Testing Evaporative Systems For Leaks (16 01 07)

TESTING EVAPORATIVE SYSTEMS FOR LEAKS

TECHNICAL SERVICE BULLETIN

SUBJECT

Testing Evaporative Systems for Leaks 

EVAPORATIVE SYSTEM TANK LEAKAGE DMTL TEST MODULE OPERATING HINTS

Evaporative system leakage is found using the DMTL tank leakage test plan: 

If a leakage is found to be present using the DMTL leakage test plan, the following points should be verified.

1. Check that the fuel cap is properly closed.
2. Testing the evaporative system requires all venting pipes and electrical connectors to be properly connected.
3. Search for leakage; if needed, use the VACUTEC® Smoke Machine 625-522B-BMW.
4. Do not replace the DMTL pump or fuel cap.

Evaporative system leakage is NOT found using the DMTL tank leakage test plan: 

Only perform the applicable test plans for the faults stored. Performing additional leak measurements using a smoke machine on a vehicle that does not fail the DMTL leakage test plan will not be reimbursed by Warranty. Do not replace the fuel cap, DMTL pump or carbon canister.

DMTL pump "system error" fault is stored in the vehicle: 

Only perform the applicable test plan for the fault stored. If the test plan states to replace the DMTL pump, only replace that component.

• Do not smoke test the vehicle.
• Do not replace the fuel cap.
• Do not drain the fuel tank or refill.

TROUBLESHOOTING HINTS WHEN USING THE VACUTEC SMOKE MACHINE

Testing evaporative systems for leaks is very challenging. We have developed some diagnostic hints, along with the introduction of a new special tool, to properly connect a smoke machine to the DMTL fresh air vent/filter connection.

Recently the VACUTEC® Smoke Machine 625-522B-BMW was added to the BMW Equipment Program. The VACUTEC® Smoke Machine 625-522B-BMW is the only approved testing device for the fuel and evaporative systems. This device automatically converts air to high purity nitrogen, using Pressure Swing Absorption (PSA) nitrogen technology. Orders for the VACUTEC® Smoke Machine, 625-522B-BMW, can be placed by calling the BMW Equipment program at 1-888-222-7997.

Included with the new VACUTEC® smoke machine are various caps and adaptors to help connect the applicator hose to the vehicle. It is always suggested not to disturb the system before testing; try to create as little disturbance as possible to the system when connecting the smoke machine. This smoke machine utilizes an UltraTraceUV® smoke solution. The smoke solution incorporates an ultraviolet dye, which helps pinpoint the leak with an ultraviolet residue surrounding the leak area. Determining the source of the leak is made easy when the included Hi-Density True UV LED light and incandescent white light are used.

When testing the vehicle's evaporative system using the flow meter on the VACUTEC smoke machine, the ball indicator should not lift from the zero measurement on the scale when the system is leak-free. All BMWs are designed to be 100% leak-free. A flow meter indicating zero flow would be the same as placing your finger over or kinking the application hose of the VACUTEC smoke machine (no flow = 100% leak-free).

For more information regarding evaporative system testing, describing possible fire hazards using oxygen vs. nitrogen, please refer to the following SAE website:

www.sae.org/technical/papers/2007-01-1235

Shown below is the Evaporative Test Adaptor, which can connect directly to DMTL (Diagnosis Module Tank Leakage) pump-equipped vehicles only after the fresh air filter connection has been removed.

Evaporative Test Adaptor (for vehicles equipped with a DMTL pump) P/N 83 30 0 433 207

Hose Connection to DMTL

When properly connecting the tool to the system, the main benefit is that it does not disturb the integrity of the system. This tool should be used anytime the vehicle is in the workshop for a small or large leak in the evaporative system. Shown in the picture is the tool connected to the DMTL at the fresh air filter connection.

All vehicles equipped with a LDP (Leak Diagnosis Pump) system

Vehicles equipped with the LDP system will require a series of small pieces of rubber hose to adapt the smoke machine application hose.

WARRANTY INFORMATION

Covered under the terms of the BMW New Vehicle/SAV Limited Warranty, any applicable Federal, State or BMW Emissions Warranty or the BMW Certified Pre-Owned Limited Warranty (only applies to CPO vehicles that are still within the CPO coverage period but beyond any Emissions Warranty).

1. If evaporative system leakage IS found  using the DMTL tank leakage test plan and the tank ventilation valve is the root cause of the leak  , use the following defect code:

   Defect Code:

   13 90 01 14 00

2. If evaporative system leakage IS found  using the DMTL tank leakage test plan and the fuel filler cap is the root cause of the leak  , use the following defect code when:

   Defect Code:

   16 11 02 48 00

   NOTE: Do not use defect code 16 11 02 48 00  for any other tank ventilation repair warranty claim. Issues resulting from improperly secured fuel filler caps are not covered.
3. If evaporative system leakage IS found  using the DMTL tank leakage test plan and a leak is found in another portion of the evaporative system  , use the following defect code when:

   Defect Code:

   16 13 10 48 00

   NOTE: Do not use defect code 16 13 10 48 00  for a tank ventilation valve leak warranty claim.
4. If evaporative system leakage is NOT found  using the DMTL tank leakage test plan, use the following defect code.

   Defect Code:

   16 13 10 96 00

   NOTE: Do not use defect code 16 13 10 96 00  for a tank ventilation valve leak warranty claim.
5. If a DMTL pump "system error  " fault is stored and an evaporative system leak is NOT detected  , use the following defect code:

   Defect Code:

   16 13 05 12 00

Vehicle test labor operation code 00 00 006 is a main labor operation. If you are using a main labor code for another repair; use the plus code labor operation 00 00 556 instead.

Claim eligible work that results from performing ISTA diagnostics and the related test plans with the applicable defect code together with the labor operations listed in KSD2.

Work time (WT) labor operations require an individual punch times.