Dodge Ram Truck 1500-2500-3500. Manual — part 1139
*CHECKING THE ACCELERATOR PEDAL SENSOR CALIBRATION
Possible Causes
MIS-WIRED APPS
VOLTAGE NOT CHANGING DURING SWEEP
THROTTLE PEDAL NOT MOVING FREELY
APPS
Diagnostic Test
1.
MIS-WIRED APPS
Turn the ignition off.
Remove the APPS cover.
Inspect both APPS connector and ECM for proper wiring.
Are both connectors wired correctly?
Yes
>> Go To 2
No
>> Repair mis-wired APPS connector at APPS or ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
2.
THROTTLE PEDAL NOT MOVING FREELY
Ignition on, engine not running.
Look for proper Throttle operation.
Does the Throttle Pedal move freely between the upper and lower stops?
Yes
>> Replace the APPS.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No
>> Repair as necessary.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
9 - 1478
ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL
DR/DH
*CHECKING THE ECM POWER AND GROUNDS
Possible Causes
ECM GROUND CIRCUIT(S) OPEN
FUSED B+ CIRCUIT OPEN
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Diagnostic Test
1.
ECM GROUND CIRCUIT(S) OPEN
Turn the ignition off.
Disconnect the ECM harness connectors.
Using a 12-volt test light connected to 12-volts, check each of the ECM ground circuits in ECM harness connector.
Did the test light illuminate for each cavity?
Yes
>> Go To 2
No
>> Repair the ECM Ground circuit(s) for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
2.
FUSED IGNITION SWITCH OUTPUT CIRCUIT OPEN
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 con-
nector.
Is the test light on?
Yes
>> Go To 3
No
>> Repair the Fused Ignition Switch Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
3.
FUSED B+ CIRCUIT OPEN
Turn the ignition off.
Disconnect the ECM harness connectors.
Using a 12-volt test light connected to ground, check each Fused B+ circuit in the ECM harness connector.
Does the test light illuminate brightly for each circuit?
Yes
>> Test Complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No
>> Repair the Fused B+ Output circuit for an open.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
DR/DH
ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL
9 - 1479
*CHECKING PRESSURE LIMITING VALVE ON THE FUEL RAIL FOR INTERNAL
LEAKS
Possible Causes
PRESSURE LIMITING VALVE DIAGNOSTICS
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Diagnostic Test
1.
PRESSURE LIMITING VALVE
Using the scan tool, measure the rail pressure and determine if the rail pressure is excessive (above 185,000 kpa/
26,831 psi), if it is, troubleshoot for excessive rail pressure first.
Remove the banjo bolt from the pressure-limiting valve on the fuel rail.
Install fuel system test fitting (9013) into the pressure-limiting valve.
Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container.
Perform the tests listed below to determine if the pressure-limiting valve is leaking.
a. Operate the engine at idle and watch for fuel flow into the fuel container.
b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow
into the fuel container.
If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting
valve, the test is complete.
NOTE: do not drive the vehicle with any portion of this test kit installed.
view repair
Yes
>> Repair complete
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
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ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL
DR/DH
*FUEL HEATER THERMOSTAT TEST
Possible Causes
FUEL HEATER THERMOSTAT TEST
Diagnostic Test
1.
FUEL HEATER THERMOSTAT TEST
To check the operating resistance levels on the thermostat and fuel heater perform the following:
1. Unplug the wiring harness from the thermostat.
2. Check the resistance across the two pins of the thermostat with an Ohm meter.
3. The ambient temperature must be below the
9
Circuit close temperature; 1° +/- 3° C
9
to perform this check.
4. If necessary, induce this ambient temperature by placing ice packs on the thermostat to produce an
9
effective
ambient temperature
9
below the circuit close temperature.
5. The resistance across the two pins should be within the range of 0.3 Ohms to 0.45 Ohms for a properly operating
thermostat and heater.
6. If the resistance from step 2 is out of range, remove the thermostat and check the resistance across the terminal
connections of the heater (the heater can be checked at room temperatures).
7. The resistance across the terminal pins of the heater should be within the same range of step 2.
8. Replace the heater if resistance is not within the proper operation range.
9. Replace the heater if resistance is not within the proper operation range. Re-install the thermostat with a new
o-ring.
10. If the heater resistance is within the proper operating.
11. Circuit close temperature; 1° +/- 3° C
12. Circuit open temperature; 18° +/- 4° C
13. Fuel Heater Thermostat 0.3 - 0.45 Ohms at less than 1 degree C
14. Fuel Heater 0.3 - 0.45 Ohms at room temperature
View Repair
Repair
Test complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
DR/DH
ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL
9 - 1481
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