P0441 on 2011-2018 Chrysler 300: EVAP Incorrect Purge Flow Causes and Fixes

What's Unique About the 2011-2018 Chrysler 300

For the 2011-2018 Chrysler 300, a unique aspect of troubleshooting P0441 is the potential for a software-related fix. Chrysler has issued multiple Technical Service Bulletins (TSBs) indicating that an update to the Powertrain Control Module (PCM) software can resolve this code. This is an unusual and important first check before replacing hardware, as a simple reflash at a dealership could be the entire solution. 🎬 Watch: Diagnostic walkthrough for P0441 on a Chrysler 300 The TSBs suggest the original software logic for monitoring the EVAP system was overly sensitive. [Bulletin #18-067-15, Bulletin #18-067-15 REV A]

Diagnostic Flowchart

Tap your situation to follow the diagnostic path that matches what you're seeing on this vehicle.

Symptoms You May Notice

• Check Engine Light is on
• Remote Start is disabled or shuts off after a few seconds.
• Slightly rough idle, particularly after startup
• Difficulty starting the engine, especially right after refueling (classic sign of a stuck-open purge valve)
• A faint smell of fuel
• Gas pump clicks off repeatedly when trying to refuel

Most Likely Causes

1. Faulty EVAP Purge Valve/Solenoid 🔴 High Probability This is a very common failure point across many Chrysler/Dodge/Jeep vehicles. The solenoid gets stuck open or closed, directly causing the 'incorrect purge flow' condition detected by the PCM.
   How to confirm: With the engine off, disconnect the hose from the purge valve leading to the intake manifold and attempt to blow through it; it should be closed and not allow air to pass. You can also use a scan tool to command the valve open and closed while listening for an audible click.
   Typical fix: Replace the purge valve. It is located on the engine and is a common DIY repair.
   Est. part cost: $25-$70
2. Outdated PCM Software 🟡 Medium Probability Chrysler has released specific TSBs (#18-067-15, #18-067-15 REV A, #18-094-16) that list P0441 as a code that can be resolved with a PCM software update. The logic for monitoring the EVAP system may be too sensitive in older software versions, falsely triggering the code.
   How to confirm: A Chrysler dealership or a well-equipped independent shop can check for available software updates for your vehicle's VIN. This is the only way to confirm.
   Typical fix: Reflash the Powertrain Control Module (PCM) with the latest software.
   Est. part cost: $150 - $300 at a dealership.
3. Cracked, Disconnected, or Clogged EVAP Hoses 🟡 Medium Probability The rubber and plastic hoses in the EVAP system can become brittle and crack over time due to engine heat and age, causing vacuum leaks or blockages that disrupt purge flow.
   How to confirm: Visually inspect all EVAP lines between the engine bay, charcoal canister (near the fuel tank), and the purge valve for any visible cracks, loose connections, or blockages. A smoke test is the most effective way to find small, hard-to-see leaks.
   Typical fix: Replace the damaged section of hose.
   Est. part cost: $10-$50
4. Faulty Evaporative System Integrity Monitor (ESIM) Switch ⚪ Low Probability The ESIM is Chrysler's specific leak detection device. It can fail internally and incorrectly report a flow problem to the PCM. While less common for P0441, it's a known issue in the Chrysler EVAP system.
   How to confirm: A technician can monitor the ESIM switch status with a professional scan tool during an EVAP system test to see if it changes state correctly as vacuum is applied.
   Typical fix: Replace the ESIM switch, which is mounted on the charcoal canister near the fuel tank.
   Est. part cost: $40-$80

Rare But Worth Checking

• Faulty or Loose Gas Cap: While more commonly associated with leak codes like P0456 or P0457, a very poor seal can sometimes contribute to incorrect flow readings. On 2015+ models with a capless system, inspect the filler door seal for debris or damage.
• Clogged or Failed Charcoal Canister: If the canister becomes saturated with fuel (often from habitually overfilling the gas tank) or the internal filter becomes clogged with charcoal granules, it can restrict vapor flow and trigger P0441.
• Faulty Fuel Tank Pressure Sensor: An inaccurate fuel tank pressure sensor can cause the PCM to misinterpret the pressure changes during a purge cycle, leading it to believe the flow is incorrect. This may sometimes be accompanied by other pressure-related codes.

Diagnosis Steps

1. Read the code with an OBD-II scanner and document any other codes present. Note if P0455/P0456 are also present.
2. Check with a Chrysler dealer if any PCM software updates are available for your VIN, referencing TSBs #18-067-15 and #18-094-16.
3. Inspect the gas cap for a tight seal and any signs of damage. For 2015+ models, check the capless fuel filler neck for debris or a damaged seal.
4. Visually inspect the EVAP purge valve and its connecting hoses in the engine bay for obvious cracks or disconnections. The purge valve is mounted on the engine.
5. Test the purge valve. With the engine off, it should be closed. Disconnect it and try to blow through it. If air passes, it's faulty. A hand vacuum pump can also be used to see if it holds vacuum when closed.
6. With the engine running, disconnect the electrical connector to the purge valve and feel the port for suction. If you feel vacuum, the valve is stuck open and needs replacement.
7. If the valve and hoses appear fine, inspect the lines running to the rear of the vehicle and the charcoal canister for damage.
8. If no visible issues are found, a smoke test is the most reliable method to find a hard-to-see leak in the EVAP system.
9. If no leaks are found, the ESIM switch on the charcoal canister should be tested for proper operation using a capable scan tool.

Parts You'll Likely Need

• Vapor Canister Purge Valve / Solenoid (OEM #04891731AA) — This is the most common mechanical part to fail for a P0441 code. It's a solenoid that gets stuck, directly causing the incorrect flow detected by the computer. This part number fits both 3.6L and 5.7L engines for this vehicle range.
  Trusted brands: Mopar, Dorman, Bosch, Standard Motor Products (SMP)
  OEM price range: $40-$70
  Aftermarket price range: $25-$50
• Evaporative System Integrity Monitor (ESIM) Switch (OEM #04861963AD) — A less common but known failure point on Chrysler vehicles. This module is responsible for leak testing and can fail internally, causing false flow codes. This part number supersedes older versions ending in AA, AB, and AC.
  Trusted brands: Mopar, Dorman
  OEM price range: $50-$90
  Aftermarket price range: $40-$80

Related Codes That Often Appear With This One

• P0456 — EVAP System Small Leak. A failing purge valve or cracked hose can cause both a small leak and an incorrect flow reading. These codes are often seen together in Chrysler TSBs and owner forums. [Bulletin #18-094-16, Bulletin #1807517, 10]
• P0455 — EVAP System Large Leak. Similar to P0456, a component failure can be interpreted as both a large leak and a flow performance issue. [Bulletin #1807517]
• P2610 — PCM Internal Engine Off Timer Performance. This code appears alongside P0441 in TSBs, suggesting a potential PCM software issue that affects multiple systems. [Bulletin #1807517, Bulletin #18-094-16]

Technical Service Bulletins (TSBs) & Recalls

• Bulletin #1807517: Notes P0441 appearing with other EVAP and engine sensor codes.
• Bulletin #18-094-16: Lists P0441 as a potential DTC that can be set along with misfire and other EVAP codes.
• Bulletin #18-067-15 & #18-067-15 REV A: Specifically state that a software update is available to address P0441 - Evap Purge System Performance on 2011-2012 models with the 5.7L engine.

Platform-Specific Known Issues

• A PCM software update may be required to fix this code, as documented in TSBs #18-067-15, #18-067-15 REV A, and #18-094-16. This should be investigated before replacing parts.
• The code often appears with other EVAP codes like P0455 and P0456, as noted in TSBs #1807517 and #18-094-16 and confirmed by owner experiences.
• The presence of a Check Engine Light for P0441 will almost certainly disable the remote start functionality. The engine may start and then immediately shut down.