Hyundai TSB 00-30-003

Technical Service Bulletin

Group

30 - Fuel System

Number

00-30-003

Subject Date

Enhanced Evaporative Emission Control Diagnosis and Repair For P0442, P0455 and P1443 Leak Codes Using a Low Pressure Gauge

09-2000

ModelAccent 1995-2001, Elantra 1992-2001, Excel 1986-1994, Santa Fe 2001, Scoupe 1991-1995, Sonata 1989-2001, Tiburon 1997-2001 and XG 300 2001

enhanced evaporative emission control diagnosis and repair for P0442, p0455 and p1443 leak codes using a low pressure gaugedescription:This bulletin provides information describing how to use a Low Pressure Gauge for diagnosis of leak codes on enhanced evaporative emission systems. Diagnostic Trouble Codes (DTCs) P0442,P0455, and P1443 can be diagnosed using a low pressure gauge. In some instances DTCs P0446, P0440 and P0441 can also be diagnosed using a low pressure gauge.THE BASICS:By pressurizing a sealed evaporative emission system, the pressure leakdown rate can easily be measured using a low pressure gauge. The system should be slowly pressurized to a very low pressure(in this case 20" H20). A properly operating system (one that does not leak) will not lose any pressure; in fact, with high fuel temperature and high ambient temperature, pressure may increase due to fuel vaporization. If the gauge drops more than 2 inchesof water (0.072 psi) in 1 minute, a leak is present. [ If the gauge pressure drops, a leak is present, and the technician must find the location of the leak and repair it.]Note 1: 1" H2O = 0.036 psi; 30" H20 = 1.08 psiNote 2: The low pressure gauge is a very sensitive tool. DO NOT exceed 30" H20 (1 psi) when pressurizing the system (pressurize SLOWLY!) or the gauge will be damaged.Low Pressure Gauge Tool - SPX EVAP Tester P/N J-44680

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CONNECTING THE LOW PRESSURE GAUGE (KENT-MOORE / SPX P/N J-44680)1. Refer to the appropriate schematic (pages 6 - 14) and determine the correct hose

to to use for the test. Thenselect the correct size hose barb fitting for the tool based onthe I.D of the hose. The low pressure gauge tool should be installed on the fresh air side of the canister close valve (whenever possible).

2. Install the proper size of hose barb onto the low pressure tester. Use teflon tape (or equivalent) to insure a good seal.

3. Slide the hose clamp over the barb connector to prevent any leaks.4. Use a bungee cord (or equivalent) to suspend or support the tool. This will

prevent kinking of any system hoses.5. Two pairs of hose pinching pliers (Snap-On part #BLC2 or equivalent) will be

needed to diagnose the system.

USING THE LOW PRESSURE GAGENOTE 1: DO NOT exceed 30" H2O when pressurizing the system (pressurize SLOWLY!) or the gauge will be damaged. The low pressure gauge is a very sensitive tool.NOTE 2: NEVER use shop air.NOTE 3: NEVER pressurize the evap tester (low pressure gauge) by itself. Connect it to an evaporative emission system,or leave the 1/2" end open to fresh air. TheMityvac (YA4000) can over-pressurize the evap tester in less thanone stroke.

1. Use a Mityvac pump (Snap-On P/N YA4000 or equivalent) to pressurize the system through the pressure port of the pump; connect the Mityvac to the one-way valve.

2. SLOWLY pressurize the system up to 20" H20 (use the bleeder valve to bleed off pressure if over 20" H20). The system will "settle" (drop 3 - 7" H20) over a short period of time to equalize pressure throughout the system (see note below).

A. Vehicles with the canister at the front of the vehicle should be allowed 45 seconds for the system to settle.

B. Vehicles with the canister at the rear of the vehicle should be allowed 30 seconds for the system to settle.

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Repressurize the system pressure up to 20" H20 after the "settling" has stabilized with the Mityvac pump.

