LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Chrysler >> 2021 >> Voyager LX, Gas >> Repair and Diagnosis >> Engine Performance >> System >> 3.6L - DTCS P0440 To P060B >> Diagnosis And Testing >> P04D2-Cooled EGR Temperature Sensor Circuit Intermittent/Erratic >> Diagnostic Test

Diagnostic Test

  1. ENGINE COOLANT TEMPERATURE 
    1. Turn the ignition off.
    2. Allow the vehicle to sit with the ignition off in an environment where the temperature is consistent and above -64°C (-83°F) until the engine coolant temperature is equal to ambient temperature.
    3. Turn the ignition on.
    4. With the scan tool, compare the AAT, ECT, IAT and EGR Temperature Sensor values.

      Is the EGR Temperature Sensor value within 15°C (59°F) of the other sensor values?

      Yes 

      • Go To  2

      No 

      • Go To  7
  2. LOW COOLANT LEVEL 
    1. Diagnose all other DTCs before continuing.
    2. Check the cooling system to make sure that the coolant is in good condition, at the proper level, and meets OEM specifications. Refer to DIAGNOSIS AND TESTING .

      Is the coolant level and condition OK?

      Yes 

      • Go To  3

      No 

  3. CHECK FOR AN ACTIVE DTC 
    1. Start the engine.
    2. Allow the engine to reach normal operating temperature.
    3. Test drive the vehicle under the conditions in which the fault originally set by reviewing the Freeze Frame data.
    4. With the scan tool, read DTCs and record on the repair order.

      Is the DTC active or pending?

      Yes 

      • Go To  4

      No 

  4. CHECK COOLING SYSTEM OPERATION 
    1. Check the following cooling system components:
      • Verify condition and operation of the accessory belt and tensioner.
      • Verify proper airflow through the radiator.
      • Verify that the Thermostat is opening correctly.
      • Verify the correct coolant flow throughout the system.
      • During engine warm-up, monitor the coolant temperature and the operation of the Cooling Fan.

      Is the Cooling system operating correctly?

      Yes 

      • Go To  5

      No 

  5. CHECK THE FUEL DELIVERY SYSTEM 
    1. Perform the CHECKING THE FUEL DELIVERY SYSTEM test procedure. Refer to CHECKING THE FUEL DELIVERY SYSTEM (HARD START) .

      Were any problems found with the fuel system?

      Yes 

      No 

      • Go To  6
  6. ENGINE MECHANICAL 
    1. Turn the ignition off.
    2. Check for any of the following conditions/mechanical problems:
      • AIR INDUCTION SYSTEM - must be free from restrictions.
      • ENGINE VALVE TIMING - must be within specifications.
      • CAM PHASER/OIL CONTROL VALVE - must be operating correctly and not sticking.
      • FUEL - must be free of contamination.
      • FUEL INJECTOR - leaking or improper spray pattern.

      Are there any engine mechanical problems?

      Yes 

      No 

      • Replace the EGR Temperature Sensor in accordance with the Service Information.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  7. CHECK FOR HIGH RESISTANCE IN THE (K932) EGR TEMPERATURE SENSOR SIGNAL CIRCUIT 
    1. Turn the ignition off.
    2. Disconnect the EGR Temperature Sensor harness connector.
    3. Disconnect the PCM C2 harness 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 the GPEC Diagnostic Adaptor to perform the diagnosis.

    4. Connect the (special tool #10436, Adapter, GPEC Diagnostic).
    5. Measure the resistance of the (K932) EGR Temperature Sensor Signal circuit between the EGR Temperature Sensor harness connector and the GPEC Adaptor.

      Is the resistance below 3.0 Ohms?

      Yes 

      • Go To  8

      No 

      • Repair the (K932) EGR Temperature Sensor Signal circuit for an open or high resistance.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  8. CHECK FOR HIGH RESISTANCE IN THE (K900) SENSOR GROUND CIRCUIT 
    1. Measure the resistance of the (K900) Sensor Ground circuit between the Engine Coolant Temperature Sensor harness connector and the GPEC Adaptor.

      Is the resistance below 3.0 Ohms?

      Yes 

      • Go To  9

      No 

      • Repair the (K900) Sensor ground circuit for an open or high resistance.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  9. EGR TEMPERATURE SENSOR VOLTAGE 
    1. Turn the ignition off.
    2. Reconnect the PCM C2 harness connector.
    3. Turn the ignition on.
    4. With the scan tool, read the EGR Temperature Sensor voltage.
      NOTE:

      The sensor voltage should be approximately 5.0 volts (plus or minus 0.1 volts) with the connector disconnected.

    5. Connect a jumper between the (K932) EGR Temperature Sensor Signal circuit and the (K900) Sensor Ground circuit at the EGR Temperature Sensor harness connector.
      NOTE:

      The sensor voltage should be approximately 0.0 volts (plus or minus 0.1 volts) with the jumper in place.

      Does the scan tool display the voltage as described above?

      Yes 

      • Replace the EGR Temperature Sensor in accordance with the Service Information.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

      No 

      • Go To  10
  10. CHECK RELATED PCM AND COMPONENT CONNECTIONS 
    1. Perform any Service Bulletins that apply.
    2. Disconnect all PCM harness connectors.
    3. Disconnect all related in-line harness connections (if equipped).
    4. Disconnect the related component harness connectors.
    5. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
      • Proper connector installation.
      • Damaged connector locks.
      • Corrosion.
      • Other signs of water intrusion.
      • Weather seal damage (if equipped).
      • Bent terminals.
      • Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
      • Terminals that have been pushed back into the connector cavity.
      • Check for spread terminals and verify proper terminal tension.

      Repair any conditions that are found.

    6. Reconnect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
    7. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
    8. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
    9. With the scan tool, erase DTCs.
    10. Test drive or operate the vehicle in accordance with the when monitored and set conditions.
    11. With the scan tool, read DTCs.

      Did the DTC return?

      Yes 

      No 

scientia non olet · About LEMON Manuals