
138
DRIVEABILITY - DIESEL
TEST
ACTION
APPLICABILITY
3
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.
Is the Glow Plug Relay clicking?
All
Yes
→
Replace the Glow Plug Relay.
Perform ROAD TEST VERIFICATION - VER-2.
No
→
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.
Connect 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?
All
Yes
→
Repair the Glow Plug Relay Control circuit for a short to voltage.
Perform ROAD TEST VERIFICATION - VER-2.
No
→
5
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.
139
DRIVEABILITY - DIESEL
P1635-GLOW RELAY 1 CONTROLLER SHORT CIRCUIT —
Continued
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