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.

Ignition on, engine not running.
With the DRBIII®, read DTCs and record the related Freeze Frame data.

Is the Good Trip displayed and equal to zero?
1. Yes --> Go To 2
2. No --> Refer to the SYMPTOM: INTERMITTENT CONDITION symptom in the Driveability category.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .

NOTE: If the vehicle is running rough at idle (DRBIII® not actuating) follow the yes path to continue.

Turn all accessories off.
Start the engine.

Allow the engine to reach normal operating temperature.

With the DRB, enter Engine System Test, then EGR System Test.

Actuate the FLOW function in the EGR System Test.

Did the engine run rough or stall?
1. Yes --> Go To 3
2. No --> Go To 6
Turn the ignition off.
Disconnect the EGR Solenoid Assembly harness connector.

Start engine.

Attempt to allow the engine to idle.

Does the engine run rough or stall?
1. Yes --> Inspect the EGR tube assembly. If OK, replace the EGR valve.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 4
Ignition on, engine not running.
Measure the voltage on the (K35) EGR Solenoid Control circuit in the EGR Solenoid Connector.

Is the voltage above 1.0 volt?
1. Yes --> Repair the short to battery voltage in the (K35) EGR Solenoid Control circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 5
Inspect the EGR Assembly for the following.
Gasket(s) for leaking

Damage and/or holes in the EGR tube(s)

Carbon build up on or near the EGR pintle and passage ways.

Obstruction in the EGR tubes Were any problem found?
1. Yes --> Repair or replace the EGR Assembly as necessary.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 10
Ignition on, engine not running.
Turn all accessories off.

Disconnect the EGR Solenoid harness connector.

Using a 12-volt Test Light, jump across the EGR Solenoid harness connector.

With the DRB, actuate the EGR solenoid.

Does the 12-volt test light flash on and off?
1. Yes --> Inspect the tube(s) for obstructions and damage, repair as necessary. If OK, replace the EGR Solenoid Assembly.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 7
Turn the ignition off.
Disconnect the EGR Solenoid harness connector.

Using a 12-volt test light connected to battery voltage, probe (Z335) EGR Solenoid ground circuit in the EGR Solenoid harness connector.

Does the 12-volt test light illuminate brightly?
1. Yes --> Go To 8
2. No --> Repair the open in the (Z335) EGR Solenoid ground circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
Disconnect the PCM harness connector.
Measure the resistance between ground and the (K35) EGR Solenoid Control circuit in the EGR Solenoid harness connector.

Is the resistance below 100 ohms?
1. Yes --> Repair the short to ground in the (K35) EGR Solenoid Control circuirt.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 9

CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMINALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.

Measure the resistance of the (K35) EGR Solenoid Control circuit from the EGR Solenoid harness connector to the appropriate terminal of special tool #8815.
Is the resistance below 5.0 ohms?
1. Yes --> Go To 10
2. No --> Repair the open in the (K35) EGR Solenoid 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 .