Diagnostic Test

1. Ignition on, engine not running.
2. With the scan tool, select View DTCs. Record the related Freeze Frame data if any DTCs are present.
3. Whether or not any DTCs are active you will want to check the following items which may assist in repairing the customer's complaint successfully.
4. Check the vehicle's 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 DTCs.
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  2.

1. Start the engine.
2. Allow the engine to reach normal operating temperature.
3. Using the scan tool, perform the ESIM Forced Monitor test. Allow the test to complete.
4. With the scan tool, select View DTCs.

   Is the DTC Active or Pending at this time?

   Yes 

   • Go To  3.

   No 

   • Perform the INTERMITTENT CONDITION Diagnostic Procedure. Refer to INTERMITTENT CONDITION .

Inspect the Evap System for any of the following conditions:

• Holes or cracks
• Loose seal points
• Damaged or missing components
• Incorrect routing of hoses and tubes
• Loose or missing Fuel Cap
• Damaged or missing Fuel Cap seal
• Improper installation of the Fuel Cap
• Damaged Locking tabs on the Fuel Cap and/or filler tube
• Damaged seal points on the Fuel Cap and/or filler tube

Were any of the above conditions found?

Yes 

• Repair as necessary.
• Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

No 

• Go To  4.

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. Refer to POWERTRAIN VERIFICATION TEST .

   No 

   • Go To  5.

1. Using a hand vacuum pump, apply 10 in Hg to the "CAN" side of the Evap Purge Solenoid.
   NOTE:

   The solenoid should hold vacuum for a minimum of 15 seconds.

2. Ignition on, engine not running.
3. With the scan tool, actuate the Evap Purge Solenoid to the ON position.
   NOTE:

   The vacuum should drop when the solenoid is actuated.

   Does the solenoid function as described above?

   Yes 

   • Go To  6.

   No 

   • Verify that there is good pin to terminal contact in the Solenoid and the Powertrain Control Module connectors. Replace the Evap Purge Solenoid if no problems were found in the connectors.
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

Fig 1: Esim Switch Harness Connector

Courtesy of CHRYSLER LLC

1. Turn the ignition off.
2. Connect the previously disconnected vacuum hose.
3. Disconnect the ESIM switch harness connector.
4. Ignition on, engine not running.
5. Monitor the ESIM switch state on the scan tool.
6. Carefully connect a jumper wire between the (K107) ESIM Signal circuit and the (Z914) Ground circuit in the ESIM switch harness connector.
7. Monitor the ESIM switch state on the scan tool.

   Did the switch change from OPEN to CLOSED when the jumper wire was installed?

   Yes 

   • Go To  9.

   No 

   • Go To  7.
     NOTE:

     Remove the jumper wire before continuing.

Fig 2: Measuring Resistance Of (K107) Esim Signal Circuit From Esim Switch Harness Connector To Appropriate Terminal Of PCM Pinout Box 8815

Courtesy of CHRYSLER LLC

1. Turn the ignition off.
2. Disconnect the C3 PCM 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 PCM Pinout Box (special tool #8815A, Kit, NGC, 38 Position) to perform diagnosis.

3. Measure the resistance of the (K107) ESIM Signal circuit from the ESIM switch harness connector to the appropriate terminal of PCM Pinout Box (special tool #8815A, Kit, NGC, 38 Position).

   Is the resistance below 5.0 Ohms?

   Yes 

   • Go To  8.

   No 

   • Repair the excessive resistance in the (K107) ESIM Signal circuit.
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

Fig 3: Using 12-volt Test Light Connected To B+ To Probe (Z914) Ground Circuit In Esim Switch Harness Connector

Courtesy of CHRYSLER LLC

1. Using a 12-volt test light connected to B+, probe the (Z914) Ground circuit in the ESIM switch harness connector.
   NOTE:

   The test light should illuminate brightly. Compare the brightness to that of a direct connection to B- (ground).

   Does the test light illuminate brightly?

   Yes 

   • Go To  13.

   No 

   • Repair the excessive resistance in the (Z914) Ground circuit.
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

1. Turn the ignition off.
2. To continue testing you will need Evap Emission Leak Detector (EELD) (special tool #8404B, Kit, EELD And Accessory).
   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 (special tool #8404-14, Adapter, Evaporative Service Port) on the vehicle's service port (if equipped) or install the adapter (special tool #8404-ADP, Smoke Machine Adapters) into the filter line.
12. Connect the Air supply hose from the EELD to the service port (if equipped) or to the adapter (special tool #8404-ADP, Smoke Machine Adapters).
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  10.

    No 

    • Go To  11.

1. Remove the Air supply hose from the service port or the adapter (special tool #8404-ADP, Smoke Machine Adapters).
2. Connect the SMOKE supply tip (black hose) to the service port (if equipped) or to the adapter (special tool #8404-ADP, Smoke Machine Adapters).
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 (special tool #8404-CLL, Light, White) 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 (special tool #8404-UVL, Light, UV) and the yellow goggles (special tool #8404-20, Goggles, Yellow) 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 4: Identifying Evap System Zone 1

   Courtesy of CHRYSLER LLC

   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
   Fig 5: Identifying Evap System Zone 2

   Courtesy of CHRYSLER LLC

   ZONE 2

   1. Filter
   2. Evap System Integrity Monitor (ESIM) switch
   3. Canister Vent Line
   4. Evap Canister
   5. Chassis Purge Valve
   6. Fuel Tank to Canister Vapor Line connection
   7. Evap Purge connection
   Fig 6: Identifying Evap System Zone 3

   Courtesy of CHRYSLER LLC

   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
   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.

   Was a leak found?

   Yes 

   • Repair or replace the leaking component as necessary.
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

   No 

   • Go To  11.

1. Inspect the Evap Purge hose/tube for proper routing and installation between the Evap Purge Solenoid and the Fuel Tank and between the Fuel Tank and the Evap Purge Canister.
2. Make sure the hose/tube is not damaged or kinked and is free from any obstructions or blockage.

   Were any problems found?

   Yes 

   • Repair or replace as necessary.
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

   No 

   • Go To  12.

1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the ESIM switch 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. Perform any Technical Service Bulletins that may apply.

   Were any problems found?

   Yes 

   • Repair as necessary.
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

   No 

   • Replace the ESIM switch in accordance with the Service Information.
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the ESIM switch 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. Perform any Technical Service Bulletins that may apply.

   Were any problems found?

   Yes 

   • Repair as necessary.
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

   No 

   • Replace and program the Powertrain Control Module (PCM) in accordance with the Service Information.
   • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .