Chrysler Voyager. Manual — part 88

TEST

ACTION

APPLICABILITY

2

Perform a visual and physical inspection of the entire Evaporative Emission 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?

All

Yes

→ Repair as necessary.

Perform POWERTRAIN VERIFICATION TEST VER - 5 - NGC.

No

→ Go To 3

3

Turn the ignition off.
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 Purge Solenoid.
Ensure the vacuum port at the throttle body is free from any blockage.
Were any problems found?

All

Yes

→ Repair the vacuum supply, hose/tube as necessary.

Perform POWERTRAIN VERIFICATION TEST VER - 5 - NGC.

No

→ Go To 4

4

Disconnect the vacuum supply hoses form the EVAP Purge Solenoid.
Using a hand vacuum pump, apply 10 in Hg to the

9CAN9 side of the EVAP Purge

Solenoid.
Ignition on, engine not running.
Observe the vacuum gauge.
With the DRBIII

t, actuate the EVAP Purge Solenoid .

Does the vacuum drop when the solenoid is actuated?

All

Yes

→ Go To 5

No

→ Replace the Evap Purge Solenoid.

Perform POWERTRAIN VERIFICATION TEST VER - 5 - NGC.

5

NOTE: The fuel level must be below 85%, or the Onboard Refueling Vapor
Recovery (ORVR) system control valve will seal the tank.
Turn the ignition off.
Install the Miller #8382 gas cap adaptor. Attach the gas cap to the adapter.
Connect a hand-held vacuum pump to the gas cap adapter.
NOTE: At 1

( in Hg the switch should close. Using a manometer (Miller

#6872A) connected to the service port can aid in properly reading the
system vacuum.
Slowly apply vacuum while monitoring the NVLD Switch State on the DRBIII

t. Do

not exceed 2

9 in Hg while performing this step.

NOTE: The NVLD Switch reads normally open. When the vacuum is applied
and 1

( in Hg is reached the switch state should be in the closed position.

Once the vacuum has been released the Switch state should return to the
open position.
Did the NVLD Switch operate as described above?

All

Yes

→ Refer to the INTERMITTENT CONDITION symptom in the

Driveability category.
Perform POWERTRAIN VERIFICATION TEST VER - 5 - NGC.

No

→ Go To 6

351

DRIVEABILITY - NGC

P0440-GENERAL EVAP SYSTEM FAILURE —

Continued

TEST

ACTION

APPLICABILITY

6

To continue testing you will need Miller Tool #8404 Evaporative Emission Leak
Detector (EELD).
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 between 20% and 80% of fuel tank capacity
to properly test the Evap system.
Connect the red power lead of EELD to the battery positive terminal and the black
ground lead to battery negative terminal.
NOTE: See Charts and Graph support material EELD Calibration Setup for
an example.
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 .040 orifice on the tester’s
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 is now
calibrated the flow meter in liters per minute.
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.
NOTE: Larger volume fuel tanks, lower fuel levels or if the vehicle is
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?

All

Yes

→ Go To 7

No

→ Go To 8

352

DRIVEABILITY - NGC

P0440-GENERAL EVAP SYSTEM FAILURE —

Continued

TEST

ACTION

APPLICABILITY

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 Miller Tool #8404 Evaporative Emissions Leak
Detector (EELD).
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.
NOTE: The flow meter indicator ball will not move at this point.
Press the remote smoke/air start button.
NOTE: 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.
NOTE: 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 (i.e., top of fuel tank), release the remote smoke/air
start button, and use the ultraviolet (UV) black light #8404-UVL and the yellow
goggles 8404-20 to look for residual traces of dye that are 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.
NOTE: 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 visual.
Introducing smoke into the filtered side of the canister may assist in
locating the leak.
Was a leak found?

All

Yes

→ Repair or replace the leaking component as necessary.

Perform POWERTRAIN VERIFICATION TEST VER - 6 - NGC.

No

→ NOTE: Before continuing, check the PCM harness connector

terminals for corrosion, damage or terminal push out. Repair as
necessary. Replace and program the Powertrain Control Module
in accordance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5 - NGC.

8

Turn the ignition off.
Disconnect the NVLD electrical harness connector.
Check connectors - Clean/repair as necessary.
Using a jumper wire, jumper across the (K107) NVLD Switch Sense circuit and the
(Z1) Ground circuit in the NVLD electrical harness connector.
Monitor the NVLD Switch state on the DRBIII

t.

Does the Switch change from OPEN to CLOSED.

All

Yes

→ Replace the NVLD Assembly.

Perform POWERTRAIN VERIFICATION TEST VER - 5 - NGC.

No

→ Go To 9

353

DRIVEABILITY - NGC

P0440-GENERAL EVAP SYSTEM FAILURE —

Continued

TEST

ACTION

APPLICABILITY

9

Turn the ignition off.
Disconnect the NVLD electrical harness connector.
Measure the resistance between the (Z1) Ground circuit and ground.
Is the resistance below 5.0 ohms?

All

Yes

→ Go To 10

No

→ Repair the open in the (Z1) Ground circuit.

Perform POWERTRAIN VERIFICATION TEST VER - 5 - NGC.

10

Turn the ignition off.
Disconnect the NVLD electrical harness connector.
Disconnect the PCM harness connector.
CAUTION: DO NOT PROBE THE PCM HARNESS CONNECTORS. PROBING
THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI-
NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION. INSTALL
MILLER SPECIAL TOOL #8815 TO PERFORM DIAGNOSIS.
Measure the resistance of the (K107) NVLD Switch Signal circuit from the NVLD
electrical harness connector to the appropriate terminal of the special tool #8815.
Is the resistance below 5.0 ohms?

All

Yes

→ NOTE: Before continuing, check the PCM harness connector

terminals for corrosion, damage or terminal push out. Repair as
necessary. Replace and program the Powertrain Control Module
in accordance with the Service Information.
Perform POWERTRAIN VERIFICATION TEST VER - 5 - NGC.

No

→ Repair the open in the (K107) NVLD Switch Signal Circuit.

Perform POWERTRAIN VERIFICATION TEST VER - 5 - NGC.

354

DRIVEABILITY - NGC

P0440-GENERAL EVAP SYSTEM FAILURE —

Continued