Dodge Ram Truck 1500-2500-3500. Manual - part 310

POWERTRAIN VERIFICATION TEST VER - 5 (DIESEL)

Diagnostic Test

POWERTRAIN VERIFICATION TEST VER - 5 (DIESEL)

1. Check if any of the following conditions exist.

2. The ECM has been disconnected or replace.

3. The Battery power has been disconnected.

4. Inspect the vehicle to ensure that all engine components are properly installed and connected. Reassemble and
reconnect components as necessary.

5. If any existing diagnostic trouble codes have not been repaired, go to Symptom List and follow path specified.

6. Connect the scan tool to the data link connector.

7. Ensure the fuel tank has at least a quarter tank of fuel. Turn off all accessories.

8. Perform steps 15 through 17 if the PCM has been replaced. Then proceed with the verification. If the ECM has
not been replaced skip those steps and continue verification.

9. If ECM has been changed and correct VIN and mileage have not been programmed, a DTC will be set in ABS
and Air bag modules. In addition, if vehicle is equipped with a Sentry Key Immobilizer Module (SKIM), Secret Key
data must be updated to enable start.

10. For ABS and Air Bag systems: Enter correct VIN and Mileage in ECM. Erase codes in ABS and Air Bag mod-
ules.

11. For SKIM theft alarm: Connect scan tool to data link connector to Theft Alarm, SKIM, Misc. and place SKIM in
secured access mode by using appropriate PIN code for this vehicle. Select Update the Secret Key data. Data will
be transferred from SKIM to PCM.

12. If a Comprehensive Component DTC was repaired, perform steps 10-13. If a Major OBDII Monitor DTC was
repaired skip those steps and continue verification.

13. After the ignition has been off for at least 10 seconds, restart the vehicle and run 2 minutes.

14. If there are no new DTC’s, the repair was successful and is now complete. Erase DTC’s and disconnect the
scan tool.

15. If the repaired DTC has reset, the repair is not complete. Check for any related TSB’s or flash updates and
return to the Symptom list.

16. If another DTC has set, return to the Symptom List and follow the path specified for that DTC.

17. With the scan tool, monitor the appropriate pre-test enabling conditions until all conditions have been met. Once
the conditions have been met, switch screen to the appropriate OBDII monitor, (Audible beeps when the monitor is
running).

18. If the monitor ran, the repair was successful and is now complete. Erase DTC’s and disconnect the scan tool.

19. If the repaired OBDII trouble code has reset or was seen in the monitor while on the road test, the repair is not
complete. Check for any related technical service bulletins or flash updates and return to Symptom List.

20. If another DTC has set, return to the Symptom List and follow the path specified for that DTC.

Is any DTC(s) present?

Yes

>> Repair is not complete, refer to appropriate symptom.

>> Repair is complete.

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ELECTRONIC CONTROL MODULES - SERVICE INFORMATION

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REMOVAL

The Engine Control Module (ECM) (16) is bolted to a support bracket near the fuel filter. The support bracket
mounts to the block with four capscrews and vibration isolators. A ground wire is fastened to the bracket. The other
end of the wire is fastened to the engine block.

1. Record any Diagnostic Trouble Codes (DTC’s) found in the ECM.

To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative battery cables must
be disconnected before unplugging ECM connectors.

2. Disconnect both negative battery cables at both batteries.

3. Remove the 50–way and 60–way connector bolts at the ECM. Note: The connector bolt is a female allen head.

As bolt is being removed, very carefully remove connectors from the ECM.

4. Remove five ECM mounting bolts and remove ECM from vehicle.

CUMMINS FUEL SYSTEM COMPONENTS

1 - ENGINE COOLANT TEMPERATURE (ECT) SENSOR

14 - FUEL DRAIN TUBE

2 - INTAKE MANIFOLD AIR HEATER/ELEMENTS

15 - OIL PRESSURE SWITCH

3 - FUEL PRESSURE SENSOR

16 - ENGINE CONTROL MODULE (ECM)

4 - FUEL PRESSURE LIMITING VALVE

17 - FUEL INJECTION PUMP

5 - HIGH-PRESSURE FUEL LINES

18 - CRANKSHAFT POSITION (ENGINE SPEED) SENSOR

6 - FUEL HEATER

19 - CAMSHAFT POSITION SENSOR (CMP)

7 - HIGH-PRESSURE FUEL RAIL

20 - FUEL CONTROL ACTUATOR (FCA)

8 - FUEL HEATER TEMPERATURE SENSOR (THERMOSTAT)

21 - CASCADE OVERFLOW VALVE

9 - FUEL FILTER/WATER SEPARATOR
10 - FUEL DRAIN MANIFOLD (CYLINDER HEAD FUEL RETURN
LINE)
11 - DRAIN VALVE
12 - FUEL RETURN LINE CONNECTION (TO FUEL TANK)
13 - FUEL SUPPLY LINE (LOW-PRESSURE, TO ENGINE)

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ELECTRONIC CONTROL MODULES - SERVICE INFORMATION

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INSTALLATION

Do not apply paint to ECM or a poor ground will result.

1. Position the ECM (16) to the ECM support bracket and install the five mounting bolts. Tighten bolts to 24 N·m

(18 ft. lbs.).

2. Check pin connectors in ECM, 50–way and 60–way connectors for corrosion or damage. Repair as necessary.

3. Clean pins in the 50–way and 60–way electrical connectors with a electrical contact cleaner.

4. Install the 50–way and 60–way connectors to ECM. Tighten connector bolts to 3 N·m (27 in. lbs.).

5. Reconnect both negative battery cables.

6. Use a diagnostic scan tool to erase any Diagnostic Trouble Codes (DTC’s) from ECM.

CUMMINS FUEL SYSTEM COMPONENTS

1 - ENGINE COOLANT TEMPERATURE (ECT) SENSOR

14 - FUEL DRAIN TUBE

2 - INTAKE MANIFOLD AIR HEATER/ELEMENTS

15 - OIL PRESSURE SWITCH

3 - FUEL PRESSURE SENSOR

16 - ENGINE CONTROL MODULE (ECM)

4 - FUEL PRESSURE LIMITING VALVE

17 - FUEL INJECTION PUMP

5 - HIGH-PRESSURE FUEL LINES

18 - CRANKSHAFT POSITION (ENGINE SPEED) SENSOR

6 - FUEL HEATER

19 - CAMSHAFT POSITION SENSOR (CMP)

7 - HIGH-PRESSURE FUEL RAIL

20 - FUEL CONTROL ACTUATOR (FCA)

8 - FUEL HEATER TEMPERATURE SENSOR (THERMOSTAT)

21 - CASCADE OVERFLOW VALVE

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ELECTRONIC CONTROL MODULES - SERVICE INFORMATION

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MODULE-FRONT CONTROL

DESCRIPTION

The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It
is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this
vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the
battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems.
The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs
received from hard wired switch inputs and data received on the PCI bus circuit.

(Refer to 8 - ELECTRICAL/POWER DISTRIBUTION/INTELLIGENT POWER MODULE - DESCRIPTION) for addi-
tional information on the IPM.

OPERATION

As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control
Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing
the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following
functions are Controlled by the FCM:

•

Headlamp Power with Voltage Regulation

•

Windshield Wiper “ON/OFF” Relay Actuation

•

Windshield Wiper “HI/LO” Relay Actuation

•

Windshield Washer Pump Motor

•

Fog Lamp Relay Actuation

•

Park Lamp Relay Actuation

•

Horn Relay Actuation

The following inputs are Received/Monitored by the FCM:

•

B+ Connection Detection

•

Power Ground

•

Ambient Temperature Sensing

•

Ignition Switch Run

•

Washer Fluid Level Switch

•

Windshield Wiper Park Switch

•

PCI Data Bus Circuit

DIAGNOSIS AND TESTING

FRONT CONTROL MODULE

The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM
interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data
bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide
inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior
to further diagnosing any FCM related issues.

The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and
accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Pro-
cedures manual.

Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground
connections inspected around the affected areas on the vehicle.

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