Archived Stock o5 2500 4x4 p0243 p0541 p0483

[Gumby79]

Helping my frend with his 05 2500. He had bad batteries , when he replacedthem he had 3 codes p0243 (wastegate solenoid malfunction ) po541( Intake Air Heater Relay 1 Low) and p0483 (Fan speed)

History
248350mi original owner.complaint of low power suspects 2nd set of injectors needed first set at 100k mi . Week batteries replaced then codes. Cleaned power leads to grid silinoids, inspected fan wires ok

p0483 and p0541 were able to be cleared with a scanner.
However wastegate solenoid wires appear to be munged new solenoid will be here Tuesday the truck needs to be driven from Oregon to Texas next week just want to make sure that it's not going to wet the bed in route so why is your to fix these things at home any advice would be appreciated

 

[p-Bar]

Your on the right track. Also check for chaffing of wires below the air cond.compressor. I had a blown fuse when some of these codes came up I think it was #36

 

[cerberusiam]

The P0243 will not hurt anything other than limiting boost to the low to mid 20's. To override just crimp the boost reference hose and drive easy.

 

[Gumby79]

Wires have black insulation yet they were green with copper corrosion the battery cable negative is positioned in very tight clearance where the wires come out bending the two wires around the canister and eventually shaped through them and then they brought it out test drive is minutes away to go get the codes cleared it Napa

 

[Gumby79]

Code is staying clear. Thanks for the advice.

Cause and effect analysis
The negative battery cable bolted to the side of the block was routed too close to the solenoid. Causing the cable to chatter agents the solenoid wires bending them over at the end of the strain relief at over 90° and rubbing through the insulation on 1 side and squishing the wires agenst the sheet metal flange of the solenoid can.
in closing
If you haven't had this failure you may be able to prevent this failure...
Reach down and relocate the negative battery cable away from the solenoid... check for green (sign of compromised isolator) if green this means it is only a matter of time before the copper oxides awayand you experience this failure.

 

[p-Bar]

Thanks for the advice

 

[Gumby79]

Correlation becoming causation

Got another friend with an 06 it appears to be a manufacturing defect not taking into account the gravity of the copper in the battery cable causing it to reach over and smack the wiring for the solenoid every time you hit a bump

View From the Bottom showing the wiring for the solenoid bent 180 at the center this bend is where the wiring broke on the 05 that is fixed

View from the front of the truck.


How many of thas solenoids have failed as a result of this minor oversight?

Moderators :This ready is ready to be moved to its proper final location it is no longer a 911 situation