disconnecting ecm connectors?
#1
#3
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/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No >> Go To 3
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/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
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/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No >> Go To 3
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/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
#4
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/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
5. RETURN CIRCUIT SHORTED TO BATTERY NEGATIVE
Measure the resistance of the return circuit between the intake air heater relay connector and battery negative.
I s resistance less than 10 ohms?
Yes >> Go To 6
No >> Repair the return circuit shorted to battery negative.
6. 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/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No >> Go To 7
7. 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 P2608?
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/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
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/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
5. RETURN CIRCUIT SHORTED TO BATTERY NEGATIVE
Measure the resistance of the return circuit between the intake air heater relay connector and battery negative.
I s resistance less than 10 ohms?
Yes >> Go To 6
No >> Repair the return circuit shorted to battery negative.
6. 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/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No >> Go To 7
7. 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 P2608?
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/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
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