Diagnostic Test

1. Ignition on, engine not running.
2. With a scan tool, read DTCs and record the related Freeze Frame data if any DTC(s) are present.
3. Whether or not any DTC(s) are present you will want to check the following items which may assist in repairing the customer's complaint successfully.
4. Check the vehicles repair history.
5. If the vehicle has a repair history that pertains to the customer's current complaint, review the repair.
6. Inspect the vehicle for any aftermarket accessories that may have been installed incorrectly.
7. Check for any service bulletin(s) related to the customer's complaint or DTC(s).
8. If a service bulletin applies, follow the instructions per the service bulletin.

   Choose the following scenario that best applies.

   The service bulletin repaired the customer's complaint. 

   • Testing complete.

   A DTC is present, no service bulletins apply, or the service bulletin didn't repair the customer's complaint. 

   • Go to step  2

1. Ignition on, engine not running.
2. With a scan tool, read DTCs.

   Is the DTC active at this time?

   Yes 

   • Go to step  3

   No 

   • Perform the INTERMITTENT CONDITION diagnostic procedure. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

1. Turn the ignition off.
2. Perform a visual and physical inspection of the entire Evaporative Emission system.
3. Check for the following conditions:

• Hoses disconnected or left off
• Holes or cracks
• Loose seal points
• Evidence of damaged components
• Incorrect routing of hoses and tubes
• Fuel Cap left off or bad gasket seal

1. Carefully inspect the EVAP Purge Solenoid vacuum supply hose for proper routing.
2. Check for a pinched or plugged hose from the throttle body or intake manifold to the Purge Solenoid.
3. Make sure the vacuum port at the throttle body or intake manifold is free from any blockage.

   Were any problems found?

   Yes 

   • Repair the vacuum supply, hose/tube as necessary.
   • Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

   No 

   • Go to step  5

1. Connect the red power lead of the EELD to the battery positive terminal and the black ground lead to battery negative terminal.
2. Disconnect the vacuum hoses at the EVAP Purge Solenoid.
3. Connect the SMOKE supply tip (black hose) to the "CAN" port on the EVAP Purge Solenoid.
4. Set the smoke/air control switch to SMOKE.
5. While still holding the remote smoke/air start button, check to see if smoke is exiting the purge valve. This indicates that there is a leak internal to the purge valve.

   Is smoke visible from the EVAP Purge Solenoid?

   Yes 

   • Replace the EVAP Purge Solenoid.
   • Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

   No 

   • Go to step  6

1. Disconnect the Smoke supply tip from the vacuum supply hoses at the EVAP Purge Solenoid.
2. Using a hand vacuum pump, apply 10 in Hg to the "CAN" side of the EVAP Purge Solenoid.
3. Observe the vacuum gauge for at least 15 seconds.

   Does the EVAP Purge Solenoid hold vacuum?

   Yes 

   • Go to step  7

   No 

   • Replace the EVAP Purge Solenoid.
   • Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

1. Connect the previously disconnected vacuum hose.
2. Start the engine.
3. Allow the engine to idle.
4. Using the scan tool, perform the NVLD FORCED MONITOR TEST.
5. Monitor the NVLD Switch state.
   NOTE: As the test runs, the NVLD Switch should go from an OPEN state to a CLOSED state and then return to OPEN when the test is complete This may take up to 10 minutes.

   Did the NVLD Switch operate as described above?

   Yes 

   • Go to step  9

   No 

   • Go to step  8

1. Start the engine.
2. Allow the engine to idle.
3. Using the scan tool, perform the NVLD FORCED MONITOR TEST for a second time.
4. While the NVLD FORCED MONITOR TEST is running, open/remove the gas cap.
5. Monitor the NVLD Switch state.

   Did the NVLD Switch go from CLOSED to OPEN?

   Yes 

   • Replace the NVLD Assembly.
   • Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

   No 

   • Go to step  9

1. Turn the ignition off.
2. To continue testing you will need Miller Tool 8404A Evaporative Emission Leak Detector (EELD).
   NOTE: The fuel tank should have between 20% and 80% of fuel tank capacity to properly test the EVAP system.
3. Connect the red power lead of EELD to the battery positive terminal and the black ground lead to battery negative terminal.
4. Block the vent hose of the EVAP Canister.
5. Connect shop air to the EELD.
6. Set the smoke/air control switch to AIR.
7. Insert the tester's AIR supply tip (clear hose) into the.040 orifice on the tester's control panel.
8. Press the remote smoke/air start button.
9. Position the red flag on the air flow meter so it is aligned with the indicator ball.
10. When the calibration is complete, release the remote button. The EELD flow meter is now calibrated in liters per minute.
11. Install the service port adapter 8404-14 on the vehicle's service port (if equipped) or install the 8404-ADP into the filter line.
12. Connect the Air supply hose from the EELD to the service port (if equipped) or to the 8404-ADP adapter.
13. Press the remote button to activate AIR flow.
14. Compare the flow meter indicator ball reading to the red flag.
15. ABOVE the red flag indicates a leak present.
16. BELOW the red flag indicates a sealed system.

    Is the indicator ball above the red flag?

    Yes 

    • Go to step  10

    No 

    • Go to step  12

1. Remove the Air supply hose from the service port or the 8404-ADP adapter.
2. Connect the SMOKE supply tip (black hose) to the service port (if equipped) or to the 8404-ADP adapter.
3. Set the smoke/air control switch to SMOKE.
   NOTE: The flow meter indicator ball will not move at this point.
4. Press the remote smoke/air start button.
   NOTE: Make sure that smoke has filled the EVAP system by continuing to press the remote smoke/air start button, remove the vehicle fuel cap, and wait for the smoke to exit. Once smoke is indicated reinstall the fuel cap.
   NOTE: For optimal performance, introduce smoke into the system for an additional 60 seconds; continue introducing smoke at 15 second intervals, as necessary.
5. While still holding the remote smoke/air start button, use the white light (8404-CLL) to follow the EVAP system path, and look for the source of the leak indicated by exiting smoke.
6. If a leak is concealed from view (i.e., top of fuel tank), release the remote smoke/air start button, and use the ultraviolet (UV) black light 8404-UVL and the yellow goggles 8404-20 to look for residual traces of dye that are left behind by the smoke.
7. The exiting smoke deposits a residual fluid that is either bright green or bright yellow in color when viewed with a UV light.
   NOTE: The EVAP System is divided into three zones. A leak from any of these zones can cause this DTC to set. The lists below specify the possible leak points in that specific zone. For further assistance see the Zone Identification Charts below.
   Fig 1: Identifying EVAP System Zone 1

   Courtesy of CHRYSLER LLC
   Fig 2: Identifying EVAP System Zone 2

   Courtesy of CHRYSLER LLC
   Fig 3: Identifying EVAP System Zone 3

   Courtesy of CHRYSLER LLC
   NOTE: Carefully inspect the vent side of the EVAP Canister. Due to the filtering system in the canister the smoke or dye may or may not be visible. Introducing smoke into the filtered side of the canister may assist in locating the leak.

   Select the appropriate response from the list below:

   A leak was found at the gas cap or fuel filler tube 

   • Go to step  11

   A leak was found in one or more of the EVAP System zones 

   • If the leak is at a hose connection, remove the hose then reconnect the hose and check for a leak again. All other leaks repair as necessary.
   • Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

   No leaks were detected 

   • Go to step  12

ZONE 1

1. Fuel Cap
2. Recirculation Check Valve
3. Vapor Recirculation Line
4. Signal Vapor Line for FVM
5. Flow Management Valve
6. Fuel Tank to Canister Vapor Line
7. Fuel Tank Vent (Check Valve)
8. Vapor Line to Canister
9. Flow Control Orifice
10. Control Valve
11. Liquid Trap
12. Fuel Tank
13. Check valve
14. Fuel Fill Tube to Tank connector
15. Fuel Fill Tube

ZONE 2

1. Filter
2. EVAP System Monitor Switch
3. Canister Vent Line
4. EVAP Canister
5. Chassis Purge Valve
6. Fuel Tank to Canister Vapor Line connection
7. EVAP Purge connection

ZONE 3

1. EVAP Purge Vacuum Line
2. Connection to Chassis Line
3. Connection to Canister
4. Chassis Purge Line
5. EVAP Purge Vacuum Line
6. Connection to EVAP Purge Harness
7. Chassis EVAP Purge Line connection to Engine Vacuum
8. EVAP Purge Valve
9. Service Port

1. Remove the SMOKE supply tip (black hose) from the service port (if equipped) or to the 8404-ADP adapter.
2. Install gas cap adapter, Miller Tool 8382 (1/4 turn cap) or 6922 (screw cap) and 8399* (secondary seal depressor) and repeat test 5.
   NOTE: The gas cap adapter is being used as a known good cap.

   Was a leak found at the gas cap adapter?

   Yes 

   • Replace the Fuel Filler tube assembly.
   • Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

   No 

   • Replace the gas cap.
   • Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

Fig 4: Checking NVLD Switch Signal Circuit

Courtesy of CHRYSLER LLC

1. Turn the ignition off.
2. Disconnect the NVLD electrical harness connector.
3. Check connectors - Clean/repair as necessary.
4. Ignition on, engine not running.
5. Connect a jumper wire between the (K107) NVLD Switch Signal circuit and the (Z904) Ground circuit in the NVLD electrical harness connector.
6. Monitor the NVLD Switch state on the scan tool.

   Does the Switch change from OPEN to CLOSED when the jumper wire is installed?

   Yes 

   • Replace the NVLD Assembly.
   • Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

   No 

   • Go to step  13
     NOTE: Remove the jumper wire before continuing.

Fig 5: Checking Ground Circuit

Courtesy of CHRYSLER LLC

1. Turn the ignition off.
2. Measure the resistance between the (Z904) Ground circuit and ground.

   Is the resistance below 5.0 ohms?

   Yes 

   • Go to step  14

   No 

   • Repair the open in the (Z904) Ground circuit.
   • Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

Fig 6: Checking NVLD Switch Signal Circuit

Courtesy of CHRYSLER LLC

1. Disconnect the PCM harness connectors.
   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 to perform diagnosis.
2. Measure the resistance of the (K107) NVLD Switch Signal circuit from the NVLD electrical harness connector to the appropriate terminal of the special tool 8815.

   Is the resistance below 5.0 ohms?

   Yes 

   • Go to step  15

   No 

   • Repair the open in the (K107) Signal circuit.
   • Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .

1. Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all Power and Ground circuits.

   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 per Service Information.
   • Perform the POWERTRAIN VERIFICATION TEST. See DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure .