Engine Controls - Troubleshooting Procedures & Tests: Diagnosis Dodge Magnum I facelift

Diagnostic Test

1. 1) FUEL PUMP MODULE NOTE: Before continuing, thoroughly inspect the fuel delivery system. Repair or replace any damaged or leaking parts as necessary. 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 personal injury or death. Install special tool #6539 (5/16") or #6631 (3/8") fuel line adapter. Install the fuel pressure gauge. Start the engine and allow the fuel system to reach maximum pressure. Turn the ignition off. NOTE: Fuel specification is 407 kPa +/- 34 kPa (59 psi +/- 5 psi). If the fuel pressure is not within specification refer to «*CHECKING THE FUEL DELIVERY SYSTEM»(ref-304544-S11771868502008111000000) . Using special tool #C4390, Hose Clamp Pliers, pinch the rubber fuel line between the fuel pressure gauge and the engine. Monitor the fuel pressure gauge for a minimum of 5 minutes. NOTE: The pressure should not fall below 241 kPa (35 psi) Does the fuel pressure drop? Yes Replace Fuel Pump Module. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 2) .
2. 2) FUEL INJECTOR(S) 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 personal injury or death. Remove special tool #C4390. Start the engine and allow the fuel system to reach maximum pressure. Turn the ignition off. NOTE: NOTE: Fuel specification is 407 kPa +/- 34 kPa (59 psi +/- 5 psi). Using special tool #C4390, Hose Clamp Pliers, pinch the rubber fuel line between the fuel pressure gauge and fuel pump module. Monitor the fuel pressure gauge for a minimum of 5 minutes. NOTE: The pressure should not fall below 241 kPa (35 psi) Does the fuel pressure drop? Yes Replace the leaking fuel injectors. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Test complete.

Scheme 551

For complete wiring diagrams refer to

SYSTEM WIRING DIAGRAMS for 300.

SYSTEM WIRING DIAGRAMS for Charger.

SYSTEM WIRING DIAGRAMS for Magnum.

