P0455
System/Wiring Diagram:
��OSystem/Wiring Diagram:
CIRCUIT DESCRIPTION
WITHOUT ON-BOARD REFUELING VAPOR RECOVERY SYSTEM
The evaporative emission control system used in this vehicle consists of those parts as shown in figure. When the pressure of the vapor generated in the fuel tank increases higher than specified value, it pushes open the tank pressure control valve and enters EVAP canister.
However, under the conditions that the ignition switch is ON, the fuel level is lower than the specified level, possibility of the fuel liquid flowing into the vapor line is little, tank pressure control solenoid valve is turned ON by ECM (PCM) and vacuum is as applied to the diaphragm of tank pressure control valve while the engine is running.
Thus, the vapor passage of tank pressure control valve opens to allow continuity between the fuel tank and EVAP canister. As a result, under above conditions, the vapor in the fuel tank flows into EVAP canister without being stopped by tank pressure control valve.
The EVAP canister purge valve is controlled by ECM (PCM) according to signals from various sensors.When none of the following conditions exists, ECM (PCM) controls ON/OFF (open/close) switching of the purge valve at a constant rate (10 times per second) and its opening (amount of purge air) by increasing and decreasing its ON time.
- When throttle valve is at closed position.
- When engine coolant temp. is low.
- When engine speed is low and engine load is low.
- When vehicle is stopped.
- For specified time after engine start.
The higher the engine speed rises and the more fuel mixture is drawn in, the larger amount of air is purged. When the purge valve opens, fuel vapor in the canister is sucked into intake manifold.
In this state, the EVAP canister is purged or cleaned by air drawn through the EVAP canister air valve. Also, ECM (PCM) seals the EVAP system by turning ON (closing) the EVAP canister air valve and checks the EVAP gas leakage from the EVAP system at this time by checking variation in the output voltage of the tank pressure sensor.
WITH ON-BOARD REFUELING VAPOR RECOVERY SYSTEM
The component parts of this system are as shown in the figure. Its role is to prevent the fuel vapor from emitting into the air.
Operation
1. The vapor produced in the fuel tank is stored in the EVAP canister.
The vapor in the tank flows to the EVAP canister and is stored there. When the fuel tank becomes full, the float in the vapor control valve works to close the vapor passage, rejecting further refueling.
When the pressure in the fuel tank rises to the specified level, the pressure valve in the tank pressure control valve opens and the vapor flows into the EVAP canister and is stored there.
2. When the EVAP canister purge valve opens, the fuel vapor stored in the EVAP canister is drawn into the intake manifold together with the air coming in through the suction filter and burned.
The EVAP canister purge valve is controlled as follows by ECM according to signals from various sensors. When the engine is normal operating temperature, throttle valve opens wider than closed throttle position and the A/F is being fed back, ECM controls ON/OFF (open/close) switching of EVAP canister purge valve at a constant rate of 10 time/sec. and the length of this ON time depending on the following factors so as to prevent the A/F from being changed suddenly.
- Engine speed
- Engine load
- Concentration of fuel vapor in purge line (fuel vapor concentration is calculated based on short term fuel trim and vapor purge rate.)
The EVAP canister air valve and the fuel tank pressure sensor among the component parts are installed so that ECM diagnoses leakage of the fuel vapor from the evaporative emission control system. The EVAP canister air valve is usually open but it is closed by ECM when checking such leakage.
Step 1 - 3:
DTC CONFIRMATION PROCEDURE
WARNING:
- When performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident.
- Road test should be carried out with 2 persons, a driver and a tester, on a level road.
NOTE: Check to make sure that following conditions are satisfied when using this "DTC CONFIRMATION PROCEDURE".
- Intake air temp.: -8 °C (18 °F) or higher
- Engine coolant temp.: -8 - 110 °C (18 - 230 °F)
- Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)
- Indication of fuel level meter in combination meter: Lower than 3/4
1. Connect scan tool with ignition switch OFF.
2. Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and start engine.
3. Increase vehicle speed to 55 km/h (35 mph) or more.
4. Keep driving above vehicle speed for about 20 min. (Change of vehicle speed is permitted in this step).
5. Keep driving 50 - 60 km/h (30 - 40 mph) for about 3 min (Throttle valve opening is kept constant in this step).
6. Stop vehicle and check if DTC and pending DTC exists by using scan tool. If not, check if evaporative system monitoring test has completed by using scan tool. If not in both of above checks (i.e., no pending DTC and evaporative system monitoring test not completed) check vehicle conditions (environmental) and repeat Step 3) through 6).
Step 1 - 11:
Step 12 - 16:
TROUBLESHOOTING
WARNING: This work must be performed in a well ventilated area and away from any open flames such as gas hot water.
EVAP CANISTER PURGE SYSTEM CHECK
1. Warm up engine to normal operating temperature.
2. Hoist vehicle so that all wheels rotate freely.
3. Set M/T in "Neutral" or A/T in "P" position and parking brake.
4. Disconnect purge hose (1) from EVAP canister.
5. Place finger against the end of disconnected hose (1) and check that vacuum is not felt there when engine is running at idle speed.
6. Release parking brake lever, set transfer in "2H" and M/T in "1st" or A/T in "L".
WARNING: Make sure that transfer is set to "2H" range position for this check. If it is set to "4H" or "4L" position, front and rear wheels turn at high speed and a very dangerous situation may occur.
7. Also check that vacuum is felt when engine speed is increased to higher than about 1,500 r/min. and keep it for 3 min. or more. If check result is not described in steps 5) and 7), check EVAP canister purge valve, wire harness and vacuum passage.
VACUUM PASSAGE INSPECTION
Start engine and run it at idle speed. With finger placed against vacuum nozzle (1), check that vacuum is applied.
If it is not applied, clean vacuum passage by blowing compressed air.
VACUUM HOSE INSPECTION
Check hoses for connection, leakage, clog and deterioration. Replace as necessary.
EVAP CANISTER PURGE VALVE AND ITS CIRCUIT CHECK
1. When using SUZUKI scan tool:
a. Connect SUZUKI scan tool to DLC (1) with ignition switch OFF and disconnect vacuum hoses from each pipe.
b. Turn ignition switch ON, clear DTC and select "MISC TEST" mode on SUZUKI scan tool.
2. When not using SUZUKI scan tool:
a. Disconnect vacuum hoses from each pipe.
b. Turn ignition switch ON.
Using service wire, ground C51-2-17 terminal of ECM (PCM) connector (valve ON) and unground it (valve OFF).
3. Check purge valve for operation and vacuum passage for clog when valve is switched ON and OFF by using SUZUKI scan tool or service wire.
EVAP canister purge valve:
Valve OFF [A] : When blowing into hose "A", air should not come out of hose "B".
Valve ON [B] : When blowing into hose "A", air should come out of hose "B".
If check result is not described, check vacuum hoses, purge valve, wire harness and connections.
EVAP CANISTER PURGE VALVE INSPECTION
1. With ignition switch OFF, disconnect coupler from canister purge valve.
2. Check resistance between two terminals of EVAP canister purge valve (1).
If resistance is as specified, proceed to next operation check. If not, replace.
Resistance of EVAP canister purge valve:
28 - 35 ohm at 20 °C (68 °F)
3. Disconnect vacuum hoses from intake manifold and its EVAP canister.
4. With coupler disconnected, blow into hose "A" (1). Air should not come out of hose "B" (2).
5. Connect 12 V-battery to EVAP canister purge valve (3) terminals. In this state, blow hose "A" (1).
Air should come out of hose "B" (2).
If check result is not as described, replace EVAP canister purge valve.
WARNING: Do not suck the air through valve. Fuel vapor inside valve is harmful.
6. Connect vacuum hoses.
7. Connect EVAP canister purge valve coupler securely.
EVAP CANISTER AIR VALVE AND ITS CIRCUIT CHECK
WARNING: Do not suck the air through valve. Fuel vapor inside valve is harmful.
1. Disconnect vacuum hose from EVAP canister.
2. With ignition switch ON, blow into hose "A" (1). Air should come out of hose "B" (2).
3. If you have SUZUKI scan tool, perform step a). If not, perform step b).
a. When using SUZUKI scan tool:
i. Connect SUZUKI scan tool (1) to DLC (2) with ignition switch OFF.
ii. Turn ON EVAP canister air valve by using SUZUKI scan tool with ignition switch ON.
In this state, blow hose "A" (3).
Air should not come out of hose "B" (4).
If check results are as describe above, EVAP canister air valve and its circuit are in good condition, connect vacuum hoses securely.
If not, check air valve, wire harness and connections.
b. When not using SUZUKI scan tool:
i. Using service wire (2), connect C51-2-5 terminal of ECM (PCM) (1) coupler and body ground with ignition switch OFF.
ii. Turn ON ignition switch.
In this state, blow hose "A" (3).
Air should not come out of hose "B" (4).
If check results are as described above and C51-2-5 terminal to ECM (PCM) connection is OK, EVAP canister air valve and its circuit are in good condition, connect vacuum hoses securely.
If not, check air valve, wire harness and connections.
EVAP CANISTER AIR VALVE INSPECTION
1. With ignition switch OFF, disconnect coupler from EVAP canister air valve.
2. Remove canister bracket from vehicle body (with ORVR).
3. Check resistance between two terminals of EVAP canister air valve.
If resistance is as specified, proceed to next step. If not, replace.
Resistance of EVAP canister air valve:
25 - 30 ohm at 20 °C (68 °F)
4. Disconnect vacuum hoses from EVAP canister.
5. With coupler disconnected, blow into hose "A". Air should come out of hose "B".
If not, replace EVAP canister air valve.
6. Connect 12 V-battery to EVAP canister air valve terminals.
In this state, blow hose "A".
Air should not come out of hose "B".
If check result is not specified above, replace EVAP canister air valve.
WARNING: Do not suck the air through valve. Fuel vapor inside valve is harmful.
7. Install EVAP canister air valve (2) to canister bracket (1) and canister bracket to vehicle body (vehicle with ORVR system).
8. Connect vacuum hose.
9. Connect EVAP canister air valve coupler securely.
TANK PRESSURE CONTROL SOLENOID VALVE AND ITS CIRCUIT INSPECTION (IF EQUIPPED)
1. Disconnect vacuum hose from tank pressure control solenoid valve (1).
2. Start engine and run it at idle speed.
3. With finger placed against disconnected vacuum hose (2), check that vacuum is applied. If it is not applied, clean vacuum passage by blowing compressed air or replace vacuum hose.
4. Connect SUZUKI scan tool (1) to DLC (2) with ignition switch OFF.
5. Turn OFF tank pressure control solenoid valve by using SUZUKI scan tool with ignition switch ON after clearing DTC.
In this state, blow nozzle "A" (4).
Air should come out of filter (3) and not out of nozzle "B" (5).
6. Turn ON tank pressure control solenoid valve by using SUZUKI scan tool (1) with ignition switch ON.
In this state, blow nozzle "A" (3).
Air should come out of nozzle "B" (4) and not out of filter (2).
7. If check results are as described above, tank pressure control solenoid valve and its circuit are in good condition, connect vacuum hoses securely.
If not, check tank pressure control solenoid valve, wire harness and connectors.
TANK PRESSURE CONTROL SOLENOID VALVE INSPECTION (IF EQUIPPED)
1. With ignition switch OFF, disconnect coupler from valve.
2. Check resistance between two terminals of tank pressure control solenoid valve (1).
If resistance is as specified, proceed to next step. If not, replace.
