Kia EVAPorative System Dianosis

EvaporativeSystemsDiagnosis

Course Guide

Course Guide

Student Guide

KESD.01

KESD.01 IG Cover 122010:Layout 1 12/28/2010 9:57 AM Page 1

SAFETY FIRST

Appropriate service methods and proper repair procedures are essential for safe,reliable operation of all motor vehicles as well as the personal safety of the individualperforming the repair. There are numerous variations in procedures, techniques, toolsand parts for servicing vehicles, as well as in the skill of the individual performing theservice. This module cannot possibly anticipate all such variations and provide adviceor caution to each. Accordingly, anyone who departs from the instruction provided inthis module must first establish that they compromise neither their personal safety northe vehicle integrity by their choice of methods, tools or parts. The following listcontains general warnings that should always be followed while working on a vehicle.

• Always wear safety glasses for eye protection.

• Use safety stands whenever a procedure requires underbody work.

• Be sure the ignition switch is always off unless otherwise specified by a procedure.

• Set the parking brake when working on the vehicle.

• Operate the engine only in a well ventilated area.

• Keep clear of moving parts when the engine is running.

• To prevent serious burns, avoid contact with hot metal parts such as the radiator,exhaust manifold, tail pipe, catalytic converter and muffler.

• Do not smoke while working on a vehicle.

Within this module you will find Notes, Cautions and Warnings which provide criticalinformation and help you do your job safely and efficiently. Below are the definitionsof these terms.

When you see a Note, Caution or Warning, be certain you understand the messagebefore you attempt to perform any part of a service procedure.

NOTEThe purpose of a Note is to help you do your job more efficiently. A Note mayprovide additional information to help clarify a particular point or procedure.

CAUTIONA Caution alerts you to the possibility of damage to tools, equipment, or thevehicle. A Caution recommends that a procedure must be done in a certain wayto avoid potential problems resulting from improper techniques or methods.

WARNINGA Warning alerts you to the highest level of risk. Warnings inform you that aprocedure must be done in a particular way to minimize the chances of anaccident that could result in personal injury or even loss of life.

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Copyright © 2011 Kia Motors America, Inc.

All rights reserved. No part of this publication may be reproduced, stored electronically, or transmitted in anyform or by any means without prior written approval from Kia Motors America, Inc. (“KMA”). KMA reserves theright to make changes in the descriptions, specifications, or procedures.

The content of this course is intended for informational and educational purposes only. Any reliance placed onsuch information is therefore strictly at your own risk. In no event will Kia Motors America, Inc. ("KMA") or Kia

University be liable for any loss or damage including, without limitation, indirect or consequential loss or damage,property loss, damage, personal injury or death caused to any persons arising out of or in connection with the

use of this course.

While KMA makes all reasonable efforts to ensure that all course materials are correct, accuracy cannot be guar-anteed and KMA does not assume any responsibility for the accuracy, completeness, or authenticity of any infor-

mation contained in these course materials. Nothing in this course is intended as a guarantee of success.


TT-KESD207-IL-CG014th Printing - January 2011


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Module Title

Kia Evaporative System Diagnosis

KESD Course Guide Module 01 1

Kia Evaporative System Diagnosis Course Guide

COURSE OVERVIEW

COURSE GOAL

COURSE OBJECTIVES

EXPECTATIONS

TARGET AUDIENCES

PREREQUISITES

This course is for Kia service technicians to increase their EVAP diagnostic proficiency by developing the skills required, such as MIL ON due to an EVAP DTC, through intermediate to advanced level theory and instructor supervised hands-on guided practices. This course provides Kia service technicians with the theory and opportunity to practice diagnosing EVAP concerns to obtain a first visit fix. Upon completion of this course, the Kia service technician will be able to demonstrate the following diagnostic procedures with 80% or greater accuracy: � List the operations of the EVAP system � Use an EVAP diagnostic flow chart � Perform non-intrusive inspection and pressure

testing of fuel cap � Perform non-intrusive inspection the EVAP system � Locate EVAP components � Use two types of EVAP leak test and detection units � Test an EVAP system using a manual procedure � Using GDS for current data, DTC, and EVAP test � Perform service bay tests to verify the repair � Inspect fuel tank air filter In this course, you will be expected to use diagnostic processes to diagnose enhanced EVAP systems, electrical circuits, and ORVR to fix the vehicle on the first visit. The EVAP system software programming is based upon the PCM manufacturer’s specific design. This course focuses on the Delphi system used in the Sedona 3.8L and Optima 2.7L. Technicians should look up specifications and DTC detecting conditions for the vehicle they are working on. Kia service technicians who service EVAP concerns and have successfully completed the prerequisite courses prior to the start of the KESD course. � Diagnosing with GDS ILT � Kia Automotive Electrical Diagnosis (AED) ILT

2 KESD Course Guide Module 01


ABOUT TRAINING MODULES

INSTRUCTOR DEMONSTRATION

THEORY

GUIDED PRACTICE

PERFORMANCE ASSESSMENT

GETTING THE MOST OUT OF THIS COURSE

Today's complex automotive technology demands that you, the professional Kia service technician, stay up to date with the latest service information, special tools and complex repair procedures. We have adopted a modular training delivery system that breaks down the critical information into logical groups. First, a demonstration of the EVAP system, followed by system theory and operation, then practice what you have learned and finally, a Performance Assessment test. The Instructor Demonstration Module will show critical tasks performed when diagnosing and servicing an evaporative system. A Theory Module explains the subject. This allows you to obtain a working knowledge of a component or system, which helps guide you to successful diagnosis and repair. The Guided Practice Module allows you the opportunity to familiarize yourself through hands-on experience. The tasks are to be instructor supervised and verified. These exercises may include the use of service manuals or the Kia service information system, Kdealer.net, lab disassembly and reassembly, live vehicle activities, and much more. The Performance Assessment Module provides you the opportunity to demonstrate and prove that you can diagnose evaporative systems related concerns. Each technician must successfully complete this module. It is designed to test your cognitive knowledge in diagnosing a customer concern. These modules are designed to be part of a structured training plan consisting of lecture, interactive classroom discussion, and hands-on shop activities under the direction of a trained Kia instructor. After completing the course modules, your understanding of the material will be verified through the Performance Assessment Module; you must pass the written and hands-on evaluations.

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Module Title


KESD Course Guide Module 01 3

COURSE MATERIAL

AGENDA

COURSE ACHIEVEMENT

PERFORMANCE SCORECARD

SCORECARD ROUTING

ANSWER SHEET

Mod

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KESD 01 Course Guide X KESD 02 System Testing

Demonstration X

KESD 03 EVAP System Principles X

KESD 04 EVAP System Diagnosis X

KESD 05 EVAP Diagnostic

X

KESD 06 Performance Assessment

X

KESD.01 Course Guide 8:00 – 8:30 AMKESD.02 Instructor Demo 8:30 – 10:00 AMBreak 10:00 – 10:15 AMKESD.03 Theory: System 10:15 – 11:30 AMLunch 11:30 – 12:30 PMKESD.04 Guided Practice 12:30 – 3:15 PMBreak 3:15 – 3:30 PMKESD 05 Theory: Diagnostic 3:30 – 4:00 PMKESD 06 Performance Assessment 4:00 – 4:45 PMWrap up 4:45 – 5:00 PM

A final score of 80% or higher is needed for completion credit of this course. The Performance Scorecard is used to track your performance on guided practices, diagnosis and troubleshooting, and any written knowledge assessments.

One copy of the scorecard is yours and one copy is used to update your Kia technical training records. Should you not complete the course, the third copy is forwarded to your Kia District Parts and Service.

Record your Progress Check and Performance Assessment answers on this sheet and turn it in to your instructor for grading. Your score will be transferred to the scorecard.

4 KESD Course Guide Module 01


COURSE MANAGEMENT

TAKE NOTES

ASK QUESTIONS

TEAMWORK

LEARN AT EVERY OPPORTUNITY

ICONS

The course and its materials are here for you to learn and keep. Use them and your time in a way that will benefit you when you return to your dealership. Make drawings, jot down notes, and highlight these materials to help you remember important details. Each module is designed with ample margins for your important notes. If you do not understand something in this course, ask your instructor for clarification. Asking questions is strongly encouraged to help you get the most out of this course. During the hands-on activities, you will often be working as a team. By actively engaging in each activity, you will maximize your learning experience. While in the lab, feel free to ask the instructor questions at any time. This course is an opportunity for you to learn in a controlled environment under the guidance of a trained Kia instructor. Through active participation you can build confidence in your abilities to diagnose customer concerns right the first time, every time! The Note, Caution and Warning Icons are located on the inside of each module front cover. The Reference Icon indicates you must refer to additional publications in order to complete the questions or activity. The Activities Icon indicates an activity that supports a critical learning objective. These activities are offered to help you master the material. The Feedback Icon indicates a progress check meant to provide you with feedback on your understanding of the course material.


InstructorDemonstration

KIA Evaporative SystemsTesting

Student Guide

KESD.02

KESD.02 IG cover 122010:Layout 1 12/28/2010 10:00 AM Page 1

SAFETY FIRST















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use of this course.




TT-KESD207-IL-ID024th Printing - January 2010


Module Title


KESD EVAP System Test Instructor Demonstration Module 02 1

Kia Evaporative System Demonstration Evaporative Systems Testing

MODULE GOAL

MODULE OBJECTIVES

REQUIRED MATERIALS

Vehicle, Equipment and Tools

Materials and Parts

TIME TO COMPLETE

Upon completion of this module, the Kia service technician will improve their skills by participating in a demonstration of EVAP gas cap testing, system and component operation, leak testing, and monitor results. The following demonstrated tasks have been identified as being critical to the accurate diagnosis of Kia EVAP systems. Technicians improve their skills to accurately diagnose EVAP systems by performing the following with an accuracy of 80% or greater. � Pressure testing gas caps. � Manually operating EVAP system and components. � Measuring FTPS under various EVAP operations. � Manually closing the CCV and opening the PCSV. � Verify an EVAP Leak using EVAP test equipment � Verify an EVAP Leak with out EVAP test equipment � Performing a manual EVAP Test � Testing EVAP system with GDS. � Inspecting EVAP monitoring test results. To complete this module, you will need the following: � 2.4L and 2.7L Optima (MG) � Gas cap tester with black and brown adapters � EVAP test station � EVAP tester with adapters, smoke unit and NI tank � Hand held type EVAP tester with N2 tank and cart � Portable EVAP tester with CO2 tank � Leak detection lamp with enhancer glasses � GDS with VCI � DMM � BOB Pro � 12V 25 amp power supply � T-Connectors and appropriate jumper wires � Good gas cap, quarter turn type � Failed gas cap, quarter turn type � Gas cap, full turn type � Fuel filler neck Approximately 1 hour 15 minutes


2 KESD Instructor Demonstration Module 02

MODULE INTRODUCTION

TECHNICIAN DISCUSSION WITH CLASS AND

INSTRUCTOR

EXPECTATION

STATION 1: STATION 2:

STATION 3: STATION 4:

When assigned a Repair Order (RO) with a Malfunction Indicator Lamp (MIL) ON concern, it is important to retrieve the DTC and determine if it is EVAP related. The ability to understand and visualize the events occurring within the EVAP system is necessary to meet the customer’s expectation of a first visit fix. Technicians are accurate with their diagnosis when they understand the events within the EVAP system. Let’s discuss this further. 1. List the EVAP system components shown above. 2. How does the PCM determine that the EVAP system

has a leak that’s above acceptable limits? 3. What action does the PCM take if it “thinks” there is a

leak? 4. What else can cause the PCM to set an EVAP DTC? 5. What choices do we have to verify that the EVAP

system has a leak and what are you using? 6. What choices do we have to diagnose the location of

a confirmed leak and what are you using? Now that we’ve had a good discussion, your instructor will demonstrate testing gas caps, manually operating an EVAP test station to observe the system’s operation, and then go out to a car to run the GDS based EVAP leak test. Technicians are expected to take notes, ask questions, and participate with the following: Inspect and test gas caps. Operate, monitor fuel tank pressure and discuss EVAP components and operation including vacuum decay. Perform EVAP inspection/testing to verify a leak concern. Perform a Manual EVAP leak test (with out the tester) Using GDS perform and review an EVAP monitoring test.

Module Title



STATION 1 – OBDII GAS CAP TESTING DEMONSTRATION

CAP SEALING INSPECTION

A gas cap and filler pipe can be quickly inspected for damage or obstruction that can prevent the holding of pressure and setting a DTC or failing emission testing. 1. Inspect cap on the vehicle for correct installation,

including position of the tether strap. Check if the customer recently re-fueled the vehicle.

