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Home >> Suzuki >> 2001 >> Vitara JS, 4D Utility, Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Self-Diagnostics >> Diagnostic Tests >> DTC P0440: EVAP Circuit, Malfunction, Or DTC P0455: EVAP Circuit, Large Leak Detected >> Diagnosis & Repair Procedure

Diagnosis & Repair Procedure

  1. Perform DTC CONFIRMATION TEST . If DTC P0440 or P0455 is set, go to next step. If DTCs P0440 and P0455 are not set, problem is intermittent. System is okay at this time. See TROUBLE SHOOTING - NO CODES article.
  2. Check fuel filler cap for tightness. Check fuel filler cap gasket for proper sealing. Tighten cap or replace as necessary and go to DTC CONFIRMATION TEST . If fuel filler cap is okay, go to next step.
  3. Check vacuum hoses for proper connection, leakage, plugging, and deterioration. If problem exists, repair as necessary and go to DTC CONFIRMATION TEST . If problem does not exist, go to next step.
  4. Check EVAP canister purge system for proper operation. See EVAP CANISTER PURGE SYSTEM in SYSTEM & COMPONENT TESTING article. If EVAP canister purge system operation is as specified, go to step  6. If EVAP canister purge system operation is not as specified, go to next step.
  5. Check EVAP canister purge valve and circuit operation. See EVAP CANISTER PURGE VALVE in SYSTEM & COMPONENT TESTING article. If EVAP canister purge valve and circuit operation is as specified, go to next step. If EVAP canister purge valve and circuit operation is not as specified, check for plugged vacuum passage. Clean or repair as necessary. If vacuum passage is okay, go to step  13.
  6. Check EVAP canister air valve and circuit operation. See EVAP CANISTER AIR VALVE in SYSTEM & COMPONENT TESTING article. If EVAP canister air valve and circuit operation is as specified, go to next step. If vehicle is equipped with ORVR, go to step  8. If EVAP canister air valve and circuit operation is not as specified, go to step  15.
  7. Check fuel tank pressure control solenoid valve and circuit operation. See FUEL TANK PRESSURE CONTROL SOLENOID VALVE in SYSTEM & COMPONENT TESTING article. If fuel tank pressure control solenoid valve and circuit operation is as specified, go to next step. If fuel tank pressure control solenoid valve and circuit operation is not as specified, go to step  17.
  8. Check fuel tank pressure control valve operation. See FUEL TANK PRESSURE CONTROL VALVE in SYSTEM & COMPONENT TESTING article. If fuel tank pressure control valve operation is as specified, go to next step. If fuel tank pressure control valve operation is not as specified, replace fuel tank pressure control valve and go to DTC CONFIRMATION TEST .
  9. Check EVAP canister for damage or clogged passages. See EVAP CANISTER INSPECTION in SYSTEM & COMPONENT TESTING article. If EVAP canister operation is as specified, go to next step. If EVAP canister operation is not as specified, replace EVAP canister and go to DTC CONFIRMATION TEST .
  10. Inspect purge line, evaporative system components and fuel tank for leaks. See EVAP LEAKAGE INSPECTION in SYSTEM & COMPONENT TESTING article. If any leaks are found, repair or replace system or components as necessary and go to DTC CONFIRMATION TEST . If no leaks are found, go to next step.
  11. Check FTP sensor operation. See FUEL TANK PRESSURE SENSOR in SYSTEM & COMPONENT TESTING article. If FTP sensor operation is not as specified, replace sensor and go to DTC CONFIRMATION TEST . If FTP sensor operation is as specified, go to next step.
  12. Check fuel level sensor operation. See DTC P0461: FUEL LEVEL SENSOR CIRCUIT PERFORMANCE PROBLEM . If fuel level sensor operation is not as specified, repair as necessary and go to DTC CONFIRMATION TEST . If fuel level sensor operation is as specified, problem is intermittent. System is okay at this time. See TROUBLE SHOOTING - NO CODES article. If intermittent problem is not found, replace PCM and go to DTC CONFIRMATION TEST .
  13. Check EVAP canister purge valve operation. See EVAP CANISTER PURGE VALVE in SYSTEM & COMPONENT TESTING article. If EVAP canister purge valve operation is as specified, go to next step. If EVAP canister purge valve operation is not as specified, replace canister purge valve and go to DTC CONFIRMATION TEST .
  14. Check for short or open in Blue/Black wire between EVAP canister purge valve, main relay and PCM 26-pin connector C51-3 terminals No. 4 and No. 15. Also check for short or open in Green/Black wire between EVAP canister purge valve and PCM 30-pin connector C51-2 terminal No. 17. See WIRING DIAGRAM article. Repair as necessary and go to DTC CONFIRMATION TEST . If wires are okay and scan tool was used to check system, replace PCM and go to DTC CONFIRMATION TEST .
  15. Check EVAP canister air valve operation. See EVAP CANISTER AIR VALVE in SYSTEM & COMPONENT TESTING article. If EVAP canister air valve operation is as specified, go to next step. If EVAP canister air valve operation is not as specified, EVAP canister air valve and go to DTC CONFIRMATION TEST .
  16. Check for short or open in Blue/Black wire between EVAP canister air valve, main relay and PCM 26-pin connector C51-3 terminals No. 4 and No. 15. Also check for short or open in Purple/Red wire between EVAP canister air valve and PCM 30-pin connector C51-2 terminal No. 5. See WIRING DIAGRAM article. Repair as necessary and go to DTC CONFIRMATION TEST . If wires are okay and scan tool was used to check system, replace PCM and go to DTC CONFIRMATION TEST .
  17. Check fuel tank pressure control solenoid valve operation. See FUEL TANK PRESSURE CONTROL SOLENOID VALVE in SYSTEM & COMPONENT TESTING article. If fuel tank pressure control solenoid valve operation is as specified, go to next step. If fuel tank pressure control solenoid valve operation is not as specified, replace fuel tank pressure control solenoid valve and go to DTC CONFIRMATION TEST .
  18. Check for short or open in Blue/Black wire between fuel tank pressure control solenoid valve, main relay and PCM 26-pin connector C51-3 terminals No. 4 and No. 15. See WIRING DIAGRAMS article. Also check short or open in Green/White wire between solenoid valve and PCM 30-pin connector C51-2 terminal No. 6. Repair as necessary and go to DTC CONFIRMATION TEST . If wires are okay and scan tool was used to check system, replace PCM and retest system.
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