2005 KJ CRD tow bar wiring short fixed now wont start FIXED

Ludi Neethling · **Joined:** Sat Feb 02, 2013 11:04 am **Posts:** 87

During a recent long distance trip I had to hire a trailer. I did not realize the trailer's wiring was dodgy until I saw that the left indicator light on the dash stayed on continuously. After I returned the trailer I checked the fuses, replaced fuse 9 and completed a 700+ mile journey back home. The engine ran faultlessly.
At home I discovered there was a short, which blew fuse 9 (10 Amp) (Right Park Light/Right Tail Lamp/License Plate Lamp/Cluster). When I started investigating I found that the tow bar wiring was spliced into the rear light wiring instead of connected with the applicable harness. I also identified a break in the insulation of the earth wire of the tow bar wiring.
I disconnected the battery, replaced the wiring from the rear light cluster to the tow bar socket with new wiring and soldered all the joints. I used a test light to check all the connections before I insulated everything and re-installed the tail lights. I replaced the blown fuse (no 9), pulled and checked all the fuses in the cabin as well as in the PDC under the hood.
Upon connecting the battery and turning on the ignition it was back to the original problem (blown fuse and rear lights not working properly. I disconnected the tow bar wiring and now all the rear lights work perfectly.
Now the engine cranks but will not start. SKIM light comes on as well as the "lightning bolt". The fuel meter shows zero and the low fuel warning light comes on (there is diesel in the tank).

I only have an Autel AL301 scanner which shows the following DTC's:
0047 Turbocharger Boost pressure Solenoid Short Circuit to Ground.
0091 Fuel Quantity Solenoid Short to ground.
0489 EGR Solenoid Circuit Short Circuit
0562 Battery Voltage low.
0670 Glow Plug Control Circuit Malfunction.
1251 Vacuum Reservoir Solenoid Short to ground.
2141 EGR Air Flow Valve Short to ground.
2295 Fuel Pressure Solenoid Short to ground.
Tried to erase codes but when I scan again I get the same codes.
I am a novice when it comes to auto electronics, so any assistance/suggestions would be highly appreciated.

flash7210 · **Posted:** Tue Jan 21, 2020 8:28 pm

Could be:

Blown ASD fuse

Bad ASD relay

Bad SKIM module

Or ignition key lost its code.

My guess is the ASD fuse. It’s happened to me before.
Also wouldn’t hurt to put the battery on a charger just to make sure it’s fully charged.

Billybob · **Posted:** Wed Jan 22, 2020 2:17 am

Ludi, If the SKIM light comes on solid and the engine turns over but refuses to fire...it means that the ECM is happy with the SKEES code it got from the SKIM module on top of the steering column
The ECM then energizes the ASD relay.
The ECM then expects to receive acknowledgement from the ASD Relay that it...the Relay...has in fact energized. If it does not receive this signal then you get the SKIM light ON as you have.

I had this exact problem on my 2002 Export CRD.
The one lead going to the coil on the ASD Relay had broken somewhere in the wiring loom...I cut off the existing wire and replaced it with a new one. You need to flip over the Relay Box (PDC) to get to the wiring...check if you get +12 volts where needed and ground where needed.
You can also carefully open the ASD Relay so that you can physically see if the contact is moving.

You have so many codes registered though that you may have a bigger problem somewhere causing a this error and other errors....check all fuses first...mainly the ASD fuse and swap the ASD Relay over with an identical one nearby.
Main fuses to check under the hood are F6 30A, F16 15A and F26 25A....best to check all fuses.
Ground for the ECM is G100 bolted to the Firewall below Left Wiper I think.

First thing is to get the ASD Relay energizing properly and making good contact inside. and as Flash posted it is worth charging the battery up!

Is your Tow Package the Factory fitted one with several relays at work or are all the wires from the tow-bar connector spliced into the tail light assembly?

I presume you have the 2005 KJ Service Manual with the wiring diagrams?
You will need a digital multimeter....test lights are pretty limited in diagnosing wiring issues.

The problem with my 2002 RHD Export 2.5 CRD is that a wire from Point A to Point B does not take the shortest route but travels around the whole engine bay and goes through a metal tube under the radiator.....a distance of about 8 feet! Probably your 2005 RHD CRD has the wire routing the same but hopefully your issue is something simpler!

I had a lot of wire damage up front when my GF drove into a tree that jumped in front of her.
Every few months I pick up another problem..... find bad wiring....cut off the bad wiring and its splices at all ends and replace with new wires taking the shortest route. I have replaced about 14 bad wires so far and have marked my changes on the wiring diagrams which I will leave inside the vehicle for the poor new owner of my Jeep if I ever do sell it! :wink:

Ludi Neethling · **Joined:** Sat Feb 02, 2013 11:04 am **Posts:** 87

flash7210
I checked all the fuses in the cabin and under the hood. Only fuse no 9 in the cabin was blown.
I swapped the ASD relay with the "Radiator Fan Low" relay which is the same.
I've charged the battery.
How do I determine if the SKIM module is busted?
What would cause the loss of the ignition key code? Do I have to contact the dealership to rectify this?

