CEL, Transmission overlay harness recall, O2 sensors, and O2 module, saga continues

[TSkoropad]

Greetings folks,

Been a member here since August, obviously lurking. Now I’m looking for some advice from the Cummins gurus.

Brief history of the truck
Purchased new in August of 2011, now at 32200km.
Installed S&B Filters cold air kit w/scoop, and MBRP dual cat back system in June of 2012.
No other performance mods.

Everything was great until this past spring. Took the vehicle in for the tie rod recall, and was told that there was an additional recall, namely the transmission harness overlay or O2 sensor harness recall.

The aforementioned recall was completed and this October the check engine light came on. Returned to dealer for service, to find that codes P2626, P2195, and P241A were logged. Both O2 sensors were found to be sooted and uncleanable, and the O2 module had an internal circuit failure. All three were replaced and the harness and connectors were checked for corrosion.

Codes cleared vehicle test driven for 100km or so and deemed repaired.

Now yesterday, less than 1000km later the check engine light came back on. Returned to dealer, and managed an appointment for this morning. Final diagnosis, same codes logged as previously. Technician checked all previous work, harness, connectors, etc. and stated all appeared okay. Codes once again cleared, and vehicle returned.

Service writer stated that the possible cause was the fact that I had modified the vehicle with the cold air kit and that the engine was receiving too much air, thus logging the fault codes. He also stated the next step if the CEL reappears, would be to contact Chrysler tech, but that as soon as they found out about the cold air kit, they would refuse tech support or any warranty service.

My feeling... I believe I was being fed a load of “bovine scat.”

I did contact S&B and spoke with their tech person to see if they’ve had report of this issue. He advised never. He did have me send him the previous dealer work orders, and advised he would have his top tech guy contact my dealer’s service department to discuss the situation. Awaiting the result as I write this.

Looking for thoughts and insight from the folks here.

Thanks

 

[SnoKing]

Welcome to the slippery slope! You have become your own warranty station if they so choose! SNOKING

 

[Bob4x4]

Cold air kits can trip dtc's but not o2 system codes from my experience

 

[TSkoropad]

Just to update, as of this morning, I have had some very interesting correspondence from S&B Filters, including the S&B owner himself. They want to get fully involved if necessary. I will post the details of the correspondence a bit later. Awesome customer service from S&B!

 

[sag2]

Any modification to the intake system has the propensity to upset the mass air flow sensor. The sensor is only used for EGR control, so there is a possibility the EGR is not operating quite as designed. If they did the overlay with crimp connectors from the early TSB the chances of screwing that up are also pretty good. They either don't use the crimps, don't use the correct crimps, or don't use the correct crimping tool.

 

[TSkoropad]

I'm going to go with the later, a screwed up install of the transmission overlay harness.
As stated previously the issue first reared it's head after the recall was done. The first time this October, then again a couple of days ago.
In October the O2 sensors and O2 module were replaced, connectors inspected for corrosion, and stripped exhaust system threads repaired. Then the same issue 3 days ago. Both times the fault codes below were logged.

P241A O2 SENSOR 1/1 AND 1/2 OXYGEN CONCENTRATION MISMATCH
P2195 O2 SENSOR 1/1 OUT OF RANGE HIGH
P2626 O2 SENSOR 1/1 PUMP CELL CURRENT TRIM CIRCUIT OPEN

The cold air kit, has been on the vehicle for about 2 years now with no issues.

I called S&B to inquire if they've had any reported issues with their product on 4th gen Cummins trucks. They advised not a single issue. Matter of fact I even received a call from the company owner himself, (Berry Carter) who was quite distressed that the dealer was pointing the finger at their product being the cause. He assured me that they have had no reports pf this issue before. He also stated that he would be willing to call the dealer to interject on my my behalf.

So, the next step will be to remove the intake (pain in the *****), and monitor the situation. My gut feeling, is that the CEL will soon enough come back on, proving that the intake system is not at fault.

Then we'll see what answers the dealer has.

Will keep this thread updated with any new news.

Any modification to the intake system has the propensity to upset the mass air flow sensor. The sensor is only used for EGR control, so there is a possibility the EGR is not operating quite as designed. If they did the overlay with crimp connectors from the early TSB the chances of screwing that up are also pretty good. They either don't use the crimps, don't use the correct crimps, or don't use the correct crimping tool.

 

[Bob4x4]

You may not be aware but there is a new style harness kit that should be able to repair the one you have now

 

[TSkoropad]

Thanks Bob, my vehicle does have the latest generation harness, and I won't even get into how that transpired.

You may not be aware but there is a new style harness kit that should be able to repair the one you have now