2006 DODGE RAM SRT-10 air condition

When Monitored:
When the ignition is on.
Set Condition:
When the signal from the #2 intake air heater output does not match the signal from the #2 intake air heater
feedback.
Possible Causes
LOOSE CONNECTION
INTAKEAIRHEATERRELAY
SIGNAL CIRCUIT OPEN FROM RELAY TO ECM
SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE
ECM
INTERMITTENT CONDITION
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Diagnostic Test
1.RELAY CLICKING
Ignition on, engine not running.
With the scan tool, actuate the #1 Intake Air Heater.
Can you hear the Relay clicking?
Ye s>>
Go To 2
No>>
Go To 3
2.LOOSE CONNECTION
While the relay is clicking , wiggle the wiring harness and connectors.
Does this interrupt the clicking?
Ye s>>
Repair the poor connection.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 3
3.INTAKE AIR HEATER RELAY
Turn the ignition off.
Remove the Intake Air Heater #1 Relay.
Check connectors - Clean/repair as necessary.
Measure the resistance between the signal and return posts of the intake air heater relay.
Is the resistance between 15 and 25 Ohms?
Ye s>>
Go To 4
No>>
Replace the Intake Air Heater #1 relay.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)

4.SIGNAL CIRCUIT OPEN FROM RELAY TO ECM
Disconnect the ECM harness connectors.
Check connectors - Clean/repair as necessary.
Measure the resistance of the intake air heater relay signal circuit between the ECM connector and the intake air
heater relay connector.
Is the resistance less than 10 Ohms?
Ye s>>
Go To 5
No>>
Repair the open signal circuit from PDC to ECM harness connector.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
5.RETURN CIRCUIT SHORTED TO BATTERY NEGATIVE
Measure the resistance of the return circuit between the intake air heaterrelay connector and battery negative.
I s resistance less than 10 ohms?
Ye s>>
Go To 6
No>>
Repair the return circuit shorted to battery negative.
6.SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE
Measure the voltage between the signal circuit of the intake air heater relay and battery negative.
Is the voltage greater than 1 volts?
Ye s>>
Repair the signal circuit shorted to Battery negative.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 7
7.ECM
Reconnect the ECM harness connectors.
Disconnect the intake air heater relay signal wire and use a jumper to connect it to battery negative.
Turn the ignition on.
With the scan tool, read DTCs.
Did DTC P2608?
Ye s>>
Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
No>>
Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)

When Monitored:
When the ignition is on.
Set Condition:
When the signal from the #2 Intake Air Heater output does not match the signal from the #2 Intake Air Heater
feedback.
Possible Causes
LOOSE CONNECTION
INTAKEAIRHEATERRELAY
SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE
ECM
INTERMITTENT CONDITION
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Diagnostic Test
1.RELAY CLICKING
Ignition on, engine not running.
With the scan tool, actuate the Intake Air Heater relay.
Can you hear the Relay clicking?
Ye s>>
Go To 2
No>>
Go To 3
2.LOOSE CONNECTION
While the relay is clicking , wiggle the wiring harness and connectors.
Does this interrupt the clicking?
Ye s>>
Repair the poor connection.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 3
3.INTAKE AIR HEATER RELAY
Turn the ignition off.
Remove the Intake Air Heater Relay.
Check connectors - Clean/repair as necessary.
Measure the resistance between the signal and return posts of the intake air heater relay.
Is the resistance between 15 and 25 Ohms?
Ye s>>
Go To 4
No>>
Replace the Intake Air Heater relay.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)

4.SIGNAL CIRCUIT SHORTED TO BATTERY NEGATIVE
Disconnect the ECM harness connector(s).
NOTE: Check connectors - Clean/repair as necessary.
Measure the resistance between the signal circuit of the intake air heaterrelay and battery negative.
Is the resistance greater than 100 K ohms?
Ye s>>
Go To 5
No>>
Repair signal circuit shorted to battery negative.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
5.HARNESS SHORTED
Measure the resistance between intake air heater relay signal circuit andall other ECM circuits in the ECM con-
nectors.
Is the resistance greater than 100k ohms?
Ye s>>
Go To 6
No>>
Repair the shorted harness.
6.ECM
Reconnect the ECM harness connectors.
Turn the ignition on.
Disconnect the intake air heater relay signal wire.
Did DTC P0542 or 2608 set?
Ye s>>
Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
No>>
Replace the ECM.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)

