For 1990-2009 cars
Engine Controls Components
EVAP Tank, Purge and Intake Plenum, Resonance Solenoid Valves
OBD II Symbol Description Notice
Handling ESD Sensitive Parts Notice

### Circuit Description

During specific operating conditions, the engine control module (ECM) performs various tests on the evaporative emission system. The system tests consist of the following series of events. After ensuring that the evaporative emission (EVAP) purge solenoid valve duty cycle has dropped to 0 percent, indicating that the valve is closed, the ECM commands the EVAP canister vent solenoid valve closed, sealing the system. The ECM monitors the accumulation of vapor pressure within the fuel tank via the fuel tank pressure (FTP) sensor. The EVAP test is aborted if the vapor pressure is too high. If any vapor pressure is measured, the pressure will be used later in order to compensate for a pressure reading during the small leak detection test. If a vacuum is measured which exceeds a calculated limit during vapor accumulation, diagnostic trouble code (DTC) P0440 will set. The EVAP canister purge solenoid valve is then opened. Simultaneously, the vent solenoid is opened. If the vapor pressure does not bleed off or bleeds off too slowly, DTC P0440 is set. Once the EVAP purge solenoid valve reached the desired position for the remainder of the diagnostic test, the vent solenoid will be closed again. This causes a vacuum to be applied to the entire EVAP system. The ECM monitors the vacuum level within the system. If the desired vacuum level cannot be achieved, or if the vacuum level is reached but took too much time, DTC P0455 will set. Once the desired vacuum level is reached, the purge solenoid is closed, sealing the system. The ECM continues to monitor the fuel tank pressure sensor signal, measuring the rate of vacuum decay. If the system holds vacuum, the vent solenoid is opened and the test is completed. In addition to the system tests, the ECM monitors the circuit integrity of the purge solenoid (DTC P0443), the vent solenoid (DTC P0446) and the fuel tank pressure sensor (DTC P0450).

### Conditions for Running the DTC

• | Any of the following DTCs are not set: P0100, P0115, P0116, P0130-P0161, P0300-P0306, P0443, P0446, P0450, P0500, P0506, P0507, P0560, P1120 or P1220.

• | The vehicle speed is 0 km/h (0 mph).

• | The engine is at idle.

• | The engine coolant temperature (ECT) at start is between -8°C (17°F) and 75°C (167°F).

• | Fuel system is in Closed Loop.

• | The engine load is less than 30 percent.

• | The intake air temperature (IAT) is between -8°C (17°F) and 50°C (122°F).

• | The system voltage is more than 11 volts.

• | The engine run time is at least 17 minutes.

• | The secondary AIR system is inactive.

• | The secondary AIR system diagnostic is not running.

• | The short term fuel trim at the beginning of the test is more than -5 percent.

### Conditions for Setting the DTC

The EVAP system is unable to achieve vacuum or the time required to achieve vacuum is too long during the diagnostic test.

### Action Taken When the DTC Sets

The ECM illuminates the malfunction indicator lamp (MIL) and records the operating conditions in the Freeze Frame on the second consecutive drive trip that the diagnostic runs and fails.

### Conditions for Clearing the MIL/DTC

• | The ECM turns OFF the MIL after three consecutive drive trips that the diagnostic runs and passes.

• | A History DTC clears after forty consecutive warm-up cycles in which no failures are reported by this diagnostic or any other emission related diagnostic.

• | The scan tool clears the MIL/DTC.

### Diagnostic Aids

The fuel tank assembly consists of an inner fuel tank, EVAP canister, ORVR system and the associated plumbing all encased within an outer fuel tank housing. The outer housing contains a tube that allows air between the inner tank and the outer housing to vent. A leak in any of the internal components of the fuel tank assembly will exit this vent. The vent is located in front of the fuel tank above the fuel filter. If a leak is detected by air exiting this vent while the EVAP system is pressurized, the fuel tank assembly will require replacement. The internal components of the fuel tank assembly are not serviceable. A similar vent for the fuel tank pressure sensor is also located in front of the fuel tank. A leak from this vent while the EVAP system is pressurized indicates the fuel tank pressure sensor is leaking.

Check for the following conditions:

• | A damaged, loose, missing, or incorrect fuel cap

• | A disconnected, damaged, pinched, or blocked EVAP purge line

• | A disconnected or damaged EVAP vent hose

• | An EVAP purge valve that is not opening

• | An EVAP vent valve that is not closing

• | A leaking fuel sender assembly O-ring

• | A leaking fuel tank or fuel filler neck

### Test Description

The numbers below refer to the step numbers on the diagnostic table.

1. This step verifies that there is sufficient vacuum available for proper system operation.

2. This step is to determine if the loss of vacuum is due to the purge valve or the supply.

3. 20.37 mm Hg (10.86 in. H2O) is the maximum value displayed on the scan tool even though the actual pressure in the system may be higher.

4. Inspect the purge valve and lines for traces of carbon. Any carbon that is escaping from the canister may be preventing the valve from closing properly. If this condition is found, disconnect both ends of the purge line and blow out any contaminants by using the pressurized gas from the EVAP pressure/purge cart. Replace the purge valve and the canister/fuel tank.

#### DTC P0455 EVAP System Large Leak Detected

Step | Action | Values | Yes | No
--- | --- | --- | --- | ---
1 | Did you perform the Powertrain On-Board Diagnostic System Check? | -- | Go to Step 2 | Go to the Powertrain On Board Diagnostic (OBD) System Check
2 | Is DTC P0443, P0446 or P0450 also set? | -- | Go to the applicable DTC | Go to Step 3
3 |

1. Before continuing with the diagnostic table, perform a visual/physical inspection of the EVAP system. Check for the following conditions:

• | Disconnected, kinked, or deteriorated hoses/lines

• | Loose hose connections

• | A missing or loose fuel cap

• | Obvious damage to any of the system components

2. Repair as necessary.

Did you find and correct a problem?

--

Go to Step 20

Go to Step 4

4 |

1. Disconnect the purge line from the EVAP service port.
2. Connect a vacuum gauge to the purge line from the purge valve (the in. Hg vacuum gauge on the J 41750 EVAP pressure/purge cart can be used for this purpose).
3. Start the engine and allow it to idle.
4. Using the scan tool, command the purge valve to 100 percent.
5. Observe the vacuum gauge.

Does the vacuum gauge indicate the value specified or more?

50.79 kPa (15 in Hg)

Go to Step 6

Go to Step 5

5 |

1. Turn OFF the ignition.
2. Disconnect the manifold vacuum source line from the purge valve.
3. Connect a vacuum gauge to the manifold vacuum source line (the in. Hg vacuum gauge on the J 41750 EVAP pressure/purge cart can be used for this purpose).
4. Start the engine and allow it to idle.

Does the vacuum gauge indicate the value specified or more?

50.79 kPa (15 in Hg)

Go to Step 15

Go to Step 14

6 |

1. Turn OFF the ignition.
2. Reconnect the purge line to the EVAP service port.
3. Remove the fuel cap.
4. Turn ON the ignition with the engine OFF.
5. Observe the fuel tank pressure on the scan tool.

Is the fuel tank pressure within the specified range?

-1.87 to +1.87 mm Hg (-1 to +1 in. H2O)

Go to Step 7

Go to DTC P0450 Fuel Tank Pressure Sensor Circuit

7 | Important: Before continuing with the diagnosis, zero the EVAP Pressure and Vacuum gauges on J 41750 EVAP pressure/purge cart (refer to the tool operating instructions).

1. Connect the EVAP pressure/purge cart to the EVAP service port.
2. Replace the fuel cap.
3. Using the scan tool, command the vent valve ON (closed).
4. Attempt to pressurize the EVAP system with the pressure/purge cart. Monitor the pressure with the gauge on the cart.

Can specified value be achieved?

28.02 mm Hg (15 in. H2O)

Go to Step 8

Go to Step 11

8 |

1. Adjust the system pressure to the first value using the valve on the cart.
2. Observe the fuel tank pressure on the scan tool.

Is the fuel tank pressure at or above the second value?

20.55 mm Hg (11 in. H2O)

18.68 mm Hg (10 in. H2O)

Go to Step 10

Go to Step 9

9 |

1. Inspect the purge line from the purge valve to the fuel tank for the following conditions:

• | Kinks

• | Restrictions

• | Blockages

2. Repair as necessary.

Did you find and correct any of these conditions?

--

Go to Step 20

Go to Step 16

10 |

1. Pressurize the system to the first specified value.
2. Rotate the valve on the cart to HOLD and observe the EVAP pressure gauge.

Does the pressure drop below the second specified value within 2 minutes?

28.02 mm Hg (15 in. H2O)

18.68 mm Hg (10 in. H2O)

Go to Step 11

Go to Diagnostic Aids

11 |

1. Turn OFF the ignition.
2. Disconnect the vent hose from the fuel tank at the vent valve.
3. Block off the hose using a suitable stopper.
4. Pressurize the system to the first specified value with the gauge on the cart.
5. Rotate the valve on the cart to HOLD.

Does the pressure drop below the second value within 2 minutes?

28.02 mm Hg (15 in. H2O)

18.68 mm Hg (10 in. H2O)

Go to Step 12

Go to Step 18

12 |

1. Disconnect the purge line at the purge valve.
2. Block off the line using a suitable stopper.
3. Pressurize the system to the first specified value with the gauge on the cart.
4. Rotate the valve on the cart to HOLD.

Does the pressure drop below the second value within 2 minutes?

28.02 mm Hg (15 in. H2O)

18.68 mm Hg (10 in. H2O)

Go to Step 13

Go to Step 17

13 |

1. With the cart connected to the EVAP service port, continuously pressurize the EVAP system by leaving the cart control knob in the pressurize position.
2. Test for leaks with the J 41416 ultrasonic leak detector. Test the following areas and repair or replace as necessary:

• | Fuel tank - refer to Diagnostic Aids.

• | Filler cap/fill pipe area

• | Sending unit and the sending unit to tank seal

• | Fuel tank pressure sensor and seal

• | Purge line from the purge valve to the fuel tank

• | EVAP service port

• | Vent hose from the fuel tank to the vent valve

Is the action complete?

--

Go to Step 20

--

14 | Check for the following conditions and repair as necessary:

• | A damaged vacuum source line

• | A blocked or restricted manifold vacuum port

• | A low engine vacuum

Is the action complete?

--

Go to Step 20

--

15 |

1. Test the purge line from the purge valve to the EVAP service port for the following conditions:

• | Leaks

• | Blockages

• | Restrictions

2. Repair or replace as necessary.

Did you find and correct a problem?

--

Go to Step 20

Go to Step 17

16 | Test for a restriction or blockage in the purge line going into the canister/fuel tank. Did you find a problem? | -- | Go to Step 19 | Go to DTC P0450 Fuel Tank Pressure Sensor Circuit
17 | Important: Contamination can cause the valve to fail. Refer to Test Description for inspection/cleaning procedures. Replace the purge valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement . Is the replacement complete? | -- | Go to Step 20 | --
18 | Replace the vent valve. Refer to Evaporative Emission Vent Valve Replacement . Is the replacement complete? | -- | Go to Step 20 | --
19 | Replace the fuel tank . Refer to Fuel Tank and Evaporation Emission Canister Replacement . Is the replacement complete? | -- | Go to Step 20 | --
20 |

1. Turn ON the ignition.
2. Using the scan tool, command the vent valve ON (closed).
3. Pressurize the EVAP system to the first value with the J 41750 EVAP pressure/purge cart. (Monitor the pressure using the gauge on the cart).
4. Rotate the valve on the cart to HOLD and observe the pressure gauge.

Does the pressure drop below the second value within 2 minutes?

28.02 mm Hg (15 in. H2O)

18.68 mm Hg (10 in. H2O)

Go to Step 7

Go to Step 21

21 |

1. Using the scan tool, clear the DTCs.
2. Turn OFF the ignition for 15 seconds.
3. Start the engine and allow it to idle.
4. Select DTC and the Specific DTC function.
5. Enter the DTC number that was set.
6. Operate the vehicle within the Conditions for Running this DTC until the scan tool indicates the diagnostic ran.

Does the scan tool indicate the Diagnostic Passed?

--

Go to Step 22

Go to Step 2

22 | Does the scan tool display any additional, undiagnosed DTCs? | -- | Go to the applicable DTC table | System OK