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Test TC-160A - EVAP Leak Monitor Small Leak Detected

NOTE: For connector terminal ID, see CONNECTOR IDENTIFICATION  Directory. For wiring diagram, see WIRING DIAGRAMS article.
CAUTION: When performing test procedures keep all ignition sources away from test area. Ensure test area is well ventilated. Ensure fuel tank is at least 1/2 full before performing test. Pressurizing fuel tank with less than 3 gallons of fuel may result in an explosion caused by ignition of the fumes. Wear safety glasses when performing test procedures. If vehicle is not being tested on a hoist, ensure parking brake is applied and drive wheels are blocked before performing test procedures.
  1. A defective secondary seal in fuel filler neck or leaving fuel cap loose or off could set this trouble code. To properly diagnose this trouble code, Miller Tool Kit (6872A) and Ultrasonic Leak Detector (6904) is necessary. Perform evaporative system pressure pump self-test specified on cover of tool kit.
  2. Turn ignition off. Connect evaporative system pressure pump supply hose to Leak Detection Pump (LDP) EVAP system test port. See Fig 1. Set pressure hold to OPEN position and set vent to CLOSED position. Turn pump timer on. Tee an auxiliary vacuum pump to EVAP system test port. Using auxiliary vacuum pump, apply 18 in. of water vacuum to LDP. If LDP holds vacuum, go to next step. If LDP does not hold vacuum, repair leaking LDP vacuum supply line. To verify repair, perform TEST TC-160A again.
    Fig 1: Locating EVAP System Test Port
    G96C01581
  3. Turn ignition on. Using scan tool, actuate LDP solenoid. Observe vacuum gauge. If vacuum dropped when LDP solenoid was actuated, go to next step. If vacuum did not drop when LDP solenoid was actuated, replace LDP. To verify repair, perform TEST TC-160A again.
  4. Using auxiliary vacuum pump, raise vacuum to 18 in. of water vacuum. Perform IM240 simulation described on cover of Tool Kit (6872A) while scan tool is still actuating self-test. If pressure drops more than 6 in. of water vacuum (to 8 in. of water vacuum) in 2 minutes, go to step 7). If pressure does not drop more than 6 in. of water vacuum (to 8 in. of water vacuum) in 2 minutes, go to next step.
  5. Condition to set trouble code is not present at this time. EVAP LEAK MONITOR SMALL LEAK DETECTED DTC sets if a leak larger than .080" in evaporative system. Possible causes are: a leak larger than .080" in evaporative system or LDP failure. Go to next step.
  6. Inspect all related wiring, connectors and hoses and repair as necessary. Perform TEST VER-2A. If no problems found with wiring, connectors and hoses, see INACTIVE TROUBLE CODE CONDITION . Test is complete. Perform TEST VER-2A.
  7. To continue test, Ultrasonic Leak Detector (6904) is necessary. Set pressure hold to OPEN and set vent to OPEN position. Turn pump timer on. Move Miller Tool Kit (6872A) away from vehicle to prevent operating noise from interfering with testing procedure.
  8. Using ultrasonic leak detector, start listening for leaks at fuel cap, fuel tank rollover valve, EVAP canister, LDP and EVAP solenoid. If any leaks are heard with ultrasonic leak detector, repair or replace leaking component. Perform TEST VER-5A. If no leaks are heard with ultrasonic leak detector, replace LDP. Perform TEST VER-5A.
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