Resistance of tank pressure control solenoid valve: 28 - 36 ohm at 20 °C (68 °F)
3. With coupler disconnected, blow into nozzle "A" (1). Air should come out of filter (3) and not out of nozzle "B" (2). If not, replace tank pressure control solenoid valve.
4. Connect 12 V battery (4) to tank pressure control solenoid valve terminals.
In this state, blow air (3) into nozzle "A" (1).
Air should come out of nozzle "B" (2) and not out of filter.
If check result is not described above, replace tank pressure control solenoid valve.
5. Connect vacuum hoses.
6. Connect tank pressure control solenoid valve coupler securely.
TANK PRESSURE CONTROL VALVE INSPECTION
[VEHICLE WITHOUT ORVR SYSTEM]
WARNING: DO NOT SUCK air through tank pressure control valve. Fuel vapor inside the valve is harmful.
1. Disconnect hoses from tank pressure control valve and then remove tank pressure control valve.
2. Air should pass through valve smoothly from fuel tank side (TANK mark (4) side of tank pressure control valve) to EVAP canister side when blown hard.
3. From CAN mark (5) side, even when blown softly, air should come out of TANK mark (4) side.
4. If air doesn't pass through valve in step 2) or hard blow is required in step 3), replace tank pressure control valve.
5. Apply vacuum to vacuum port (2).
In this state, blow TANK mark (4) port. Air should come out of CAN mark (5) port.
If check result is not as described, replace tank pressure control valve.
6. Install tank pressure control valve.
[VEHICLE WITH ORVR SYSTEM]
1. Disconnect hoses and remove tank pressure control valve.
2. Air should pass through valve smoothly from black side (3) of tank pressure control valve (1) to orange side (2) when blown hard.
3. From orange side, even when blown softly, air should come out of black side.
4. If air doesn't pass through valve in Step 2) or hard blow is required in Step 3), replace tank pressure control valve.
WARNING: DO NOT SUCK air through tank pressure control valve. Fuel vapor inside the valve is harmful.
5. Plug orange nozzle and apply 26 kPa (20 cmHg) vacuum to black nozzle. Check that vacuum is held at that level (there is no leakage).
If vacuum leaks, replace.
6. Install tank pressure control valve to fuel tank in such direction that vapor flows from its black nozzle side (1) to wards canister side (2).
Tightening torque
Tank pressure control valve mounting screw (a):
1.6 N.m (0.16 kg.m, 1.0 lb-ft)
7. Connect hoses to tank pressure control valve and clamp them securely.
EVAP CANISTER CHECK
WARNING: DO NOT SUCK nozzles on EVAP canister. Fuel vapor inside EVAP canister is harmful.
1. Disconnect vacuum hoses from EVAP canister.
2. When air is blown into tank pipe, there should be no restriction of flow through purge pipe and air pipe.
3. If operation differs from above description, EVAP canister must be replaced.
4. Connect hoses to canister.
EVAP LEAKAGE INSPECTION
1. Disconnect purge hose from intake manifold and tank pressure control valve hose (if equipped) from solenoid vacuum valve.
2. Turn EVAP canister purge valve ON (open) using SUZUKI scan tool or service wire.
3. Plug air valve hose end.
4. If equipped with tank pressure control valve (1), connect vacuum pump gauge to disconnected tank pressure control valve hose end. And apply vacuum to tank pressure control valve.
5. Apply 3.5 kPa (14.0 in Aq, 26.0 mmHg) to purge hose and seal it. After 15 second, check to make sure that pressure is higher than 3.3kPa (13.6 in Aq, 24.5 mmHg).
If check result is not satisfactory, locate pressure leaking point by using soap water or leak detector.
If no pressure leakage exists in vapor purge line, fuel filler cap, filler neck and etc., remove fuel tank from vehicle and check for leakage from installation face of parts installed on fuel tank and hose joint.