Series 60 DDEC V Troubleshooting – Section 42.2 Troubleshooting Flash Code 38, PID 95/FMI 4

Section 42.2
Troubleshooting Flash Code 38, PID 95/FMI 4

This diagnostic condition is typically:‪

• Open sensor signal circuit
• Open sensor +5 volt supply circuit
• Sensor signal is shorted to sensor return circuit or to ground
• Sensor +5 volt supply is shorted to the sensor return circuit

Section 42.2.1
Multiple Code Check

Perform the following steps to check for multiple codes.‪

1. Turn vehicle ignition switch ON.
2. Plug the diagnostic tool.
3. Read active codes.
   1. If active code p 95/4 and no other codes were logged, refer to "42.2.2 Sensor Check" .
   2. If active code p 95/4 and any or all of the following codes were logged, p 95/3, p 100/3 or 4, p 101/3 or 4, p 110/3 or 4, p 174/3 or 4, p 175/3 or 4, refer to "79 Engine Harness" .
   3. If active code 95/4 and codes other than the following codes were logged, p 95/3, p 100/3 or 4, p 101/3 or 4, p 110/3 or 4, p 174/3 or 4, p 175/3 or 4, refer to "42.2.2 Sensor Check" .

Section 42.2.2
Sensor Check

Perform the following steps to check the sensor.‪

1. Turn ignition switch OFF.
2. Disconnect FRS/Fuel Restriction Sensor connector and install a jumper wire between sockets B and C of the FRS/Fuel Restriction Sensor harness connector. See Figure "FRS/Fuel Restriction Sensor" .
3. Turn ignition ON.
4. Read logged codes.
5. If active codes p 95/3 or 4 are not logged, start and run the engine until either these active codes display or engine temperature (COOLANT TEMP & OIL on DDR) has been greater than 60°C (140°F) for more than one minute.
   1. If active code p 95/4 and any other codes are logged, refer to "42.2.3 Check for +5 Volts" .
   2. If active code p 95/3 and any other codes except code 95/4 are logged, check to ensure ECM/ECU and FPS/FRS connectors are wired properly. Go to step 6 .
6. Inspect terminals at the FRS/Fuel Restriction Sensor connectors (both the sensor and harness side) for damage: bent, corroded, and unseated pins or sockets. See Figure "FRS/Fuel Restriction Sensor" .
   

   Figure 1. FRS/Fuel Restriction Sensor

   1. If the terminals and connectors are damaged, repair them and refer to "42.2.8.1 Verify Repairs" .
   2. If the terminals and connectors are not damaged, replace the FRS/Fuel Restriction Sensor and refer to "42.2.8.1 Verify Repairs" .

Section 42.2.3
Check for +5 Volts

Perform the following steps to check for +5 volts.‪

1. Turn vehicle ignition OFF and remove jumper wire. Turn ignition ON.
2. Measure voltage on FRS/Fuel Restriction Sensor harness connector, socket C to socket A.
   1. If the voltage measurement is greater than 6 volts, refer to "42.2.6 Check for Short to Battery +" .
   2. If the voltage measurement is less than 4 volts, refer to "42.2.5 Check for Open +5 Volt Line and Short" .
   3. If the voltage measurement is between 4 and 6 volts, refer to "42.2.4 Check for Signal Open" .

Section 42.2.4
Check for Signal Open

Perform the following steps to check for signal open.‪

1. Turn vehicle ignition OFF and disconnect Engine Harness connector at the ECM/ECU.
2. Install a jumper wire between pins A and B of the FRS/Fuel Restriction Sensor harness connector. See Figure "FRS/Fuel Restriction Sensor" .
   

   Figure 2. FRS/Fuel Restriction Sensor

3. Measure resistance between sockets E-16 and E-15 on the Engine Harness connector.
   1. If resistance measurement is less than or equal to 5 Ω refer to "42.2.7 Check for Short to Ground" .
   2. If the resistance measurement is greater than 5 Ω or open, the signal line (E-16) or return line (E-15) is open. Repair the open and refer to "42.2.8.1 Verify Repairs" .

