General Procedures - Fuel Vapor Containment System Leak Check

Check

1. 1
   Place the vehicle in NEUTRAL on the lift.
   Refer to: Lifting and Jacking (100-02 Jacking and Lifting — 2.5 L Duratec — Hybrid (121 kW/164 L PS) (BG)).
2. 2

   NOTICE: Do not apply smoke to the EVAP leak detection module. This may damage the internal module.

   Disconnect the fuel vapor containment system purge line and connect the VACUTEC smoke machine tester to detect fuel vapor at the quick-connect fitting of the evaporator purge line, as shown. Refer to the manufacturer's instructions.
   Refer to: Quick-Connect Coupling (310-00 Fuel System - General Information — 2.5 L Duratec — Hybrid (121 kW/164 L PS) (BG)).

   

3. 3
   Using the VACUTEC Smoke Machine fuel evaporative leak tester, pressurize the EVAP system.
4. 4
   Monitor the VACUTEC Smoke Machine fuel evaporative leak tester indicator. If the reading is below the indicator flag, the system passed the leak test and the procedure is complete. If the reading is above the indicator flag, the system failed the leak test. If the leak check fails, proceed to the next step.
5. 5
   Supply smoke from the VACUTEC Smoke Machine fuel evaporative emission tester into the EVAP system. Refer to the manufacturer's instructions.
6. 6
   Use the halogen light included with the VACUTEC Smoke Machine fuel evaporative tester to locate smoke escaping from the EVAP system. This will indicate the leak location.
7. 7
   If necessary, repair all leaks and reinstall components.

1. 1

   NOTICE: Do not apply smoke to the EVAP leak detection module. This may damage the internal module.

   Disconnect the fuel vapor containment system load line and connect the VACUTEC smoke machine tester to detect fuel vapor at the quick-connect fitting of the emissions system load line, as shown. Refer to the manufacturer's instructions.
   Refer to: Quick-Connect Coupling (310-00 Fuel System - General Information — 2.5 L Duratec — Hybrid (121 kW/164 L PS) (BG)).

   

2. 2
   Using the VACUTEC Smoke Machine fuel evaporative leak tester, pressurize the EVAP system.
3. 3
   Monitor the VACUTEC Smoke Machine fuel evaporative leak tester indicator. If the reading is below the indicator flag, the system passed the leak test and the procedure is complete. If the reading is above the indicator flag, the system failed the leak test. If the leak check fails, proceed to the next step.
4. 4
   Supply smoke from the VACUTEC Smoke Machine fuel evaporative emission tester into the EVAP system. Refer to the manufacturer's instructions.
5. 5
   Use the halogen light included with the VACUTEC Smoke Machine fuel evaporative tester to locate smoke escaping from the EVAP system. This will indicate the leak location.
6. 6
   If necessary, repair all leaks and reinstall components.

1. 1

   NOTICE: Do not apply smoke to the EVAP leak detection module. This may damage the internal module.

   With the fuel vapor management system canister purge valve (disconnected in step 8) in the open position, connect the VACUTEC Smoke Machine EVAP Tester to the emissions system load line. Quick-connect fitting as shown. Refer to the manufacturer's instructions.
   Refer to: Quick Connect Coupling (310-00 Fuel System - General Information — 2.5 L Duratec — Hybrid (121 kW/164 L hp) (BG)).
2. 2
   Using FDRS, command the EVAP system changeover valve (EVAP_SW_VLV) to the open position.

   

3. 3
   Using the VACUTEC Smoke Machine fuel evaporative leak tester, pressurize the EVAP system.
4. 4
   Monitor the VACUTEC Smoke Machine fuel evaporative leak tester indicator. If the reading is below the indicator flag, the system passed the leak test and the procedure is complete. If the reading is above the indicator flag, the system failed the leak test. If the leak check fails, proceed to the next step.
5. 5
   Supply smoke from the VACUTEC Smoke Machine fuel evaporative emission tester into the EVAP system. Refer to the manufacturer's instructions.
6. 6
   Use the halogen light included with the VACUTEC Smoke Machine fuel evaporative tester to locate smoke escaping from the EVAP system. This will indicate the leak location.
7. 7
   If necessary, repair all leaks and reinstall components.

1. 1

   Item	Port
   1	Load port
   2	Purge port
   3	Fresh air port
   4	Dust filter
   5	ELCM

   

2. 2
   Remove the fuel vapor management canister.
   Refer to: Fuel Vapor Filter — Plug-In Hybrid Electric Vehicle (PHEV) (303-13C Evaporative Emissions, Removal and Installation).
3. 3
   Use suitable plugs or caps to seal the load and purge ports on the fuel vapor management canister.
4. 4
   If the VACUTEC Smoke Machine EVAP Tester was operated in smoke mode during previous tests, purge the smoke from the machine.
5. 5

   NOTICE: Do not apply smoke to the EVAP leak detection module. This may damage the internal module.

   Connect the VACUTEC Smoke Machine EVAP Tester to the fresh air port.
6. 6
   Spray the fuel vapor management canister with soapy water.
7. 7
   Apply pressure (do not smoke) and check the EVAP canister for leaks. Leaks are indicated by bubbles in the soapy water.
8. 8
   If necessary, repair all leaks or replace components.
9. 9
   The test is located in FDRS under Self Test > PCM > Run KOEO. EVAP Leak Test. Repeat the leak test until the system passes.