2. Visually inspect and clean cap and gasket. If cap

has damage that may prevent its ability to seal the tank, it should be replaced. Is the cap OK?

a. YES NO Reason: _____________

3. Visually inspect the gas filler pipe area that contacts

the gas cap sealer ring. Dirt type of contamination can prevent a proper seal. Is the area OK? a. YES NO Reason: _____________

4. Holding the threaded part, twist the cap and feel the “ratchet” until clicking/breakaway. Is it OK? a. YES NO Reason: _____________

Next, use the cap tester tool (special service tool) to determine if the cap can hold pressure.

Quarter turn cap with tether

Cap sealing gasket

Filler pipe seal ring

Gas Cap



STATION 1 CONTINUED – OBDII GAS CAP TESTING

CAP PRESSURE TESTING

TSB KT2005100502

5. Select proper cap adapter. a. Black for threaded type cap b. Brown for newer quarter turn type cap

6. Connect the adapter to the tester, without cap.

7. Push the “Press to Start” button. Auto-zero function is

performed. The green LED lights illuminates for pass. When the red LED illuminates, the tester is ready.

8. Install the gas cap and tighten at least 3 clicks.

9. Pump the handle until the green “STOP” LED illuminates. Test may take up to 15 seconds.

10. Green “PASS” LED flashing: Do not replace.

11. Red “OBD II FAIL” LED: Repeat test, if cap continues to fail, then replace.

12. Test replacement gas cap, if pass, install new cap. Note: The tester will not test vacuum release ability and testing is required to replace the cap under warranty.

Brown Adaptor Cap Tester

Black Adaptor

Pum

p Handle

Threaded Type Cap

Quarter Turn Cap

Module Title



STATION 2 - EVAP TEST STATION DEMONSTRATION

EVAP SYSTEM OPERATION

An EVAP testing station will be used to demonstrate the system’s operation and testing if system has a leak. Turn the power supply ON; operate the system while reviewing the location and operation of each component. Next, measure and record the FTPS output with the gas cap removed (atmospheric pressure): ____volts, which is a valid base line representing EVAP _________ pressure. Operate the PCSV & CCV and turn ON the pump/engine as shown below. Discuss the results before continuing. State: Pump: PCSV: CCV: FTPS V: Rest OFF Closed Open VSignal ON Open Open VPurge ON Open Closed VDecay OFF Closed Closed V

Describe the decay rate: ______________________

Fuel tank air filter ON Open Open V

Discuss a plugged air filter and its effect on the system.

Cap Filler Neck

Air Filter

Engine

To To To Air Purge Tank

Fuel Tank Pressure Sensor



PROCESS OF VERIFING, TESTING AND LEAK DETECTION – CART STYLE

Fuel cap adapter and fuel cap

Fuel tank filler and fuel tank adapter

Nitrogen tank

Regulator

Flow flag

Test hose

Test ports:

Self test

.040” orifice

.020” orifice

“Y” Test hose

Test hose

Flow meter

Smoke unit

Flow ball

Module Title



SET UP TESTER FOR TESTING AND VERIFING A

LEAK (CART STYLE SHOWN)

VACUUM DECAY

Fill the EVAP system with low pressure to discuss the amount and volume of pressure applied and decay. Perform the following: 1. Turn tester control to “Hold” position. 2. Connect nitrogen tank supply hose to bottom of

flow meter and open valve on Nitrogen tank. 3. Connect vehicle test hose to self test port. 4. Turn control knob to “Test” position and adjust

regulator to 14 in H2O. 5. Turn control knob to “Hold” and move test hose to

appropriate preset orifice for the vehicle being tested.

6. Turn control knob to “Test” and set flow meter flag. 7. Turn control knob to “Hold” and connect vehicle test

hose to “Y” test hose with fuel filler/cap test adapters.

8. Connect the test adapters to fuel cap and filler neck 9. Manually energize the CCV to close the CCV valve. 10. Turn control knob to “test” position and allow

system to pressurize and verify if there is a leak: � If the flow ball rises above preset, system has a

leak � If the flow ball falls below preset, system passes.

11. Describe to your instructor what’s happening.



LEAK DETECTION

After verifying the leak, with the CCV closed and flow occurring, diagnose for the point of the leak. Fill the system with smoke by connecting the smoke heater/pump to 12V, depress the push-button switch to activate smoke and allow the system to fill with smoke. Discuss what is happening. Close the CCV, open the PCSV and switch ON the pump. Discuss what’s happening and visually look for leaks. If no leak, induce one and look for smoke leaking using a 12V leak detection spot light. Note: There maybe one leak or several smaller leaks that add up to >0.020” and set a DTC. Caution: Do not use O2 (such as compressed shop air) to test due to the increased chance of combustion.

Module Title



INTRODUCTION OF TESTING USING HANDHELD EVAP TESTER

PRESSURIZATION TEST

The handheld EVAP tester is designed to pressurize and test the vehicle EVAP system’s ability to hold pressure, monitor system pressure and pressure decay on the precision gauge. The pressure manifold maintains system pressure while diagnosing the source of the leak. The diagnosis process includes: � Checking the gas cap for leaks � Closing the canister close valve (CCV) � Determine the fuel tank level (50 to 100%) � Installing the universal adapter to the gas filler neck � Connecting the test manifold to the adapter and

pressurizing the system with a compressed nitrogen tank, NOT shop compressed air

� Monitoring the amount of time for the pressure to drop 6 in. H2O on the gauge to verify a leak. The time is based on tank capacity and percentage of fuel in tank

� Leak detection by maintaining a constant pressure on the system and using an ultrasonic or soapy water solution

Caution: Do not remove or obstruct the safety control valve. Ground unit (green screw) to vehicle’s chassis.

Universal Adapter

Pressure Manifold

Safety Control Valve



INTRODUCTION OF TESTING USING PORTABLE EVAP TESTER

PRESSURIZATION TEST

The portable style EVAP tester is designed to pressurize and measure the flow of nitrogen through two calibrated leaks of (.020” and .040”) and can be compared to the actual flow into a vehicle EVAP system. The portable EVAP tester � Connect the tester to the vehicle battery and a inert

gas such as Nitrogen (N2) or Carbon Dioxide (CO2) � Position the Selector Switch on the control panel to

.020” � Start the flow of gas by pressing and releasing the

ON/OFF button and observe the position of the indicator ball in the flow meter then position the red pointer at the center of the ball

� Stop the flow of gas by again pressing and releasing the ON/OFF button

� Position the Selector Switch on the control panel to TEST

� Connect the test adaptors to fuel cap/filler neck adapter

� Close the CCV by grounding or pinching the hose closed

� Start the flow of gas by pressing and releasing the ON/OFF button and observe the position of the indicator ball in the flow meter o If the ball rises above preset, the system has a

leak larger than the calibrated value o If the ball fall below the preset, the system

leakage is less than the calibrated value LEAK __________ NO LEAK ___________

� If a leak is indicated set the Selector Switch to SMOKE. Allow the fuel system to fill with smoke and visually look for leaks using the 12V leak detection spot light.

Module Title



STATION 3 - MANUAL (WITH OUT TESTER) EVAP LEAK TEST

Monitoring FTPS voltage with BOB Pro Monitoring FTPS voltage directly

PURPOSE:

STEP 1, PREPARING TO MEASURE THE FTPS

STEP 2, MEASURING THE FTPS

Except 2006.5 to current Optima and Rondo 07 to

current Amanti and 09 Borrego 3.8L

2006.5 to current Optima and Rondo 07 to current

Amanti and 09 Borrego 3.8L

To verify if an EVAP system leak is present when EVAP test equipment is not available. NOTE: Verify the fuel tank is between 1/4 - 3/4 full. Specifications between vehicles maybe different. Hook up BOB (up to 2002 MY vehicles, if available) or BOB-PRO (2003-current MY vehicles) to ECM/PCM, monitor FTPS input through BOB with voltmeter or connect voltmeter to the FTPS using a T-connector. Leave the voltmeter hooked up because you will be referring back to it through out the test. � Check FTPS voltage Key On Engine Off (KOEO)

with gas cap OFF, it should be 2.3v - 2.7v (2.5v) � If voltage is within 2.3v - 2.7v go to step 3 � If voltage is out of 2.3v -2.7v then using a T-

connector o check voltage on all 3 wires at FTPS, with KOEO,

gas cap OFF and sensor plugged in o Results should be 5 volt supply voltage, ground

and 2.5v signal o If not, diagnose and repair as necessary. Refer

to ETM for pin configuration. � Check FTPS voltage KOEO with gas cap OFF � It should be 1.4 - 1.5 volts � If voltage is 1.4 - 1.5 volts go to step 3 � If voltage is not 1.4 - 1.5 then go check voltage on

all 3 wires at FTPS as above but signal is 1.5v. Record test results: _____________________________

BOB PRO

KOEO and gas cap OFF



STATION 3 CONTINUED – RESTRICTION INSPECTION

Open PCSV with BOB By-pass PCSV Applying a vacuum

STEP 3, INSPECTING FOR A RESTRICTION

Up to 2002 MY vehicles

2003 and later vehicles,

except 2006.5 to current Optima, Rondo, 07 to

current Amanti, and 09 Borrego 3.8L

INSPECTION

For 2006.5 to current

Optima and Rondo 07 to current Amanti and 09

Borrego 3.8L

Install the gas cap, KOER and based upon the vehicle: Ground the PCSV control wire with an Ammeter (DMM), through BOB (if available) to open the PCSV and pull a vacuum in the system with KOER. Leave the PCSV connected to the electrical connector, clear any DTC, disconnect the PCSV tank side hose and apply vacuum using a Mighty Vacuum; or engine vacuum applied to tank side of Purge Valve to pull a vacuum in the system. WARNING: Do not use the BOB PRO to ground, jump or short circuits as this may cause damage to the BOB PRO or vehicle ECM, which is not covered by warranty. Monitor the FTPS voltage with voltmeter for 25 seconds. The voltage should not drop below 1.5v. If it drops below 1.5v then there is a restriction in the EVAP system because we did NOT closed the CCV. Be sure to check the fuel tank air filter, if voltage stays above 1.5v then go to step 4. Voltage should not go up higher then 1.9v. If it goes higher then 1.9v then there is a restriction in the EVAP system because we did NOT closed the CCV, if voltage stays around 1.5v then go to step 4. Return PCSV to its normal condition. CAUTION: If a DTC sets (MIL ON) when the PCSV is disconnected, grounded or during the test, the test results may not be valid. Record test results: _____________________________

BOB

Module Title



STATION 3 CONTINUED – INSPECTING PCSV FOR LEAKS

Disconnected PCSV CCV energized to close the valve

STEP 4, INSPECT PCSV FOR

LEAKING



For 2006.5 to current Optima and Rondo 07 to


Unplug the PCSV 2 wire connector at PCSV to keep it closed (because these can purge at idle). Disconnect and manually energize the CCV to close it using another battery or a jump box (NO BATTERY CHARGERS) and jumper wires or T Connectors. Lower the vehicle and start the engine. Does FTPS voltage drop with Purge Valve connector unplugged, and keeps dropping? If voltage stays the same then go to step 5. If volt drops and keeps dropping then PCSV is leaking and needs to be replaced (that's why we unplugged PCSV connector). Does FTPS voltage rises and keep rising? If voltage stays the same then go to step 5. If voltage rises and keeps rising then PCSV is leaking and needs to be replaced. Record test results: _____________________________



STATION 3 CONTINUED – VERIFYING A PRESENT LEAK

EVAP line pinched closed Applying vacuum Measuring FTPS voltage

STEP 5, VERIFYING A LEAK

THAT IS PRESENT



2006.5 to current Optima and Rondo 07 to current

Amanti and 09 Borrego 3.8L

With the CCV still closed manually, disconnect PCSV hose (Tank Side) and pull a vacuum manually, using a mighty vacuum or engine vacuum while monitoring the FTPS voltage. FTPS voltage will drop from 2.5v; when reading reaches approximately 1.5v stop applying vacuum and hold. Voltage reading should remain constant and should not increase more than 0.3v inside one minute of constant monitoring. If voltage increases more than 0.3v, there is a leak. Apply vacuum as above, the FTPS voltage will rise to 2.0 v - 2.4v, then stop applying vacuum and monitor FTPS voltage for 1 minute. Voltage should not drop more then 0.3v in 1 minute, if it does then you have a leak in the system. You can start pinching hoses till voltage stops dropping or use a smoke machine if available to find the leak or use approved Kia EVAP Leak Detector. Record test results: _____________________________ Caution: do not crimp plastic fuel or vapor lines as this can cause a crack and possible leak which could cause the system to fail the onboard EVAP test.

Module Title



STATION 4 – GDS EVAP LEAKAGE TEST

GDS EVAP TEST SET UP OPTIMA (MG) 2.7L

Next, your instructor will show GDS commanding ON a manual EVAP test on a vehicle in the shop. 1. Connect GDS – VCI and select vehicle being tested.

Check and clear any DTC prior to the test. 2. Will clearing DTC erase the monitor test results? ___ 3. Select EVAP leak test on the home page. The EVAP

leak test appears, listing the required conditions for the vehicle being tested as shown above.

4. Review and meet the test conditions shown above.

If conditions are met, click “OK”. Note: GDS screens will vary depending upon vehicle’s ECM and GDS software.



STATION 4 CONTINUED – GDS EVAP LEAKAGE TEST

Start engine and test Test Complete Pass Test Complete Fail

GDS EVAP TEST RUN OPTIMA (MG) 2.7L

5. Start engine, click “OK” and the test will run when the criteria is meet.

6. When the test is complete, the window will indicate:

“No leak detected” or “Fail” and why. 7. Next, click “OK.” The screen will return to the

inspection/test menu.

Module Title



STATION 4 CONTINUED – GDS EVAP LEAKAGE TEST

GDS MONITORING TEST

RESULTS MENU

7. Under Inspection/Test (left side) under Vehicle S/W Management, Click on “Monitoring Test Results.”

8. This expands the drop down menu under the key. 9. Next, click on GDS EVAP leak test that you want to

see the results of or the test that failed. In this case, EVAP Monitor (Cap Off) for large leak.

10. Test results are shown. Click on cancel before

selecting another test result.



STATION 4 CONTINUED – EVAP MONITORING TEST RESULTS

GDS EVAP MONITORING TEST RESULTS

Some systems will show different test results that make up the EVAP monitor. The failure of any of the tests will set a code and turn on the MIL on the second consecutive trip. Note: Return to the main menu before running additional tests. The test titles may vary from system to system and screens shown are subject to change during a GDS update.

Module Title



Note Page

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Note Page

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Theory Module

Evaporative SystemsPrinciples

Student Guide

KESD.03


SAFETY FIRST















!

!




The content of this course is intended for informational and educational purposes only. Any reliance placed on suchinformation is therefore strictly at your own risk. In no event will Kia Motors America, Inc. ("KMA") or Kia Universitybe liable for any loss or damage including, without limitation, indirect or consequential loss or damage, property

loss, damage, personal injury or death caused to any persons arising out of or in connection with theuse of this course.

While KMA makes all reasonable efforts to ensure that all course materials are correct, accuracy cannot be guaran-teed and KMA does not assume any responsibility for the accuracy, completeness, or authenticity of any information

contained in these course materials. Nothing in this course is intended as a guarantee of success.


TT-KESD207-IL-TH034th Printing - January 2011


Module Title


KESD EVAP System Principles Theory Module 03 1

Kia Evaporative System Diagnosis Evaporative Systems Principles

MODULE GOAL

MODULE OBJECTIVES

MODULE INSTRUCTIONS

REQUIRED MATERIALS

ACRONYMS

TIME TO COMPLETE

Upon completion of this module, the Kia service technician will be able to apply EVAP system theory to the diagnostic process.

After completing this module and a written test, the technician will be able to perform the following with 80% or greater accuracy: � Select the purpose of the EVAP system � Select four modes of the EVAP system operation

with and without a leak detection pump � Match operating, inspection and units of pressures � Match seven EVAP components operation/locations � Match solenoid valves operation � Match eight EVAP DTC to components � Select EVAP system service

Carefully read the material, and take notes based on the classroom discussion, demonstrations, and illustrations. There are Progress Check questions at the end of the module for you to answer. Use the sheet to record your answers, which will be turned in to your instructor.

In order to complete this module, you will need: � Pass around parts

CCV – Canister Closed Valve DTC – Diagnostics Trouble Code FAM – Front Area Module FTPS – Fuel Tank Pressure Sensor KOEO – Key ON Engine OFF KOER – Key ON Engine RUN NC – Normally Closed NO – Normally Open NVLD – Natural Vacuum Leak Detection PCSV – Purge Canister Solenoid Valve ORVR – On-board Refueling Vapor Recovery

Approximately 1 hour, 30 minutes

EVAP systems are similar; but there are variations between vehicle models and years. Refer to the service information when diagnosing an EVAP concern.

2 KESD EVAP System Principles Theory Module 03



INTRODUCTION

The Evaporative Emissions Control System (EVAP) is designed to prevent gasoline hydrocarbon (HC) vapors from being released into the atmosphere. The EVAP system uses the following four modes of operation: 1. Refueling: During fueling and fuel evaporation in

the tank, the created HC vapors are drawn into the canister and temporarily stored by the canister

2. Venting: Expanding air is allowed to vent out of the fuel tank without allowing gasoline vapor to escape

3. Purging: During certain operating conditions, the ECM use intake manifold vacuum to purge HC vapors out of the system, including the canister, and into the combustion chambers

4. Testing: The PCM monitor tests the system’s integrity.

Note: A blockage in the vent section may: � Restrict canister evacuation during purge. � Prevent canister filling during shutdown with the

result of vapor venting through the fuel cap. � Slow down or prevent refueling in extreme cases.

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EVAP SYSTEM OPERATION – WITH PUMP

Spectra to ‘04 used a Diagnostic Module Tank Leakage (DM-TL) pump to test the evaporative system for leaks under pressure instead of using engine vacuum. Testing operation includes: � The pump is switched on for a short time

with changeover valve closed to obtain motor current (mA) reference.

� The pump is switched on to pressurize the system and motor amperage is monitored and compared to the reference amperage.

� As a system without leaks would pressurize, the pump would get harder to turn and the amp draw would increase.

� If it leaked, the system would not pressurize, and the pump would draw fewer amps.

Note: A catch tank was used in both systems to hold liquid fuel that has condensed in the purge hose until it changes back into a vapor and then evacuates during engine operation.



TYPICAL AUTOMOTIVE OPERATING PRESSURES

Systems: Low: High: Vacuum: Tires 28 PSI 32 PSI Fuel Pressure 36 PSI 48 PSI HVAC 28 PSI 350 PSI 29 In.Hg Vac Fuel Cap/EVAP 0.2 PSI 0.5 PSI -0.5 PSI

The operating pressures in an EVAP system are very low. The table above compares typical EVAP pressures to other automotive systems. � Positive pressure (above atmospheric) and negative

pressure (below atmospheric; usually called vacuum) may never exceed 1.5-2 PSI (positive) or -0.5 PSI (negative).

� Since EVAP systems normally operate at pressures

very close to atmospheric, they must also be tested with low pressure.

Caution: Do not apply more than 0.5 PSI pressure to the EVAP system, including high pressure shop air.

The images above represent how small a leak can be and cause the EVAP system to fail its leak test and set a DTC. � The 0.020” (0.5 mm) diameter is a very small leak

and 25% of the 0.40” leak flow rate (not 50 %.) � The 0.040” (1.0 mm) diameter is a small leak. � Gas cap OFF detected is a large leak (> 1.0mm.)

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UNITS OF PRESSURE

Approximate

PSI: In.Hg kPa In.H20 hPa/mBar

1.0 = 2 = 7 = 27.7 = 69

0.5 = 1 = 3.5 = 14 = 34

0.25 = 0.5 = 1.75 = 7 = 17

EVAP operating pressures are very small; pounds per square inch (PSI) therefore are not the best units to use for measurements. It would be similar to attempting to measure crankshaft journal diameter with a ruler instead of a micrometer. � Inches of mercury (in. Hg) are a commonly used

unit of measure for pressure. Automotive technicians’ vacuum gauges are calibrated in in.Hg, and are useful when checking engine vacuum.

� Kilopascals (kPa) is a measure of pressure

(perpendicular force per unit) best known for barometric pressure and bicycle tire readings.

� Inches of water (in. H2O) is even more accurate for

measuring very small pressure variations and is the unit most EVAP test equipment uses for service bay testing.

� Engineers typically use the metric unit hectoPascals

(hPa) when very high precision is needed such as EVAP monitor tests using Mode 6 data.

Note: You may see inches of water shown as in.Aq. Depending upon the vehicle selected, GDS may use PSI, Vac, mBar or hPa. 1 millibar (mBar) = 1 hectoPascal (hPa).



EVAP COMPONENTS AND LOCATIONS

SYSTEM COMPONENTS

The EVAP system includes the following components: � Gas cap (fuel filler pipe) � Charcoal canister � Fuel tank air filter (canister filter) � Purge Control Solenoid Valve (PCSV) � Canister Close Valve (CCV) � Fuel Tank Pressure Sensor (FTPS) � Hoses and connectors throughout the system The ORVR system (not shown above) prevents HC emissions during refueling and will be discussed later in the module. ORVR components and their location vary.

FTPS

CCV Canister

Fuel Cap Fuel Filler Pipe

Fuel Tank Filter

PCSV – Location varies by model

Engine Room Compartment

Under vehicle

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GAS CAP

When fuel tank is under pressure When fuel tank is under vacuum

Description: The gas cap is a fuel filler sealing device. There are different types of tightening procedures depending on the cap type. Most caps have a ratchet type mechanism that causes a clicking sound when the cap is tightened; these are typically tight when you hear three clicks. A new type of cap requires less effort to tighten. It only requires one click to be tight, and the clicking sound may not be easily heard. � They are designed to hold vapor pressure up to

approximately 1.5-2 PSI and then relieve if needed for safety.

� If fuel tank vacuum becomes excessive, the cap

will vent at approximately 1.5” Hg vacuum to prevent collapse of tank.

Inspection: Carefully inspect cap for cracks and gasket condition. Be sure to check filler neck mating surface condition. � Driver may leave cap loose or tighten cap on tether

strap interfering with sealing the system. Inspect the cap first before tightening to determine if loose.



Testing: Cap can be tested using a gas cap pressure tester designed to check for leaks. Related Sedona 3.8L leak related DTCs: � P0442 Small leak � P0455 Large leak (usually with a loose gas cap) � P0456 Very small leak Note: 2006 Rio has a “Check Gas Cap Light” that can illuminate after a fill-up, without monitor completion if the cap is loose and certain conditions are met.

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CHARCOAL CANISTER

Description: The canister contains activated charcoal and is designed to absorb and hold any gasoline vapors (not liquid) from the fuel tank, as well as those created during refueling (ORVR). The canister must be purged of vapors to recover its absorbing capability. Service is usually not required unless the canister is damaged or filled with liquid fuel. Location: Under rear of vehicle near fuel tank. Inspection: Check canister for cracks, accident damage, broken mounts, hose connections, and liquid gasoline. Testing: The charcoal canister is tested for leaks and adequate flow by the OBD II system when the EVAP monitor is run. Related Sedona 3.8L leak related DTCs: � PO442 Small leak � P0455 Large leak � P0456 Very small leak



FUEL TANK AIR FILTER

VENT FILTER FUEL TANK AIR FILTER

CANISTER FILTER

Description: The EVAP system contains an air filter to prevent dirt and debris from entering the system during purge and is part of the maintenance schedule. � When the purge valve opens, intake manifold low

pressure (vacuum) causes EVAP system pressure to begin to drop

� Atmospheric pressure outside the filter causes air to

begin to flow through the filter, through the open CCV, and through the canister

� This airflow is what carries the hydrocarbons forward

through the open purge valve and into the intake manifold

Location: Rear of vehicle near canister or up on fuel tank fill pipe inside left rear wheel house liner. Inspection (15,000 miles): Check filter housing for damage and secure hose connections. Visually check for restriction due to dirt, spider webs, or other foreign debris. You should be able to easily blow through filter with no restriction. Do not use high pressure shop air. Related Sedona DTCs: � P2422 Canister clogging

Canister Close Valve Or

Leak Detection Pump

Air

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PURGE CONTROL SOLENOID VALVE (PCSV)

Charcoal Canister

Intake Manifold



PURGE CONTROL SOLENOID VALVE (PCSV) CONTINUED

Description: The PCSV is a PCM controlled duty type solenoid normally closed (NC) valve. The PCSV is in line, controlling the flow of vacuum from the intake manifold to the EVAP system. It is commanded open by the PCM providing a ground. When opened, it allows a path for HC vapors to flow from the EVAP canister into the low pressure (or vacuum) of the intake manifold. Inspection: Check valve for cracks, hose deterioration, and contamination with granules of charcoal. Inspect electrical terminals/connector for corrosion, damage, and fit. Testing: Valve should hold vacuum when applied with a hand pump. With KOEO, jumper control wire to ground should cause solenoid to “click”, open valve, and bleed off vacuum. The coil’s resistance specification varies depending upon the model. Locate resistance specification with GDS and check solenoid with ohmmeter. With engine running, verify vacuum supply from intake manifold is present at PCSV. Note: Verify purge hoses are installed at the correct fitting on the valve. Hose may have a red line to assist with correct installation. Related Sedona 3.8L DTCs: � P0441 Incorrect purge flow � P0442 Small leak � P0444 Circuit open � P0445 Circuit shorted � P0455 Large leak � P0456 Very small leak Note: Flow and leak related DTCs are only monitored under certain conditions, electrical related DTCs are continuously monitored. Any codes relating to PCSV should be addressed before continuing EVAP troubleshooting procedures. Some models have a purge valve filter.

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CANISTER CLOSE VALVE (CCV)

Canister

Air Filter



CANISTER CLOSE VALVE (CCV) CONTINUED

Description: The CCV is a PCM controlled, normally open (NO) in-line valve controls the air flow from the fuel tank filter to the canister during leak check. The PCM provides a ground to close the valve during leak detection. When NO, fresh air flows to the canister including during engine purge. The vent valve orifice is much larger than the PCSV lines so flow is not restricted. The fresh air inlet is normally filtered with a serviceable dust filter that helps prevent contaminants from being drawn into the EVAP system. Inspection: Visually check the CCV, hoses, and clamps. Check for spider webs, corrosion or damage at the electrical terminals and connector. Testing: Disconnect hoses and blow (low pressure) through the valve; there should be no restriction. Do not inhale gas vapors. The solenoid coil should measure approximately 19.8~21.8 or 23~26 ohms depending upon the vehicle @ 68° F. With 12V and ground supplied to the solenoid, a “click” should be heard and you should now not be able to blow through the valve. It will draw approximately 40-50mA. Related Sedona 3.8L DTCs: � P0442 Small leak � P0455 Large leak � P0456 Very small leak � P0447 Circuit open � P0448 Circuit shorted � P2422 Canister Clogging

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FUEL TANK PRESSURE SENSOR (FTPS)

The following pressure vs. voltage scale is an example of two types of FTPS:

5V 0V Pressure

Normal 2.5V Atmospheric 1.5V

Pressure

Vacuum 0V 5V

Fuel Tank Pressure

Vent to Atmosphere

Rondo UN Optima MG Borrego 3.8L Amanti 3.8L

All other Kia vehicles





Description: The FTPS monitors pressure, vacuum and vacuum decay in the EVAP system. It’s located in the EVAP system, such as the canister or on top of the fuel tank depending upon the vehicle. It’s a three wire sensor that changes its output signal voltage as it measures the difference between tank air pressure and outside air pressure. This is to check the PCSV operation and leak detection by monitoring pressure levels. The PCM relies on the FTPS signal to complete the OBD-II EVAP system monitor. Note: Even though the FTPS is usually located at the tank, it senses pressure changes in the entire system and can indicate that the vent is blocked. Inspection: Check the FTP sensor for corrosion or damaged terminals or connector. Testing: The FTPS signal output should be 2.5V with KOEO and gas cap removed. Check specs as some models will be closer to 1.5V at rest. A baseline (calibration) is important and can be determined at this time. PCM baselines this prior to EVAP testing. Note: When testing FTPS, verify that the CCV is open and will close if powered. Verify that the hose is clear between CCV and canister. Related Sedona 3.8L DTCs: � P0442 Small leak � P0455 Large leak � P0456 Very small leak � P0451 Range/performance � P0452 Low input � P0453 High input � P0454 Intermittent Caution: Do not block or cap the atmospheric port on the FTPS.

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EVAP ETM

PCSV AND CCV CIRCUITS

Highlight the following 2008 Sedona EVAP electrical circuits with the highlighters provided. � Power (B+) to the PCSV and CCV is supplied from

the engine control relay through a 15A fuse. Note: PCSV is also referred to as a canister purge solenoid valve in some ETMs.

� Ground for each solenoid is controlled by the PCM

� The PCSV is pulse width modulated � The CCV is an ON/OFF type of switch



NVLD COMPONENTS AND LOCATIONS

SYSTEM COMPONENTS

The Natural Vacuum Leak Detection EVAP system includes the following components: � Gas cap (fuel filler pipe) � Charcoal canister (MAIN & AUX) � Fuel tank air filter (canister filter) � Purge Control Solenoid Valve (PCSV) located on the

engine � NVLD Module incorporating

o Pressure Switch o Temperature Sensor o Diaphragm o Poppet Seal

� Hoses and connectors throughout the system

NVLD

Canister (MAIN) Canister (AUX)

Fuel Tank Air Filter

Gas Cap

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NVLD SYSTEM

The Natural Vacuum Leak Detection method is used on the Hybrid vehicle due to the fact that the engine is not running all the time. The system works on the relationship temperature and pressure in a sealed system. � Temperature Increase – Pressure Increase � Temperature Decrease – Pressure Decrease The NVLD Module monitors tank pressure/vacuum and temperature. Using diaphragms and a switch it keeps the system sealed to prevent vapors from escaping and allows fresh air to enter the canister when canister purge is required. The Purge Control Solenoid Valve purges the canister when the engine is running.



NVLD

The NVLD Module uses a diaphragm to compare atmospheric pressure with tank pressure/vacuum. The Switch monitors whether the tank contains a vacuum or pressure. The Temperature Sensor monitors the temperature of the fuel tank vapor. The Poppet Seal is used to prevent the tank from developing excessive pressure or vacuum in the tank.

DiaphragmPoppet Seal

Switch/Temperature Sensor

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NVLD OPERATION

ENGINE OFF TANK VACUUM

When the engine is OFF and the tank develops a vacuum the diaphragm is pulled up and the switch contact closes at -2.5 mbar.

ENGINE RUNNING TANK VACUUM

When the engine is running and the PCSV is turned on vacuum increases in the tank. At -6.0 mbar the poppet opens allowing fresh air to enter into the canister.



NVLD OPERATION

ENGINE OFF TANK PRESSURE

When the engine is OFF and the tank develops pressure, the diaphragm is pushed down and the switch contacts open. If the pressure increases above 1.0 mbar the poppet opens allowing excessive pressure to escape.

ENGINE OFF REFUELING

When refueling if the pressure in the tank increases above 6.0 mbar the diaphragm pushes down forcing the poppet valve to open.

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NVLD LEAK DETECTION

ENGINE OFF SMALL LEAK

Small leak detection is performed with the engine and ignition OFF. With the tank sealed the temperature of the fuel vapor is measured. When the tank cools the pressure in the tank decreases into a vacuum and the switch contacts close. The ECM monitors the switch to determine the tank can hold a vacuum. If so no small leak exists.

ENGINE RUNNING

LARGE LEAK Large leak detection is performed with the engine running. With the engine running the PCSV is opened to maximum flow. The ECM monitors the switch to determine if a vacuum can be drawn in the tank within a defined time. If so no large lead exists.



NVLD ETM

NVLD MODULE Highlight the following 2011 Optima Hybrid NVLD electrical circuits with the highlighters provided. � B+ at all time to allow for serial data transmission � Ground is provided by GF02 � Serial Data to the PCM every 10 minutes

� Switch Position � Fuel Vapor Temperature

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EVAP ETM CONTINUED

FUEL TANK PRESSURE SENSOR

Highlight the following 2008 Sedona EVAP electrical circuits with the highlighters provided. � 5V power to the FTPS is supplied from the PCM with

a junction at the FAM � Ground is provided by the PCM through the FAM � Varying voltage signal is sent to the PCM through

the FAM � Voltage will vary based on pressure

Note: In some vehicles such as ’07 Optima (MG): � Without a FAM, the circuit may go through the E/R

junction box � The PCM provides a single supply voltage to both

the FTPS and the A/C pressure transducer Caution: Shorting the 5V reference voltage can damage the PCM.



REFUELING VAPOR RECOVERY

ON-BOARD REFUELING VAPOR RECOVERY SYSTEM

(ORVR)

Fuel Filler Pipe

Check Valve

Vapor/2-Way/Cut Valve

ORVR Valve

Starting in 1998, vehicles were required to have an ORVR system to control vapors created during refueling by routing them to the canister during fuel refill. Some states have enacted stage two systems at refueling stations. The ORVR system can consist of the following: � Fill vent valve � Fuel shut off valve � Fuel cut/roll-over valve � Two-way valve for pressure/vacuum relief � Fuel liquid/vapor separator beside the filler pipe � Charcoal canister � Narrowing size fuel tank filler tube During refueling, a small amount of air is drawn into the filler pipe to prevent fuel vapors from escaping into the air during refueling. These vapors are drawn into the fuel nozzle and returned to the station’s tank. The fill pipe diameter reduces after the unleaded restrictor plate. This restricted pipe size forms a liquid seal into the tank rather than let fumes escape. The check valve is spring loaded to prevent fuel from coming up the filler pipe. The vapor valve vents to the canister through the ORVR valve, which has a float to close off the vent when the tank is full. A faulty ORVR valve can leak or cause difficulty when filling the tank, as pressure builds and causes early shut off of filler nozzle. Both valves shut off during a roll over event.

Check Valve

Stage II Nozzle

Liquid Seal

Vapor Valve

ORVR Valve

Canister

Pressure Vent

Unleaded Restrictor Plate

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RECOVERY CONTINUED

Pressure relief valve

A faulty ORVR valve can leak or cause difficulty when filling the tank, as pressure builds and causes early shut off of filler nozzle. Related Sedona DTCs: P0442 Small Leak P0456 Very small leak The ORVR valve may have a pressure relief valve, spring loaded in both directions for zero pressure in the tank and zero vacuum, that is vented to atmosphere. In hot weather conditions, a buzzing noise may be heard just as the engine is turned off. This is because the tank is being sealed under low pressure. Note: ORVR components vary in name and location. The vapor valve is also known as the 2-way and cut valve, while the ORVR is known as a float valve.

From the 2-Way & Cut Valve To the

Charcoal Canister

Pressure Relief Valve

ORVR Valve

Gasket



SUMMARY

With the completion of this module, you should be able to apply EVAP system theory to the diagnostic process. � The purpose of the evaporative emission control

system (EVAP) is to reduce the release of hydrocarbons into the atmosphere.

� The four modes of EVAP operation are:

� Refueling � Venting � Purging � Testing

� The EVAP electrical system contains a purge valve

(NC), canister close valve (NO), and a pressure sensor.

� The air filter needs regular inspection and

service. � Visual inspection is very important in diagnosis

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PROGRESS CHECK QUESTIONS

FILL IN OR SELECT THE BEST ANSWER HERE AND

RECORD ON THE ANSWER SHEET

1. Technician A says that the EVAP purge valve is normally open. Technician B says that the purge valve is normally closed but the canister vent valve is normally open. Who is correct?

a. Technician A b. Technician B c. Both Technician A and B d. Neither Technician A nor B

2. Technician A says that the charcoal canisters are

normally replaced during the 30k service. Technician B says that fuel tank air filters are inspected as part of the maintenance schedule. Who is correct?


3. All of the following statements are true EXCEPT:

a. The OBD II monitor tests the EVAP system for leaks

b. The OBD II monitor tests the EVAP system electrical components for faults

c. A vehicle owner can cause an EVAP DTC to be set after refueling the vehicle

d. The OBD II operates the EVAP system during normal operation, and Tech Line should always be consulted in case of a DTC



FILL-IN OR SELECT THE BEST ANSWER HERE AND


4. Technician A says that using an ohmmeter to perform a resistance check will not always identify a bad solenoid. Technician B says that faulty EVAP components can often be identified by a thorough visual inspection. Who is correct?


5. Technician A says that the fuel tank air filter is a

maintenance item. Technician B says that a dirty filter can set a DTC. Who is correct?


6. Technician A says that the electrical circuits of the EVAP system are continuously monitored, but the leak test and flow tests are only run under certain conditions. Technician B says that the EVAP system is continuously monitored by the PCM for leaks and flow whenever the key is on. Who is correct?


7. Technician A says the canister can exhaust HC not

captured through a filter during normal operation. Technician B says the EVAP system’s purpose is to prevent HC vapors from being released into the atmosphere. Who is correct?


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FILL-IN OR SELECT THE BEST ANSWER HERE AND


8. What passes though the canister close valve during purge?

a. Gasoline vapors b. Vacuum c. Filtered air d. Nothing; it is closed

9. Technician A says address EVAP PCSV related codes

first. Technician B says an EVAP related DTC tells a technician which component to replace. Who is correct?


10. All of the following are EVAP system operating

modes, EXCEPT:

a. Testing b. Fueling c. Resetting d. Purging e. Venting



Note Page

_________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________

Guided Practice


Guided Practice

Student Guide

KESD.04


SAFETY FIRST















!

!






use of this course.




TT-KESD207-IL-GP044th Printing - January 2011


Module Title


KESD EVAP Diagnosis Guided Practice Module 04 1

Kia Evaporative System Diagnosis Guided Practice

MODULE GOAL

MODULE OBJECTIVES

MODULE INSTRUCTIONS

INTRODUCTION

EXPECTATIONS

Upon completion of this module, the Kia service technician will measure FTPS voltage on an EVAP test station, practice component testing, EVAP system testing, and leak detection tasks. Given this module, EVAP test station, vehicle test equipment and components, the technician will be able to demonstrate the following task with 80% or greater accuracy: � Fuel Tank Pressure Sensor measurements � Purge Control Solenoid testing � Canister Closed Valve testing � Fuel Tank Pressure Sensor testing � EVAP vacuum decay monitoring � EVAP system leak testing � Leak diagnosing by smoke detection � Ultrasonic leak detection testing � Verifying an EVAP related concern � Fuel tank air filter inspection Read and follow the instructions carefully for each task. Answer the questions and fill in the blanks with the requested information as you perform the task. When you have finished, have your training instructor evaluate your work and sign off on the scorecard showing the work has been completed. Clean up your area as instructed. EVAP systems having a fault or customer concerns are not that difficult to diagnose as long as you follow a logical theory of diagnosis. With this module you should practice and have the ability to demonstrate this. Customers expect EVAP system to be trouble-free. Some owners do not know the importance of properly installing the fuel cap. When a vehicle does come in with a MIL for an EVAP DTC it is up to you, the service professional, to verify the concern such as does the leak exceed the limit. Next diagnose verified concern and fix the vehicle on the first visit. This may also include explaining the cause to the customer.

2 KESD EVAP Diagnosis Guided Practice Module 04


REQUIRED MATERIALS

TASK STATIONS

TIME TO COMPLETE

In order to complete this module, you will need the following items: Vehicles: � Sedona 3.8L � Optima 2.7L � Optima 2.4L � 2008 Optima 2.4L � Borrego 3.8L Equipment and Tools: � EVAP testing station � DMM (4) and T-connectors or jumper wires � BOB Pro � 5V, 12V 3A and 12V 25A power supplies � Vacuum pump, handheld � Flashlight and Hose clamp pliers � Waekon style EVAP tester � Fuel cap tester � Nitrogen tank w/regulator � Ultrasonic leak detection � K-Line style EVAP tester � Scan tool with printer – GDS (2) � Leak tubes (brass 0.20 & 0.40) Resources: � Scan tool (service information) Materials: � PCSV, CCV and 2 FTPS test boards � Good gas cap labeled #1, No Good gas cap #2 � CCV (3) and PCSV (3) � 2 FTPS, MG 2.7 L, and other Station 1: EVAP System Pressure Measurements Station 2: Test and inspect PCSV, CCV, and FTPS Station 3: Component identification and location Station 4A: Leak testing (hand-held tester) Station 4B: Leak detection (Ultrasonic) Station 5: Leak verification and detection Station 6: Leak verification and detection Station 7: Leak testing Station 8: GDS based EVAP test, verify repair Station 9: Fuel tank air filter inspection Approximately 2 hours 45 minutes

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STATION 1 - EVAP SYSTEM COMPONENT MEASUREMENTS


The EVAP test station will be used to measure FTPS output under various pressures. Explain if the CCV and PCSV are normally open (NO) or normally closed (NC) to your instructor. Turn the power supply ON, measure and record the FTPS output with the gas cap removed: _______ volts. Discuss if this is a valid base line and its importance. Operate the PCSV and CCV as noted below, momentarily switch ON the pump and record the FTPS output. Item: Good Cap

Purge OFFCCV OFF

Purge ON CCV OFF

Purge ON CCV On

FTPS: V V V Item: Bad Cap

Purge OFFCCV OFF

Purge ON CCV OFF

Purge ON CCV On

FTPS: V V V Feedback: Discuss your results with your instructor. Clean up your area as instructed.



STATION 2A: PCSV AND CCV INSPECTION AND TESTING

SERVICE INFORMATION

PURGE CONTROL

SOLENOID VALVE (PCSV)

CANISTER CLOSED VALVE (CCV)

Using GDS, look up and record the 2009 Sedona specs: PCSV: ___________ � CCV: _____________ � Discuss where the specs were located. Using a DMM measure and record the resistance below: PCSV: _____ � CCV: _____ � Results: Good No Good Connect and apply vacuum to the PCSV engine side fitting. Record the results with and without battery voltage applied to pin 1 and ground to pin 2. Voltage applied, vacuum is: Released Maintained No voltage applied, vacuum is: Released Maintained Was a faint click from the solenoid heard? YES NO The solenoid is: Good No Good Does it affect the long term operation of the valve if the hoses are connected backwards? YES NO Apply pressure into CCV large fitting. Record the results with and without battery voltage and ground applied. Voltage applied, air is: Released Maintained No voltage applied, air is: Released Maintained The solenoid is: Good No Good

E/R JUNCTION BOX Supplying B+

PCSV CCV

PCSV maybe shown as CPSV on ETM schematics

PCM controlled

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STATION 2B: FTPS INSPECTION AND TESTING

FUEL TANK PRESSURE

SENSOR (FTPS)

Connect 5 volts to pin 1 (red) and ground to pin 3 (black). Measure and record the pin 2 (test port) output voltage below with a vacuum pump using very slight low pressure applied (5 in.Hg maximum). Sedona 0 pressure + pressure - pressure Volts:

Optima 0 pressure + pressure - pressure Volts:

Discuss the differences between the two sensors. Feedback: Review your findings with your instructor. Clean up your area as instructed.

2.7L Optima (MG) 3.8L Sedona (VQ) Optima Sedona (VQ)



STATION 3: COMPONENT IDENTIFICATION AND LOCATION

Using the vehicle assigned to you by your instructor and a flashlight, identify and draw the location each of the EVAP components listed. Note: Depending upon the vehicle used, the location will vary.

Vehicle: Locate and record the location of each component below on the vehicle outline: 1. Fuel Tank Air Filter

2. Canister

3. Canister Close Valve

4. Fuel Tank Pressure Sensor

5. Purge Control Solenoid Valve

List the steps to replace the Fuel Tank Air Filter: __________________________ __________________________

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STATION 4A: EVAP SYSTEM LEAK DETECTION – HAND-HELD STYLE

LEAK TEST

Fuel Cap Test

Record the type of vehicle your instructor assigned you: Model: _______________________ Year: _______ Attach the correct cap adapter to the tester Check fuel cap for leaks using the cap tester 1. Install fuel cap onto the cap adaptor. 2. Press start to initiate auto-zero. Green LED ON. 3. Steady red LED ON, unit ready, install fuel cap. 4. Pump the handle until the green STOP LED is ON. 5. Up to 15 seconds for test until appropriate LED ON. Was the cap: GOOD NO GOOD Next, continue with leak testing the system.



STATION 4A: EVAP LEAK VERIFICATION & DETECTION – HAND-HELD

EVAP Leak Tester Pressure Guideline Chart

Capacity in gallons:

Percentage of Fuel in Tank (50% to 100%) 50% 55% 60% 65% 70% 75% 80% 85% 90% 95% 100%

10 70 66 62 58 55 51 47 43 39 36 32 11 76 72 68 64 59 55 51 47 43 38 34 12 82 78 73 69 64 60 55 50 46 41 37 13 88 84 79 74 69 64 59 54 49 44 39 14 95 89 84 79 73 68 63 58 52 47 42 15 101 95 90 84 78 72 67 61 55 50 44 16 107 101 95 89 83 77 71 65 59 53 46 17 113 107 100 94 88 81 75 68 62 55 49 18 120 113 106 99 92 85 79 72 65 58 51 19 126 119 111 104 97 90 83 75 68 61 54 20 132 124 117 109 102 94 87 79 71 64 56 21 138 130 122 114 106 98 90 83 75 67 59 22 145 136 128 119 111 103 94 86 78 69 61

After pressurizing the system to 14" H2O, monitor the pressure gauge for the number of seconds listed above.

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EVAP System Test

Record fuel level: _________________________. Is this the proper level to run EVAP test? YES NO 1. Install universal adaptor into the fuel tank filler

neck. 2. Close the CCV by either:

a. Grounding the CCV b. Clamping close the hose after the CCV c. GDS activating the CCV

Record the method used to close the CCV: ___________________________________________ 3. Install the pressure manifold tool and ground. 4. Using the hand held leak tester, pressurize the

system to 14 in. H2O with regulated nitrogen. The gauge does not read system pressure while filling.

Warning: Air & fuel vapors are explosive; using nitrogen reduces the chances of an accident. Do not apply more than 14-15 in. H2O (0.5 PSI) to the system. 5. If system cannot be pressurized, check that the filler

neck adaptor is properly attached. If so, check the closed status of the CCV and then to leak detection.

6. Using the chart, monitor the pressure gauge to

check for leaks for the length of test time based on fuel capacity.

Did pressure drop more than 6 in. H2O during the time period? ____________ Test results: Leak ________ No Leak _________ Leave the tester and GDS connected to the vehicle. Next, continue with leak detection.

PASS

FAIL



STATION 4B: LEAK LOCATING - ULTRASONIC

LEAK LOCATING: ULTRASONIC

Pressurize the system again (test); create a small leak by loosening the hose fitting onto the tank adaptor until small leak is present on the gauge. This tool can help pinpoint the leak. Nitrogen gas flowing through a leak will produce a sound that can be detected with this type of tool. Use the yellow filler latch on the manifold to maintain a constant pressure on the system while you locate the leak. 1. Plug in headphones and Turn ON, green light will

illuminate (Red indicates a low battery). 2. Point the sensor horn toward the suspected leak. 3. Start with the highest sensitivity setting (X100), and

then reduce the sensitivity by turning the thumb wheel or selecting a lower sensitive range.

What do you hear when a leak is located? __________ Feedback: Review your results with your instructor. Clean up your workstation as instructed.

Sensor Horn LED Thumb Wheel

HeadPhone

Volume

CoarseSettingSwitch

BatteryLevel

LED

Module Title



STATION 5: EVAP LEAK VERIFICATION & DETECTION – K-LINE STYLE

SETUP

LEAK TEST

Record the type of vehicle your instructor assigned you:

Model: _______________________ Year: _______ 1. Turn tester control to “Hold” position 2. Connect nitrogen tank supply hose to bottom of

flow meter and open valve on nitrogen tank 3. Connect vehicle test hose to self test port 4. Turn control knob to “Test” position and adjust

regulator to 14 in H2O 5. Turn control knob to “Hold” and move test hose to

appropriate preset orifice for vehicle being tested 6. Turn control knob to “Test” and set flow meter flag 7. Turn control knob to “Hold” and connect vehicle test

hose to “Y” test hose with fuel filler/cap test adaptors

8. Connect the test adaptors to fuel cap and filler neck 9. Close the CCV by grounding or pinching the hose

closed



STATION 5: CONT.

LEAK LOCATING: SMOKE

10. Turn control knob to “test” position and allow system to pressurize: � If the flow ball rises above preset, system has a

leak � If the flow ball falls below preset, system passes

Leak _____ No Leak _____ Review with your instructor. 11. Connect smoke machine to 12V. Push button to

activate smoke. Allow fuel system to fill with smoke and visually look for leaks using a 12V leak detection spot light. Record your results:

__________________________________________ Feedback: Locate the leak and review with your instructor. Cleanup your area as instructed.

Module Title



STATION 6: EVAP LEAK TEST – EVAP TESTER

SETUP

LEAK TEST

Record the type of vehicle your instructor assigned you:

Model: _______________________ Year: _______ 1. Position the Selector Switch on the control panel to

.020” 2. Start the flow of CO2 by pressing and releasing the

ON/OFF button and observe the position of the indicator ball in the flow meter and position the red pointer at the center of the ball

3. Stop the flow of CO2 by again pressing and

releasing the ON/OFF button 4. Position the Selector Switch on the control panel to

TEST 5. Connect the test adaptors to fuel cap and filler neck 6. Close the CCV by grounding or pinching the hose

closed 7. Start the flow of CO2 by pressing and releasing the

ON/OFF button and observe the position of the indicator ball in the flow meter � If the ball rises above preset, the system has a

leak � If the ball fall below the preset, the system

passes LEAK __________ NO LEAK ___________



STATION 6:

LEAK LOCATING: SMOKE

8. If a leak is indicated set the Selector Switch to SMOKE. Allow the fuel system to fill with smoke and visually look for leaks using the 12V leak detection spot light. Record your results:

__________________________________________

When finished stop the flow of CO2

Feedback: Locate the leak and review with your instructor.

Cleanup your area as instructed.

Module Title



STATION 7: EVAP LEAK TEST – WITH OUT TESTER

SETUP & TEST

When verifying an EVAP related leak DTC and the test equipment is not available, try the following procedure. Record the type of vehicle your instructor assigned you: Model: _______________________ Year: _______ 1. Record the fuel tank level: Using BOB Pro (2003-current MY vehicles), monitor FTPS output signal voltmeter or connect voltmeter to the FTPS using a T-connector. With Key On Engine Off (KOEO) and gas cap OFF, record results:

Is reading within specs?

If voltage is not within specs, list the next test step(s): Why is the gas cap left OFF during the test?

Leave the voltmeter hooked up because you will be referring back to it through out the test.



STATION 7: RESTRICTION & PCSV LEAK INSPECTION

SETUP TO INSPECT FOR A RESTRICTION

INSPECTION

INSPECT PCSV FOR LEAKING

VERIFYING IF A LEAK IS

PRESENT

Install the gas cap, KOER and based upon the vehicle, pull a vacuum in the system at the tanks side of the PCSV. Monitor the FTPS voltage with voltmeter for 25 seconds. Record the results: _________________volts Base upon the vehicle being tested, list the voltage should not drop below: _____________volts If it did, then there is a ______________in the system. Why leave the PCSV connected and clear any DTC? ____________________________

Unplug the PCSV 2 wire connector. Disconnect and manually energize the CCV to close it Lower the vehicle and start the engine. Record the FTPS voltage: ________________v. What does the above results indicate: ______________ With the CCV still closed manually, disconnect PCSV hose (Tank Side) and pull a vacuum manually. The FTPS voltage will ________, stop applying vacuum and hold when voltage reaches approximately _________v. If voltage changes more than 0.3v in 1 minute of constant monitoring, there is a ___________.

Module Title



STATION 8: GDS BASED EVAP LEAK TEST – VERIFY REPAIR

SETUP

TESTING

RESULTS

After repairing the EVAP system, the repair must be verified. The drive cycle is the most comprehensive method to verify the repair. Another way is to use the GDS leakage test. Record the type of vehicle your instructor assigned you: Model: _______________________ Year: _______ 1. Install the GDS, VCI and select vehicle. 2. Inspect and clear all DTCs. 3. From the home menu, click on EVAP Leak Test. 4. Click on EVAP leakage test. 5. Perform leakage test. 6. Record test results:

LEAK DETECTED NO LEAK DETECTED 7. Select monitoring test results from vehicle S/W

management. 8. Select EVAP Emission Monitoring. 9. Review the following results with your instructor.

a. EVAP Vacuum Test: _______________________ b. EVAP Weak Vacuum Test: __________________ c. Small Leak 0.20”: _________________________ d. Small Leak 0.40”: _________________________ e. Purge Leak Vacuum: ______________________

Feedback: Review your results with your instructor. Cleanup your area as instructed.



STATION 9: FUEL TANK AIR FILTER INSPECTION

SERVICE

The fuel tank air filters have different locations and filter elements depending upon the vehicle, as shown above. A common issue is a contamination restriction. Performing on-time maintenance inspection and service reduces the likelihood of the vehicle MIL illuminating due to an EVAP DTC P2422. Recommended service inspection is usually at _____________ miles with service replacement at _____________ miles.

Filter

Module Title



STATION 9 CONTINUED - FUEL TANK FILTER SYSTEM INSPECTION Discuss with your team on the best way to inspect the

fuel tank air filter system on the vehicle your instructor assigned to you. Record the method below.

_____________________________________________ Discuss what happens to the pressure in the EVAP system while under purge with a restricted air filter.

____________________________________________ The following are general directions based on the 3.8L. 1. Safely prepare the vehicle on a lift for KOER

operation and visually inspect air filter. 2. Connect the GDS with VCI and select the vehicle

and set the configuration to mBar. 3. GDS: Select current data, then fuel tank pressure

sensor. Record the results below: a. Fuel tank pressure KOEO: __________________ b. Discuss the results.________________________ c. Discuss the unit of measurement GDS is using

on the vehicle (vacuum vs. voltage) 4. Bypass or ground the PCSV so purge occurs and

with KOER (no DTC), record the fuel tank pressure: _______________

Discuss with your team the various results to see if you can determine the filter’s status. If the filter was restricted, list the part(s) to replace:

____________________________________________

Note: A restriction in the air filter system such as a nest or web can set a DTC P2422. Sorento has an intake vent valve attached to the filler neck that can be cleaned out using compressed air. The valve goes to the air filter that’s next to the canister. Note: When replacing a filter, do not replace the canister assembly unless needed.

Feedback: Review your results with your instructor. Cleanup your station as instructed.



Note Page

_________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________ _________________________________________________________________


Theory Module

Theory Module

Student Guide

KESD.05


SAFETY FIRST















!

!






use of this course.




TT-KESD207-IL-TH054th Printing - January 2011


Module Title


KESD EVAP Diagnostic Theory Module 05 1

Kia Evaporative System Diagnosis EVAP DIAGNOSTIC THEORY AND TIPS

MODULE GOAL

MODULE OBJECTIVES

ACRONYMS

TIME TO COMPLETE

Upon completion of this module, the Kia service technician will be able to demonstrate knowledge of the EVAP system and Diagnostics. Given this module and a written test, the technician will be able to complete the following with 80% or greater accuracy: � Select the 5 steps to the EVAP diagnostic process � Identify the 3 EVAP monitoring checks � Select 4 EVAP enable criteria conditions � Select 4 types of leak detecting methods � Select 3 methods of determining component failure � Identify diagnosis tips for various EVAP components FTP: Federal Test Procedure OBD: On-Board Diagnostics Approximately 30 minutes

2 KESD EVAP Diagnostic Theory Module 05


EVAP DIAGNOSTIC FLOW CHART

Module Title



INTRODUCTION

EVAP FLOW CHART

The vehicle’s EVAP system is a simple system to service and diagnose. In this module we’ll recap some of what you have already learned and cover the next step in diagnostics, including some of the best EVAP diagnostics practices. The EVAP flow chart will help you determine the root cause of the customer’s concern by following a logical organized diagnostic plan. 1. First, confirm the customers concern such as the

MIL is ON. a. Next, determine if it’s an EVAP related code.

2. If so, select Hot Fix: a. Print related service information b. Review warranty history for subsequent repair

i. If so, open TechLine case

3. Review the specific DTC diagnostic guide a. Review code setting information b. Inspect detecting conditions c. Perform step-by-step inspection

4. Repair vehicle

5. Verify repair with drive cycle If this is the second or subsequent repair, open a TechLine case on KGIS. Also if +30 minutes is spent diagnosing the confirmed concern without a conclusion. Note: An example of a software related issue can be found in service information TSB #KT2006092601, 2006 Sedona VQ, P0441 code. Not all DTC faults are related to components. This PCM re-flash can fix a concern that cannot be fixed by repairing the circuit or replacing the service component.



OBD II – EVAP SYSTEM

MONITOR

ENABLE CRITERIA

FAULT

NON-CONTINUOUS AND CONTINUOUS MONITOR

As a part of the OBD II emissions system required on all passenger vehicles sold in the U.S. since 1996, the EVAP system is required to be able to test itself for leaks, adequate flow, and electrical faults. This test is called a monitor and is automatically run by the PCM. To make the test results reliable, the monitor will only run when certain specific conditions are met. These conditions are called enable criteria. Examples for EVAP include: � Fuel level 15%-85% � Cold startup (less than 180F) � 12 hours since monitor ran last � Drive cycle type operation If an EVAP leak fault is detected by the PCM during the monitor, a DTC Pending is stored in memory. If the same fault occurs again during the next monitor, a DTC is stored, data is recorded in Freeze Frame, and the MIL is illuminated. Most EVAP DTC ON condition is 2 trips (driving cycles) and is listed in the DTC detecting conditions. The EVAP monitor is non-continuous, but the EVAP electrical circuits are continuously monitored for opens, shorts, and out-of-range. An electrical fault will set a DTC on two drive cycles. MIL is turned off by one of the following methods: � Scan tool (best choice) � Battery power removed from PCM � Three consecutive trips completing the monitor with

no faults

Trip means vehicle operation, enable conditions have been met, followed by a key off and a computer shutdown.

Module Title



EVAP SYSTEM MONITORING – OBD II - INTRODUCTION

EVAP System Monitoring

The system opens the PCSV to determine the signal fluctuations due to present conditions; then both the PCSV and CCV are closed to stabilize the pressure prior to the EVAP monitoring system performing the following checks: � Fuel vapor generation � Evacuation � Leak check At first the OBD II system checks if the vapor generation, due to fuel temperature, is small enough to start monitoring. Next, the system is evacuated by opening the PCSV using a ramp in order to maintain a certain vacuum level. The final step is to check if there is vacuum loss due to any leakage in the system.



EVAP SYSTEM MONITORING – OBD II - CHECKING

VAPOR GENERATION

CHECKING

EVACUATION

During the stabilization period, the PCSV and CCV are closed and the system pressure is measured with the FTPS: � At DP_A to establish the starting pressure � Again at DP_B after a defined time period (T1) The difference (DP_B – DP_A) is calculated. If this is larger than a predetermined threshold, there is excessive vapor and the monitor is aborted. If the difference is lower, the PCSV is regarded as being stuck or clogged in an open position, setting a pending P0441 related EVAP code. The PCSV is opened with a ramp for the pressure to decrease to a certain level. If pressure cannot be lowered below a predetermined threshold, the system is determined to have a loose gas cap leak or large leak, setting a pending P0455 related EVAP code.

Module Title



EVAP SYSTEM MONITORING – OBD II - CHECKING CONTINUED

LEAKAGE CHECKING

System Decay

Small Leak Checking

The PCSV is closed and the system delays time (waits) to get stabilized system pressure and for a leak to be detected. The system is monitoring vacuum decay thru the FTPS. While the system is closed for a predetermined amount of time, it must maintain a certain amount of vacuum with very minimal loss or the system will set a pending P0442 related EVAP code. Next, during the T2 time period, Small Leak Checking is performed by measuring the beginning (DP_C) and ending (DP_D) system pressure. The diagnosis is based upon the difference (DP_D – DP_C) corrected by the natural vapor generation (DP_B – DP_A) rate from the earlier vapor generation checking step. A pending P0456 related EVAP code is set.



J 1979-MODE 6 TEST

ID TID DESCRIPTION COMPONENT ID (CID) CID DESCRIPTION

$0A Request Enhanced EVAP System (0.020” Leak)

$42 EVAP Excess Vacuum Test

$03 EVAP Weak Vacuum Test

$06 0.020” Leak Test

$05 0.040” Leak Test

$48 EVAP Purge Leak Vacuum Fail

SEDONA 3.8L MODE 6

Mode 6 data is raw data that is used by engineers to program software to meet FTP requirements. It usually runs in the background. The 2006 Sedona data chart is shown from the service information on KGIS. The processed DATA is displayed on GDS under the vehicle S/W tab, Inspection/Test, Monitoring test results, OBD monitoring test results, EVAP emission monitoring (shown on the next page). KIA monitors EVAP emissions using five tests: Request Enhanced EVAP System 0.020” Leak � CID $42: EVAP EXCESS VACUUM TEST

� Test is for Restriction � Related Delphi DTC: P2422.

� CID $03: EVAP WEAK VACUUM TEST

� Test is for system leaks; vacuum leak is small but greater than 1.0mm

� Related Delphi DTC: P0455.

� CID $06: SMALL LEAK 0.020” (0.5 mm) � 0.5mm = 0.020 leak � Related Delphi DTC: P0456.

� CID $05: Large LEAK 0.040” (1.0 mm)

� 1.0mm = 0.040 leak � Related Delphi DTC: P0442.

� CID $48: EVAP PURGE LEAK VACUUM FAIL

� Vacuum / no vacuum can be achieved � Related Delphi DTC: P0441.

Module Title



EVAP EMISSION RESULTS

The GDS EVAP Monitor processed data is shown, which is GDS representation of the Mode 6 test results. Other systems will vary the location and information provided, such as PASS / FAIL / or no information.

Restriction

LARGE LEAK (1.0 mm)



ENABLE CRITERIA FOR EVAP DIAGNOSITCS Item 2008 Sedona P0441 Detecting Condition Possible cause

DTC Strategy � Check if tank vacuum exceeds threshold/time � PCSV

� PCM

Enable Conditions

� 10V < Ignition Volt < 16V

� Barometric pressure > 72 kPa

� Engine off time > 720 min

� Startup ECT -Startup IAT < 12°C (53.6 °F)

� 0°C( 32 °F) < Startup ECT < 40°C (104 °F)

� 0°C( 32 °F) < Startup IAT < 40°C (104 °F)

� Start-up IAT-IAT < 1°C (33.8 °F)

� 1sec < Engine Run Time < 100sec

Threshold value � Tank vacuum � threshold value > 2 sec.

Diagnosis Time � Continuous

MIL On Condition � 1 driving cycle

Item 2007 Optima 2.4L P0441 Detecting Condition Possible Cause

DTC Strategy � Monitoring canister purge valve stuck open � Faulty EVAP

canister purge valve

(PCSV)

Enable Conditions

� Coolant temperature >50°C (122°F)

� Modeled ambient air temperature >-10°C (14°F)

� Vehicle speed <10km/h (6mph)

� Time after start >100 sec.

� Estimated altitude <2.4km (8000ft)

� Canister load <1

� Minimum canister purge time: 3~25sec.

� Idle speed engine operating state

� Differential fuel tank pressure: -11 ~ 4hPa

� Time since last EVAP monitoring test abortion >60 sec.

� No relevant failure

� Battery voltage >10V

Threshold Value � Differential fuel tank pressure during vapor generation

Diagnostic Time � 6 sec.

MIL On Condition � 2 Driving Cycles

TEST ENABLE CONDITIONS

EVAP test only runs under DTC-specific enable conditions. These conditions can vary based upon the PCM/ECM programming criteria. In the two examples shown, compare the conditions between the vehicles.

PCSV stuck open

PCSV Leaking

Module Title



EVAP DIAGNOSTIC METHOD AND TEST SEQUENCE

Item 08 Sedona P0455 Detecting Condition Possible cause

DTC Strategy � Monitor the fuel tank’s vacuum

� Fuel Filler Cap missing � Leakage in each hose, fuel filler pipe � Leakage in CCV, Canister, Fuel tank � Stuck in each purge line between fuel tank and intake manifold

Enable Conditions

� 10V < Battery voltage < 16V � Barometric pressure > 72 kPa (0.72 bar) � ECT - IAT < 12° F at startup � ECT and IAT at startup: 40~95° F � Fuel level: 15~85%

Threshold value � Fuel tank’s vacuum < a prescribed threshold

Diagnosis Time � On time during Evaporative system diagnosis

MIL On Condition � 1 driving cycles

FOUR MAJOR TESTS

The EVAP diagnostic performs four major tests in this sequence: 1. P0441 – The Continuous Purge Flow / purge valve

leak test is run first. If the purge valve is leaking, the small and very small decay tests may not be capable of detecting leaks.

2. P0455 – The Large Leak/low tank vacuum shown above runs next. The Small and Very Small Leak tests need an initial vacuum level for the decay tests. The large leak test provides a stable starting point.

3. P0442 and P0456 – Small (>0.040” and >0.020”) and Very Small Leak tests follow and run concurrently as a twenty-five second decay test.

4. P2422 – The Blocked Vent test runs next for high tank vacuum.

Next, let’s look closer at each of these four tests. Note: The following EVAP tests are for the electrical circuits (Sedona VQ shown): Item: Open Short PCSV P0444 P0445 CCV P0447 P0448 Range Low High Intermittent FTPS P0451 P0452 P0453 P0454 Fuel Level

P0461 P0462 P0463 P0464



PURGE VALVE LEAK TEST

CARB & EPA CONCERNS

TEST REQUIREMENT

TEST METHOD

An HC leak thru the PCSV with engine off or non-metered fuel to the engine during cold start. Detect a leak (0.020 or larger) thru the PCSV, set the fault code P0441 and illuminate the MIL based upon the condition. With engine running, shut both the PCSV and CCV valves and inspect for an increase in pressure over time. � High/increase in system vacuum indicates a leak

thru the PCSV since the main source of vacuum is the manifold.

� A timer determines the test length.

PCSV normally closed

FTPS

CCV commanded closed

Module Title



PURGE VALVE LEAK TEST - CONTINUED

TEST REQUIREMENT

TEST METHOD

The tank pressure is monitored for a decrease in order to determine flow. The CCV is opened and the PCSV is duty cycled from 0 – 100% during the second cycle to lower the system pressure.

CCV commanded closed

FTPSPCSV commanded open



LARGE LEAK TEST

CARB & EPA CONCERNS

TEST REQUIREMENT

TEST METHOD

A large leak can allow HC to leak into the atmosphere. � Component failure (cracks, holes, seals) � Customer not replacing cap correctly Detect the large leak, stop the test and set the P0455 conditions. � Retest on next key cycle in case gas cap was the

cause and extinguish the MIL lamp for this concern. With engine running, shut the CCV, open the PCSV to purge the system, and inspect for EVAP system vacuum increase over time. � High system vacuum indicates no leak � Low system vacuum indicates a system leak There are two large leak tests: � Cold large leak test—standard test that runs when

the enable criteria are met � Warm large leak test—runs after a large leak fault is

logged and cold tests are not enabled. The test by passes the enable criteria.

CCV commanded closed FTPS

PCSV commanded open

Module Title



SMALL LEAK TEST

CARB & EPA CONCERNS

TEST REQUIREMENT

TEST METHOD

A small leak can allow HC to leak into the atmosphere. � Component failure (cracks, holes, seals). Detect small leak and set P0442/P0456 conditions. Vacuum decay with fuel vapor correction. Small Leak detects 0.040 or smaller leaks by measuring the vacuum decay rate in a sealed EVAP system. � Typical decay period is 10 seconds � Decay rate correlated to leak size and vapor space � Failing slope sets P0442 fault, aborts Very Small

Leak test, and exits subsequent EVAP diagnostics. Very Small Leak detects 0.020 or smaller by measuring the vacuum decay rate in a sealed EVAP system � Typical decay period is 25 seconds � Decay rate correlated to leak size and vapor space � Failing slope sets P0456 fault.

CCV commanded closed PCSV

normally closed

FTPS

Normal Purge Operation



NORMAL PURGE OPERATION & BLOCKED VENT TEST

CARB & EPA CONCERNS

TEST REQUIREMENT

TEST METHOD

A block in the vent system, such as the tank filter: � May prevent removal of vapors from the canister � May prevent canister filling with vapors during shut-

down and may result in fuel cap venting � May slow or prevent fuel re-filling � May not allow decay test to complete Detect a 100% blockage in the vent system and set P2422 conditions. Test is run with CCV open, engine running, and purge commanded open at a constant purge flow rate. Look for an increase in EVAP system vacuum over time. Tank vacuum is continuously monitored (FTPS) and, if it exceeds a threshold condition, there is a blocked vent path.

Module Title



EVAP DIAGNOSTIC TIPS

GASKETS, SEALS, AND LINES

Carefully inspect o-rings and lines during EVAP inspection, including: � Technicians need to inspect for cracked lines, cut o-rings,

or non-sealing gaskets. � Care should be taken when moving or removing lines. � When replacing these lines the technician should watch

out for other parts that are connected in order not to damage those when installing the lines and/or components.

� A nick in an o-ring will cause a leak to be created. Moving

EVAP lines to gain access to other components or wiggling lines during inspection can cause cracks, or bends, or kinks in these lines.

� A system with a very small leak may not set a DTC, but 2

or more of these small leaks can add up and set a DTC.

ORVR gasket Fuel Cap gasket

FTPS O-Ring



TIPS FOR LOCATING LEAKS

It’s important to inspect the system for weak points or leaks before connecting leak detection equipment. Next, test the system to confirm a leak, then inspect for the leak’s location. Below are four methods of finding the leak. � Insert smoke into the system and use a bright spot lamp. � Since EVAP is a dry system, smoke is used. Today’s

smoke does not have dye but may have a lemon smell. � Using a Ultra Sonic Leak detection tool � Pressure system at 14 in. H2O with nitrogen, then with a

spray bottle of soapy water spray the joints and lines and look for bubbles.

� When using ultrasonic leak detection do not use

soapy water because the bubbles will attenuate the ultrasound.

� Look at a flow gauge while clamping off sections of hose

to isolate the leak. When flow stops the leak is found. Technicians may have to inspect for leaks using more than one method to be successful. Warning: Do not use shop air. It can promote combustion and insert dirt into your testing equipment and the system.

Smoke Unit

Module Title



CHARCOAL CANISTER CONCERNS AND TIPS

Customers may fuel the vehicle and continue to top off the system, trying to get the maximum amount in. When this happens, fuel can reach the canister’s liquid fuel trap. Older canisters can release charcoal into the EVAP system, keeping valves from closing or opening. � During inspection, check for granules of charcoal

(older systems). � Compare the weight of the canister to a known

good one to determine if fuel soaked. � Inspect for cracks, hose misalignments, and visible

damage due to collision, etc. � When smoke testing, look for smoke around the

canister as well as the hoses. There is no scheduled service for the canister and the charcoal is not replaceable.



FUEL TANK PRESSURE SENSOR (FTPS) CONCERNS AND TIPS

06 Sedona 3.8L Optima MG,

Rondo UN, Borego 3.8L 2007 – Current Sedona

2005 - Sportage 2.7L

-6.67 kPa 0.5 V -3.75 kPa 4.5 V -2.5 kPa/-.26psi 0.5 V 0 2.5 V 0 1.5 V 0 2.5 V

6.67 kPa 4.5 V 1.25 kPa 0.5 V 2.5 kPa/.36psi 4.5 V

Since the FTPS converts EVAP system pressure to a proportional analog voltage signal for the PCM to evaluate the EVAP system operation, it is important the FTPS is reading correctly (baseline). This can be inspected by removing the gas cap and reading atmospheric pressure voltage with KOEO. � Remember a general rule for most Kia FTPS: at

KOEO status the return voltage should be 2.5 + /- 0.3 volts.

� Optima MG, Rondo UN, Borrego 3.8L 07-current

Sedona FTPS is 1.5 + / - 0.3 V. � Refer to service information for specifications

� Inspect if fuel was forced into the sensor due over-

filling the fuel tank.

Sedona Optima Sportage

Module Title



PURGE CONTROL SOLENOID VALVE (PCSV) CONCERNS AND TIPS

PCM controlled PCSV purges any collected vapors from the canister back to the engine for combustion. The following are simple checks that can be done during the inspection when flow or a leak is a concern: � Inspect the hoses to ensure they are connected

correctly and in good condition with no leaks. � A new, incorrectly connected PCSV will operate but

have a reduced service life. � Inspect the PCSV. � Unplug the purge valve. � Verify vacuum source is OK. � Check the fuel tank side of the valve for vacuum; if

vacuum is constant and the valve has been unplugged, it is faulty.

� Test the resistance value of the solenoid. � Check for charcoal granules or other debris in this

valve that will cause problems. � Check for a stuck pintle.

From Canister

To Intake



CANISTER CLOSE VALVE (CCV) CONCERNS AND TIPS

The PCM controlled CCV is normally open to fresh air through the fuel tank air filter, including times of canister purging. It is commanded closed during leak detection. The following are simple checks that can be done during the inspection when flow or a leak is a concern: � Inspect the hoses and clamps. � Inspect the CCV. � Test the resistance value of the solenoid. � Check for flow with CCV at rest (de-energized). � Manually energize CCV and check for sealing. � Inspect for case cracks, this has simple mechanical

pintle inside like the PCSV.

To Air Filter

To Canister

Module Title



ORVR VALVE / TANK VENT / CATCH TANK CONCERNS AND TIPS

ORVR system forces HC vapors during fuel fill into the canister via the tank vent valve. Failures usually: � Makes it difficult to refuel the vehicle due to the

nozzle clicking off. � Leave a gas smell around the vehicle.

The tank vent valve can fail by:

� Clogs or sticks closed, causing fill problems � Vent can stick open and allow sloshing fuel to be

drawn into the canister.

A Catch Tank is used to capture fuel that is drawn into the system, preventing it from entering the canister. The fuel evaporates and is drawn in during purge.

Note: To make this a two stage vapor recovery system, certain states have fueling stations recovering HC vapors at the pump during fueling.

Note: Some newer vehicles such as the 2011 Sportage have the ORVR and Vent Valve located inside the tank and connected to the fuel pump assembly with a flex hose. Removing the fuel pump assembly without disconnecting the flex hose will cause the valves to become dislodged and must be put back in place in the top of the tank.

ORVR Valve Vent Valve Catch Tank Catch Can



FUEL TANK AIR FILTER CONCERNS AND TIPS

Air Filter

Pre-Canister

CCV

Canister

Filter’s effectiveness in reducing contamination

Module Title



Item P2422 Detecting Condition (2008 Sedona) Possible cause

DTC Strategy 1) Monitor vacuum when purging at a prescribed rate.

1) Faulty Canister Close Valve 2) Clogging of canister air filter 3) Open in ground harness of FTPS 4) Faulty PCM

Enable Conditions

1) 10V< Ignition Volt < 16V 2) Barometric pressure > 72 kPa 3) Engine off time > 720min 4) Startup ECT -Startup IAT < 12°C( 53.6 °F) 5) 0°C( 32 °F) < Startup ECT < 40°C(104 °F) 6) 0°C( 32 °F) < Startup IAT < 40°C(104 °F) 7) Startup IAT-IAT < 1°C(33.8 °F) 8) Engine Run Time > 1sec 9) Purge enable time < Threshold (mapped in PCM) 10 Cold Start Time < 300sec. 11 0.03 %< Fuel Level < 0.97 %

Threshold value 1) Tank vacuum � 8 inH2O (for more than 5 sec.) 2) Purge rate : 0.15 g/s

Diagnosis Time 1) -

MIL On Condition 1) 1 driving cycle

The fuel tank air filter design has different sizes and thickness of filter depending upon the vehicle. Some vehicles, such as the Spectra, have a pre-canister that has charcoal coated honeycomb interior. It’s located before the canister and after the CCV. Depending upon the model, the filter is inspected between 12,000-15,000 miles and replaced at 30,000 mile service as a maintenance item to help prevent a P2422 DTC (shown above). � Check fuel tank air filter for blockage or reduced air

flow. � The fuel tank air filter is sold and serviced

separately from the canister assembly. The filter is effective in filtering the air flowing through the CCV and canister. The interior of the CCV shown does not show contamination, including the foam filter inside the canister. When the vacuum increases to the threshold value, a restricted flow is indicated and a DTC P2422 is set. Note: The fuel tank air filter may also be called the canister air filter.





ON THE ANSWER SHEET

1. When following the EVAP flowchart, it is always necessary to contact TechLine and advise them that you have an EVAP problem.

a. TRUE b. FALSE

2. Technician A says that when you have an EVAP

failure you should use the smoke tester first. Technician B says that you should use the smoke machine if you have a leak and cannot spot it. Who is correct?

a. Technician A only b. Technician B only c. Both Technician A and B d. Neither Technician A nor B

3. Customer states that MIL came on after having a

60K service. The first thing you should do is:

a. Have the service manager pull the warranty history

b. Tighten fuel cap c. Verify MIL on d. Disconnect the battery and clear the code

4. Technician A says overfilling the fuel tank can

damage the FTPS. Technician B says that the charcoal canister can also be damaged by overfilling the fuel tank. Who is correct? a. Technician A only b. Technician B only c. Both Technician A and B d. Neither Technician A nor B

Module Title





ON THE ANSWER SHEET

5. The EVAP monitor runs when certain specific enable criteria conditions are met. All of the following are conditions, EXCEPT:

a. Fuel tank level b. Engine coolant startup temperature c. Time since monitor ran last d. Drive cycle type operation e. Drive wheels off the ground

6. After confirming a leak, all of the following are

methods that a technician can use to find the leak EXCEPT:

a. Insert smoke into the system b. Visual inspection c. Use Ultra Sonic Leak d. Pressure system and spray the joints and lines

with nitrogen

7. Technician A says that a visual inspection, including hoses and connectors, is a good place to start diagnosing if an EVAP component has failed. Technician B says that checking the electrical and mechanical operation is also a good place to start diagnosing if an EVAP component has failed. Who is correct?


8. Technician A says that the canister air filter needs to

be replaced at the 30,000 mile service. Technician B says that the canister should be replaced at the 120,000 service. Who is correct?






ON THE ANSWER SHEET

9. Technician A says that an EVAP failure concern could be corrected by a PCM software upgrade. Technician B says that a failed gasket may cause and EVAP failure. Who is correct?


10. Technician A says that the Optima 2.4L FTPS

voltage will be 1.5V with the gas cap OFF. Technician B says that the FTPS can measure the vacuum decay rate in a sealed EVAP system. Who is correct?



PerformanceAssessment

PerformanceAssessment

Student Guide

KESD.06


SAFETY FIRST















!

!






use of this course.




TT-KESD207-IL-PA064th Printing - January 2011


KESD EVAP Performance Assessment Module 06 3


KESD Performance Assessment Module 06 1


Performance Assessment

MODULE GOAL

MODULE OBJECTIVES

MODULE INSTRUCTIONS

COURSE QUESTIONAIRE

The goal of this module is to allow the Kia service technician to be tested for a successful completion of the Kia EVAP System Diagnosis Course. Given the previous five course modules, the technician will be able to answer the Performance Assessment questions with 80% or greater accuracy. Answer the questions with the best answers and record the requested information on your answer sheet. When you have finished, turn in the answer sheet to your instructor, who will grade and record the results on your scorecard. When finished with the performance assessment, complete the course questionnaire located in the back of the PA model, pages 13-14. Thank you.


2 KESD Performance Assessment Module 06

PERFORMANCE ASSESSMENT QUESTIONS

FILL IN OR SELECT THE BEST ANSWER

1. A vehicle comes in with the MIL ON due to an EVAP related DTC. Technician A says that the EVAP monitor can be run at any time by just starting the engine, KOER. Technician B says that the EVAP monitor can be run at any time by using the scan tool. Who is correct?


2. A fuel cap failed while being tested with the fuel

cap tester. Technician A says that it needs a new cap. Technician B says that the cap could have failed the test because of a crack on the fuel tank filler pipe. Who is correct?


3. An EVAP concern is being diagnosed. Technician A

says that FTP sensor voltage changes as pressure changes. Technician B says that FTP sensor amperage changes as pressure changes. Who is correct?


4. The car is running and you are monitoring FTPS

voltage. The voltage is not indicating a vacuum in the tank. Which of the following EVAP components most likely is the cause?

a. Closed CCV b. Faulty FTPS c. Mechanically opened PCSV d. Restricted canister air filter






5. Technician A says that ultrasonic testers are designed to be used for locating an EVAP leak. Technician B says that the EVAP system must be pressurized before using this tester. Who is correct?


6. While using a smoke generator during EVAP testing

smoke is noticed coming out of the filter. What is the most likely cause?

a. Improper use of GDS b. Clogged filter c. CCV is open d. Filter needs to be replaced

7. Technician A says that the EVAP system must be

able to contain fuel system CO emissions. Technician B says that it must be able to contain fuel system HC emissions. Who is correct?


8. Technician A says that the purge control solenoid

valve is normally open. Technician B says that the purge control solenoid valve is normally closed, but the canister close valve is normally open. Who is correct?






9. Technician A says that nitrogen gas is used for EVAP system testing because it is inert (nonflammable and dry). Technician B says that shop air is safer to use because it is compressed.


10. Technician A says that the EVAP system is

continuously monitored by the PCM for leaks and flow whenever the key is ON. Technician B says that the electrical circuits of the EVAP system are continuously monitored, but the leak test and flow tests are only run under certain conditions. Who is correct?


11. An EVAP system is being tested with an external

testing unit and will not hold pressure. Technician A says that the canister close valve could be open. Technician B says that the purge control solenoid valve could be sticking open. Who is correct?







12. Any of the components listed below could cause insufficient purge flow EXCEPT:

a. Gas cap b. PCSV c. Filter d. CCV

13. What usually passes through the PCSV?

a. Liquid fuel b. Fuel vapors c. Vacuum d. Filtered air

14. Technician A says that enable criteria for the EVAP

monitor to run include the gas cap being tight. Technician B says that enable criteria include pressurizing the system with nitrogen. Who is correct?


15. Technician A says that it is important to always

address any PCSV related codes before continuing troubleshooting. Technician B says that it is important to tighten the gas cap before beginning any inspection. Who is correct?






16. Which of the following best describes a PCSV?

a. Sends a signal to the PCM during purge b. A normally open-type solenoid valve c. A normally closed-type solenoid valve d. A variable resistance-type solenoid valve

17. Charcoal canisters are scheduled to be replaced

every 60,000 miles.

a. TRUE b. FALSE

18. The following question involves the FTPS operation

on a 2007 Sedona (VQ). Technician A says that as tank positive pressure increases, sensor signal voltage increases. Technician B says that as tank vacuum increases, sensor signal voltage increases. Who is correct?


19. Technician A says that the canister filter is able to

capture and hold hydrocarbons when the canister is full. Technician B says that the canister air filter is scheduled for replacement at 30k miles service on some Kia vehicles. Who is correct?


20. A vehicle with a dirty, restricted EVAP canister air filter would most likely have:

a. Reduced fuel economy b. Low power c. Extended cranking on start up d. The MIL illuminated






21. The Leak Detection pump that was used on some Kia models:

a. Runs to complete the OBD II monitor b. Helps increase purge flow c. Draws vacuum so the PCM can test decay time d. Is part of the enhanced PCV system

22. Technician A says that the EVAP diagnostic flow

cart has you check service history which will allow you to determine if this is the first or second repair attempt. Technician B says that if you cannot find a problem after following the EVAP diagnostic flow chart and spending +30 minutes diagnosing, then you should open a Tech Line case. Who is correct?


23. Technician A says that the CCV must be energized

during EVAP leak checks. Technician B says when the CCV is closed the PCM will monitor vacuum decay through the FTPS. Who is correct?


24. The EVAP system diagnostic performs all of the following tests, EXCEPT:

a. Blocked vent b. Leak test c. Leak flow d. Purge flow/purge leak





25. What does the PCM/ECM monitor while using a leak detection pump?

a. Voltage draw b. Ohms c. Pressure in the system d. Pump motor amp draw

26. Technician A states that a 0.5mm leak is

considered a very small leak and 25% of the flow rate of a 0.40” leak. Technician B states that mode 6 data is monitor test results. Who is correct?


27. During smoke testing, Technician A says that clamping off the nylon/hard plastic lines while watching the flow gauge will help isolate the leak. Technician B says smoke can help find the leak’s location. Who is correct?


28. Why is shop air not used to test for leaks in the EVAP system?

a. Shop air contains a lubricant b. Shop line pressure can be difficult to regulate

pressure c. Promotes combustion in an EVAP system d. Shop air line pressure will be lowered during

testing, which affects the operation of other tools.






29. While checking a MIL ON EVAP concern you find the PCSV is stuck open with some type of black rock-type material. What else should you also inspect?

a. Charcoal canister issues b. Damage from collision c. Lines for misalignments d. None of the above

30. Customer states that after fuel was purchased, the

MIL was illuminated. What is the first thing a technician should check?

a. Fuel cap b. Charcoal Canister c. Verify MIL ON d. None of the above

31. What would you expect to see for FTPS signal voltage on a 2007 Sedona (VQ) with the gas cap off?

a. 0.0 V b. 6.0 V c. 2.5 V d. None of the above

32. Which test below will give you the most accurate information on the state of health of a CCV?

a. Measure voltage and amp draw b. Check ohms / manually energize the solenoid

and try to blow through it c. Using shop air, command the valve closed and

confirm that it’s closed d. None of the above





33. What is a characteristic of ORVR failure?

a. Vehicle misfire on hard turns b. Low fuel pressure c. Mil ON with cycle misfire d. Difficult to fuel the vehicle

34. What is the purpose of the catch tank?

a. Hold excess vacuum for later needs b. Capture condensed vapors and release them

into the atmosphere c. Capture condensed fuel that is drawn into the

EVAP system until it evaporates and is removed as vapor through purge

d. Saves the fuel to be used at a later time

35. The following question involves the fuel tank air filter. Technician A says that the CCV must be replaced anytime the filter is contaminated. Technician B says some vehicles have a pre-canister before the filter. Who is correct?


36. Technician A says that the EVAP monitor is actually

several tests. Technician B says that the system must pass all the tests that are part of the monitor. Who is correct?






FILL IN OR SELECT THE

BEST ANSWER

37. While reviewing the ETM diagram above, Technician A says that the canister purge solenoid valve and mass airflow sensor get power from the same fuse. Technician B says they share the same controlling ground. Who is correct?


38. All of the components below are Kia EVAP system

components EXCEPT:

a. Gas cap b. PCV valve c. Charcoal canister d. CCV

39. 0.5 PSI is equal to approximately ____in. H2O.

a. 1 b. 14 c. 28 d. 2




FILL IN OR SELECT THE

BEST ANSWER

40. While reviewing the ETM diagram above, Technician A says that the FTPS is grounded at the PCM. Technician B says that the FTPS uses 5V supplied from the PCM. Who is correct?





KESD






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Kia EVAPorative System Dianosis