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 before continuing.
NOTE: The difference in ambient temperature, outside temp VS shop temp, may conceal a leak, it is best to perform this test after the vehicle's temperature has stabilized in the work area.

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 (NGC) POWERTRAIN VERIFICATION TEST VER - 6 .
Perform a visual and physical inspection of the entire Evaporative Emission system.
Check for the following conditions:
- Holes or cracks
- Loose seal points
- Evidence of damaged components
- Incorrect routing of hoses and tubes
- Fuel Cap gasket seal
Were any of the above conditions found?
1. Yes --> Repair as necessary.
  Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 6 .
2. No --> Go To 3

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.

NOTE: The flow meter indicator ball will not move at this point.

NOTE: Ensure 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.

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.

Use the Miller Tool #8404A Evaporative Emissions Leak Detector (EELD).
Connect the SMOKE supply tip (black hose) to the service port (if equipped) or install the #8404-ADP service adaptor into the filter line.

Set the smoke/air control switch to SMOKE.

Press the remote smoke/air start button.

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.

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.

The exiting smoke deposits a residual fluid that is either bright green or bright yellow in color when viewed with a UV light.

Was a leak found?
1. Yes --> Repair or replace the leaking component as necessary.
  Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 6 .
2. No --> Go To 4

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 rollover valve. Replace/repair as necessary.

NOTE: Monitor the vacuum gauge for at least 15 seconds.

Turn the ignition off.
Disconnect the vacuum hoses at the Evap Purge Solenoid.

Using a hand vacuum pump, apply 10 in Hg to the "CAN" side of the EVAP Purge Solenoid.

Does the Evap Purge Solenoid hold vacuum?
1. Yes --> Refer to the SYMPTOM: INTERMITTENT CONDITION Symptom (Diagnostic Procedure).
  Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 6 .
2. No --> Replace the Evap Purge Solenoid.
  Perform (NGC) POWERTRAIN VERIFICATION TEST VER - 6 .