[khnitz]

I have to error codes on my truck (a 2005 Ram2500) - P0243 and P0480. This summer, I replaced the wastegate solenoid, and the fan clutch wiring had to be re-worked because it got caught in the fan blade (that was the resultof a repair I had a shop do to replace the fan clutch the previous summer - the wiring worked its way into the path of the fan blade).

I still have both error codes, and the shop will still warranty the work on the fan clutch to correct the P0480 code, but I wanted to be sure there wasn't a complication from the wastegate solenoid that was a contributing factor.

Yesterday, I stepped through the wastegate solenoid P0243 diagnostic procedure from the FSM. I traced and verified every step of the path from the wastegate solenoid connector back to the fuse block (this is an '05, so it should be PRE-TIPM - it should not have the complicated TIPM from the '06 and later trucks).

When everything is assembled, I cannot measure from the fuse location (36) to the pin on the wastegate solenoid. However, I can measure a connection from the wastegate solenoid to the C5 connector (its Blue, not Black as the FSM states) and its pin 25 (not pin 26, as the FSM states). I can also measure a short from Fuse 36 to the C5 pin 25 socket on the fuse block. BUT, when everything is connected, I do not get a measurement from Fuse 36 to the wastegate connector pin. I unwrapped everything in the wiring loom alongside the battery, between C5 of the fuse block and C130 - what I found was a continuous wire for that length, too, which surprised me as the FSM says there should be a splice (S140) in that path.

I'm stumped...

 

[ShaunM]

Its difficult to fully grasp your situation but I'd go with what the FSM says. Just a week ago I had a (self caused) wiring issue and I resorted to the FSM for pinouts and wire routing. I followed it exactly and was able to find my problem and correct it. If there's supposed to be a splice somewhere, well, I don't know your skill level but I would put one in one way or another! Oddly enough my problem also involved splices that I was missing. Good luck nonetheless, keep at it and you'll figure it out

 

[khnitz]

My skills are up to the task, but the FSM does not match the physical reality of what is in the vehicle. That last stretch of the connection between the wastegate solenoid and the fuse block is the mismatch (see image).

The truck has not been modified, so I am dealing with the from-the-factory wiring.

 

[rghavana]

Using a test light ??
FSM is full or errors and and IMO Dodge used whatever colors/wires available.
So if your sure proper circuit then I would not sweat it.

 

[khnitz]

Was using a volt/ohm-meter - I need to get a test light, too.

 

[rghavana]

Yeah, certain test require test light to function properly

 

[ShaunM]

What's strange is that it doesn't tell you where s140 leads to, normally it'll indicate that. It's all the same circuit so if one length of wire connects everything then, yes, I guess if there's not an issue then best leave it be. I haven't had problems with the FSM but maybe that splice is for another trim package or something of that nature.

 

[PWong]

error codes on my truck (a 2005 Ram2500) - P0243 and P0480.
I still have both error codes,
sure there wasn't a complication from the wastegate solenoid that was a contributing factor.

http://www.rambodybuilder.com/2005sbbgl/docs/wd/dr/wiringdiagrams/8w30fuelignitionsystem.pdf

According wiring diagram 8W-30-37 & 38) Fuse #36 (circuit F504 GY/PK) sends B+ power to wastegate solenoid and "Fused Ignition Switch Output (RUN)" signal to fan clutch, so ons stone two birds.>

 

[PWong]

Yesterday, I stepped through the wastegate solenoid P0243 diagnostic procedure from the FSM. I traced and verified every step of the path from the wastegate solenoid connector back to the fuse block

When everything is assembled, I cannot measure from the fuse location (36) to the pin on the wastegate solenoid. However, I can measure a connection from the wastegate solenoid to the C5 connector (its Blue, not Black as the FSM states) and its pin 25 (not pin 26, as the FSM states). I can also measure a short from Fuse 36 to the C5 pin 25 socket on the fuse block. BUT, when everything is connected, I do not get a measurement from Fuse 36 to the wastegate connector pin. I unwrapped everything in the wiring loom alongside the battery, between C5 of the fuse block and C130 - what I found was a continuous wire for that length, too, which surprised me as the FSM says there should be a splice (S140) in that path.

So "step 3 F504 Fused Ignition Switch Output Open" failed, right ???

Try to do:

Disconnect C5 at IPM and wastegate connector, check resistance of F504 (both ends should have the same color) for less than 10 ohms.
So it's Blue and ends up at C5-25 instead of GY/PK at C5-26?
Any wire, what color was on C5-26?
May be C5-26 goes to fan clutch connector pin 6?

If C5-25 and 26 were connected together then Fuse #36 should send B+ power to C5-25 and 26 at the same time.

Reconnect C5 to IPM.
Install Fuse#36, key RUN, check for B+ power on F504.
If B+ is not present then IPM is defective.:wink2:

 

[khnitz]

Sorry for the delayed feedback on this one. I got back into the truck tonight to check and straighten things out before dropping the truck off at the shop to have the A/C Fan Clutch repaired (and likely replaced) under their warranty.

With C5 disconnected, and Fuse 36 removed, I tested the connection through the IPM to its connector pins. The load side of Fuse 36 connects to C5-26 AND C5-25. Both wires are Gray/Pink (GY/PK). The FSM does not show C5-25 as populated, though it is electrically tied to C5-26, too. C5-26 powers the HVAC panel - in particular the switch and backlighting for the A/C and Rear Defogger switches.

The connection to the wastegate solenoid is verified, and the truck is now waiting at the shop. Hopefully once they replace the A/C fan clutch, this will clear the P0480 and P0243 (and P0483 showed up recently, too).

 

[PWong]

Sorry for the delayed feedback on this one. I got back into the truck tonight to check and straighten things out before dropping the truck off at the shop to have the A/C Fan Clutch repaired (and likely replaced) under their warranty.

With C5 disconnected, and Fuse 36 removed, I tested the connection through the IPM to its connector pins. The load side of Fuse 36 connects to C5-26 AND C5-25. Both wires are Gray/Pink (GY/PK). The FSM does not show C5-25 as populated, though it is electrically tied to C5-26, too. C5-26 powers the HVAC panel - in particular the switch and backlighting for the A/C and Rear Defogger switches.

The connection to the wastegate solenoid is verified, and the truck is now waiting at the shop. Hopefully once they replace the A/C fan clutch, this will clear the P0480 and P0243 (and P0483 showed up recently, too).

Same codes, same circuit failure even though with different fuse/wiring info.:wink2:

 

[khnitz]

Thanks for the link to that video. That was one of the ones I reviewed when I first started digging into the issue. Fortunately, I do not have any chafing of the wiring (I wasn't blowing fuses, either - just throwing the codes). Same thing down at the wastegate actuator - no wiring issues there, either.

I'll post feedback after the shop is done with it.

 

[khnitz]

To close this thread out, the shop found that the wiring to the Fan Clutch was also chafed at the aluminum guide that comes out and down from the Fan Clutch. The shop replaced the Fan Clutch (under their repair warranty), and I am free of error codes, now.

BUT, I now hear a noise when on the throttle starting around 2000 RPM and up. It's sort of like an alternator whine through the speakers (but it's not), and sort of like the sound you get when you use a blade of grass as a reed between your thumbs and blow. I'm wondering, now that the P0243 code is cleared and maybe my new wastegate actuator valve is working, if the noise is due to the cheap actuator valve I installed. Otherwise, there is something wrong with how they installed the new Fan Clutch, because that noise was NOT there before. I will start a separate thread here in the forum to figure that one out (after some searching).