3. After repressurizing the "settled" stabilized system to 20" H2O, observe the gauge.

A. Steady gauge:1. The system does not leak at current conditions. However:a. A leak may occur from a poor sealing canister close valve*.b. A leak may occur from a DM-TL* that isn't sealing properly internally.c. If DTC P0455 was set, the vehicle may have a pinched hose (blockage) in the purge line.* The sealing ability of the canister close valve or DM-TL is not being tested using the gauge test. If thecanister close valve or DM-TL is suspected of leaking, it should be swapped with a known good unit, and the system checked with the Hi-Scan Pro.B. If the gauge drops 2" H20 (0.07 psi) in 1 minute, a leak is present.1. Place a set of hose pinching pliers between the one way valve and the gauge to prevent leaks past the one way valve on the gauge. 2. Find the leak by isolating each segment from the canister (purge line, fresh air line, to-tank line, etc.).3. Soapy water, or a listening device will help with locating the leak.4. Leaks can also be internal to the system. Example: a leak through the purge control valve would leak into the intake manifold, so there is no external leak thatsoapy water could find. However, using hose pinching pliers beforeor after the purge control valve would stop the low pressure gauge fromdropping, indicating a leak at the purge valve.

Use The Hi-Scan Pro To Activate The Evaporative Emission Self-Check:It is highly recommended to use the Hyundai Hi-Scan Pro to activate the evaporative emission self check. Using the Hi-Scan Pro will save time and provide more consistent results. For most OBD-II Hyundai vehicles (with the exception of the 1996 Elantra),it is possible to use the Hi-Scan Pro to activate the evaporative emissions self check in the

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service bay to verify repairs. "Roadtesting" is not practical to verify a repair for the 2000 MY Accent, because it requires up to a 4 day time period of vehicle operation.The self check can be found on the main menu after selecting Model and Year of the vehicle. For all vehicles except the 2000 Accent, the menu item is labeled "Evap Leakage Test". For the 2000 Accent, the menu item is labeled DM-TL Test. Both the self checks inspect the system for leaks (see TSB 00-30-002 "2000 Accent Evaporative Emissions System Operation").To familiarize yourself with the operation of the self check, remove the gas cap of a known vehicle that is operating properly and activate the self check (follow the instructions on the Hi ScanPro screen). With the gas cap removed, DTCs P0455, P0442 or P1443should register after the test is finished. Erase the code when finished, and replace the gas cap. If no code appears, turn the ignition key to off until the main power relay shuts off and retry the process. If no code appears at this point, call the HyundaiTech Line.Troubleshooting Tips See TSB 98-30-002 for additional information and troubleshooting techniques.P0440: A. Inspect the canister purge valve (CPV) for a mechanicallyP0441: "partially open" condition. Replace valve as necessary.P0455: A. Check for a missing / loose gas cap first. P1443:B.Inspect for pinched hoses in the "Purge or Tank" circuits causing a vacuum restriction to DPS.C.Isolate the leak to the front or rear of the car (or fuel tank from canister) using the appropriate schematic to isolatecomponents. Apply hose pinching pliers at different locations untilthe source of the leak is found.P0442: A. Isolate the leak to the front or rear of the car (or fuel tank from canister) using the appropriate schematicto isolate components. Apply hose pinching pliers at different locationsuntil the source of the leak is found.B. For 1998-2000 Elantra/Tiburon with no apparent leak found, verify that the white fill vent valve plunger movesfreely inside its cage.C. For 1998-2000 Elantra/Tiburon with no apparent leak found, verify that the canister close valve seals properly. Replace valve if necessary.D. For 1998 Sonata, check for a missing gas cap.E. For 2000 Accent, inspect the canister purge valve (CPV) for a mechanically "partially open" condition. Replace valve as necessary.

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This was found at http://www.hmaservice.com/index.jsp?SSOSESSIONID=%2BYCgiWYjq9BWEalTmnvyodvf .

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