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Home >> Suzuki >> 1999 >> Swift Automatic >> Repair and Diagnosis >> Engine Performance >> Testing & Diagnosis >> Engine Controls - Self-Diagnostics >> Diagnostic Tests >> DTC P0440: Evaporative (EVAP) Emission Control System Malfunction, Or P0455: Evaporative (EVAP) Emission Control System Gross Leak

DTC P0440: Evaporative (EVAP) Emission Control System Malfunction, Or P0455: Evaporative (EVAP) Emission Control System Gross Leak

WARNING: This work must be performed in a well ventilated area away from any open flame.
  1. Check fuel filler cap for tightness. Check fuel filler cap gasket for proper sealing. Tighten cap or replace as necessary and retest system. If fuel filler cap is okay, go to next step.
  2. Check vacuum hoses for proper connection, leakage, clogging, and deterioration. If problem exists, repair as necessary and retest system. If problem does not exist, go to next step.
    3. NOTE: PCM may stop purge operation when EVAP hoses are disconnected with engine running. This is a normal condition due to a change in purge gas concentration detected by PCM.
  3. Ensure engine is cool. Start engine and let idle. Disconnect purge hose from EVAP canister. Place finger over end of disconnected hose and ensure vacuum is not present. Reconnect purge hose. Allow engine to reach normal operating temperature. Disconnect purge hose and check for vacuum. Vacuum should now be present at purge hose. If operation is not as specified, go to next step. If operation is as specified, go to step  5 .
  4. Turn ignition off. Check purge valve circuit operation. Go to EVAP CANISTER PURGE VALVE CIRCUIT under FUEL EVAPORATION in SYSTEM & COMPONENT TESTING article. If operation is as specified, go to next step. If operation is not as specified, check for plugged vacuum passage. If vacuum passage is okay, go to next step.
  5. Check operation of Tank Pressure Control Valve (TPCV). Go to FUEL TANK PRESSURE CONTROL VALVE under FUEL EVAPORATION in SYSTEM & COMPONENT TESTING article. Repair as necessary. If TPCV operation is as specified, go to next step.
  6. Test operation of Tank Pressure Control Solenoid Valve (TPCSV) circuit. Go to TANK PRESSURE CONTROL SOLENOID VALVE (TPCSV) CIRCUIT under FUEL EVAPORATION in SYSTEM & COMPONENT TESTING article. Repair as necessary. If TPCSV operation is as specified, go to next step.
  7. Test EVAP Canister Air Valve (ECAV) operation. Go to EVAP CANISTER AIR VALVE CIRCUIT under FUEL EVAPORATION in SYSTEM & COMPONENT TESTING article. Repair as necessary. If TPCSV operation is as specified, go to next step.
  8. Visually inspect EVAP canister for damage or leaks. See Fig 1 . Go to EVAP CANISTER under FUEL EVAPORATION in SYSTEM & COMPONENT TESTING article. If EVAP canister operates as specified, go to next step. Replace EVAP canister if it does not operate as specified. Retest system.
    Fig 1: Identifying EVAP Canister Ports
    G98I12334Courtesy of SUZUKI OF AMERICA CORP.
  9. Inspect for EVAP system leaks. Go to EVAP SYSTEM LEAKAGE CHECK under FUEL EVAPORATION in SYSTEM & COMPONENT TESTING article. If system operates as specified, go to next step. If system does not operate as specified, locate pressure leak by using soap and water or leak detector. Repair leak and retest system.
  10. Check fuel level sensor and its circuit. See DTC P0461: FUEL LEVEL SENSOR (GAUGE) CIRCUIT PERFORMANCE PROBLEM  . If vehicle is equipped with a tachometer, also check Brown/Yellow (Esteem) or Black/Blue (Swift) wire between PCM and instrument cluster for short to ground. If system operates as specified, go to next step. If system does not operate as specified, repair or replace malfunction as necessary. Retest system.
  11. Check fuel tank pressure sensor. Go to FUEL TANK PRESSURE SENSOR under FUEL EVAPORATION in SYSTEM & COMPONENT TESTING article. If sensor operates as specified, go to next step. If sensor does not operate as specified, repair or replace malfunction as necessary. Retest system.
  12. Check TPCSV operation. Go to TANK PRESSURE CONTROL SOLENOID VALVE (TPCSV)TANK PRESSURE CONTROL SOLENOID VALVE (TPCSV) under FUEL EVAPORATION in SYSTEM & COMPONENT TESTING article. If operation is as specified, go to next step. If resistance is not as specified, replace TPCSV. Retest system.
  13. Check EVAP canister purge valve operation. Go to EVAP CANISTER PURGE VALVE under FUEL EVAPORATION in SYSTEM & COMPONENT TESTING article. If operation is not as specified, replace purge valve and retest system. If operation is as specified, check for open or short circuits between purge valve and main relay (Red/Black wire on Esteem, or White/Black wire on Swift) and between purge valve and PCM (Red/Blue wire on Esteem, or Red/Green wire on Swift). Repair as necessary. If wiring and connectors are okay, replace PCM and retest system.
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