Combating Carbon Build-up in Chrysler Engines
This technical analysis examines prevalent mechanical challenges in Chrysler vehicles, focusing on carbon accumulation, fuel injector performance, intake manifold integrity, EGR system functionality, diesel particulate filter efficiency, and fuel system reliability. Below, we outline common issues, affected models, and targeted solutions to address these concerns.
Carbon Build-Up issues
Cause:
Direct injection engines (where applicable) and poor crankcase ventilation contribute to carbon deposits on intake valves and combustion chambers.
Symptoms:
- Rough idle, cold-start misfires.
- Reduced power and fuel efficiency.
- Check engine light (P0300 misfire codes).
Affected Models:
- Chrysler 300 (3.6L V6, 5.7L HEMI V8).
- Chrysler 200 (2.4L Tigershark, 3.6L V6).
- Pacifica (3.6L V6).
Solutions:
- Walnut blasting (for severe buildup on intake valves).
- Fuel additives (Techron, GM Top Engine Cleaner) to reduce deposits.
- Oil catch can installation to limit oil vapour recirculation.
Injectors Issues
Cause:
Clogging from carbon deposits or ethanol corrosion, particularly with low-quality fuel.
Symptoms:
- Misfires under acceleration.
- Poor fuel economy.
- Fuel odour (leaking injectors).
Solutions:
- Ultrasonic cleaning or replacement of faulty injectors.
- Premium fuel and injector cleaners.
Intake Manifold Issues
Common Failures:
- Gasket leaks causing vacuum issues.
- Carbon-clogged runners in direct-injection models.
Symptoms:
- Lean condition codes (P0171/P0174).
- Oil consumption (if gasket leaks into cylinders).
Solutions:
- Gasket replacement (upgraded MLS gaskets).
- Manual cleaning of intake ports.
EGR System Issues
Cause:
Clogged EGR valves/pipes due to carbon buildup, especially in stop-and-go driving.
Symptoms:
- P0404/P0406 codes (EGR flow/position errors).
- Engine overheating.
Affected Models:
- Town & Country (3.8L V6).
- 300 (3.6L V6).
Solutions:
- EGR valve cleaning (carb cleaner and scrubbing).
- Sensor replacement (if faulty).
DPF Filter Issues
Symptoms:
- DPF warning light.
- Limp mode activation.
Solutions:
- Forced regeneration via diagnostic tools.
- DPF replacement is required if severely blocked.
Fuel System Issues
Common Issues:
- Fuel pump failures (whining noise, hard starts).
- Clogged filters causing lean conditions.
Affected Models:
- Town & Country (reported pump failures).
- Pacifica Hybrid (high-pressure fuel system issues).
Solutions:
- Pump/filter replacement (OEM parts recommended).
- Regular fuel system maintenance (every 30,000 Km).
Solutions
- Walnut blasting: Mechanically clean intake valves every 50,000-80,000 km.
- Hydrogen carbon cleaning: Non-invasive method for removing deposits.
- Use high-quality, Top-tier fuel to minimise carbon buildup.
- Perform regular “Italian tune-ups” (high-speed highway driving) to help burn off deposits.
- Clean the EGR valve periodically to prevent clogging and maintain proper exhaust gas recirculation.
- For diesel models, ensure proper DPF regeneration through highway driving or DPF Filter cleaning.
- Regular maintenance, including oil changes and filter replacements.
Preventative Measures
- High-quality fuel: Reduces injector/valve deposits.
- Frequent oil changes: Limits carbon-forming contaminants.
- Italian tune-ups: Occasional highway driving aids DPF/EGR health.
- Catch cans: Mitigate oil vapour entry into the intake.
By addressing these issues proactively, Chrysler owners can mitigate performance declines and costly repairs. Regular maintenance and adherence to manufacturer guidelines are critical for longevity.
Carbon Build-Up Related OBD-II Diagnostic Trouble Codes
The following OBD-II codes may indicate carbon buildup issues in your engine.
Use our searchable table to identify and address potential problems:
| Code | Description | Symptoms | Affected System |
|---|---|---|---|
| P246C | Diesel Particulate Filter - Soot Accumulation for Bank 1 | Check engine light | DPF |
| P246B | Diesel Particulate Filter - Soot Accumulation for Bank 2 | Check engine light | DPF |
| P2463 | Diesel Particulate Filter Restriction - Soot Accumulation | Check engine light, reduced power, limp mode activation | DPF |
| P2459 | Diesel Particulate Filter Regeneration Frequency Too High | Check engine light | DPF |
| P2458 | Diesel Particulate Filter Regeneration Duration Too Long | Check engine light | DPF |
| P244A | Diesel Particulate Filter Differential Pressure Too Low | Check engine light | DPF |
| P242F | Diesel Particulate Filter Regeneration Incomplete | Check engine light, poor acceleration | DPF |
| P2176 | Throttle Actuator Control System - Forced Limited Power | Reduced power, check engine light | Manifold |
| P2008 | Intake Manifold Runner Control Stuck Closed | Check engine light, poor acceleration | Manifold |
| P2007 | Intake Manifold Runner Control Stuck Open | Check engine light, rough idle | Manifold |
| P2006 | Intake Manifold Runner Control Actuator Performance Problem | Similar to P2004 symptoms | Manifold |
| P2004 | Intake Manifold Runner Control (IMRC) Actuator Range/Performance Problem | Check engine light, reduced engine performance | Manifold |
| P2002 | Diesel Particulate Filter Efficiency Below Threshold (Bank 1) | Check engine light, reduced fuel efficiency, possible limp mode | DPF |
| P0421 | Warm Up Catalyst Efficiency Below Threshold (Bank 1) | Similar to P0420 symptoms | Carbon Build-Up |
| P0420 | Catalyst System Efficiency Below Threshold (Bank 1) | Check engine light, failed emissions test | Carbon Build-Up |
| P0404 | EGR Control Range/Performance Problem | Check engine light, rough idling, hesitation in acceleration, poor fuel economy | EGR |
| P0403 | EGR Control Circuit Malfunction | Check engine light | EGR |
| P0402 | EGR Flow Excessive | Check engine light, surging at idle | EGR |
| P0401 | EGR Flow Insufficient | Check engine light, engine knocking, poor acceleration | EGR |
| P0400 | EGR Flow Malfunction | Check engine light, rough idling, reduced power | EGR |
| P0304 | Cylinder 4 Misfire Detected | Similar to P0301 symptoms | Carbon Build-Up & Injector |
| P0303 | Cylinder 3 Misfire Detected | Similar to P0301 symptoms | Carbon Build-Up & Injector |
| P0302 | Cylinder 2 Misfire Detected | Similar to P0301 symptoms | Carbon Build-Up & Injector |
| P0301 | Cylinder 1 Misfire Detected | Rough running, poor acceleration | Carbon Build-Up & Injector |
| P0300 | Random/Multiple Cylinder Misfire Detected | Rough idle, engine shaking, reduced power | Carbon Build-Up & Injector |
| P0230 | Fuel Pump Primary Circuit Malfunction | Hard starting, stalling while driving | Fuel System |
| P0206 | Injector Circuit Malfunction - Cylinder 6 (if applicable) | Similar to P0201 symptoms | Injector |
| P0205 | Injector Circuit Malfunction - Cylinder 5 (if applicable) | Similar to P0201 symptoms | Injector |
| P0204 | Injector Circuit Malfunction - Cylinder 4 | Similar to P0201 symptoms | Injector |
| P0203 | Injector Circuit Malfunction - Cylinder 3 | Similar to P0201 symptoms | Injector |
| P0202 | Injector Circuit Malfunction - Cylinder 2 | Similar to P0201 symptoms | Injector |
| P0201 | Injector Circuit Malfunction - Cylinder 1 | Check engine light, rough idle, poor acceleration | Injector |
| P0200 | Injector Circuit/Open | Active check engine light, engine misfires, rough running | Injector |
| P0183 | Fuel Temperature Sensor Circuit High Voltage | Check engine light; possible performance issues | Fuel System |
| P0182 | Fuel Temperature Sensor Circuit Low Voltage | Check engine light; possible performance issues | Fuel System |
| P0174 | System Too Lean (Bank 2) | Increased fuel consumption and decreased performance | Fuel System & Injector & Manifold |
| P0172 | System Too Rich (Bank 1) | Black exhaust smoke, poor performance, increased fuel consumption | Fuel System |
| P0171 | System Too Lean (Bank 1) | Check engine light, poor acceleration | Carbon Build-Up & Fuel System |
| P0106 | Manifold Absolute Pressure (MAP) Sensor Range/Performance Problem | Check engine light, poor acceleration, rough idle | Manifold |
| P0101 | Mass Air Flow (MAF) Sensor Range/Performance Problem | Check engine light, reduced power, poor fuel economy | Manifold |
| P0093 | Fuel System Large Leak Detected | Check engine light, rough running, decreased performance | Fuel System |
| P0090 | Fuel Pressure Regulator Control Circuit Malfunction | Check engine light, poor fuel economy | Fuel System |
| P008B | Low Pressure Fuel System Pressure - Too High | Check engine light, rough idle, reduced power | Fuel System |
| P008A | Low Pressure Fuel System Pressure - Too Low | Check engine light, poor acceleration, engine stalling | Fuel System |