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TSB 18-37-97

Hard Starting, No Start, Or Reduced Power In Cold Temperatures

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Models: 1998 BR/BE Ram with Cummins built before 12/15/97

NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH THE 5.9L CUMMINS DIESEL BUILT BEFORE DECEMBER 15, 1997 (MDH 1215XX).

Symptoms:
The vehicle may exhibit a no start or hard start condition in cold temperatures (20F or less) or the customer may complain of reduced power in cold temperatures (20 F or less).

Diagnosis:
Remove the cover to the Power Distribution Center (PDC). Inspect fuse cartridge #7 (fuel heater fuse link) (Figure 1). If the fuse cartridge is missing, perform the Repair Procedure. If fuse cartridge #7 is installed, remove the fuel heater relay and inspect cavity 30 for the presence of a wire terminal. If the wire terminal is missing from cavity 30, perform the following Repair Procedure. If the wire terminal is in cavity 30 and the #7 fuse cartridge is installed in the PDC, further diagnosis is required. Refer to the 1998 Dodge Truck (Except Ram Van) Powertrain Diagnostic Procedures Manual (Publication No. 81-699- 97027) for additional information.

Parts: 

1 (AR) 06102077AA    Fuse, Cartridge, 40 Amp
1 (AR) 05012852AA   Wire With Terminals, Al 12 Circuit
1 (AR) 04481478         Holder, Relay Circuit

Repair: 

This bulletin involves installing the fuel heater fuse, the Al12 circuit, and the relay circuit holder as required.

1.   Disconnect both right and left battery negative terminals.

2.   Remove the bolt-down engine in-line connector located inside the PDC.

3.   Remove the fuel heater relay.

4.   Unbolt the two fasteners retaining the PDC to the inner fender panel.

5.   Locate the six latches around the perimeter of the PDC and unlock the PDC base from the PDC lower cover.

NOTE: THE LOWER COVER WILL REMAIN ATTACHED TO THE VEHICLE WHEN THE PDC BASE IS DETACHED.

6.   Lift the PDC base up, exposing the wiring circuits.

7.   On the underside of the PDC base, carefully remove the inner cartridge fuse rear circuit holder and the fuel heater relay rear circuit holder by releasing the four locking tabs on each holder.

NOTE: THE REAR CARTRIDGE FUSE REAR CIRCUIT HOLDER ONLY NEEDS TO BE MOVED ENOUGH TO CLEAR THE PDC BASE. ADDITIONALLY, EXTREME CAUTION SHOULD BE USED TO NOT DAMAGE THE HEATER RELAY REAR CIRCUIT HOLDER. REPLACE THE RELAY REAR CIRCUIT HOLDER WITH P/N 04481478 IF THE HEATER RELAY REAR CIRCUIT HOLDER BECOMES DAMAGED DURING REMOVAL.

8.   Insert the Al12 wire circuit (p/ln 05012852AA) female end into cavity 30 of the fuel heater relay. Ensure the terminal is locked into position by gently pulling on the wire.

NOTE: THE TERMINAL CRIMP WILL FACE TOWARD THE NEAREST EDGE OF THE PDC WHEN PROPERLY INSTALLED.

9.   Insert the Al12 wire circuit male end into cavity 7 of the cartridge fuse holder. Ensure the terminal is locked into position by gently pulling on the wire.

NOTE: THE TERMINAL CRIMP WILL FACE TOWARD THE NEAREST EDGE OF THE PDC WHEN PROPERLY INSTALLED.

10.   Install the cartridge fuse rear circuit holder and the fuel heater relay rear circuit holder onto the PDC.

11.   Align the six locking tabs of the PDC base to the lower cover and push the base onto the cover until the locking tabs are engaged. Be careful to not pinch any wires between the PDC base and the lower cover.

12.   Install the 40 Ampr cartridge fuse (pln 06102077AA) into cavity 7 of the PDC.

13.   Install the relay into the fuel heater relay socket.

14.   Secure the PDC to the inner fender panel with the two fasteners.

15.   Attach the bolt-down engine in-line connector located inside the PDG. The connector will "click" when the connection is completely bolted down.

16.   Connect the battery negative terminals onto both batteries.

17.   Disconnect the two-wire connector at the fuel heater (located near the fuel filter assembly).

18.   Turn the ignition key to the RUN position and verify the operation of the fuel heater circuit by measuring for battery voltage at terminal I of the fuel heater connector (Figure 2). Further diagnosis of the fuel heater relay circuit is necessary if battery voltage is not available at terminal I of the fuel heater. Refer to the 1998 Dodge Truck (Except Ram Van) Powertrain Diagnostic Procedures Manual (Publication No. 81 -699-97027) for additional information.

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:
Labor Operation No:    08-94-TC-90 . . . . . . . . 0.4 Hrs.

Failure Code:  P8 - New Part 

note: see customer satisfaction notice 770 for additional details


Thanks to Bob Bergevin and Barry Drodge for supplying this TSB information

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This page was edited on: May 3, 2004