Dtcs P0128 to P0202: Diagnosis Dodge Nitro I

Diagnostic Test

1. ACTIVE DTC NOTE: Check for contaminants that may have damaged the O2 Sensor: contaminated fuel, unapproved silicone, oil and coolant. NOTE: After the repairs have been made, verify proper O2 Sensor operation. If all the O2 Sensor voltage readings have not returned to normal, follow the diagnostic procedure for the remaining O2 Sensors. Start the engine. Allow the engine 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, select View DTCs. NOTE: It may be necessary to drive the vehicle to meet the conditions to set this DTC, try to repeat the conditions in which the fault originally set by reviewing the Freeze Frame data. Is the DTC Active or Pending at this time? Yes Go To 2 . No Refer to the «INTERMITTENT CONDITION»(ref-306207-S19641665412008120900000) Diagnostic Procedure.
2. 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 or #8404-EC 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 #8404-ECT 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 152.4 mm (6 inches) behind the downstream O2 sensor - O2 sensor seal points - O2 sensor boss welds - Flange/joint connection(s) - Exhaust manifold to cylinder head connection(s) - EGR solenoid gasket base and tube seal points (if equipped) Watch for the liquid/soapy 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 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 27.6 kPa (4 psi) reveal bubble size: Welded joints Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor seal points Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor boss welds Type 1, 1 mm (0.04 of an inch) or greater Flange / joint connections Type 2, 8 mm (0.3 of an inch) or greater Exhaust Manifold to cylinder head connections Type 2, 8 mm (0.3 of an inch) or greater EGR gasket and tube seal points Type 2, 8 mm (0.3 of an inch) 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 «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 3 .
3. (K41) O2 1/1 SIGNAL CIRCUIT Turn the ignition off Disconnect the 1/1 O2 Sensor harness connector. Ignition on, engine not running. Measure the voltage on the (K41) O2 1/1 Signal circuit in the O2 Sensor harness connector. Is the voltage between 4.1 and 5.0 volts? Yes Go To 4 . No Check the (K41) O2 1/1 Signal circuit for a short to ground, open, or short to voltage. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
4. (K902) O2 RETURN UPSTREAM CIRCUIT Measure the voltage on the (K902) O2 Return Upstream circuit in the O2 Sensor harness connector. Is the voltage at 2.5 volts? Yes Go To 5 . No Check the (K902) O2 Return Upstream circuit for a short to ground, open, or short to voltage. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
5. O2 SENSOR NOTE: Check for signs of contaminants that may have damaged the O2 Sensor, such as contaminated fuel, unapproved silicone, oil and coolant. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the 1/1 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. Refer to any Technical Service Bulletins that may apply. Were any problems found? Repair Replace the O2 Sensor Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .

1. ACTIVE DTC Turn the ignition on. With a scan tool, select View DTCs. Record DTC and Freeze Frame information. Start the engine and allow it to idle for at least 60 seconds. 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, select View DTCs. Is the DTC Active at this time? Yes Go To 2 . No Refer to the «INTERMITTENT CONDITION»(ref-306207-S19641665412008120900000) Diagnostic Procedure.
2. (K141) O2 1/2 SIGNAL CIRCUIT Turn the ignition off. Disconnect the 1/2 O2 Sensor harness connector. Ignition on, engine not running. With a scan tool, monitor the 1/2 O2 Sensor voltage. Is the O2 Sensor voltage between 4.1 and 5.0 volts? Yes Go To 3 . No Go To 5 .
3. O2 SENSOR Measure the voltage on the (K904) O2 Return Downstream circuit in the O2 Sensor harness connector. Is the voltage at 2.5 volts? Yes Verify that there is good pin to terminal contact in the O2 Sensor and Powertrain Control Module connectors. If OK, replace the 1/2 O2 Sensor. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 4 .
4. (K904) O2 RETURN DOWNSTREAM CIRCUIT SHORTED TO GROUND Turn the ignition off. Disconnect the C2 PCM harness connector. Measure the resistance between ground and the (K904) O2 Return Downstream circuit in the O2 Sensor harness connector. Is the resistance below 100 ohms? Yes Repair the short to ground in the (K904) O2 Return Downstream circuit. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 8 .
5. (K141) O2 1/2 SIGNAL CIRCUIT SHORTED TO GROUND Turn the ignition off. Disconnect the C1 and C2 PCM harness connectors. Measure the resistance between ground and the (K141) O2 1/2 Signal circuit in the O2 Sensor harness connector. Is the resistance below 100 ohms? Yes Repair the short to ground in the (K141) O2 1/2 Signal circuit. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 6 .
6. (K141) O2 1/2 SIGNAL CIRCUIT SHORTED TO THE (K904) O2 RETURN DOWNSTREAM CIRCUIT Measure the resistance between the (K141) O2 1/2 Signal circuit and the (K904) O2 Return Downstream circuit in the O2 Sensor harness connector. Is the resistance below 100 ohms? Yes Repair the short between the (K904) O2 Return Downstream circuit and the (K141) O2 1/2 Signal circuit. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 7 .
7. (K141) O2 1/2 SIGNAL CIRCUIT SHORTED TO THE (Z933) O2 1/2 HEATER GROUND CIRCUIT Measure the resistance between the (K141) O2 1/2 Signal circuit and the (Z933) O2 1/2 Heater ground circuit in the O2 Sensor harness connector. Is the resistance below 100 ohms? Yes Repair the short between the (Z933) O2 1/2 Heater ground circuit and the (K141) O2 1/2 Signal circuit. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 8 .
8. POWERTRAIN CONTROL MODULE (PCM) Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen Sensor 1/2 and the Powertrain Control Module (PCM). Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the 1/2 O2 Sensor and Powertrain Control Module connectors. Refer to any Technical Service Bulletins that may apply. Were there any problems found? Yes Repair as necessary. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .

1. ACTIVE DTC NOTE: Check for contaminants that may have damaged the O2 Sensor: contaminated fuel, unapproved silicone, oil and coolant. NOTE: After the repairs have been made, verify proper O2 Sensor operation. If all the O2 Sensor voltage readings have not returned to normal, follow the diagnostic procedure for the remaining O2 Sensors. Start the engine. Allow the engine to reach normal operating temperature. With a scan tool, select View DTCs. NOTE: It may be necessary to drive the vehicle to meet the conditions to set this DTC, try to repeat the conditions in which the fault originally set by reviewing the Freeze Frame data. Is the DTC Active or Pending at this time? Yes Go To 2 . No Refer to the «INTERMITTENT CONDITION»(ref-306207-S19641665412008120900000) Diagnostic Procedure.
2. 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 or #8404-EC 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 #8404-ECT 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 152.4 mm (6 inches) behind the downstream O2 sensor - O2 sensor seal points - O2 sensor boss welds - Flange/joint connection(s) - Exhaust manifold to cylinder head connection(s) - EGR solenoid gasket base and tube seal points (if equipped) Watch for the liquid/soapy 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 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 27.6 kPa (4 psi) reveal bubble size: Welded joints Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor seal points Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor boss welds Type 1, 1 mm (0.04 of an inch) or greater Flange / joint connections Type 2, 8 mm (0.3 of an inch) or greater Exhaust Manifold to cylinder head connections Type 2, 8 mm (0.3 of an inch) or greater EGR gasket and tube seal points Type 2, 8 mm (0.3 of an inch) 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 «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 3 .
3. (K141) O2 1/2 SIGNAL CIRCUIT Turn the ignition off Disconnect the 1/2 O2 Sensor harness connector. Ignition on, engine not running. Measure the voltage on the (K141) O2 1/2 Signal circuit in the O2 Sensor harness connector. Is the voltage between 4.1 and 5.0 volts? Yes Go To 4 . No Check the (K141) O2 1/2 Signal circuit for a short to ground, open, or short to voltage. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
4. (K904) O2 RETURN DOWNSTREAM CIRCUIT Measure the voltage on the (K904) O2 Return Downstream circuit in the 1/2 O2 Sensor harness connector. Is the voltage at 2.5 volts? Yes Go To 5 . No Check the (K904) O2 Return Downstream circuit for a short to ground, open, or short to voltage. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
5. 1/2 O2 SENSOR NOTE: Check for signs of contaminants that may have damaged the O2 Sensor, such as contaminated fuel, unapproved silicone, oil and coolant. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the 1/2 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. Refer to any Technical Service Bulletins that may apply. Were any problems found? Repair Replace the 1/2 O2 Sensor Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .

1. ACTIVE DTC NOTE: Check for contaminants that may have damaged the O2 Sensor: contaminated fuel, unapproved silicone, oil and coolant. NOTE: After the repairs have been made, verify proper O2 Sensor operation. If all the O2 Sensor voltage readings have not returned to normal, follow the diagnostic procedure for the remaining O2 Sensors. Start the engine. Allow the engine 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, select View DTCs. NOTE: It may be necessary to drive the vehicle to meet the conditions to set this DTC, try to repeat the conditions in which the fault originally set by reviewing the Freeze Frame data. Is the DTC Active at this time? Yes Go To 2 . No Refer to the «INTERMITTENT CONDITION»(ref-306207-S19641665412008120900000) Diagnostic Procedure.
2. 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 or #8404-EC 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 #8404-ECT 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 152.4 mm (6 inches) behind the downstream O2 sensor - O2 sensor seal points - O2 sensor boss welds - Flange/joint connection(s) - Exhaust manifold to cylinder head connection(s) - EGR solenoid gasket base and tube seal points (if equipped) Watch for the liquid/soapy 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 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 27.6 kPa (4 psi) reveal bubble size: Welded joints Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor seal points Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor boss welds Type 1, 1 mm (0.04 of an inch) or greater Flange / joint connections Type 2, 8 mm (0.3 of an inch) or greater Exhaust Manifold to cylinder head connections Type 2, 8 mm (0.3 of an inch) or greater EGR gasket and tube seal points Type 2, 8 mm (0.3 of an inch) 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 «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 3 .
3. (K141) O2 1/2 SIGNAL CIRCUIT Turn the ignition off Disconnect the 1/2 O2 Sensor harness connector. Ignition on, engine not running. Measure the voltage on the (K141) O2 1/2 Signal circuit in the O2 Sensor harness connector. Is the voltage between 4.1 and 5.0 volts? Yes Go To 4 . No Check the (K141) O2 1/2 Signal circuit for a short to ground, open, or short to voltage. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
4. (K904) O2 RETURN DOWNSTREAM CIRCUIT Measure the voltage on the (K904) O2 Return Downstream circuit in the 1/2 O2 Sensor harness connector. Is the voltage at 2.5 volts? Yes Go To 5 . No Check the (K904) O2 Return Downstream circuit for a short to ground, open, or short to voltage. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
5. 1/2 O2 SENSOR NOTE: Check for signs of contaminants that may have damaged the O2 Sensor, such as contaminated fuel, unapproved silicone, oil and coolant. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the 1/2 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. Refer to any Technical Service Bulletins that may apply. Were any problems found? Repair Replace the 1/2 O2 Sensor Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .

Scheme 61

1. ACTIVE DTC NOTE: Check for contaminants that may have damaged the O2 Sensor: contaminated fuel, unapproved silicone, oil and coolant. NOTE: After the repairs have been made, verify proper O2 Sensor operation. If all the O2 Sensor voltage readings have not returned to normal, follow the diagnostic procedure for the remaining O2 Sensors. Start the engine. Allow the engine 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, select View DTCs. NOTE: It may be necessary to drive the vehicle to meet the conditions to set this DTC, try to repeat the conditions in which the fault originally set by reviewing the Freeze Frame data. Is the DTC Active at this time? Yes Go To 2 . No Refer to the «INTERMITTENT CONDITION»(ref-306207-S19641665412008120900000) Diagnostic Procedure.
2. 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 or #8404-EC 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 #8404-ECT 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 152.4 mm (6 inches) behind the downstream O2 sensor - O2 sensor seal points - O2 sensor boss welds - Flange/joint connection(s) - Exhaust manifold to cylinder head connection(s) - EGR solenoid gasket base and tube seal points (if equipped) Watch for the liquid/soapy 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 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 27.6 kPa (4 psi) reveal bubble size: Welded joints Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor seal points Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor boss welds Type 1, 1 mm (0.04 of an inch) or greater Flange / joint connections Type 2, 8 mm (0.3 of an inch) or greater Exhaust Manifold to cylinder head connections Type 2, 8 mm (0.3 of an inch) or greater EGR gasket and tube seal points Type 2, 8 mm (0.3 of an inch) 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 «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 3 .
3. (K243) O2 2/2 SIGNAL CIRCUIT Turn the ignition off Disconnect the 2/2 O2 Sensor harness connector. Ignition on, engine not running. Measure the voltage on the (K243) O2 2/2 Signal circuit in the O2 Sensor harness connector. Is the voltage between 4.1 and 5.0 volts? Yes Go To 4 . No Check the (K243) O2 2/2 Signal circuit for a short to ground, open, or short to voltage. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
4. (K904) O2 RETURN DOWNSTREAM CIRCUIT Measure the voltage on the (K904) O2 Return Downstream circuit in the 2/2 O2 Sensor harness connector. Is the voltage at 2.5 volts? Yes Go To 5 . No Check the (K904) O2 Return Downstream circuit for a short to ground, open, or short to voltage. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
5. 2/2 O2 SENSOR NOTE: Check for signs of contaminants that may have damaged the O2 Sensor, such as contaminated fuel, unapproved silicone, oil and coolant. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the 2/2 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. Refer to any Technical Service Bulletins that may apply. Were any problems found? Repair Replace the 2/2 O2 Sensor Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .

1. ACTIVE DTC Turn the ignition on. With a scan tool, select View DTCs. Record DTC and Freeze Frame information. Start the engine and allow it to idle for at least 60 seconds. 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, select View DTCs. Is the DTC Active at this time? Yes Go To 2 . No Refer to the «INTERMITTENT CONDITION»(ref-306207-S19641665412008120900000) Diagnostic Procedure.
2. (K43) O2 2/1 SIGNAL CIRCUIT Turn the ignition off. Disconnect the 2/1 O2 Sensor harness connector. Ignition on, engine not running. With a scan tool, monitor the 2/1 O2 Sensor voltage. Is the O2 Sensor voltage between 4.1 and 5.0 volts? Yes Go To 3 . No Go To 5 .
3. O2 SENSOR Measure the voltage on the (K902) O2 Return Upstream circuit in the O2 Sensor harness connector. Is the voltage at 2.5 volts? Yes Verify that there is good pin to terminal contact in the Sensor and Control Module connectors. If OK, replace the 2/1 O2 Sensor. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 4 .
4. (K902) O2 RETURN UPSTREAM CIRCUIT SHORTED TO GROUND Turn the ignition off. Disconnect the C1 PCM harness connector. Measure the resistance between ground and the (K902) O2 Return Upstream circuit in the O2 Sensor harness connector. Is the resistance below 100 ohms? Yes Repair the short to ground in the (K902) O2 Return Upstream circuit. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 8 .
5. (K43) O2 2/1 SIGNAL CIRCUIT SHORTED TO GROUND Turn the ignition off. Disconnect the C1 and C2 PCM harness connectors. Measure the resistance between ground and the (K43) O2 2/1 Signal circuit in the O2 Sensor harness connector. Is the resistance below 100 ohms? Yes Repair the short to ground in the (K43) O2 2/1 Signal circuit. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 6 .
6. (K43) O2 2/1 SIGNAL CIRCUIT SHORTED TO THE (K902) O2 RETURN UPSTREAM CIRCUIT Measure the resistance between the (K43) O2 2/1 Signal circuit and the (K902) O2 Return Upstream circuit in the O2 Sensor harness connector. Is the resistance below 100 ohms? Yes Repair the short between the (K902) O2 Return Upstream circuit and the (K43) O2 2/1 Signal circuit. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 7 .
7. (K43) O2 2/1 SIGNAL CIRCUIT SHORTED TO THE (Z933) HEATER GROUND CIRCUIT Measure the resistance between the (K43) O2 2/1 Signal circuit and the (Z933) O2 Heater ground circuit in the O2 Sensor harness connector. Is the resistance below 100 ohms? Yes Repair the short between the (Z933) O2 Heater ground circuit and the (K43) O2 2/1 Signal circuit. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 8 .
8. POWERTRAIN CONTROL MODULE (PCM) Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen Sensor 2/1 and the Powertrain Control Module (PCM). Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the 2/1 O2 Sensor and Powertrain Control Module connectors. Refer to any Technical Service Bulletins that may apply. Were there any problems found? Yes Repair as necessary. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .

1. ACTIVE DTC NOTE: Check for contaminants that may have damaged the O2 Sensor: contaminated fuel, unapproved silicone, oil and coolant. NOTE: After the repairs have been made, verify proper O2 Sensor operation. If all the O2 Sensor voltage readings have not returned to normal, follow the diagnostic procedure for the remaining O2 Sensors. Start the engine. Allow the engine 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, select View DTCs. NOTE: It may be necessary to drive the vehicle to meet the conditions to set this DTC, try to repeat the conditions in which the fault originally set by reviewing the Freeze Frame data. Is the DTC Active or Pending at this time? Yes Go To 2 . No Refer to the «INTERMITTENT CONDITION»(ref-306207-S19641665412008120900000) Diagnostic Procedure.
2. 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 or #8404-EC 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 #8404-ECT 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 152.4 mm (6 inches) behind the downstream O2 sensor - O2 sensor seal points - O2 sensor boss welds - Flange/joint connection(s) - Exhaust manifold to cylinder head connection(s) - EGR solenoid gasket base and tube seal points (if equipped) Watch for the liquid/soapy 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 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 27.6 kPa (4 psi) reveal bubble size: Welded joints Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor seal points Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor boss welds Type 1, 1 mm (0.04 of an inch) or greater Flange / joint connections Type 2, 8 mm (0.3 of an inch) or greater Exhaust Manifold to cylinder head connections Type 2, 8 mm (0.3 of an inch) or greater EGR gasket and tube seal points Type 2, 8 mm (0.3 of an inch) 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 «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 3 .
3. (K43) O2 2/1 SIGNAL CIRCUIT Turn the ignition off Disconnect the O2 Sensor harness connector. Ignition on, engine not running. Measure the voltage on the (K43) O2 2/1 Signal circuit in the O2 Sensor harness connector. Is the voltage between 4.1 and 5.0 volts? Yes Go To 4 . No Check the (K43) O2 2/1 Signal circuit for a short to ground, open, or short to voltage. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
4. (K902) O2 RETURN UPSTREAM CIRCUIT Measure the voltage on the (K902) O2 Return Upstream circuit in the O2 Sensor harness connector. Is the voltage at 2.5 volts? Yes Go To 5 . No Check the (K902) O2 Return Upstream circuit for a short to ground, open, or short to voltage. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
5. 2/1 OXYGEN SENSOR NOTE: Check for signs of contaminants that may have damaged the O2 Sensor, such as contaminated fuel, unapproved silicone, oil and coolant. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the 2/1 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. Refer to any Technical Service Bulletins that may apply. Were any problems found? Repair Replace the 2/1 O2 Sensor Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .

1. ACTIVE DTC Turn the ignition on. With a scan tool, select View DTCs. Record DTC and Freeze Frame information. Start the engine and allow it to idle for at least 60 seconds. 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, select View DTCs. Is the DTC Active at this time? Yes Go To 2 . No Refer to the «INTERMITTENT CONDITION»(ref-306207-S19641665412008120900000) Diagnostic Procedure.
2. (K243) O2 2/2 SIGNAL CIRCUIT Turn the ignition off. Disconnect the 2/2 O2 Sensor harness connector. Ignition on, engine not running. With a scan tool, monitor the 2/2 O2 Sensor voltage. Is the O2 Sensor voltage between 4.1 and 5.0 volts? Yes Go To 3 . No Go To 5 .
3. O2 SENSOR Measure the voltage on the (K904) O2 Return Downstream circuit in the O2 Sensor harness connector. Is the voltage at 2.5 volts? Yes Verify that there is good pin to terminal contact in the Oxygen Sensor and Powertrain Control Module connectors. If OK, replace the 2/2 O2 Sensor. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 4 .
4. (K904) O2 RETURN DOWNSTREAM CIRCUIT SHORTED TO GROUND Turn the ignition off. Disconnect the C2 PCM harness connector. Measure the resistance between ground and the (K904) O2 Return Downstream circuit in the O2 Sensor harness connector. Is the resistance below 100 ohms? Yes Repair the short to ground in the (K904) O2 Return Downstream circuit. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 8 .
5. (K243) O2 2/2 SIGNAL CIRCUIT SHORTED TO GROUND Turn the ignition off. Disconnect the C1 and C2 PCM harness connectors. Measure the resistance between ground and the (K243) O2 2/2 Signal circuit in the O2 Sensor harness connector. Is the resistance below 100 ohms? Yes Repair the short to ground in the (K243) O2 2/2 Signal circuit. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 6 .
6. (K243) O2 2/2 SIGNAL CIRCUIT SHORTED TO THE (K904) O2 RETURN DOWNSTREAM CIRCUIT Measure the resistance between the (K243) O2 2/2 Signal circuit and the (K904) O2 Return Downstream circuit in the O2 Sensor harness connector. Is the resistance below 100 ohms? Yes Repair the short between the (K904) O2 Return Downstream circuit and the (K243) O2 2/2 Signal circuit. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 7 .
7. (K243) O2 2/2 SIGNAL CIRCUIT SHORTED TO THE (Z933) O2 2/2 HEATER GROUND CIRCUIT Measure the resistance between the (K243) O2 2/2 Signal circuit and the (Z933) O2 2/2 Heater ground circuit in the O2 Sensor harness connector. Is the resistance below 100 ohms? Yes Repair the short between the (Z933) O2 2/2 Heater ground circuit and the (K243) O2 2/2 Signal circuit. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 8 .
8. POWERTRAIN CONTROL MODULE (PCM) Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen Sensor 2/2 and the Powertrain Control Module (PCM). Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the 2/2 Oxygen Sensor and Powertrain Control Module connectors. Refer to any Technical Service Bulletins that may apply. Were there any problems found? Yes Repair as necessary. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .

1. ACTIVE DTC NOTE: Check for contaminants that may have damaged the O2 Sensor: contaminated fuel, unapproved silicone, oil and coolant. NOTE: After the repairs have been made, verify proper O2 Sensor operation. If all the O2 Sensor voltage readings have not returned to normal, follow the diagnostic procedure for the remaining O2 Sensors. Start the engine. Allow the engine to reach normal operating temperature. With a scan tool, select View DTCs. NOTE: It may be necessary to drive the vehicle to meet the conditions to set this DTC, try to repeat the conditions in which the fault originally set by reviewing the Freeze Frame data. Is the DTC Active or Pending at this time? Yes Go To 2 . No Refer to the «INTERMITTENT CONDITION»(ref-306207-S19641665412008120900000) Diagnostic Procedure.
2. 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 or #8404-EC 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 #8404-ECT 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 152.4 mm (6 inches) behind the downstream O2 sensor - O2 sensor seal points - O2 sensor boss welds - Flange/joint connection(s) - Exhaust manifold to cylinder head connection(s) - EGR solenoid gasket base and tube seal points (if equipped) Watch for the liquid/soapy 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 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 27.6 kPa (4 psi) reveal bubble size: Welded joints Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor seal points Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor boss welds Type 1, 1 mm (0.04 of an inch) or greater Flange / joint connections Type 2, 8 mm (0.3 of an inch) or greater Exhaust Manifold to cylinder head connections Type 2, 8 mm (0.3 of an inch) or greater EGR gasket and tube seal points Type 2, 8 mm (0.3 of an inch) 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 «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 3 .
3. (K243) O2 2/2 SIGNAL CIRCUIT Turn the ignition off Disconnect the 2/2 O2 Sensor harness connector. Ignition on, engine not running. Measure the voltage on the (K243) O2 2/2 Signal circuit in the O2 Sensor harness connector. Is the voltage between 4.1 and 5.0 volts? Yes Go To 4 . No Check the (K243) O2 2/2 Signal circuit for a short to ground, open, or short to voltage. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
4. (K904) O2 RETURN DOWNSTREAM CIRCUIT Measure the voltage on the (K904) O2 Return Downstream circuit in the O2 Sensor harness connector. Is the voltage at 2.5 volts? Yes Go To 5 . No Check the (K904) O2 Return Downstream circuit for a short to ground, open, or short to voltage. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
5. 2/2 OXYGEN SENSOR NOTE: Check for signs of contaminants that may have damaged the O2 Sensor, such as contaminated fuel, unapproved silicone, oil and coolant. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the 2/2 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. Refer to any Technical Service Bulletins that may apply. Were any problems found? Repair Replace the 2/2 O2 Sensor Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .

1. ACTIVE DTC Diagnose all other trouble codes before continuing. NOTE: Check for contaminants that may have damaged an O2 Sensor: contaminated fuel, unapproved silicone, oil and coolant. Start the engine. Allow the engine to reach normal operating temperature. With a scan tool, select View DTCs. NOTE: It may be necessary to drive the vehicle to meet the conditions to set this DTC, try to repeat the conditions in which the fault originally set by reviewing the Freeze Frame data. Is the DTC Active or Pending at this time? Yes Go To 2 . No Refer to the «INTERMITTENT CONDITION»(ref-306207-S19641665412008120900000) Diagnostic Procedure.
2. CHECKING 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 personal injury or death. Turn the ignition off. Install a fuel pressure gauge. 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). Turn the ignition off. Choose a conclusion that best matches your fuel pressure reading. Within Specification Go To 3 . Above Specification Replace the fuel filter/pressure regulator. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . Below Specification Go To 13 . CAUTION: Stop All Actuations.
3. 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 or #8404-EC 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 #8404-ECT 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 152.4 mm (6 inches) behind the downstream O2 sensor - O2 sensor seal points - O2 sensor boss welds - Flange/joint connection(s) - Exhaust manifold to cylinder head connection(s) - EGR solenoid gasket base and tube seal points (if equipped) Watch for the liquid/soapy 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 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 27.6 kPa (4 psi) reveal bubble size: Welded joints Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor seal points Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor boss welds Type 1, 1 mm (0.04 of an inch) or greater Flange / joint connections Type 2, 8 mm (0.3 of an inch) or greater Exhaust Manifold to cylinder head connections Type 2, 8 mm (0.3 of an inch) or greater EGR gasket and tube seal points Type 2, 8 mm (0.3 of an inch) 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 «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 4 .
4. O2 SENSOR OPERATION Start the engine. Allow the engine to reach normal operating temperature. NOTE: If one of the O2 Sensor's Signal or Return circuit is shorted to ground the scan tool will display all O2 Sensor voltage readings low. The O2 Sensor that is shorted to ground will display a voltage reading near or at 0 volts. NOTE: If one of the O2 Sensor Signal or Return circuits are shorted to voltage, the scan tool will display all O2 Sensor voltage readings high. NOTE: After the repairs have been made, verify proper O2 Sensor operation. If all the O2 Sensor voltage readings have not returned to normal, follow the diagnostic procedure for the remaining O2 Sensors. With a scan tool, monitor all of the O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 volts for all the O2 Sensors? Yes Go To 5 . No Go To 9 .
5. 1/1 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. Ignition on, engine not running. With a scan tool, actuate the 1/1 O2 Heater Test. With the scan tool, monitor 1/1 O2 Sensor voltage for at least 2 minutes. Does the voltage stay above 4.5 volts? Yes Verify that there is good pin to terminal contact in the O2 Sensor and Powertrain Control Module connectors. Replace the 1/1 O2 Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 6 .
6. MAP SENSOR OPERATION Ignition on, engine not running. 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 this vehicle to the value of a known good vehicle of a similar make and model. Turn the ignition off. Connect a Vacuum Gauge to a Manifold Vacuum source. Start the engine. Allow the engine to idle. NOTE: If engine will not idle, maintain a constant RPM above idle. With the scan tool, read the MAP Sensor vacuum value. Is the scan tool reading for MAP Vacuum within 1 inch of Hg on the Vacuum Gauge and is the Barometric Pressure reading of the vehicle the approximately the same as actual Barometric Pressure? Yes Go To 7 . No Verify that there is good pin to terminal contact in the MAP Sensor and Powertrain Control Module connectors. Replace the MAP Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
7. ECT SENSOR OPERATION NOTE: For this test to be valid, the thermostat must be operating correctly. NOTE: This test works best if performed on a cold engine (cold soak) Ignition on, engine not running. With a scan tool, read the Engine Coolant Temperature (ECT) Sensor value. If the engine was allowed to sit overnight (cold soak), the temperature value should be a sensible value that is somewhere close to the ambient temperature. NOTE: If engine coolant temperature is above 82° C (180° F), allow the engine to cool until 65° C (150° F) is reached. Start the Engine. During engine warm-up, monitor the ECT Sensor value. The temperature value change should be a smooth transition from start up to normal operating temperature 82° C (180° F). The value should reach at least 82° C (180° F). Did the ECT value increase smoothly and did it reach at least 182° C (180° F)? Yes Go To 8 . No Verify that there is good pin to terminal contact in the ECT Sensor and Powertrain Control Module connectors. Replace the ECT Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
8. ENGINE MECHANICAL PROBLEM Turn the ignition off. Check for any of the following conditions/mechanical problems. AIR INDUCTION SYSTEM - must be free from leaks. ENGINE VACUUM - must be at least 13 inches in neutral ENGINE VALVE TIMING - must be within specifications ENGINE COMPRESSION - must be within specifications ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks. ENGINE PCV SYSTEM - must flow freely TORQUE CONVERTER STALL SPEED - must be within specifications POWER BRAKE BOOSTER - no internal vacuum leaks FUEL - must be free of contamination FUEL INJECTOR - plugged or restricted injector; control wire not connected to correct injector Are there any engine mechanical problems? Yes Repair as necessary. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 12 .
9. 1/1 O2 SENSOR Turn the ignition off. Disconnect the 1/1 O2 Sensor harness connector. Ignition on, engine not running. With a scan tool, monitor the 1/1 O2 Sensor voltage. O2 Sensor voltage should read between 4.1 and 5.0 volts on the scan tool with the connector disconnected. Connect a jumper wire between the (K41) Signal circuit and the (K902) O2 Return Upstream circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from between 4.1 and 5.0 volts to 2.5 volts with the jumper wire in place. Did the O2 Sensor voltage change from 5.0 volts to 2.5 volts with the jumper wire installed? Yes Verify that there is good pin to terminal contact in the O2 Sensor and Powertrain Control Module connectors. Replace the 1/1 O2 Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 10 . NOTE: Remove the jumper wire before continuing.
10. (K41) O2 SENSOR 1/1 SIGNAL CIRCUIT With a scan tool, monitor the 1/1 O2 Sensor voltage reading with the jumper wire removed. NOTE: The scan tool will display all O2 Sensor voltage readings approximately 5.0 volts when only one O2 Sensor's Signal circuit is shorted to voltage. NOTE: The scan tool will display one O2 Sensor voltage close to zero and the others will read lower than normal when one O2 Sensor Signal circuit contains excessive resistance. Is the voltage between 4.1 and 5.0 volts? Yes Go To 11 . No Check the (K41) O2 Sensor 1/1 Signal circuit for a short to ground, open, or short to voltage. Inspect the O2 Sensor connector and the PCM harness connector. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
11. (K902) O2 RETURN UPSTREAM CIRCUIT Disconnect the 1/1 O2 Sensor harness connector. Measure the voltage on the (K902) O2 Return Upstream circuit in the O2 Sensor harness connector. Is the voltage at 2.5 volts? Yes Go To 12 . No Check the O2 Return Upstream circuit for a short to ground, open, or short to voltage. Inspect the O2 Sensor connector and the PCM harness connector. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
12. POWERTRAIN CONTROL MODULE (PCM) Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Sensors and the Powertrain Control Module (PCM). Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the Sensor and Control Module connectors. Refer to any Technical Service Bulletins that may apply. Were there any problems found? Yes Repair as necessary. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
13. 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 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. 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). Is the fuel pressure within specification? Yes Repair or replace fuel supply line as necessary. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 14 . CAUTION: Stop All Actuations.
14. FUEL PUMP INLET STRAINER 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. Turn the ignition off. 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 «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 15 .
15. FUEL PUMP MODULE If there are no possible causes remaining, view repair. Repair Verify that there is good pin to terminal contact in the Fuel Pump Module, TIPM, and Powertrain Control Module connectors. Replace the Fuel Pump Module if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .

1. ACTIVE DTC Diagnose all other trouble codes before continuing. NOTE: Check for contaminants that may have damaged an O2 Sensor: contaminated fuel, unapproved silicone, oil and coolant. Start the engine. Allow the engine to reach normal operating temperature. With a scan tool, select View DTCs. NOTE: It may be necessary to drive the vehicle to meet the conditions to set this DTC, try to repeat the conditions in which the fault originally set by reviewing the Freeze Frame data. Is the DTC Active or Pending at this time? Yes Go To 2 . No Refer to the «INTERMITTENT CONDITION»(ref-306207-S19641665412008120900000) Diagnostic Procedure.
2. CHECKING 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 personal injury or death. Turn the ignition off. Install a fuel pressure gauge to the fuel rail. 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). Turn the ignition off. Choose a conclusion that best matches your fuel pressure reading. Within Specification Go To 3 . Above Specification Replace the fuel filter/pressure regulator. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . CAUTION: Stop All Actuations.
3. O2 SENSOR OPERATION Start the engine. Allow the engine to reach normal operating temperature. NOTE: If one of the O2 Sensor's Signal or Return circuit is shorted to ground or voltage, all the other O2 Sensor voltage readings will be affected. NOTE: After the repairs have been made, verify proper O2 Sensor operation. If all the O2 Sensor voltage readings have not returned to normal, follow the diagnostic procedure for the remaining O2 Sensors. With the scan tool, monitor the 1/1 O2 Sensor voltage reading. Is the voltage switching between 2.5 and 3.4 volts? Yes Go To 4 . No Go To 9 .
4. 1/1 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. Ignition on, engine not running. With the scan tool, perform the 1/1 O2 Heater Test. With the scan tool, monitor the O2 Sensor voltage while performing the Heater test for at least 2 minutes. Does the voltage stay above 4.5 volts during the Heater test? Yes Verify that there is good pin to terminal contact in the O2 Sensor and Powertrain Control Module connectors. Replace the 1/1 O2 Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 5 .
5. MAP SENSOR OPERATION Ignition on, engine not running. 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 this vehicle to the value of a known good vehicle of a similar make and model. Turn the ignition off. Connect a Vacuum Gauge to a Manifold Vacuum source. Start the engine. Allow the engine to idle. NOTE: If engine will not idle, maintain a constant RPM above idle. With a scan tool, read the MAP Sensor vacuum value. Is the scan tool reading for MAP Vacuum within 1 inch of Hg on the Vacuum Gauge and is the Barometric Pressure reading of the vehicle the approximately the same as actual Barometric Pressure? Yes Go To 6 . No Verify that there is good pin to terminal contact in the MAP Sensor and Powertrain Control Module connectors. Replace the MAP Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . NOTE: Remove the vacuum gauge before continuing.
6. ECT SENSOR OPERATION NOTE: For this test to be valid, the thermostat must be operating correctly. NOTE: This test works best if performed on a cold engine (cold soak) Ignition on, engine not running. With a scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to sit overnight (cold soak), the temperature value should be a sensible value that is somewhere close to the ambient temperature. NOTE: If engine coolant temperature is above 82° C (180° F), allow the engine to cool until 65° C (150° F) is reached. Start the Engine. During engine warm-up, monitor the Engine Coolant Temperature value. The temp value change should be a smooth transition from start up to normal operating temp 82° C (180° F). The value should reach at least 82° C (180° F). Did the ECT value increase smoothly and reach at least 82° C (180° F)? Yes Go To 7 . No Verify that there is good pin to terminal contact in the ECT Sensor and Powertrain Control Module connectors. Replace the Engine Coolant Temperature Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
7. EVAP PURGE SOLENOID OPERATION Turn the ignition off. Disconnect the hoses at the EVAP Purge Solenoid. Using a hand vacuum pump, apply 10 inches of vacuum to the EVAP Purge Solenoid vacuum source port on the component side. Did the EVAP Purge Solenoid hold vacuum? Yes Go To 8 . No Verify that there is good pin to terminal contact in the Solenoid and Powertrain Control Module connectors. Replace the EVAP Purge Solenoid if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . NOTE: Connect the vacuum hoses before continuing.
8. ENGINE MECHANICAL PROBLEM Check for any of the following conditions/mechanical problems. AIR INDUCTION SYSTEM - must be free from 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 of any restrictions or leaks. ENGINE PCV SYSTEM - must flow freely TORQUE CONVERTER STALL SPEED - must be within specifications POWER BRAKE BOOSTER - no internal vacuum leaks FUEL - must be free of contamination FUEL INJECTOR - plugged or restricted injector; control wire not connected to correct injector Are there any engine mechanical problems? Yes Repair as necessary. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 12 .
9. 1/1 O2 SENSOR Turn the ignition off. Disconnect the 1/1 O2 Sensor harness connector. Ignition on, engine not running. With a scan tool, monitor the 1/1 O2 Sensor voltage. O2 Sensor voltage should read between 4.1 and 5.0 volts on the scan tool with the connector disconnected. Connect a jumper wire between the (K41) O2 Sensor 1/1 Signal circuit and the (K902) O2 Return Upstream circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from between 4.1 and 5.0 volts down to 2.5 volts with the jumper wire connected. Did the O2 Sensor voltage drop from between 4.1 and 5.0 volts to 2.5 volts when the jumper wire was installed? Yes Verify that there is good pin to terminal contact in the O2 Sensor and Powertrain Control Module connectors. Replace the 1/1 O2 Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 10 . NOTE: Remove the jumper wire before continuing.
10. (K41) O2 SENSOR 1/1 SIGNAL CIRCUIT Ignition on, engine not running. Measure the voltage on the (K41) O2 Sensor 1/1 Signal circuit in the O2 Sensor harness connector. Is the voltage between 4.1 and 5.0 volts? Yes Go To 11 . No Check the (K41) O2 Sensor 1/1 Signal circuit for damage, short to ground, open, or short to voltage. Inspect the O2 Sensor connector and the PCM harness connector. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
11. (K902) O2 SENSOR RETURN UPSTREAM CIRCUIT Measure the voltage on the (K902) O2 Return Upstream circuit in the 1/1 O2 Sensor harness connector. Is the voltage at 2.5 volts? Yes Go To 12 . No Check the (K902) O2 Return Upstream circuit for damage, short to ground, open, or short to voltage. Inspect the O2 Sensor connector and the PCM harness connector. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . NOTE: Turn the ignition off before continuing.
12. POWERTRAIN CONTROL MODULE (PCM) Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Sensors and the Powertrain Control Module (PCM). Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the Sensor and Control Module connectors. Refer to any Technical Service Bulletins that may apply. Were there any problems found? Yes Repair as necessary. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .

1. ACTIVE DTC Diagnose all other trouble codes before continuing. NOTE: Check for contaminants that may have damaged an O2 Sensor: contaminated fuel, unapproved silicone, oil and coolant. Start the engine. Allow the engine to reach normal operating temperature. With a scan tool, select View DTCs. NOTE: It may be necessary to drive the vehicle to meet the conditions to set this DTC, try to repeat the conditions in which the fault originally set by reviewing the Freeze Frame data. Is the DTC Active or Pending at this time? Yes Go To 2 . No Refer to the «INTERMITTENT CONDITION»(ref-306207-S19641665412008120900000) Diagnostic Procedure.
2. CHECKING 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 personal injury or death. Turn the ignition off. Install a fuel pressure gauge to the fuel rail. 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). Turn the ignition off. Choose a conclusion that best matches your fuel pressure reading. Within Specification Go To 3 . Above Specification Replace the fuel filter/pressure regulator. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . Below Specification Go To 13 . CAUTION: Stop All Actuations.
3. 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 or #8404-EC 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 #8404-ECT 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 152.4 mm (6 inches) behind the downstream O2 sensor - O2 sensor seal points - O2 sensor boss welds - Flange/joint connection(s) - Exhaust manifold to cylinder head connection(s) - EGR solenoid gasket base and tube seal points (if equipped) Watch for the liquid/soapy 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 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 27.6 kPa (4 psi) reveal bubble size: Welded joints Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor seal points Type 1, 1 mm (0.04 of an inch) or greater O2 Sensor boss welds Type 1, 1 mm (0.04 of an inch) or greater Flange / joint connections Type 2, 8 mm (0.3 of an inch) or greater Exhaust Manifold to cylinder head connections Type 2, 8 mm (0.3 of an inch) or greater EGR gasket and tube seal points Type 2, 8 mm (0.3 of an inch) 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 «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 4 .
4. O2 SENSOR OPERATION Start the engine. Allow the engine to reach normal operating temperature. NOTE: If one of the O2 Sensor's Signal or Return circuit is shorted to ground the scan tool will display all O2 Sensor voltage readings low. The O2 Sensor that is shorted to ground will display a voltage reading near or at 0 volts. NOTE: If one of the O2 Sensor Signal or Return circuits are shorted to voltage, the scan tool will display all O2 Sensor voltage readings high. NOTE: After the repairs have been made, verify proper O2 Sensor operation. If all the O2 Sensor voltage readings have not returned to normal, follow the diagnostic procedure for the remaining O2 Sensors. With the scan tool, monitor the 2/1 O2 Sensor voltage reading. Is the voltage switching between 2.5 and 3.4 volts? Yes Go To 5 . No Go To 9 .
5. 2/1 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. NOTE: Perform the following test on all O2 Sensors. Ignition on, engine not running. With a scan tool, actuate the 2/1 O2 Heater Test. With the scan tool, monitor 2/1 O2 Sensor voltage for at least 2 minutes. Does the voltage stay above 4.5 volts? Yes Verify that there is good pin to terminal contact in the O2 Sensor and Powertrain Control Module connectors. Replace the 2/1 O2 Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 6 .
6. MAP SENSOR OPERATION Ignition on, engine not running. 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 this vehicle to the value of a known good vehicle of a similar make and model. Turn the ignition off. Connect a Vacuum Gauge to a Manifold Vacuum source. Start the engine. Allow the engine to idle. NOTE: If engine will not idle, maintain a constant RPM above idle. With the scan tool, read the MAP Sensor vacuum value. Is the scan tool reading for MAP Vacuum within 1 inch of Hg on the Vacuum Gauge and is the Barometric Pressure reading of the vehicle the approximately the same as actual Barometric Pressure? Yes Go To 7 . No Verify that there is good pin to terminal contact in the MAP Sensor and Powertrain Control Module connectors. Replace the MAP Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
7. ECT SENSOR OPERATION NOTE: For this test to be valid, the thermostat must be operating correctly. NOTE: This test works best if performed on a cold engine (cold soak). Ignition on, engine not running. With the scan tool, read the Engine Coolant Temperature (ECT) Sensor value. If the engine was allowed to sit overnight (cold soak), the temperature value should be a sensible value that is somewhere close to the ambient temperature. NOTE: If engine coolant temperature is above 82° C (180° F), allow the engine to cool until 65° C (150° F) is reached. Start the Engine. During engine warm-up, monitor the ECT Sensor value. The temperature value change should be a smooth transition from start up to normal operating temperature 82° (180° F). The value should reach at least 82° C (180° F). Did the ECT value increase smoothly and did it reach at least 82° (180° F)? Yes Go To 8 . No Verify that there is good pin to terminal contact in the ECT Sensor and Powertrain Control Module connectors. Replace the Engine Coolant Temperature Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
8. ENGINE MECHANICAL PROBLEM Turn the ignition off. Check for any of the following conditions/mechanical problems. AIR INDUCTION SYSTEM - must be free from leaks. ENGINE VACUUM - must be at least 13 inches in neutral ENGINE VALVE TIMING - must be within specifications ENGINE COMPRESSION - must be within specifications ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks. ENGINE PCV SYSTEM - must flow freely TORQUE CONVERTER STALL SPEED - must be within specifications POWER BRAKE BOOSTER - no internal vacuum leaks FUEL - must be free of contamination FUEL INJECTOR - plugged or restricted injector; control wire not connected to correct injector Are there any engine mechanical problems? Yes Repair as necessary. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 12 .
9. O2 SENSOR Turn the ignition off. Disconnect the 2/1 O2 Sensor harness connector. Ignition on, engine not running. With the scan tool, monitor the 2/1 O2 Sensor voltage. O2 Sensor voltage should read between 4.1 and 5.0 volts on the scan tool with the connector disconnected. Connect a jumper wire between the (K43) O2 Sensor 2/1 Signal circuit and the (K902) O2 Return Upstream circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from between 4.1 and 5.0 volts to 2.5 volts with the jumper wire in place. Did the O2 Sensor voltage change from between 4.1 and 5.0 volts to 2.5 volts when the jumper wire was installed? Yes Verify that there is good pin to terminal contact in the O2 Sensor and Powertrain Control Module connectors. Replace the 2/1 O2 Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 10 . NOTE: Remove the jumper wire before continuing.
10. O2 SENSOR SIGNAL CIRCUIT With the scan tool, monitor all the O2 Sensor voltage reading with the jumper wire removed. NOTE: The scan tool will display all O2 Sensor voltage readings approximately 5.0 volts when only one O2 Sensor's Signal circuit is shorted to voltage. NOTE: The scan tool will display one O2 Sensor voltage close to zero and the others will read lower than normal when one O2 Sensor Signal circuit contains excessive resistance. Is the voltage between 4.1 and 5.0 volts? Yes Go To 11 . No Check all the O2 Signal circuits for a short to ground, open, or short to voltage. Inspect the O2 Sensor connector and the PCM harness connector. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
11. (K902) O2 RETURN UPSTREAM CIRCUIT Disconnect the 2/1 O2 Sensor harness connector. Measure the voltage on the (K902) O2 Return Upstream circuit in the O2 Sensor harness connector. Is the voltage at 2.5 volts? Yes Go To 12 . No Check the (K902) O2 Return Upstream circuit for a short to ground, open, or short to voltage. Inspect the O2 Sensor connector and the PCM harness connector. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
12. POWERTRAIN CONTROL MODULE (PCM) Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Sensors and the Powertrain Control Module (PCM). Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the Sensor and Control Module connectors. Refer to any Technical Service Bulletins that may apply. Were there any problems found? Yes Repair as necessary. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
13. 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 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. 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 Repair or replace fuel supply line as necessary. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 14 . CAUTION: Stop All Actuations.
14. FUEL PUMP INLET STRAINER 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. Turn the ignition off. 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 «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 15 .
15. FUEL PUMP MODULE If there are no possible causes remaining, view repair. Repair Verify that there is good pin to terminal contact in the Fuel Pump Module, TIPM, and Powertrain Control Module connectors. Replace the Fuel Pump Module if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .

1. ACTIVE DTC Diagnose all other trouble codes before continuing. NOTE: Check for contaminants that may have damaged an O2 Sensor: contaminated fuel, unapproved silicone, oil and coolant. Start the engine. Allow the engine to reach normal operating temperature. With a scan tool, select View DTCs. NOTE: It may be necessary to drive the vehicle to meet the conditions to set this DTC, try to repeat the conditions in which the fault originally set by reviewing the Freeze Frame data. Is the DTC Active or Pending at this time? Yes Go To 2 . No Refer to the «INTERMITTENT CONDITION»(ref-306207-S19641665412008120900000) Diagnostic Procedure.
2. CHECKING 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 personal injury or death. Turn the ignition off. Install a fuel pressure gauge to the fuel rail. 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). Turn the ignition off. Choose a conclusion that best matches your fuel pressure reading. Within Specification Go To 3 . Above Specification Replace the fuel filter/pressure regulator. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . CAUTION: Stop All Actuations.
3. O2 SENSOR OPERATION Start the engine. Allow the engine to reach normal operating temperature. NOTE: If one of the O2 Sensor's Signal or Return circuit is shorted to ground or voltage, all the other O2 Sensor voltage readings will be affected. NOTE: After the repairs have been made, verify proper O2 Sensor operation. If all the O2 Sensor voltage readings have not returned to normal, follow the diagnostic procedure for the remaining O2 Sensors. With the scan tool, monitor the 2/1 O2 Sensor voltage reading. Is the voltage switching between 2.5 and 3.4 volts? Yes Go To 4 . No Go To 9 .
4. 2/1 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. Ignition on, engine not running. With the scan tool, perform the 2/1 O2 Heater Test for each O2 Sensor. With the scan tool, monitor the 2/1 O2 Sensor voltage while performing the Heater test for at least 2 minutes. Does the voltage stay above 4.5 volts for each Sensor? Yes Verify that there is good pin to terminal contact in the O2 Sensor and Powertrain Control Module connectors. Replace the 2/1 O2 Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 5 .
5. MAP SENSOR OPERATION Ignition on, engine not running. 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 this vehicle to the value of a known good vehicle of a similar make and model. Turn the ignition off. Connect a Vacuum Gauge to a Manifold Vacuum source. Start the engine. Allow the engine to idle. NOTE: If engine will not idle, maintain a constant RPM above idle. With the scan tool, read the MAP Sensor vacuum value. Is the scan tool reading for MAP Vacuum within 1 inch of Hg on the Vacuum reading and is the Barometric Pressure reading of the vehicle the approximately the same as actual Barometric Pressure? Yes Go To 6 . No Verify that there is good pin to terminal contact in the MAP Sensor and Powertrain Control Module connectors. Replace the MAP Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . NOTE: Remove the vacuum gauge before continuing.
6. ECT SENSOR OPERATION NOTE: For this test to be valid, the thermostat must be operating correctly. NOTE: This test works best if performed on a cold engine (cold soak). Ignition on, engine not running. With the scan tool, read the Engine Coolant Temperature Sensor value. If the engine was allowed to sit overnight (cold soak), the temperature value should be a sensible value that is somewhere close to the ambient temperature. NOTE: If engine coolant temperature is above 82° C (180° F), allow the engine to cool until 65° C (150° F) is reached. Start the Engine. During engine warm-up, monitor the Engine Coolant Temperature value. The temp value change should be a smooth transition from start up to normal operating temp 82° C (180° F). The value should reach at least 82° C (180° F). Did the ECT value increase smoothly and reach at least 82° C (180° F)? Yes Go To 7 . No Verify that there is good pin to terminal contact in the ECT Sensor and Powertrain Control Module connectors. Replace the Engine Coolant Temperature Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
7. EVAP PURGE SOLENOID OPERATION Turn the ignition off. Disconnect the hoses at the EVAP Purge Solenoid. Using a hand vacuum pump, apply 10 inches of vacuum to the EVAP Purge Solenoid vacuum source port on the component side. Did the EVAP Purge Solenoid hold vacuum? Yes Go To 8 . No Verify that there is good pin to terminal contact in the EVAP Purge Solenoid and Powertrain Control Module connectors. Replace the EVAP Purge Solenoid if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . NOTE: Connect the vacuum hoses before continuing.
8. ENGINE MECHANICAL PROBLEM Check for any of the following conditions/mechanical problems. AIR INDUCTION SYSTEM - must be free from 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 of any restrictions or leaks. ENGINE PCV SYSTEM - must flow freely TORQUE CONVERTER STALL SPEED - must be within specifications POWER BRAKE BOOSTER - no internal vacuum leaks FUEL - must be free of contamination FUEL INJECTOR - plugged or restricted injector; control wire not connected to correct injector Are there any engine mechanical problems? Yes Repair as necessary. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 12 .
9. 2/1 O2 SENSOR Turn the ignition off. Disconnect the 2/1 O2 Sensor harness connector. Ignition on, engine not running. With the scan tool, monitor the 2/1 O2 Sensor voltage. O2 Sensor voltage should read between 4.1 and 5.0 volts on the scan tool with the connector disconnected. Connect a jumper wire between the (K43) O2 Sensor 2/1 Signal circuit and the (K902) O2 Return Upstream circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from between 4.1 and 5.0 volts down to 2.5 volts with the jumper wire connected. Did the O2 Sensor voltage drop from between 4.1 and 5.0 volts to 2.5 volts when the jumper wire was installed? Yes Verify that there is good pin to terminal contact in the O2 Sensor and Powertrain Control Module connectors. Replace the 2/1 O2 Sensor if no problems were found with the connectors. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Go To 10 . NOTE: Remove the jumper wire before continuing.
10. O2 SENSOR SIGNAL CIRCUIT 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. Measure the voltage on the (K43) O2 Sensor 2/1 Signal circuit in the O2 Sensor harness connector. Is the voltage between 4.1 and 5.0 volts? Yes Go To 11 . No Check the (K43) O2 Sensor 2/1 Signal circuit for damage, short to ground, open, or short to voltage. Inspect the O2 Sensor connector and the PCM harness connector. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .
11. (K902) O2 SENSOR RETURN UPSTREAM CIRCUIT Engine still running. Measure the voltage on the (K902) O2 Return Upstream circuit in the O2 Sensor harness connector. Is the voltage at 2.5 volts? Yes Go To 12 . No Check the (K902) O2 Return Upstream circuit for damage, short to ground, open, or short to voltage. Inspect the O2 Sensor connector and the PCM harness connector. If OK, replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . NOTE: Turn the ignition off before continuing.
12. POWERTRAIN CONTROL MODULE (PCM) Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Sensors and the Powertrain Control Module (PCM). Look for any chafed, pierced, pinched, or partially broken wires. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the Sensor and Control Module connectors. Refer to any Technical Service Bulletins that may apply. Were there any problems found? Yes Repair as necessary. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) . No Replace and program the Powertrain Control Module per Service Information. Perform «POWERTRAIN VERIFICATION TEST»(ref-306217-S13377649292008120900000) .

Scheme 62