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 Counter equal to zero?
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.
Disconnect the EGR Solenoid harness connector.

Ignition on, engine not running.

Turn off all accessories.

Using a 12-volt test light connected to the (Z335) EGR Solenoid ground circuit, probe the (K35) EGR Solenoid Control circuit.

With the DRBIII®, actuate the EGR solenoid.

Does the 12-volt test light flash on and off?
1. Yes --> Replace the EGR Solenoid Assembly.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 3
Turn the ignition off.
Disconnect the PCM harness connectors.

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

Does the test light illuminate brightly?
1. Yes --> Go To 4
2. No --> Repair the open in the (Z335) EGR Solenoid ground circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .POWERTRAIN VERIFICATION TEST VER - 5 .
Ignition on, engine not running.
Measure the voltage on the (K35) EGR Solenoid Control circuit at the EGR Solenoid connector.

Is the voltage above 1.0 volt?
1. Yes --> Repair the short to voltage in the (K35) EGR Solenoid Control circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 5
Turn the ignition off.
Measure the resistance between ground and the (K35) EGR Solenoid Control circuit at the EGR Solenoid harness connector.

Is the resistance below 100 ohms?
1. Yes --> Repair the short to ground in the (K35) EGR Solenoid Control circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 6
Measure the resistance between the (K35) EGR Solenoid Control circuit and the (K900) Sensor ground circuit at the EGR Solenoid connector.
Is the resistance below 5.0 ohms?
1. Yes --> Repair the short between the (K900) Sensor ground circuit and the (K35) EGR Solenoid Control circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 7

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 8
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 .