Dodge Caliber. Manual - part 770

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When Monitored:
With the engine running after a cold start, with the difference between ECT and AAT is less than 10° C (18 °F),
fuel level between 12% and 88%, manifold vacuum greater than a minimum value, ambient temperature
between 4° C and 37° C (39° F and 89° F) and altitude less than 8500 feet.

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Set Condition:
When monitor conditions are met, the PCM will ramp in purge flow. If the PCM does not sense an ESM switch
closure after a calculated amount of purge flow accumulation, an error is detected. Two Trip Fault. Three good
trips to turn off the MIL.

Possible Causes

INTERMITTENT DTC

EVAP PURGE SOLENOID VACUUM SUPPLY

EVAP SYSTEM LEAK

EVAP PURGE HOSE/TUBE OBSTRUCTION

(Z965) GROUND CIRCUIT OPEN OR HIGH RESISTANCE

(K107) ESM SIGNAL CIRCUIT OPEN OR HIGH RESISTANCE

EVAP PURGE SOLENOID

EVAP SYSTEM MONITOR SWITCH

POWERTRAIN CONTROL MODULE (PCM)

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING).

Diagnostic Test

EVAP SYSTEM PRETEST

Ignition on, engine not running.

With a scan tool, select View DTCs. Record the Freeze Frame data if any DTCs are present.

Review the vehicle repair history for items related to the current condition.

Inspect the vehicle for any aftermarket accessories that may have been installed incorrectly.

Check for any related technical service bulletins (TSBs) and, if any apply, follow the recommended procedure.

Select the appropriate response from the list below:

A technical service bulletin (TSB) repaired the condition.

Test complete.

A DTC is present, no TSBs apply, or the TSB did not repair the condition.

Go to 2

DTC IS ACTIVE

NOTE: Allow the vehicle to cool to ambient temperature before continuing with this procedure.

NOTE: A loose gas cap may have caused this DTC to set. Make sure gas cap is tight and in good condition.
Make sure the gas cap meets OEM specifications.
Start the engine.

Allow the engine to idle.

Using the scan tool, perform the ESIM FORCED MONITOR TEST. Allow the test to complete.

With a scan tool, select View DTCs.

Is the status Active for this DTC?

Yes

>> Go to 3

>> Refer to the *CHECKING FOR AN INTERMITTENT DTC Diagnostic Procedure. (Refer to 9 - ENGINE -

DIAGNOSIS AND TESTING)

ENGINE ELECTRICAL DIAGNOSTICS - GPEC

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EVAP SYSTEM INSPECTION

Inspect the EVAP System for any of the following conditions:

- Holes or cracks

- Loose seal points

- Damaged or missing components

- Incorrect routing of hoses and tubes

- Loose or missing Fuel Cap

- Damaged or missing Fuel Cap seal

- Improper installation of the Fuel Cap

- Damaged Locking tabs on the Fuel Cap and/or filler tube

- Damaged seal points on the Fuel Cap and/or filler tube

Were any problems found?

Yes

>> Repair as necessary.

Perform the PCM Verification Test Ver. 1 (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).

>> Go to 4

INSUFFICIENT VACUUM SUPPLY TO THE EVAP PURGE SOLENOID

Inspect the Evap Purge Solenoid vacuum supply hose for proper routing and installation.

Make sure the vacuum supply hose between the throttle body or intake manifold and the EVAP Purge Solenoid is
free from any obstructions or blockage.

Make sure the vacuum port at the throttle body or intake manifold is free from any obstructions or blockage.

Were any problems found?

Yes

>> Repair as necessary.

Perform the PCM Verification Test Ver. 1 (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).

>> Go to 5

EVAP PURGE SOLENOID

NOTE: After disconnecting the Evap Purge vacuum connections, inspect the lines and solenoid for signs of
contamination.
Using a hand vacuum pump, apply 10 in Hg to the

CAN

side of the EVAP Purge Solenoid.

NOTE: The solenoid should hold vacuum for a minimum of 15 seconds.
Turn the ignition on.

With the scan tool, actuate the EVAP Purge Solenoid to the ON position.

NOTE: The vacuum should drop when the solenoid is actuated.

Does the solenoid function as described above?

Yes

>> Go to 6

>> Replace the EVAP Purge Solenoid.

Perform the PCM Verification Test Ver. 1 (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).

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ENGINE ELECTRICAL DIAGNOSTICS - GPEC

ESIM SWITCH STATE

Turn the ignition off.

Disconnect the Evap System Monitor Switch harness connector.

Turn the ignition on.

Monitor the ESIM Switch state on the scan tool.

Carefully connect a jumper wire between the (K107) ESM Signal circuit
and the (Z965) Ground circuit in the Evap System Monitor Switch har-
ness connector.

Monitor the ESIM Switch state on the scan tool.

Does the Switch change from OPEN to CLOSED with the
jumper in place?

Yes

>> Go to 9

>> Go to 7

(K107) ESM SIGNAL CIRCUIT OPEN OR HIGH RESISTANCE

Turn the ignition off.

Disconnect the PCM harness connectors.

Measure the resistance of the (K107) ESM Signal circuit between the
Evap System Monitor Switch harness connector and the Powertrain
Control Module (PCM) harness connector.

Is the resistance below 5.0 ohms?

Yes

>> Go to 8

>> Repair the (K107) ESM Signal circuit for an open circuit or

high resistance.

Perform the PCM Verification Test Ver. 1 (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING).

(Z965) GROUND CIRCUIT OPEN OR HIGH RESISTANCE

Turn the ignition off.

Using a 12 volt test light connected to 12 volts, check the (Z965)
Ground circuit in the Evap System Monitor Switch harness connector.

NOTE: The test light should be illuminate and bright. Compare the
brightness to that of a direct connection to the battery.

Is the test light illuminated and bright?

Yes

>> Go to 13

>> Repair the (Z965) Ground circuit for an open circuit or high

resistance.

Perform the PCM Verification Test Ver. 1 (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING).

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VERIFY EVAPORATIVE EMISSION LEAK

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. Failure to follow these instructions can
result in personal injury or death.
Turn the ignition off.

To continue testing you will need Miller Tool #8404 Evaporative Emission Leak Detector (EELD).

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.

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 flow meter is now calibrated in liters per
minute.

Install the service port adapter #8404-14 on the vehicle’s service port (if equipped) or install the #8404-ADP into the
filter line.

Connect the Air supply hose from the EELD to the service port (if equipped) or to the #8404-ADP adapter.

Press the remote button to activate AIR flow.

Compare the flow meter indicator ball reading to the red flag.

ABOVE the red flag indicates that a leak is present.

BELOW the red flag indicates that the system is sealed.

Does the flow meter indicate that a leak is present?

Yes

>> Go to 10

>> Go to 11

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ENGINE ELECTRICAL DIAGNOSTICS - GPEC

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