TRUCK SURGES WHILE RUNNING

2003 Dodge Ram Truck 4x4 surges while driving.And check engine light came ON.

Got the truck engine module scanned.

RECEIVED MULTIPLE OBD ERROR CODES

List of received error codes:---
P0633, P0837, P0839, P2121, P2122.

Its 5.9 Cummins Engine with Standard Transmission.

NOW FROM WHERE TO START THE TROUBLESHOOTING?

Its a multiple error code issue.There are few different parts in your vehicle that needs to be inspected.
First you need to know what this codes are telling and i want to know If you have replaced the ECM(engine control module) on your vehicle or not.

OK, ECM IS NOT REPLACED?

Why i asked about ECM got replaced because of error code P0633.

The error code P0633 sets when the SKIM information hasn't been properly transferred to the ECM after replacement. If  ECM replaced then  this code set because ECM is not programmed and just replaced. This code tells you to get the New ECM programmed.

But as you mentioned above that ECM is not replaced in your vehicle then the code is set erroneously or because of an aftermarket programmer being used. This code isn't related to the problem you are having.
Its nothing to worry,but other codes are.

OK,WHAT EXACTLY THESE ALL ERROR CODES MEAN?

The other codes which you noticed are real problems.
The Error code P0837 and P0839 are both for the transfer case position sensor. These could be wiring or the sensor itself.Mostly its the sensor problem.
But this both error codes are not related to your driveability problem.Yes its related to transfer case position sensor but not related to vehicle surges while driving.

And Error codes .
P2121 and 2122 are both for the accelerator pedal position sensor (APPS).
And this error codes are definitely related to drive ability issues which are noticing.

OK,WHERE IS APPS LOCATED?


The APPS (Accelerator pedal position sensor) is  mounted to the bracket under the black plastic cover at the left front corner of the cylinder head.Its exactly where the throttle cables enter. On the back of the bracket is the APPS. These sensor tells the ECM how far the throttle is open.But if the signal from this sensor is incorrect then ECM will not control the throttle and you notice such problems.
Vehicle surges, hesitates,stalling,jerks,stumbling etc.

SO SHOULD I REPLACE ACCELERATOR PEDAL POSITION SENSOR

Before replacing this sensor i suggest to inspect the wiring.
Error codes P2121 and 2122 can be caused by a wiring problem between the sensor and ECM, or the sensor itself, or problem with the ECM.
Wiring or the ECM are possible but not common at all, although failures of the APPS is majorly noticed. What I would recommend is a visual inspection of the wiring and connection, try cleaning the Sensors plug terminals then re-insert and see if its helping.But if wiring checked ok and cleaning the Accelerator pedal position sensor connectors is not helping  then replace the APPS.That will solve the problem.

This details will help.
Thanks.

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how to test Chevy accelerator pedal sensor and other parts?

The accelerator pedal or lever position sensor sends a signal to the ECM when the operator pushes on the accelerator pedal or lever. The accelerator position circuit consists of the accelerator pedal or lever position sensor, the ECM, accelerator pedal/lever position +5 volt, accelerator pedal/lever position signal, and accelerator pedal/lever position return wires.

Then monitor the accelerator position sensor for proper operation. If not, follow the troubleshooting procedures in this section. Disconnect the 3-pin connector from the accelerator position sensor.

Connect the test connector.

Connect the multimeter positive (+) test lead to the accelerator pedal/lever position +5 volt supply test connector wire. Connect the negative (-) multimeter test probe to the accelerator pedal/lever position return test connector wire. Measure the resistance. The multimeter

must show between 2000 and 3000 ohms when the accelerator pedal is released (idle position) or depressed (full -fuel position). If the resistance is not within the specification, the accelerator position sensor has failed. Replace the accelerator position sensor.

Remove the multimeter probe from the accelerator pedal/lever position +5 volt supply test connector wire and connect it to the accelerator pedal/lever position signal test connector wire.

