EVAP System Leak Inspection (EVAP Leak Check Model)
EVAP System Leak Inspection (EVAP Leak Check Model)
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 the Ultra Trace UVTM Smoke Producing Fluid in the 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 re-calibrated. 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 the nitrogen gas tank from your local supplier of compressed gas. We recommend the tank with 125 cubic feet capacity for the nitrogen gas tank.
- If the nitrogen gas tank pressure is lower than 100 psi, it is required to ask your local supplier of compressed gas to replenish the nitrogen gas to the tank.
1) Unpack the tester from its shipping carton.
2) Bring the tester (1) up through the EVAP cart's handlebar, and place it on the two tabs (2) located on the bracket on the EVAP cart.
NOTE:
Rotate the tester slightly to one side so that the remote cable clears the handlebar.
3) Install handlebar brackets (1) on the right and left side and the remote switch cord wrap (2) to the tester (3) by using the hexagon screws (4).
4) Attach the nitrogen tank (3) securely to the EVAP cart (1) by using the tank fixing bands (2) that should be attached to the EVAP cart (1).
5) Remove valve cover cap from the nitrogen tank.
6) Install the pressure regulator (1) to the nitrogen tank.
7) Tighten the nut (2) with wrench.
NOTE:
No sealant is required.
8) Install the 90° adapter (1) onto the nitrogen inlet (2) on the left side of the tester.
9) Connect regulator to tester hose (1) to pressure regulator (2) and 90° adapter (3).
NOTE:
Connection should be finger-tightened.
10) Fill the tester with two bottles of smoke producing fluid according to the following procedures.
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 the refill plug (1) located on the right side of the tester.
b) Cut the end off the plastic tip on top of each smoke producing fluid bottle.
c) With the tester in an upright position, empty the contents of two smoke producing fluid bottles into the refill port.
Filling amount of smoke producing fluid
0.95 liters (32 / 33 US/Imp.oz)
d) Secure the plug back into the refill port.
e) Record your name and the date of the fluid change.
11) Upon completion of all jobs, calibrate evaporative emissions system tester referring to the following.
Output pressure calibration
NOTE:
- Perform the following calibration when assembling the evaporative emission system tester or replacing the pressure regulator.
- Once you make this adjustment, you should not have to adjust the tester's regulator again, unless you change the pressure regulator.
12) Connect the power cables (1) from the tester to a fully charged 12 V-battery.
13) Attach the nitrogen/smoke hose (2) to the self-test port (3).
14) Set the NITROGEN/SMOKE valve (4) on the front control panel to NITROGEN.
15) Press and release the remote switch (5) to activate the tester.
NOTE:
The remote switch operates in a push ON, push OFF manner.
16) Check whether the pressure/vacuum gauge of evaporative emission system tester indicates 13 in. H2O. If it does not, perform the following regulation.
a) Remove the plastic cap (1) from the regulator located on the bottom of the tester.
b) Press and release the 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-blade screwdriver to adjust the regulator plunger until the pressure/vacuum gauge reads 13 in. H2O pressure.
d) Disconnect and reconnect the nitrogen/smoke hose from the self-test port.
e) Press and release the remote switch.
f) Verify pressure is at 13 in. H2O. If not, repeat Steps b) to f), as necessary.
g) Press and release the remote switch to deactivate the tester.
h) Replace the plastic cap on the regulator, and then disconnect the nitrogen/smoke hose from the 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 the vehicle temperature and shop temperature will seriously affect the accuracy of the tests. Always allow enough time for the vehicle's temperature to adjust to the shop temperature.
If the pressure regulator is replaced, perform the calibration referring to Output pressure calibration
in this instructions.
1) Connect the red battery clip from the tester to the positive battery terminal, and then connect the black battery clip from the tester to chassis ground.
NOTE:
The vehicle battery must be fully charged for optimum tester performance.
2) Turn the NITROGEN/SMOKE valve (1) on the front control panel to NITROGEN.
NOTE:
Unwind the nitrogen/smoke hose completely from the bracket to optimize the tester's performance.
3) Connect the nitrogen/smoke hose (2) to 0.020 in. (0.5 mm) test orifice (3) on the bottom-front of the tester.
4) Press and release the remote switch (4) to activate the tester.
5) Position the red flag (1) on the flowmeter to align with the floating indicator (2). When the red flag is set, press and release the remote switch to deactivate the tester.
6) Disconnect the nitrogen/smoke hose from the test orifice.
7) Connect the nitrogen/smoke hose onto the fuel cap adapter (1).
8) Remove fuel cap, and then install fuel cap adapter onto the fuel filler neck.
9) Install fuel cap (2) onto the fuel cap adapter.
NOTE:
Connections must be tight and leak-free.
10) Turn the ignition switch ON leaving the engine OFF.
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) Using the scan tool, close the canister vent valve referring to Step 6) of EVAP System Smoke Test (EVAP Leak Check Model) EVAP System Smoke Test (EVAP Leak Check Model).
12) Disconnect pipe from the outlet nozzle (1) of EVAP leak check module.
13) Plug outlet nozzle with finger or the rubber plug.
The 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 the remote switch to activate the nitrogen flow and fill the system. Watch the flowmeter's indicator until it stabilizes.
NOTE:
- The remote switch operates in a push ON, push OFF manner.
- Larger volume fuel tanks and/or those with lower fuel levels may require several minutes to fill with nitrogen.
15) Compare the stable floating indicator position to the red flag as follows.
a) If indicator floats above the red flag, the result is UNACCEPTABLE. Locate and repair a leak referring to EVAP System Smoke Test (EVAP Leak Check Model) EVAP System Smoke Test (EVAP Leak Check Model).
b) If indicator floats below the red flag, the result is ACCEPTABLE. Test is completed.
16) Press and release the remote switch to deactivate the tester.
17) Charge the battery as necessary.