Help! P003A code. Exhaust brake no longer works.

[KonjikiNoDiesel]

Hello! I'm new here so thanks for understanding. So, about a week ago I got my truck (2011 RAM 5500 6.7 Cummins C&C) into the shop for a "Service DEF system will not start in 200 miles" warning. Before my mechanic and I did anything to the truck. He used a Snap-on scanning tool and Code P003A appeared. We did the DPF and DOC cleaning and put new gaskets in the exhaust system. All sensors were not damaged and DEF injector doser was also clean and free from any DEF crystals. Code was still there after the cleaning. However, after that I noticed a coolant leak in the return line of the EGR system and was leaking a lot of liquid. I'm not sure if the coolant had something to do with it but I did a LOT of research online and some experts suggest to check the engine wire harness and some fuses - M21 and Smart Power Relay.

I may need to buy a new Turbo but it makes me wonder why the *Exhaust Brake stopped working out of the blue. I did several trips out of town using the EB* and had no problems. Also, I downloaded some schematics online and I have an idea of what to look in the Turbo speed sensor and actuator harness.

Any ideas, comments, suggestions will be appreciate it. More more thing - truck runs and drives like a champ. No overheating or extra fuel consumption. Engine oil was changed to fully synthetic less than 100 miles, transmission oil (AS68RC) was also changed, DEF, Crankcase, Fuel (Nano), and Air Filters are new. Also EGR system was clean with no issues.

Thanks everyone!

 

[PTsideshow]

https://www.yourmechanic.com/articl...sition-exceeded-learning-limit-by-elan-mcafee This may help

 

[Hoefler]

Have you checked the level of DEF in the tank?? I get that message every time I need DEF, I add 5 gallon and it goes away.

 

[KonjikiNoDiesel]

That's the same website my clueless mechanic was reading when the code came up. Thanks for trying...

 

[KonjikiNoDiesel]

I have check the DEF level. Had it tested to get the 32.5% urea. Had about 31.9% on my tank. Also, that's not the problem I'm trying to solve.

 

[KonjikiNoDiesel]

So, there is not a lot of info regarding this code. I had a plan on what to check and do to rule-out other less expensive causes.

1. I have check all 5 fuses/relays. I found one with severe amount of corrosion but that didn't change anything. *Exhaust Brake is not working.
2. Next, I disconnected the actuator cable to check the 4-pin connector. Had 2.56V, 2.36V, Ground (-), & 10-12V. Disconnected the EGR sensors and valve to check a good connection to the ECM harness. So far, they are all good. No exposed wires or resistance in the line.
3. The Turbo Speed Sensor was also check with a multimeter to make sure there was not an open circuit failure. Levels should be between 900-1600 ohms - mine tested 921 ohms. We are all good there.
4. Got a little curious to see how the EGR system was after cleaning it 3 months ago. Pull the return line sensor and it was full of soot like the day started the 67,500 Service.

Conclusion, I have rule out ALL other possible causes of the *EB from not working. I'm 75% sure my turbo is full of soot and needs a rebuild. The truck has now 300,000+ miles in it and lots of engine hours. I'm currently looking for a Turbocharger (Holset HE351VE) at a good price of eBay and found one that sounds to good to be true. I'll do a lot of research on this seller as its located in California. Anyway, my local mechanic has never remove a diesel engine turbocharger and I don't have a full size garage for this project. Removing the Turbo looks simple but complex. Have to disconnect lines of oil and coolant from top and bottom of turbo housing, 4 stud bolts and disconnect pipe line. I might do this myself to learn as I have multiple trucks with the same engine and turbo.

More updates coming soon.

 

[Bob4x4]

There is some missing information here.........def warning but no def codes.Are you sure it was not DPF and maybe some codes cleared?Failed turbo and def warning doesn't make sense

 

[KonjikiNoDiesel]

No DEF codes at all. Had a "200 Miles warning" but was clear after the DPF cleaning. Turbo seems full of soot. I may delete the EGR system to check some codes out.