Evaporative Emission System Leak Inspection
Evaporative Emission System Leak Inspection
WARNING:
Failure to take proper precautions when performing the leak inspection of the EVAP system may result in death, serious injury or fire.
- Be sure to read, understand and follow all instructions in the WARNINGs, CAUTIONs and NOTICEs as well as in the operating procedures.
- Be sure to use only nitrogen gas for this inspection. If any other gas is used, the gasoline in the fuel system may ignite and explode.
- Handle compressed nitrogen correctly. Contact your local supplier of compressed gases for the procedures to follow and precautions to observe to correctly handle compressed nitrogen.
- Wear eye protection that meets OSHA standards.
- Perform the tests only with the engine stopped.
- Close the nitrogen cylinder valve after completing the test.
- The halogen lamp is very hot when it is lit. Do not touch the top part or lens of a hot halogen lamp or place it near flammable items. Wait until the halogen lamp cools down before storing it.
- Do not perform the test near a spark or heat source. Leaking fuel or gasoline vapor may catch fire.
- Use only the Ultra Trace UVTM smoke producing fluid specified by the tester manufacturer.
NOTE:
Failure to take proper precautions may result in damage to or operational problems with the testing equipment and vehicle systems.
- Use the tester only in the manner specified by the manufacturer.
- Use the smoke-producing fluid only for testing the evaporative emission system. This fluid will degrade the performance of vehicle systems other than the evaporative emission system.
- Connect the tester correctly to the battery and the chassis ground connection.
- Operate and store the tester only in its upright positions.
- Use the halogen light or optional UVTM light intermittently to prevent overheating.
- If the smoke leak test is performed more than 5 times for the same vehicle, the performance of the EVAP canister will deteriorate. Replace the EVAP canister if the evaporative emission control system has undergone the leak test 5 times.
NOTE:
Change Ultra Trace UV TM Smoke Producing Fluid in tester once a year.
Evaporative Emission System Tester Components
Locations
Evaporative Emission System Tester Setup
Assembly
WARNING:
Failure to use the specified gas and to take proper precautions may result in death, serious injury or fire.
- Be sure to use only nitrogen gas for this inspection. If any other gas is used, the gasoline in the fuel system may ignite and explode.
- Handle compressed nitrogen correctly. Contact your local supplier of compressed gases for the procedures to follow and precautions to observe to correctly handle compressed nitrogen.
NOTE:
Failure to take proper precautions when using compressed gas can cause damage to the cylinder valve, pressure regulator, or tester.
- Do not remove the valve cover cap until the cylinder is securely attached to the EVAP cart. If the valve cover cap is removed and the tank falls down, the valve may be damaged.
- Do not try to detach the black vinyl cover from the pressure regulator and turn the valve inside. If the original setting of the pressure regulator on the tester is disturbed, the tester will not operate correctly unless it is recalibrated. If it is absolutely necessary to adjust the pressure regulator, refer to Output pressure calibration.
NOTE:
- Nitrogen gas tank is not attached to this tester. Obtain a nitrogen gas tank from your local compressed gas supplier. We recommend a tank with 3.54 m3 (125 cubic feet) capacity.
- If nitrogen gas tank pressure is lower than 690 kPa (7.0 kgf/cm2, 100 psi, 6.9 bar), it is required to ask your local compressed gas supplier to replenish nitrogen gas.
1) Unpack tester from its shipping carton.
2) Bring tester (1) up through EVAP cart's handlebar, and place it on two tabs (2) located on bracket on EVAP cart.
NOTE:
Rotate tester slightly to one side so that the remote cable clears handlebar.
3) Install handlebar brackets (1) on right and left sides and remote switch cord wrap (2) to tester (3) using hexagon head screws (4).
4) Attach nitrogen tank (3) securely to EVAP cart (1) using tank fixing bands (2) that are provided on EVAP cart (1).
5) Remove valve cover cap from nitrogen tank.
6) Install pressure regulator (1) to nitrogen tank.
7) Tighten nut (2) with wrench.
NOTE:
No sealant is required.
8) Install 90° adapter (1) onto nitrogen inlet (2) on left side of tester.
9) Connect regulator-to-tester hose (1) to pressure regulator (2) and 90° adapter (3).
NOTE:
Connections should be finger-tightened.
10) Fill tester with two bottles of smoke producing fluid according to the following procedure.
WARNING:
There is a risk of personal injury and damage to the tester if smoke-producing fluid not approved by the manufacturer is used in the tester.
Use only the manufacturer-specified smoke-producing fluid.
a) Remove refill plug (1) located on the right side of tester.
b) Cut end of plastic tip on top of each smoke producing fluid bottle.
c) With tester in an upright position, pour two full bottles of smoke producing fluid into refill port.
Filling amount of smoke producing fluid
0.95 liters (32 / 33 US/Imp. oz)
d) Secure plug back into refill port.
e) Record your name and date of fluid change.
11) Adjust pressure regulator according to the following procedure.
Output pressure calibration
NOTE:
- Perform following calibration when assembling evaporative emission system tester or replacing pressure regulator.
- Once you make this adjustment, you should not adjust tester's regulator again, unless you change pressure regulator.
12) Connect power cables (1) from tester to a fully charged 12 V-battery.
13) Attach nitrogen/smoke hose (2) to self-test port (3).
14) Set NITROGEN/SMOKE valve (4) on front control panel to NITROGEN position.
15) Press and release remote switch (5) to activate tester.
NOTE:
Remote switch operates push-ON, push-OFF manner.
16) Check whether pressure/vacuum gauge of evaporative emission system tester indicates 13 in. H2O. If it does not, perform the following adjustment.
a) Remove plastic cap (1) from regulator located on bottom of tester.
b) Press and release remote switch.
NOTE:
Careless adjustment will damage the pressure regulator.
Do not turn the regulator plunger too far clockwise since this will cause the plunger to lock up. Do not turn the plunger too far counterclockwise since this will cause the plunger and spring to fall out of the regulator.
c) Use a flat-bladed screwdriver to adjust regulator plunger until pressure/vacuum gauge reads 13 in. H2O pressure.
d) Disconnect and reconnect nitrogen/smoke hose from self-test port.
e) Press and release remote switch.
f) Verify pressure is at 13 in. H2O. If not, repeat Steps b) to f), if necessary.
g) Press and release remote switch to deactivate tester.
h) Replace plastic cap on regulator, and then disconnect nitrogen/smoke hose from self-test port.
Pressurization Test
WARNING:
If any gas other than nitrogen gas is used, the gasoline in the fuel system may ignite and explode.
Be sure to use only nitrogen gas for this inspection.
NOTE:
A large difference between vehicle temperature and shop temperature will seriously affect accuracy of test. Always allow enough time for vehicle's temperature to adjust to shop temperature.
If pressure regulator is replaced, perform calibration referring to "Output Pressure Calibration" described earlier.
1) Connect red battery clip from tester to positive battery terminal, and then connect black battery clip from tester to chassis ground.
NOTE:
Vehicle battery must be fully charged for optimum tester performance.
2) Turn NITROGEN/SMOKE valve (1) on front control panel to NITROGEN position.
NOTE:
- Determine which test orifice is to be used by 0.5 mm (0.020 in).
- Unwind nitrogen/smoke hose completely from bracket to optimize tester's performance.
3) Connect nitrogen/smoke hose (2) to correct test orifice (3) on bottom-front of tester.
4) Press and release remote switch (4) to activate tester.
5) Position red flag (1) on flowmeter in alignment with the floating indicator (2). Then press and release remote switch to deactivate tester.
6) Disconnect nitrogen/smoke hose from test orifice.
7) Connect nitrogen/smoke hose to fuel cap adapter (1).
8) Remove fuel cap, and then install fuel cap adapter onto fuel filler neck.
9) Install fuel cap (2) onto fuel cap adapter.
NOTE:
Connections must be tight and leak-free.
10) Push engine switch to change ignition mode of keyless push start system to "ON" without depressing brake pedal (CVT model) or clutch pedal (M/T model).
WARNING:
There is a risk of personal injury and damage to the tester if the evaporative emission system tester is used while the engine is running.
Make sure the engine is off before performing the test.
11) Close the EVAP canister vent valve in EVAP leak check module referring to step 6) of Evaporative Emission System Smoke Test Evaporative Emission System Smoke Test.
12) Disconnect suction pipe from air port (1) of EVAP leak check module. Service and Repair
13) Plug air port with rubber plug.
Evaporative emission system should now be sealed and ready to be tested.
NOTE:
Be sure to block the ventilation nozzle of the EVAP leak check module securely when performing the test. If the ventilation nozzle of the EVAP leak check module is not blocked securely, the module is open to the atmosphere through the leak detection pump even with the EVAP canister vent valve and the EVAP canister purge valve both closed. Nitrogen gas will then leak through the nozzle, giving a false indication of leakage.
14) Press and release remote switch to charge system with nitrogen gas. Watch flowmeter's indicator until it stabilizes.
NOTE:
- Remote switch operates push-ON, push-OFF manner.
- Large volume fuel tanks or tanks with lower fuel levels may require several minutes to be filled with nitrogen.
15) Compare floating indicator position to the red flag and make judgement as follows.
a) If floating indicator position is above red flag, result is UNACCEPTABLE. Locate and repair a leak. Evaporative Emission System Smoke Test
b) If floating indicator position is below red flag, result is ACCEPTABLE. Test is completed.
16) Press and release remote switch to deactivate tester.
17) Charge battery if necessary.