P0202 — Injector Circuit/Open - Cylinder 2 — 5.9 Cummins Common Rail
P0202 on 5.9 Cummins Common Rail 2003-2007 means the ECM detected an electrical fault in the fuel injector circuit for cylinder 2. Injectors are Bosch…
What it means
The ECM has detected an electrical fault in the fuel injector circuit for cylinder number two. On this platform the 5.9L Cummins Common Rail 2003-2007 ISB uses Bosch common-rail solenoid injectors; electrical faults show as P0201-P0206; contribution/balance as P0263-family. No EGR/DPF/SCR/DEF, no VGT, grid heater not glow plugs, CP3 pump with FCA/MPROP and rail pressure sensor/relief valve.1
Most likely causes
- Open or short in injector 2 wiring harness / connector corrosion — Inspect injector 2 connector and harness for chafing, oil intrusion, or corrosion; check continuity to ECM. Typical on this platform: 5.9L Cummins Common Rail 2003-2007 ISB. Injectors are Bosch common-rail solenoid type; electrical faults show as P0201-P0206; contribution/balance as P0263-family.1234
- Faulty injector 2 solenoid / internal open — Solenoid coil resistance out of spec indicates injector electrical failure.1234
- ECM driver fault for cylinder 2 injector circuit — If wiring and injector test good, ECM internal driver may be suspect. Generic definition: The engine control module has detected an electrical fault in the fuel injector circuit for cylinder number two.1
- Intermittent connection causing misfire/jerking — NHTSA report of 2003 Dodge Ram 3500 jerking at 55 mph with no diagnosis determined; approximate failure mileage 130,000.5
- Related electrical issues from recalls affecting drivability — Owner reports recalls 13V-528 and 09E-001 relating to these issues with inspection but no repair.6
How to diagnose
- Verify code P0202 present and freeze frame data; confirm platform is 5.9 Cummins Common Rail 2003-2007.
- Visually inspect injector 2 connector, harness routing, and ECM harness for chafing/corrosion; check for oil in connector.
- Measure injector 2 solenoid resistance per spec and compare to other cylinders; inspect connector pin tension.
- Perform continuity and isolation tests from injector 2 connector to ECM pins; check for shorts to ground or power.
- If wiring and injector pass, evaluate ECM injector driver output with scan tool bi-directional control or scope; confirm fault follows injector swap.
- Clear codes, road test, and re-check for recurrence; monitor related codes P0201-P0206. Contribution/balance codes P0263-family indicate mechanical/performance issues, not circuit faults.
Parts and tools you may need
- Digital multimeter
- Scan tool with Cummins enhanced codes
- Wiring diagram for 2003-2007 Ram 2500/3500 5.9 ISB
- Injector breakout harness / test leads
- Dielectric grease
- Contact cleaner
Tools you’ll need
- digital multimeter — Measures injector 2 solenoid resistance and checks continuity/isolation from injector connector to ECM pins for opens/shorts to ground or power.
- OBD-II scan tool — Reads P0202 and freeze frame, monitors P0201-P0206 recurrence, and provides bi-directional injector control to test ECM driver output.
- inspection mirror and flashlight — Allows visual inspection of injector 2 connector, harness routing, chafing, corrosion, and oil intrusion in tight engine bay areas.
- oscilloscope — Captures injector 2 solenoid drive waveform from ECM to verify switching and detect intermittent electrical faults not seen with a multimeter.
Rough cost and difficulty
| Likely repair | Parts | Shop labor | Who usually does it |
|---|---|---|---|
| Wiring or connector repair | $10–$100 | 1–4 hrs | DIY with tools and a manual |
| Injector wiring harness / under-valve-cover harness | $50–$300 | 2–5 hrs | Shop |
| Fuel injector (each) | $300–$600 | 1–2 hrs | Shop |
| ECM/PCM replacement (programmed) | $600–$2,000 | 1–3 hrs | Shop |
Typical US independent-shop figures; labor runs about $120–$180 per hour (dealers charge more). Confirm the diagnosis before buying parts.
When to see a pro
If wiring tests good and injector resistance is normal but code persists, have a qualified diesel technician evaluate ECM driver output. Do not attempt high-pressure fuel system disassembly. If drivability symptoms like sudden jerking occur, have vehicle inspected promptly for safety.
Check for recalls
Recalls are tied to your truck’s VIN, so check yours directly: enter the VIN at NHTSA’s recall lookup. Open safety recalls are repaired free at a dealer.
Sources
Repair videos: P0202 on the 5.9 Cummins CR
Third-party videos, not ours — picked for this engine. Confirm anything against the factory service information for your truck.
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