Posted on by

Electronic Control System Gas Plus Engines – FAULT CODE 2192

Heated Oxygen Sensor Circuit – Heater Shorted Low

Overview

CODE REASON EFFECT
Fault Code: 2192
PID: S151
SPN: 611
FMI: 3
LAMP: Amber
SRT: 

Heated Oxygen Sensor Circuit – Heater Shorted Low. Heater voltage to heated oxygen sensor low.

Possible reduced performance.

Heated Oxygen Sensor Circuit

SMALL | MEDIUM | LARGE

Circuit Description

The electronic control module (ECM) uses this sensor to determine the composition of the exhaust gas and then, to adjust fueling.

Component Location

The heated oxygen sensor is located in the exhaust outlet connection, after the turbocharger.

Shop Talk

The heated oxygen sensor measures the partial pressure of oxygen present in the exhaust gas. It measures this oxygen presence in lambda (L). The air/fuel ratio (stoichiometric) is 1L :17. The approximate lean-burn condition for the engine is 1.4.

Cautions and Warnings

 WARNING 

Do not touch the heated oxygen sensor until it has cooled. The heated oxygen sensor operates at high temperature and can cause personal injury.
 CAUTION 

Do not use any lubricant in the heated oxygen sensor connector. The sensor will not perform correctly with any grease in the connector.
 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 lead when taking a measurement:
Part Number 3822758 – male Deutsch/AMP/Metri-Pack test lead.

Troubleshooting Steps

STEPS SPECIFICATIONS
STEP 1. Check the fault codes.  
  STEP 1A. Read the fault codes. Fault Code 2192 active?
STEP 2. Check the heated oxygen sensor.  
  STEP 2A. Inspect the engine harness and heated oxygen sensor connector pins. Dirty or damaged pins?
  STEP 2B. Read the fault codes. Fault Code 2192 active?
  STEP 2C. Check for an open circuit in the heated oxygen sensor. 2.9 to 3.7 ohms at room temperature?
STEP 3. Check the engine harness.  
  STEP 3A. Inspect the engine harness and ECM connector pins. Dirty or damaged pins?
  STEP 3B. Check the supply voltage to engine harness. 11 to 14 VDC?
  STEP 3C. Check for an open circuit. Less than 10 ohms?
  STEP 3D. Check for a short circuit to ground. More than 100k ohms?
  STEP 3E. Check for an open circuit in the heated oxygen sensor. 2.9 to 3.7 ohms at room temperature?
STEP 4. Clear the fault codes.  
  STEP 4A. Disable the fault code. Fault Code 2192 inactive?
  STEP 4B. Clear the inactive fault codes. All fault codes cleared?

Guided Step 1 – Check the fault codes.

Guided Step 1A – Read the fault codes.

Conditions

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

Fault Code 2192 active?
YES NO
No Repair No Repair

Procedure 019-362

Guided Step 2 – Check the heated oxygen sensor.

Guided Step 2A – Inspect the engine harness and heated oxygen sensor connector pins.

Conditions

  • Turn keyswitch OFF
  • Disconnect engine harness connector 1 and connector 2 from the ECM
  • Disconnect the engine harness from the heated oxygen sensor.

Action

  • Corroded pins
  • Bent or broken pins
  • Pushed back or expanded pins
  • Wire insulation damage
  • 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 Components Connector and Pin Inspection, Procedure 019-361.

Dirty or damaged pins?
YES NO

Repair the damaged pins. 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.
  • Repair the engine harness. Refer to Procedure 019-203.
  • Replace the engine harness. Refer to Procedure 019-043.
  • Replace the heated oxygen sensor. Refer to Procedure 019-100.
 No Repair

Guided Step 2B – Read the fault codes.

Conditions

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

Action

  • Start the engine and let it idle for 1 minute.
  • Use INSITE™ electronic service tool to read the fault codes.

Fault Code 2192 active?
YES NO
No Repair No Repair

Guided Step 2C – Check for an open circuit in the heated oxygen sensor.

Conditions

  • Turn keyswitch OFF
  • Disconnect the heated oxygen sensor form the engine harness
  • Disconnect the engine harness connector 1 and connector 2 from the ECM.

Action

  • Measure the resistance between the heated oxygen sensor heater SUPPLY pin and the heated oxygen sensor heater RETURN pin at the heated oxygen sensor connector.
  • Make sure to check the resistance at room temperature 23°C [73°F] ± 5 degrees.

2.9 to 3.7 ohms at room temperature?
YES NO
No Repair

Replace the heated oxygen sensor. Refer to Procedure 019-100.

Guided Step 3 – Check the engine harness.

