Evaporative Emission (EVAP) System - DTC P0440


Here is some information I gathered about what could cause a DTC P0440 to occur.  This has to do with the Evaporative Emission (EVAP) System of the van.  The basic summary is the ability to draw and hold a vacuum so that fuel system vapors do not escape into the atmosphere is tested.

The Leak Test:
- The test is based on applying a vacuum to the system and monitoring the vacuum over time.
- The Power train Control Module (PCM or "computer") monitors the vacuum level through a Fuel Tank Sensor.
- After some time, the EVAP canister purge valve/solenoid & EVAP vent valve/solenoid are turned ON, allowing the engine vacuum to draw a small vacuum on the entire evaporative emission system.
- If a sufficient vacuum level cannot be achieved, or decreases too fast, a "large leak" or faulty purge valve/solenoid is detected and could set the P0440 code.

This can be caused by any of the following conditions:
- Leaking fuel tank or fuel filler neck.
- Leaking fuel sender assembly O-ring.
- Disconnected or faulty fuel tank pressure sensor.
- Missing, not completely installed or faulty fuel fill cap.
- Disconnected, damaged, pinched, or blocked purge line.
- Disconnected or damaged EVAP vent hose.
- Disconnected, damaged, pinched, or blocked fuel tank vapor line.
- Disconnected or faulty canister purge valve/solenoid.
- Disconnected or malfunctioning vent valve/solenoid.
- Open ignition feed circuit to the vent or purge valve/solenoid.
- Damaged EVAP canister.

Conditions for the test to run (by the control system):
- Certain DTCs are NOT set (from TP sensor, IAT sensor, or MAP sensors) 
- System voltage is between 10 & 16 volts.
- Fuel tank fuel level is between 15% & 85%.
- The barometric Pressure (BARO) is more than 75 kPa.
- The Intake Air Temperature (IAT) is between 40°F and 86°F.
- The Engine Coolant Temperature (ECT) is between 40°F & 86°F.
- The startup IAT & ECT are within 16°F of each other.

Clearing the code or turning OFF the Malfunction Indicator Lamp (MIL):
- The code will clear if the fill cap is tightened or reinstalled.
- This DTC can be cleared by using the scan tool Clear Info function or by disconnecting the PCM battery feed.
- The PCM will turn the MIL OFF when the diagnostic has been run & the fault condition is no longer present.
- A "history" DTC P0440 will clear after 40 consecutive warm-up cycles have occurred without a fault.

Notes:
- The control module will illuminate the Malfunction Indicator Lamp (MIL) during the 2nd consecutive trip in which the diagnostic is run and fails.
- The system will store conditions present when the DTC set as Freeze Frame/Failure Records data.

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