Scheme 552

Scheme 553

Scheme 554

Scheme 555

Scheme 556

1. 1) GENERATOR FULL FIELD TEST NOTE: Diagnose and repair any generator sense or field control circuit DTCs before proceeding with this test. Start the engine and allow it to reach 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 can result in personal injury or death. With the scan tool, perform the Generator Full Field test. Follow the instructions displayed on the scan tool. Monitor the system (battery) voltage and the generator sense voltage on the scan tool while performing the test. NOTE: With the engine running, the difference between the system (battery) voltage and the generator sense voltage should be below.2 volts. NOTE: With the generator field fully actuated, the system (battery) voltage should be above 14.0 volts. NOTE: With the generator field actuated off, the system (battery) voltage should be below 13.0 volts, and eventually drop as battery load is increased. Did the system voltage change as described above during the Generator Full Field test? Yes Test complete. No Go to step 2) .
2. 2) CHARGING SYSTEM INSPECTION Inspect and test the battery in accordance with the Service Information. Inspect the generator drive belt for proper alignment and adjustment. Inspect the vehicle for aftermarket accessories that may exceed the generator system output. Inspect the fuses in the PDC and TIPM. If an open fuse is found, use the wire diagram/schematics as a guide and inspect the wiring and connectors for a damaged or shorted circuit. Were any problems found? Yes Repair as necessary. No Go to step 3) .
3. 3) BATTERY POSITIVE (+) CIRCUIT HIGH RESISTANCE NOTE: Make sure all testing equipment and cables are clear of any engine parts before starting the engine. 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 can result in personal injury or death. Measure the voltage between the B (+) Terminal at the Generator and the Battery Positive (+) Post. Is the voltage below 0.4 volts? Yes Go to step 4) . No Repair the battery positive (+) circuit between the generator and battery for high resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
4. 4) GENERATOR CASE GROUND HIGH RESISTANCE NOTE: Make sure all testing equipment and cables are clear of any engine parts before starting the engine. 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 can result in personal injury or death. Measure the voltage between the Generator case and the Battery Negative (-) post. Is the voltage below 0.1 volt? Yes Go to step 5) . No Repair the Generator Case ground for high resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
5. 5) (K20) GEN FIELD CONTROL CIRCUIT HIGH RESISTANCE Turn the ignition off. 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 along with the #8815-1 to perform the diagnosis. Using a voltmeter, perform a voltage drop test by backprobing the (K20) Gen Field Control circuit at the Generator harness connector and probing the appropriate terminal of the special tool #8815. 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 can result in personal injury or death. Start the engine. Is the voltage below 0.5 volts? Yes Go to step 6) . No Repair the (K20) Gen Field Control circuit for high resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
6. 6) GENERATOR Turn the ignition off. Disconnect the Generator harness connector. Connect a 12 volt test light connected between the (Z904) Ground circuit and the (K20) Gen Field Control circuit in the Generator harness connector. Turn the ignition on. With the scan tool, actuate the Alternator Field Control State to toggle. NOTE: The test light should toggle on and off with the actuation. NOTE: If a DTC is active, the actuation test may not be allowed by the PCM. If may be necessary to clear DTCs before starting the actuation. Does the test light illuminate on and off with the actuation? Yes Replace the Generator in accordance with the Service Information. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 7) .
7. 7) (K20) GEN FIELD CONTROL CIRCUIT SHORTED TO VOLTAGE Turn the ignition off. Disconnect the Powertrain Control Module (PCM) connector. Turn the ignition on. Measure the voltage of the (K20) Gen Field Control circuit in the Generator harness connector. Is there any voltage present? Yes Repair the (K20) Gen Field Control circuit for a short to voltage. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 8) .
8. 8) (K20) GEN FIELD CONTROL CIRCUIT SHORTED TO GROUND Turn the ignition off. Measure the resistance between ground and the (K20) Gen Field Control circuit in the Generator harness connector. Is the resistance below 100 ohms? Yes Repair the (K20) Gen Field Control circuit for a short to ground. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 9) .
9. 9) (K20) GEN FIELD CONTROL CIRCUIT OPEN OR HIGH RESISTANCE 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 (K20) Gen Field Control circuit between the Generator harness connector and the appropriate terminal of special tool #8815. Is the resistance below 5.0 ohms? Yes Go to step 10) . No Repair the (K20) Gen Field Control circuit for an open circuit or high resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
10. 10) (Z904) GROUND CIRCUIT OPEN OR HIGH RESISTANCE Measure the resistance between ground and the (Z904) Ground circuit in the Generator harness connector. Is the resistance below 5.0 ohms? Yes Go to step 11) . No Repair the (Z904) Ground circuit for an open circuit or high resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
11. 11) CHECKING THE PCM POWER AND GROUND CIRCUITS Perform the diagnostic procedure for CHECKING THE PCM POWER AND GROUND CIRCUITS. Were any problems found? Yes Repair the PCM power and ground circuit(s) as necessary. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 12) .
12. 12) POWERTRAIN CONTROL MODULE (PCM) Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Generator 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. Refer to any Technical Service Bulletins that may apply. Were any problems found? Yes Repair as necessary. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Replace and program the Powertrain Control Module (PCM) in accordance with the Service Information. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .

Scheme 557

For complete wiring diagrams refer to

SYSTEM WIRING DIAGRAMS for 300.

SYSTEM WIRING DIAGRAMS for Charger.

SYSTEM WIRING DIAGRAMS for Magnum.

Scheme 558

Scheme 559

1. 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(s) 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(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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 2) .
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 personal injury including extreme burns, scalding, or death. 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 3) .
3. 3) THERMOSTAT 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 personal injury including extreme burns, scalding, or death. Using the appropriate service information, determine the proper opening temperature of the thermostat. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. Monitor the sensor value 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 can result in personal injury or death. NOTE: The thermostat should not open until the engine reaches the temperature specified in the Service Information. Were any problems found? Yes Repair as necessary in accordance with the Service Information. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 4) .
4. 4) ENGINE COOLANT TEMPERATURE SENSOR NOTE: Allow the engine to cool to ambient temperature before proceeding. 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 personal injury including extreme burns, scalding, or death. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to cool completely, the value should be approximately equal to the ambient temperature. Monitor the sensor value on the scan tool and the actual coolant temperature with a thermometer. 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 can result in personal injury or death. NOTE: The sensor value transition should be smooth as the engine reaches operating temperature. The thermometer reading and the coolant temperature value on the scan tool should remain relatively close. Were any problems found? Yes Go to step 5) . Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Test complete.
5. 5) (K2) ECT SIGNAL CIRCUIT HIGH RESISTANCE Turn the ignition off. 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 along with the #8815-1 to perform the diagnosis. Using a voltmeter, perform a voltage drop test by backprobing the (K2) ECT Signal circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. 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 can result in personal injury or death. Start the engine. Is the voltage below 0.5 volts? Yes Go to step 6) . No Repair the (K2) ECT Signal circuit for excessive resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
6. 6) (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE Turn the ignition off. 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 along with the #8815-1 to perform the diagnosis. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the Engine Coolant Temperature Sensor harness connector and by probing the appropriate terminal of the special tool #8815. 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 can result in personal injury or death. Start the engine. Is the voltage below 0.5 volts? Yes Go to step 7) . No Repair the (K900) Sensor Ground circuit for excessive resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
7. 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. Refer to any Technical Service Bulletins that may apply. Were any problems found? Yes Repair as necessary. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Replace the Engine Coolant Temperature Sensor. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .

1. 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Test Complete.

1. 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 #8404-EC to Air Pressure Regulator (with hose) #W-18-MIL-1146AS. CAUTION: The air pressure must not exceed 4 psi, otherwise engine damage can occur. Attach shop air to the air pressure regulator. Adjust the Air Pressure Regulator to 4 psi Insert the exhaust cone into the vehicle tail pipe. If equipped with dual exhaust, plug the other exhaust pipe. Apply Mopar® Air Leak Detector (or equivalent) to the following areas: - All welded joints from 6 inches rearward of the downstream O2 sensor forward - 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 leak detector solution water 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 (1mm 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, 8mm 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) or greater O2 Sensor seal points Type 1 (1 mm) or greater O2 Sensor boss welds Type 1 (1 mm) or greater Flange / joint connections Type 2 (8 mm) or greater Exhaust Manifold to cylinder head connections Type 2 (8 mm) or greater EGR gasket and tube seal points Type 2 (8 mm) 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Test complete.

1. 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 step 2) . No Go to step 7) .
2. 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 personal injury or death. Install a fuel pressure gauge on the fuel rail. Turn the ignition on. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: The 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 step 3) . Fuel pressure is above the stated specification Replace the fuel filter/pressure regulator. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
3. 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 personal injury or death. Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module. Install special 5/16 fuel line adapter tool #6539 between disconnected fuel line and the fuel pump module. Attach a fuel pressure test gauge to the T fitting on tool #6539. Turn the ignition on. With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 kPa +/- 34 kPa (59 psi +/- 5 psi). CAUTION: Stop all actuation tests before proceeding. Is the fuel pressure within specification? Yes Repair or replace fuel supply line as necessary. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 4) .
4. 4) SADDLE FUEL TANK Is the vehicle equipped with a saddle type fuel tank? Yes Go to step 5) . No Go to step 6) .
5. 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 personal injury or death. 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 6) .
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 personal injury or death. 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Replace the Fuel Pump Module. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
7. 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Repair the Fuel Pump Ground circuit for an open circuit or high resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .

Scheme 560

For complete wiring diagrams refer to

SYSTEM WIRING DIAGRAMS for 300.

SYSTEM WIRING DIAGRAMS for Charger.

SYSTEM WIRING DIAGRAMS for Magnum.

Scheme 561

Scheme 562

1. 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 2) .
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. NOTE: 6.1L coils must have a spark tester installed on both sides of the coil during the following test. During the test, each side of the coil should output a crisp blue spark that is able to jump the gap of the spark tester. NOTE: On the 2.7 and 3.5 engines, cylinders 1, 3 and 5, it is necessary to remove the upper intake manifold to access the ignition coils. Once the ignition coil has been removed, the intake must be installed in order to crank the engine. Move the ignition coil harness connector through the slots in the upper intake and then connect the coil to the harness connector. Secure the upper intake to the lower intake in accordance with the Service Information. 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 step 7) . No Go to step 3) .
3. 3) MAIN/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 Main/ASD Relay to on. Using a 12 volt test light connected to ground, check the Main/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 step 4) . No Repair the Main/ASD Relay output circuit for an open circuit or high resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
4. 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 can result in personal injury or death. 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 5 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 5) .
5. 5) IGNITION COIL CONTROL CIRCUIT OPEN OR HIGH RESISTANCE 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 Ignition Coil control circuit for the cylinder being tested between the Ignition Coil harness connector and the appropriate terminal of special tool #8815. Is the resistance below 5.0 ohms? Yes Go to step 6) . No Repair the Ignition Coil control circuit for an open circuit or high resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
6. 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. Refer to any Technical Service Bulletins that may apply. Were any problems found? Yes Repair as necessary. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Replace and program the Powertrain Control Module (PCM) in accordance with the Service Information. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
7. 7) SPARK PLUG(S) Turn the ignition off. Remove the spark plug. NOTE: Vehicles equipped with 5.7L or 6.1L engines must have both spark plugs (per cylinder) removed and inspected to ensure proper operation. 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Test Complete.

Scheme 563

For complete wiring diagrams refer to

SYSTEM WIRING DIAGRAMS for 300.

SYSTEM WIRING DIAGRAMS for Charger.

SYSTEM WIRING DIAGRAMS for Magnum.

Scheme 564

Scheme 565

1. 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 2) .
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. NOTE: 6.1L coils must have a spark tester installed on both sides of the coil during the following test. During the test, each side of the coil should output a crisp blue spark that is able to jump the gap of the spark tester. NOTE: On the 2.7 and 3.5 engines, cylinders 1, 3 and 5, it is necessary to remove the upper intake manifold to access the ignition coils. Once the ignition coil has been removed, the intake must be installed in order to crank the engine. Move the ignition coil harness connector through the slots in the upper intake and then connect the coil to the harness connector. Secure the upper intake to the lower intake in accordance with the Service Information. 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 step 7) . No Go to step 3) .
3. 3) MAIN/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 Main/ASD Relay to on. Using a 12 volt test light connected to ground, check the Main/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 step 4) . No Repair the Main/ASD Relay output circuit for an open circuit or high resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
4. 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 can result in personal injury or death. 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 5 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 5) .
5. 5) IGNITION COIL CONTROL CIRCUIT OPEN OR HIGH RESISTANCE 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 Ignition Coil control circuit for the cylinder being tested between the Ignition Coil harness connector and the appropriate terminal of special tool #8815. Is the resistance below 5.0 ohms? Yes Go to step 6) . No Repair the Ignition Coil control circuit for an open circuit or high resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
6. 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. Refer to any Technical Service Bulletins that may apply. Were any problems found? Yes Repair as necessary. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Replace and program the Powertrain Control Module (PCM) in accordance with the Service Information. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
7. 7) SPARK PLUG(S) Turn the ignition off. Remove the spark plug. NOTE: Vehicles equipped with 5.7L or 6.1L engines must have both spark plugs (per cylinder) removed and inspected to ensure proper operation. 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Test Complete.

Scheme 566

For complete wiring diagrams refer to

SYSTEM WIRING DIAGRAMS for 300.

SYSTEM WIRING DIAGRAMS for Charger.

SYSTEM WIRING DIAGRAMS for Magnum.

1. 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 2) .
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 can result in personal injury or death. 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 step 4) . Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 3) .
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 step 4) . Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Test complete.
4. 4) (F856) 5 VOLT SUPPLY CIRCUIT HIGH RESISTANCE Turn the ignition off. 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 along with the #8815-1 to perform the diagnosis. Using a voltmeter, perform a voltage drop test by backprobing the (F856) 5 Volt Supply circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. 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 can result in personal injury or death. Start the engine. Is the voltage below 0.5 volts? Yes Go to step 5) . No Repair the (F856) 5 Volt Supply circuit for excessive resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
5. 5) (K1) MAP SIGNAL CIRCUIT HIGH RESISTANCE Turn the ignition off. 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 along with the #8815-1 to perform the diagnosis. Using a voltmeter, perform a voltage drop test by backprobing the (K1) MAP Signal circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. 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 can result in personal injury or death. Start the engine. Is the voltage below 0.5 volts? Yes Go to step 6) . No Repair the (K1) MAP Signal circuit for excessive resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
6. 6) (K900) SENSOR GROUND CIRCUIT HIGH RESISTANCE Turn the ignition off. 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 along with the #8815-1 to perform the diagnosis. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the MAP Sensor harness connector and by probing the appropriate terminal of the special tool #8815. 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 can result in personal injury or death. Start the engine. Is the voltage below 0.5 volts? Yes Go to step 7) . No Repair the (K900) Sensor Ground circuit for excessive resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
7. 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. Refer to any Technical Service Bulletins that may apply. Were any problems found? Yes Repair as necessary. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Replace the MAP Sensor. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .

Scheme 567

For complete wiring diagrams refer to

SYSTEM WIRING DIAGRAMS for 300.

SYSTEM WIRING DIAGRAMS for Charger.

SYSTEM WIRING DIAGRAMS for Magnum.

1. 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 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 2) .
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 can result in personal injury or death. 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 step 3) . Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 4) .
3. 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, perform the O2 Sensor Heater Test for the applicable sensor. With the scan tool, monitor O2 Sensor voltage for at least 2 minutes. Does the voltage stay above 4.5 volts? Yes Go to step 4) . Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Test complete.
4. 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 5) .
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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 6) .
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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 7) .
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. Refer to any Technical Service Bulletins that may apply. Were any problems found? Yes Repair as necessary. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Replace and program the Powertrain Control Module (PCM) in accordance with the Service Information. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .

1. 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 step 2).
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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000). No Go to step 3).
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 step 4). No Go to step 5).
4. 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.1 volt) with the connector disconnected. Does the scan tool display the voltage as described above? Yes Replace the sensor. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000). No Go to step 5).
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 step 6). No Repair the signal circuit for a short to ground. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000).
6. 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 step 7). No Repair the signal circuit for a short to the sensor ground circuit. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000).
7. 7) SIGNAL CIRCUIT HIGH RESISTANCE Turn the ignition off. Connect the temperature sensor harness connector. 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 along with the #8815-1 to perform the diagnosis. Using a voltmeter, perform a voltage drop test by backprobing the signal circuit at the sensor harness connector and at the applicable module connector (or by probing the appropriate terminal of the special tool #8815). 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 can result in personal injury or death. Start the engine. Is the voltage below 0.5 volts? Yes Go to step 8). No Repair the signal circuit for high resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000).
8. 8) SENSOR GROUND CIRCUIT HIGH RESISTANCE Turn the ignition off. 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 along with the #8815-1 to perform the diagnosis. Using a voltmeter, perform a voltage drop test by backprobing the sensor ground circuit at the sensor harness connector and at the applicable module connector (or by probing the appropriate terminal of the special tool #8815). 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 can result in personal injury or death. Start the engine. Is the voltage below 0.5 volts? Yes Go to step 9). No Repair the sensor ground circuit for high resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000).
9. 9) 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 system schematic. see scheme 21 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. Refer to any Technical Service Bulletins that may apply. Were any problems found? Yes Repair as necessary. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000). No Replace the applicable control module in accordance with the Service Information. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000).

1. 1) UNDERCHARGED BATTERY NOTE: The battery must be fully charged and in good condition. An undercharged battery may produce invalid test results. Test the battery in accordance with the Service Information. Were any problems found? Yes Charge or replace the battery as necessary and retest. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 2) .
2. 2) SYSTEM DTCS PRESENT NOTE: If the battery was low, make sure the battery is properly charged and attempt to start the vehicle. Crank 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. With the scan tool, select System DTCs to read DTCs in all modules. If any DTCs are present, perform the appropriate diagnostic procedure before continuing with this test. If a no response condition is detected in any module, refer to «ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS»(ref-304477) and perform the appropriate diagnostic procedure. Were any problems found? Yes Perform the appropriate diagnostic procedure and repair as necessary. If any pending DTCs are detected, perform the diagnostic procedure as if the DTC is active. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 3) .
3. 3) PCM POWER OR GROUND CIRCUIT OPEN OR HIGH RESISTANCE Turn the ignition off. Disconnect the PCM harness connector(s). Using a 12 volt test light, check all PCM power and ground circuits. NOTE: The test light must be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright when checking each of the PCM power and ground circuits? Yes Repair the PCM power or ground circuit for an open circuit or high resistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 4) .
4. 4) OPEN FUSE(S) Inspect all of the fuses in the PDC and TIPM. If any open fuses are found, check the related circuit(s) for a short to ground or high resistance. Were any problems found? Yes Repair as necessary. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 5) .
5. 5) *CHECKING THE FUEL DELIVERY SYSTEM NOTE: Verify that the fuel tank is not empty before continuing. Perform the diagnostic procedure for «*CHECKING THE FUEL DELIVERY SYSTEM»(ref-304544-S11771868502008111000000) . Were any problems found? Yes Repair as necessary in accordance with the Service Information. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 6) .
6. 6) FUEL CONTAMINATION Check the fuel system for contamination in accordance with the Service Information. Was any evidence of fuel contamination found? Yes Clean and repair the fuel system as necessary in accordance with the Service Information. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 7) .
7. 7) *CHECKING THE IGNITION COIL OPERATION Perform the diagnostic procedure for «*CHECKING THE IGNITION COIL OPERATION - 2.7L/3.5L»(ref-304544-S20446297272008111000000) or «*CHECKING THE IGNITION COIL OPERATION - 5.7L/SRT8»(ref-304544-S27022266762008111000000) . Were any problems found? Yes Repair as necessary in accordance with the Service Information. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go to step 8) .
8. 8) *CHECKING THE ENGINE MECHANICAL SYSTEM Perform the diagnostic procedure for «*CHECKING THE ENGINE MECHANICAL SYSTEM»(ref-304544-S18093187682008111000000) . Were any problems found? Yes Repair as necessary in accordance with the Service Information. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Test complete. Refer to any Technical Service Bulletins that may apply. Refer to appropriate engine ELECTRICAL DIAGNOSTICS article .

1. 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 personal injury or death. Install a fuel pressure gauge at the engine. Ignition on, engine not running. With a scan tool, actuate the ASD Fuel System test and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 kPa +/- 34 kPa (59 psi +/- 5 psi). Choose a conclusion that best matches your fuel pressure reading. Below Specification Go To step 2) . Within Specification Go To step 4) .
2. 2) 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 personal injury or death. Raise vehicle on hoist, and disconnect the fuel supply line at the fuel pump module. Install special tool #6539 (5/16") #6631(3/8") fuel line adapter and the fuel pressure gauge between the fuel supply line and the fuel pump module. Ignition on, engine not running. With the scan tool, actuate the ASD Fuel System test and observe the fuel pressure gauge. NOTE: Fuel pressure specification is 407 kPa +/- 34 kPa (59 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 «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go To step 3) .
3. 3) CHECKING THE FUEL 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 personal injury or death. Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer. Is the Fuel Inlet Strainer plugged? Yes Replace the Fuel Pump Inlet Strainer. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Replace the Fuel Pump Module. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .
4. 4) FUEL PUMP MODULE NOTE: Before continuing visually and physically inspect the fuel delivery system for external leaks or damage. Repair / replace as necessary. 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 personal injury or death. Install special tool #6539 (5/16") or #6631 (3/8") fuel line adapter. Install the fuel pressure gauge. Start the engine and allow the fuel system to reach maximum pressure. Turn the ignition off. NOTE: Fuel specification is 407 kPa +/- 34 kPa (59 psi +/- 5 psi). Using special tool #C4390, Hose Clamp Pliers, pinch the rubber fuel line between the fuel pressure gauge and the engine. Monitor the fuel pressure gauge for a minimum of 5 minutes. NOTE: The pressure should not fall below 241 kPa (35 psi) Does the fuel pressure drop? Yes Replace Fuel Pump Module. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Go To step 5) .
5. 5) FUEL INJECTOR(S) 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 personal injury or death. Remove special tool #C4390. Start the engine and allow the fuel system to reach maximum pressure. Turn the ignition off. NOTE: Fuel specification is 407 kPa +/- 34 kPa (59 psi +/- 5 psi). Using special tool #C4390, Hose Clamp Pliers, pinch the rubber fuel line between the fuel pressure gauge and fuel pump module. Monitor the fuel pressure gauge for a minimum of 5 minutes. NOTE: The pressure should not fall below 241 kPa (35 psi) Does the fuel pressure drop? Yes Replace the leaking fuel injectors. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Check the fuel for contaminants. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .

1. 1) ETC STARTER INHIBIT NOTE: ETC equipped engines will try to relearn ETC position when the key is left in the on position for an extended period of time and will not allow the starter to crank during this procedure. This procedure can take up to 2.5 seconds. To verify the cause of the no crank condition or delayed crank use the scan tool, and read the ETC Starter Inhibit mileage. The controller will store the mileage at which the no start condition occurred because of the ETC testing procedure. This is considered normal operation for a vehicle equipped with an Electronic Throttle Control System and no repairs are necessary. Is a mileage stored under the ETC Starter Inhibit? Yes Test Complete. No Refer to the diagnostic procedure for «*CHECKING FOR A NO CRANK CONDITION»(ref-304543-S38090184312008111000000) for further assistance. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) .

*PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE

For complete wiring diagrams refer to

SYSTEM WIRING DIAGRAMS for 300.

SYSTEM WIRING DIAGRAMS for Charger.

SYSTEM WIRING DIAGRAMS for Magnum.

1. 1) NO RESPONSE NOTE: For vehicle communication problems, use the scan tool to refer to the Network Review Screen. The screen depicts a high level view of the vehicle network. Fault and problem areas appear in red. Does the scan tool display a Vehicle Network problem or NO RESPONSE condition? Yes Refer to the appropriate BUS Communication test in «ELECTRONIC CONTROL MODULES - ELECTRICAL DIAGNOSTICS»(ref-304477) . No Go to step 2) .
2. 2) NO START Does the vehicle have a NO START condition? Yes Check the vehicle for any DTC(s), including Vehicle Theft Security related DTC(s), that may cause a no-start condition. If no DTC(s) are present that relate to a no-start condition, refer to the Non DTC Diagnostic Procedures in this article that relate to Fuel and Starting. No Go to step 3) .
3. 3) VEHICLE REPAIR HISTORY AND TSB(s) Check the vehicle repair history for repairs that may relate to the current condition. Inspect the vehicle for aftermarket accessories that may have been installed incorrectly. Check for any TSB(s) related to the condition or DTC(s). If a TSB applies, follow the procedure outlined in the TSB. Select the appropriate response for the condition that applies: Performing a TSB procedure repaired the condition. Test Complete. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . A DTC is present, no TSB applies, or the TSB didn't repair the condition. Go to step 4) . No DTC(s) or other conditions are present. Refer to the «*CHECKING FOR AN INTERMITTENT DTC»(ref-304543-S01730377832008111000000) Diagnostic Procedure.
4. 4) VEHICLE INSPECTION 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 can result in personal injury or death. Based on the diagnostic condition that applies, review the following list and perform any tests that relate to the condition: If multiple DTCs are set in the PCM, review the wiring schematics for problems in any shared supply or ground circuits. Inspect the air intake system and, if equipped, any turbocharger related tubes for damage, restriction, or poor connection. Inspect the exhaust system and related tubes for damage, restriction, or poor connection. Remove and inspect the Air Filter for excessive dirt and debris which may cause an air flow restriction. When the PCM detects and stores a DTC, the PCM also stores the environmental conditions under which the DTC was set. Before erasing stored DTCs, record these conditions. Attempting to duplicate these conditions may assist when checking for an active DTC. With the scan tool, clear the stored DTC(s). Attempt to duplicate the environmental conditions under which the DTC was set. Review the DTC When Monitored and Set Conditions. If possible, try to duplicate the vehicle conditions under which the DTC conditions will be monitored. Operate the vehicle under those conditions. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the component and the module. If the DTC(s) are fuel or air related, check the fuel level and quality. Were any repairs made that corrected the DTC or condition? Yes Test complete. Perform «*PCM VERIFICATION TEST»(ref-304545-S42850134272008111000000) . No Refer to the diagnostic test procedure related to the DTC.