Dodge Ram Truck 1500-2500-3500. Manual — part 1098

P0541-LOW VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY (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:
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 OPEN FROM RELAY TO ECM

SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE

ECM

INTERMITTENT CONDITION

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)

Diagnostic Test

1.

RELAY CLICKING

Ignition on, engine not running.

With the scan tool, actuate the #1 Intake Air Heater.

Can you hear the Relay clicking?

Yes

>> Go To 2

No

>> Go To 3

2.

LOOSE CONNECTION

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). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)

No

>> Go To 3

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ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL

DR/DH

P0541-LOW VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY (CONTINUED)

3.

INTAKE AIR HEATER RELAY

Turn the ignition off.

Remove the Intake Air Heater #1 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 #1 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 OPEN FROM RELAY TO ECM

Disconnect the ECM harness connectors.

Check connectors - Clean/repair as necessary.

Measure the resistance of the intake air heater relay signal circuit between the ECM connector and the intake air
heater relay connector.

Is the resistance less than 10 Ohms?

Yes

>> Go To 5

No

>> Repair the open signal circuit from PDC to ECM harness connector.

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 BATTERY NEGATIVE

Measure the voltage between the signal circuit of the intake air heater relay and battery negative.

Is the voltage greater than 1 volts?

Yes

>> Repair the 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)

No

>> Go To 6

6.

ECM

Reconnect the ECM harness connectors.

Disconnect the intake air heater relay signal wire and use a jumper to connect it to battery negative.

Turn the ignition on.

With the scan tool, read DTCs.

Did DTC P0542 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)

DR/DH

ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL

9 - 1315

P0542-HIGH VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY

9 - 1316

ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL

DR/DH

P0542-HIGH VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY (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:
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

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)

Diagnostic Test

1.

RELAY CLICKING

Ignition on, engine not running.

With the scan tool, actuate the Intake Air Heater relay.

Can you hear the Relay clicking?

Yes

>> Go To 2

No

>> Go To 3

2.

LOOSE CONNECTION

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). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)

No

>> Go To 3

DR/DH

ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL

9 - 1317