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Old 09-05-2010, 02:57 PM
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DaveDees DaveDees is offline
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Join Date: Aug 2008
Location: Chesapeake, VA
Age: 62
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Vehicle: 2010 Jeep Patriot
Trim Level: Latitude
Color: Brilliant Black
Engine: 2003-2008 345ci (5.7L) Hemi V8 345hp 375lb/ft
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From the manual, again:

P0442-EVAP PURGE SYSTEM MEDIUM LEAK

Diagnostic Test

1. VEHICLE HISTORY AND SERVICE BULLETIN INVESTIGATION
Ignition on, engine not running.
With a scan tool, read DTCs and record the related Freeze Frame data if any DTCs) are present.
Whether or not any DTCs are present you will want to check the following items which may assist in repairing the customerís complaint successfully.
Check the vehicles repair history.
If the vehicle has a repair history that pertains to the customerís current complaint, review the repair.
Inspect the vehicle for any aftermarket accessories that may have been installed incorrectly.
Check for any service bulletin(s) related to the customerís complaint or DTCs.
If a service bulletin applies, follow the instructions per the service bulletin.

Choose the following scenario that best applies.
The service bulletin repaired the customerís complaint.
Testing complete.
A DTC is present, no service bulletins apply, or the service bulletin didnít repair the customerís complaint.
Go To 2.
9 - 456 ENGINE - ELECTRICAL DIAGNOSTICS DR

2. ACTIVE DTC
Ignition on, engine not running.
With a scan tool, read DTCs.

Is the DTC active at this time?
Yes >> Go To 3.
No >> Refer to the INTERMITTENT CONDITION Diagnostic Procedure.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

3. LOOSE OR MISSING FUEL FILL CAP
Inspect the fuel fill cap.
Inspect the cap for any abnormal defects.
Was the cap off, missing, or broken?
Yes >> Properly install the fuel fill cap and proceed to step.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
No >> Go To 4.

4. NVLD SERVICE TEST
With the scan tool perform the NVLD Service Test.

Does the NVLD Service Test pass?
Yes >> Test complete.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
No >> Go To 5

5. VERIFY EVAPORATIVE EMISSION LEAK
To continue testing you will need Miller Tool #8404A Evaporative Emission Leak Detector (EELD).

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 between 20% and 80% of fuel tank capacity to properly test the Evap system.

Connect the red power lead of the EELD to the battery positive terminal and the black ground lead to battery negative terminal.
Block the vent hose of the canister if using the service port.
Connect shop air to the EELD.
Set the smoke/air control switch to AIR.
Insert the testerís AIR supply tip (clear hose) into the appropriate calibration orifice on the testerís control panel (based on DTC leak size).
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 to the size leak indicated by the DTC set in the PCM.
Install the service port adapter #8404-14 on the vehicleís service port and block the vent hose of the EVAP Canister (if equipped) or install the #8404-ADP service adaptor 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.
NOTE: Larger volume fuel tanks, lower fuel levels or if the vehicle is equipped with a Flow Management Valve may indicate high flow and will require 4 to 5 minutes to fill.
Compare the flow meter indicator ball reading to the red flag.
DR ENGINE - ELECTRICAL DIAGNOSTICS 9 - 457
ABOVE the red flag indicates a leak present.
BELOW the red flag indicates a sealed system.

Is the indicator ball above the red flag?
Yes >> Go To 6.
No >> Refer to the INTERMITTENT CONDITION Diagnostic Procedure.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

6. 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 also aid diagnosis.
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 ultraviolet (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 theZone 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 connection.
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.
9 - 458 ENGINE - ELECTRICAL DIAGNOSTICS DR

ZONE 2
1 Filter.
2 NVLD.
3 Canister Vent Line.
4 Evap Canister.
5 Chassis Purge Valve.
6 Fuel Tank to Canister Vapor Line connection.
7 Evap Purge connection.

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.
Was a leak found?
Yes >> Go To 7.
No >> Go To 8.

7. LEAK AT GAS CAP
Remove the SMOKE supply tip (black hose) from the service port (if equipped) or to the #8404ĖADP adapter.
Install gas cap adapter, Miller Tool #8382 (1/4 turn cap) or #6922 (screw cap) and #8399* (secondary seal depressor) and repeat test 5.

Was a leak found at the gas cap adapter?
Yes >> Replace the Fuel Filler tube assembly.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
No >> Replace the gas cap.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

8. EVAP PURGE SOLENOID OPERATION
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 inoperative check valve. Replace/repair as necessary.
Turn the ignition off.
Disconnect the vacuum hoses at the Evap Purge Solenoid.
Press the remote smoke/air start button on the EELD.
While holding the remote smoke/air start button, check to see if smoke is exiting the purge valve. This indicates that there is a leak internal to the purge valve.

NOTE: Below is an optional method of checking the purge valve for leaks if the EELD is unavailable.
Turn the ignition off.
Disconnect the vacuum hoses at the Evap Purge Solenoid.
Using a hand vacuum pump, apply 10 in HG to the ďCANĒ of the Evap Purge Solenoid.

NOTE: Monitor the vacuum gauge for at least 15 seconds.

Is smoke visible from the EVAP Purge Solenoid if using the EELD, or not hold a vacuum?
Yes >> Go To 9.
No >> Replace the Evap Purge Solenoid.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)

9. NVLD SWITCH OPERATION
Reconnect all vacuum hoses.
Start the engine.
Allow the engine to idle.
Using the scan tool, perform the NVLD FORCED MONITOR TEST.
Monitor the NVLD Switch.

NOTE: As the test runs, the NVLD Switch should go from an OPEN state to CLOSED. After the vacuum is released form the EVAP system the Switch state will return to OPEN.

Did the NVLD Switch operate as described above?
Yes >> Refer to the INTERMITTENT CONDITION Diagnostic Procedure. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING)
No >> Replace the NVLD Assembly.
Perform the POWERTRAIN VERIFICATION TEST. (Refer to 9 - ENGINE - STANDARD PROCEDURE)
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