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DTC P0440: General EVAP System Failure: Testing

NOTE: If DTC P0443, P0452, P0453, P0498 or P0499 is also set with this DTC, diagnose those DTCs before continuing with this test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS  and perform appropriate test(s).
  1. Turn the ignition on, with the engine off. With the DRBIII(R), read DTCs and record the related Freeze Frame data. Is the Good Trip counter displayed and equal to zero? If yes, go to next step. If no, see INTERMITTENT FAILURES  under ON-BOARD DIAGNOSTICS.
  2. Turn the ignition off. Perform a visual and physical inspection of the entire EVAP system. Check for the following conditions:
    • Hoses disconnected or left off.
    • Holes or cracks.
    • Loose seal points.
    • Evidence of damaged components.
    • Incorrect routing of hoses and tubes.
    • Fuel Cap left off or bad gasket seal.

    Were any of the above conditions found? If yes, repair as necessary. If no, go to next step.

  3. Carefully inspect the EVAP Purge Solenoid vacuum supply hose for proper routing. Check for a pinched or plugged hose from the throttle body to the EVAP Purge Solenoid. Ensure the vacuum port at the throttle body is free from any blockage. Were any problems found? If yes, repair the vacuum supply hose/tube as necessary. If no, go to next step.
  4. Disconnect the vacuum supply hoses form the EVAP Purge Solenoid. Using a hand vacuum pump, apply 10 in. Hg to the EVAP Canister side of the EVAP Purge Solenoid. Turn the ignition on, with the engine off. Observe the vacuum gauge. With the DRBIII(R), actuate the EVAP Purge Solenoid. Does the vacuum drop when the solenoid is actuated? If yes, stop all actuations and go to next step, If no, stop all actuations and replace the EVAP Purge Solenoid.
    5. NOTE: As this test runs, the NVLD Switch should go from an OPEN state to a CLOSED state and then return to OPEN when the test is complete.
  5. Start the engine. Allow the engine to idle. Using the DRBIII(R), perform the NVLD Forced Monitor Test. Monitor the NVLD Switch state. Did the NVLD Switch operate as described above? If yes, stop the NVLD Forced Monitor Test and see INTERMITTENT FAILURES  under ON-BOARD DIAGNOSTICS. If no, stop the NVLD Forced Monitor Test and go to next step.
    6. WARNING: Keep lighted 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 EVAP Emission Leak Detector (EELD) Tool (8404).
  6. Connect the Red power lead of the EELD to the battery positive terminal and the Black ground lead to the 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 EELD AIR supply tip (clear hose) into the 0.04 orifice on the EELD control panel. 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 has now calibrated the flow meter in Liters Per Minute (LPM). 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. Larger volume fuel tanks, and/or those with less fuel, may require 4-5 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  8 .
    7. 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. To continue testing, you will need the EELD.
  7. 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 (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, such as on top of fuel tank, release the remote Smoke/Air Start button, and use the Ultraviolet Black Light (8404-UVL) and the Yellow Goggles (8404-20) to look for residual traces of dye left behind by the smoke. The exiting smoke deposits a residual fluid that is either Bright Green or Bright Yellow when viewed with UVL. 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. Was a leak found? If yes, repair or replace the leaking component as necessary. If no, check the PCM harness connector terminals for corrosion, damage, or terminal push-out. Repair as necessary. If terminals are okay, replace the PCM.
  8. Turn the ignition off. Disconnect the NVLD Pump harness connector. Check and clean/repair connectors necessary. Connect a jumper wire between the NVLD Switch Signal circuit and the Ground circuit in the NVLD Pump harness connector. Monitor the NVLD Switch state on the DRBIII(R). Does the Switch change from OPEN to CLOSED. If yes, replace the NVLD Pump. If no, go to next step.
  9. Measure the resistance between ground and the Ground circuit in the NVLD Pump harness connector. Is the resistance less than 5.0 ohms? If yes, go to next step. If no, repair the open in the Ground circuit.
    10. 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 Miller Special Tool (8815) to perform diagnosis.
  10. Disconnect the PCM harness connectors. Measure the resistance of the NVLD Switch Signal circuit from the NVLD Pump harness connector to the appropriate terminal of the Miller Special Tool. Is the resistance less than 5.0 ohms? If yes, check the PCM harness connector terminals for corrosion, damage, or terminal push-out. Repair as necessary. If terminals are okay, replace the PCM. If no, repair open in NVLD Switch Signal circuit.
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