Diagnostic Test

ACTIVE DTC
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.

NOTE:
Check for contaminants that may have damaged the O2 Sensor: contaminated fuel, unapproved silicone, oil and coolant.
1. Start the engine.
2. Allow the engine to reach normal operating temperature.
3. With the 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
  - Peform the INTERMITTENT CONDITION diagnostic procedure. Refer to INTERMITTENT CONDITION .

CHECKING THE EXHAUST SYSTEM FOR LEAKS

Turn the ignition off.
Raise the vehicle in accordance with the Service Information.
WARNING:
The normal operating temperature of the exhaust system is very high. Never work around or attempt to service any part of the exhaust system until it has cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operating time.
Connect Exhaust Cone (special tool #8404-EC, Exhaust Cone) or (special tool #8404-EC, Exhaust Cone) to Air Pressure Regulator (with hose) W-18-MIL-1146AS.
CAUTION:
The air pressure must not exceed 27.6 kPa (4 psi), otherwise engine damage can occur.
Attach shop air to the air pressure regulator.
Adjust the Air Pressure Regulator to 27.6 kPa (4 psi).
Insert the exhaust cone into the vehicle tail pipe.
If the vehicle is equipped with dual exhaust. Use the (special tool #8404-ECT, Exhaust Cone, Truck) with equipped attached plug, plug one side of the dual exhaust pipe. Pressurize the other as described above.
Apply Mopar® Air Leak Detector PN# 05191804AA (or an equivalent leak finder liquid) to the following areas:
- All welded joints from the exhaust manifold to 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 the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
No
- Go To 3.

(K141) O2 1/2 SIGNAL CIRCUIT

Fig 1: Measuring Voltage Of O2 Sensor Signal Circuit In O2 Sensor Harness Connector
Courtesy of CHRYSLER GROUP, LLC
1. Turn the ignition off
2. Disconnect the 1/2 O2 Sensor harness connector.
3. Ignition on, engine not running.
4. 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 PCM in accordance with the Service Information. Refer to MODULE, POWERTRAIN CONTROL, REMOVAL .
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
(K904) O2 RETURN DOWNSTREAM CIRCUIT

Fig 2: Measuring Voltage On O2 Sensor Return Circuit In O2 Sensor Harness Connector
Courtesy of CHRYSLER GROUP, LLC
1. 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 PCM in accordance with the Service Information. Refer to MODULE, POWERTRAIN CONTROL, REMOVAL .
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
OXYGEN SENSOR
NOTE:
Check for signs of contaminants that may have damaged the O2 Sensor, such as contaminated fuel, unapproved silicone, oil and coolant.
1. 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).
2. Look for any chafed, pierced, pinched or partially broken wires.
3. Look for broken, bent, pushed out or corroded terminals.
4. Perform any Technical Service Bulletins that may apply.
  Were any problems found?
  
  Yes
  - Repair as necessary.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  No
  - Replace the 1/2 Oxygen Sensor in accordance with the Service Information. Refer to SENSOR, OXYGEN, REMOVAL .
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .