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.

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
1. Go to 2).
No
1. Refer to INTERMITTENT CONDITION 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 SNOOP leak finder liquid or a mixture of liquid dish soap and water 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 .

Go to 3).

3) (K141) O2 1/2 SIGNAL CIRCUIT

Fig 1: Checking O2 Sensor Signal Circuit
Courtesy of CHRYSLER LLC

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
1. Go to 4).
No
1. 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.
2. Perform POWERTRAIN VERIFICATION TEST .
4) (K904) O2 RETURN DOWNSTREAM CIRCUIT

Fig 2: Checking O2 Sensor Return Upstream & Downstream Circuits
Courtesy of CHRYSLER LLC

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
1. Go to 5).
No
1. 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.
2. Perform POWERTRAIN VERIFICATION TEST .
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 1/2 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?

Yes
1. Repair as necessary.
2. Perform POWERTRAIN VERIFICATION TEST .
No
1. Replace the 1/2 Oxygen Sensor in accordance with the Service Information.
2. Perform POWERTRAIN VERIFICATION TEST .