Engine/Transmission (1998.5 - 2002) Codes PO382,PO380 and P1693

[Smokin' Larry]

Hi folks, I'm a new member with my first diesel. It's a 2001 4X4 Quad Cab Automatic long bed. It's got 237000+ miles on it. I've owned it for about five weeks. The truck came with an Edge Comp box but I had it changed out for an Edge Juice w/Attitude to monitor EGT and Fuel Pressure and other functions. I have read the Codes in Frequently Asked Questions but need to know what is causing these and how critical are they. Also degree of difficulty in correcting them. It's throwing the PO380 and PO382 because it takes too long for my "Wait To Start" light to go off. It starts immediately and idles with 14/15 pounds of fuel pressure. Any advice for a newbie would be highly appreciated. Thanks in advance. Larry

 

[rkressg]

P0382 (M) Intake Air Heater Relay #2 Control
Circuit
Problem detected in #2 air heater solenoid/relay circuit
(not heater element)


P0380 (M) Intake Air Heater Relay #1 Control
Circuit
Problem detected in #1 air heater solenoid/relay circuit
(not heater element)

1693 just means a code exists in the ECM
P1693 (M) DTC Detected in PCM/ECM or DTC
Detected in ECM
A 9Companion DTC9 was set in both the ECM and PCM.

 

[JLandry]

Welcome aboard Larry!



Can you tell if the intake grid heaters are coming on when you turn on the ignition and after starting the engine?



If you're not sure, using a multimeter measure the battery voltage across the battery terminals with the ignition key off, then turn the ignition key on. If the grid heaters are working, the battery voltage should drop at least 0. 5 volt. Immediately after starting the engine when cold, you should also be able to detect the grid heaters cycling by seeing the engine rpm and charging system voltage drop slightly each time they come on.



If the intake grid heaters are not working, then let us know and we can help you troubleshoot.



Regards,



John L.

 

[Smokin' Larry]

Thank you very much folks, I'll check the intake grid heaters and go from there. I'm sure glad I found this website. You guys already saved me money with the starter solenoid rebuild fix. Ordered a kit from Geno's and got 'er dun! The copper contact was about as thick as my thumbnail. Not a problem since. I love saving money. Thanx again I'll let you guys know what happens. Gotta run.

 

[Smokin' Larry]

Yep, the intake grid heaters are working. a slight voltage drop at the meter, rpm fluctuation, even a little headlight flicker when I started up to go to work last night. Will have to look a little deeper. Thanx, Larry

 

[JLandry]

Yep, the intake grid heaters are working. a slight voltage drop at the meter, rpm fluctuation, even a little headlight flicker when I started up to go to work last night. Will have to look a little deeper.

Larry,



Can you please expand a little more on the exact conditions and symptoms when these DTC's are set? You said it takes too long for your wait-to-start lamp to go off. Are you saying the wait-to-start light never goes off?



John L.

 

[Smokin' Larry]

Hello John L. , sorry it took a while before I got back to you,I been busy. I have this problem only when the engine is COLD. Yes, the Wait to Start light does go off but it takes considerably longer on cold start ups. When the light hangs on is when it turns on the MIL. I also noticed that on some cold starts the heater grid effect on the volt meter doesn't seem as strong even though the engine was just as cold as other times. This may be intermittent, but unsure. Glow plug issue? I really appreciate your help. Larry

 

[JLandry]

Glow plug issue?

Hi Larry,



There are no glow plugs on these engines, only intake air heating elements much like the heating elements you'd find in a toaster. When necessary, the Cummins ECM activates a set heavy-duty relays during the wait-to-start cycle, which in turn provide power the intake air heating elements. Apparently the ECM can sense if current is passing through the coils of the relays, and if not, it triggers the P0380 and P0382 DTC's you've been getting. In theory, only three things could cause these trouble codes: 1. The relays are malfunctioning, 2. There's a wiring problem somewhere, or 3. The ECM itself is malfunctioning.



If you don't want too start off throwing money at this, then the first thing to do might be to verify the relays are indeed being energized properly when the error occurs. That should be done by measuring for voltage present at terminals 2 and 4 of the intake air heater relay pack. The relays are located on the driver's side fender just under and to the rear of the battery. Take a look at the attached wiring schematic for the wiring layout.



You could also consider just replacing the relays to rule them out as the problem. The Dodge part number is 56026842, and they can be purchased online for under $60 at Mopar-Wholesale.com. You only need to buy one unit because it contains both relays.



Good luck,



John L.

 

[Smokin' Larry]

OK John that sounds simple enough. I'll check it out later. I am VERY appreciative of your help. I hope all the folks at TDR have a very nice Christmas holiday and thanks so much. Needless to say I'm going to upgrade my TRIAL membership. Larry

 

[gtwitch]

A couple of years ago I had a similar problem, although I can't read the codes on my 99, but tracked it down to the lugs on the drivers side battery that go to the heater elementw and there is two relays fot the two elements in the air horn base. I had one of the lugs going to the positive battery that was severly corroded, I replaced (soldered) the lug and the problem solved!!



gtwitch in wyoming

 

[Smokin' Larry]

gtwitch,sorry it took me bit to get back,been away. I'll check that out also. TDR is a wealth of information. Thank you! HAPPY NEW YEAR to all at TDR!