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 .

NOTE: Diagnose all other EGR DTC(s) first before continuing.

Start the engine.
With the DRBIII®, read the EGR Position Sensor voltage.

Choose a conclusion that best matches the EGR voltage reading.
1. Below 3.5 volts
  1. Go To 3
2. Between 3.5 volts to 4.3 volts
  1. Go To 5
3. Above 4.3 volts
  1. Go To 7
Turn the ignition off.
Disconnect the EGR Solenoid harness connector.

Disconnect the PCM harness connectors.

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 (F856) 5-volt Supply 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 4
2. No --> Repair the excessive resistance in the (F856) 5-volt Supply circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
Measure the resistance between ground and the (K34) EGR Sensor Signal circuit at the EGR Solenoid harness connector.
Is the resistance below 5.0 ohms?
1. Yes --> Repair the short to ground in the (K34) EGR Sensor Signal circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Replace the EGR Assembly.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
Ignition on, engine not running.
With the DRBIII®, actuate the EGR Solenoid.

Allow the EGR Solenoid to actuate for at least 15 seconds.

Feel the EGR Solenoid for operation.

Stop actuation.

Does EGR Solenoid operate while actuating and then turn off when actuation test is stopped?
1. Yes --> Go To 6
2. No --> Refer to the Driveability category and perform P0403-EGR CONTROL CIRCUIT .
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .

NOTE: The conditions that set the DTC are not present at this time. The following list may help in identifying the intermittent condition.

NOTE: Closely inspect the EGR tube(s) for obstructions, damage and holes. Also, inspect the gasket(s) for leaks.

WARNING: WHEN THE ENGINE IS OPERATING, DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR FAN. DO NOT WEAR LOOSE CLOTHING.

With the engine running at normal operating temperature, monitor the DRBIII® parameters related to the DTC while wiggling the wire harness. Look for parameter values to change and/or a DTC to set.
Review the DRBIII® Freeze Frame information. If possible, try to duplicate the conditions under which the DTC was set.

Refer to any Technical Service Bulletins (TSB) that may apply.

Visually inspect the related wire harness. Look for any chafed, pierced, pinched, or partially broken wires.

Visually inspect the related wire harness connectors. Look for broken, bent, pushed out, or corroded terminals.

Were any of the above conditions present?
1. Yes --> Repair as necessary.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Test Complete.
Turn the ignition off.
Disconnect the EGR Solenoid harness connector.

Ignition on, engine not running.

Measure the voltage of the (K34) EGR Sensor Signal circuit at the EGR Solenoid harness connector.

Is the voltage above 4.30 volts?
1. Yes --> Go To 8
2. No --> Go To 9
Turn the ignition off.
Disconnect the PCM harness connectors.

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 (K900) Sensor ground circuit from the EGR Solenoid harness connector to the appropriate terminal of special tool #8815.

Is the resistance below 5.0 ohms?
1. Yes --> Replace the EGR Assembly.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Repair the open in the (K900) Sensor ground circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
Turn the ignition off.
Disconnect the PCM harness connectors.

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 (K34) EGR Sensor Signal 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 (K34) EGR Sensor Signal circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
Measure the resistance between ground and the (K34) EGR Sensor Signal circuit at the EGR Solenoid harness connector.
Is the resistance below 100 ohms?
1. Yes --> Repair the short to ground in the (K34) EGR Sensor Signal circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 11

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 .