Billybob
I do have a volt meter. I am actually tip-toeing when it comes to auto electronics because I realize what can go wrong if I screw up. I was actually worried about the fact that I used a soldering iron on the tail lights wiring which could have damaged one of the modules (BCM, etc.)
I will start by checking the power feed to the ASD relay.
I am the second owner. The tow bar was already fitted when I got the Jeep in 2013. The wires are spliced in.
I do have the wiring diagrams.
This is the first time since getting the Jeep that I am totally stumped. Why all those fault codes? Could it be that a specific part of the wiring that feeds all those components got damaged while I tried to sort out the tow bar short?

Ludi Neethling · **Joined:** Sat Feb 02, 2013 11:04 am **Posts:** 87

I am so glad nobody can see my face right now :oops:

When I pulled all the fuses in the PDC I inadvertently put Fuse 16 (ASD Feed 15 Amp) into slot 17. Fortunately, before I started taking out the PDC to check the ASD power feed I saw this. I corrected this and the engine started immediately.

Flash and Billybob. I am so sorry for wasting your time and expertise due to my negligence. Thank you for your assistance.

As an aside, I assume the fault codes I listed were stored when I replaced the glow plugs and injectors some time ago.

Hopefully someone else will learn from my stupidity.

TKB4 · **Posted:** Wed Jan 22, 2020 11:16 am

don't feel bad I have probably wasted more of theirs and others time and like you said its not really wasted . others cab learn from it. I know I have overlooked early simple things.

Billybob · **Posted:** Wed Jan 22, 2020 1:51 pm

When I make a stupid mistake I always claim something like "I found fuse 25 was blown" :oops:

Glad it is working...definitely try clear all your stored codes now...always good to have a clean slate for when a new error appears. :wink:

WWDiesel · **Posted:** Wed Jan 22, 2020 3:49 pm

Everyone makes mistakes, it takes a real person to admit to them. :5SHOTS:

Glad you solved the problem and it turned out not to be nothing major. :BANANA:

Ludi Neethling · **Joined:** Sat Feb 02, 2013 11:04 am **Posts:** 87

Thank you Guys.

The fault codes have been deleted, Check Engine Light is off and the Jeep is back to normal.

I still need to re-connect the tow bar wiring. Contacted dealer yesterday for Mopar harness. They will try to get one but did not sound to optimistic about it. Has anyone made up their own harness and if so what relay, etc. is needed?

Billybob · **Posted:** Fri Jan 24, 2020 8:14 am

Ludi check the 2005 Jeep KJ Service Manual Wiring section 8W

I Have personally not delved into the Tow Bar wiring as mine has never given me any problems on my 2002 Export CRD Sport.

When I ordered my Jeep in early 2002...stating color, interior etc. I ordered the Tow Package, Mud Flaps, Roof Rack etc. but I believe the Tow Package was not a factory option on the Sport Models and Cargo Motors in Randburg I believe sent my Jeep to a local fitment centre nearby to connect it all up.

I suspect that they merely tapped into the existing wiring as I cannot find any extra relays!

The Tow Package basically has a separate relay for each lamp....instead of the brake switch energizing the tow brake lamps it energizes the Jeep Brake lights and a separate relay for the tow bar brake lights for example.

So look through the Wiring Diagrams and see if you have these extra relays installed..if not...it is not the end of the world if you tap directly into the existing harness so that the trailer lamps are in parallel with your Jeep lamps. I am pretty sure that is how my Jeep is connected...maybe with uprated fuses! :wink:

WWDiesel · **Posted:** Fri Jan 24, 2020 4:37 pm

Looking at the FSM, http://www.colorado4wheel.com/manuals/Jeep/KJ/

see section 8W-54 in the 2005 FSM Manual. There are four (4) Power Relays.
2005 FSM Manual:> http://www.colorado4wheel.com/manuals/J ... Manual.pdf

They are shown as simple common five lug relays like are used on aftermarket Fog lamps and a multitude of other applications.
Basic Relay:

12v Power Supply w/relay to Trailer Towing Connector:

Brake & Turn Signal Circuits w/relays to Trailer Towing Connector:

WWDiesel · **Posted:** Fri Jan 24, 2020 4:57 pm

Another option I have used on many, many vehicles that have separate turn signal lights from the brake and tail/running lights is to use a converter box.
It converts the separate turn signal and brake/tail/running light signals into one signal for each side L&R.
This could be used in place of the factory relay system if you wanted to abandon the OEM wiring and use existing tail/brake/turn circuits using a converter box of this type.
For me though, I would try and fix/repair existing wiring & relays even if I had to replace some of the existing wiring if it got toasted.

Ludi Neethling · **Joined:** Sat Feb 02, 2013 11:04 am **Posts:** 87

Thank you Billybob & WWDiesel.
I think the relay option is the one I'll go for.
Your feedback is really appreciated.

TKB4 · **Posted:** Sat Jan 25, 2020 11:24 am

I used a similar kit to the curtis WW posted pic of on one of mine just for a flat 4 way connector. The one I got from them even worked with LED bulbs without resistors. It just plugged in where twilight assembly does then plug the original plug into it. i believe I had to run one wire from twilight on opposite side and ground a wire to install. Seems like they had a 7 way kit also. It wasn't very expensive seems about $40.

2005 KJ CRD tow bar wiring short fixed now wont start FIXED

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