Section 42.2.5
Check for Open +5 Volt Line and Short

Perform the following steps to check for open +5 volt line.‪

1. Turn vehicle ignition OFF.
2. Disconnect the Engine Harness connectors at the ECM/ECU.
3. Install a jumper wire between sockets A and C of the FRS harness connector.
4. Measure resistance between sockets E-12 and E-15 on the Engine Harness connector.
   1. If resistance measurement is less than or equal to 5 Ω, go to step 5 .
   2. If the resistance measurement is greater than 5 Ω or open, the engine +5 volt line (E-16) is open. Repair the open and refer to "42.2.8.1 Verify Repairs" .
5. Remove jumper wire.
6. Measure resistance between sockets A and C of the FRS sensor connector.
   1. If the resistance measurement is greater than 100 Ω or open, refer to "42.2.8 Replace FRS/Fuel Restriction Sensor" .
   2. If the resistance measurement is less than or equal to 100 Ω, the return line (E-15) is shorted to the engine +5 volt line (E-12). Repair the short and refer to "42.2.8.1 Verify Repairs" .

Section 42.2.6
Check for Short to Battery +

Perform the following steps to check for a short to battery.‪

1. Remove both fuses to the ECM/ECU.
2. Disconnect the Vehicle Interface Harness connector at the ECM/ECU. See Figure "ECM/ECU Vehicle Harness Connector" .
3. Measure resistance between socket E-12 on the Engine Harness connector and socket V-15 of the Vehicle Interface Harness connector, and between E-12 and the 5-way power harness sockets V-61 and V-65.
   1. If the resistance measurement is greater than 1,000 Ω or open, refer to "42.2.8 Replace FRS/Fuel Restriction Sensor" .
   2. If the resistance measurement is less than or equal to 1,000 Ω, a short exists between sockets where less than 1,000 Ω was measured. Repair short and reinsert fuses. Refer to "42.2.8.1 Verify Repairs" .
   

   Figure 3. ECM/ECU Vehicle Harness Connector

Section 42.2.7
Check for Short to Ground

Perform the following steps to check for a short to ground.‪

1. Turn ignition switch OFF.
2. Remove jumper wires.
3. Measure resistance between sockets E-16 and E-15 on the Engine Harness connector. Also measure resistance between socket E-16 and a good ground.
   1. If both resistance measurements are greater than 100 Ω or open, refer to "42.2.8 Replace FRS/Fuel Restriction Sensor" .
   2. If either resistance measurement is less than or equal to 100 Ω, the signal line (E-16) and return line (E-15) are shorted together, or the signal line (E-16) is shorted to battery ground. Repair the short. Refer to "42.2.8.1 Verify Repairs" .

Section 42.2.8
Replace FRS/Fuel Restriction Sensor

Perform the following steps to replace the FRS/Fuel Restriction Sensor.‪

1. Turn ignition switch OFF.
2. Replace FRS/Fuel Restriction Sensor. Reconnect all connectors.
3. Turn ignition ON. Clear codes.
4. Start and run the engine for one minute.
   1. If Amber Warning Lamp comes on, go to step 5 .
   2. If Amber Warning Lamp does not come on, refer to "42.2.8.1 Verify Repairs" .
5. Check terminals at the ECM/ECU harness connector (both ECM/ECU and harness side) for damage: bent, corroded, and unseated pins or sockets. Check E-12, E-16 and E-15 terminals at ECM/ECU.
   1. If terminals and connectors are damaged, repair them. Refer to "42.2.8.1 Verify Repairs" .
   2. If terminals and connectors are not damaged, install a test ECM/ECU. Refer to "42.2.8.1 Verify Repairs" .

Section 42.2.8.1
Verify Repairs

Perform the following steps to verify repairs.‪

1. Turn ignition switch OFF.
2. Reconnect all connectors.
3. Turn ignition ON. Clear codes.
4. Start and run the engine for one minute. Stop engine.
5. Check diagnostic tool for codes.
   1. If no codes are logged, troubleshooting is complete.
   2. If code p 95/4 is not logged, and other codes are logged, refer to "18.3 First Step for Diagnosing a Fault Within the DDEC System" .
   3. If code p 95/4 is logged, and other codes are logged, review this section from the first step to find the error. Refer to "42.2.1 Multiple Code Check" .