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.

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

Is the voltage above 4.5 volts?
1. Yes --> Go To 2
2. No --> Go To 8
Turn the ignition off.
Disconnect the EGR Solenoid harness connector.

Disconnect the PCM harness connectors.

Measure the resistance between the (K34) EGR Position Sensor Signal circuit and the (F856) 5-volt Supply circuit at the EGR Solenoid harness connector.

Is the resistance below 100 ohms?
1. Yes --> Repair the short between the (K34) EGR Position Sensor Signal circuit and the (F856) 5-volt Supply circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 3
Ignition on, engine not running.
Measure the voltage on the (K34) EGR Sensor Signal circuit at the EGR Solenoid harness connector.

Is the voltage above 5.2 volts?
1. Yes --> Repair the short to battery voltage in the (K34) EGR Position Sensor Signal circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 4
Turn the ignition off.
Connect the PCM harness connectors.

Connect a jumper wire between the (K34) EGR Position Sensor Signal circuit and the (K900) Sensor ground circuit.

With the DRBIII®, monitor the EGR Position Sensor voltage.

Ignition on, engine not running.

Is the voltage below 0.5 of a volt?
1. Yes --> Replace the EGR Solenoid Assembly.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 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 Position 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 6
2. No --> Repair the open in the (K34) EGR Position Sensor Signal circuit.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .

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 30 ohms?
1. Yes --> Go To 7
2. No --> Repair the open in the (K900) Sensor ground 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 .

NOTE: The engine will run rough and possibly stall in the following test. Feather the accelerator pedal to keep the engine from stalling.

Start the engine.
With the DRBIII®, enter Engine System Test and then EGR System Test. Push the 4=VARIABLE function.

Monitor the EGR voltage while slowly pushing the up arrow.

Is the voltage change smooth?
1. Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Replace the EGR Solenoid Assembly.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .