Dodge Sprinter. Manual - part 474

TEST

ACTION

APPLICABILITY

Turn the ignition off.
Disconnect the ECM harness connectors.
Disconnect all of the Cylinder Fuel Injector harness connectors.
Measure the resistance of each Fuel Injector Control circuit between its respective
injector harness connector and the ECM harness connector.
Is the resistance below 10.0 ohms for each measurement?

All

Yes

→ Go To 7

→ Repair the appropriate Fuel Injector Control circuit for an open.

Perform ROAD TEST VERIFICATION - VER-2.

Turn the ignition off.
Replace the Cylinder Fuel Injector that was identified in the DTC in accordance with
the Service Information.
With the DRBIII

t, erase the ECM DTCs.

Test drive the vehicle.
With the DRBIII

t, read the ECM DTCs.

Does the DRBIII

t display this DTC?

All

Yes

→ Replace and program the Engine Control Module in accordance

with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.

→ The repair is complete.

Perform ROAD TEST VERIFICATION - VER-2.

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.
NOTE: The conditions that set the DTC are not present at this time. The
following list may help in identifying the intermittent condition.
With the engine running at normal operating temperature, monitor the DRB
parameters related to the DTC while wiggling the wiring harness. Look for param-
eter values to change and/or a DTC to set.
Review the DTC When Monitored and Set Conditions. If possible, try to duplicate the
conditions under which the DTC was set.
Refer to any Technical Service Bulletins (TSB) that may apply.
Visually inspect the related wiring harness. Look for any chafed, pierced, pinched, or
partially broken wires.
Visually inspect the related wiring harness connectors. Look for broken, bent, pushed
out, or corroded terminals.
Were any of the above conditions present?

All

Yes

→ Repair as necessary.

Perform ROAD TEST VERIFICATION - VER-2.

→ Test Complete.

DRIVEABILITY - DIESEL

P0201-CYLINDER 1-INJECTOR CIRCUIT EXCESSIVE CURRENT —

Continued

Symptom List:

P0300-MISFIRE DETECTED
P2113-MISFIRE CYLINDER #1
P2114-MISFIRE CYLINDER #2
P2115-MISFIRE CYLINDER #3
P2116-MISFIRE CYLINDER #4
P2117-MISFIRE CYLINDER #5
P2567-LEAKAGE CYLINDER #1
P2567-MISFIRE CYLINDER #1
P2568-LEAKAGE CYLINDER #2
P2568-MISFIRE CYLINDER #2
P2569-LEAKAGE CYLINDER #3
P2569-MISFIRE CYLINDER #3
P2570-LEAKAGE CYLINDER #4
P2570-MISFIRE CYLINDER #4
P2571-LEAKAGE CYLINDER #5
P2571-MISFIRE CYLINDER #5
P2573-GENERAL LEAKAGE
P2574-INJECTOR 1 INJECTION TIME ABOVE LIMIT
P2574-INJECTOR 1 INJECTION TIME BELOW LIMIT
P2575-INJECTOR 2 INJECTION TIME ABOVE LIMIT
P2575-INJECTOR 2 INJECTION TIME BELOW LIMIT
P2576-INJECTOR 3 INJECTION TIME ABOVE LIMIT
P2576-INJECTOR 3 INJECTION TIME BELOW LIMIT
P2577-INJECTOR 4 INJECTION TIME ABOVE LIMIT
P2577-INJECTOR 4 INJECTION TIME BELOW LIMIT
P2578-INJECTOR 5 INJECTION TIME ABOVE LIMIT
P2578-INJECTOR 5 INJECTION TIME BELOW LIMIT

Test Note:

All symptoms listed above are diagnosed using the same tests.

The title for the tests will be P0300-MISFIRE DETECTED.

When Monitored and Set Condition:

P0300-MISFIRE DETECTED

When Monitored:

With the engine running.

Set Condition:

The ECM detects multiple misfires from one or more cylinders.

