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18615 Dr Pwrtrn Sgmldiag

18615 Dr Pwrtrn Sgmldiag

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4.5

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Published by api-3818270
DC Manual describing Fault codes and diagnostics of the Powertrain control module of the Dodge Ram. (DR 3.7L, 4.7L, and 5.7L vehicles are equipped with the Powertrain Control Module and Transmission Control Module combined in a single control module.)
DC Manual describing Fault codes and diagnostics of the Powertrain control module of the Dodge Ram. (DR 3.7L, 4.7L, and 5.7L vehicles are equipped with the Powertrain Control Module and Transmission Control Module combined in a single control module.)

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Published by: api-3818270 on Oct 17, 2008
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TABLE OF CONTENTS
1.0
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1SYSTEM COVERAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2SIX-STEP TROUBLE SHOOTING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . .1
2.0
IDENTIFICATION OF SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.0
SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION. . . . . . . . . . . . . . . . . . . . . .2
3.1GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.2FUNCTION OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2.1
FUEL CONTROL (GAS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2.2
ON-BOARD DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2.3
TRANSMISSION CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.2.3.1TRANSMISSION OPERATION AND SHIFT SCHEDULING AT
VARIOUS OIL TEMPERATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.2.3.2LINE PRESSURE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 3.2.3.3DRIVE LEARN PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 3.2.4

TRANSMISSION CONTROL (48RE). . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.2.5
O2 SENSOR (NGC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.2.6
OTHER CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.2.7
NON-MONITORED CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.3DIAGNOSTIC TROUBLE CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.3.1
HARD CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.3.2
ONE TRIP FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.3.3
INTERMITTENT CODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.3.4
STARTS SINCE SET COUNTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.3.5
TROUBLE CODE ERASURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.3.6
RFE QUICK LEARN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.3.7
RFE CLUTCH VOLUMES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.3.8
NO START INFORMATION (POWERTRAIN). . . . . . . . . . . . . . . . . . . .22
3.4USING THE DRBIII\ue002. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.5DRBIII\ue002 ERROR MESSAGES AND BLANK SCREEN. . . . . . . . . . . . . . . . . . . . .22
3.5.1
DRBIII\ue002 DOES NOT POWER UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.5.2
DISPLAY IS NOT VISIBLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.5.3
SOME DISPLAY ITEMS READ \u2018\u2018___\u2019\u2019. . . . . . . . . . . . . . . . . . . . . . . . . .23
3.6EATX DTC EVENT DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.7
TRANSMISSION SIMULATOR (MILLER TOOL # 8333) AND ELECTRONIC
TRANSMISSION ADAPTER KIT (MILLER TOOL #8333-1A). . . . . . . . . . . . . . 23
4.0
DISCLAIMERS, SAFETY, WARNINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.1DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.2SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.2.1
TECHNICIAN SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . .24
4.2.2
VEHICLE PREPARATION FOR TESTING. . . . . . . . . . . . . . . . . . . . . . .24
4.2.3
SEVICING SUB-ASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.2.4
DRBIII\ue002 SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4.3WARNINGS AND CAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.3.1
ROAD TEST WARNINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.3.1
VEHICLE DAMAGE WARNINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
4.3.2
ROAD TESTING A COMPLAINT VEHICLE (TRANSMISSION). . . . . .25
4.3.3
RFE ELECTRONIC PINION FACTOR WARNINGS (IF
APPLICABLE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
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TABLE OF CONTENTS - Continued
4.4.4
BULLETINS AND RECALLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
5.0
REQUIRED TOOLS AND EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.0
ACRONYMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.2DEFINITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
7.0
DIAGNOSTIC INFORMATION AND PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . .29
COMMUNICATION

*NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY. . . . . . . . . . . . . . . . . . . . . .30 *NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY. . . . . . . . . . . . . . . . . . . . .32 *NO RESPONSE FROM PCM (PCI BUS) - NGC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 *NO RESPONSE FROM PCM (PCM SCI ONLY) - NGC. . . . . . . . . . . . . . . . . . . . . . . .35 *NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE. . . . . . . . . . . . . . . .38 *NO RESPONSE FROM TRANSFER CASE CONTROL MODULE. . . . . . . . . . . . . . . .40 *NO RESPONSE FROM TRANSMISSION CONTROL MODULE. . . . . . . . . . . . . . . . .42 *PCI BUS COMMUNICATION FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

DRIVEABILITY - DIESEL

INTERMITTENT CONDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 P0016-ENGINE SPEED SIGNAL MISMATCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 P0071-INLET AIR TEMP SENSOR RATIONALITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 P0072-INLET AIR TEMP SENSOR VOLTAGE TOO LOW. . . . . . . . . . . . . . . . . . . . . . .51 P0073-INLET AIR TEMP SENSOR VOLTAGE TOO HIGH. . . . . . . . . . . . . . . . . . . . . . .53 P0088-FUEL RAIL PRESSURE SIGNAL IS ABOVE MAX LIMIT. . . . . . . . . . . . . . . . . .55 P0106-INLET AIR PRESSURE SENSOR RATIONALITY. . . . . . . . . . . . . . . . . . . . . . . .56 P0107-INLET AIR PRESSURE SENSOR VOLTAGE TOO LOW. . . . . . . . . . . . . . . . . .57 P0108-INLET AIR Pressure Sensor Voltage Too high. . . . . . . . . . . . . . . . . . . . . . . . . . .60 P0111-INTAKE AIR TEMPERATURE (IAT) SENSOR RATIONALITY. . . . . . . . . . . . . . .62 P0112-INTAKE AIR TEMPERATURE (IAT) SENSOR VOLTAGE TOO LOW. . . . . . . . .63 P0113-INTAKE AIR TEMPERATURE (IAT) SENSOR VOLTAGE TOO HIGH. . . . . . . .65 P0116-ENGINE COOLANT TEMPERATURE (ECT) SENSOR RATIONALITY. . . . . . .67 P0117-ENGINE COOLANT TEMPERATURE (ECT) SENSOR VOLTAGE TOO LOW .68 P0118-ENGINE COOLANT TEMPERATURE (ECT) SENSOR VOLTAGE TOO HIGH .70 P0128-THERMOSTAT RATIONALITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM. . . . . . . . . . . . . . . . .73 P0169-WATER IN FUEL (WIF) LIGHT ON TOO LONG. . . . . . . . . . . . . . . . . . . . . . . . .76 P0192-FUEL PRESSURE SENSOR VOLTAGE TOO LOW. . . . . . . . . . . . . . . . . . . . . .77 P0193-FUEL PRESSURE SENSOR VOLTAGE TOO HIGH. . . . . . . . . . . . . . . . . . . . . .80 P0201-INJECTOR #1 CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 P0202-INJECTOR #2 CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 P0203-INJECTOR #3 CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 P0204-INJECTOR #4 CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 P0205-INJECTOR #5 CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 P0206-INJECTOR #6 CONTROL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 P0217-DECREASED ENGINE PERFORMANCE DUE TO ENGINE OVERHEAT

CONDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 P0219-CRANKSHAFT POSITION SENSOR OVER SPEED SIGNAL. . . . . . . . . . . . . .86 P0234-TURBO BOOST LIMIT EXCEEDED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 P0236-MAP SENSOR TOO HIGH TOO LONG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 P0237-MAP SENSOR VOLTAGE TOO LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89 P0238-MAP SENSOR VOLTAGE TOO HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

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TABLE OF CONTENTS - Continued

P0251-CP3 PUMP REGULATOR CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 P0300-MULTIPLE CYLINDER MISFIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 P0301-CYLINDER # 1 MISFIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 P0302-CYLINDER # 2 MISFIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 P0303-CYLINDER # 3 MISFIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 P0304-CYLINDER # 4 MISFIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 P0305-CYLINDER # 5 MISFIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 P0306-CYLINDER # 6 MISFIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 P0335-CRANKSHAFT POSITION (CKP) LOST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 P0336-CRANKSHAFT POSITION (CKP) SENSOR SIGNAL. . . . . . . . . . . . . . . . . . . .104 P0337-CRANKSHAFT POSITION (CKP) SENSOR VOLTAGE TOO LOW. . . . . . . . .107 P0338-CRANKSHAFT POSITION (CKP) SENSOR VOLTAGE TOO HIGH. . . . . . . . .109 P0340-CAMSHAFT POSITION (CMP) LOST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 P0341-CAMSHAFT POSITION (CMP) SENSOR SIGNAL. . . . . . . . . . . . . . . . . . . . . .113 P0381-WAIT TO START LAMP INOPERATIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 P0461-Fuel Level Unit No Change Over Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 P0462-LOW VOLTAGE DETECTED AT THE FUEL LEVEL SENSOR. . . . . . . . . . . . .121 P0463-HIGH VOLTAGE DETECTED AT THE FUEL LEVEL SENSOR. . . . . . . . . . . .123 P0477-LOW VOLTAGE ON THE ENGINE BRAKE DRIVER. . . . . . . . . . . . . . . . . . . .124 P0478-HIGH VOLTAGE ON THE ENGINE BRAKE DRIVER. . . . . . . . . . . . . . . . . . . .126 P0480-FAN CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..128 P0483-FAN SPEED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..130 P0500-NO VEHICLE SPEED SENSOR SIGNAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . .133 P0514-BAT TEMPERATURE SENSOR RATIONALITY. . . . . . . . . . . . . . . . . . . . . . . .135 P0516-LOW VOLTAGE AT THE BAT TEMP SENSOR. . . . . . . . . . . . . . . . . . . . . . . . .136 P0517-HIGH VOLTAGE AT THE BAT TEMP SENSOR. . . . . . . . . . . . . . . . . . . . . . . . .138 P0521-OIL PRESSURE SWITCH RATIONALITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 P0524-OIL PRESSURE TOO LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..142 P0532-A/C SENDING UNIT VOLTS TOO LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143 P0533-A/C SENDING UNIT VOLTS TOO HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 P0541-LOW VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY. . . . . . . . . . . . . . .148 P2607-LOW VOLTAGE AT THE #2 INTAKE AIR HEATER RELAY. . . . . . . . . . . . . . .148 P0542-HIGH VOLTAGE ON THE #1 INTAKE AIR HEATER RELAY. . . . . . . . . . . . . .150 P2608-HIGH VOLTAGE AT THE #2 INTAKE AIR HEATER RELAY. . . . . . . . . . . . . . .150 P0562-BATTERY VOLTAGE LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..152 P0563-BATTERY VOLTAGE HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..154 P0572-LOW VOLTAGE DETECTED AT THE BRAKE SWITCH. . . . . . . . . . . . . . . . . .156 P0573-HIGH VOLTAGE DETECTED AT THE BRAKE SWITCH. . . . . . . . . . . . . . . . .157 P0580-LOW VOLTAGE DETECTED AT THE SPEED CONTROL SWITCH. . . . . . . .158 P0581-HIGH VOLTAGE DETECTED AT THE SPEED CONTROL SWITCH. . . . . . . .160 P0583-LOW VOLTAGE DETECTED AT THE SPEED CONTROL VACUUM

DRIVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..163
P0584-HIGH VOLTAGE DETECTED AT THE SPEED CONTROL VACUUM

DRIVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..165 P0587-LOW VOLTAGE DETECTED AT THE SPEED CONTROL VENT DRIVER . . .167 P0588-HIGH VOLTAGE DETECTED AT THE SPEED CONTROL VENT DRIVER. . .169 P0595-LOW VOLTAGE DETECTED AT THE S/C BRAKE SWITCH OUTPUT. . . . . .171 P0596-HIGH VOLTAGE DETECTED AT THE S/C BRAKE SWITCH OUTPUT. . . . . .173 P0602-CHECKSUM ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..175 P0604-ECM SOFTWARE ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..176 P0606-ECM HARDWARE ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..177 P0607-ECM INTERNAL FAILURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..178 P0622-GENERATOR FIELD NOT SWITCHING PROPERLY. . . . . . . . . . . . . . . . . . . .179

iii