When the accelerator pedal is in the released (idle) position, measure the resistance. The multimeter must show between 1500 and 3000 ohms.

Depress the accelerator pedal assembly (full-fuel position) and measure the resistance. The multimeter must show between 250 and 1500 ohms. This resistance value must be at least 1000 ohms lower than the resistance value of 1500 to 3000 ohms measured in the above check. If the resistance values in the two previous steps are not within the specification, the accelerator position sensor has failed. Replace the accelerator position sensor according to the vehicle manufacturer's procedures.

NOW TO CONFIRM ITS FAULTY WIRING OR FAULTY APS.

Check short circuits for ground wiring and connections:----

Connect the multimeter positive (+) probe to the accelerator pedal/lever position return test connector wire. Touch the negative (-) multimeter probe to the chassis ground and measure the resistance. The multimeter must show an open circuit (100k ohms or more).

Remove the multimeter positive (+) probe from accelerator pedal/lever position return test connector wire and connect it to the accelerator pedal/lever position signal test connector wire. Measure the resistance. The multimeter must show an open circuit (100k ohms or more).

Remove the multimeter positive (+) probe from the accelerator pedal/lever position signal test connector wire and connect it to the accelerator pedal/lever position +5 volt supply test connector wire. Measure the resistance. The multimeter must show an open circuit (100k ohms or more). If the resistance values are not within the specifications in the previous check, the

accelerator position sensor has failed. Replace the accelerator position sensor according to the vehicle manufacturer's procedures.

To replace the accelerator pedal sensor follow this procedure as follows:------

Accelerator Pedal Position Sensor Replacement

REMOVAL PROCEDURE:---


Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type.

1. 
   
   

   Right click on the image and select option "open image in new web" if the image is not seen full or its very small to see.-----------

   
   
2. Remove the connector position assurance (CPA) retainer.
3. Disconnect the accelerator pedal position (APP) sensor electrical connector.
4. Reposition the carpet to access the lower nut.
   
   

   Right click on the image and select option "open image in new web" if the image is not seen full or its very small to see.-----------

   
   
5. Remove the accelerator pedal nuts.
6. Remove the accelerator pedal assembly.

INSTALLATION PROCEDURE:----

1. Install the accelerator pedal assembly. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
   
   
2. Install the accelerator pedal nuts. Tighten
   Tighten the nuts to 20 N·m (15 lb ft).
   
3. Connect the APP sensor electrical connector.
   
4. Reposition the carpet.
5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
7. Verify that the vehicle meets the following conditions:

   •	The vehicle is not in a reduced engine power mode.

   •	The ignition is ON.

   •	The engine is OFF.

8. Inspect the carpet fit under the accelerator pedal
9. 
   
10. 
    
11. ----------------------
12. For checking tachometer:----
13. In vehicles equipped with this connector, a tachometer may be connected between terminals 6 and G.
    A tachometer connection is incorporated in the wiring connector on the side .
14. 
    Never connect a wire directly between the Tach terminal of the connector and ground as this will damage the electronic circuitry of the module. When using a timing light to adjust ignition timing, the connection should be made at the No. 1 spark plug. Forcing foreign objects through the boot at the No. 1 spark plug terminal will damage the boot and cause engine misfire.
    
    
15. To find a tachometer wire with a multi-meter:
    1. Set meter to AC voltage.
    2. Attach the (-) probe of the meter to chassis ground.
    3. Start and run the vehicle
    4. Probe the wire suspected of being the tachometer wire with the other prob
    5. If this is the correct wire, the meter will read between 1V and 6V. This wire will increase in voltage as the RPMs are increased.----------------------------------
16. Connect the tachometer tester probe to terminal IG of the Data Link Connector . Connect terminals TE1 and E1 of the DLC1 with a jumper connector.Inspect the tachometer's timing. It should be between 8 and 12 degrees Before Top Dead Center. Set the timing as necessary.Tighten the hold-down bolt and make sure the ignition timing advances.
17.