REPAIR PROCEDURE - wiTECH™ Diagnostic Application
Note. If this flash process is interrupted or aborted, the flash should be restarted.
- Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 Volts.
- Connect the wiTECH™ Vehicle Connection Interface (VCI) pod to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position.
- Launch the wiTECH™ Diagnostic Application and connect to the appropriate wiTECH™ device.
- From the wiTECH™ Diagnostic Application Home screen, Select "HELP" Select "HELP CONTENTS" Follow the "HELP TOPIC" for flashing an ECU.
Diagnostic Test
- NO RESPONSE NOTE: For vehicle communication problems, use the scan tool to refer to the Network Review Screen. The screen depicts a high level view of the vehicle network. Fault and problem areas appear in red. Does the scan tool display a Vehicle Network problem or NO RESPONSE condition? Yes Perform the appropriate diagnostic procedure. Refer to «DTC-Based Diagnostics/MODULE, Totally Integrated Power (TIPM) - Diagnosis and Testing»(ref-350093-S06268540512009121400000) No Go to step 2
- NO START Does the vehicle have a NO START condition? Yes Check the vehicle for any DTC(s), including Vehicle Theft Security related DTC(s), that may cause a no-start condition. If no DTC(s) are present that relate to a no-start condition, refer to the Non DTC Diagnostic Procedures that relate to Fuel and Starting. Refer to «Non-DTC Diagnostics/Driveability - Diesel - Diagnosis and Testing»(ref-350101-S38901574232009121400000) . No Go to step 3
- VEHICLE REPAIR HISTORY AND TSB(s) Check the vehicle repair history for repairs that may relate to the current condition. Inspect the vehicle for aftermarket accessories that may have been installed incorrectly. Check for any TSB(s) related to the condition or DTC(s). If a TSB applies, follow the procedure outlined in the TSB. Select the appropriate response for the condition that applies: Performing a TSB procedure repaired the condition. Test Complete. Perform the ECM Verification Test. See «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) A DTC is present, no TSB applies, or the TSB didn't repair the condition. Go to step 4 No DTC(s) or conditions are present. Refer to the INTERMITTENT CONDITION Diagnostic Procedure. See «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000)
- VEHICLE INSPECTION WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING. Based on the diagnostic condition that applies, review the following list and perform any tests that relate to the condition: If multiple DTCs are set in the ECM, review the wiring schematics for problems in any shared supply or ground circuits. Refer to the diagnostic procedure for Checking the ECM Power and Ground Circuits. Inspect the air intake system and turbocharger related tubes for damage, restriction, or poor connection. Inspect the exhaust system and related tubes for damage, restriction, or poor connection. Remove and inspect the Air Filter for soiling or excessive dirt and debris which may cause an air flow restriction. If the ECM detects and stores a DTC, the ECM also stores the environmental conditions under which the DTC was set. Before erasing stored DTCs, record these conditions. Attempting to duplicate these conditions may assist when checking for an active DTC. With the scan tool, Clear the stored DTC(s). Attempt to duplicate the environmental conditions under which the DTC was set. Review the DTC When Monitored and Set Conditions. If possible, try to duplicate the vehicle conditions under which the DTC conditions will be monitored. Operate the vehicle under those conditions. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the component and the module. If the DTC(s) are fuel or air related, check the fuel level and quality. Were any repairs made that corrected the DTC or condition? Yes Test complete. Perform the ECM Verification Test. See «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) No Refer to the diagnostic test procedure related to the DTC.
For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS .
- SELECT THE PROPER VERIFICATION TEST Select the verification test for the repair that has been completed: Speed Control repair Go to step 2 Charging System repair Go to step 3 No Start repair Go to step 4 Diesel Particulate Filter repair Go to step 5 Differential Pressure Sensor repair Go to step 6 DTC and all other repairs Go to step 7
- SPEED CONTROL VERIFICATION TEST NOTE: If the battery was disconnected for any reason, you must perform the Battery Reconnection procedure in the 8F-Engine Systems section of the Service Information. Inspect the vehicle to make sure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary. With the scan tool, erase all diagnostic trouble codes (DTCs). Road test the vehicle at a speed above 60 km/h (35 MPH). Turn the speed control ON/OFF switch on. Depress and release the SET switch. If the speed control does not engage, the repair is not complete, continue with 12 . Quickly depress and release the RESUME/ACCEL switch. If the vehicle speed does not increase by 3 km/h (2 MPH), the repair is not complete, continue with 12 . Using caution, depress and release the brake pedal. If the speed control does not disengage, the repair is not complete, continue with 12 . With the vehicle speed at least 60 km/h (35 MPH), depress the RESUME/ACCEL switch. If the speed control does not resume at the previously set speed, the repair is not complete, continue with 12 . Hold down the COAST switch. If the vehicle does not decelerate, the repair is not complete, continue with 12 . While still holding down the COAST switch, make sure the vehicle speed is at least 60 km/h (35 MPH) and release the COAST switch. If the vehicle does not adjust and set a new vehicle speed, the repair is not complete, continue with 12 . With the speed control engaged, depress the ON/OFF switch. If the speed control does not disengage, the repair is not complete, continue with 12 . If the vehicle did not successfully perform all of the previous steps, check for Technical Service Bulletins (TSBs) that pertain to this speed control problem and then, if necessary, return to the DTC or non DTC list if necessary. If the vehicle successfully performed all of the previous steps, the speed control system is now functioning as designed. The repair is now complete. Are any DTCs or symptoms remaining? Yes Repair is not complete, perform the appropriate diagnostic procedure. No Repair is complete.
- CHARGING SYSTEM VERIFICATION TEST NOTE: If the battery was disconnected for any reason, you must perform the Battery Reconnection procedure in the 8F-Engine Systems section of the Service Information. Inspect the vehicle to make sure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary. With the scan tool, erase all diagnostic trouble codes (DTCs). Start the engine. Raise the engine speed to 2000 RPM for at least 30 seconds. Allow the engine to idle. Turn the ignition off for 20 seconds. Turn the ignition on. With the scan tool, read ECM DTCs. If this DTC has set again, or another DTC has set, look for any Technical Service Bulletins (TSBs) that may relate to this condition. Return to the DTC or non DTC Symptom list if necessary. If the charging system is functioning correctly and there are no DTCs, the repair is now complete. Are any DTCs or symptoms remaining? Yes Repair is not complete, perform the appropriate diagnostic procedure. No Repair is complete.
- NO START VERIFICATION TEST NOTE: If the battery was disconnected for any reason, you must perform the Battery Reconnection procedure in the 8F-Engine Systems section of the Service Information. NOTE: IMPORTANT! If the Engine Control Module or Wireless Control Module (WCM) has been replaced, make sure the programming procedure for the module has been performed in accordance with the Service Information. Inspect the vehicle to make sure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary. Inspect the engine oil for contamination. If it is contaminated, change the oil and filter. With the scan tool, erase all diagnostic trouble codes (DTCs). Turn the ignition off for at least 10 seconds. Attempt to start the engine. If the engine is unable to start, look for any Technical Service Bulletins (TSBs) that may relate to this condition. Return to the DTC or non DTC Symptom List if necessary. If the engine starts and continues to run, the repair is now complete. Are any DTCs or symptoms remaining? Yes Repair is not complete, perform the appropriate diagnostic procedure. No Repair is complete.
- DIESEL PARTICULATE FILTER VERIFICATION TEST NOTE: If the battery was disconnected for any reason, you must perform the Battery Reconnection procedure in the 8F-Engine Systems section of the Service Information. Inspect the vehicle to make sure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary. This procedure should be performed after the Diesel Particulate Filter has been replaced. With the scan tool, erase all diagnostic trouble codes (DTCs). With the scan tool, perform the Diesel Particulate Filter Replacement procedure located in the Engine Misc. Function section. Attempt to start the vehicle. If the engine is unable to start, look for any Technical Service Bulletins (TSBs) that may relate to this condition. Return to the DTC or non DTC Symptom list if necessary. If the engine starts and continues to run, the repair is now complete. Are any DTCs or symptoms remaining? Yes Repair is not complete, perform the appropriate diagnostic procedure. No Repair is complete.
- DIFFERENTIAL PRESSURE SENSOR VERIFICATION TEST NOTE: If the battery was disconnected for any reason, you must perform the Battery Reconnection procedure in the 8F-Engine Systems section of the Service Information. Inspect the vehicle to make sure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary. This procedure should be performed after the Differential Pressure Sensor has been replaced. With the scan tool, erase all diagnostic trouble codes (DTCs). With the scan tool, perform the Differential Pressure Sensor Replacement procedure located in the Engine Misc. Function section. Attempt to start the vehicle. If the engine is unable to start, look for any Technical Service Bulletins (TSBs) that may relate to this condition. Return to the DTC or non DTC Symptom list if necessary. If the engine starts and continues to run, the repair is now complete. Are any DTCs or symptoms remaining? Yes Repair is not complete, perform the appropriate diagnostic procedure. No Repair is complete.
- ROAD TEST VERIFICATION TEST NOTE: If the battery was disconnected for any reason, you must perform the Battery Reconnection procedure in the 8F-Engine Systems section of the Service Information. Inspect the vehicle to make sure that all engine components are properly installed and connected. Reassemble and reconnect components as necessary. If this verification procedure is being performed after a non-DTC test, perform steps 3 and 4. If not, proceed to step 5. Check to see if the initial symptom still exists. If there are no trouble codes and the symptom no longer exists, the repair was successful and testing is now complete. If the initial or another symptom or DTC exists, the repair is not complete. Check all pertinent Technical Service Bulletins (TSBs) and return to the DTC List if necessary. For previously read DTCs that have not been dealt with, return to the DTC or non DTC Symptom list and follow the diagnostic path for that DTC; otherwise, continue. If the Engine Control Module (ECM) has been replaced, continue with step 9. With the scan tool, erase all diagnostic trouble codes (DTCs), then disconnect the scan tool. Turn the ignition off for at least 10 seconds. If equipped with a Transfer Case Position Switch, perform step 10, otherwise, continue with step 11. With the ignition switch on, place the Transfer Case Shift Lever in each gear position, stopping for 15 seconds in each position. Road test the vehicle. For some of the road test, go at least 64 km/h (40 MPH). If this test is for an A/C Relay Control Circuit, drive the vehicle for at least five minutes with the A/C on. At some point, stop the vehicle and turn the engine off for at least 10 seconds, then restart the engine and continue. Upon completion of the road test, turn the engine off and check for DTCs with the scan tool. If the repaired DTC has set again, the repair is not complete. Check for any pertinent Technical Service Bulletins (TSBs) and return to the DTC List. If there are no DTCs, the repair was successful and is now complete. Are any DTCs or symptoms remaining? Yes Repair is not complete, perform the appropriate diagnostic procedure. No Repair is complete.
For complete wiring diagrams, refer to SYSTEM WIRING DIAGRAMS .
- INTERMITTENT DTC WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts, or fan. Do not wear loose clothing. Failure to follow these instructions can result in personal injury or death. The conditions necessary to set this DTC are not present at this time. Review the scan tool environmental data. If possible, try to duplicate the conditions under which the DTC set. If applicable, actuate the component with the scan tool. Monitor the scan tool data relative to this circuit and wiggle test the wiring and connectors. Look for the data to change, the actuation to be interrupted, or for the DTC to reset during the wiggle test. Refer to any Technical Service Bulletins (TSBs) that may apply. Turn the ignition off. Visually inspect the related wire harness. Disconnect all the related harness connectors. Look for any chafed, pierced, pinched, partially broken wires and broken, bent, pushed out, or corroded terminals. Perform a voltage drop test on the related circuits between the suspected component and the ECM. Inspect and clean all ECM, engine, and chassis grounds that are related to the most current DTC. If numerous trouble codes were set, use a schematic and inspect any common ground or supply circuits. For intermittent Misfire DTCs check for restrictions in the Intake and Exhaust system, proper installation of Sensors, vacuum leaks, and binding components that are run by the accessory drive belt. Use the scan tool to perform a System Test if one applies to the component. A co-pilot, data recorder, and/or lab scope should be used to help diagnose intermittent conditions. Were any problems found during the above inspections? Yes Perform the necessary repairs. Perform the ECM Verification Test. See «DTC-Based Diagnostics/MODULE, Engine Control (ECM) - Standard Procedure»(ref-350096-S37095296402009121400000) No Test Complete.