Engine Controls - MIL ON, Oxygen Sensor DTC's Set
NUMBER: 25-003-13GROUP: Emissions Control
DATE: March 01, 2013
THIS SERVICE BULLETIN IS ALSO BEING RELEASED AS RAPID RESPONSE
TRANSMITTAL (RRT) 13-014. 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:
Malfunction Indicator Lamp Illumination Due To Oxygen Sensor
OVERVIEW:
This bulletin involves inspecting for the part number of the transmission harness and based on the part number suffix, determining if the Oxygen Sensor Module Connector requires repair.Some model year 2011 harness' were built with tin plated terminals in 5 of the connector cavities that should have been gold plated. Based on the transmission harness part number, the terminals will be replaced as required.
NOTE:
Service Bulletin's 25-004-12 and 18-012-12 REV. A (or later bulletins) must also be performed (if not previously performed).
MODELS:
2011 (DJ) Ram Pick Up (2500)
2011 (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 following DTCs for O2 Sensors, Stored, Pending or Active, perform the Repair Procedure BEFORE replacing any parts.
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.
1. Determine if the Oxygen Sensor Module wiring harness terminals require replacement. Inspect the tag on the Transmission Wiring Harness for the part number suffix (the last two digits). This wiring harness tag is attached to the harness at a point usually most visible from under the hood. Initially, it is easiest to locate the tag from under the vehicle. Follow the harness from the PCM (front) connector up to the takeout that
heads toward the drivers side of the vehicle. The tag is located on this takeout, near the frame rail, behind the left front wheel well splash shield. See (Fig. 1) and (Fig. 2) for tag location references.
2. The harness part number is located on the left side of the tag between the two bar codes. Does the part number end with the suffix AC ?
a. Yes >>> If the suffix is AC, The Repair Procedure for Module Connector IS required. Perform the repair procedure below.
b. No >>> This bulletin does not apply. Ensure SB's 25-004-12 and 18-012-12 REV. A (or later bulletins) have been completed.
SPECIAL TOOLS / EQUIPMENT REQUIRED:
PARTS REQUIRED:
REPAIR PROCEDURE:
Specific female terminals on the Oxygen Sensor Module Vehicle Harness Connector on the vehicle transmission harness will be removed and replaced with a new terminal and pigtail. Replacement terminals are gold plated.
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 Oxygen Sensor Module Connector and remove the protective tape and plastic shield on the connector.
5. Using a narrow blade, flat screwdriver (3 mm wide max), pry the white TPA (white cover seen when looking in connector). Notice the travel of white TPA is only 5 mm or until a "click" is heard. This is the release point of the TPA. The TPA is a device that locks the release finger so that when seated, terminal will not and cannot be disengaged, (Fig. 3) and (Fig. 4).
6. Insert either J-38125-217 (Kent Moore number) OR MX 150-MX150L / 63813-1500 (Molex) OR a fabricated tool, (consisting of a chamfered 1mm drill bit installed with the cutting end of the drill in the handle of Miller Tool # 8351), into TPA (module side of connector) into the desired "service port" until resistance is felt. (Fig. 5)
7. Push the wire into the connector from the back, and while keeping the tool or drill at 90° angle to face of TPA, push the tool or drill in until it releases the lock finger in the connector. At this point the wire should pull out the back. Note the orientation of the terminal in the connector for ease of installation later.
NOTE:
The following splice procedure requires the use of splice bands crimped in place BEFORE soldering. Soldering wires alone may cause too much circuit resistance.
8. Replace terminals # 3, 9, 11, 13 & 15 (one at a time) as called out with RED ARROWS in (Fig. 6) with the gold terminal / pigtail included in Wire Repair Kit, p/n 68203454AA.
The pigtail splice points should be staggered to eliminate bulk in the harness;
a. Cut each wire, (one at a time) in a staggered manner.
b. Slide heat shrink tube on wire prior to splicing. Strip insulation on each wire and crimp together using band clamp BEFORE SOLDERING using Mopar splice band tool, p/n 05019912AA (or equivalent) then solder the crimped connection and heat shrink each wire individually.
9. With the TPA still in the "released" position, install the terminal into the connector through the insulator noting proper orientation of terminal as noted in Step # 7 above.
10. Repeat for all 5 terminals to be replaced.
11. Relock the TPA into original position.
12. Clean (with shop air) Oxygen Sensor Module connector and secure connector to the module.
13. Secure all wiring to proper anchors.
14. Tape wires together then install the removed plastic protector and continue taping convolute to connector body.
15. Lower vehicle, reconnect batteries.
16. Perform SB 18-012-12 REV. A (or later bulletin).
17. Perform SB 25-004-12 (or later bulletin).
18. Perform Verification procedure at the end of SB 25-004-12 (or later bulletin).
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.