POSSIBLE CAUSES

CHECKING FOR FUEL LEAKAGE

CHECKING INJECTOR CLASSIFICATION

DRIVEABILITY - DIESEL

POSSIBLE CAUSES

CORRECTION QUANTITY CHECK

CYLINDER SPEED CHECK

ENGINE COMPRESSION

INJECTOR LEAKAGE

INTERMITTENT CONDITION

TEST

ACTION

APPLICABILITY

NOTE: If the ECM detects and stores a DTC, the ECM also stores the
engine/vehicle operating conditions under which the DTC was set. Some of
these conditions are displayed on the DRB at the same time the DTC is
displayed.
NOTE: Before erasing stored DTCs, record these conditions. Attempting to
duplicate these conditions may assist when checking for an active DTC.
With the DRBIII

t, erase ECM DTCs.

Test drive the vehicle and attempt to duplicate the problem.
With the DRB, read ECM DTC’s.
Did this DTC set again?

All

Yes

→ Go To 2

→ Go To 8

Start and idle the engine for 5 minutes.
Turn the ignition off.
Inspect the fuel rail, fuel pressure sensor, fuel pressure solenoid and all fuel injectors
for evidence of fuel leakage.
Is there fuel leakage near any of the injectors or the fuel rail?

All

Yes

→ Refer to the Service Information to repair fuel leakage.

Perform ROAD TEST VERIFICATION - VER-2.

→ Go To 3

Turn the ignition off.
With the DRBIII

t, perform the Cylinder Compression Test.

Is the cylinder compression within specification for all cylinders?

All

Yes

→ Go To 4

→ Repair as necessary in accordance with the Service Information.

Perform ROAD TEST VERIFICATION - VER-2.

Turn the ignition off.
Read and note the six-digit code located on the top of each injector.
Turn the ignition on.
With the DRBIII

t, check the current programmed injector classifications to the

six-digit codes from the vehicles current fuel injectors.
Are all of the Fuel Injectors classified correctly?

All

Yes

→ Go To 5

→ Using the DRB III, reset injectors to correct classification.

Perform ROAD TEST VERIFICATION - VER-2.

DRIVEABILITY - DIESEL

P0300-MISFIRE DETECTED —

Continued

TEST

ACTION

APPLICABILITY

With the DRBIII

t, select System Test, Smooth Eng Run Check, then Correction

Quantity Check.
Perform this test at Idle, 2000 rpm and 3000 rpm.
NOTE: Readings per cylinder should be below ± 0.00450 mm

/stroke for each

cylinder at each engine speed.
Did any of the cylinders exceed ± 0.00450 mm

/stroke during this test?

All

Yes

→ Replace Fuel Injector of the cylinder(s) that had readings above ±

0.00450 mm

/stroke.

Perform ROAD TEST VERIFICATION - VER-2.

→ Go To 6

With the DRBIII

t, select System Test, Smooth Eng Run Check, then Cylinder Speed

Check.
NOTE: Readings for all cylinders should be close to each other. Look for one
or two cylinders to differ high or low from the other cylinders.
Did any of the cylinders differ significantly from the majority of the other cylinders?

All

Yes

→ Replace Fuel Injector of the cylinder(s) that had readings signif-

icantly above or below the other fuel injectors.
Perform ROAD TEST VERIFICATION - VER-2.

→ Go To 7

Turn the ignition off.
Perform the INJECTOR LEAKAGE TEST in accordance with the Service Informa-
tion.
Were any problems found?

All

Yes

→ Repair or replace as necessary in accordance with the Service

Information.
Perform ROAD TEST VERIFICATION - VER-2.

→ Test Complete.

All

Yes

→ Repair as necessary.

Perform ROAD TEST VERIFICATION - VER-2.

→ Test Complete.

DRIVEABILITY - DIESEL

P0300-MISFIRE DETECTED —

Continued

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