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

Conditions

  • Turn keyswitch OFF
  • Disconnect engine harness connector 1 and connector 2 from the ECM
  • Disconnect the engine harness from the OEM harness at the 31-pin OEM connector.

Action

  • Corroded pins
  • Bent or broken pins
  • Pushed back or expanded pins
  • Wire insulation damage
  • 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 Components Connector and Pin Inspection, Procedure 019-361.

Dirty or damaged pins?
YES NO

Repair the damaged pins. Repair or replace the engine harness, or replace the ECM, 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 019-208 or 019-204.
  • Replace the engine harness. Refer to Procedure 019-043.
  • Replace the ECM. Call for pre-authorization. Refer to Procedure 019-031.
 No Repair

Guided Step 3B – Check the supply voltage to engine harness.

Conditions

  • Turn keyswitch OFF
  • Disconnect the engine harness from the OEM harness at the 31 pin OEM connector
  • Turn keyswitch ON.

Action

  • Measure the SUPPLY voltage to the heated oxygen heater SUPPLY pin in the 31-pin connector, OEM side.
SMALL | MEDIUM | LARGE

11 to 14 VDC?
YES NO
No Repair
  • Repair or replace the OEM harness. Refer to the OEM troubleshooting and repair manual.

Note: Make sure that the 10 Ampere fuse is not blown in the OEM harness.

Guided Step 3C – Check for an open circuit.

Conditions

  • Turn keyswitch OFF
  • Disconnect engine harness connector 2 from the ECM
  • Disconnect the engine harness from the heated oxygen sensor
  • Disconnect the engine harness from the OEM harness at the 31 pin OEM connector.

Action

  • Measure the resistance from the heated oxygen heater SUPPLY pin at the 31 pin OEM connector of the engine harness to the heated oxygen heater SUPPLY pin in the engine harness sensor connector.
  • Measure the resistance from the heated oxygen reference SIGNAL pin in the engine harness ECM connector to the heated oxygen reference SIGNAL pin in the engine harness sensor connector.
  • Measure the resistance from the heated oxygen reference RETURN pin in the engine harness ECM connector to the heated oxygen reference RETURN pin in the engine harness sensor connector.
SMALL | MEDIUM | LARGE

Less than 10 ohms?
YES NO
No Repair

Repair the damaged pins. Repair or replace the engine harness, or replace the ECM, 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 019-203 or 019-204.
  • Replace the engine harness. Refer to Procedure 019-043.

Guided Step 3D – Check for a short circuit to ground.

Conditions

  • Turn keyswitch OFF
  • Disconnect engine harness connector 2 from the ECM
  • Disconnect the 31-pin OEM connector from the engine harness
  • Disconnect the engine harness from the heated oxygen sensor.

Action

  • Measure the resistance from the heated oxygen heater SUPPLY pin in the engine harness sensor connector to engine block ground.
SMALL | MEDIUM | LARGE

Greater than 100k ohms?
YES NO
No Repair

Repair the damaged pins. Repair or replace the engine harness, or replace the ECM, 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 019-203 or 019-204.
  • Replace the engine harness. Refer to Procedure 019-043.

Guided Step 3E – Check for a pin to pin short circuit in the engine harness.

Conditions

  • Turn keyswitch OFF
  • Disconnect the engine harness connector 1 and connector 2 from the ECM
  • Disconnect the 31 pin and 23 pin connectors from the OEM harness
  • Disconnect the heated oxygen sensor from the engine harness.

Action

  • Measure the resistance between the heated oxygen sensor SUPPLY pin at the 31 pin OEM connector of the engine harness and all other pins in the 31 pin connector.
  • Measure the resistance between the heated oxygen sensor SUPPLY pin at the 31 pin OEM connector of the engine harness and all other pins in the 23 pin connector.

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

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

Greater than 100k ohms?
YES NO
No Repair

A pin to pin short circuit on the heated oxygen sensor supply line has been detected in the engine harness.

Repair the damaged pins. 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.
  • Repair the engine harness. Refer to Procedure 019-204.
  • Replace the engine harness. Refer to Procedure 019-043.

Guided Step 4 – Clear the fault codes.

Guided Step 4A – 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 Fault Code 2192 is inactive.

Fault Code 2192 inactive?
YES NO
No Repair

Troubleshooting procedures need to be repeated from the beginning.

Guided Step 4B – 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

Troubleshoot any remaining active fault codes.
Repair complete
Appropriate troubleshooting charts
Last Modified:  22-Sep-2004
Avatar photo

Published by Jack

Hello, I'm Jack, a diesel engine fan and a blogger. I write about how to fix and improve diesel engines, from cars to trucks to generators. I also review the newest models and innovations in the diesel market. If you are interested in learning more about diesel engines, check out my blog and leave your feedback.