Driveability - Gas - Non-Dtc Based Diagnostics: Diagnosis Dodge Avenger II facelift

DIAGNOSTIC TEST

1. COOLING FAN OPERATION (LOW SPEED) With a scan tool, actuate the cooling fans in low speed operation. NOTE: During low speed actuation the Cooling Fan Motors are barely audible. Are the Cooling Fan Motors operating? Yes Go To 2 . No Go To 3 .
2. COOLING FAN OPERATION (HIGH SPEED) With a scan tool, actuate the cooling fans in high speed operation. NOTE: During high speed actuation the Cooling Fan Motors are easily audible. Are both Cooling Fan Motors operating? Yes The Cooling Fan Motors are operating properly. No, Cooling Fan Motor 1 is inoperative Go To 8 . No, Cooling Fan Motor 2 is inoperative Go To 11 .
3. CHECK THE (A16) COOLING FAN 12 VOLT SUPPLY CIRCUIT Turn the ignition on. Remove the Hi-Med. Fan Relay. Using a 12-Volt test light connected to ground, probe the (A16) Cooling Fan 12 Volt Supply circuit at the Relay connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes Go To 4 . No Repair the (A16) Cooling Fan 12 Volt Supply circuit for an open. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
4. CHECK THE (N23) COOLING FAN MOTOR 1 OUTPUT VOLTAGE Disconnect the Cooling Fan Motor 1 harness connector. Using a Voltmeter connected to ground, probe the (N23) Cooling Fan Motor 1 Output circuit at the Cooling Fan Motor 1 harness connector. NOTE: The voltage reading should be approximately Battery voltage. Is the voltage reading equal to Battery voltage? Yes Go To 5 . No Repair the (N23) Cooling Fan Motor 1 Output circuit for an open or high resistance. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
5. CHECK THE COOLING FAN MOTOR 2 OUTPUT VOLTAGE Reconnect the Cooling Fan Motor 1 harness connector. Disconnect the Cooling Fan Motor 2 harness connector. NOTE: Cooling Fan Motor 1 must be connected before checking for voltage at the (N24) circuit. Measure the voltage of the (N24) Cooling Fan Motor 2 Output circuit at the Cooling Fan Motor 2 harness connector. NOTE: The voltage reading should be approximately Battery voltage. Is the voltage reading equal to Battery voltage? Yes Go To 6 . No Go To 7 .
6. CHECK THE (Z901) GROUND CIRCUIT Using a 12-Volt test light connected to 12 Volts, probe the (Z901) Ground circuit at the Cooling Fan Motor 2 harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes Replace the Cooling Fan Motor 2 in accordance with the service information. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Repair the (Z901) Ground circuit for an open. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
7. CHECK THE COOLING FAN MOTOR 2 SUPPLY Turn the ignition off. Disconnect the Cooling Fan Motor 1 harness connector. Measure the resistance from the (N210) Cooling Fan Lo-Hi Control circuit at the Cooling Fan Motor 1 harness connector and the (N24) Cooling Fan Motor 2 Output circuit at the Cooling Fan Motor 2 harness connector. Is the resistance below 5.0 Ohms? Yes Replace the Cooling Fan Motor 1 in accordance with the service information. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Repair the open or high resistance in the circuit or circuits. Try switching the Hi-Lo Fan Relay with a known good relay and rechecking the circuit before checking the (N210) and (N24) circuits for an open. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
8. CHECK THE (A16) COOLING FAN 12 VOLT SUPPLY CIRCUIT Turn the ignition on. Remove the Hi-Med. Fan Relay. Using a 12-Volt test light connected to ground, probe the (A16) Cooling Fan 12 Volt Supply circuit at the Relay connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes Go To 9 . No Repair the (A16) Cooling Fan 12 Volt Supply circuit for an open. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
9. CHECK THE (N23) COOLING FAN MOTOR 1 OUTPUT VOLTAGE Connect a jumper between the (A16) Cooling Fan 12 Volt Supply circuit and the (N23) Cooling Fan Motor 1 Output circuit at the Hi-Med. Fan Relay. Disconnect the Cooling Fan Motor 1 harness connector. Using a Voltmeter connected to ground, probe the (N23) Cooling Fan Motor 1 Output circuit at the Cooling Fan Motor 1 harness connector. NOTE: The voltage reading should be approximately Battery voltage. Is the voltage reading equal to Battery voltage? Yes Go To 10 . No Repair the (N23) Cooling Fan Motor 1 Output circuit for an open or high resistance. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
10. CHECK THE GROUND CIRCUIT With a scan tool, actuate the cooling fans in high speed operation. Using a 12-Volt test light connected to 12 Volts, probe the (N210) Cooling Fan Lo-Hi Control circuit at the Cooling Fan Motor 1 harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes Replace the Cooling Fan Motor 1 in accordance with the service information. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Repair the open or high resistance in the circuit or circuits. Try switching the Hi-Lo Fan Relay with a known good relay and rechecking the circuit before checking the (N210) and (Z901) circuits for an open. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
11. CHECK THE (A16) COOLING FAN 12 VOLT SUPPLY CIRCUIT Turn the ignition on. Remove the Series-Parallel Fan Relay. Using a 12-Volt test light connected to ground, probe the (A16) Cooling Fan 12 Volt Supply circuit at the Relay connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes Go To 12 . No Repair the (A16) Cooling Fan 12 Volt Supply circuit for an open. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
12. CHECK THE (N24) COOLING FAN MOTOR 2 OUTPUT VOLTAGE Connect a jumper between the (A16) Cooling Fan 12 Volt Supply circuit and the (N24) Cooling Fan Motor 2 Output circuit at the Series-Parallel Fan Relay. Disconnect the Cooling Fan Motor 2 harness connector. Using a Voltmeter connected to ground, probe the (N24) Cooling Fan Motor 2 Output circuit at the Cooling Fan Motor 2 harness connector. NOTE: The voltage reading should be approximately Battery voltage. Is the voltage reading equal to Battery voltage? Yes Go To 13 . No Repair the (N24) Cooling Fan Motor 2 Output circuit for an open or high resistance. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
13. CHECK THE (Z901) GROUND CIRCUIT Using a 12-Volt test light connected to 12 Volts, probe the (Z901) Ground circuit at the Cooling Fan Motor 2 harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes Replace the Cooling Fan Motor 2 in accordance with the service information. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Repair the (Z901) Ground circuit for an open or high resistance. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .

Scheme 475

For a complete wiring diagram, refer to appropriate SYSTEM WIRING DIAGRAMS article .

1. ENGINE COOLANT TEMPERATURE SENSOR WIRING OR CONNECTORS NOTE: Diagnose and repair any ECT circuit DTCs before proceeding with this test. NOTE: Allow the engine to cool to ambient temperature before proceeding. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor and the PCM. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Turn the ignition on. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. Look for the data to change or for a DTC to set during the wiggle test. Were any problems found? Yes Repair as necessary in accordance with the Service Information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 2 .
2. ENGINE COOLANT LEVEL AND CONDITION WARNING: Make sure the engine cooling system is cool before removing the pressure cap or any hose. The cooling system is pressurized when hot. Failure to follow these instructions can result in possible serious or fatal injury. Check the engine coolant level and the condition of the engine coolant. Refer to the appropriate Service Information. Were any problems found? Yes Repair as necessary in accordance with the Service Information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 3 .
3. THERMOSTAT Using the appropriate service information, determine the proper opening temperature of the thermostat. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. Monitor the sensor values on the scan tool. Start the engine. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: Each thermostat should open at the temperature specified in the Service Information. Were any problems found? Yes Repair as necessary in accordance with the Service Information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 4 .
4. ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. With the scan tool, read the Engine Coolant Temperature Sensor value for each sensor. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. Monitor each sensor value on the scan tool and the actual coolant temperature with a thermometer. Start the engine. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature values on the scan tool should remain relatively close. Were any problems found? Yes Go To 5 . No Test complete.
5. ECT SIGNAL CIRCUIT HIGH RESISTANCE NOTE: Perform this procedure for the sensor where erratic sensor values were detected in the previous test step. Turn the ignition off. Using a voltmeter, perform a voltage drop test by backprobing the ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and the PCM C2 harness connector. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. Start the engine. Is the voltage below 0.5 Volt? Yes Go To 6 . No Repair the ECT Signal circuit for excessive resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
6. SENSOR GROUND CIRCUIT HIGH RESISTANCE Turn the ignition off. Using a voltmeter, perform a voltage drop test by backprobing the Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and the PCM C2 harness connector. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. Start the engine. Is the voltage below 0.5 Volts? Yes Go To 7 . No Repair the Sensor Ground circuit for excessive resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
7. ENGINE COOLANT TEMPERATURE SENSOR Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Engine Coolant Temperature Sensor 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. Perform any Technical Service Bulletins that may apply. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Replace the Engine Coolant Temperature Sensor. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .

1. CHECKING THE ENGINE MECHANICAL SYSTEM Turn the ignition off. Check for any of the following conditions/mechanical problems: AIR INDUCTION SYSTEM - must be free from leaks and restrictions 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 from leaks and restrictions ENGINE OIL - must be clean, at the proper level, free from contamination or fuel 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(s); control wire not connected to the correct injector CAM LOBES - must not be worn excessively CYLINDER LEAKAGE TEST - must be within specifications VALVE SPRINGS - cannot be weak or broken Were any problems found? Yes Repair as necessary in accordance with the Service Information. Perform the PCM VERIFICATION Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Test Complete.

1. CHECKING THE EXHAUST SYSTEM FOR LEAKS Turn the ignition off. 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. Connect Exhaust Cone (special tool #8404-EC, Exhaust Cone) or (special tool #8404-EC, Exhaust Cone) to 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. Attach shop air to the air pressure regulator. Adjust the Air Pressure Regulator to 27.6 KPA (4 psi). Insert the exhaust cone into the vehicle tail pipe. 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. 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 45.72 cm (18 in.) 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) Watch for the Mopar® Air Leak Detector PN 05191804AA (or the equivalent leak finder liquid) to bubble. Use the following definitions to help determine if system or component repair/replacement is necessary: Type 1 Leak is defined as a leak where very small foam like bubbles 1 mm (0.04 of an inch) or less appear. 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. Type 2 Leak is defined as a leak where larger bubbles pea size, 8 mm (0.3 of an inch) or greater appear. 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 4 psi reveal bubble size: Welded joints Type 1: 1 mm (0.04 in.) or greater O2 Sensor seal points Type 1: 1 mm (0.04 in.) or greater O2 Sensor boss welds Type 1: 1 mm (0.04 in.) or greater Flange/joint connections Type 2: 8 mm (0.31 in.) or greater Exhaust Manifold to cylinder head connections Type 2: 8 mm (0.31 in.) or greater EGR gasket and tube seal points Type 2: 8 mm (0.31 in.) or greater If a leak is found that matches the above definition, repair or replace the component as necessary. 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 PCM Verification Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Test complete.

1. CHECKING THE FUEL PUMP OPERATION Turn the ignition on. NOTE: Diagnose and repair any fuel pump control circuit or relay DTCs before continuing with this test. With a scan tool, actuate the fuel pump control to ON (100%). NOTE: It may be necessary to use a mechanics stethoscope in the next step. Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly, without excessive noise. If necessary, compare to a known good vehicle of similar year, make, and model. NOTE: If the pump has excessive noise or grinding, the pump should be replaced. CAUTION: Stop all actuation tests before continuing. Is the fuel pump operating when actuated? Yes Go To 2 . No Go To 7 .
2. CHECKING THE FUEL PRESSURE Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Turn the ignition off. Install the Fuel Pressure Decay Tester (special tool #8978A, Decay Tool, Fuel) on the fuel line near the intake manifold Ignition on, engine not running. With a scan tool, actuate the Fuel Pump and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi). CAUTION: Stop all actuation tests before continuing. Select the conclusion that best matches the result of the test: Fuel pressure is within the stated specification Test complete. Fuel pressure is below the stated specification Go To 3 . Fuel pressure is above the stated specification Replace the fuel filter/pressure regulator. Perform the PCM Verification Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
3. RESTRICTED FUEL SUPPLY LINE Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Turn the ignition off. Remove the Fuel Pressure Decay Tester (special tool #8978A, Decay Tool, Fuel). Raise the vehicle on a hoist, and disconnect the fuel supply line at the fuel pump module. Install the Fuel Pressure Decay Tester (special tool #8978A, Decay Tool, Fuel) at the fuel pump. Ignition on, engine not running. Read the Fuel Pressure Gauge and record the reading. The fuel pressure specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi). Is the fuel pressure within specification? Yes Repair or replace fuel supply line as necessary. Perform the PCM Verification Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 4 .
4. SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes Go To 5 . No Go To 6 .
5. FUEL TANK SIPHON HOSE OR FUEL LINE RESTRICTED OR DAMAGED Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Gain access to the fuel pump module and the fuel tank module. Inspect the fuel line and siphon hose between the fuel pump module and the fuel tank module. Look for disconnected or damaged lines and hoses. Inspect the fuel pressure regulator for damage or a condition that might cause a fuel flow problem. Make sure that it is seated in the module properly. Were any problems found? Yes Repair as necessary. Perform the PCM Verification Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 6 .
6. FUEL PUMP INLET STRAINER Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Remove the fuel pump module and inspect the fuel inlet strainer for damage or a condition that might cause a fuel flow problem. Were any problems found? Yes Replace the Fuel Pump Inlet Strainer. Perform the PCM Verification Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Replace the Fuel Pump Module. Perform the PCM Verification Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
7. FUEL PUMP GROUND CIRCUIT OPEN OR HIGH RESISTANCE Turn the ignition off. Disconnect the Fuel Pump Module harness connector. Using a 12-volt test light connected to 12 volts, check the Fuel Pump Motor Ground circuit at the Fuel Pump Module harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes Replace the Fuel Pump Module in accordance with the Service information. Perform the PCM Verification Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Repair the Fuel Pump Ground circuit for an open circuit or high resistance. Perform the PCM Verification Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .

Scheme 476

For a complete wiring diagram, refer to appropriate SYSTEM WIRING DIAGRAMS article .

Scheme 477

Scheme 478

1. IGNITION COIL WIRING OR CONNECTORS NOTE: Diagnose and repair any ignition coil, CMP sensor, or CKP sensor DTCs before proceeding with this test. Turn the ignition off. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Ignition Coil for the cylinder being tested and the PCM. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. NOTE: If the vehicle is not equipped with the coil on plug ignition system, check the resistance of the ignition wire(s) before checking the cylinder with a spark tester. The resistance should be below 10k Ohms. Were any problems found? Yes Repair as necessary in accordance with the Service Information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 2 .
2. IGNITION COIL OPERATION NOTE: Inspect the ignition coil for damage, carbon tracking on the coil or a damaged spark plug insulator boot. If a problem is found, replace the ignition coil. Turn the ignition off. If the vehicle is equipped with coil on plug ignition system, remove the ignition coil for the cylinder being tested. Disconnect the fuel injector harness connector for the cylinder being tested. For coil on plug ignition systems, install a spark tester(s) on the ignition coil, otherwise install the spark tester to the ignition wire. While cranking the engine observe the spark coming from the spark tester. NOTE: A crisp blue spark that jumps the gap of the spark tester should be generated. Is good spark present? Yes Go To 7 . No Go To 3 .
3. ASD RELAY OUTPUT CIRCUIT OPEN OR HIGH RESISTANCE Turn the ignition off. Disconnect the Ignition Coil harness connector. Turn the ignition on. With the scan tool, actuate the ASD Relay to on. Using a 12-Volt test light connected to ground, check the ASD Relay output circuit in the ignition coil harness connector. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright during the actuation? Yes Go To 4 . No Repair the ASD Relay output circuit for an open circuit or high resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
4. IGNITION COIL WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. Using a 12-Volt test light connected to 12 Volts, check the Ignition Coil control circuit for the cylinder being tested in the Ignition Coil harness connector. Crank the engine for five seconds. NOTE: The test light should BLINK each time the circuit is activated by the PCM. Does the test light blink each time the circuit is activated by the PCM? Yes Replace the Ignition Coil in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 5 .
5. IGNITION COIL CONTROL CIRCUIT OPEN OR HIGH RESISTANCE Measure the resistance of the Ignition Coil control circuit for the cylinder being tested between the Ignition Coil harness connector and the PCM C2 harness connector. Is the resistance below 5.0 Ohms? Yes Go To 6 . No Repair the Ignition Coil control circuit for an open circuit or high resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
6. POWERTRAIN CONTROL MODULE (PCM) Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Ignition Coil for the cylinder being tested and the PCM. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Perform any Technical Service Bulletins that may apply. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Replace and program the Powertrain Control Module (PCM) in accordance with the Service Information. Refer to «MODULE, POWERTRAIN CONTROL, REMOVAL»(ref-485482-S06048014282012071300000) . Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
7. SPARK PLUG(S) Turn the ignition off. Remove the spark plug. Inspect the spark plug for any of the following conditions: Cracks or damage Carbon tracking Foreign material Gap not within specification Loose or broken electrode NOTE: Lightly tap the bottom of the spark plug on a solid surface. The electrode in the spark plug should not move. Were any problems found? Yes Replace the spark plug. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Test Complete.

1. MAP SENSOR WIRING OR CONNECTORS NOTE: Diagnose and repair any MAP Sensor circuit DTCs before proceeding with this test. NOTE: Diagnose and repair any sensor supply or system voltage DTCs before proceeding with this test. Turn the ignition off. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor and the PCM. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Turn the ignition on. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes Repair as necessary in accordance with the Service Information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 2 .
2. MAP VACUUM/BAROMETRIC PRESSURE With a scan tool, read the Barometric Pressure. NOTE: The Barometric Pressure should be approximately equal to the actual barometric pressure. If necessary, compare the Barometric Pressure value of the tested vehicle to the value of a known good vehicle of a similar make and model. Connect a vacuum gauge to a manifold vacuum source. Start the engine. NOTE: If engine will not idle, maintain a constant RPM above idle. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. With the scan tool, read the MAP Sensor vacuum. NOTE: The scan tool reading for MAP vacuum should be within 1" of the vacuum gauge reading. Were any problems found? Yes Go To 4 . No Go To 3 .
3. MAP SENSOR VOLTAGE With the scan tool, monitor the MAP Sensor signal voltage. With the engine idling in neutral or park, snap the throttle. NOTE: The MAP Sensor signal voltage should change from below 2.0 Volts at idle to above 3.5 Volts at wide open throttle. Were any problems found? Yes Go To 4 . No Test complete.
4. (F856) 5-VOLT SUPPLY CIRCUIT HIGH RESISTANCE Turn the ignition off. Using a Voltmeter, perform a voltage drop test by backprobing the (F856) 5-Volt Supply circuit at the MAP Sensor harness connector and the PCM C2 harness connector. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. Start the engine. Is the voltage below 0.5 Volt? Yes Go To 5 . No Repair the (F856) 5-Volt Supply circuit for excessive resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
5. (K1) MAP SIGNAL CIRCUIT HIGH RESISTANCE Turn the ignition off. Using a Voltmeter, perform a voltage drop test by backprobing the (K1) MAP Signal circuit at the MAP Sensor harness connector and the PCM C2 harness connector. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. Start the engine. Is the voltage below 0.5 Volt? Yes Go To 6 . No Repair the (K1) MAP Signal circuit for excessive resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
6. (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE Turn the ignition off. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the MAP Sensor harness connector and the PCM C2 harness connector. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. Start the engine. Is the voltage below 0.5 Volt? Yes Go To 7 . No Repair the (K900) Sensor Ground circuit for excessive resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
7. MAP SENSOR Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the MAP Sensor 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. Perform any Technical Service Bulletins that may apply. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Replace the MAP Sensor. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .

Scheme 479

For a complete wiring diagram, refer to appropriate SYSTEM WIRING DIAGRAMS article .

1. OXYGEN SENSOR, WIRING OR CONNECTORS NOTE: Diagnose and repair any O2 sensor or rationality DTCs before proceeding with this test. NOTE: When performing this procedure as part of another diagnostic process, it may be necessary to repeat this test for all of the Oxygen Sensors on the vehicle. Turn the ignition off. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen Sensor 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. Turn the ignition on. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 2 .
2. OXYGEN SENSOR VOLTAGE Start the engine and allow it to reach normal operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. With a scan tool, monitor all O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 Volts for all O2 Sensors? Yes Go To 3 . No Go To 4 .
3. O2 SENSOR HEATER OPERATION 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. Turn the ignition on. With a scan tool, actuate the O2 Sensor heater. With the scan tool, monitor O2 Sensor voltage for at least two minutes. Does the voltage stay above 4.5 Volts? Yes Go To 4 . No Test complete.
4. O2 SENSOR Turn the ignition off. NOTE: Check for contaminants that may cause improper O2 Sensor operation, such as contaminated fuel, unapproved silicone, or evidence of oil or coolant. Disconnect the O2 Sensor harness connector. Turn the ignition on. With a scan tool, monitor the O2 Sensor voltage. NOTE: The voltage should be approximately 5.0 Volts with the connector disconnected. Connect a jumper wire between the signal circuit and the return circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from 5.0 Volts to 2.5 Volts with the jumper wire in place. Is the O2 Sensor voltage displayed on the scan tool as described? Yes Replace the O2 Sensor. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 5 .
5. O2 SENSOR SIGNAL CIRCUIT Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Signal circuit and connectors between the O2 Sensor and the PCM. Check the O2 Sensor signal circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 6 .
6. O2 SENSOR RETURN CIRCUIT Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Return circuit and connectors between the O2 Sensor and the PCM. Check the O2 Sensor return circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 7 .
7. POWERTRAIN CONTROL MODULE (PCM) Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 Sensor and the PCM. Look for any chafed, pierced, pinched or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Monitor the scan tool data relative to the components tested in this procedure and wiggle test the wiring and connectors. Look for the data to change or for a DTC to set during the wiggle test. Perform any Technical Service Bulletins (TSBs) that may apply. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Replace and program the Powertrain Control Module (PCM) in accordance with the Service Information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .

1. COMPARE TEMPERATURE SENSOR VALUES Turn the ignition off. Allow the vehicle to sit with the ignition off in an environment where the temperature is consistent and above - 7°C (19.4°F) until the engine coolant temperature is equal to ambient temperature. Turn the ignition on. Using a thermometer, measure and record the underhood and ambient temperatures. With a scan tool, read the ambient air temperature (AAT), engine coolant temperature (ECT), engine oil temperature (EOT) and intake air temperature (IAT) sensor values, as applicable. Are all temperature sensor values within 10°C (18°F) of the thermometer and the other sensor values? Yes Test complete. No Go To 2 .
2. TEMPERATURE SENSOR WIRING OR CONNECTORS NOTE: Perform the following procedures for each sensor that was not within the specified range as described in the previous step. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the temperature sensor(s) and the applicable control module. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Turn the ignition on. Monitor the scan tool data relative to the sensor(s) and wiggle test the wiring and connectors. Look for the data to change or for a DTC to set during the wiggle Test. Were any problems found? Yes Repair as necessary in accordance with the Service Information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 3 .
3. SENSOR VOLTAGE Turn the ignition off. Disconnect the temperature sensor harness connector. Connect a jumper wire between the signal circuit and the sensor ground circuit in the sensor harness connector. Turn the ignition on. With a scan tool, read the sensor voltage. NOTE: The sensor voltage should be approximately 0.0 Volts (plus or minus.1 Volt) with the jumper wire in place. Does the scan tool display the voltage as described above? Yes Go To 4 . No Go To 5 .
4. TEMPERATURE SENSOR Turn the ignition off. Remove the jumper wire from between the signal circuit and the sensor ground circuit in the sensor harness connector. Turn the ignition on. With a scan tool, read the sensor voltage. NOTE: The sensor voltage should be approximately 5.0 Volts (plus or minus 0.1 Volt) with the connector disconnected. Does the scan tool display the voltage as described above? Yes Replace the sensor. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 5 .
5. SIGNAL CIRCUIT SHORTED TO GROUND Turn the ignition off. Measure the resistance between ground and the signal circuit in the sensor harness connector. Is the resistance above 100 Ohms? Yes Go To 6 . No Repair the signal circuit for a short to ground. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
6. SIGNAL CIRCUIT SHORTED TO SENSOR GROUND CIRCUIT Measure the resistance between the signal circuit and the sensor ground circuit in the sensor harness connector. Is the resistance above 100 Ohms? Yes Go To 7 . No Repair the signal circuit for a short to the sensor ground circuit. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
7. SIGNAL CIRCUIT HIGH RESISTANCE Turn the ignition off. Connect the temperature sensor harness connector. Using a voltmeter, perform a voltage drop test by backprobing the signal circuit at the sensor harness connector and at the module harness connector. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. Start the engine. Is the voltage below 0.5 Volt? Yes Go To 8 . No Repair the signal circuit for high resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
8. SENSOR GROUND CIRCUIT HIGH RESISTANCE Turn the ignition off. Using a voltmeter, perform a voltage drop test by backprobing the sensor ground circuit at the sensor harness connector and at the module harness connector. Make sure the voltmeter leads are connected so that positive polarity is displayed on the voltmeter. Start the engine. Is the voltage below 0.5 Volt? Yes Go To 9 . No Repair the sensor ground circuit for high resistance. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
9. CONTROL MODULE Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the sensor and the applicable control module. Refer to the appropriate system schematic. Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Monitor the scan tool data relative to this circuit and wiggle Test. the wiring and connectors. Look for the data to change or for the DTC to reset during the wiggle Test. Perform any Technical Service Bulletins that may apply. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Replace the applicable control module in accordance with the Service Information. Perform the POWERTRAIN VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .

1. NO START PRE-TEST NOTE: The following list of items must be checked before continuing with any no start tests. The battery must be fully charged and in good condition. A low charged battery may produce invalid test results. If the battery is low, charge the battery and then attempt to start the vehicle by cranking the engine for 15 seconds, 3 consecutive times. This will allow any DTCs to set that may have been erased due to a dead battery. Attempt to communicate with the PCM using the scan tool. If the PCM is experiencing a no response condition, for the proper Loss of Communication diagnostic procedure. Refer to «DIAGNOSIS AND TESTING»(ref-485491-S29601655582012071300000) . Read the PCM DTCs with the scan tool. If any DTCs are present, they must be repaired before continuing with any other No Start diagnostic tests. Perform the appropriate diagnostic procedure. Inspect all fuses in the TIPM and the Junction Box. If an open fuse(s) is found, check the related circuit(s) for a short to ground or high resistance. Using a test light, check the Powers and Ground to the PCM. The test light must illuminate brightly as if jumpered across a battery. Attempt to communicate with the Instrument Cluster and VTSS. If you are unable to establish communications perform the appropriate diagnostic procedures. The Wireless Control Module (WCM) must be operating properly. Check for proper communication with the scan tool and check for DTCs that may be stored in the WCM. Repair the DTC(s) before continuing. If no DTCs are found, using the scan tool, select Clear PCM (BATT Disconnect). Crank the engine several times. Using the scan tool, read DTCs. If a DTC is present perform the DTC diagnostics before continuing. Were any problems found? Yes Repair as necessary. Perform the PCM VERIFICATION Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 2 .
2. OPEN FUSE Check for any open fuses in both TIPM or Junction Block that may be related to the no start condition. NOTE: If an open fuse is found, inspect the related circuit(s) for a short to ground or high resistance. Are any of the fuses open? Yes Replace the open fuse and check the related circuit(s) for a short to ground. Perform the PCM VERIFICATION Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 3 .
3. SECONDARY INDICATORS PRESENT NOTE: Diagnose only the Secondary Indicators that would cause a no start. Ignition on, engine not running. With the scan tool, check the Secondary Indicators while cranking the engine that would cause a no start condition. Are there any Secondary Indicators present while cranking the engine? Yes Refer to the appropriate Engine Electrical Diagnostics information and perform the tests related to the no start secondary indicator that is reported by the scan tool. Perform the PCM VERIFICATION Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 4 .
4. POSSIBLE MECHANICAL PROBLEMS Check for any of the following conditions/mechanical problems: ENGINE VALVE TIMING - must be within specifications, check for broken timing components. ENGINE COMPRESSION - must be within specifications. ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks. Are there any engine mechanical problems? Yes Repair as necessary. Perform the PCM VERIFICATION Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 5 .
5. FUEL PUMP DELIVERY Verify that the Fuel tank is not empty before continuing. Follow the diagnostics for Checking Fuel Delivery in this information. Was the No Start condition solved after following the above diagnostic test? Yes Test Complete. No Check for contamination/water in the fuel. Make sure the fuel being used in this vehicle meets manufactures Fuel Requirement, refer to «FUEL SYSTEM»(ref-485510) «FUEL REQUIREMENTS»(ref-485472-S32983059082012071300000) in the service information. Perform the PCM VERIFICATION Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .

FUEL DELIVERY SYSTEM OUTPUT - FLOW TEST

For a complete wiring diagram, refer to appropriate SYSTEM WIRING DIAGRAMS article .

Scheme 480

Scheme 481

Scheme 482

Scheme 483

1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes Repair or replace as necessary. Perform the PCM VERIFICATION TEST. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 2 .
2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM THE GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A Turn the ignition off. WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. Install the appropriate Fuel Line Adapters / Fitting from the Gas and Diesel Fuel Pressure/Decay Tester (special tool #8978A, Decay Tool, Fuel). Proceed Go To 3 .
3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Connect Fuel Pressure Gauge Assembly (special tool #8978A, Decay Tool, Fuel), Fuel Inlet Hose (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. Connect special tool Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). Connect Reservoir Assembly 534960 (4) to Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed Go To 4 .
4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Close the Flow Test Valve (2). Ignition on, engine not running. With the scan tool, actuate the fuel pump. Open the Flow Test Valve (1) for 10 seconds, then close the Valve. CAUTION: Stop All Actuations. Turn the ignition off. Disconnect, empty and then reconnect the Reservoir Assembly. Turn the ignition on, wait five seconds, turn the ignition off and then wait one minute before proceeding. Read the Fuel Pressure Gauge (3) and record the reading. The fuel pressure specification is 407 kPa +/- 34 kPa (59 psi +/- 5 psi). Is the fuel pressure within specifications? Yes Go To 5 . No Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. Refer to «DIAGNOSIS AND TESTING»(ref-485545-S29788819262012071300000) .
5. CHECK FUEL DELIVERY SYSTEM OUTPUT WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Ignition on, engine not running. With the scan tool, actuate the fuel pump. Open the Flow Test Valve (1) for 20 seconds, then close the Valve. CAUTION: Stop All Actuations. Turn the ignition off. Measure the amount of fuel in the Reservoir Assembly (2). The fuel output specification is ml/s X 20 seconds = fuel flow in ml. FUEL FLOW ENGINE ml/s ml per 20 Seconds 4 Cylinder and 6 Cylinder 20.8333A 417 8 Cylinder 38.88889 778 Does the amount of fuel in the reservoir meet or exceed the specification? Yes Test complete. No Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. Refer to «DIAGNOSIS AND TESTING»(ref-485545-S29788819262012071300000) .

1. CHECKING FUEL PRESSURE Turn the ignition off. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Turn the ignition off. Install the Fuel Pressure Decay Tester (special tool #8978A, Decay Tool, Fuel) on the fuel line near the intake manifold Ignition on, engine not running. With a scan tool, actuate the Fuel Pump and observe the fuel pressure gauge. NOTE: All gas engines except SRT-4 fuel pressure specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi). SRT-4 only fuel pressure specification is 552 KPa +/- 34 KPa (80 psi +/- 5 psi). Choose a conclusion that best matches your fuel pressure reading. Below Specification Go To 2 . Within Specification Go To 4 .
2. RESTRICTED FUEL SUPPLY LINE WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Turn the ignition off. Remove the Fuel Pressure Decay Tester (special tool #8978A, Decay Tool, Fuel). Raise the vehicle on a hoist, and disconnect the fuel supply line at the fuel pump module. Install the Fuel Pressure Decay Tester (special tool #8978A, Decay Tool, Fuel) at the fuel pump. Ignition on, engine not running. Read the Fuel Pressure Gauge and record the reading. Non SRT-4 fuel pressure specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi). SRT-4 fuel pressure specification is 552 KPa +/- 34 KPa (80 psi +/- 5 psi). Is the fuel pressure within specification? Yes Visually and physically inspect the fuel supply lines between the fuel tank and the fuel rail. Repair/replace as necessary. Perform the PCM Verification Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Go To 3 .
3. CHECKING THE FUEL PUMP INLET WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Turn the ignition off. Remove the Fuel Pump Module and Fuel Tank Module (if equipped), inspect the Fuel Pump Inlet and the bottom of the fuel tank for debris that could cause the fuel pump inlet to be plugged. Is the Fuel Inlet Strainer plugged? Yes Repair/Replace as necessary. Perform the PCM Verification Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No Replace the Fuel Pump Module. Perform the PCM Verification Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) .
4. FUEL PUMP MODULE NOTE: Before continuing visually and physically inspect the fuel delivery system for external leaks or damage. Repair / replace as necessary. WARNING: The fuel system is under a constant pressure even with the engine off. Before testing or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. Turn the ignition off. Install the Fuel Pressure Decay Tester (special tool #8978A, Decay Tool, Fuel) at the intake manifold. Start the engine and allow the fuel system to reach maximum pressure. Turn the ignition off. Close the Fuel System Isolation Valve and then wait five minutes before proceeding. NOTE: All gas engines except SRT-4 fuel pressure specification is 407 KPa +/- 34 KPa (59 psi +/- 5 psi). SRT-4 only fuel pressure specification is 552 KPa +/- 34 KPa (80 psi +/- 5 psi). Read the Fuel Inlet and Fuel Outlet Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Monitor the fuel pressure gauge for a minimum of five minutes. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge Replace Fuel Pump Module. Perform the PCM Verification Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . Yes - On Fuel Outlet Gauge Replace the leaking fuel injector(s). Perform the PCM Verification Test. Refer to «2.4L - PCM/TCM PROGRAMMING, INTERMITTENT CONDITION, PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE & PCM VERIFICATION TEST»(ref-485547) or «3.6L - INTERMITTENT CONDITION, PCM/ECM PROGRAMMING - GAS, POWERTRAIN VERIFICATION TEST & PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE»(ref-485569) . No If directed here by another test, return to that test. Otherwise, test complete.