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Home >> Chrysler >> 2009 >> Sebring Base, 2D Convertible, ED3 >> Repair and Diagnosis >> Engine Performance >> System >> DTCS P0353 To P0503 - GPEC >> P0491-Secondary Air Injection System Insufficient Flow >> Diagnostic Test

Diagnostic Test

  1. DTC IS ACTIVE 
    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 any part of the exhaust system. The temperature rises to a high level after a short period of engine operating time.
    NOTE: Diagnose and repair any Secondary Air system sensor signal or relay control circuit DTCs before proceeding with this procedure.
    1. Turn the ignition on.
    2. With the scan tool, select View DTCs and review the DTC environmental data for this DTC.

      Is the good trip counter greater than 0?

      Yes 

      No 

      • Go to step  2
  2. AIR INJECTION SYSTEM COMPONENT INSPECTION 
    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 any part of the exhaust system. The temperature rises to a high level after a short period of engine operating time.
    1. Turn the ignition off.
    2. Inspect the Secondary Air Pump Airflow Sensor, the Secondary Air Pump Assembly, the Secondary Air Pump Valve and the connection tubes between them.
    3. Look for damage, obstructions, leaks, or any condition that would obstruct or interfere with airflow between the components.
    4. Using the wiring diagram/schematic as a guide, inspect the wiring and electrical connectors at the Secondary Air Pump Airflow Sensor, Secondary Air Pump Relay, and the Secondary Air Pump Assembly.
    5. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the related connectors.

      Were any problems found?

      Yes 

      No 

      • Go to step  3
  3. SECONDARY AIR PUMP ACTUATION 
    1. Turn the ignition on.
    2. With the scan tool, actuate the Secondary Air Pump Relay control to on.
    3. With the scan tool, monitor the Secondary Air MAF Sensor value.
      CAUTION: Do not allow the Air Pump actuation to run for more than 30 seconds at a time. Pump damage may occur. Allow the pump to cool down for at least 10 minutes between actuations.

      Is the Secondary Air MAF Sensor value greater than 25 kg/h with the pump actuated on?

      Yes 

      No 

      • Go to step  4
  4. SECONDARY AIR CHECK VALVE 
    Fig 1: Air Injection Check Valve
    GC0099922Courtesy of CHRYSLER LLC
    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 any part of the exhaust system. The temperature rises to a high level after a short period of engine operating time.
    1. Turn the ignition off.
    2. Disconnect the air pump outlet tube (3) from the secondary air check valve (1).
    3. Turn the ignition on.
    4. With the scan tool, actuate the Secondary Air Pump Relay control to on.
    5. With the scan tool, monitor the Secondary Air MAF Sensor value.
      CAUTION: Do not allow the Air Pump actuation to run for more than 30 seconds at a time. Pump damage may occur. Allow the pump to cool down for at least 10 minutes between actuations.

      Is the Secondary Air MAF Sensor value greater than 25 kg/h with the pump actuated on?

      Yes 

      No 

      • Go to step  5
  5. (Z931) GROUND CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 2: Checking Ground Circuit
    GC0099923Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Disconnect the Secondary Air Pump connector.
    3. Using a 12-volt test light connected to 12 volts, check the (Z931) Ground circuit in the Secondary Air Pump 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 

  6. SECONDARY AIR PUMP CONTROL OUTPUT 
    Fig 3: Checking Secondary Air Pump Control Output Circuit
    GC0099924Courtesy of CHRYSLER LLC
    1. Turn the ignition on.
    2. With the scan tool, actuate the Secondary Air Pump Relay control to on.
    3. Using a 12-volt test light connected to ground, check the (A161) Secondary Air Pump Relay Output circuit in the Secondary Air Pump 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  7

      No 

      • Go to step  16
  7. (F343) FUSED MAIN RELAY OUTPUT CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 4: Checking Fused Main Relay Output Circuit
    GC0123844Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Disconnect the Airflow Sensor connector.
    3. Turn the ignition on.
    4. Using a 12-volt test light connected to ground, check the (F343) Fused Main Relay Output circuit in the Airflow Sensor 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  8

      No 

  8. (K157) SAF SIGNAL CIRCUIT VOLTAGE 
    Fig 5: Checking SAF Signal Circuit
    GC0123845Courtesy of CHRYSLER LLC
    1. Turn the ignition on.
    2. Measure the voltage of the (K157) SAF Signal circuit in the Airflow Sensor harness connector.

      Is the voltage between 4.8 and 50.1 of a volt?

      Yes 

      • Go to step  9

      No 

      • Go to step  12
  9. (K957) SENSOR GROUND CIRCUIT TEST 
    Fig 6: Checking SAF Ground Circuit
    GC0123846Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Using a 12-volt test light connected to 12 volts, check the (K957) Sensor Ground circuit in the Airflow Sensor 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  10

      No 

      • Go to step  14
  10. AIRFLOW SENSOR WIRING AND CONNECTORS 
    1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Airflow 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. Verify that there is good pin to terminal contact in the related connectors.
    4. Monitor the scan tool data relative to this circuit and wiggle test the wiring and connectors.
    5. Look for the data to change or for the DTC to reset during the wiggle test.
    6. Perform any Technical Service Bulletins that may apply.

      Were any problems found?

      Yes 

      No 

      • Go to step  11
  11. AIRFLOW SENSOR 
    1. Turn the ignition off.
    2. Replace the Airflow Sensor.
    3. Verify that all Secondary Air Pump Assembly wiring, connectors, tubes, and hoses are connected properly.
    4. Turn the ignition on.
    5. With the scan tool, actuate the Secondary Air Pump Relay control to on.
    6. With the scan tool, monitor the Secondary Air MAF Sensor value.
      CAUTION: Do not allow the Air Pump actuation to run for more than 30 seconds at a time. Pump damage may occur. Allow the pump to cool down for at least 10 minutes between actuations.

      Is the Secondary Air MAF Sensor value greater than 25 kg/h with the pump actuated on?

      Yes 

      No 

      • Go to step  19
  12. (K157) SAF SIGNAL CIRCUIT SHORTED TO VOLTAGE 
    Fig 7: Checking SAF Signal Circuit
    GC0123845Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Disconnect the Powertrain Control Module (PCM) connector.
    3. Turn the ignition on.
    4. Measure the voltage of the (K157) SAF Signal circuit in the Airflow Sensor harness connector.

      Is there any voltage present?

      Yes 

      No 

      • Go to step  13
  13. (K157) SAF SIGNAL CIRCUIT SHORTED TO GROUND 
    Fig 8: Checking SAF Signal Circuit
    GC0123847Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Measure the resistance between ground and the (K157) SAF Signal circuit in the Airflow Sensor harness connector.

      Is the resistance above 100 Ohms?

      Yes 

      • Go to step  14

      No 

  14. (K157) SAF SIGNAL CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 9: Checking SAF Signal Circuit
    GC0123848Courtesy of CHRYSLER LLC
    NOTE: When checking circuits at the Powertrain Control Module (PCM), be careful not to damage or distort the connector terminals. Improper measurement technique could result in poor pin to terminal contact.
    1. Measure the resistance of the (K157) SAF Signal circuit between the Airflow Sensor harness connector and the PCM.

      Is the resistance below 5.0 Ohms?

      Yes 

      • Go to step  20

      No 

  15. (K957) SENSOR GROUND CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 10: Checking SAF Ground Circuit
    GC0123849Courtesy of CHRYSLER LLC
    NOTE: When checking circuits at the Powertrain Control Module (PCM), be careful not to damage or distort the connector terminals. Improper measurement technique could result in poor pin to terminal contact.
    1. Measure the resistance of the (K957) Sensor Ground circuit between the Airflow Sensor harness connector and the PCM.

      Is the resistance below 5.0 Ohms?

      Yes 

      • Go to step  20

      No 

  16. (A161) SECONDARY AIR PUMP CONTROL OUTPUT CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 11: Checking Secondary Air Pump Control Output Circuit
    GC0123850Courtesy of CHRYSLER LLC
    1. Turn the ignition off.
    2. Remove the Secondary Air Pump Relay.
    3. Measure the resistance of the (A161) Secondary Air Pump Relay Output circuit between the Secondary Air Pump Relay connector and the Secondary Air Pump harness connector.

      Is the resistance below 5.0 Ohms?

      Yes 

      • Go to step  17

      No 

  17. (A929) FUSED B+ CIRCUIT OPEN OR HIGH RESISTANCE 
    Fig 12: Checking Fused B+ Circuit
    GC0123851Courtesy of CHRYSLER LLC
    1. Turn the ignition on.
    2. Using a 12-volt test light connected to ground, check the (A929) Fused B+ circuit in the Secondary Air Pump Relay 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 

      No 

  18. SECONDARY AIR PUMP RELAY 
    1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Secondary Air Pump Relay 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. Verify that there is good pin to terminal contact in the related connectors.
    4. Monitor the scan tool data relative to this circuit and wiggle test the wiring and connectors.
    5. Look for the data to change or for the DTC to reset during the wiggle test.
    6. Perform any Technical Service Bulletins that may apply.

      Were any problems found?

      Yes 

      No 

  19. SECONDARY AIR PUMP 
    1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Secondary Air Pump 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. Verify that there is good pin to terminal contact in the related connectors.

      Were any problems found?

      Yes 

      No 

  20. POWERTRAIN CONTROL MODULE (PCM) 
    1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Secondary Air Pump 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. Verify that there is good pin to terminal contact in the related connectors.
    4. Monitor the scan tool data relative to this circuit and wiggle test the wiring and connectors.
    5. Look for the data to change or for the DTC to reset during the wiggle test.
    6. Perform any Technical Service Bulletins that may apply.

      Were any problems found?

      Yes 

      No 

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