Improved Fault Tracing / Prior Approval For Fuel Distribution System (TJ25477)

IMPROVED FAULT TRACING FOR FUEL DISTRIBUTION SYSTEM (PEM)

TECHNICAL SERVICE BULLETIN

ATTACHMENT

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VEHICLE TYPE

Type	Eng	Eng Desc	Sales	Body	Gear	Steer	Model Year	Plant	Chassis range	Struc Week Range
5XX	38						2004-2010		0000295-0514413	200338-201019
5XX	39						2005-2010		0000295-0514301	200420-201019
5XX	67						2008-9999		0000295-9999999	200720-999952
5XX	68						2004-2008		0000295-0058153	200339-200819

CSC CUSTOMER SYMPTOM CODES

Code	Description
1Q	Driving/Poor performance/lacks power/At take off
AJ	Driving/Poor performance/lacks power
AK	Driving/Hesitates/surges/Unsure when/at all times
AL	Driving/Hesitates/surges/During acceleration
AM	Driving/Hesitates/surges/During deceleration
BB	Driving/Engine stalls/Unsure when/at all times
AP	Idling/Engine stalls/Unsure when/at all times
7A	Starting/Engine stalls
AA	Starting/Engine does not start/Engine turns
AB	Starting/Engine hard to start/cranks slowly/Unsure when/at all times
BJ	Starting/Engine does not start/Unsure when/at all times
DL	Warning lights and chimes/Malfunction Indicator Light ("Check engine" light) indication/no indication

VST OPERATION NUMBER

VST Operation Number	Description
36001-2	Diagnostic Trouble Codes, read / reset. DTCs in VIDA
28466-3	Engine Control Module, fault tracing DTC
28411-2	Fuel pump control module, replace

DTC DIAGNOSTIC TROUBLE CODES

Control Module	Code	Fault Type
ECM	2120	Permanent
ECM	2100	Permanent
ECM	291A	Permanent
ECM	260A	Permanent
ECM	2600	Permanent
ECM	2610	Permanent
ECM	261A	Permanent
ECM	291B	Permanent
ECM	291C	Permanent
ECM	291D	Permanent
ECM	2800	Permanent
ECM	280B	Permanent
ECM	280C	Permanent
ECM	280D	Permanent
ECM	2900	Permanent
ECM	290B	Permanent
ECM	290C	Permanent
ECM	290D	Permanent
ECM	962A	Permanent
ECM	961A	Permanent
CEM	3A04	Permanent
CEM	3A05	Permanent
CEM	3A07	Permanent
CEM	3A08	Permanent

Rows beginning with * are modified

TEXT

CSC = Customer Symptom Code 

DTC = Diagnostic Trouble Code 

DESCRIPTION

Analysis of replaced PEM's (Pump Electronic Modules) from the field have shown to have no errors. To prevent faulty replacement and repeat repair please follow this document.

For more information, please see component and function descriptions in VIDA, Design and Function section 2 Engine with mountings and equipment - > 28 Ignition and control systems -> 284 control system, fuel supply.

SERVICE

Fault tracing steps:

Diagnostic Trouble Codes (DTCs) for fuel distribution related faults (customer complaints related to Check Engine Light (CEL) illuminated): 

1. If any of following DTC's are set (after following the Vida fault tracing and checking the wiring harness, connectors and fuse/relay) the PEM may be at fault:

   CEM 3A04, 3A05, 3A07, 3A08

   or

   ECM 2610 (B5244S4/B5244S7/B5244T7)

   or

   ECM 2120 (engine B5244S4/B5244S7/B5244T7)

   or

   ECM 291B, 291C, 291D (engine B5254T3 2004)

2. The PEM may be at fault if any other ECM DTCs, related to fuel distribution (e.g. fuel trim, fuel pressure sensor, fuel pressure control etc.), are stored.

   However, all possible causes in listed VIDA instructions first have to be investigated.

   If any of the following DTC's are stored, the fuel pressure sensor should be investigated first:

   ECM 2600, 2600A (engine B5244S4/B5244S7/B5244T7)

   or

   ECM 2100 (engine B5254T3 MY2004)

   or

   ECM 2800, 280B, 280C, 280D (engine B5254T7/B5254T3 MY2005-)

   If any of the following DTCs are stored, the fuel pump should be investigated first:

   ECM 261A (engine B5244S4/B5244S7/B5244T7)

   or

   ECM 291A (engine B5254T3 MY2004)

   or

   ECM 2900, 290B, 290C, 290D (B5254T7/B5254T3 MY2005-)

   Before determining that the PEM is at fault, quick test of the fuel pressure system (engine B5254T7 / B5254T3) or test of fuel pump (engine B5244S4/B5244S7/B5244T7) should be performed, you can find this in VIDA Repair -> Cleaning, Inspection and Adjustment -> Section 2 Engine with mountings and equipment -> 23 Fuel system -> 238 Control system and Fuel system pressure, checking.

   If wiring harness connectors and fuse/relay related faults have been dismissed and the quick test proves that there is a fault, then the PEM should be replaced.

   Customer complaints related to crank-no start/long crank time and/or engine stall/hesitation: 

   If the customer complaint is related to crank-no start/long crank time, engine stall, or engine hesitation and if there are no DTC's set, then follow basic fault tracing based on the symptom (e.g. fuel level check, fuel pressure check, check for proper spark at the plugs, etc.) If any fuel distribution related DTC's mentioned above are stored, please follow instructions in point 1 and 2. If all diagnostic is ok PEM replacement should be the correct repair.

   For all DTC's, frozen values and DTC counters first have to be investigated. Wiring harness, connectors and fuse/relay related faults need to be checked first.

   In all other cases, PEM replacement is the wrong remedy and will most likely end up with repeat repair. Instead, please follow VIDA instructions to find other possible causes to solve the issue.