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Home >> Jeep >> 2014 >> Wrangler Sahara, Standard Trans >> Repair and Diagnosis >> External Pages >> Different car >> Section 222 (3.6L - DTCS P0157 To P0457) >> DTC Troubleshooting >> P0440-General EVAP System Failure >> Diagnostic Test

Diagnostic Test

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  1. CHECK FOR AN ACTIVE CONDITION 
    NOTE:

    Diagnose and repair any purge system or purge solenoid circuit DTCs before continuing with this test procedure.

    NOTE:

    A hot vehicle may conceal a potential leak. For best results, allow the vehicle to cool to 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 tubes/hoses between the Fuel tank and Evaporative Canister, ESIM, and the ESIM Vent Filter before continuing.

    1. Turn the ignition on.
    2. Using the scan tool, navigate to System Test and start the ESIM Forced Monitor Test. Allow the test to run until finished.
    3. Read the Large Leak test results.
      NOTE:

      This is a test of the overall operation of the evaporative system components. It does not necessarily indicate that a large leak was the failure.

      Did the Large Leak test pass or fail?

      Passed 

      • Go To  2

      Failed 

      • Go To  3
  2. EVAP SYSTEM INSPECTION 
    NOTE:

    If the switch is not in the proper orientation, it may cause the weighted pressure and vacuum vents to intermittently not seal correctly. The ESIM wiring harness connector should be in the 3 O'clock position.

    1. Turn the ignition off.
    2. The condition that caused the fault is intermittent and not present at this time. Perform a visual inspection of the entire Evaporative Emission System for any of the following conditions:
      • Proper orientation of the ESIM switch wiring connector (3 O'clock position)
      • 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 seal points on the Fuel Filler Cap (if applicable) or Capless Fuel Filler Assembly
      • Ice or intermittent blockage in the ESIM Vent Filter or hose

      Were any problems found?

      Yes 

      No 

      • Testing complete.
  3. EVAP PURGE SOLENOID VACUUM SUPPLY HOSE INSPECTION 
    1. Inspect the Purge Solenoid vacuum supply hose for proper routing and installation.
    2. Check for a pinched or plugged hose between the Throttle Body or Intake Manifold and 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 

      No 

      • Go To  4
  4. 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 both 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. Start the engine.
    4. Using the scan tool, navigate to system test, and start the Purge Vapors System test. Select open to actuate the Purge Solenoid to the ON position.
      NOTE:

      The vacuum should drop when the Purge Solenoid is actuated.

      Does the solenoid function as described above?

      Yes 

      • Go To  5

      No 

      • Verify that there is good pin to terminal contact at the Evap Purge Solenoid and PCM harness connectors. Replace the Evap Purge Solenoid if no problems were found in the connectors.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  5. ESIM SWITCH STATE 
    1. Turn the engine off.
    2. Attach the hand vacuum pump into the hose leading to the Evaporative Canister (Call out #8 in figure above).
    3. Turn the engine on.
    4. Using the hand vacuum pump, apply vacuum and monitor the Fuel Tank Pressure Sensor reading and the ESIM Switch state with the scan tool.
      NOTE:

      Normally, the Fuel Tank Pressure Sensor should read approximately -0.7 psi and the ESIM Switch should display as closed on the scan tool. The reading should remain stable with no fluctuations.

      Which of the following conditions are present?

      ESIM Switch open and Fuel Tank Pressure Sensor DOES NOT read negative PSI or vacuum: 

      • Go To  10

      ESIM Switch open and Fuel Tank Pressure Sensor DOES read negative PSI or vacuum: 

      • Go To  6
  6. CHECK THE ESIM SWITCH 
    1. Disconnect the ESIM Switch harness connector.
    2. Using the scan tool, read the ESIM Switch state.
    3. Connect a jumper between the ESIM Signal circuit and the Ground circuit at the ESIM Switch harness connector.
    4. Using the scan tool, read the ESIM Switch state.

      Does the ESIM Switch state change from OPEN when disconnected to CLOSED when the jumper is installed?

      Yes 

      • Replace the ESIM in accordance with the service information.
      • Run the ESIM Forced Monitor Test again to verify the repair is complete.

      No 

      • Go To  7
  7. CHECK THE 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 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 ESIM Signal circuit for an open or high resistance.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  8. CHECK THE GROUND CIRCUIT FOR AN OPEN/HIGH RESISTANCE 
    1. Measure the resistance between ground and the Ground circuit at the ESIM Switch harness connector.

      Is the resistance below 5.0 Ohms?

      Yes 

      • Go To  9

      No 

      • Repair the Ground circuit for an open or high resistance.
      • Perform the POWERTRAIN VERIFICATION TEST. Refer to POWERTRAIN VERIFICATION TEST .
  9. 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 

      No 

  10. EVAP PURGE HOSE/TUBE AND VENT FILTER OBSTRUCTION 
    1. Disconnect the Tube And Vent Filter from the ESIM.
    2. Using a hand vacuum pump, apply vacuum and monitor the Fuel Tank Pressure Sensor reading and the ESIM Switch state with the scan tool.

      Did the ESIM Switch close?

      Yes 

      • Repair the obstruction in the vent tube or filter.
      • Run the ESIM Forced Monitor Test again to verify the repair is complete.

      No 

      • Go To  11
  11. EVAPORATIVE EMISSION LEAK DETECTION 
    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 Evaporative Leak Detector (EELD) and Accessory Kit (special tool #8404C, Kit, EELD And Accessory).
    2. Connect the red power lead of EELD to the battery positive terminal and the black ground lead to battery negative terminal.
    3. Connect shop air to the EELD.
    4. Remove the ESIM Vent Filter and install the appropriate Smoke Machine Adaptors (special tool #8404-ADP, Smoke Machine Adapters) into the vent line.
    5. Connect the SMOKE supply tip (black hose) to the adapter.
    6. Set the smoke/air control switch to SMOKE.
    7. Press and hold the remote smoke/air start button to allow the system to fill with smoke.
    8. 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.
    9. 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) 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.
      NOTE:

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

      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).
      • Run the ESIM Forced Monitor Test again to verify the repair is complete.

      A leak was found in the Evaporative System 

      • 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.
      • Run the ESIM Forced Monitor Test again to verify the repair is complete.
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