NUMBER:
GROUP:
DATE:

25-002-14
Emissions Control
August01 , 2014

This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of Chrysler Group LLC.

THIS SERVICE BULLETIN IS ALSO BEING RELEASED AS RAPID RESPONSE
TRANSMITTAL (RRT) 13-014. ALL APPLICABLE SOLD AND UN-SOLD RRT VIN's
HAVE BEEN LOADED. TO VERIFY THAT THIS RRT SERVICE ACTION IS
APPLICABLE TO THE VEHICLE, USE VIP OR PERFORM A VIN SEARCH IN
TECHCONNECT. ALL REPAIRS ARE REIMBURSABLE WITHIN THE PROVISIONS OF
WARRANTY.
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 25-003-13, DATED MARCH 01,
2013 AND 25-004-13, DATED AUGUST 15, 2013, WHICH SHOULD BE REMOVED
FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS WILL BE
INCLUDED.
SUBJECT:
Malfunction Indicator Lamp Illumination Due To Oxygen Sensor
OVERVIEW:
This bulletin involves the installation of an Oxygen (02) Sensor Overlay Harness for any
Oxygen Sensor related DTC(s). The Overlay Harness will consist of twelve 18 AWG wires
(six from each Oxygen Sensor) that run to a new Oxygen Sensor Module connector. Four
wires will be removed from the original vehicle 02 Module connector and installed in the
new overlay harness 02 Module connector.
Do NOT replace any parts prior to performing this bulletin and the Verifications test below.
MODELS:
2010-2012

(DJ)

Ram Pick Up (2500)

2010 - 2012

(D2)

Ram Pick Up (3500)

NOTE: This Bulletin applies to vehicles equipped with a Cummins 6.7L engine (sales
code ETJ)

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-2-

SYMPTOM/CONDITION:
If the vehicle has any of the following DTC's for 02 Sensors, Stored, Pending or
Active, perform the Repair Procedure.
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P013A 02 Sensor 1/2 Slow Response - Rich To Lean (Soot related code , see
P013B 02 Sensor 1/2 Slow Response - Lean To Rich (Soot related code, see
P014C 02 Sensor 1/1 Slow Response - Rich To Lean (Soot related code , see
P014D 02 Sensor 1/1 Slow Response - Lean To Rich (Soot related code , see
P0030 02 Sensor 1/1 Heater Circuit
P0031 02 Sensor 1/1 Heater Circuit Low
P0032 02 Sensor 1/1 Heater Circuit High
P0036 02 Sensor 1/2 Heater Circuit Malfunction
P0037 02 Sensor Heater Circuit Low 1/2
P0038 02 Sensor Heater Circuit High 1/2
P0053 02 Sensor Heater 1/1 Resistance
P0054 02 Sensor Heater 1/2 Resistance
P064D Internal Control Module 02 Sensors Processor Performance - Bank 1
P0131 1/1 02 Sensor Shorted To Ground
P0132 1/1 02 Sensor Shorted To Voltage
PO 135 02 Sensor 1/1 Heater Performance
P0137 1/2 02 Sensor Shorted To Ground
P0138 1/2 02 Sensor Shorted To Voltage
P0141 02 Sensor 1/2 Heater Performance
P113C 02 Sensor Power Supply Circuit Performance
P2195 02 Sensor 1/1 Out Of Range High
P2196 02 Sensor 1/1 Out Of Range Low
P22AB 02 Sensor Positive Current Control Circuit/Open - Bank 1 Sensor 2
P22AE 02 Sensor Reference Voltage Circuit/Open - Bank 1 Sensor 2
P22B2 02 Sensor Negative Current Control Circuit/Open - Bank 1
P22B5 02 Sensor 1/2 Pump Cell Current Trim Circuit Open
P2237 02 Sensor 1/1 Pump Cell Current Circuit Low
P2243 02 Sensor 1/1 Reference Voltage Circuit Open
P2251 02 Sensor 1/1 Negative Current Control Circuit/Open
P2270 02 Sensor 1/2 Out Of Range High
P2271 02 Sensor 1/2 Out Of Range Low
P241A 02 Sensor 1/1And1/2 Oxygen Concentration Mismatch
P2626 02 Sensor 1/1 Pump Cell Current Trim Circuit/Open
P2AOO 02 Sensor 1/1 Circuit Performance
P2A01 02 Sensor 1/2 Circuit Performance
U011A Lost Communication With Exhaust Gas Sensor Module

note)*
note)*
note)*
note)*

NOTE: Soot related codes noted above with an asterisk(*) may be the result of other
system(s) and must be validated as described on the Diesel Diagnostic
Worksheet, Section 4D. Vehicles that DO NOT pass the Validation Test
require further diagnosis to determine the cause of excess soot build up.

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25-002-14

DIAGNOSIS:
Vehicles that exhibit any DTC 's should always have a Scan report generated and saved .
Vehicles that exhibit any DTC 's listed above required you to complete a Diesel Diagnostic
Worksheet per instructions in Service Bulletin 18-016-14 Dated March 12, 2014 and U. S.
Warranty Bulletin D-11-55 Dated May 10, 2012 . All DTC's need to be recorded on the
WRO and DTC's other than the ones listed above may require additional diagnosis and
repair after completing this Bulletin .

Vehicles that exhibit ANY DTC('s) (Stored or Active) , pertaining to Oxygen Sensors or
Oxygen Sensor related components must have this Repair Procedure completed BEFORE
any parts are replaced .
SPECIAL TOOLS I EQUIPMENT REQUIRED:

NPN

Soldering Iron

NPN

Electrical Tape

NPN

Wire Stripper I Cutter

NPN

Narrow Blade, Flat Screwdriver (3mm Wide Max)

1 (AR)

Molex Terminal Release Tool. MX 150-MX150L I 63813-1500
(Molex) OR

1 (AR)

A 1 mm Drill Bit (CHAMFERED ON THE NON-CUTTING
END) and Handle From Miller Tool #8351 Which is Part of Kit
8283 or 8529)

1 (AR)

05019912AA Mopar (Miller Tool# 10042)

(AR)

Rosin Core Solder

1 (AR)

Heat Gun I Compact Torch

PARTS REQUIRED:

Qty.

Part No.

Description

1

68250763AA

Harness, Oxygen Sensor Overlay

NOTE: Prior to replacing any parts, (Oxygen Sensors, Oxygen Sensor Module,
Transmission Wiring Harness or PCM) perform the Repair Procedure below
and also perform an Oxygen Sensor Verification test drive also described
below.
NOTE: Vehicles experiencing P013A, P013B, P014C or P014D DTC's must have the
Aftertreatment Validation Test (Section 40 of the Diesel Diagnostic
Worksheet) performed to ensure excess soot is not causing the DTC(s). IF
excess soot is found during Aftertreatment Validation Test, perform
appropriate repairs to eliminate soot accumulation. The repair procedure
below should be performed regardless of outcome or repairs performed for
other issues.

25-002-14

-4-

REPAIR PROCEDURE:
The Oxygen Sensor harness , (connecting the Oxygen Sensor Module to both of the
Oxygen Sensors) will now be serviced with an over-lay harness.
Please read through the entire REPAIR PROCEDURE before performing the repai r.
1. Open hood .
2. Disconnect and isolate both negative battery cables.
3. Raise and support vehicle on a suitable hoist.
4. Position the overlay harness, p/n 68250763AA starting at the rear Oxygen Sensor
(tagged #2 on the overlay harness) following the existing harness loosely securing with
wire ties , (included) . Pay close attention to the location designation of the Oxygen
Sensor connectors on the overlay harness . Do not secure too close to the Sensor or
the Module at this time. Extra length of the overlay harness can be taken up as a loop
between components .
5. Disconnect and cut the wires on the original vehicle harness at the vehicle side of the
connector near the rear Oxygen sensor.
6. Tape up the cut end of the convolute tubing and secure .
7. Clean (with shop air) the rear Oxygen Sensor connector and secure to the Overlay
Harness Oxygen Sensor connector ensuring lock tab snaps into place .
8. Disconnect and cut the wires on the original vehicle harness at the vehicle side of the
at the connector near the front Oxygen sensor.
9. Tape up the cut end of the convolute tubing and secure.
10. Clean (with shop air) the front Oxygen Sensor connector and secure to the Overlay
Harness Oxygen Sensor connector ensuring lock tab snaps into place .
NOTE: In the following steps, four of the terminals will be removed from the original
Oxygen Sensor Module connector and installed in the 68250763AA overlay
harness Oxygen Sensor Module connector. Of those four terminals, some
MY11 trucks were built with tin terminals and should have been gold plating.
Three of the four terminals, (if required, determined below) will need to be
replaced with the gold plated terminals supplied in the 68250763AA kit.
NOTE: Do NOT cut the original Oxygen Sensor Module connector wiring until
instructed to do so.
11 . Disconnect the original Oxygen Sensor Module Connector and remove the
protective tape and plastic shield on the connector.
12. Carefully cut the tape securing the convolute tubing to the wiring near the new Oxygen
Sensor Module connector and pull convolute tubing off wire bundle about 8" (203 MM)
from connector.
13. The four terminals that need to be removed from the original vehicle 02 Sensor
Module connector and installed in the overlay 02 Sensor Module connector are
term inals 3, 9, 10 and 11 as shown in (Fig. 1). Terminal 10 will always be gold plated .
Terminals 3, 9 and 11 will need to be inspected on MY 2011 vehicles for plating to
determine if new terminals are required .

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25-002-14

8

16

Fig. 1 FOUR WIRES FROM TRUCK MUST BE TRANSFERED TO OVERLAY HARNESS
1 - Terminal 10 -Always a Gold Plated Terminal
2 - Terminals 3, 9 and 11 - Must be Inspected on Model Yea r 20 11 For Gold Plating

14. To release the terminals from the original Oxygen Sensor Module connector; use a
narrow blade, flat screwdriver (3 mm wide max), and pry the white TPA (white cover
seen when looking in connector). Notice the travel of wh ite TPA is only .2" (5 mm) or
until a "click" is heard . This is the release point of the TPA. The TPA is a device that
locks the release finger so that when seated , terminal will not and cannot be
disengaged , (Fig. 2) and (Fig . 3). Do not extend the TPA past .2" (5 mm) or the TPA
may be damaged.

Fig. 2 LIFT TPA 5MM

25-002-14

-6-

Fig. 3 PROPER EXTENSION OF TPA
1 - TPA Extended .2" (5MM)

NOTE: Terminal #10 is ALWAYS gold plated and is not required to be changed ON
ANY APPLICATION. Inspect terminal #10 to see what the gold terminals look
like for a reference when inspecting terminals #3, 9 & 11 in the following
steps.
15. Starting with terminal #10 (Fig . 4 ), push the wire into the connector from the back, and
while keeping the tool or drill at 90° angle to the face of the TPA, push the tool or drill
in until it releases the lock finger in the connector as shown in (Fig . 5). At this point the
wire should pull out the back. As the terminal is removed ; note the orientation of the
terminal in the connector for ease of installation later.

25-002-14

-7-

8

I

16

9

Fig. 4 TERMINAL 10 IS A GOLD TERMINAL
Remove Terminal 10

Fig. 5 INSERT TOOL IN SERVICE PORT ADJACENT TO THE TERMINAL TO BE
REPLACED
1 - 1MM Drill Bit Used as Service Tool

NOTE: Do NOT cut the original Module connector wiring until instructed to do so.
(Not all wires will be cut).

25-002-14

-8-

NOTE: If necessary to do any splicing in the following steps, use ONLY the brass,
Mopar splice band 05073034AA (included in 68250763AA) and always CRIMP
AND SOLDER, per instructions below.
16. Remove the other three terminals (one at a time) to be replaced (connector terminal
numbers 3, 9 and 11 ), start with #3 .
a. Insert either J-38125-217 (Kent Moore number) OR MX 150-MX150L I 63813-1500
(Molex) OR a fabricated tool , (cons isting of a chamfered 1mm drill bit installed with
the cutting end of the drill in the handle of Miller Tool #8351 ), into TPA (module side
of connector) into the desired "service port" until resistance is felt. Push the wire into
the connector slightly, then push tool in to release the terminal.
b. For Model Year 2011 only; Inspect terminal end for gold plating , (compare to
terminal #10 previously inspected in Step #15). If plating of terminal is NOT gold ,
replace the term inal pigtail with gold plated terminals supplied in the kit, p/n
68250763AA by proceeding to Step 16 (d) . Repeat this for terminals in cavities 9
and 11.
c. If terminals are gold already or the vehicle is a 2010 or 2012 , proceed to Step #17.
d. If terminals are tin ; cut terminal #3 wire near the Oxygen Sensor Module connector
on the overlay harness .
e. Slide heat shrink tube on wire prior to splicing. Strip insulation on each wire and
crimp together using BRASS band clamp BEFORE SOLDERING using Mopar
splice band tool, pin 05019912AA (or equivalent) then solder the crimped
connection and heat shrink each wire individually.
17. Working with the Overlay Harness Oxygen Sensor Module connector; use a narrow
blade , flat screwdriver (3 mm wide max), and pry the white TPA (white cover seen
when looking in connector). Notice the travel of white TPA is only 5 mm or until a
"click" is heard. This is the release point of the TPA. The TPA is a device that locks the
release finger so that when seated , terminal will not and cannot be disengaged ,(Fig. 2)
and (Fig. 3) above.
18. Install the terminals into the connector through the insulator noting proper orientation
of terminal as noted in Step #15 above.
19. Repeat Steps 16d and 16e for the remaining two terminals (#9 & #11) making splices
in a staggered manner, to eliminate bulk in the harness.
20 . Clean (with shop air) Oxygen Sensor Module connector and secure connector to the
module .
21. Cut the other remaining 12 wires from the original Module connector about 8" (203
MM) from connector.
22. Tape the wire bundle toward the connector, then Install and tape the plastic connector
shield to the connector body and install the removed convolute tubing adjacent to the
connector body with a continuous tape wrap joining the four wires from the vehicle
harness forming a "Y".
23. Tape wires together then install and tape the removed convolute tubing adjacent to the
connector body.
24. Inspect and clean (with shop air) Oxygen Sensor Module connector terminals and
secure connector to the vehicle harness .
25 . Secure all wiring with additional wire ties as necessary and tighten up loosely installed
wire ties and trim wire tie tails .
26 . Lower vehicle , reconnect batteries .
27. Perform Verification below.

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25-002-14

Verification:
Verification will ensure Oxygen Sensors are properly "relearned" and functioning as
desired.

1. Ensure PCM software is current. If software is not current, please update software
using appropriate Service Bulletin .
2. Connect WiTECH to vehicle if not already connected .
3. Operate the vehicle until warm and then drive the vehicle at 50 MPH . Perform a zero
fueling event (deceleration condition for 10 seconds, with foot off of accelerator pedal) .
Repeat 3-5 times.
4. Monitor Oxygen Sensor percent in WiTECH , Data Display; percent should not vary
more than 4 .0% from each other during any of the drive events . Variance of greater
than 4% will result in MIL illumination .
5. Further diagnosis will be required if variance is exceeded . Refer to TechCONNECT for
DTC(s) set during verification.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:

Description

Amount

08-90-24-94

1.0Hrs.
MY 10 - 12, Harness, Oxygen Sensor Overlay,
Install - Includes Verification Road Test (2 - Skilled)

08-90-24-95

MY 11 - Additional Time Necessary to Install Gold
Terminals (2 - Skilled)

FAILURE CODE:

lzz

IService Action

1.1Hrs.