Engine Controls - Intermittent DTC P0201
NUMBER: 08-033-11GROUP: Electrical
DATE: June 22, 2011
THIS SERVICE BULLETIN IS ALSO BEING RELEASED AS RAPID RESPONSE TRANSMITTAL (RRT) 11-059. ALL APPLICABLE SOLD AND UN-SOLD RRT VIN's HAVE BEEN LOADED. TO VERIFY THAT THIS RRT SERVICE ACTION IS APPLICABLE TO THE VEHICLE, USE VIP OR PERFORM A VIN SEARCH IN TECHCONNECT. ALL REPAIRS ARE REIMBURSABLE WITHIN THE PROVISIONS OF WARRANTY.
SUBJECT:
Intermittent Diagnostic Trouble Code P0201 - Fuel Injector 1 Circuit Open/Closed
OVERVIEW:
This bulletin involves replacing terminal number 26 from the 6.7L Cummins Diesel Powertrain Control Module (PCM) C1 (76-way) connector.
MODELS:
2011 DJ/D2 2500/3500 Ram Pickup
2011 DD/DP 3500/4500/5500 Ram Cab Chassis
NOTE:
This bulletin applies to a small number of vehicles equipped with the 6.7L Cummins Turbo Diesel engine (Sales Code ETJ) built between March 1, 2011 (MDH 0301XX) and March 11, 2011 (MDH 0311XX).
SYMPTOM/CONDITION:
Suspect vehicles may intermittently set DTC P0201 - Fuel Injector 1 Circuit Open/Closed.
DIAGNOSIS:
If a customer's VIN is listed in the RRT VIN list, perform the repair. For all other customers that describe the symptom/condition or if the technician finds the DTC, this repair may not address the customer's concern and further diagnosis may be necessary.
PARTS REQUIRED:
NOTE:
Only a small number of vehicles are affected and parts are of limited supply. Do not order any of the Wire Terminal Repair Kits unless the customer's VIN is listed in the RRT VIN list.
SPECIAL TOOLS/EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
1. Open hood.
2. Disconnect and isolate both battery's negative cable.
3. Disconnect the PCM C1 connector (Fig 1).
4. Remove the cover from the connector (Fig 2).
5. Remove the red locking tab that locks the terminals into the connector (Fig 3).
6. Locate the wire that operates injector number one and terminates in the PCM C1 connector cavity number 26 (Fig. 4). Injector number one circuit is a tan wire with a yellow tracer.
7. Using a wire terminal removal tool, remove the wire terminal number 26 from the connector (Fig. 5).
8. Cut the wire approximately 2 inches (50 mm) from the terminal end (Fig. 6).
9. Remove one-half (1/2) inch (13 mm) of insulation from the harness end of the wire.
10. Remove all but 2 1/2 inches (65 mm) of wire from the terminal repair kit wire (p/n 68148035AA) and remove one half (1/2) inch (13 mm) of insulation from the wire.
11. Place a piece of adhesive lined heat shrink tubing on the wire from the wire terminal repair kit (p/n 68148035AA).
12. Place the strands of wire overlapping each other inside of the splice band (p/n 05018527AA)(Fig. 7).
13. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together (Fig 8).
14. Solder the connection together using rosin core type solder only (Fig 9).
CAUTION:
DO NOT USE ACID CORE SOLDER.
15. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig. 10).
16. Insert the new terminal into cavity 26 of the PCM connector (Fig 11).
NOTE:
The terminal will only go in one way. The terminal should not need to be forced into the cavity.
17. Slightly tug on the wire to ensure that the terminal is securely locked into place (Fig. 12).
18. Reinstall the red terminal locking tab (Fig. 13).
CAUTION:
If the red terminal lock cannot easily be inserted completely into the housing, reverify that all of the female terminals have been fully inserted and locked. Then, proceed to insert the red terminal locking tab again.
19. Reinstall the PCM cover onto the connector (Fig. 14). Ensure the black and red locking slides (2) are out of the way and the gray lever (1) is in the position as shown in (Fig 14).
20. Reinstall the connector onto the PCM (Fig 15).
21. Reconnect the battery negative cables.
22. Start the engine and monitor the check engine lamp to verify that the repair has been performed properly.
23. Close the hood.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.