Diagnostics Procedures

WARNING: This page is about a different car, the 2004 Dodge Pickup and 2004 Dodge Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

Turn the ignition off.
NOTE: Wait a minimum of 8 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 volts.

Ignition on, engine not running.

With the DRBIII®, actuate the O2 Heater Test.

With the DRBIII®, monitor O2 Sensor voltage for at least 2 minutes.

Does the O2 Sensor voltage stay above 4.5 volts?
1. Yes --> Go To 2
2. No --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
Turn the ignition off.
NOTE: Allow the O2 Sensor to cool down to room temperature.

Disconnect the O2 Sensor harness connector.

Measure the resistance across the O2 Sensor Heater element component side.

NOTE: O2 Heater Element resistance values should be measured at 70°F (21.1°C). The resistance value will vary with different temperature values.

Is the O2 Sensor Heater Element resistance between 2.0 and 30.0 ohms?
1. Yes --> Go To 3
2. No --> Replace the O2 Sensor.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
Ignition on, engine not running.
With the DRBIII®, actuate the O2 Heater Test with the Sensor harness connector still disconnected.

Using a 12-volt test light connected to ground, probe the O2 Heater Control circuit in the O2 Sensor harness connector.

Does the test light illuminate brightly and flash on and off?
1. Yes --> Go To 4
2. No --> Go To 5
Turn the ignition off.
Measure the resistance between engine ground and the O2 Heater ground circuit in the O2 Sensor harness connector.

Is the resistance below 5.0 ohms?
1. Yes --> Replace the O2 Sensor.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Repair the open in the O2 Heater ground circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
Turn the ignition off.
Disconnect the PCM harness connectors.

Ignition on, engine not running.

Measure the voltage on the O2 Heater Control circuit at the O2 Sensor harness connector.

Does the voltmeter indicate any voltage present?
1. Yes --> Repair the short to voltage in the O2 Heater Control circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 6
Turn the ignition off.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PEST CONNECTION. INSTALL MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.

Measure the resistance of the O2 Heater Control circuit from the O2 Sensor harness connector to the appropriate terminal of special tool #8815.

Is the resistance below 5.0 ohms?
1. Yes --> Go To 7
2. No --> Repair the open in the O2 Heater Control circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .

NOTE: Before continuing, check the PCM harness connector terminals for corrosion, damage, or terminal push out. Repair as necessary.

Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all Power and Ground circuits.
If there are no possible causes remaining, view repair.
1. Repair
  1. Replace and program the Powertrain Control Module per Service Information.
  2. Perform POWERTRAIN VERIFICATION TEST VER - 5 .