File: 06-t05-325 Page 1 of 14

FAULT CODE 325 - Injector Solenoid Driver Cylinder 6 Circuit - Current Below
Normal or Open Circuit
TROUBLESHOOTING SUMMARY

WARNING
The injector solenoids receive high voltage when the engine is operating. To reduce the possibility of
personal injury from electrical shock, do not wear jewelry or damp clothing, and do not touch the injector
solenoids or the solenoid wires when the engine is operating.

CAUTION
To reduce the possibility of damaging a new engine control module (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 3164133 - male Deutsch™ test lead, Part Number 3164132 - female Deutsch™ test
lead, Part Number 3822758 - male Deutsch™/AMP™/Metri-Pack™ test lead, and Part Number 3822917 - female
Deutsch™/AMP™/Metri-Pack™ test lead.

STEPS SPECIFICATIONS SRT CODE

STEP 1: Check for active fault codes.
STEP 1A: Read the fault codes with Fault Code 325 active?
INSITE™ electronic service tool.
STEP 1B: Read the fault codes with Fault Codes for other injectors
INSITE™ electronic service tool. on the same bank active?
STEP 2: Check the injector and injector circuit for an open circuit.
STEP 2A: Inspect the engine harness Connector properly connected?
connections.
STEP 2B: Inspect the engine harness and Dirty or damaged pins?
ECM connector pins.
STEP 2C: Check for an open circuit. Less than 2 ohms?
STEP 2C-1: Check for high resistance or Less than 2 ohms?
an open circuit in the
injector solenoid and
circuit.
STEP 2D: Check for high resistance or an Fault code follow the injector?
open circuit in the injector
solenoid.
STEP 3: Check the engine harness.
STEP 3A: Inspect the engine harness and Dirty or damaged pins?
injector pass-through connector
pins.
STEP 3B: Check the injector harness Greater than 100k ohms?
circuits for short circuits to
ground.
STEP 3C: Check the injector solenoids for Greater than 100k ohms?
short circuits to ground.
STEP 4: Isolate the ECM or injector malfunction.
STEP 4A: Check for active fault codes. Same or multiple (same bank)
injector fault codes active?
STEP 4A-1: Injector isolation. Multiple (same bank) injector
fault codes active?

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
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File: 06-t05-325 Page 2 of 14

STEP 4A-2: Injector isolation. Multiple (same bank) injector

fault codes active?
STEP 4A-3: Check for active fault codes. Multiple (same bank) injector
fault codes active?
STEP 5: Clear the fault codes.
STEP 5A: Disable the fault code. Same or multiple (same bank)
injector fault codes active?
STEP 5B: Clear the inactive fault codes. All fault codes cleared?

TROUBLESHOOTING STEP

STEP 1: Check for active fault codes.

STEP 1A: Read the fault codes with INSITE™ electronic service tool.
Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Operate the engine and observe the fault codes. Fault Code 325 active? 1B
• Use INSITE™ electronic service tool to clear YES
the fault codes.
• Operate engine and let it idle for 1 minute.
• Use INSITE™ electronic service tool to read Fault Code 325 active? Refer to
the fault codes. NO Procedure
019-362 in
Section 19.

STEP 1B: Read the fault codes with INSITE™ electronic service tool.
Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Read the fault codes. Fault codes for other injectors on the same 3A
• Use INSITE™ electronic service tool to read bank active?
the fault codes. YES
Note: Cylinders 1, 2, and 3 (Cylinders 1 and 2 for
4-cylinder engines) are on the same injector Fault codes for other injectors on the same 2A
bank. Cylinders 4, 5, and 6 (Cylinders 3 and 4 for bank active?
4-cylinder engines) are on the same injector
bank. NO

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
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File: 06-t05-325 Page 3 of 14

STEP 2: Check the injector and injector circuit for an open circuit.
STEP 2A: Inspect the engine harness connections.
Condition:
• Turn keyswitch OFF.

Action Specification/Repair Next Step

Make sure the following engine harness Connectors properly connected? 2B

connections are properly made: YES
• Engine harness connected to the ECM
• Engine harness connected to the injector
pass-through connectors at the rocker Connectors properly connected? 5A
housing. NO
Repair:
Install the engine harness connectors
properly.

STEP 2B: Inspect the engine harness and ECM connector pins.
Condition:
• Turn keyswitch OFF.
• Disconnect the engine harness from the ECM connector.

Action Specification/Repair Next Step

Inspect the engine harness and ECM connector Dirty or damaged pins? 5A
pins for the following: YES
• Loose connector
• Corroded pins Repair:
• Bent or broken pins Clean the connector and pins.
• Pushed back or expanded pins
• Moisture in or on the connector Repair the damaged harness, connectors, or
• Missing or damaged connector seals pins, if possible.
• Dirt or debris on or in the connector pins Repair the engine harness.
• Connector shell broken
• Wire insulation damage Replace the engine harness. Refer to
• Damaged connector locking tab. Procedure 019-043 in Section 19.

Use the following procedure for general

Dirty or damaged pins? 2C
inspection techniques. Refer to Procedure
019-361 in Section 19. NO

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
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File: 06-t05-325 Page 4 of 14
STEP 2C: Check for an open circuit.
Condition:
• Turn keyswitch OFF.
• Disconnect the engine harness from the ECM.

Action Specification/Repair Next Step

Check for an open circuit. Less than 2 ohms? 2D

• Measure the resistance between the cylinder YES
number 6 DRIVER pin and the cylinder
number 6 RETURN pin on the harness.
Less than 2 ohms? 2C-1
Refer to the circuit diagram or the wiring diagram
for connector pin identification. NO

Use the following procedure for general

resistance measurement techniques. Refer to
Procedure 019-360 in Section 19.

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
All Rights Reserved. Last Modified: 25-Jun-2012
File: 06-t05-325 Page 5 of 14
STEP 2C-1: Check for high resistance or an open circuit in the injector solenoid and circuit.
Condition:
• Turn keyswitch OFF.
• Remove the rocker cover.
• Disconnect the injector harness from the injector solenoid.

Action Specification/Repair Next Step

Check for an open circuit. Less than 2 ohms? 5A

• Measure the resistance between the cylinder YES
number 6 DRIVER pin and the cylinder
number 6 RETURN pin on the injector Repair:
solenoid. Troubleshoot the engine wiring harness,
Refer to the circuit diagram or the wiring diagram injector harness, and pass-through connector
for connector pin identification. for an open circuit.
Use the following procedure for general Repair or replace the damaged component.
inspection techniques. Refer to Procedure
019-361 in Section 19. Less than 2 ohms? 5A
NO
Repair:
Replace the injector. Use the following
procedure in the ISB, ISBe, ISBe4, QSB4.5,
QSB5.9, and QSB6.7 (Common Rail Fuel
System) Service Manual, Bulletin 4021271.
Refer to Procedure 006-026 in Section 6.

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
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File: 06-t05-325 Page 6 of 14
STEP 2D: Check for high resistance or an open circuit in the injector solenoid.
Condition:
• Turn keyswitch OFF.
• Remove the rocker cover.
• Disconnect the injector harness from the injector solenoid.

Action Specification/Repair Next Step

Check for an open circuit. Did the fault code follow the injector? 5A
• Remove the injector and swap it with an YES
injector in another bank. Refer to Procedure
006-026 in Section 6. Repair:
• Turn keyswitch ON. Replace the injector. Use the following
• Operate engine and let it idle. procedure in the ISB, ISBe, ISBe4, QSB4.5,
• Use INSITE™ electronic service tool to read QSB5.9, and QSB6.7 (Common Rail Fuel
the fault codes. System) Service Manual, Bulletin Number
Note: Cylinders 1, 2, and 3 (Cylinders 1 and 2 for 4021271. Refer to Procedure 006-026 in
4-cylinder engines) are on the same injector Section 6.
bank. Cylinders 4, 5, and 6 (Cylinders 3 and 4 for
4-cylinder engines) are on the same injector Did the fault code follow the injector? 5A
bank.
NO
Repair:
Replace the ECM. Refer to Procedure
019-031 in Section 19.

STEP 3: Check the engine harness.

STEP 3A: Inspect the engine harness and injector pass-through connector pins.
Condition:
• Turn keyswitch OFF.
• Disconnect the engine harness from the ECM.

Action Specification/Repair Next Step

Inspect the engine harness and connector pins Dirty or damaged pins? 5A
for the following: YES
• Loose connector
• Corroded pins Repair:
• Bent or broken pins Clean the connector and pins.
• Pushed back or expanded pins
• Moisture in or on the connector Repair the damaged harness, connectors, or
• Missing or damaged connector seals pins, if possible.
• Dirt or debris on or in the connector pins Repair the engine harness. Refer to
• Connector shell broken Procedure 019-043 in Section 19.
• Wire insulation damage
• Damaged connector locking tab.
Dirty or damaged pins? 3B
Use the following procedure for general NO
inspection techniques. Refer to Procedure
019-361 in Section 19.

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
All Rights Reserved. Last Modified: 25-Jun-2012
File: 06-t05-325 Page 7 of 14
STEP 3B: Check the injector harness circuits for short circuits to ground.
Condition:
• Turn keyswitch OFF.
• Disconnect the engine harness from the ECM.

Action Specification/Repair Next Step

Check for a short circuit to ground. Greater than 100k ohms? 4A

• Measure the resistance between the cylinder YES
number 4 SIGNAL pin and engine block
ground.
• Measure the resistance between the cylinder Greater than 100k ohms? 3C
number 5 SIGNAL pin and engine block NO
ground.
• Measure the resistance between the cylinder
number 6 SIGNAL pin and engine block
ground.
Refer to the circuit diagram or the wiring diagram
for connector pin idenfication.
Use the following procedure for general
resistance measurement techniques. Refer to
Procedure 019-360 in Section 19.

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
All Rights Reserved. Last Modified: 25-Jun-2012
File: 06-t05-325 Page 8 of 14
STEP 3C: Check the injector solenoids for short circuits to ground.
Condition:
• Turn keyswitch OFF.
• Remove the rocker cover.
• Disconnect the injector harness from the injectors being tested.

Action Specification/Repair Next Step

Check for a short circuit to ground. Greater than 100k ohms? 5A

• Measure the resistance between the cylinder 4 YES
SIGNAL pin and engine block ground.
• Measure the resistance between the cylinder 5 Repair:
SIGNAL pin and engine block ground Troubleshoot the engine wiring harness,
• Measure the resistance between the cylinder 6 injector harness, and pass-through connector
SIGNAL pin and engine block ground. for a short circuit.
Reference the circuit diagram or the wiring • Repair or replace the damaged
diagram for connector pin identification. component.
Use the following procedure for general
resistance measurement techniques. Refer to Greater than 100k ohms? 5A
Procedure 019-360 in Section 19. NO
Repair:
Replace the injector. Use the following
procedure in the ISB, ISBe, ISBe4, QSB4.5,
QSB5.9, and QSB6.7 (Common Rail Fuel
System) Service Manual, Bulletin Number
4021271. Refer to Procedure 006-026 in
Section 6.

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
All Rights Reserved. Last Modified: 25-Jun-2012
File: 06-t05-325 Page 9 of 14

STEP 4: Isolate the ECM or injector malfunction.

STEP 4A: Check for active fault codes.
Condition:
• Connect all components.
• Place the rocker cover on the cylinder head and install the capscrews loosely so that the engine may run at idle.
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Operate the engine and observe the fault codes. Same or multiple (same bank) injector fault 4A-1
• Use INSITE™ electronic service tool to clear codes active?
the fault codes. YES
• Operate the engine and let it idle for 1 minute.
• Use INSITE™ electronic service tool to read
the fault codes. Same or multiple (same bank) injector fault 5A
codes active?
Bank fault codes:
NO
• Bank 1 - Front Bank: Fault Codes 322, 324,
and 331.
• Bank 2 - Rear Bank: Fault Codes 323, 325,
and 332.

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
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File: 06-t05-325 Page 10 of 14
STEP 4A-1: Injector isolation.
Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Complete injector isolation. Multiple (same bank) injector fault codes 4A-2
• Remove the valve cover. Use the following active?
procedure in the ISB, ISBe, ISBe4, QSB4.5, YES
QSB5.9, and QSB6.7 (Common Rail Fuel
System) Service Manual, Bulletin Number
4021271. Refer to Procedure 003-011 in Multiple (same bank) injector fault codes 5A
Section 3. active?
• Disconnect the injector wiring harness from NO
injector number 4. Use the following procedure
Repair:
in the ISB, ISBe, ISBe4, QSB4.5, QSB5.9, and
QSB6.7 (Common Rail Fuel System) Service Replace injector number 4. Use the following
Manual, Bulletin Number 4021271. Refer to procedure in the ISB, ISBe, ISBe4, QSB4.5,
Procedure 006-026 in Section 6. QSB5.9, and QSB6.7 (Common Rail Fuel
• Place tape on the ends of the injector wiring System) Service Manual, Bulletin Number
harness to make sure the harness ends do 4021271. Refer to Procedure 006-026 in
not come in contact with each other or the Section 6.
engine block.
• Place the valve cover on the engine.
Note: It is not necessary to bolt the valve cover
in place.
Operate the engine and observe the fault codes.
• Use INSITE™ electronic service tool to clear
the fault codes.
• Operate the engine and idle for 1 minute.
• Use INSITE™ electronic service tool to read
the fault codes.

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
All Rights Reserved. Last Modified: 25-Jun-2012
File: 06-t05-325 Page 11 of 14
STEP 4A-2: Injector isolation.
Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Complete injector isolation. Multiple (same bank) injector fault codes 4A-3
• Remove the valve cover. Use the following active?
procedure in the ISB, ISBe, ISBe4, QSB4.5, YES
QSB5.9, and QSB6.7 (Common Rail Fuel
System) Service Manual, Bulletin Number
4021271. Refer to Procedure 003-011 in Multiple (same bank) injector fault codes 5A
Section 3. active?
• Connect the injector wiring harness to injector NO
4.
Repair:
• Disconnect the injector wiring harness from
injector number 5. Use the following procedure Replace injector number 5. Use the following
in the ISB, ISBe, ISBe4, QSB4.5, QSB5.9, and procedure in the ISB, ISBe, ISBe4, QSB4.5,
QSB6.7 (Common Rail Fuel System) Service QSB5.9, and QSB6.7 (Common Rail Fuel
Manual, Bulletin Number 4021271. Refer to System) Service Manual, Bulletin Number
Procedure 006-026 in Section 6. 4021271. Refer to Procedure 006-026 in
• Place tape on the ends of the injector wiring Section 6.
harness to make sure the harness ends do
not come in contact with each other or the
engine block.
• Place the valve cover on the engine.
Note: It is not necessary to bolt the valve cover
in place.
Operate the engine and observe the fault codes.
• Use INSITE™ electronic service tool to clear
the fault codes.
• Operate engine and idle for 1 minute.
• Use INSITE™ electronic service tool to read
the fault codes.

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
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File: 06-t05-325 Page 12 of 14
STEP 4A-3: Check for active fault codes.
Condition:
• Turn keyswitch ON.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Check for active fault codes. Multiple (same bank) injector fault codes 5A
• Remove the valve cover. Use the following active?
procedure in the ISB, ISBe, ISBe4, QSB4.5, YES
QSB5.9, and QSB6.7 (Common Rail Fuel
System) Service Manual, Bulletin Number Repair:
4021271. Refer to Procedure 003-011 in Replace the ECM. Refer to Procedure
Section 3. 019-031 in Section 19.
• Connect the injector wiring harness to injector
5.
• Disconnect the injector wiring harness from Multiple (same bank) injector fault codes 5A
injector number 6. Use the following procedure active?
in the ISB, ISBe, ISBe4, QSB4.5, QSB5.9, and NO
QSB6.7 (Common Rail Fuel System) Service Repair:
Manual, Bulletin Number 4021271. Refer to
Procedure 006-026 in Section 6. Replace injector number 6. Use the following
• Place tape on the ends of the injector wiring procedure in the ISB, ISBe, ISBe4, QSB4.5,
harness to make sure the harness ends do QSB5.9, and QSB6.7 (Common Rail Fuel
not come in contact with each other or the System) Service Manual, Bulletin Number
engine block. 4021271. Refer to Procedure 006-026 in
• Place the valve cover on the engine. Section 6.
Note: It is not necessary to bolt the valve cover
in place.
Operate the engine and observe the fault codes.
• Use INSITE™ electronic service tool to clear
the fault codes.
• Operate engine and idle for 1 minute.
• Use INSITE™ electronic service tool to read
the fault codes.

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
All Rights Reserved. Last Modified: 25-Jun-2012
File: 06-t05-325 Page 13 of 14

STEP 5: Clear the fault codes.

STEP 5A: Disable the fault code.
Condition:
• Connect all components.
• Connect INSITE™ electronic service tool.

Action Specification/Repair Next Step

Disable the fault code. Same or multiple (same bank) injector fault 1B
• Start the engine and let it idle for 1 minute. codes active?
• Use INSITE™ electronic service tool to verify YES
that the fault codes are inactive.
Repair:
Return to the troubleshooting steps or
contact a Cummins® Authorized Repair
Location if all steps have been completed
and checked again.

Same or multiple (same bank) injector fault 5B

codes active?
NO

STEP 5B: Clear the inactive fault codes.

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

Action Specification/Repair Next Step

Clear the inactive fault codes. All fault codes cleared? Repair
• Use INSITE™ electronic service tool to clear YES complete
the inactive fault codes.
All fault codes cleared? Appropriate
NO troubleshooti
ng steps
Repair:
Troubleshoot any remaining active fault
codes.

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
All Rights Reserved. Last Modified: 25-Jun-2012
File: 06-t05-325 Page 14 of 14

© 2008 Cummins Inc., Box 3005, Columbus, IN 47202-3005 U.S.A. Printed from QuickServe® Online.
All Rights Reserved. Last Modified: 25-Jun-2012