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Electronic Control System Gas Plus Engines – FAULT CODE 442

Battery Number 1 Voltage High – Data Valid but Below Above Operational Range – Moderately Severe Level

Overview

CODE REASON EFFECT
Fault Code: 442
PID: P168
SPN: 168
FMI: 1/16
LAMP: Amber
SRT: 

Battery Number 1 Voltage High – Data Valid but Above Normal Operational Range – Moderately Severe Level. ECM supply voltage is above the minimum system voltage level.

Possible electrical damage to all electrical components.

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 442 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 and 15.0 VDC?
  STEP 2C. Determine voltage on the 12 VDC side of the OEM voltage regulator. Voltage between 11.5 and 15.0 VDC?
STEP 3. Check the charging system.  
  STEP 3A. Inspect the alternator for correct charging voltage. Charging system performing properly and voltage between 11.5 VDC and 15.0 VDC?
STEP 4. Check the OEM a harness.  
  STEP 4A. Inspect the OEM harness and connector pins. Dirty or damaged pins?
  STEP 4B. Check the voltage at the 23 pin OEM connector. Voltage between 11.5 VDC and 15.0 VDC?
  STEP 4C. Check for an inactive fault code. Fault Code 442 inactive?
STEP 5. Clear the fault codes.  
  STEP 5A. Disable the fault code. Fault Code 442 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 442 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 troubleshooting and repair 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 troubleshooting and repair manual.

Guided Step 3 – Check the charging system.

Guided Step 3A – Check the alternator for correct charging voltage.

Conditions

  • Turn keyswitch OFF.

Action

  • Refer to Procedure 013-001 in the C8.3g (Natural Gas) Engines Troubleshooting and repair manual, Bulletin 3666206 or Procedure 013-001 in the B5.9G, B5.9LPG, B Gas Plus, and B LPG Plus Troubleshooting and Repair Manual, Bulletin 3666164.

Charging system performing properly and voltage between 11.5 VDC and 15.0 VDC?
YES NO
No Repair

A defective charging system has been detected.

Repair the charging system.

Refer to Procedure 013-001 in the C8.3g (Natural Gas) Engines Troubleshooting and repair manual, Bulletin 3666206 or Procedure 013-001 in the B5.9G, B5.9LPG, B Gas Plus, and B LPG Plus Troubleshooting and Repair Manual, Bulletin 3666164.

Guided Step 4 – Check the OEM harness.

Guided Step 4A – Inspect the OEM harness 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.

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 23 pin OEM connector.

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 23 pin OEM connector.

Conditions

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

A high voltage source in the OEM harness has shorted to one of the unswitched battery supplies.

Repair or replace the OEM wiring harness.

Refer to the OEM troubleshooting and repair manual.

Guided Step 4C – 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 442 inactive?
YES NO
No Repair No Repair

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 442 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:  01-Sep-2004
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