For 1990-2009 cars

# Info - Test Guidelines for Use of Essential Tool J41413-200 Evaporative System Tester

Subject: | Test Guidelines for Use of Essential Tool J 41413-200 Evaporative System Tester

Models: | 2002 and Prior Passenger Cars and Light Duty Trucks

| with Non-Enhanced and Enhanced EVAP Systems

The J 41413-200 Evaporative Emission System Tester (EEST) updates the J 41413 Evaporative Pressure/Purge Diagnostic Station. Continue to use the appropriate Service Information substituting the J 41413-200 Evaporative Emission System Tester (EEST) and this bulletin procedure in any diagnostic step requiring the use of the J 41413. This includes the Inspection Maintenance (I/M) Emissions Diagnostic Manual Pre-OBD II GMPT/97-IM240.

Some 1996 to 1998 and all 1999 and newer GM cars and light trucks are required to illuminate the malfunction indicator lamp (MIL) when the On-Board Diagnostic (OBD II) system detects an evaporative emissions (EVAP) system leak equivalent to an orifice of 1 mm (0.040 in) diameter or greater. In model year 2000, GM introduced software on some vehicles which requires illumination of the MIL when the OBD II system detects an EVAP system leak equivalent to an orifice of 0.5 mm (0.020 in) diameter or greater. The new J 41413-200 EEST can be used on all GM cars and light duty trucks.

GM cars and light duty trucks that meet this new standard cannot be diagnosed using the existing ultrasonic leak detection equipment. The new J 41413-200 EEST can be used to identify leaks and to verify repairs.

The J 41413-200 EEST introduces chemically inert smoke into the sealed EVAP system under low pressure. System leaks are located by using the J 41413-SPT high intensity white light to inspect for traces of smoke escaping from the sealed EVAP system.

### Non-Enhanced EVAP System Diagnostic Procedure

1. Pinch off or plug the EVAP vapor line to seal the EVAP system.
2. Connect the EEST red battery clip to the positive (+) battery terminal. Connect the black battery clip to chassis ground.
3. Install the appropriate fuel fill cap adapter to the fuel fill pipe. Refer to the Service Information for the appropriate fuel fill cap adapter part number.
4. Connect the EEST's nitrogen/smoke supply hose and vehicle fuel fill cap to the adapter.
5. Turn the nitrogen/smoke valve on the EEST control panel to SMOKE.
6. Use the remote switch to introduce smoke into the EVAP system for 60 seconds.

Important: Additional smoke may need to be introduced at 15-second intervals until the leak source has been located.

7. Inspect the entire EVAP system for exiting smoke using the high intensity white light (J 41413-SPT).

### Enhanced EVAP System Leak Detection Procedure

When diagnosing DTCs P0440, P0442, P0446 and P0455, use the J 41413-200 EEST along with the following procedure anytime the diagnostic calls for the J 41413 EVAP Pressure/Purge Diagnostic Station.

Important: ENSURE THAT THE VEHICLE UNDERBODY TEMPERATURE IS SIMILAR TO THE AMBIENT TEMPERATURE AND ALLOW THE SURROUNDING AIR TO STABILIZE BEFORE STARTING THE DIAGNOSTIC PROCEDURE.

1. Turn ON the ignition with the engine OFF.
2. Command the EVAP vent valve closed with a scan tool.*

*Prizm: In order to seal the EVAP system on the 1998-2002 Prizm, bypass the EVAP canister by connecting the fuel tank vapor hose to the canister purge line. Refer to the Service Information for additional information.

3. Connect the EEST red battery clip to the positive (+) battery terminal. Connect the black battery clip to chassis ground.
4. Install the appropriate fuel fill cap adapter to the fuel fill pipe. Refer to the Service Information for the appropriate fuel fill cap adapter part number.
5. Connect the EEST's nitrogen/smoke supply hose and vehicle fuel fill cap to the adapter.
6. Turn the nitrogen/smoke valve on the EEST control panel to SMOKE.
7. Use the remote switch to introduce smoke into the EVAP system.
8. Use the J 41413-VLV EVAP Port Vent Fitting tool to open the EVAP service port (if equipped) until smoke is observed.
9. Remove the J 41413-VLV EVAP Port Vent Fitting tool once smoke is observed.

Important: Additional smoke may need to be introduced at 15-second intervals until the leak source has been located.

10. Continue to introduce smoke into the EVAP system for an additional 60 seconds.
11. Inspect the entire EVAP system for exiting smoke with the J 41413-SPT high intensity white light. If leak source was located, repair as necessary and proceed to verification process.
12. If the leak source was not located, stop introducing smoke into the EVAP system.
13. Disconnect the fuel fill cap adapter from the fuel fill pipe. Install the fuel fill cap to the vehicle.
14. Connect the EEST's nitrogen/smoke supply hose to the EVAP service port (if equipped).
15. Use the remote switch to introduce smoke into the EVAP system.
16. Inspect the entire EVAP system for exiting smoke with the J 41413-SPT high intensity white light. If leak source was located, repair as necessary and proceed to verification process.
17. If no leak was located, proceed to Fuel Tank Pressure (FTP) Sensor check.

### Fuel Tank Pressure (FTP) Sensor Check

The J 41413-200 EEST provides a tight seal to the nitrogen/smoke hose when the tester is turned off. This allows pressurizing of the sealed EVAP system. Use the following procedure to test for a functional FTP sensor.

1. Turn ON the ignition with the engine OFF.
2. Connect the EEST red battery clip to the positive (+) battery terminal. Connect the black battery clip to chassis ground.
3. Install the appropriate fuel fill cap adapter to the fuel fill pipe. Refer to the Service Information for the appropriate fuel fill cap adapter part number.
4. Connect the EEST's nitrogen/smoke supply hose and vehicle fuel fill cap to the adapter.
5. Compare the FTP parameter, with a scan tool, to the EEST pressure/vacuum gage.
6. If the FTP parameter is not within 1 in H20 of the EEST pressure/vacuum gage, replace the FTP sensor.
7. Command the vent valve closed with a scan tool.
8. Turn the nitrogen/smoke valve on the EEST control panel to Nitrogen.
9. Use the remote switch to introduce nitrogen into the EVAP system.
10. Observe the Fuel Tank Pressure (FTP) parameter with a scan tool. The FTP sensor parameter should increase to more than 5 in H20.
11. If the FTP parameter is not more that 5 in H20, replace the FTP sensor.
12. If the FPT parameter is more than 5 in H20, continue with appropriate Service Information.

### Verification Procedure

#### Service Bay Test

Important: Disconnect the fuel fill cap adapter and install the fuel fill cap onto the vehicle prior to performing the EVAP Service Bay Test.

Perform the EVAP Service Bay Test (if available) using a scan tool. If the Service Bay Test is not available, proceed to Flow Meter Test.

The Service Bay Test will verify the proper operation of the EVAP system and reset the Emissions Inspection/Maintenance EVAP flag.

#### Results

• | If the Service Bay Test is passed, testing is complete.

• | If the Service Bay Test is not passed, return to the appropriate Service Information.

### Flow Meter Test

The flow meter test must be used to verify repairs on vehicles with enhanced EVAP systems that do not have the EVAP Service Bay Test.

1. Turn the nitrogen/smoke valve to nitrogen.
2. Disconnect the nitrogen/smoke hose from the fuel fill cap adapter.
3. Connect the nitrogen/smoke hose to the correct test orifice on the bottom-front of the EEST. The correct test orifice can be determined by referencing the table below.
4. Use the remote switch to activate the EEST.
5. Align the red flag on the flow meter with the floating indicator. Use the remote switch to de-activate the EEST.
6. Remove the nitrogen/smoke hose from the test orifice and reinstall the hose onto the fuel fill cap adapter.
7. Turn ON the ignition with the engine OFF.
8. Command the EVAP vent valve closed with a scan tool.

Important: Larger volume fuel tanks and/or those with lower fuel levels may require several minutes for the floating indicator to stabilize.

9. Use the remote switch to introduce nitrogen and fill the EVAP system. Watch the floating indicator until it stabilizes.
10. Compare the flow meter's stable floating indicator position to the red flag. If the indicator floats:

• | ABOVE the red flag--UNACCEPTABLE (EVAP system leak still exists--go to Enhanced EVAP System Leak Detection Procedure earlier in this bulletin).

