Diagnostic Test

ACTIVE DIAGNOSTIC TROUBLE CODE (DTC)
NOTE: Diagnose and repair any EGR circuit DTCs before continuing with this procedure.
1. Turn the ignition on.
2. Using the scan tool, select View DTCs. Copy 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 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
  - Perform the INTERMITTENT CONDITION diagnostic procedure. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .
ROUGH IDLE OR STALLING AT IDLE
1. Turn the ignition off.
2. Turn all accessories off.
3. Start the engine.
  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 can result in possible serious or fatal injury.
  
  Does the engine run rough or stall at idle?
  
  Yes
  - Go to step 3
  No
  - Go to step 5
EGR VALVE ASSEMBLY CONTROL CIRCUIT
1. Turn the ignition off.
2. Disconnect the EGR Valve Assembly harness connector.
3. Start the engine.
  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 can result in possible serious or fatal injury.
  
  Does the engine continue to run rough or stall with the EGR Valve Assembly connector disconnected?
  
  Yes
  - Go to step 8
  No
  - Go to step 4
(K35) EGR SOLENOID CONTROL CIRCUIT SHORTED TO VOLTAGE

Fig 1: Measuring Voltage Of EGR Solenoid Control Circuit
Courtesy of CHRYSLER LLC
1. Turn the ignition off.
2. Disconnect the C2 PCM harness connector.
3. Disconnect the EGR Solenoid harness connector.
4. Ignition on, engine not running.
5. Measure the voltage on the (K35) EGR Solenoid Control circuit in the EGR Solenoid connector.
  Is there any voltage present?
  
  Yes
  - Repair the short to voltage in the (K35) EGR Solenoid Control circuit.
  - Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .
  No
  - Go to step 9
EGR SYSTEM TEST
1. Turn all accessories off.
2. 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 can result in possible serious or fatal injury.
3. Using the scan tool, perform the EGR System Test.
4. Select OPEN to open the EGR valve.
  Did the engine run rough or stall when the valve was opened during the system test?
  
  Yes
  - Go to step 8
  No
  - Go to step 6
(Z42) EGR SOLENOID GROUND CIRCUIT OPEN

Fig 2: Using 12-Volt Test Light Connected To 12 Volts To Check Ground Circuit In EGR Valve Assembly Harness Connector
Courtesy of CHRYSLER LLC
1. Turn the ignition off.
2. Using a 12-volt test light connected to battery voltage, probe the (Z42) EGR Solenoid ground circuit in the EGR Solenoid harness connector.
  Does the 12-volt test light illuminate brightly?
  
  Yes
  - Go to step 7
  No
  - Repair the open in the (Z42) EGR Solenoid ground circuit.
  - Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .
(K35) EGR CONTROL CIRCUIT HIGH RESISTANCE

Fig 3: Checking EGR Control Circuit
Courtesy of CHRYSLER LLC
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 PCM Pinout Box 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 can result in possible serious or fatal injury.
5. Using 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 8
  No
  - Repair the (K35) EGR Control circuit for excessive resistance.
  - Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .
EGR VALVE ASSEMBLY
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.
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 EGR Solenoid and the Powertrain Control Module connectors.
5. Perform any Technical Service Bulletins that may apply.
6. Inspect the EGR Valve Assembly for the following:
  - Proper mounting, leaking gasket(s)
  - Damaged, leaking, or obstructed EGR tube(s)
  - Carbon build up on or near the EGR pintle or within passages.
  Were any problem 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.
  - Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .
POWERTRAIN CONTROL MODULE (PCM)
1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the EGR Solenoid 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 Solenoid and the Powertrain Control Module connectors.
4. Perform any Technical Service Bulletins that may apply.
  Were there any problems found?
  
  Yes
  - Repair as necessary.
  - Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .
  No
  - Replace and program the Powertrain Control Module in accordance with the service information.
  - Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .