Engine Controls - MIL ON, Multiple O2 Sensor DTC's Stored
NUMBER: 25-004-13GROUP: Emissions Control
DATE: March 26, 2013
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 25-004-12, DATED DECEMBER
18, 2012, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A NEW LOP.
SUBJECT:
Malfunction Indicator Lamp Illumination Due To Oxygen Sensor
OVERVIEW:
This bulletin involves replacement of the Oxygen Sensor Connectors for any Oxygen Sensor related DTC. Do NOT replace any parts prior to performing this bulletin and the Verifications test below.
MODELS:
2010 - 2012 (DJ) Ram Pick Up (2500)
2010 - 2012 (D2) Ram Pick Up (3500)
NOTE:
This bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales code ETJ)
SYMPTOM/CONDITION:
If the vehicle has any of the DTCs for O2 Sensors, Stored, Pending or Active, perform the Repair Procedure.
DIAGNOSIS:
Complete a Diesel Diagnostic Worksheet per instructions in Service Bulletin 18-045-11 Dated October 19, 2011 and U.S. Warranty Bulletin D-11-55 Dated October, 2011. All DTC's need to be recorded on the WRO and DTC's other than the ones listed above may require additional diagnosis and repair after completing this Bulletin.
Vehicles that exhibit ANY DTC('s)(Stored or Active), pertaining to Oxygen Sensors or Oxygen Sensor related components must have this Repair Procedure completed BEFORE any parts are replaced.
SPECIAL TOOLS / EQUIPMENT REQUIRED:
PARTS REQUIRED:
NOTE:
Prior to replacing any parts, (Oxygen Sensors, Oxygen Sensor Module,
Transmission Wiring Harness or PCM) perform the Repair Procedure below
and also perform an Oxygen Sensor Verification test drive also described
below.
NOTE:
Vehicles experiencing P013X or P014X DTCs must have the Aftertreatment
Validation Test (Section 4D of the Diesel Diagnostic Worksheet) performed to ensure excess soot is not causing the DTC(s). IF excess soot is found during Aftertreatment Validation Test, perform appropriate repairs to eliminate soot accumulation. The repair procedure below should be performed regardless of outcome or repairs performed for other issues.
REPAIR PROCEDURE:
Both Oxygen Sensor connectors should be removed and new connectors with pigtails installed. The pigtail splice points should be staggered to eliminate bulk in the harness.
1. Open hood.
2. Disconnect and isolate both negative battery cables.
3. Raise and support vehicle on a suitable hoist.
4. Disconnect the Front Oxygen Sensor Connector and remove the protective tape and plastic convoluted tubing near the sensor connector.
5. Replace the front Oxygen Sensor Connector;
a. Cut and splice each wire, (one at a time) in a staggered manner to prevent excess bulk accumulation in the harness.
b. Using Mopar splice band tool and heat shrink with glue, splice and seal each wire individually. Refer to DealerCONNECT > TechCONNECT > 29 - Non-DTC Diagnostics > Circuit Testing Procedures > Standard Procedure > WIRE SPLICING.
6. Tape wires together then install and tape the removed convolute adjacent to the connector body.
7. Clean (with shop air) Oxygen Sensor connector and secure connector to the vehicle harness.
8. Secure all wiring to proper anchors
9. Repeat Step # 4 through Step # 8 for the Rear Oxygen Sensor Connector.
10. Lower vehicle, reconnect batteries.
11. Perform Verification below.
Verification:
Verification will ensure Oxygen Sensors are properly "relearned" and functioning as desired.
1. Ensure PCM software is current. If software is not current, please update software using appropriate Service Bulletin.
2. Connect WiTECH to vehicle if not already connected.
3. Operate the vehicle until warm and then drive the vehicle at 50 MPH. Perform a zero fueling event (deceleration condition for 10 seconds, with foot off of accelerator pedal). Repeat 3-5 times.
4. Monitor Oxygen Sensor percent in WiTECH, Data Display; percent should not vary more than 4.0% from each other during any of the drive events. Variance of greater than 4% will result in MIL illumination.
5. Further diagnosis will be required if variance is exceeded. Refer to TechCONNECT for DTC(s) set during verification.
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.