• | BELOW the red flag--ACCEPTABLE (PASS--test complete).

The following chart should be used to select the correct orifice for the Verification Process if the Service Information does not specifically list the information.

Year | Engine | Body Style | Test Orifice
--- | --- | --- | ---
1996-1999 | All | All | 0.040
2000 | L4 | All, except S Pickup | 0.040
2000 | L4 | S Pickup | 0.020
2000 | V6 | All, except Malibu, Lumina, Grand Prix, Century, Alero, Grand Am, Intrigue, Monte Carlo, Regal, Sierra with 26 gal tank, Silverado with 26 gal tank, AWD Astro and Safari van with L35 engine, S and T Pickup with L35 engine, Blazer 2-door, Jimmy 2-door, Envoy 2-door | 0.040
2000 | V6 | Malibu, Lumina, Grand Prix, Century, Alero, Grand Am, Intrigue, Monte Carlo, Regal, Sierra with 26 gal tank, Silverado with 26 gal tank, AWD Astro and Safari van with L35 engine, S and T Pickup with L35 engine, Blazer 2-door, Jimmy 2-door, Envoy 2-door | 0.020
2000 | V8 | All except, Sierra and Silverado with 26 gal tank, Yukon and Tahoe | 0.040
2000 | V8 | Sierra and Silverado with 26 gal tank, Yukon, Tahoe | 0.020
2001 | L4 | All, except S Pickup and Prizm | 0.040
2001 | L4 | S Pickup and Prizm | 0.020
2001 | V6 | All Except: Malibu, Lumina, Grand Prix, Century, Alero, Grand Am, Intrigue, Monte Carlo, Regal, Sierra with 26 gal tank, Silverado with 26 gal tank, AWD Astro and Safari van with L35 engine, S and T pickup with L35 engine, Blazer 2-door, Jimmy 2-door, Envoy 2-door, Venture Long Wheel base, Montana Long Wheel base, Silhouette Long Wheel base | 0.040
2001 | V6 | Malibu, Lumina, Grand Prix, Century, Alero, Grand Am, Intrigue, Monte Carlo, Regal, Sierra with 26 gal tank, Silverado with 26 gal tank, AWD Astro and Safari van with L35 engine, S and T pickup with L35 engine, Blazer 2-door, Jimmy 2-door, Envoy 2-door, Venture Long Wheel base, Montana Long Wheel base, Silhouette Long Wheel base | 0.020
2001 | V8 | All Except Sierra and Silverado with 26 gal tank, Yukon and Tahoe, Denali | 0.040
2001 | V8 | Sierra and Silverado with 26 gal tank, Yukon, Tahoe, Denali | 0.020
2002 | L4 | All, Except S pickup, Prizm, Cavalier, Sunfire, Alero, Grand Am | 0.040
2002 | L4 | S Pickup, Prizm, Cavalier, Sunfire, Alero, Grand Am | 0.020
2002 | V6 and L6 | Aurora, Firebird, Camaro, Aztec, Rendezvous, T crew cab pickup, Blazer 4-door, Envoy 4-door, Bravada, short wheel base Venture, short wheel base Montana, short wheel base Silhouette, Tracker, G Van Sierra with 34 gal tank, Silverado with 34 gal tank | 0.040
2002 | V6 and L6 | All except Aurora, Firebird, Camaro, Aztek, Rendezvous, T crew cab pickup, Blazer 4-door, Envoy 4-door, Bravada, short wheel base Venture, short wheel base Montana, short wheel base Silhouette, Tracker, G Van Sierra with 34 gal tank, Silverado with 34 gal tank | 0.020
2002 | V8 | All except Sierra and Silverado with 26 gal tank, Yukon, Tahoe, Denali, Suburban, Yukon XL, Aurora, Seville, DeVille | 0.040
2002 | V8 | Sierra and Silverado with 26 gal tank, Yukon, Tahoe, Denali, Suburban, Yukon XL, Aurora, Seville, DeVille | 0.020