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DTC P0440: General EVAP System Failure: Testing

    NOTE: If DTC P0443, P0452, P0453, P0498 or P0499 is also present, diagnose DTCs before continuing with this test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS .
  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  11.
  2. Visually inspect the entire Evaporative Emission system. Check for disconnected hoses, 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. Carefully inspect the EVAP Purge Solenoid vacuum supply hose for proper routing. Also check for a pinched or plugged hose from the throttle body to the Purge Solenoid. Inspect the vacuum nipple at the throttle body for any damage or plugging. Were any problems found? If yes, repair as necessary. If no, go to next step.
  4. Using a hand vacuum pump, apply 10 in. Hg of vacuum to the EVAP Purge Solenoid vacuum source port (CAN port on component side). Turn ignition on, engine not running. With the DRBIII®, actuate the EVAP Purge Solenoid and observe the vacuum gauge. Does the vacuum drop when the solenoid is actuated? If yes, go to next step. If no, replace the EVAP Purge Solenoid.
  5. Reconnect all hoses and connectors. Start the engine. Allow the engine to idle. With the DRBIII®, perform the NVLD FORCED MONITOR TEST. Monitor the NVLD Switch state. As the test runs, the NVLD Switch should go from an open state to a closed stated, and then return to open when the test is complete. Did the NVLD Switch operate as described above? If yes, go to step  11. If no, go to next step.
    6. 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).
  6. Connect the Red power lead of 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 .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 to 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. 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  8.
  7. 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 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 (8404-CLL) to follow the EVAP system path. 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. 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? 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 connectors are okay, replace PCM. Program the new PCM. See PROGRAMMING .
  8. Turn the ignition off. Disconnect the NVLD Assembly harness connector. Check connector and clean/repair as necessary. Using a jumper wire, jumper across the NVLD Switch Sense circuit and the Ground circuit in the NVLD Assembly harness connector. Monitor the NVLD Switch state on the DRBIII®. Does the Switch change from open to closed? If yes, replace the NVLD Assembly. If no, go to next step.
  9. Ensure the ignition is off. Measure the resistance between the Ground circuit at the NVLD Assembly harness connector and ground. Is the resistance below 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. Use Miller Special Tool (8815) when performing diagnosis at PCM harness connectors.
  10. Turn the ignition off. Disconnect the PCM harness connectors. Measure the resistance of the NVLD Sense circuit from the NVLD Assembly harness connector to the appropriate terminal at Miller Special Tool. Is the resistance below 5.0 ohms? If yes, check the PCM harness connector terminals for corrosion, damage or terminal push out. Repair as necessary. If connectors are okay, replace PCM. Program the new PCM. See PROGRAMMING  If no, repair the open in the NVLD Sense circuit.
  11. Review the DRBIII® Freeze Frame information. If possible, try to duplicate the conditions under which the DTC was set. Refer to any Technical Service Bulletins (TSB) that may apply. A loose gas cap could have caused the DTC to set. Make sure the gas cap is tight and in good condition. Ensure the gas cap meets OEM specifications. Perform a visual and physical inspection of the entire Evaporative Emission system. Check for disconnected hoses, holes or cracks, loose sealing points, damaged components, incorrect hose/tube routing or bad gas cap gasket. Were any problems found? If yes, repair as necessary. If no, test is complete.
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