Diagnostic Test

WARNING: This page is about a different car, the 2015 RAM 3500 HD and 2015 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.

VEHICLE HISTORY AND SERVICE BULLETIN INVESTIGATION
1. Turn the ignition on.
2. Using the scan tool, read DTCs. Record the related Freeze Frame data if any DTCs are present.
3. Check the following items which may assist in repairing the customer's complaint successfully:
  - Check the vehicle's repair history. If the vehicle has a repair history that pertains to the customer's current complaint, review the repair.
  - Inspect the vehicle for any aftermarket accessories that may have been installed incorrectly.
  - Check for any service bulletin(s) related to the customer's complaint or DTCs. If a service bulletin applies, follow the instructions of the service bulletin.
  Choose the following scenario that best applies:
  
  The vehicle inspection or service bulletin repaired the customer's complaint.
  - Testing complete.
  A DTC is present, the vehicle inspection revealed no concerns, no service bulletins apply, or the service bulletin did not repair the customer's complaint.
  - Go To 2
ACTIVE DTC
NOTE:
Because a hot vehicle can conceal a potential leak, allow the vehicle to reach ambient temperature before continuing with this procedure.

NOTE:
If the customer is experiencing an early fuel shut off during the fuel filling process in addition to DTC P0440, P0441, or P0452, check for restrictions in the Evap Purge tubes/hoses as well as the Fresh Air Filter before continuing.
1. Start the engine.
2. Allow the engine to idle.
3. Using the scan tool, perform the ESIM FORCED MONITOR TEST. Allow the test to complete.
4. Using the scan tool, read DTCs.
  Is the DTC Active or Pending at this time?
  
  Yes
  - Go To 3
  No
  - Test complete, the condition or conditions that originally set this DTC are not present at this time. Using the wiring diagrams as a guide, check all related splices and connectors for signs of water intrusion, corrosion, pushed out or bent terminals, and correct pin tension.
  - Perform the INTERMITTENT CONDITION diagnostic procedure. Refer to INTERMITTENT CONDITION .
EVAP SYSTEM INSPECTION
1. Visually and physically Inspect the entire Evaporative Emission 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 Filler Cap (if applicable) or seal
  - Damaged locking tabs on the Fuel Filler Cap (if applicable) and/or filler tube
  - Damaged seal points on the Fuel Filler Cap (if applicable) and/or filler tube
  Were any problems found?
  
  Yes
  - Repair as necessary.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  No
  - Go To 4
EVAP VACUUM SUPPLY HOSE INSPECTION
1. Inspect the Evap Purge Solenoid vacuum supply hose for proper routing and installation.
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 contamination, obstruction, or blockage.
  Were any problems found?
  
  Yes
  - Repair as necessary.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  No
  - Go To 5
EVAP PURGE SOLENOID
WARNING:
Keep lit cigarettes, sparks, flames, and other ignition sources away from the test area to prevent the ignition of explosive gases. Keep the test area well ventilated. Failure to do so may result in possible serious or fatal injury.

NOTE:
After disconnecting the Evap Purge Solenoid vacuum connections, inspect the lines and solenoid for signs of contamination.
1. Disconnect the vacuum hoses at the Evap Purge Solenoid.
2. Using a hand vacuum pump, apply 5 in. Hg. to the "ENGINE" side of the Evap Purge Solenoid.
3. Turn the ignition on.
4. Using 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 PCM harness connectors. Replace the Evap Purge Solenoid if no problems were found in the connectors. Refer to SOLENOID, EVAPORATIVE EMISSIONS PURGE, REMOVAL .
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
ESIM SWITCH STATE

Fig 1: ESIM Switch Harness Connector
Courtesy of CHRYSLER GROUP, LLC
1. Turn the ignition off.
2. Disconnect the ESIM Switch harness connector.
3. Turn the ignition on.
4. Using the scan tool, read the ESIM Switch state.
5. Connect a jumper between the (K108) ESIM Signal circuit and the Ground circuit at the ESIM Switch harness connector.
6. Using the scan tool, read the ESIM Switch state.
  Does the ESIM Switch state change from OPEN to CLOSED when the jumper is installed?
  
  Yes
  - Go To 9
  No
  - Go To 7
CHECK THE (K108) ESIM SIGNAL CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Turn the ignition off.
2. Disconnect the PCM C1 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.
3. Connect the (special tool #10436, Adapter, GPEC Diagnostic).
4. Measure the resistance of the (K108) ESIM Signal circuit between the ESIM Switch harness connector and the GPEC Adaptor.
  Is the resistance below 5.0 Ohms?
  
  Yes
  - Go To 8
  No
  - Repair the (K108) ESIM Signal circuit for an open or high resistance.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
CHECK THE (K915) SENSOR GROUND CIRCUIT FOR AN OPEN/EXCESSIVE RESISTANCE
1. Measure the resistance of the (K915) Sensor Ground circuit between the ESIM Switch harness connector and the GPEC Adaptor.
  Is the resistance below 5.0 Ohms?
  
  Yes
  - Go To 13
  No
  - Repair the (K915) Sensor Ground for an open or high resistance.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
VERIFY EVAPORATIVE EMISSION LEAK
WARNING:
Keep lit cigarettes, sparks, flames, and other ignition sources away from the test area to prevent the ignition of explosive gases. Keep the test area well ventilated. Failure to do so may result in possible serious or fatal injury.
1. Turn the ignition off.
2. To continue testing, you will need the special tool #8404C, 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. Connect shop air to the EELD.
5. Set the smoke/air control switch to AIR.
6. Insert the tester's AIR supply tip (clear hose) into the .040 orifice on the tester's control panel.
7. Press the remote smoke/air start button.
8. Position the red flag on the air flow meter so it is aligned with the indicator ball.
9. When the calibration is complete, release the remote button. The EELD flow meter is now calibrated in liters per minute.
10. Remove the Vent Filter and install the service adapter (special tool #8404-ADP, Smoke Machine Adapters) into the vent line.
11. Connect the AIR supply hose from the EELD to the adapter.
12. Press the remote button to activate AIR flow.
  NOTE:
  Larger volume fuel tanks, lower fuel levels, or vehicles equipped with a Flow Management Valve may indicate high flow and will require four to five minutes to fill.
13. Compare the flow meter indicator ball reading to the red flag.
14. ABOVE the red flag indicates a leak present.
15. BELOW the red flag indicates a sealed system.
  Is the indicator ball above the red flag?
  
  Yes
  - Go To 10
  No
  - Go To 11

EVAPORATIVE EMISSION LEAK DETECTION

NOTE:

A thorough visual inspection of the Evap system hoses, tubes, and connections may save time in your diagnosis. Look for any physical damage or signs of wetness at connections. The strong smell of fuel vapors may aid diagnosis also.

Remove the Air supply hose from the adapter.
Connect the SMOKE supply tip (black hose) to the adapter.
Set the smoke/air control switch to SMOKE.
NOTE:
The flow meter indicator ball will not move at this point.
Press and hold the remote smoke/air start button to allow the system to fill with smoke.
NOTE:
If the vehicle is equipped with a fuel filler cap, remove the vehicles cap, and wait for the smoke to exit. Once smoke is indicated reinstall the fuel filler cap.

NOTE:
For optimal performance, continue introducing smoke at 15 second intervals, as necessary.
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.
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.

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 2: Evaporative System Components Zone 1

Courtesy of CHRYSLER GROUP, LLC

ZONE 1 EVAP SYSTEM COMPONENTS
CALLOUT	DESCRIPTION
1	Fuel Tank
2	Fuel Tank Vent (Check Valve)
3	Vapor Line to Canister
4	Fuel Tank to Canister Vapor Line
5	Control Valve
6	Fuel tank Pressure Sensor
7	Vapor Recirculation Line
8	Fuel Cap (if applicable)
9	Fuel Fill Tube (System may be equipped with either a Fuel Cap or the Capless Fuel Filler system, depending on the vehicles application)
10	Fuel Fill Tube to Tank connector
11	Fuel Fill Check Valve

Fig 3: Evaporative System Components Zone 2

Courtesy of CHRYSLER GROUP, LLC

ZONE 2 EVAP SYSTEM COMPONENTS
CALLOUT	DESCRIPTION
1	ESIM Switch
2	Filter
3	Evaporative Purge connection
4	Fuel Tank to Canister Vapor Line
5	Evaporative Canister
6	ESIM Switch O-Ring Seal

Fig 4: Evaporative System Components Zone 3

Courtesy of CHRYSLER GROUP, LLC

ZONE 3 EVAP SYSTEM COMPONENTS
CALLOUT	DESCRIPTION
1	Connection to Canister
2	Chassis Purge Line
3	Connection to Evaporative Purge Harness
4	Chassis Evaporative Purge to Engine Vacuum line and connection
5	Evaporative Purge Valve
6	Evaporative Purge Vacuum Line
7	Connection to Chassis Line

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 Fuel Cap (if applicable) or Fuel Filler Tube Assembly

Perform the appropriate repair by replacing the Fuel Filler Tube Assembly and/or the Fuel Cap (if applicable).
Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .

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. Refer to POWERTRAIN VERIFICATION TEST .

No leaks were detected

Go To 11

EVAP PURGE HOSE/TUBE AND VENT FILTER OBSTRUCTION
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 and Vent Filter are not damaged, kinked, and are free from any obstructions.
  Were any problems found?
  
  Yes
  - Repair or replace as necessary.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  No
  - Go To 12
ESIM SWITCH
1. Use the wiring diagram/schematic as a guide, inspect the wiring and connections between the ESIM Switch and the PCM.
2. Look for any chafed, pierced, pinched, or partially broken wires.
3. Look for any broken, bent, pushed out, or corroded terminals.
4. Verify that there is good pin to terminal contact in the ESIM Switch and the Powertrain Control Module harness connectors.
5. Perform any Technical Service Bulletins that may apply.
  Were any problems found?
  
  Yes
  - Repair and Replace as necessary.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  No
  - Verify that there is good pin to terminal contact in the ESIM Switch and PCM harness connectors. Replace the ESIM Switch in accordance with the service information if no problems were found in the connectors.
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
POWERTRAIN CONTROL MODULE (PCM)
1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the ESIM Switch and the 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. Refer to MODULE, POWERTRAIN CONTROL, REMOVAL . Refer to PCM/ECM REPROGRAMMING - GAS .
  - Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .