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Home >> Chrysler >> 2002 >> Intrepid Base >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Self-Diagnostics >> Diagnostic Tests >> DTC P0442: EVAP System Medium Leak Or DTC P0455: EVAP System Large Leak >> Testing

DTC P0442: EVAP System Medium Leak Or DTC P0455: EVAP System Large Leak: Testing

    NOTE: A hot vehicle can conceal a leak. It's best to perform this test at room temperature. A loose gas cap could have caused this DTC to set. Make sure gas cap is tight and in good condition. Ensure the gas cap meets OEM specifications.
  1. Turn ignition on, engine not running. With the DRBIII®, read DTCs and record related Freeze Frame data. Is the Good Trip counter displayed and equal to zero? If yes, go to next step. If no, go to step  6.
  2. Perform a visual and physical inspection of the entire Evaporative Emission system. Check for holes or cracks, loose sealing points, damaged components, incorrect hose/tube routing, bad fuel cap gasket or fuel cap left off. Were any problems found? If yes, repair as necessary. If no, go to next step.
    3. 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.
    NOTE: The fuel tank should have 20-80 percent of fuel tank capacity to properly test the EVAP system. To continue testing you will need Miller Evaporative Emission Leak Detector (8404).
  3. Connect the Red power lead of the Evaporative Emission Leak Detector (EELD) to the battery positive terminal and the Black ground lead to battery negative terminal. Block the vent hose of the EVAP Canister. Connect shop air to the EELD. Set the smoke/air control switch to AIR. 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). Press the remote smoke/air start button. Position the Red flag on the air flow meter so it is aligned with the indicator ball. When the calibration is complete, release the remote button. The EELD is now calibrated the flow meter in liters per minute to the size leak indicated by the DTC set in the PCM. Install the Service Port Adapter (8404-14) on the vehicle's service port. Connect the Air supply hose from the EELD to the service port. Press the remote button to activate AIR flow. On vehicles with larger volume fuel tanks, lower fuel levels or if equipped with a Flow Management Valve, this may indicate high flow and will require 4 to 5 minutes to fill. Compare the flow meter indicator ball reading to the Red flag. Above the Red flag indicates a leak present. Below the Red flag indicates a sealed system. Is the indicator ball above the Red flag? If yes, go to next step. If no, go to step  6.
    4. 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.
  4. To continue testing, you will need Miller Evaporative Emissions Leak Detector (8404). Remove the Air supply hose from the service port. Connect the SMOKE supply tip (Black hose) to the service port. Set the smoke/air control switch to SMOKE. The flow meter indicator ball will not move at this point. Press the remote smoke/air start button. 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. For optimal performance, introduce smoke into the system for an additional 60 seconds; continue introducing smoke at 15 second intervals, as necessary. While still holding the remote smoke/air start button, use the White Light (8404CLL) 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 Ultra Violet (UV) Black light (8404-UVL) and the Yellow Goggles (8404-20) to look for residual traces of dye that is 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? If yes, repair or replace the leaking component as necessary. If no, go to next step.
  5. Disconnect vacuum hoses at EVAP Purge Solenoid. Inspect hoses and solenoid for any signs of contamination from the EVAP canister. This may indicate a faulty rollover valve. Repair or replace as necessary. Using a hand vacuum pump, apply 10 in. Hg of vacuum to the EVAP Purge Solenoid vacuum source port (CAN port on component side). Monitor vacuum for at least 15 seconds. Does the EVAP Purge Solenoid hold vacuum? If yes, go to next step. If no, replace the EVAP Purge Solenoid.
  6. The conditions that set the DTC are not present at this time. The following may help in identifying the intermittent condition. Use the Freeze Frame Data to help you duplicate the conditions that set the DTC. Pay particular attention to the DTC set conditions, such as, VSS, MAP, ECT, and Load. 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. Refer to any Technical Service Bulletins (TSB) that may apply. With the DRBIII® in System Tests, perform the LDP Monitor Test. This will force the PCM to run the LDP Monitor. If the monitor fails, further diagnosis is required to find faulty component. If the monitor passes, the condition is not present at this time. Were any problems found? If yes, repair as necessary. If no, test is complete.
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