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HOMESERVICE MANUALSCHRYSLER2004PT CRUISER TOURING, 2.4 B, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 19 (ENGINE CONTROLS - SELF-DIAGNOSTICS)DIAGNOSTIC TESTSDTC P0440: GENERAL EVAP SYSTEM FAILURETESTING
2004 Chrysler PT Cruiser Touring, 2.4 B, Automatic

DTC P0440: General EVAP System Failure: Testing

2004 Chrysler PT Cruiser Touring, 2.4 B, AutomaticSECTION Testing
WARNING: This page is about a different car, the 2004 Chrysler Intrepid, 2003 Dodge Intrepid, 2003 Chrysler Intrepid, 2003 Chrysler Concorde, and 2003 Chrysler 300M. However, it is still accessible from the selected car via links, so may be relevant.
  1. If any of the following DTCs are set (DTC P0443, DTC P0452, DTC P0453, DTC P0498 or DTC P0499) diagnose them first before continuing with P0440, see DIAGNOSTIC TROUBLE CODE DEFINITIONS . Ignition on, engine not running. With the DRBIII® scan tool, read DTCs and record the related freeze frame data. Is the Good Trip Counter displayed and equal to zero? If yes, go to next step. If no, see INTERMITTENT CONDITION  under SELF-DIAGNOSTIC SYSTEM.
  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 conditions found? If yes, repair as necessary. If no, go to next step.
  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? If yes, repair or replace the vacuum supply, hose/tube as necessary. If no, go to next step.
  4. Disconnect the vacuum supply hoses form the EVAP purge solenoid. Using a hand vacuum pump, apply 10 in. Hg to the "CAN" side of the EVAP purge solenoid. Ignition on, engine not running. Observe the vacuum gauge. With the DRBIII® scan tool, actuate the EVAP purge solenoid. Does the vacuum drop when the solenoid is actuated? If yes, go to next step. If no, replace the EVAP purge solenoid.
  5. The fuel level must be below 85 percent, or the Onboard Refueling Vapor Recovery (ORVR) system control valve will seal the tank. Turn the ignition off. Install the Miller Gas Cap Adapter (8382). 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 Miller Manometer (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® scan tool. Do not exceed 2 in. Hg while performing this step. 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? If yes, see INTERMITTENT CONDITION  under SELF-DIAGNOSTIC SYSTEM. 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.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.