When Monitored:
First 15 seconds of engine operation.
Set Condition:
The ECM does not detect a voltage drop on the intake air heater circuit.
Possible Causes
INTAKE AIR HEATER OPEN
INTAKE AIR HEATER GROUND OPEN
OPEN BATTERY CABLE FROM INTAKE AIR HEATER RELAY
BATTERY CABLE OPEN
#1 INTAKE AIR HEATER RELAY
#2 INTAKE AIR HEATER RELAY
INTERMITTENT CONDITION
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Diagnostic Test
1.INTAKE AIR HEATER OPEN
Measure the resistance between the intake air heater supply and ground terminal on each intake air heater.
Is the resistance less than 10 Ohms?
Ye s>>
Go To 2
No>>
Replace the open Intake Air Heater.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
2.INTAKE AIR HEATER GROUND OPEN
Measure the resistance of the intake air heater ground circuit between theintake air heater terminal and the intake
manifold cover ground connection.
NOTE: The intake air heater circuit is grounded through a conductive gasket on the top and bottom of the
air heater (grey colored gaskets).
Is the resistance less than 10 Ohms?
Ye s>>
Go To 3
No>>
Repair the open Intake Air heater ground or replace both heater gaskets with the proper conductive
gaskets..
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
3.OPEN BATTERY CABLE FROM INTAKE AIR HEATER RELAY
Measure the resistance of the battery cable between the intake air heater and the intake air heater relay for both
intake air heaters.
Is the resistance less than 10 Ohms?
Ye s>>
Go To 4
No>>
Repair The open or high resistance battery cable from the intake heater relay to heater.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)

4.BATTERY CABLE OPEN
Measure the resistance of the battery cable between the battery and the intake air heater relay for both relays.
Is the resistance less than 10 Ohms?
Ye s>>
Go To 5
No>>
Replace the battery cable from the battery to the Intake Air Heater Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
5.#1 INTAKE AIR HEATER RELAY
Disconnect the #1 intake air heater relay signal wire.
Connect a jumper wire from the signal terminal of the #1 intake air heater relay to battery positive.
Did the relay click when 12 volts was applied?
Ye s>>
Go To 6
No>>
Replace #1 Intake Air Heater Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
6.#2 INTAKE AIR HEATER RELAY
Disconnect the #2 intake air heater relay signal wire.
Connect a jumper wire from the signal terminal of the #2 intake air heater relay to battery positive.
Did the relay click when 12 volts was applied?
Ye s>>
Refer to the INTERMITTENT CONDITIONSymptom (Diagnostic Procedure).
No>>
Replace #2 Intake Air Heater Relay.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)

*ENGINE SURGES
Possible Causes
DTC/PRODUCT IMPROVEMENT
FUEL SUPPLY SYSTEM
INJECTION SYSTEM
FUEL RETURN
INTAKE SYSTEM
OTHER VEHICLE SYSTEMS
BASE ENGINE
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
Diagnostic Test
1.DTC/PRODUCT IMPROVEMENT
Check for any TSB’s related to customer’s complaint or DTC’s present.
Follow appropriate guidelines in DTC troubleshooting tree or instructions in TSB.
Is vehicle repaired?
Ye s>>
Repair complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 2
2.FUEL SUPPLY SYSTEM
Verify proper fuel quality, grade and level in vehicle.
Use scan tool to monitor fuel rail pressure. If pressure does not fluctuatemore then +/- 500 psi of setpoint than the
fuel system is not the cause of the complaint. Proceed to step3. If condition exist continue.
Verify proper low pressure supply to the Injection Pump by performing the “*IN-TANK FUEL LIFT PUMP FLOW
TEST - DIESEL” Procedure.
Use the “*HIGH PRESSURE FUEL PUMP PERFORMANCE TEST - DIESEL” to check for failed fuel pump.
Perform “*CHECKING PRESSURE LIMITING VALVE ON THE FUEL - DIESEL”.
Is vehicle repaired?
Ye s>>
Repair complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 3

4.ENGINE TIMING
Inspect speed indicator ring for damaged/missing teeth.
Inspect for dirty or damaged pins at Crankshaft position sensor (CKP) or Camshaft position sensor (CMP).
Verify proper overhead adjustments.
Is vehicle repaired?
Ye s>>
Repair complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 5
5.FUEL SUPPLY SYSTEM
Verify proper fuel quality, grade and level in vehicle.
Use scan tool to monitor fuel rail pressure. If pressure does not fluctuatemore then +/- 500 psi of setpoint than the
fuel system is not the cause of the complaint. Proceed to step 6. If condition exist continue.
Verify proper low pressure supply to the Injection Pump by performing the “*IN-TANK FUEL LIFT PUMP FLOW
TEST - DIESEL” Procedure.
Use the “*HIGH PRESSURE FUEL PUMP PERFORMANCE TEST - DIESEL” to check for failed fuel pump.
Perform “*CHECKING PRESSURE LIMITING VALVE ON THE FUEL - DIESEL”.
Is vehicle repaired?
Ye s>>
Repair complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 6
6.INJECTION SYSTEM
Perform “*INJECTOR RETURN FLOW TEST”. If okay go next step.
Check for correct injectors and injector shims.
Visuslly inspect injector wire nuts and pass through connectors for damageorcorrosion.
Is vehicle repaired?
Ye s>>
Repair complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 7
7.FUEL RETURN
Check for kinked or restricted fuel return lines.
Check fuel tank venting.
Is vehicle repaired?
Ye s>>
Repair complete.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No>>
Go To 8