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Home >> Jeep >> 2014 >> Wrangler Sahara, Standard Trans >> Repair and Diagnosis >> Engine Performance >> Testing & Diagnosis >> 3.6L - DTCS P0157 To P0457 >> Diagnosis And Testing >> P0455-EVAP System Large Leak >> Diagnostic Test

Diagnostic Test

  1. VEHICLE HISTORY AND SERVICE BULLETIN INVESTIGATION 
    1. Ignition on, engine not running.
    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
  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.

    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 .
  3. EVAP SYSTEM INSPECTION 
    1. Visually and physically Inspect the entire Evaporative Emission System for any of the following conditions:
      • Holes or cracks
      • Damaged or missing components
      • Incorrect routing of hoses and tubes
      • Loose or missing Fuel Filler Cap (if applicable) or flap
      • Damaged locking tabs on the Fuel Filler Cap (if applicable) and/or filler tube flap
      • Damaged seal points on the Fuel Filler Cap (if applicable) and/or filler tube flap

      Were any problems found?

      Yes 

      No 

      • Go To  4
  4. 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. 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.

    2. Connect the red power lead of the EELD to the battery positive terminal and the black ground lead to battery negative terminal.
    3. Connect shop air to the EELD.
    4. Set the smoke/air control switch to AIR.
    5. Insert the tester's AIR supply tip (clear hose) into the appropriate calibration orifice on the tester's control panel (based on DTC leak size).
    6. Press the remote smoke/air start button.
    7. Position the red flag on the air flow meter so it is aligned with the indicator ball.
    8. When the calibration is complete, release the remote button. The EELD flow meter is now calibrated in liters per minute to the size leak indicated by the DTC set in the PCM.
    9. Remove the Vent Filter and install the service adapter (special tool #8404-ADP, Smoke Machine Adapters) into the vent line.
    10. Connect the AIR supply hose from the EELD to the adapter.
    11. 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.

    12. Compare the flow meter indicator ball reading to the red flag.
    13. ABOVE the red flag indicates a leak present.
    14. BELOW the red flag indicates a sealed system.

      Is the indicator ball above the red flag?

      Yes 

      • Go To  5

      No 

      • Review the Freeze Frame data recorded in step 1. If the data indicates that the vehicle was in motion when the DTC was set, verify that all hoses are properly connected.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  5. 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.

    1. Remove the Air supply hose from the adapter.
    2. Connect the SMOKE supply tip (black hose) to the adapter.
    3. Set the smoke/air control switch to SMOKE.
      NOTE:

      The flow meter indicator ball will not move in the smoke mode.

    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 (if applicable) or open the flap (capless), and wait for the smoke to exit. Once smoke is indicated reinstall the fuel cap or close the flap.

      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 is 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: Evaporative System Components Zone 1
      GC0145425Courtesy 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 2: Evaporative System Components Zone 2
      GC0145426Courtesy 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 3: Evaporative System Components Zone 3
      GC0145427Courtesy 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 may not be as thick. 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  6
  6. EVAP PURGE SOLENOID 
    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 10 in. Hg. to the "CAN" side of the Evap Purge Solenoid purge solenoid.
      NOTE:

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

    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  7

      No 

  7. EVAPORATIVE SYSTEM INTEGRITY MONITOR (ESIM) SWITCH 
    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 

      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 .
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