Diagnostic Test

ACTIVE DTC
NOTE: Diagnose and repair any EGR signal circuit high or low DTCs before continuing with this procedure.
1. Turn the ignition on.
2. With the scan tool, select View DTCs. Record DTC and Freeze Frame information.
3. 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 may result in possible serious or fatal injury.
  
  WARNING: The normal operating temperature of the EGR system is very high. Never work around or attempt to service any part of the EGR system until it has cooled. Failure to follow these instructions can result in possible serious or fatal injury.
  
  NOTE: Attempt to operate the vehicle under conditions similar to which the DTC was set.
  
  NOTE: It may be necessary to test drive the vehicle within the DTC monitoring conditions in order for this DTC to set.
4. With a scan tool, select View DTCs.
  Is the DTC Active or Pending at this time?
  
  Yes
  - Go to step 2
  No
  - Refer to the INTERMITTENT CONDITION Diagnostic Procedure. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .
EXCESSIVE RESISTANCE IN THE (F856) 5 VOLT SUPPLY CIRCUIT

Fig 1: Measuring Resistance Of 5-Volt Supply Circuit From EGR Solenoid Harness Connector To Appropriate Terminal Of Special Tool #8815
Courtesy of CHRYSLER LLC
1. 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 PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis.
2. Using a voltmeter, perform a voltage drop test by backprobing the (F856) 5 Volt Supply circuit at the EGR Valve Assembly 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 may result in possible serious or fatal injury.
3. Start the engine.
  Is the voltage below 0.5 volts?
  
  Yes
  - Go to step 3
  No
  - Repair the excessive resistance in the (F856) 5 Volt Supply circuit.
  - Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .
EXCESSIVE RESISTANCE IN THE (K34) EGR SIGNAL CIRCUIT

Fig 2: Using Voltmeter To Perform Voltage Drop Test By Backprobing EGR Signal Circuit
Courtesy of CHRYSLER LLC
1. 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 PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis.
2. Using a voltmeter, perform a voltage drop test by backprobing the (K34) EGR Signal circuit at the EGR Valve Assembly 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 may result in possible serious or fatal injury.
3. Start the engine.
  Is the voltage below 0.5 volts?
  
  Yes
  - Go to step 4
  No
  - Repair the excessive resistance in the (K34) EGR Signal circuit.
  - Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .
EXCESSIVE RESISTANCE IN THE (K900) SENSOR GROUND CIRCUIT

Fig 3: Using Voltmeter To Perform Voltage Drop Test To Sensor Ground Circuit
Courtesy of CHRYSLER LLC
1. 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 PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis.
2. Using a voltmeter, perform a voltage drop test by backprobing the (K900) Sensor Ground circuit at the EGR Valve Assembly 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 may result in possible serious or fatal injury.
3. Start the engine.
  Is the voltage below 0.5 volts?
  
  Yes
  - Go to step 5
  No
  - Repair the excessive resistance in the (K900) Sensor Ground circuit.
  - Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .
EXCESSIVE RESISTANCE IN THE (Z958) GROUND CIRCUIT

Fig 4: Using 12-Volt Test Light Connected To Battery Voltage To Probe EGR Solenoid Ground Circuit In EGR Solenoid Harness Connector
Courtesy of CHRYSLER LLC
1. Turn the ignition off.
2. Disconnect the EGR Valve Assembly harness connector.
3. Using a 12 volt test light connected to the 12 volts, check the (Z958) Ground circuit in the EGR Valve Assembly 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
  - Go to step 6
  No
  - Repair the excessive resistance in the (Z958) Ground circuit.
  - Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .
EXCESSIVE RESISTANCE IN THE (K35) EGR CONTROL CIRCUIT
1. Turn the ignition off.
2. Connect the EGR Valve Assembly 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 PCM Pinout Box 8815 along with the Adapter 8815-1 to perform the diagnosis.
3. Using a voltmeter, perform a voltage drop test by backprobing the (K35) EGR Control circuit at the EGR Valve Assembly 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.
4. 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 may result in possible serious or fatal injury.
5. With the scan tool, perform the EGR System Test.
6. Select OPEN to open the EGR valve.
7. Monitor the circuit voltage on the voltmeter.
  Is the voltage below 0.5 volts when the valve was opened during the system test?
  
  Yes
  - Go to step 7
  No
  - Repair the excessive resistance in the (K35) EGR Control circuit.
  - Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .
EGR VALVE ASSEMBLY
1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the EGR Valve Assembly and the Powertrain Control Module (PCM).
2. Look for any chafed, pierced, pinched, or partially broken wires.
3. Look for broken, bent, pushed out or corroded terminals.
4. Verify that there is good pin to terminal contact in the Solenoid and Powertrain Control Module connectors.
5. Refer to any Technical Service Bulletins that may apply.
  Were any problems found?
  
  Yes
  - Repair or replace the EGR system components as necessary.
  - Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .
  No
  - Replace the EGR Valve Assembly in accordance with the Service Information if no problems were found in the connectors.
  - Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .