Dodge Caliber. Manual - part 776

EVAPORATIVE EMISSION LEAK DETECTION

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 #8404A Evaporative Emissions Leak Detector (EELD).

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

Connect the SMOKE supply tip (black hose) to the service port (if equipped) or to the #8404-ADP adapter.

Set the smoke/air control switch to SMOKE.

NOTE: The flow meter indicator ball will not move in the smoke mode.
Press the remote smoke/air start button.

NOTE: Make sure 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 ultra-
violet (UV) black light #8404-UVL and the yellow goggles 8404-20 to look for residual traces of dye that is 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: The EVAP System is divided into three zones. A leak from any of these zones can cause this DTC to
set. The lists below specify the possible leak points in that specific zone. For further assistance see the
Zone Identification Charts below.

•

ZONE 1

1 Fuel Cap

2 Recirculation Check Valve.

3 Vapor Recirculation Line.

4 Signal Vapor Line for FVM.

5 Flow Management Valve.

6 Fuel Tank to Canister Vapor Line.

7 Fuel Tank Vent (Check Valve).

8 Vapor Line to Canister.

9 Flow Control Orifice.

10 Control Valve.

11 Liquid Trap.

12 Fuel Tank.

13 Check valve.

14 Fuel Fill Tube to Tank connector.

15 Fuel Fill Tube

Damaged or disconnected EVAP system components.

•

ZONE 2

1 Filter.

2 ESM.

3 Canister Vent Line.

4 EVAP Canister.

5 Chassis Purge Valve.

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6 Fuel Tank to Canister Vapor Line connection.

7 EVAP Purge connection.

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ZONE 3

1 EVAP Purge Vacuum Line.

2 Connection to Chassis Line.

3 Connection to Canister.

4 Chassis Purge Line.

5 EVAP Purge Vacuum Line.

6 Connection to EVAP Purge Harness.

7 Chassis EVAP Purge Line connection to Engine Vacuum.

8 EVAP Purge Valve.

9 Service Port.

NOTE: Carefully inspect the vent side of the EVAP Canister. Due to
the filtering system in the canister the smoke may not be as thick.
Introducing smoke into the filtered side of the canister may assist
in locating the leak.

Select the appropriate response from the list below:

A leak was found in one or more of the EVAP System zones

Repair or replace the leaking component as necessary.

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

A leak was found at the gas cap or fuel filler tube

Go to 6

No leaks were found

Go to 7

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ENGINE ELECTRICAL DIAGNOSTICS - GPEC

LEAK AT GAS CAP

Remove the SMOKE supply tip (black hose) from the service port (if equipped) or from the #8404–ADP adapter.

Install gas cap adapter, Miller Tool #8382 (1/4 turn cap) or #6922 (screw cap) and #8399* (secondary seal depres-
sor) and repeat test 5.

Was a leak found at the gas cap adapter?

Yes

>> Replace the Fuel Filler tube assembly.

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

>> Replace the gas cap.

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

EVAP PURGE SOLENOID

NOTE: After disconnecting the EVAP Purge Solenoid vacuum connections, inspect the lines and solenoid
for any signs of contamination from the EVAP Canister. This may indicate a problem with the check valve.
Replace/repair as necessary.
Turn the ignition off.

Disconnect the vacuum hoses at the EVAP Purge Solenoid.

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

Connect the SMOKE supply tip (black hose) to the “CAN” port of the EVAP Purge Solenoid.

Set the smoke/air control switch to SMOKE.

NOTE: The flow meter indicator ball will not move with the EELD in the smoke mode.
Press the remote smoke/air start button on the EELD.

While holding the remote smoke/air start button, check to see if smoke is leaking through the EVAP Purge Solenoid
port.

NOTE: Smoke should not pass through the solenoid.

Is smoke leaking from the EVAP Purge Solenoid port?

Yes

>> Replace the EVAP Purge Solenoid.

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

>> Go to 8

EVAP SYSTEM MONITOR SWITCH

Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Evap System Mon-
itor Switch and the Powertrain Control Module (PCM).

Look for any chafed, pierced, pinched, or partially broken wires.

Look for broken, bent, pushed out or corroded terminals.

Refer to any Technical Service Bulletins that may apply.

Were any problems found?

Yes

>> Repair as necessary.

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

>> Replace the Evap System Monitor Switch in accordance with the Service Information.

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

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P0456-EVAP SYSTEM SMALL LEAK

For a complete wiring diagram Refer to Section 8W.

•

When Monitored:
With the ignition off, fuel level less than 88%, ambient temperature between 4° C and 43° C (39° F and 109°
F), and the fuel system in closed loop.

•

Set Condition:
As temperatures change, a vacuum is created in the fuel tank and EVAP system. With the EVAP system
sealed, the PCM monitors the ESM switch. If the ESM switch does not close within a calibrated time, an error
is detected by the PCM. One Trip Fault. Three good trips to turn off the MIL.

Possible Causes

EVAP SYSTEM LEAK

EVAP PURGE SOLENOID

EVAP SYSTEM MONITOR SWITCH

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 DTC(s) 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.
Ignition on, engine not running.

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)

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