Diagnostic Procedure

WARNING: This page is about a different car, the 2004 Dodge Pickup and 2004 Dodge Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Refer to VERIFICATION TESTS for appropriate verification test procedures.

Check for any related TSBs.
Ignition on, engine not running.

With the DRBIII®, read DTCs and record the related Freeze Frame data.

Is the Good Trip Counter displayed and equal to zero?
1. Yes --> Go To 2
2. No --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
Visually inspect the Evap canister. Look for any physical damage or any signs of fuel that has entered the canister. Any signs of fuel may indicate a bad rollover valve.
Were any problems found?
1. Yes --> Repair or Replace as necessary.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 3
Visually inspect the Evap purge hose that goes from the Purge Solenoid to the Evap Canister. Look for any physical damage such as a pinched, plugged, ripped or dry rotted hose.
Were any problems found?
1. Yes --> Repair or replace hose as necessary.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 4
Visually inspect the Evap Purge hose that goes between the Evap canister and the fuel tank. Look for any physical damage such as a pinched, plugged, ripped or dry rotted hose.
Were any problems found?
1. Yes --> Repair or replace hose as necessary.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Go To 5
Carefully inspect the Evap Purge Solenoid vacuum supply hose for proper routing.
Also check for a pinched or plugged hose from the throttle body to the Purge Solenoid.

Inspect the vacuum nipple at the throttle body for any damage or plugging.

Make sure vacuum fitting at the purge solenoid is not over installed, pushed in too far.

Is the vacuum supply hose and throttle body vacuum nipple free from defects?
1. Yes --> Go To 6
2. No --> Repair the vacuum supply hose/tube as necessary.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .

NOTE: After disconnecting the Evap Purge Solenoid vacuum connections, inspect the lines and solenoid for any signs of contamination from the EVAP Canister. This may indicate a faulty fuel tank vent. Replace purge solenoid if contamination is found

Disconnect the vacuum hoses at the EVAP Purge Solenoid.
Using a hand vacuum pump, apply 10 inches of vacuum to the Evap Purge Solenoid vacuum source port, (component side)

Does the Evap Purge Solenoid hold vacuum?
1. Yes --> Go To 7
2. No --> Replace the Evap Purge Solenoid and the Evap Canister and clean out Evap lines as necessary.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
Using a hand vacuum pump, apply 10 inches of vacuum to the Evap Purge Solenoid vacuum source port, (component side)
Ignition on, engine not running.

With the DRBIII®, actuate the EVAP Purge Solenoid and observe the vacuum gauge.

Does the vacuum drop when the solenoid is actuated?
1. Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .
2. No --> Replace the Evap Purge Solenoid.
  Perform POWERTRAIN VERIFICATION TEST VER - 5 .