Evaporative Emission System Leak Inspection
Evaporative Emission System Leak InspectionWARNING:
- To prevent personal injury and damage to equipment, read, understand, and follow all "WARNING"s, "CAUTION"s and operating procedure instructions.
- Use only nitrogen gas. If other gas is used instead, gasoline may ignite and explode.
- Using improper procedure to treat compressed gas may result in death or serious injury. For correct operation procedures and precautions, contact local compressed gas supplier.
- Wear eye protection that meets OSHA standards.
- Do not perform tests with running vehicle engine.
- Close nitrogen cylinder valve after completing test.
- If halogen or ultraviolet light is hot, do not touch the top part of light or lens, do not place it near flammable items and do not put it in storage until it cools down.
- Do not perform tests near spark or ignition source.
- Use only Ultra Trace UV TM Smoke Producing Fluid specified in the operation manual.
CAUTION:
- Do not use evaporative emission tester in a manner not specified by the manufacturer.
- Do not use smoke for any other systems than evaporative emission system in order to prevent performance degradation of the other systems.
- Connect power supply cord to battery and chassis ground correctly.
- Operate and store tester in upright position.
- Intermittently use the halogen light or optional ultraviolet light.
- Do not use light if it is damaged.
- Do not perform Evaporative Emission System Smoke Test Evaporative Emission System Smoke Testfor the same vehicle more than 5 times. If Evaporative Emission System Smoke Test has been performed more than 5 times, replace EVAP canister.
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:
- Use only nitrogen gas. If other gas is used instead, gasoline may ignite and explode.
- Using improper procedure to treat compressed gas may result in death or serious injury. For correct operation procedures and precautions, contact local compressed gas supplier.
CAUTION:
- DO NOT remove valve cover cap of nitrogen gas tank until nitrogen gas tank is securely attached to EVAP cart.
- Pressure regulator has been adjusted to indicate correct pressure. Therefore, DO NOT detach black vinyl cover from pressure regulator and regulate it by turning the valve. Doing so may cause malfunction of tester. When you need to adjust regulator, refer to "Output Pressure Calibration" described later.
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 m(3) (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.
NOTE: We recommend that you install tester to EVAP cart with assistance of another person.
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: To prevent personal injury and equipment damage, use only manufacturer approved 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.
1. Connect power cables (1) from tester to a fully charged 12 V-battery.
2. Attach nitrogen/smoke hose (2) to self-test port (3).
3. Set NITROGEN/SMOKE valve (4) on front control panel to NITROGEN position.
4. Press and release remote switch (5) to activate tester.
NOTE: Remote switch operates push-ON, push-OFF manner.
5. 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.
CAUTION: Adjust pressure regulator carefully. Turning regulator plunger too far clockwise will cause plunger to lock up, whereas turning regulator plunger too far counterclockwise will cause plunger and spring to fall out of regulator.
c. Use a flat-end 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: Use only nitrogen gas. If other gas is used instead, gasoline may ignite and explode.
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 the ignition mode to "ON" without depressing brake pedal (CVT model) or clutch pedal (M/T model).
WARNING: To prevent personal injury and equipment damage, tests with Evaporative Emission System Tester must be performed with engine stopped.
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.
13. Plug air port with rubber plug.
Evaporative emission system should now be sealed and ready to be tested.
CAUTION:
- The air port must be blocked securely.
- The reason for this is that the EVAP system in its design cannot be sealed completely even though the EVAP canister vent valve and the EVAP canister purge valve are both closed because the leak check module internally opens to atmosphere through the leak detection pump. For this reason, if the air port of the leak check module is not blocked completely, nitrogen gas will leak through it possibly resulting in a diagnostic error of EVAP leak.
- For detail of EVAP leak check system, refer to EVAP Leak Check System Description.
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.
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.