Diagnostic Test

1. Diagnose all other DTCs before continuing.
2. Start the engine.
3. Allow the engine to reach normal operating temperature.
4. With the scan tool, read DTCs.
   NOTE:

   It may be necessary to drive the vehicle to meet the conditions to set this DTC, try to repeat the conditions in which the fault originally set by reviewing the Freeze Frame data.

   Is the DTC Active or Pending at this time?

   Yes 

   • Go To  2

   No 

   • Perform the INTERMITTENT CONDITION diagnostic procedure. Refer to INTERMITTENT CONDITION .

1. Turn the ignition off.
2. Install the (special tool #8978A, Decay Tool, Fuel) to the fuel rail.
3. Ignition on, engine not running.
4. Using the scan tool, actuate the ASD Fuel System test and observe the fuel pressure gauge.
   NOTE:

   Fuel pressure specification is 400 kPa +/- 14 kPa (58 psi +/- 2 psi).

5. Turn the ignition off.

   Choose a conclusion that best matches your fuel pressure reading.

   Within Specification 

   • Go To  3

   Above Specification 

   • Replace the fuel filter/pressure regulator.
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

   Below Specification 

   • Go To  13
     CAUTION:

     Before Proceeding Stop All Actuations.

1. Turn the ignition off.
2. Raise the vehicle in accordance with the Service Information.
   WARNING:

   The normal operating temperature of the exhaust system is very high. Never work around or attempt to service any part of the exhaust system until it has cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operating time.

3. Connect the (special tool #8404-EC, Exhaust Cone) with Air Pressure Regulator (with hose) W-18-MIL-1146AS.
   CAUTION:

   The air pressure must not exceed 27.6 kPa (4 psi), otherwise engine damage can occur.

4. Attach shop air to the air pressure regulator.
5. Adjust the Air Pressure Regulator to 27.6 kPa (4.0 psi).
6. Insert the exhaust cone into the vehicle tail pipe.
7. If the vehicle is equipped with dual exhaust. Use the (special tool #8404-ECT, Exhaust Cone, Truck) with equipped attached plug, plug one side of the dual exhaust pipe. Pressurize the other as described above.
8. Apply Mopar® Air Leak Detector PN# 05191804AA (or an equivalent leak finder liquid) to the following areas:
   • All welded joints from the exhaust manifold to 152.4 mm (6.0 inches) behind the downstream O2 Sensor.
   • O2 Sensor seal points.
   • O2 Sensor boss welds.
   • Flange/joint connection(s).
   • Exhaust manifold to cylinder head connection(s).
   • EGR solenoid gasket base and tube seal points (if equipped).
9. Watch for the liquid/soapy water to bubble.
10. Use the following definitions to help determine if system or component repair/replacement is necessary:
11. Type 1 Leak  is defined as a leak where very small foam like bubbles 1 mm (0.04 inch) or less appear.
12. Any Type 1 or greater leaks found in welded joints, O2 Sensor seal points or O2 Sensor boss welds must be repaired or the component must be replaced.
13. Type 2 Leak  is defined as a leak where larger bubbles pea size, 8 mm (0.3 inch) or greater appear.
14. Any Type 2 or greater leaks found in flange or joint connections, exhaust manifold to cylinder head connections or EGR gasket and tube seal points must be repaired or the components must be replaced.

    Leak Location	Repair required if results at 27.6 kPa (4 psi) reveal bubble size:
    Welded joints	Type 1, 1 mm (0.04 inch) or greater
    O2 Sensor seal points	Type 1, 1 mm (0.04 inch) or greater
    O2 Sensor boss welds	Type 1, 1 mm (0.04 inch) or greater
    Flange/joint connections	Type 2, 8 mm (0.3 inch) or greater
    Exhaust Manifold to cylinder head connections	Type 2, 8 mm (0.3 inch) or greater
    EGR gasket and tube seal points	Type 2, 8 mm (0.3 inch) or greater

15. If a leak is found that matches the above definition, repair or replace the component as necessary.
16. Once the repair is complete, repeat the procedure to verify that all leaks have been repaired.

    Were any exhaust leaks found?

    Yes 

    • Repair or replace the leaking exhaust parts as necessary.
    • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

    No 

    • Go To  4

1. Start the engine.
2. Allow the engine to reach normal operating temperature.
   NOTE:

   If one of the O2 Sensor Signal or Return circuit is shorted to ground the scan tool will display all O2 Sensor voltage readings low. The O2 Sensor that is shorted to ground will display a voltage reading near or at 0 Volts.

