Chrysler 300/300 Touring/300C, Dodge Magnum. Manual — part 1465

*CHECKING THE EGR THROTTLE VALVE

For a complete wiring diagram Refer to Section 8W

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ENGINE ELECTRICAL DIAGNOSTICS - DIESEL

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Possible Causes

EGR THROTTLE VALVE

WIRING AND/OR CONNECTORS

1.

EGR THROTTLE VALVE

Disconnect the hose/tube on the inlet side of the EGR Throttle Valve.

Use a mirror to observe the throttle plate position inside the EGR Throttle Valve for the following steps

With the scan tool, actuate the EGR Throttle Valve at 0%, 40% and 100% while observing the throttle plate position.

NOTE: The EGR Throttle Valve actuation will only occur for a short period of time then actuation will stop
automatically. Any readings, observations or measurements must be completed within shortly after the
beginning of actuation.

NOTE: With the ignition on, engine off the throttle plate position should be wide open. The throttle plate
position should be wide open at 0% actuation, midway between open and closed at 40% actuation and com-
pletely closed at 100% actuation.

Does the throttle plate move smoothly, without binding, to the correct position based on actuation per-
centage described in the note above?

Yes

>> EGR system operating correctly. Test Complete.

No

>> Check the wiring and connectors between the EGR Throttle Valve and the ECM for proper connection

and resistance. Repair as necessary. If wiring and connections are o.k., replace the EGR Throttle Valve.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

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*CHECKING THE ENGINE MECHANICAL SYSTEMS

For a complete wiring diagram Refer to Section 8W

Possible Causes

CHECKING ENGINE MECHANICAL SYSTEMS

Diagnostic Test

1.

CHECKING ENGINE MECHANICAL

NOTE: The following items should be checked as a possible cause of a Driveability or No-Start problem.

WARNING: Do not attempt to remove or separate high pressure fuel line. Attempting to do so could result
in severe bodily injury or death.
Engine Valve Timing - must be within specification

Engine Compression - must be within specifications

Camshaft Lobes - check for abnormal wear

Camshaft Position Sensor - check the camshaft position sensor tooth for debris and deterioration

Crankshaft Position Sensor - check the crankshaft tone wheel for debris and deterioration

Engine Exhaust System - must be free of any restriction

Engine Drive Chains and Sprockets - must be properly positioned

Vacuum System - must operate properly and be free of any vacuum leaks

Fuel - must have adequate supply and must be free of contamination (ie. debris, water and gasoline)

Fuel Injectors - must not be plugged or restricted

Fuel Lift Pump - must operate properly (where applicable)

Fuel Injection Pump - must be producing the correct output volume and pressure

Inspect the Fuel Lines, Fuel Filter and Fuel Pressure Relief Valve for signs of restriction and leaks

NOTE: Check for any Technical Service Bulletins that may relate to the problem.

Are there any problems evident?

Yes

>> Repair as necessary.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

No

>> Test Complete.

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CHECKING THE HIGH-SIDE FUEL SYSTEM

For a complete wiring diagram Refer to Section 8W

Possible Causes

AIR IN FUEL SYSTEM

FUEL PRESSURE SENSOR

FUEL PRESSURE SOLENOID

FUEL PRESSURE SOLENOID RETURN VOLUME TEST

LOW/SUPPLY SIDE FUEL SYSTEM PROBLEM

FUEL INJECTION PUMP

FUEL SYSTEM LEAK

INJECTOR RETURN VOLUME TEST

Diagnostic Test

1.

CHECKING FUEL PRESSURE

NOTE: The Low/Supply Side Fuel System must be working properly for this test to be valid. Refer to the
Service Information and Perform the Low/Supply Side Fuel System Test before continuing.
Turn the ignition on.

NOTE: This test requires two people. One person to test drive the vehicle while a technician observes the
scan tool readings
With the scan tool in Sensors, read and compare the Fuel Pressure (PSI) with the Fuel Pressure Desired/Setpoint
(PSI) while test driving the vehicle under various load conditions such as idle, hard acceleration, cruise and decel-
eration.

NOTE: The Fuel Pressure reading should directionally follow (trail) the Fuel Pressure Desired/Setpoint read-
ing.

Does the Fuel Pressure reading directionally follow the Fuel Pressure Desired/Setpoint reading?

Yes

>> Test Complete.

No

>> Go To 2

2.

FUEL PRESSURE SENSOR CALIBRATION

Turn the ignition on.

With the scan tool, read the Fuel Pressure Sensor volts.

Does the scan tool display between 0.45 and 0.60 volts for the Fuel Pressure Sensor?

Yes

>> Go To 3

No

>> Check the Fuel Pressure Sensor wiring and connectors for corrosion or poor terminal contact that could

cause high resistance. Repair as necessary. If wiring and connectors are o.k., replace the Fuel Pressure
Sensor.

Perform the ECM Verification Test Ver. 1. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)

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