Diagnostic Test

Ignition on, engine not running.

Start the engine.

Allow the engine to reach normal operating temperature.

With a scan tool, select View DTCs.

Is the DTC Active or Pending at this time? 

Yes 

1. Go To  2.

No 

1. Refer to the INTERMITTENT CONDITION Diagnostic Procedure.

Turn the ignition off.

Raise the vehicle in accordance with the Service Information.

Connect Exhaust Cone #8404-EC or #8404-EC to Air Pressure Regulator (with hose) #W-18-MIL-1146AS.

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

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 

1. Repair or replace the leaking exhaust parts as necessary.
2. Perform POWERTRAIN VERIFICATION TEST .

No 

1. Go To  3.

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 .

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 .

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 .