GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Express 🢒 DTC 🢒 DTC P0440

Description

The EVAP LARGE LEAK TEST applies vacuum to the evaporative emission (EVAP) system and monitors vacuum decay. The control module uses the input from the fuel tank pressure (FTP) sensor in order to determine the rate of vacuum decay. At an appropriate time, the control module turns the EVAP canister purge valve ON (open) and the EVAP canister vent valve ON (closed). This allows the engine to draw a vacuum on the system. At a calibrated time or vacuum level, the control module turns the purge valve OFF (closed), and tests the system vacuum. If the system is unable to achieve the calibrated vacuum control module, DTC P0440 will set.

Conditions for Running the DTC
    • DTC P0107, P0108, P0112, P0113, P0117, P0118, P0121, P0122, P0123, P0125, P0443, P0449, P0452, P0453, P1111, P1112, P1114, P1115, P1121 or P1122 are not set.
    • The system voltage is between 10-18 volts.
    • The startup engine coolant temperature (ECT) is between 4-30°C (39-86°F).
    • The startup intake air temperature (IAT) is between 4-30°C (39-86°F).
    • The start up ECT and IAT are within 9°C (16°F) of each other.
    • The fuel tank level is between 15-85 percent.
    • The barometric pressure (BARO) is more than 75 kPa.
    • The vehicle speed sensor (VSS) is less than 121 km/h (75 mph).

Conditions For Setting the DTC

The EVAP system is not able to achieve or maintain vacuum during the diagnostic test.

Action Taken When the DTC Sets
    • The control module illuminates the malfunction indicator lamp (MIL) when the diagnostic runs and fails.
    • The control module records the operating conditions at the time the diagnostic fails. The control module stores this information in the Freeze Frame/Failure Records.

Conditions for Clearing the MIL/DTC
    • The control module turns OFF the malfunction indicator lamp (MIL) after 3 consecutive ignition cycles that the diagnostic runs and does not fail.
    • A current DTC, Last Test Failed, clears when the diagnostic runs and passes.
    • A history DTC clears after 40 consecutive warm-up cycles, if no failures are reported by this or any other emission related diagnostic.
    • Clear the MIL and the DTC with a scan tool.

Diagnostic Aids
    •  Use the J 41413 EVAP Pressure/Purge Diagnostic Station in order to pressurize the EVAP system to aid in locating intermittent leaks.
         Move all EVAP components while testing with the J 41416 Ultrasonic Leak Detector.
    • A temporary blockage in the EVAP canister purge valve, purge pipe or EVAP canister could cause an intermittent condition. To repair a blockage in the EVAP system refer to Evaporative Emission System Cleaning .

Test Description

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

  1. This step verifies that a failure condition is active.

    2.

  2. This step is used to verify if a leak is present.

    3.

  3. This step verifies proper operation of the fuel tank pressure (FTP) sensor.

    4.

  4. This step tests the EVAP canister purge valve for a restriction or blockage.

    5.

  5. This step verifies that repairs are complete and that no other condition is present.

Step

Action

Values

Yes

No

Schematic Reference: Evaporative Emissions Hose Routing Diagram

1

Did you perform the Diagnostic System Check-Engine Controls?

--

Go to Step 2

Go to Diagnostic System Check - Engine Controls

2

Does the scan tool indicate DTC P0443 or DTC P0449 are also set?

--

Go to Diagnostic Trouble Code (DTC) List

Go to Step 3

3
  1. Inspect the EVAP system for the following conditions:
    2. • Loose, missing, or damaged service port schrader valve
    • Loose, incorrect, missing, or damaged fuel fill cap
    • A damaged EVAP canister purge valve
  2. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Inspect the EVAP system for the following conditions:
    4. • Disconnected, improperly routed, kinked, or damaged EVAP pipes and hoses
    • A damaged EVAP canister vent valve or EVAP canister

Did you find and correct the condition?

--

Go to Step 19

Go to Step 4

4

  1. With a scan tool, capture and record the Failure Records data and clear the DTCs.
  2. Perform the Service Bay Test. Refer to Service Bay Test .

Does the scan tool indicate that the Service Bay Test passed?

--

Go to Diagnostic Aids

Go to Step 5

5

Important: Always zero the EVAP pressure and vacuum (in H2O) gauges on the EVAP pressure diagnostic station before proceeding with diagnosis.

  1. Install the J 41415-40 Fuel Tank Cap Adapter.
  2. Connect the J 41413 Pressure/Purge Diagnostic Station and the vehicle fuel fill cap to the J 41415-40 .
  3. Turn ON the ignition, with the engine OFF.
  4. With the scan tool, seal the EVAP system.
  5. With the J 41413 , pressurize the system to the specified value.
  6. Rotate the J 41413 rotary switch to the OFF/HOLD position.

Did you obtain the specified value?

5 in H2O

Go to Step 6

Go to Step 9

6

Compare the J 41413 value to the scan tool fuel tank pressure (FTP) sensor value.

Does the J 41413 value measure near the scan tool value?

--

Go to Step 7

Go to Step 13

7
  1. With the J 41413 , pressurize the EVAP system to the specified value.
  2. Monitor the pressure gauge on J 41413 .
  3. With a scan tool, command the EVAP canister purge valve to 50 percent.

Does the EVAP system pressure decrease?

5 in H2O

Go to Step 8

Go to Step 10

8

Inspect the vacuum source to the EVAP purge valve for blockage, cuts, or disconnects. Repair as necessary.

Did you find and correct the condition?

--

Go to Step 19

Go to Diagnostic Aids

9
  1. With the J 41413 , continuously pressurize the EVAP system.

    2. Important: It may be necessary to partially lower the fuel tank to inspect components located in the upper portion of the tank.

  2. With the J 41416 Ultrasonic Leak Detector inspect for leaks in the following locations:
    3. • The EVAP system purge pipe
    • The EVAP vapor pipe--Refer to Fuel Tank Replacement .
    • The EVAP vent hose/pipe
    • The fuel fill pipe/hose and fuel fill cap--Refer to Filler Tube Replacement .
    • The EVAP canister--Refer to Evaporative Emission Canister Replacement .
    • The EVAP canister vent valve--Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement .
    • The EVAP canister purge valve--Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .
    • The fuel sender assembly and/or seal--Refer to Fuel Sender Assembly Replacement .
    • The fuel tank pressure sensor (FTP) seal--Refer to Fuel Tank Pressure Sensor Replacement .
    • The fill limiter vent valve, pressure relief valve, rollover valves, permanent EVAP pipes and/or fuel tank--Refer to Fuel Tank Replacement .

Did you locate and repair a leak?

--

Go to Step 19

Go to Diagnostic Aids

10

  1. Monitor the pressure gauge on J 41413 .
  2. Disconnect the EVAP purge pipe from the EVAP canister purge valve.

Does the EVAP system pressure decrease?

--

Go to Step 16

Go to Step 11

11
  1. Monitor the pressure gauge on J 41413 .
  2. Disconnect the purge pipe at the EVAP canister.

Does the EVAP system pressure decrease?

--

Go to Step 17

Go to Step 12

12
  1. Monitor the pressure gauge on J 41413 .
  2. Disconnect the EVAP vapor line from the EVAP canister.

Does the EVAP system pressure decrease?

--

Go to Step 18

Go to Step 15

13

Monitor the FTP sensor voltage with a scan tool.

Is the FTP sensor voltage more than the specified value?

4.3 V

Go to DTC P0453

Go to Step 14

14

Replace the fuel tank pressure (FTP) sensor. Refer to Fuel Tank Pressure Sensor Replacement .

Did you complete the replacement?

--

Go to Step 19

--

15

Repair for a pinched or obstructed EVAP vapor pipe between the front and rear tanks.

Did you complete the repair?

--

Go to Step 19

--

16

Replace the EVAP canister purge valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .

Did you complete the replacement?

--

Go to Step 19

--

17

Repair the restriction in the EVAP purge pipe. Refer to Evaporative Emission System Cleaning .

Did you complete the repair?

--

Go to Step 19

--

18

Replace the EVAP canister. Refer to Evaporative Emission Canister Replacement

Did you complete the replacement?

--

Go to Step 19

--

19

Perform the Service Bay Test. Refer to Service Bay Test .

Does the scan tool indicate that the Service Bay Test passed?

--

Go to Step 20

Go to Step 2

20

With a scan tool, observe the stored information, Capture Info.

Does the scan tool display any DTCs that you have not diagnosed?

--

Go to Diagnostic Trouble Code (DTC) List

System OK