   NOTE:

   If one of the O2 Sensor Signal or Return circuits are shorted to voltage, the scan tool will display all O2 Sensor voltage readings high.

   NOTE:

   After the repairs have been made, verify proper O2 Sensor operation. If all the O2 Sensor voltage readings have not returned to normal, follow the diagnostic procedure for the remaining O2 Sensors.

3. Using the scan tool, monitor the O2 Sensor 2/1 voltage reading.

   Is the voltage switching between 2.5 and 3.4 Volts?

   Yes 

   • Go To  5

   No 

   • Go To  9

1. Turn the ignition off.
   NOTE:

   Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 Volts.

   NOTE:

   Perform the following test on all O2 Sensors.

2. Ignition on, engine not running.
3. With the scan tool, actuate the O2 Sensor 2/1 Heater Test.
4. Using the scan tool, monitor O2 Sensor 2/1 voltage for at least two minutes.

   Does the voltage stay above 4.5 Volts?

   Yes 

   • Verify that there is good pin to terminal contact in the O2 Sensor 2/1 and Powertrain Control Module connectors. Replace the O2 Sensor 2/1 if no problems were found with the connectors. Refer to SENSOR, OXYGEN, REMOVAL .
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

   No 

   • Go To  6

1. Ignition on, engine not running.
2. With the scan tool, read the Barometric Pressure.
   NOTE:

   The Barometric Pressure should be approximately equal to the actual barometric pressure. If necessary, compare the value to the value of a known good vehicle of a similar make and model.

3. Turn the ignition off.
4. Connect a Vacuum Gauge to a Manifold Vacuum source.
5. Start the engine.
6. Allow the engine to idle.
   NOTE:

   If engine will not idle, maintain a constant RPM above idle.

7. Using the scan tool, read the MAP Sensor vacuum value.

   Is the scan tool reading for MAP Vacuum within 1" of Hg on the Vacuum Gauge reading and is the Barometric Pressure reading of the vehicle the approximately the same as actual Barometric Pressure?

   Yes 

   • Go To  7

   No 

   • Verify that there is good pin to terminal contact in the MAP Sensor and Powertrain Control Module connectors. Replace the MAP Sensor if no problems were found with the connectors. Refer to SENSOR, MANIFOLD AIR PRESSURE (MAP), REMOVAL .
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

1. Ignition on, engine not running.
2. Using the scan tool, read the Engine Coolant Temperature (ECT) Sensor value. If the engine was allowed to sit overnight (cold soak), the temperature value should be a sensible value that is somewhere close to the ambient temperature.
   NOTE:

   If engine coolant temperature is above 82°C (180°F), allow the engine to cool until 65°C (150°F) is reached.

3. Start the Engine.
4. During engine warm-up, monitor the ECT Sensor value. The temperature value change should be a smooth transition from start up to normal operating temperature 82° C (180° F). The value should reach at least 82°C (180°F).

   Did the ECT value increase smoothly and did it reach at least 82°C (180°F)?

   Yes 

   • Go To  8

   No 

   • Verify that there is good pin to terminal contact in the ECT Sensor and Powertrain Control Module connectors. Replace the Engine Coolant Temperature Sensor if no problems were found with the connectors. Refer to SENSOR, COOLANT TEMPERATURE, REMOVAL .
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

1. Turn the ignition off.
2. Check for any of the following conditions/mechanical problems.
   • AIR INDUCTION SYSTEM - must be free from leaks.
   • ENGINE VACUUM - must be at least 13 inches in neutral.
   • ENGINE VALVE TIMING - must be within specifications.
   • ENGINE COMPRESSION - must be within specifications.
   • ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks.
   • ENGINE PCV SYSTEM - must flow freely.
   • TORQUE CONVERTER STALL SPEED - must be within specifications.
   • POWER BRAKE BOOSTER - no internal vacuum leaks.
   • FUEL - must be free of contamination.
   • FUEL INJECTOR - plugged or restricted injector; control wire not connected to correct injector.

   Are there any engine mechanical problems?

   Yes 

   • Repair as necessary.
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

   No 

   • Go To  12

Fig 1: Checking Oxygen Sensor Circuit

Courtesy of CHRYSLER GROUP, LLC

1. Ignition on, engine not running.
2. Disconnect the O2 Sensor 2/1 harness connector.
3. Using the scan tool, monitor the O2 Sensor 2/1 voltage.
4. O2 Sensor voltage should read between 4.1 and 5.0 Volts on the scan tool with the connector disconnected.
5. Connect a jumper wire between the (K43) O2 Sensor 2/1 Signal circuit and the (K902) O2 Sensor 2/1 Return circuit in the O2 Sensor 2/1 harness connector.
   NOTE:

   The voltage should drop from between 4.1 and 5.0 Volts to 2.5 Volts with the jumper wire in place.

   Did the O2 Sensor 2/1 voltage change from between 4.1 and 5.0 Volts to 2.5 Volts when the jumper wire was installed?

   Yes 

   • Verify that there is good pin to terminal contact in the O2 Sensor 2/1 and Powertrain Control Module connectors. Replace the O2 Sensor 2/1 if no problems were found with the connectors. Refer to SENSOR, OXYGEN, REMOVAL .
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

   No 

   • Go To  10
     NOTE:

     Remove the jumper wire before continuing.

1. Using the scan tool, monitor all the O2 Sensor 2/1 voltage reading with the jumper wire removed.
   NOTE:

   The scan tool will display all O2 Sensor voltage readings approximately 5.0 Volts when only one O2 Sensor Signal circuits is shorted to voltage.

   NOTE:

   The scan tool will display one O2 Sensor voltage close to zero and the others will read lower than normal when one O2 Sensor Signal circuit contains excessive resistance.

   Is the voltage between 4.1 and 5.0 Volts?

   Yes 

   • Go To  11

   No 

   • Check all the O2 Sensor Signal circuits for an open, short to ground or short to voltage. Inspect the O2 Sensor connector and the PCM harness connector. If OK, replace and program the Powertrain Control Module in accordance with the Service Information. Refer to MODULE, POWERTRAIN CONTROL, REMOVAL .
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

Fig 2: Checking O2 Sensor Return Circuit Voltage

Courtesy of CHRYSLER GROUP, LLC

1. Measure the voltage on the (K902) O2 Sensor 2/1 Return circuit in the O2 Sensor harness connector.

   Is the voltage at 2.5 Volts?

   Yes 

   • Go To  12

   No 

   • Check the (K902) O2 Sensor 2/1 Return circuit for a short to ground, open or short to voltage. Inspect the O2 Sensor 2/1 connector and the PCM harness connector. If OK, replace and program the Powertrain Control Module in accordance with the Service Information. Refer to MODULE, POWERTRAIN CONTROL, REMOVAL .
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Sensors and the Powertrain Control Module (PCM).
   • Look for any chafed, pierced, pinched or partially broken wires.
   • Look for broken, bent, pushed out or corroded terminals.
   • Verify that there is good pin to terminal contact in the O2 Sensor 2/1 and Powertrain Control Module connectors.
   • Perform any Technical Service Bulletins that may apply.

   Were there any problems found?

   Yes 

   • Repair as necessary.
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

   No 

   • Replace and program the Powertrain Control Module in accordance with the Service Information. Refer to MODULE, POWERTRAIN CONTROL, REMOVAL .
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

1. Turn the ignition off.
2. Raise vehicle on hoist and disconnect the fuel pressure line at the fuel pump module.
3. Install the (special tool #8978A, Decay Tool, Fuel) between the fuel supply line and the fuel pump module.
4. Ignition on, engine not running.
5. Using the scan tool, actuate the ASD Fuel System test and observe the fuel pressure gauge.
   NOTE:

   Fuel pressure specification: For the 3.6L is 400 kPa +/- 14 kPa (58 psi +/- 2 psi).

   Is the fuel pressure within specification?

   Yes 

   • Repair or replace fuel supply line as necessary.
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

   No 

   • Go To  14
     CAUTION:

     Stop all actuations.

1. Turn the ignition off.
2. Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer. Refer to MODULE, FUEL PUMP, REMOVAL .

   Is the Fuel Inlet Strainer plugged?

   Yes 

   • Replace the Fuel Pump Inlet Strainer. Refer to MODULE, FUEL PUMP, REMOVAL .
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

   No 

   • Go To  15

Repair 

• Verify that there is good pin to terminal contact in the Fuel Pump Module and Powertrain Control Module connectors. Replace the Fuel Pump Module if no problems were found with the connectors. Refer to MODULE, FUEL PUMP, REMOVAL .
• Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .