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Electronic Control System Gas Plus Engines – FAULT CODE 441

Battery Number 1 Voltage Low – Data Valid but Below Normal Operational Range – Moderately Severe Level

Overview

CODE REASON EFFECT
Fault Code: 441
PID: P168
SPN: 168
FMI: 1/18
LAMP: Amber
SRT: 

Battery Number 1 Voltage Low – Data Valid but Below Normal Operational Range – Moderately Severe Level. ECM supply voltage is below the minimum system voltage level.

Possible reduced performance.

Unswitched Battery Supply Circuit
SMALL | MEDIUM | LARGE

Circuit Description

There are four battery inputs into the OEM connectors that are unswitched battery supply to the electronic control module (ECM).

Component Location

The battery voltage circuit is located in the wiring harness.

Shop Talk

The engine will not communicate or start if the battery circuit is malfunctioning.

Cautions and Warnings

 CAUTION 

To reduce the possibility of damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM.
 CAUTION 

To reduce the possibility of pin and harness damage, use the following test leads when taking a measurement:
Part Number 3823993 – male Deutsch test lead
Part Number 3822758 – male Deutsch/AMP/Metri-Pack test lead.

Troubleshooting Steps

STEPS SPECIFICATIONS
STEP 1. Check the fault codes.  
  STEP 1A. Check for an inactive fault code. Fault Code 441 inactive?
STEP 2. Check for a defective voltage source.  
  STEP 2A. Determine if vehicle has a voltage regulator. Voltage regulator installed?
  STEP 2B. Determine battery voltage. Battery voltage between 11.5 VDC and 15.0 VDC?
  STEP 2C. Determine voltage on the 12 VDC side of the OEM voltage regulator. Voltage between 11.5 VDC and 15.0 VDC?
STEP 3. Check the OEM harness.  
  STEP 3A. Inspect the OEM harness and connector pin. Dirty or damaged pins?
  STEP 3B. Check the voltage at the 23 pin OEM connector. Voltage between 11.5 VDC and 15.0 VDC?
  STEP 3C. Check for an open circuit in the unswitched battery supplies in the OEM harness. Less than 10 ohms?
  STEP 3D. Check for a pin to pin short in the unswitched battery supplies in the OEM harness. Greater than 100k ohms?
  STEP 3E. Check for an inactive fault code. Fault Code 441 inactive?
STEP 4. Check the ECM and engine harness.  
  STEP 4A. Inspect the ECM and engine harness connector pins. Dirty or damaged pins?
  STEP 4B. Check the voltage at the ECM. Voltage between 11.5 VDC and 15.0 VDC?
  STEP 4C. Check for an open circuit in the unswitched battery supplies in the engine harness. Less than 10 ohms?
  STEP 4D. Check for a pin to pin short in the unswitched battery supplies in the OEM harness. Greater than 100k ohms?
  STEP 4E. Check for an inactive fault code. Fault Code 441 inactive?
STEP 5. Clear the fault codes.  
  STEP 5A. Disable the fault code. Fault Code 441 inactive?
  STEP 5B. Clear the inactive fault codes. All fault codes cleared?

Guided Step 1 – Check the fault codes.

Guided Step 1A – Check for an inactive fault code.

Conditions

  • Turn keyswitch ON
  • Connect INSITE™ electronic service tool.

Action

  • Use INSITE™ electronic service tool to read the fault codes.

Fault Code 441 inactive?
YES NO
No Repair No Repair

Guided Step 2 – Check for a defective voltage regulator.

Guided Step 2A – Determine if vehicle has a voltage regulator.

Conditions

  • Turn keyswitch OFF.

Action

  • Inspect the vehicle for a possible voltage regulator or refer to the OEM repair manual to determine if the vehicle has a voltage regulator installed.

Note: If the vehicle has a 24 VDC or 36 VDC system, then it must have a voltage regulator to supply 12 VDC power to the unswitched battery pin in the ECM.

Voltage regulator installed?
YES NO
No Repair No Repair

Guided Step 2B – Determine battery voltage.

Conditions

  • Turn keyswitch OFF.

Action

  • Use a multimeter to read the battery voltage.

Battery voltage between 11.5 VDC and 15.0 VDC?
YES NO
No Repair

A defective battery has been detected.

Replace the defective battery or batteries. Refer to the OEM service manual.

Guided Step 2C – Determine the voltage on the 12 VDC side of the OEM voltage regulator.

Conditions

  • Turn keyswitch OFF.

Action

  • Use a multimeter to read the voltage across the voltage regulator.

Voltage between 11.5 VDC and 15.0 VDC?
YES NO
No Repair

A defective battery, battery circuit or voltage regulator has been detected.

Refer to the OEM service manual.

Guided Step 3 – Check the OEM harness.

Guided Step 3A – Inspect the OEM harness and connector pins.

Conditions

  • Turn keyswitch OFF
  • Disconnect the engine harness from the 23-pin OEM harness connector.

Action

  • Corroded pins
  • Bent or broken pins
  • Pushed back or expanded pins
  • Wire insulation damaged
  • Moisture in or on the connector
  • Missing or damaged connector seals
  • Connector shell broken
  • Dirt or debris in or on the connector pins.

For general inspection techniques, refer to Component Connector and Pin Inspection, Procedure 019-361.

Dirty or damaged pins?
YES NO

A defective connection has been detected in the 23 pin OEM connector.

Repair the damaged pins. Repair or replace the OEM or engine harness, whichever has the damaged pins.

  • Flush the dirt, debris, or moisture from the connector pins using electronic contact cleaner, Part Number 3824510.
  • Install the appropriate connector seal if it is damaged or missing.
  • Repair the engine harness. Refer to Procedure 019-204.
  • Replace the engine harness. Refer to Procedure 019-043.
  • Repair the OEM harness. Refer to the OEM troubleshooting and repair manual.
  • Replace the OEM harness. Refer to Procedure 019-071.
 No Repair

Guided Step 3B – Check the voltage at the 23 pin OEM connector.

Conditions

  • Turn keyswitch OFF
  • Disconnect the engine harness from the 23 pin OEM connector.

Action

  • Check the voltage between the 23 pin OEM connector unswitched battery SUPPLY pins and ground.

Refer to the circuit diagram or wiring diagram for connector pin identification.

Voltage between 11.5 VDC and 15.0 VDC?
YES NO
No Repair No Repair

Guided Step 3C – Check the battery voltage.

Conditions

  • Turn keyswitch OFF
  • Disconnect the engine harness from the OEM harness at the 23-pin connector
  • Disconnect the battery cables from the battery.

Action

  • Measure the resistance between the unswitched battery pins of the 23 pin OEM connector and the positive (+) battery terminal.

Note: Check for blown or corroded fuses that are in series with the unswitched battery supplies.

Refer to the circuit diagram or wiring diagram for connector pin identification.

For general resistance measurement techniques, refer to the Resistance Measurements Using a Multimeter and Wiring Diagram, Procedure 019-360.

Less than 10 ohms?
YES NO
No Repair

An open circuit has been detected in the OEM harness.

Repair or replace the OEM harness.

  • Repair the OEM harness. Refer to the OEM troubleshooting and repair manual.
  • Replace the OEM harness. Refer to Procedure 019-071.

Guided Step 3D – Check for a pin to pin short in the unswitched battery supplies in the OEM harness.

Conditions

  • Turn keyswitch OFF
  • Disconnect the engine harness from the OEM harness at the 23 pin and 31 pin OEM connectors.
  • Disconnect the battery cables from the battery.

Action

  • Measure the resistance between the unswitched battery SUPPLY pins in the 23 pin OEM connector and all other pins in the 23 pin OEM connector.
  • Measure the resistance between the unswitched battery SUPPLY pins in the 23 pin OEM connector and all other pins in the 31 pin OEM connector.

Refer to the circuit diagram or wiring diagram for connector pin identification.

For general resistance measurement techniques, refer to the Resistance Measurements Using a Multimeter and Wiring Diagram, Procedure 019-360.

Greater than 100k ohms?
YES NO
No Repair

An pin to pin short has been detected in the OEM harness.

Repair or replace the OEM harness.

  • Repair the OEM harness. Refer to the OEM troubleshooting and repair manual.
  • Replace the OEM harness. Refer to Procedure 019-071.

Guided Step 3E – Check for an inactive fault code.

Conditions

  • Connect all components
  • Turn keyswitch ON
  • Connect INSITE™ electronic service tool.

Action

  • Use INSITE™ electronic service tool to read the fault codes.

Fault Code 441 inactive?
YES NO
No Repair No Repair

Guided Step 4 – Check the ECM and engine harness.

Guided Step 4A – Inspect the ECM and engine harness connector pins.

Conditions

  • Turn keyswitch OFF
  • Disconnect the engine harness connector 1 from the ECM.

Action

  • Corroded pins
  • Bent or broken pins
  • Pushed back or expanded pins
  • Wire insulation damaged
  • Moisture in or on the connector
  • Missing or damaged connector seals
  • Connector shell broken
  • Dirt or debris in or on the connector pins.

Refer to the circuit diagram or wiring diagram for connector pin identification.

For general inspection techniques, refer to Component Connector and Pin Inspection, Procedure 019-361.

Dirty or damaged pins?
YES NO

A defective connection has been detected in the ECM connectors or engine harness connectors.

Repair the damaged pins. Repair or replace the engine harness, whichever has the damaged pins.

  • Flush the dirt, debris, or moisture from the connector pins using electronic contact cleaner, Part Number 3824510.
  • Install the appropriate connector seal if it is damaged or missing.
  • Repair the engine harness. Refer to Procedure 019-204.
  • Replace the engine harness. Refer to Procedure 019-043.
 No Repair

Guided Step 4B – Check the voltage at the ECM.

Conditions

  • Turn keyswitch OFF
  • Disconnect the engine harness connector 1 from the ECM.

Action

  • Check the voltage between the engine harness ECM connector 1 unswitched battery SUPPLY pins and ground.

Refer to the circuit diagram or wiring diagram for connector pin identification.

Voltage between 11.5 VDC and 15.0 VDC?
YES NO
No Repair No Repair

Guided Step 4C – Check for an open circuit in the unswitched battery supplies in the engine harness.

Conditions

  • Turn keyswitch OFF
  • Disconnect engine harness connector 1 from the ECM
  • Disconnect the battery cables from the battery.

Action

  • Measure the resistance between the unswitched battery SUPPLY pins in the engine connector 1 and the 23 pin OEM connector.

Refer to the circuit diagram or wiring diagram for connector pin identification.

For general resistance measurement techniques, refer to the Resistance Measurements Using a Multimeter and Wiring Diagram, Procedure 019-360.

Less than 10 ohms?
YES NO
No Repair

An open circuit has been detected in the engine harness.

Repair the damaged pins. Repair or replace the engine harness, whichever has the damaged pins.

  • Flush the dirt, debris, or moisture from the connector pins using electronic contact cleaner, Part Number 3824510.
  • Install the appropriate connector seal if it is damaged or missing.
  • Repair the engine harness. Refer to Procedure 019-204.
  • Replace the engine harness. Refer to Procedure 019-043.

Guided Step 4D – Check for a pin to pin short in the unswitched battery supplies in the engine harness.

Conditions

  • Turn keyswitch OFF
  • Disconnect the engine harness connector 1 and connector 2 from the ECM
  • Disconnect the battery cables from the battery.

Action

  • Measure the resistance between the unswitched battery SUPPLY pins in engine harness connector 1 and all other pins in the engine connector 1.
  • Measure the resistance between the unswitched battery SUPPLY pins in engine harness connector 1 and all other pins in the engine connector 2.

Refer to the circuit diagram or wiring diagram for connector pin identification.

For general resistance measurement techniques, refer to the Resistance Measurements Using a Multimeter and Wiring Diagram, Procedure 019-360.

Greater than 100k ohms?
YES NO
No Repair

An pin to pin short has been detected in the engine harness.

Repair the damaged pins. Repair or replace the engine harness, whichever has the damaged pins.

  • Flush the dirt, debris, or moisture from the connector pins using electronic contact cleaner, Part Number 3824510.
  • Install the appropriate connector seal if it is damaged or missing.
  • Repair the engine harness. Refer to Procedure 019-204.
  • Replace the engine harness. Refer to Procedure 019-043.

Guided Step 4E – Check for an inactive fault code.

Conditions

  • Connect all components
  • Turn keyswitch ON
  • Connect INSITE™ electronic service tool.

Action

  • Use INSITE™ electronic service tool to read the fault codes.

Fault Code 441 inactive?
YES NO
No Repair

Replace the ECM. Call for pre-authorization.

Refer to Procedure 019-031.

Guided Step 5 – Clear the fault codes.

Guided Step 5A – Disable the fault code.

Conditions

  • Connect all components
  • Turn keyswitch ON
  • Connect INSITE™ electronic service tool.

Action

  • Start the engine and let it idle for one minute.
  • Use INSITE™ electronic service tool to verify that the fault code is inactive.

Fault Code 441 inactive?
YES NO
No Repair No Repair

Guided Step 5B – Clear the inactive fault codes.

Conditions

  • Connect all components
  • Turn keyswitch ON
  • Connect INSITE™ electronic service tool.

Action

  • Use INSITE™ electronic service tool to erase the inactive fault codes.

All fault codes cleared?
YES NO
No Repair No Repair
Repair complete
Appropriate troubleshooting charts
Last Modified:  03-Sep-2004
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