LEMON Manuals: Even more car manuals for everyone
Home >> Chrysler >> 2009 >> PT Cruiser Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 59 (DTCS P0443 To P0533) >> P0491-Secondary Air Injection System Insufficient Flow >> Diagnostic Test

Diagnostic Test

WARNING: This page is about a different car, the 2009 Dodge Caliber. However, it is still accessible from the selected car via links, so may be relevant.
  1. DTC IS ACTIVE 
    WARNING: The normal operating temperature of the exhaust system is very high. Never work around or attempt to service any part of the exhaust system until it has cooled. Special care should be taken when working near any part of the exhaust system. The temperature rises to a high level after a short period of engine operating time.
    NOTE: Diagnose and repair any Secondary Air system sensor signal or relay control circuit DTCs before proceeding with this procedure.
    1. Turn the ignition on.
    2. With the scan tool, select View DTCs and review the DTC environmental data for this DTC.

      Is the good trip counter greater than 0?

      Yes 

      No 

      • Go to step  2
  2. AIR INJECTION SYSTEM COMPONENT INSPECTION 
    WARNING: The normal operating temperature of the exhaust system is very high. Never work around or attempt to service any part of the exhaust system until it has cooled. Special care should be taken when working near any part of the exhaust system. The temperature rises to a high level after a short period of engine operating time.
    1. Turn the ignition off.
    2. Inspect the Secondary Air Pump Assembly, the Secondary Air Pump Valve and the connection tubes between them.
    3. Look for damage, obstructions, leaks, or any condition that would obstruct or interfere with air flow between the components.
    4. Using the wiring diagram/schematic as a guide, inspect the wiring and electrical connectors at the Secondary Air Pump Assembly.
    5. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related connectors.

      Were any problems found?

      Yes 

      No 

      • Go to step  3
  3. SECONDARY AIR PUMP ACTUATION 
    1. Turn the ignition on.
    2. With the scan tool, actuate the Secondary Air Pump control to on.
    3. With the scan tool, monitor the MAF Sensor value.
      CAUTION: Do not allow the Air Pump actuation to run for more than 30 seconds at a time. Pump damage may occur. Allow the pump to cool down for at least 10 minutes between actuations.

      Is the MAF Sensor value greater than 25 kg/h with the pump actuated on?

      Yes 

      No 

      • Go to step  4
  4. SECONDARY AIR CHECK VALVE 
    Fig 1: Secondary Air Check Valve
    GC0099922Courtesy of CHRYSLER LLC
    WARNING: The normal operating temperature of the exhaust system is very high. Never work around or attempt to service any part of the exhaust system until it has cooled. Special care should be taken when working near any part of the exhaust system. The temperature rises to a high level after a short period of engine operating time.
    1. Turn the ignition off.
    2. Disconnect the air pump outlet tube (3) from the Secondary Air Check Valve (1).
    3. Turn the ignition on.
    4. With the scan tool, actuate the Secondary Air Pump control to on.
    5. With the scan tool, monitor the MAF Sensor value.
      CAUTION: Do not allow the Air Pump actuation to run for more than 30 seconds at a time. Pump damage may occur. Allow the pump to cool down for at least 10 minutes between actuations.

      Is the MAF Sensor value greater than 25 kg/h with the pump actuated on?

      Yes 

      No 

      • Go to step  5
  5. (Z932) GROUND CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 2: Checking Ground Circuit
    GC0099923Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Disconnect the C2 Secondary Air Pump Assembly connector.
    3. Using a 12 volt test light connected to 12 volts, check the (Z932) Ground circuit in the C2 Secondary Air Pump Assembly harness connector.
      NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery.

      Is the test light illuminated and bright?

      Yes 

      • Go to step  6

      No 

  6. (A929) FUSED B+ CIRCUIT OPEN 
    Fig 3: Checking Fused B+ Circuit
    GC0099924Courtesy of CHRYSLER LLC
    1. Turn the ignition on.
    2. Using a 12 volt test light connected to ground, check the (A929) Fused B+ circuit in the C2 Secondary Air Pump Assembly harness connector.
      NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery.

      Is the test light illuminated and bright?

      Yes 

      • Go to step  7

      No 

      • Go to step  14
  7. (F343) FUSED ASD/MAIN RELAY OUTPUT CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 4: Checking Fused Main Relay Circuit
    GC0099892Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Disconnect the C1 Secondary Air Pump Assembly harness connector.
    3. Turn the ignition on.
    4. Using a 12 volt test light connected to ground, check the (F343) Fused ASD/Main Relay Output circuit in the C1 Secondary Air Pump Assembly harness connector.
      NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery.

      Is the test light illuminated and bright?

      Yes 

      • Go to step  8

      No 

  8. (K157) MAF SENSOR SIGNAL CIRCUIT VOLTAGE 
    Fig 5: Checking MAF Sensor Signal Circuit
    GC0099925Courtesy of CHRYSLER LLC
    1. Turn the ignition on.
    2. Measure the voltage of the (K157) MAF Sensor Signal circuit in the C1 Secondary Air Pump Assembly harness connector.

      Is the voltage between 4.8 and 5.1 volts?

      Yes 

      • Go to step  9

      No 

      • Go to step  10
  9. (K957) MAF SENSOR GROUND CIRCUIT TEST 
    Fig 6: Checking MAF Sensor Ground Circuit
    GC0099926Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Using a 12 volt test light connected to 12 volts, check the (K957) MAF Sensor Ground circuit in the C1 Secondary Air Pump Assembly harness connector.
      NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery.

      Is the test light illuminated and bright?

      Yes 

      • Go to step  15

      No 

      • Go to step  13
  10. (K157) MAF SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE 
    Fig 7: Checking MAF Sensor Signal Circuit
    GC0099925Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Disconnect the Powertrain Control Module (PCM) harness connector.
    3. Turn the ignition on.
    4. Measure the voltage of the (K157) MAF Sensor Signal circuit in the C1 Secondary Air Pump Assembly harness connector.

      Is there any voltage present?

      Yes 

      No 

      • Go to step  11
  11. (K157) MAF SENSOR SIGNAL CIRCUIT SHORTED TO GROUND 
    Fig 8: Checking MAF Sensor Signal Circuit
    GC0099927Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Measure the resistance between ground and the (K157) MAF Sensor Signal circuit in the C1 Secondary Air Pump Assembly harness connector.

      Is the resistance above 100 Ohms?

      Yes 

      • Go to step  12

      No 

  12. (K157) MAF SENSOR SIGNAL CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 9: Checking MAF Sensor Signal Circuit
    GC0099928Courtesy of CHRYSLER LLC
    NOTE: When checking circuits at the Powertrain Control Module (PCM), be careful not to damage or distort the connector terminals. Improper measurement technique could result in poor pin to terminal contact.
    1. Measure the resistance of the (K157) MAF Sensor Signal circuit between the C1 Secondary Air Pump Assembly harness connector and the PCM.

      Is the resistance below 5.0 Ohms?

      Yes 

      • Go to step  17

      No 

  13. (K957) MAF SENSOR GROUND CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 10: Checking MAF Sensor Ground Circuit
    GC0099929Courtesy of CHRYSLER LLC
    NOTE: When checking circuits at the Powertrain Control Module (PCM), be careful not to damage or distort the connector terminals. Improper measurement technique could result in poor pin to terminal contact.
    1. Measure the resistance of the (K957) MAF Sensor Ground circuit between the C1 Secondary Air Pump Assembly harness connector and the PCM.

      Is the resistance below 5.0 Ohms?

      Yes 

      • Go to step  17

      No 

  14. (A929) FUSED B+ CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 11: Checking Fused B+ Circuit
    GC0099930Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Disconnect the Totally Integrated Power Module (TIPM) harness connector.
    3. Measure the resistance of the (A929) Fused B+ circuit between the TIPM connector and the C2 Secondary Air Pump Assembly harness connector.

      Is the resistance below 5.0 Ohms?

      Yes 

      • Go to step  16

      No 

  15. SECONDARY AIR PUMP ASSEMBLY 
    1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Secondary Air Pump Assembly and the Powertrain Control Module (PCM).
    2. Look for any chafed, pierced, pinched, or partially broken wires.
    3. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related connectors.

      Were any problems found?

      Yes 

      No 

  16. TOTALLY INTEGRATED POWER MODULE (TIPM) 
    1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Secondary Air Pump Assembly and the TIPM.
    2. Look for any chafed, pierced, pinched, or partially broken wires.
    3. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related connectors.
    4. Monitor the scan tool data relative to this circuit and wiggle test the wiring and connectors.
    5. Look for the data to change or for the DTC to reset during the wiggle test.
    6. Perform any Technical Service Bulletins that may apply.

      Were any problems found?

      Yes 

      No 

  17. POWERTRAIN CONTROL MODULE (PCM) 
    1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Secondary Air Pump Assembly and the Powertrain Control Module (PCM).
    2. Look for any chafed, pierced, pinched, or partially broken wires.
    3. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related connectors.
    4. Monitor the scan tool data relative to this circuit and wiggle test the wiring and connectors.
    5. Look for the data to change or for the DTC to reset during the wiggle test.
    6. Refer to any Technical Service Bulletins that may apply.

      Were any problems found?

      Yes 

      No 

scientia non olet · About LEMON Manuals