Dodge Ram Truck 1500-2500-3500. Manual — part 1099
P0542-HIGH VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY (CONTINUED)
3.
INTAKE AIR HEATER RELAY
Turn the ignition off.
Remove the Intake Air Heater Relay.
NOTE: 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). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
4.
SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE
Disconnect the ECM harness connector(s).
NOTE: 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). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
5.
SIGNAL CIRCUIT SHORTED TO OTHER CIRCUITS
Measure the resistance between the signal circuit of the intake air heater relay and all other circuits in the ECM
harness connector.
Is the resistance greater than 100 K ohms?
Yes
>> Go To 6
No
>> Repair signal circuit shorted to other circuits.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
6.
ECM
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 INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
No
>> Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
9 - 1318
ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL
DR/DH
P0562-BATTERY VOLTAGE LOW
DR/DH
ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL
9 - 1319
P0562-BATTERY VOLTAGE LOW (CONTINUED)
For the Engine circuit diagram (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CON-
TROL MODULE - SCHEMATIC - ELECTRICAL)
For a complete wiring diagram Refer to Section 8W.
•
When Monitored:
With the key on or the engine running.
•
Set Condition:
The battery voltage detected by the ECM is less than a calibrated value.
Possible Causes
P0622 PRESENT
P2502 PRESENT
P2503 PRESENT
BATTERY TERMINAL CONNECTIONS
ACCESSORY WIRING
BATTERY
HIGH RESISTANCE IN WIRE HARNESS
ECM
INTERMITTENT CONDITION
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Diagnostic Test
1.
P0622 PRESENT
With the scan tool, read DTCs.
Is P0622 set?
Yes
>> Repair P0622 first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No
>> Go To 2
2.
P2502 PRESENT
With the scan tool, read DTCs.
Is P2502 set?
Yes
>> Repair P2502 first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No
>> Go To 3
9 - 1320
ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL
DR/DH
P0562-BATTERY VOLTAGE LOW (CONTINUED)
3.
P2503 PRESENT
With the scan tool, read DTCs.
Is P2503 set?
Yes
>> Repair P2503 first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No
>> Go To 4
4.
BATTERY TERMINAL CONNECTIONS
Visually inspect the positive and negative connections at the batteries and inspect the battery negative connections
at the engine block.
Are the connections free of corrosion and are they tight?
Yes
>> Go To 5
No
>> Repair the poor connections.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
5.
ACCESSORY WIRING
Check for add-on or accessory wiring at positive (+) terminal of the battery
Are there any damaged wires at the battery?
Yes
>> Repair accessory wiring.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No
>> Go To 6
6.
BATTERY(S)
Perform battery load test using the Midtronics Micro 420 battery system tester.
Did the battery(s) pass the test?
Yes
>> Go To 7
No
>> Replace the weak battery or batteries.
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 - 1321
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